Customer Story: Predictive Analytics

Steam Turbine Failure Drives</br>Predictive Maintenance Mindset

AMS Asset Monitor Greatly Mitigates This Plant’s Risk

This Pulp & Paper mill experienced a catastrophic turbine failure on one of its most critical machines—responsible for manufacturing specialty paper and representing about 20% of the mill’s capacity. Thanks to an existing relationship with Scallon Controls, an ‘all hands on deck’ response enabled the customer to take advantage of newer technology, resulting in increased safety, predictive analytics, and improved operational certainty.

This situation was caused by a burst supply pipe that leaked, locked up a bearing, and ruined the entire internals of the steam turbine—in short, a catastrophic failure of a critical asset. The customer had no visibility into the condition of the bearing or shaft since their last physical monitoring, no tie into their DCS, and therefore no operator alert system. Furthermore, when dealing with superheated conditions, human safety is a real factor. Their previous reliability program relied on technicians taking readings with portable analyzers and wireless vibration monitors not designed for hazardous conditions. While acceptable in some environments, this industry calls for a more robust and proactive solution.

With the Turbine Down, the Company Was Losing $100K per Day

The Scallon Controls and Emerson team of engineers responded by custom-designing and fabricating the solution—featuring AMS Asset Monitors—in less than half the typical timeframe, due to the criticality of this customer’s turbine. While the turbine was being rebuilt, Scallon Controls was not only working to get everything back online, but also creating a long-term, proactive, and predictive maintenance approach—to improve safety, mitigate risk, and give valuable insights into the condition of this mill’s assets.