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Updated: Sep 27, 2023


Case Study Medical Centre


Challenge:

Case Study Medical Centre

A large medical clinic has thousands of traps throughout their many buildings. These are so integral to their operations that they have maintenance crews that check critical locations every 2 - 3 hours.


Some are located in hard to access spots which prove challenging for inspectors, even to the extent that sometimes workers can get burnt trying to get temperature readings to assess functionality.


Steam trap inspections took upwards of 5 hours per day.

Solution:

Monitors were installed on all steam traps and connected via LoRaWAN network to collect temperature and sound readings remotely. Failure alerts are now sent to maintenance department who can schedule repair at a time that is convenient to clinicians as well as operations. They have started doing failure trend analysis to be able to proactively calculate energy savings and resource allocation. Safety committee is thrilled with the new approach and has implemented mandatory training for specialized individuals who maintain HVAC system as well as steam.



“The amount of time we used to spend doing inspections was prohibitive. The steam system is an essential service.”



Benefits:

  • Crews that used to do inspections every 2-3 hours are now working on a number of projects that had to be sidelined due to lack of time

  • System is running smoothly and failures can be attended to immediately

  • They have seen a reduction in their energy costs

  • They no longer have to deal with process interruptions due to invasive inspections

  • Safety infractions are now a very rare occurrence

  • Exception reports and failure alerts mean they don’t need to watch dashboard all the time



Updated: Sep 27, 2023


Case Study Pharmaceutical Company


Challenge:

Case Study Pharmaceutical Company

A pharmaceutical company had a failure in their autoclave and for 3 days had to shut down the line to search for the source. When they finally narrowed it down it was too late, they had lost $100k worth of product.


They also shut down the heating aspects of their steam system in the summer and find that every fall when they start it again they have several traps that fail.


One loss of product cost company over $100k

Solution:

They installed pulse steam trap monitors on all traps and have a dedicated computer with the dashboard in view at all times to ensure instant awareness of any anomalies or failures. They proactively purchase a number of spare traps ready to replace the ones that fail every fall. They have them at the ready when they start using the heat again and instantly swap out the bad ones.


Throughout the year they are now able to have visibility in real time on all steam traps and the efficiency and health of the entire system.



“Looking at this system was the catalyst to looking at other ways we can be more sustainable”


Benefits:

  • Production lines are confidently able to run without worrying about failures interrupting process at critical times

  • They don’t worry about shutting down and starting up the system

  • They have noticed a significant reduction in their energy consumption

  • They are calculating the amount of CO2 emissions they have reduced and are going to be putting together a comprehensive sustainability mandate for their organization

  • They are using some of the money they have saved by not losing product to send needed medical supplies to third world countries




Updated: Sep 27, 2023


Case Study Chemical Company


Challenge:

Case Study Chemical Company

Chemical Manufacturing company pays a huge amount of money for their steam. They have not had a full steam audit for 3 years. They know they have had a number of closed failures because the failures destroyed heat exchangers but have no idea how many traps were currently failed open. They want to be able to plan maintenance better to fix closed failures before they destroy equipment and simultaneously fix open failures and cut their energy costs across the plant.


Heat Savings on Exchangers pays for the cost of solution and installation. ROI is almost instantaneous.

Solution:


Installing Pulse Steam Trap Monitors on all steam traps took 2 of their maintenance people 2 days. Avoiding even 1 close failure pays for those workers wages tenfold. Plus being able to schedule the time was much easier than having to adjust schedules to accommodate emergency fixes, and no production line downtime was needed.


They have a number of solutions that monitor their equipment, all the dashboards are displayed on a central computer monitor that is accessible 24 hours a day. They like that the Pulse solution runs on an independent highly secure network that doesn’t interfere with other apps and that failures are sent as alerts.



“Cutting energy costs is one of our mandates for the next few years. This is a great start.”


Benefits:

  • They are able to proactively fix closed failures and avoid the devastating consequences to their heat exchangers

  • One of their biggest costs is energy, reducing that cost will significantly impact their net revenue

  • Installers completed a full steam audit while implementing Pulse solution, the first in over 3 years

  • They don’t need to monitor the dashboard at all times as failures and even anomalies are sent via email

  • Automation and efficiency are goals for the entire operation, this is one more step towards that ideal





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