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Updated: Sep 27, 2023


Case Study Hospital


Challenge:

Case Study Hospital

A large hospital in Canada uses steam in a variety of unique ways. They heat their building with it but also use it to sterilize instruments. They need to be very careful with the use of chemicals and yet need the highest degree of cleanliness on these tools. Steam is a brilliant and efficient answer.

They are constantly being asked to cut costs and find more efficient ways of operating. They had a competitive solution in place but they only put monitors on 5% of their traps, leaving many un-monitored with potential for long term failures and unnecessary energy costs.


Solution is cost effective, easily transferable and flexible enough to fit a multitude of uses

Solution:


Pulse was able to put monitors on all steam traps in the hospital and, even with the cost of replacement of existing monitors, saw a huge reduction in energy costs which made them realize a return in investment in a very short while. The hospital has a wide variety of pipe sizes which was not a problem for Pulse whose monitors have the flexibility to fit on all sizes of pipes.


Email alerts are sent to multiple operations and maintenance personnel who work different shifts and locations. They don’t need to have to access a central monitor to quickly and easily assess failures and alerts. A few months after the initial install a wing was restructured, it was a simple matter to move and add monitors into the system.



“We are under intense scrutiny after the pandemic to be sterile and cost effective - steam gives us both”



Benefits:

  • Fits all sizes of pipes

  • System went from 5% to 90% of traps monitored at all times

  • They realized instant ROI from the project

  • Scaleable and easily transferable monitors offer flexibility of installation

  • Steam for heating and sterilization is now operating at peak efficiency enabling hospital to funnel savings into additional services





Updated: Sep 27, 2023


Case Study Pulp & Paper


Challenge:

Case Study Pulp & Paper

A pulp & paper plant in Quebec has a very extensive boiler and steam system. They use steam for a variety of processes, everything from adding it to the pulp itself as well as using rolls that are internally heated with steam. Maintaining a uniform temperature across the surface of the roll is essential for making quality product. Since steam is a gas, it fills the entire volume of the roll and evenly distributes heat as it condenses.


Steam accounts for 43% of facility energy usage. They have an entire team of engineers dedicated to increasing efficiency.

Solution:


Recovery of pre-treatment steam during pulping and steam for drying is paramount for reusing energy. In fact it can result in approx 14% energy savings. But with steam accounting for 43% of the facilities total energy usage, there is a potential for additional significant cost savings by detecting and repairing steam trap failures. They installed Pulse Steam Trap Monitors on all steam traps, connected to a series of gateways to connect all wireless IoT monitors to a cloud server. They now receive email alerts of all failures instantly and can repair traps with very little lost energy or variations in uniformity of temperatures. In the future they hope to use the AI inherent in the Pulse Solution to do additional analytics. They hope to use predictive modelling to see how different levels of steam pressure affect the cost and efficiency of the system.


“We are always looking for innovations in order to stay competitive. AI is the next level for us”



Benefits:

  • Significant energy cost savings were recognized through the instant availability of failure alerts

  • Product outputs were now more consistent and of higher quality overall

  • Future AI plans are in place to try to optimize the steam system efficiency

  • They were able to go from 3 shifts of workers to 2 as actual manufacturing only happens 16 hours a day, the third shift were only babysitting the infrastructure





Updated: Sep 27, 2023


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.





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