Diagnose any plant fault —
without crossing a safety boundary.
TRACE is a decision-support engine for PLC and SCADA equipment in steel, cement, mining and process plants. It cross-references ladder logic, P&ID diagrams, calibration history and a compounding Fault Pattern Database — then refuses to guess across LOTO, SIS or ATEX boundaries. Operators get plain language. Engineers get full depth. Nobody crosses a hazard zone without authorisation.
Mold oscillation servo thermal overload — cooling filter F-22 clogged. Overdue calibration on TT-204 contributing.
- Confirm LOTO on drive cabinet D-4
- Replace cooling filter cartridge F-22
- Engineer to validate amplitude 4–6 mm
Six-step intake. Four safety gates. Zero guessing.
Session
Emergency, scheduled, or performance check.
Machine
Confirm running PLC version against record.
Calibration
Overdue sensors surfaced before diagnosis.
Intake
Error code, symptom, quality, performance or physical.
State
Tag/value pairs of current operating conditions.
Confirm
Other active faults? TRACE runs with full context.
Safety Instrumented System faults are refused — escalated, not diagnosed.
Every physical fix requires explicit lockout/tagout confirmation.
Hazardous atmospheres force engineer-validated procedures.
PLC code mismatch reduces confidence and warns the engineer.
Every confirmed fix becomes future leverage.
When an operator confirms a resolution, TRACE upserts it into the Fault Pattern Database with confidence weighting, hazard flags and source-session lineage. The next time the same signature appears — on any machine of the same model, at any client — diagnosis is faster, surer, and already pre-validated against your safety envelope.
- ▸Skill-aware output — basic operators get plain language, engineers get ladder/ST depth.
- ▸Per-client RLS — Acme can never see Pioneer's machines, documents, calibration or patterns.
- ▸Immutable audit log — every diagnosis, escalation and resolution is append-only.
- ▸Engineer console — escalated, blocked and SIS-bounded sessions queued for review.
| signature | model | conf | seen |
|---|---|---|---|
| E-1042 | CCM-3200 | 88% | ×7 |
| E-2207 | RF-880 | 82% | ×4 |
| E-555 | KD-500 | 91% | ×11 |
| E-9001 | CV-700 | 76% | ×3 |
From alarm to verified fix in three surfaces.
Six-step guided intake
[ machine: CCM-3200 ] [ intake: SYMPTOM ] [ describe: vibration trip ] [ state: speed=82% temp=91 ]
Operator picks the session type, confirms running PLC version, then describes the symptom in plain language or pastes an error code.
Ranked causes, gated fixes
► cause 1 · cooling F-22 88% ► cause 2 · servo bearing 41% ▸ fix · 12 min · LOTO ▸ verify · plausible
TRACE returns confidence-weighted root causes against PLC code excerpts, P&IDs and the live Fault Pattern Database. SIS, LOTO and ATEX gates fire before any fix renders.
Engineer console, in-app alerts
▣ alerts (2) escalation · URGENT filter cartridge clog → engineer notes ⤴
Blocked, SIS-bounded or requires-engineer sessions queue for the on-call engineer with a realtime in-app alert. Resolution notes flow back to the operator the same way.
Engineered to deploy in real plants, today.
Answers for engineers, not marketers.
Everything plant managers, controls engineers and SI partners ask before deploying TRACE on a live line.
Book a 20-minute walkthrough against your own PLC code excerpt and a sample fault.
request a walkthrough →Your next unplanned downtime
is a solved problem.
Spin up TRACE for your fleet. Seeded demo clients, machines and fault patterns are already loaded — log in and run a real diagnosis in under a minute.