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Updated: Dec 6, 2022


Case Study Polymer Company


Challenge:

 Polymer Company

A large polymer manufacturing company used steam for their critical assets such as heated hydraulic moulding presses. It was essential that the steam was kept at a very high pressure to ensure maximum efficiency and effectiveness of their machinery. They also have recently been focused on reducing energy costs and emissions rates.


They diligently get inspections annually which left them very vulnerable to failures between audits but they didn’t really know how much the failures cost in lost energy and

production efficiency.


3 failures would have cost them over $39k per year. They also save approx 300 tonnes of CO2

Solution:


Polymer company started with a very minimal investment. They decided on a pilot installation of only 25 monitors. They installed monitors next to high pressure steam traps servicing presses, hot boxes, autoclave and the boiler room. They only required one gateway so installation was complete within 1 day. LTE connection ensured no bandwidth loss to their WIFI network and secure failure alerts instantly to their maintenance staff.


“We are so relieved to have a failsafe system in place. It was the easiest installation we have ever done”


Benefits:

  • An open failure was initially detected during installation on a float type steam trap at 120 psi. Annual losses from this leak would have cost approx $4,700

  • During the third month, another open failure was detected on a thermodynamic trap at 140 psi. Annual losses would have cost approx $3,500.

  • A large leak was found in month 6, losses from this type of trap would cost approx $31,000 per year.

  • The calculated ROI of the pilot was about 667% in a matter of only 6 months.

  • Due to the success of the pilot they decided to scale deployment across their plant to all steam traps

  • They want to ensure they don’t have any production downtime moving forward.

  • They will be able to use their energy savings toward theircarbon footprint reduction mandates.



Updated: Dec 6, 2022


Case Study Forest Products


Challenge:

Forest Products

A forest products company has a unique situation in their steam environment. They have a very self contained environment where they use offcuts to power the boiler that produces their steam. The steam in turn provides heat, powers their compressor and even helps in the wood drying process. They need to report their CO2 emissions to the government and had very strict

guidelines to adhere to.


Since 1990 Canada’s forest sector has reduced its GHG emissions by close to 70%. Ensuring failures are caught immediately is essential to ongoing improvements.

Solution:


Pulse Steam Trap Monitors were installed on all steam traps. While installing it was found that one of the steam traps was not working. It was swapped out and monitor installed on new trap however data was still irregular and they quickly ascertained that new trap was not functioning properly and had to be replaced. New trap was installed and worked properly.


They realized that if the monitor had not caught the failure it would have gone undetected for up to 12 months, the usual timeline for their next steam trap survey. Being in such a remote location makes it difficult to get inspections done more frequently.They calculated that emissions saved from that one trap would have significantly impacted their government guidelines making them potentially subject to fines and a poor rating.


"There is no future without addressing climate change and forests are a key component of that"


Benefits:

  • Forestry suppliers operate in a heavily regulated market and emissions ratings can even be a competitive disadvantage.

  • They have suffered a lot of bad press over the last few years so have vowed to decarbonize their entire manufacturing and supply chain by 2030 - installing these monitors will help them achieve that goal

  • They can now schedule annual audits and rest assured that failures will not go undetected between inspections

  • They can focus on other carbon reductions in order to deliver on their promises



Updated: Dec 6, 2022



Challenge:

Beer Manufacturing

A large beer manufacturer uses steam extensively for their heat kettles, brew house, flash pasteurizer, keg room, glycol heater, sucrose system, heat exchanger and varioclean crp. Trap failures mean more than just lost energy, they could very quickly result in lost product.


Detection was so integral to their processes that they were inspecting their traps on a weekly basis. This took a staff member up to 5 hours each week (costing approx $2000 a month in wages and lost productivity). They calculated that a large failure would ruin product if it failed for longer than 24 hours. Each year they had up to 3 of those undetected failures with a loss of approx $100K product each time.


$2,000 per month in wages plus $1000 in month in energy savings is just the tip of the iceberg in terms of money saved

Solution:


Pulse Steam Trap Monitors were placed on 163 steam traps, gateways installed and data is now recorded constantly and sent to the AI diagnostics software. Failure alerts were set up to be sent to maintenance and brewery teams.


In the first month a failure was detected and repaired with no down time necessary and no lost product. Additional failures in the future are not a worry as the system is in place and supported 24x7. They plan on rolling out the solution to their other locations over the next 12 months.


"It literally broke my heart to have to

throw out all that beer several times a year"


Benefits:

  • Failures are detected right away so no product ever needs to be ruined

  • The worker who used to do inspections every week is now happily overseeing a new project

  • They are enjoying significant energy savings in addition to the production values

  • Maintenance workers don’t have to be on site at all times or glued to a screen with analytics as they are emailed with failure alerts when a failure occurs

  • User training on Pulse AI diagnostics system is very quick and easy



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