Case Study

How VijAI AI Vision is Revolutionizing Chemical Plant Safety and Process Excellence

Chemical plants are complex ecosystems — where a single leak, spill, or missed inspection can escalate into catastrophic incidents. To help industries achieve zero incident operations and process optimization, VijAI AI Vision brings advanced computer vision intelligence to every corner of the plant floor.

PPEAI

Automatically verifies whether chemical plant technicians are wearing the correct PPE—such as chemical-resistant suits, gloves, goggles, and respirators—before entering hazardous processing zones.

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FIREAI

Identifies smoke, fire, or overheating near reactors, storage tanks, pipelines, and solvent-handling areas in real time — enabling maintenance teams to act instantly and prevent escalation.

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GESTEAI

Prevents distractions in chemical facilities by detecting unsafe gestures like using mobile phones, inattentive movement, or careless walking near pressurized lines or active equipment.

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DRIVEAI

DRIVEAI monitors vehicle and personnel movement in high-risk areas such as acid storage zones, gas filling yards, and chemical loading bays.

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ZONEAI

Monitors controlled chemical zones—like mixing areas, toxic substance rooms, and pressurized sections—allowing only authorized entry and instantly alerting teams to prevent unauthorized presence.

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PULSEAI

PULSEAI keeps a 24×7 watch on critical equipment and environmental zones

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SAFEAI

Detects unsafe acts during maintenance such as climbing without harnesses, skipping railings, or improper handling of chemical drums. Enables early intervention and targeted safety training.

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SECUREAI

Uses facial recognition and motion detection to prevent unauthorized access to chemical storage, control rooms, and high-risk operational zones—significantly reducing security breaches.

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GUARDAI

Continuously checks machinery and processing units to ensure all protective guards and enclosures are restored after maintenance. Prevents unsafe restarts of mixers, centrifuges, and chemical pumps.

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INSPECTAI

INSPECTAI visually monitors ongoing processes and product quality parameters that sensors alone can't detect.

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When integrated with Wistwin Digital Twin, VijAI AI Vision transforms static surveillance into intelligent visual maps. Operators can view live AI alerts mapped onto 3D models of the plant — enabling visual maintenance, predictive analytics, and remote inspection from the control room.

VijAI Impact Statistics

Reduced by 65%

Safety Violations

Reduced by 30%

Unplanned Downtime

Improved by 40%

Quality Inspection Speed

Reduced by 50%

Incident Response Time

The Challenge

Traditional safety and quality systems in chemical manufacturing rely heavily on manual monitoring, human inspections, and delayed reporting.This results in:

Missed detection of leaks, PPE violations, or hazardous behavior

Inaccurate process quality tracking (color, consistency, contamination)

Delayed emergency response during fire, smoke, or gas events

Equipment degradation and unplanned shutdowns

Transforming Vision into Intelligence
From PPE detection to leak identification, from process consistency to predictive maintenance, VijAI AI Vision ensures every pixel in your plant works for safety, productivity, and sustainability

Client Testimonia
VijAI AI Vision gave our chemical plant an extra set of eyes. It not only prevents accidents but also ensures our batches maintain top quality. The integration with Wistwin made our operations smarter and safer
*Plant EHS Head, Leading Petrochemical Manufacturer