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IIoT Solutions Delivering Significant Benefits 

Average ROI from Miniotec’s Most Recent
IIoT Digital Transformation Projects

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Case Studies - Rotating Equipment Condition Monitoring

Coal Mining Company

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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

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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

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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

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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

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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

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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

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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

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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

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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.