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    Case studies  A fleet of DAQ systems for all testing needs: HBM supports Sikorsky in complex helicopter testing
    Case studies  Brüel & Kjær Vibro installs their 3rd generation monitoring system at the Huntly power station in New Zealand
    Case studies  Applus+ IDIADA integrates virtual and physical testing with 2 new VI-grade driving simulators
    Case studies  Omega IoT temperature monitoring and data automation make food safety compliance more efficient and cost effective
    Case Studies  Red Lion Controls helps municipality improve communication across four pump stations along an 11-mile pipeline
    Case Studies  Volkswagen Group uses Brüel & Kjær’s noise, vibration and harshness analysis software to test gears and completed transmissions
    Case studies  

    Dutch company SoilCares uses a spectrometer from Malvern Panalytical to provide farmers with data-based precision farming tools

     

    Case study 11  

    Red Lion Controls helps Indian solar power generation company to lower operating costs

    Case study  

    Drax Power's use of Servomex analysers to optimise boiler combustion efficiency has saved them millions of pounds in direct fuel savings and lower operational costs

    case study 1  

    Use of BTG’s data management system brings improved quality, higher productivity and lower raw material costs and wastage for Spanish tissue producer.

    Case study 10  

    Brüel & Kjær Vibro’s monitoring systems help the second-largest electric utility company in Chile to optimise machine uptime and reliability and reduce maintenance costs

    FORD Case study  

    Ford Motor Company have been working with Brüel & Kjær Sound & Vibration‘s NVH simulator products for a number of years.

    case study 2  

    Oil refiner achieves increase in burn efficiency (and hence substantial cost savings) using Servomex’s gas analysers

    case study 3  

    Wind turbine operators achieve substantial cost savings through use of B&K Vibro’s remote machine condition monitoring equipment

    case study 4  

    A manufacturer of consumer goods uses Red Lion’s operator panels to reduce downtime in its parts welding facilities

    case study 6  

    Gold mining company uses ESG’s microseismic systems and services to ensure safety and production integrity of substantial mining project

    case study 7  

    A snack food company uses NDC’s near infra-red analysers to ensure consistent quality and achieve reduction in waste

    case study 8  

    Pulp producer achieves increased yield through use of BTG’s single point KAPPA analyser

    case studies  

    Malvern Panalytical help leading agricultural company, Syngenta, to improve productivity 

    Case study 9  

    Brüel & Kjær Sound & Vibration’s system helps gas turbine testers to increase test efficiency, significantly shortening test times

    •   A fleet of DAQ systems for all testing needs: HBM supports Sikorsky in complex helicopter testing

      The helicopter is a complex machine, with a multitude of systems to be tested and qualified; consequently, the test lab has a range of very different test benches. It is an advantage to have a DAQ system that can operate in a range of test applications, and under numerous test scenarios rationalize multiple channels of data in a single file. 

      HBM identified QuantumX as the ideal DAQ system for Sikorsky's testing needs. This system is modular, scalable and with a flexible architecture, meets the requirements for an easily- and fast-reconfigurable system that supports an extremely wide range of sensors and transducers. 

      The flexibility and scalability of the QuantumX data acquisition system from HBM now allows Sikorsky to use a single DAQ system to satisfy all their testing needs. The rapid reconfiguration capability of the QuantumX data acquisition system is ideal for use with all the test setups at Sikorsky.

       
    •   Brüel & Kjær Vibro installs their 3rd generation monitoring system at the Huntly power station in New Zealand

      Brüel & Kjær Vibro announced that it had received an order for the supply of VC-8000 SETPOINT® systems and services for monitoring a 250 MW gas/coal fired steam turbine, generator and main boiler feed pump at the Huntly power station, the largest in New Zealand. Huntly is owned by Genesis Energy, the third largest generating company in New Zealand in terms of production capacity. 

      The B&K Vibro system provides both protection and condition monitoring of the generating units. The SETPOINT system represents the third generation monitoring system from B&K Vibro installed at the Huntly power station since 1995; Compass Classic, VC-6000/Compass 6000 and VC-8000 SETPOINT. 

      The VC-8000 was also selected based on its ability to stream all static and dynamic vibration data into the existing OSIsoft® PI System™ data historian. By using the data historian server, this thus eliminates the need for a separate, special-purpose vibration database. This approach not only reduces IT infrastructure, but it also allows for easier correlation of process data with machinery vibration data for advanced condition monitoring and diagnostics
      Installation support, commissioning and training is being provided by B&K Vibro.

