Intelligence infrastructure for superhuman operators

Heavy Labs is an applied research lab building Industrial AI that understands how your plant actually works.

We connect plants' data, design, control logic, history, and operating knowledge so agents can take on real operational work—monitoring systems, investigating problems, and improving processes.

Talk to us How we work

Your plant’s living memory.

Every Heavy Labs solution is built on a Process-Aware Industrial Knowledge Graph.

We work with your team to transform your existing data sources and expert knowledge into a versioned, machine-readable model of how your plant is connected, controlled, and operated. Operator knowledge, validated findings, and real-world outcomes continually enrich that model, so each investigation builds on what your team has already learned.

Your plant’s Connected assets

Trace connected equipment through branches, valves, and alternate paths.

Your plant’s Control logic

See what starts an asset, what can stop it, and how failures are detected.

Inputs & feedbackCommandProtectionSelect to inspect

Your plant’s Live operating state

See measurements, setpoints, and alarm states in the context of the running plant.

LT-01Supply level23.4%

PT-01Pressure2.70bar

FT-01Outlet flow18.4m³/h

LT-02Receiving level24.6%

Operation

Mode: Auto
Motor current: 4.8 A

Setpoints

TK-02 stop level: 65%
TK-01 low trip: 10%

Alarms & faults

Overload trip: Clear
Fail to start: Normal

Your plant’s Connected knowledge

Connect equipment and its components to engineering sources, maintenance history, and operating experience.

Four views of one illustrative process-water transfer system. Two matching pumps connect a supply tank to a receiving tank through parallel branches, each with suction and discharge isolation and a discharge check valve. P-01A is running; P-01B is on standby. A decorative trace follows pump A's branch and the shared outlet. NRV-01B prevents return flow into the stopped pump; the lower suction isolation valve is not shown as closed.

In the control view, tank levels connect to the low-level running interlock and transfer demand. Motor control selects automatic or operator authority, subject to the running interlock. The interlock trips below 10% and resets at 12%. Motor overload protection trips the starter independently. The fail-to-start alarm compares the run command with motor feedback after a five-second timeout. Running feedback does not establish process flow. The live view animates authored demonstration readings around steady water transfer, with upstream feed and downstream demand. Both tank levels, pump discharge pressure, shared-outlet flow, and motor current vary slightly. Pump A remains running in Auto; setpoints and alarm states stay fixed. The final view connects pump A and its mechanical seal to engineering guidance, a replacement work order, and operator handover.

Receiving tank level: LT-02 is evaluated against transfer start and stop levels, with hysteresis — Tank transfer routine.
Tank transfer routine: The transfer routine requests automatic pump operation — Pump control logic.
Operator start and stop requests: Operator start and stop requests are accepted in operator mode; the running interlock still applies — Pump control logic.
Supply tank level: LT-01 is evaluated against the low-level running interlock trip and reset thresholds — Low-level running interlock.
Low-level running interlock: The low-level interlock inhibits starting and removes the run command when tripped — Pump control logic.
Pump control logic: Motor control sends the run command to the pump motor starter — Transfer pump A.
Transfer pump A: The pump motor starter provides a discrete running-feedback signal — Starter run feedback.
Pump control logic: The fail-to-start check monitors whether a run command has been issued — Fail-to-start alarm.
Starter run feedback: Running feedback must arrive before the configured start timeout; otherwise the alarm is raised — Fail-to-start alarm.
Motor overload protection: The overload relay trips the motor starter; this is separate from normal sequence control — Transfer pump A.
Supply tank: Focused process-water path from TK-01 through P-01A — Transfer pump A.
Transfer pump A: P-01A discharges to the shared outlet and TK-02; P-01B is on standby — Receiving tank.
Transfer system P&ID: The drawing depicts pump A and its process connections — Transfer pump A.
Pump operating procedure: The operating procedure guides starting, stopping, and restarting pump A — Transfer pump A.
Transfer pump A: Pump A contains the mechanical seal component — Pump mechanical seal.
Mechanical seal service procedure: Section 6 of the pump manual describes servicing this mechanical seal — Pump mechanical seal.
Mechanical seal replacement: WO-2048 records replacement of this mechanical seal — Pump mechanical seal.
Mechanical seal replacement: WO-2048 records maintenance carried out on pump A — Transfer pump A.
Operator handover: The operator handover references WO-2048 — Mechanical seal replacement.
Operator handover: The handover records operating observations about pump A — Transfer pump A.

Industrial AI agents that
do real work.

Your plant's living memory, put to work. Agents investigate across connected equipment, test explanations against evidence, and work with your team to turn findings into action.

XV-101·Delayed open confirmationInvestigating

Alarm-triggered investigation · XV101_OpenTimeout14:00:10 UTC

XV-101 did not confirm open within 10 seconds of the command. I’ll check the sequence and compare recent operations.

Read control logic · Evac_TK201 · PLC-01

Compared evacuation cycles · TK-201 · PT-201

Tank pressure started falling late, but the subsequent curve resembles prior cycles. I’ll check whether the delay is isolated to this valve.

Followed shared utility connections · IA-401

Compared valve opening response times · XV-102 / XV-104

XV-102 and XV-104 also confirmed open late in the last five minutes. All three actuators share instrument-air supply IA-401. I’ll check the supply under demand.

WatchtowerXV-101

Updated after post-repair checks · 14:55 UTC

Filter restriction likely caused the valve delays

Restriction at F-401, the shared instrument-air filter, is the likely main cause of the delays. Reduced air pressure under demand likely slowed the actuators.

After element replacement, pressure loss across F-401 fell from 1.8–2.1 bar to 0.1 bar under comparable demand. All three valves confirmed open within their prior ranges.

Pressure across F-401

Pressure dips begin before the marked valve commands.

Upstream · PT-400Downstream · PT-401

Time from open command to open-position feedback

Supporting evidence

PT-400 and PT-401 directly bracket F-401, with no regulator or other restriction between the taps. Upstream pressure held near 6.2 bar(g) during all three delays.

Repair and verification

Maintenance found a contaminated element and replaced it under WO-2056. XV-101, XV-102, and XV-104 then confirmed in 4 s, 3 s, and 4 s without switch or PLC timing adjustments.

These observations cover one post-repair check per valve; they support the finding without establishing sustained reliability.

Working together

Let’s build what your plant needs.

We work alongside your operators and engineers to turn your priorities into useful AI—built on your plant’s knowledge, shaped around your workflows.

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How we work

Phase 1
Audit & plan
We review your plant information and operator priorities, then agree on the scope, success criteria, and integration plan.
Phase 2
Build & connect
We build your Industrial Knowledge Graph, connect historical and live data, and validate it with your team so they can put it to use.
Phase 3
Activate your agents
We configure monitoring and investigations for your use cases, replay incidents, and validate performance with your team before bringing the agents online.