Case Study: Steam and a Polymer Manufacturing 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.

The company gets inspections annually which left them very vulnerable to failures between audits. They didn’t really know how much the failures cost in lost energy and production efficiency.

Solution:

The polymer company started with a very minimal investment. They decided on a pilot installation of only 25 Pulse steam trap monitors. Monitors were installed next to high pressure steam traps servicing presses, hot boxes, autoclave, and the boiler room. Pulse monitors only require one gateway per 100 traps so installation was complete within one 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: Approx $4,700

  • During the third month, another open failure was detected on a thermodynamic trap at 140 PSI. Annual losses: Approx $3,500

  • A large leak was found in month 6. Anual losses: Approx $31,000

  • The calculated ROI of the pilot: Approx 667% in only 6 months

3 failures would have cost them over $39k per year. They also save approx 300 ton of CO2

Due to the success of the pilot they decided to scale deployment across their plant to all steam traps to ensure they don’t have any production downtime moving forward. They will be able to use their energy savings toward their carbon footprint reduction mandates.

Pulse is a steam trap monitoring system that alerts you of steam trap failure WHEN it happens

  1. According to the U.S. Department of Energy, 30% of steam traps fail within 3-5 years. The average cost of a failed steam trap is $6,640 annually*
  2. The Pulse Monitoring System comes with a dashboard and web app that allows you to see your steam trap performance in real time and receive alerts if a trap fails
  3. Pulse is the only steam trap monitoring system that utilizes both steam and condensate temperature AND ultrasound. Competitor systems rely only on temperature
  4. One gateway can handle up to 100 steam traps within proximity
  5. Pulse has a lifetime warranty on all pricing models. This means if a Pulse monitor fails (their lifetime is approximately 7 years), you will get a replacement monitor at no charge

LEARN MORE ABOUT PULSE

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