       
    •   Applus+ IDIADA integrates virtual and physical testing with 2 new VI-grade driving simulators

       

      Applus+ IDIADA has expanded its virtual development capabilities with the acquisition of two driving simulators from VI-grade, the DiM250 and a compact simulator. These new driving simulators mean IDIADA offers virtual testing, reducing development times in areas such as chassis development, vehicle dynamics and CAV development.

      By exploiting the synergies between physical and virtual testing, IDIADA can generate and correlate models in optimal context with the possibility of using IDIADA’s tracks, available as public road data files and high-resolution graphics.

      “The driving simulator is a key facility in our chassis and vehicle dynamics development projects as it links up our virtual and real activities.” said Roger Mateu, Head of Vehicle Dynamics and NVH at Applus+ IDIADA.  

    •   Omega IoT temperature monitoring and data automation make food safety compliance more efficient and cost effective

      The Food Innovation Center at Rutgers University (FIC), is a globally recognized food business incubator and processing  facility that supports domestic and global food companies with research and development, marketing and marketing  research,  quality assurance, and business and food safety training. Additionally, a primary focus of their program is to guide companies through the USDA and FDA compliance and inspection processes. Thus, it’s important to the FIC that they set a gold standard in food safety compliance.


      Recognizing the compliance challenges the FIC still faced and seeing an opportunity to take their IoT temperature monitoring solution to the next level, OMEGA Engineering worked with the FIC and with a data automation and management firm, Data Illuminations, to develop a holistic, end-to-end automated wireless temperature monitoring and data analytics solution for the FIC.


      As part of the solution, the FIC now has access to a web-based notification center where all the paperwork that needs to be acknowledged to remain in compliance is stored. And now, in addition to receiving temperature alerts, the FIC also receives alerts about compliance documentation tied to the temperature monitoring alerts. For example, if during a production run the kettle gets too hot or too cold, creating a food safety issue, alerts pop up not only about the temperature changes, but also regarding what the QA team needs to document. 

    •   Red Lion Controls helps municipality improve communication across four pump stations along an 11-mile pipeline

      Quantum specializes in delivering professional engineering and automation control system services for the industrial and commercial manufacturing facilities. For this specific project, a municipality operates an 11-mile pipeline, which crosses two other cities to deliver water to a treatment facility. Four pump station RTU cabinets sit along the pipeline, controlling and monitoring the flow of water. Inconsistent and unreliable communication made it almost impossible to control the four pump stations remotely. Quantum consulted with the city and recommended that the town move to a 4G LTE cellular network to communicate.

      To enable the new communication system, Quantum needed to leverage the existing infrastructure while also infusing modern technology to solve the issues. This required the necessary 4G LTE equipment, working with a cellular provider, and deploying a new architecture. Critical to this was the use of a multi-carrier cellular RTU with GPS and control. Red Lion supplied Quantum with a RAM® 6000 Cellular RTU.


      Since Quantum implemented the new network, the city no longer has to worry about its aging and ineffective wireless radio infrastructure. They now have a dependable communication system that allows them to seamlessly monitor each RTU cabinet remotely. 

    •   Volkswagen Group uses Brüel & Kjær’s noise, vibration and harshness analysis software to test gears and completed transmissions

      Volkswagen Group uses Brüel & Kjær’s Discom noise, vibration and harshness analysis software to test gears at the end of their production lines and also to test the completed transmissions. Its largest gear and transmission production facility at Kassel, Germany, produces around 17,500 transmissions per day.

      Testing is primarily focused on identifying durability issues and ensuring customer acceptance for ride quality and comfort. Durability issues in gears can lead to a failure in an assembled transmission. The end-of-line transmission test simulates vehicle conditions so that any potential problems are identified early or even predicted and avoided entirely, minimising costs and improving quality.

      The Discom database and associated tools in the system help develop predictions on tool wear. The system uses a unique USB-based data acquisition front end, developed especially for Volkswagen, and a significant number of features which are now part of the standard Discom system originated from discussions with Volkswagen.

    •  

      Dutch company SoilCares uses a spectrometer from Malvern Panalytical to provide farmers with data-based precision farming tools

       

      The world’s population continues to grow, with the result that food production needs to increase to keep up with demand. In agriculture, as much as 60% of crop yields depends on the fertility of the soil. Obtaining fast, affordable and reliable access to information about soil fertility is therefore key to helping farmers increase their yields.

      Dutch company SoilCares provides the world’s farming community with data-based precision farming tools in order to increase crop yields. Based on an Epsilon 1 XRF spectrometer from Malvern Panalytical, SoilCares' subscription-based solution, called Lab-in-a-Box, enables individual farmers or farming organisations to have direct access to soil testing services on site, something which has previously only been possible in a laboratory.

