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IIoT Solutions Delivering Significant Benefits
Average ROI from Some of Miniotec’s Recent IIoT Digital Transformation Projects
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Case Studies - Rotating Equipment Condition Monitoring
Coal Mining Company
Challenge:
A 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 offered IIoT sensors were installed. A brush failure was detected 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:
IIoT sensors were installed within the operating power generation facility. The 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:
IIoT 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:
A 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:
The Wireless Vibration IIoT 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. The wear debris sensor was deployed 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 Miniotec's offered oil quality sensor, the operator can detect oil problems immediately, eliminating secondary damage and catastrophic failure. The 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.