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Sachin Rana

Digital twins

Run a live twin. Break it. Watch it find the fault.

These are working digital twins, not screenshots. A simulator plays the plant and its sensors, a health engine sees only the readings, and every part of the drawing takes its health color in real time.
Get a twin of your plant

01Live demos

Launch one

Open full screen

Live digital twin

AI Pod · liquid-cooled GPU racks

Runs fully in your browser · about 1–2 MB

Four 80 kW GPU racks on direct-to-chip cooling, a CDU and a roof dry cooler. The twin judges every loop against healthy physics and prices the energy lost.

  • CDU pump bearing wear
  • Cold-plate blockage, rack 3
  • Coolant leak
  • Dry-cooler fan 2 failure
  • Plate heat exchanger fouling
  • Rack 1 return sensor dead

Try this

  1. Press “Cold-plate blockage, rack 3” under Inject a fault
  2. Watch rack 3’s flow halve and its return run hot, red within seconds
  3. Acknowledge the alarm, then repair and watch it return to normal
Get a twin of your plant

Built by Ideaxa Solutions with simulated, generic plant data. Isometric drawing kit by Ryan, used under the MIT license.

02Why a twin

What a twin gives your operations team

  • Health per component

    Every reading judged against healthy physics at the same load and conditions, not a fixed threshold.

  • Faults blamed correctly

    Each fault lands on its own component with a reason an engineer would write, not a wall of alarms.

  • Energy lost, in kW

    What the plant draws against what a healthy plant would draw, so maintenance has a price tag.

  • Ready for agents

    The twin is a tool an AI agent can call: “what is wrong, and what does it cost?”

Digital twin loop: physical assets feed filtered telemetry into a physics simulator; discrepancies drive analysis and closed-loop control.
Physics-Informed Digital Twins & SCADA Cockpit. Reference topology; client specifics and addressing omitted.

03In production

Nine production twins

Operating 9 production-grade, physics-informed digital twins combining dynamic simulation with physical ClickHouse hardware telemetry.
  • Next.js 14+
  • SVG Vector Modeling
  • WebGL
  • Server-Sent Events
  • Physics Modeling
  • Docker

  • Metro Homes Distribution Microgrid

    300 residential households across 20 city blocks

    • SAIFI (System Average Interruption Frequency Index)
    • SAIDI (System Average Interruption Duration Index)
    • CAIDI

  • AI Factory & High-Density Data Center

    50 MW high-density computing facility housing 360 server racks (40 kW to 100 kW per rack for NVIDIA H100/B200 clusters)

    • Power Usage Effectiveness (PUE): 1.18
    • Cooling Loop Delta-T: 12.4 °C (Supply 32°C / Return 44.4°C)
    • Facility Load: 42.8 MW Compute / 7.7 MW Thermal Rejection

  • Industrial Cold Storage Facility

    4,940 Metric Ton (MT) multi-chamber industrial ammonia (NH3) refrigeration facility

    • Specific Power Consumption: kW/TR (Kilowatts per Ton of Refrigeration)
    • Chamber Holding Temp: -22.0 °C
    • Thermal Pull-Down Rate

  • Smart Village Feeder Microgrid

    Rural electrification grid covering 120 distributed agricultural and residential consumer nodes

    • Phase Imbalance % (R-Y-B phases)
    • Neutral Current Displacement
    • Technical Line Losses (I²R)

  • 33/11 kV Primary Distribution Substation

    Dual-transformer 2 × 10 MVA primary distribution substation feeding municipal districts

    • Busbar Voltage (33 kV / 11 kV)
    • MVA Loading per Transformer
    • OLTC Tap Position (1-17)

  • Commercial Office Tower VRF

    10-floor corporate office tower featuring 359 indoor VRF fan coil units and 20 rooftop outdoor condensing units

    • BEE Energy Index (kWh/m²/year)
    • Average Indoor Temperature (23.5 °C)
    • VRF Compressor Inverter Frequency (Hz)

  • Central Chiller Plant

    3 × 800 TR water-cooled centrifugal chillers with primary-secondary pumping loops and cooling towers

    • Plant Efficiency: 0.58 kW/TR
    • Chiller COP: 6.06
    • Cooling Tower Approach: 2.8 °C

  • Floor Zone Architectural VRF

    Single-floor detailed CAD architectural layout with room-level thermal load zones

    • Zone Airflow CFM
    • Room Temp vs Setpoint
    • Electronic Expansion Valve (EEV) Opening %

  • Microgrid Islanded Power

    Campus hybrid microgrid: 1.2 MW rooftop solar PV, 2.5 MWh Battery Energy Storage (BESS), 1.5 MVA diesel generator

    • State of Charge (SoC %)
    • Microgrid Grid-Tie Frequency (50.0 Hz)
    • Diesel Fuel Flow Rate (L/hr)

From the twins

  • AI Pod digital twin with rack 3 shown red: cold-plate blockage detected, flow at 62% of expected, every other part normal
    AI Pod · GPU liquid coolingCold-plate blockage on rack 3 caught in seconds and blamed on the right rack.
  • Chiller digital twin with the condenser shown red for fouled tubes, and the energy lost against a healthy chiller
    500 kW screw chillerCondenser fouling found and priced: +1.5 kW (+9%) against a healthy chiller.
  • AI Pod digital twin zoomed into the CDU: plate heat exchanger shown red for fouling, with live tags on the pumps and secondary loop
    AI Pod · CDU close-upHeat-exchanger fouling isolated at 169% zoom, with live tags and the energy lost priced.
  • 33/11 kV substation digital twin: incomers, transformer bays, capacitor bank and control building
    33/11 kV substationTwo 10 MVA transformers, eight feeders, protection and the DC system.

Want your plant to tell you what is wrong with it?

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