      The Lab‑in‑a‑Box measures soil parameters such as pH, nutrients and organic matter using SoilCares’ unique global soil database. In this way, Malvern Panalytical enables a complete soil fertility report to be delivered back to the farmer’s computer in less than two hours, together with customised recommendations for improving the soil.

      Malvern Panalytical and SoilCares are working together to develop the self-learning database in which the results are stored so that the system can provide increasing knowledge to farmers anywhere in the world.
    •  

      Red Lion Controls helps Indian solar power generation company to lower operating costs

      Azure Power, a solar power generation company in India, use a weather station tool for their solar power sites to analyse energy consumption based on the ambient conditions. To do this, they need to accurately monitor and log weather data from a number of different remotely-located field devices and send all of the data to their head office.

      The previous process involved two devices and a long run of cable from the field, which often required site visits to repair. Now, using Red Lion’s solution of a modular controller with built-in web server and Ethernet switch, combined with third-party sensors for the field devices, Azure Power can monitor data remotely and store it in the cloud. This remote monitoring and control eliminates the need for multiple devices and data cabling, reducing the number of site visits required and lowering operating costs.

      Temperatures in northern India’s solar panel fields can reach extreme highs, so the rugged, reliable design of Red Lion’s equipment, with an operating temperature range of 0° to 50°C, means that service will continue even in the most extreme of environments.

    •  

      Drax Power's use of Servomex analysers to optimise boiler combustion efficiency has saved them millions of pounds in direct fuel savings and lower operational costs

      Drax Power is the UK’s largest power station and is Europe's biggest decarbonisation project. 70% of its electricity is generated from sustainable biomass.


      Drax uses Servomex’s analysers to optimise boiler combustion efficiency control, resulting in direct fuel savings, reduced maintenance and a reduction in direct carbon monoxide emissions. The Fluegas Exact 2700 analyser measures both oxygen and carbon monoxide and is therefore suitable for continuous flow monitoring of combustion processes. It is designed for high temperature processes up to 1,750°C, so is ideal for use in extreme heated environments such as hydrocarbon processing and power generation applications.


      Over the past nine years, Servomex has supplied 48 of these analysers to monitor the boilers. Drax estimate that improved control of the combustion process has saved them millions of pounds over the years in both direct fuel savings and lower operational costs.

    •  

      Use of BTG’s data management system brings improved quality, higher productivity and lower raw material costs and wastage for Spanish tissue producer.

      A tissue paper producer in Spain, a customer for BTG’s Duroblade coating blades, is one of the first tissue mills in the world to be equipped with BTG’s new Yankee Performance Scorecard. This data aggregation and visualisation tool gives operators real-time decision making support to improve the performance and reliability of this critical part of the tissue machine.

      The system collects a discrete process data set and processes it according to calculations based on domain expertise and industry best practice to display graphical performance information which helps operators to make the correct process decisions. The customer is seeing benefits in terms of improved productivity and better quality. Savings on plant downtime and plant cost efficiency are already estimated at €95,000 per year.

    •  

      Brüel & Kjær Vibro’s monitoring systems help the second-largest electric utility company in Chile to optimise machine uptime and reliability and reduce maintenance costs

      Background

      Hydroelectric power generation is playing an increasingly vital role in global energy production. Many newer hydroelectric power stations are purpose-built for peak load operation and are subject to multiple stops and starts, and the generating units have to be fully operational when needed. Our systems detect vibration which provides an early indication of machine faults in time to avoid catastrophic failures and consequential downtime.

      The project

      Brüel & Kjær Vibro’s monitoring systems are installed in more than 750 hydro turbines around the world. The company was recently awarded a contract by Colbún, the second-largest electric utility company in Chile, for protection and condition monitoring at all six of its cascade hydropower stations on the Aconcagua river basin. Environmental impact has been minimised as no dams needed to be built and the use of hydropower means there is less dependence on coal and natural gas.

      The solution

      Brüel & Kjær Vibro’s monitoring systems will be installed in each of the six hydropower stations and a Compass 6000 condition monitoring platform will be centrally located at the Los Quilos station for remotely monitoring all the machines. The comprehensive service and training Brüel & Kjær Vibro offers was also a key factor in gaining the contract.

      Benefit to the customer

      Remote monitoring of the hydropower station machines will enable Colbún to understand machine conditions by detecting faults before they can cause failure, thus optimising machine uptime and reliability and reducing maintenance costs.

    •  

      Ford Motor Company have been working with Brüel & Kjær Sound & Vibration‘s NVH simulator products for a number of years.

      Automotive customers are increasingly demanding the provision of an integrated solution, combining hardware, software and services.

      Ford utilise Desktop Simulators (DTS) to help refine their NVH targets and troubleshoot sound quality issues. The DTS allows Ford to evaluate standard NVH test or computer-aided engineering data in a true driving environment, converting the data in real-time into an accurate representation of the sound in response to the driver‘s inputs to the controls.

