Case Studies - Rotating Equipment Condition Monitoring

 

Coal Mining Company

Challenge:     
Client was experiencing persistent failures in their in-plant generator.  Estimated loss due to downtime with each failure: $160,000 per day.

Solution:     

Miniotec's IoT sensors were installed.  We detected a brush failure within the generator 13 days after installation.

Thermal Power Plant

Challenge:     
The client was experiencing unplanned downtime on at least three (3) occasions in the past year.  Estimated $250,000+ loss in revenue each day of downtime.


Solution:     
IoT sensors were installed within the operating power generation facility.  Our technology detected a start of vane pump failure within six (6) weeks of installation.

International Airport

Challenge:     
Failures on complex baggage handling equipment have a major impact on flight schedules and passenger satisfaction. 


Solution:     
IoT sensors were installed within their facility detecting the fault in the motor bearing within one (1) week. A basic $65 bearing was replaced during a regular maintenance shutdown instead of having a $5,000 gearbox fail during peak usage.

Fertilizer Plant

Challenge:     
Client was experiencing persistent failures in two (2) of their plant motors. Estimated loss due to downtime with each failure: $150,000 per day

 

Solution:     
Our IoT sensors were installed within their facility and detected a bearing outer race failure within six (6) weeks of installation.
 

Case Studies - Fluid Condition Monitoring Sensor

 

Wind Generation

Challenge:   

Planetary bearing faults, make up a majority of  wind turbine generator failures. They are difficult to detect during their early stages and are typically managed through end of life using vibration systems alone.

Solution:     

Traditional borescope methods could not locate any fault. We deployed our wear debris sensor to assess and monitor fault severity. We observed abnormal wear levels shortly after deployment. Total savings: >$250k

Coal Mining Operations

Challenge:     

A high percentage of coolant leaks are not detected early enough using periodic oil samples, causing secondary damage or catastrophic failure of the engine. 


Solution:      

Using our oil quality sensor, the operator can detect oil problems immediately, eliminating secondary damage and catastrophic failure. Our oil sensor was installed to provide continuous online oil health so as to immediately detect faults otherwise missed by offline analysis and between planned maintenance activities. 

Case Studies - Pipeline Leak Detection Sensor

 

Pipeline Operator Remote Inspection Solution

Challenge:     
A pipeline operator was applying considerable effort manually monitoring a 23km Emulsion line. They sought to automate their pipeline inspection program with a better solution. 

Solution:     

Three (3) IoT sensors were installed along the 23km pipeline for 24/7 monitoring. Through simple alarming, the system was able to identify a leak within 0.63km of the actual location.

Operation in any Environment

Challenge:     
Canada experienced a significant cold snap resulting in temperatures falling below -30ºC across the majority of the region. Normal pipeline integrity management approaches were not feasible.


Solution:     
Dozens of devices were exposed to the drastic drop in temperature. Despite these extreme conditions, all sensors operated as normal ensuring continuous monitoring of our customer’s operations and assets.

Adopting a More Cost Effective Pipeline Monitoring System

Challenge:     
Client requested a Leak Detection system to improve the monitoring of their Condensate Export Pipeline. 


Solution:     
Considering the vertical alignment of the pipeline, three (3) high resolution pressure sensors were installed for 24/7 maintenance free coverage. The system will monitor pressures in the condensate line whilst in steady state or flowing.

 

Case Studies - Employee and Asset Tracking

Social Distancing to Support Ongoing Construction

Challenge:     
Our Client had regulatory pressures to close their construction site due to local COVID-19 restrictions unless they could adhere to social distancing guidelines.

Solution:     

Our tag-to-tag system allows tags to sense and communicate with each other. When individual tags come within a predefined distance, this case 2 metres, our tag highlights social distancing rules through buzzing the user's tag and other tags in proximity.

Challenging Refinery Turnaround

Challenge:     
Client desired to implement a personnel tracking system for a major turnaround involving thousands of contractors.  Objectives included controlling access to restricted areas, improving efficiency of mustering and role calls and ensuring supervision of critical activities.


Solution:     
Miniotec tailored a turnkey solution with various types of tags and anchors for tracking workers, enabling the Client to achieve their objectives.

Improving Team Productivity

Challenge:     
Client employed a large quantity of workers across two (2) shifts which was difficult to manage. Foremen and managers were stretched, particularly with workers operating between zones.


Solution:     
Using geofences with our tags, Miniotec automatically recorded each workers whereabouts within the facility. This was used to generate reports and make changes to streamline work processes.

Case Studies - Tank Level Monitoring Sensor

 

Cost Saving Solution to Provide Real Time Operational Data

Challenge:     
A major producer had very low visibility to their operational process data from remote production pads as data was only captured once a week. They were seeking an automated solution for multiple applications that was cost-effective, safe, low-maintenance, reliable, and easy to install that would minimize labor, time, and cost of field visits.

Solution:     

To monitor both product and interface levels of five (5) 6m high storage tanks, liquid level sensors were deployed for ease of installation. 

Wireless Monitoring Solution for Oil & Gas Chemical Injection System

Challenge:     
Our Client needed to have access to accurate tank level data for their chemical skid to ensure efficient decision making for site operations and production. They required an accurate and cost-effective solution that could provide tank level data, run status to approximate the injection rate.


Solution:     
The Client determined that our wireless solution had the greatest impact in saving time, money and provided the most visibility over improving their operational process.

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