      The limitation of the DTS is that it only handles the sound of the vehicle, not the vibration. There are many NVH phenomena where the total perception of the issue is a combination of the sound and vibration experienced by the driver or passenger, for example vibrations felt through the steering column and seat.

      Ford evaluated a prototype of a Full-Vehicle Simulator (FVS) at Brüel & Kjær Sound & Vibration‘s Engineering Services facility at Millbrook and realised this was the next step in producing a more immersive experience for NVH evaluation. Ford took delivery of their FVS in December and have begun exploring the capabilities of the new system with the goal of integrating it into their product development processes.

      “We realised that the FVS added the missing dimension of vibration and took us to the next level in improving NVH assessment and better decision-making. It requires a significant investment in resources but the benefits to our NVH development make it worthwhile" said Mark Stickler, Ford‘s Manager for Powertrain NVH.

    •  

      Oil refiner achieves increase in burn efficiency (and hence substantial cost savings) using Servomex’s gas analysers

      Description of product / application

      Servomex's oxygen analysers utilise its non-depleting paramagnetic and infrared sensor technology to deliver stable and reliable measurements of oxygen, carbon monoxide and carbon dioxide in both safe and hazardous areas.

      Benefit to customer

      A large Houston-based oil-refining customer saw a 6% reduction in fuel costs by reducing excess oxygen within the power combustion process (i.e. increasing burn efficiency). The annual savings for a small to medium-sized power plant in a refinery from such burn efficiencies are estimated at in excess of $500,000.

    •  

      Wind turbine operators achieve substantial cost savings through use of B&K Vibro’s remote machine condition monitoring equipment

      Description of product / application

      B&K Vibro's remote machine monitoring equipment is used to give wind energy producers early warnings about developing mechanical problems on wind turbine drive trains.

      Benefit to customer

      Customers experience significant cost savings from being able to take early remedial action, such as “up-tower” repairs (where the repair is undertaken without removing the gearbox from the turbine) instead of “down-tower” repairs (where the gearbox is removed from the turbine). For example, it might cost around $25,000 to replace a generator bearing, compared with around $200,000 to replace an entire generator. Furthermore, early warnings generated by this equipment enable better planning of maintenance activity and efficient execution of repairs.

    •  

      A manufacturer of consumer goods uses Red Lion’s operator panels to reduce downtime in its parts welding facilities

      Description of product / application

      Red Lion’s HMI (human machine interface) operator panels and connectivity products connect, collect and forward critical machine data and alarms to operators and management information systems for further analysis. They enable customers to easily connect, monitor and control processes across a diverse range of industries that include manufacturing, oil and gas and water/wastewater.

      Benefit to customer

      By collecting and reporting on causes of downtime, a parts welding facility of a manufacturer of consumer goods was able to increase its uptime from 85% to 90%, resulting in a daily revenue increase of $90,000 per welding machine.

    •  

      Gold mining company uses ESG’s microseismic systems and services to ensure safety and production integrity of substantial mining project

      Description of product / application

      Data acquisition arrays and other components, together with a digital recorder and in-house developed software form a microseismic system used to identify geological structures and understanding of rock mass behavior for use in the monitoring of mines.

      Benefit to customer

      Newcrest Mining, an Australian mining company, was using a “block-caving” method to extract gold-copper deposits. For reasons of both safety and production rate, Newcrest engaged ESG to install a microseismic system (at a cost of $250,000) in order that it could continually monitor the cave during mining operations. ESG’s system was able to ensure safety and production integrity for a project involving over $100m of development investment.

    •  

      A snack food company uses NDC’s near infra-red analysers to ensure consistent quality and achieve reduction in waste

      Description of product / application

      NDC’s MM710 food analyser and Infralab at-line near infra-red analyser are used for the measurement of moisture and other key product constituents in the food industry.

      Benefit to customer

      A multinational snack foods company used NDC’s analysers for the near infrared measurement of moisture, oil and degree of brownness in savoury snack foods in order to ensure consistent quality and reduce waste by around $12,000 per day.

    •  

      Pulp producer achieves increased yield through use of BTG’s single point KAPPA analyser

      Description of product / application

      BTG’s single point KAPPA analyser is used by pulp producers to measure Kappa to enable the pulp to be used in the production of paper and paperboard. The Kappa number estimates the amount of chemicals required during the bleaching of wood pulp to obtain pulp with a given degree of whiteness.

      Benefit to customer

      A large Asian producer of pulp replaced their existing multi-point unit with BTG’s analyser and, through more rapid and reliable Kappa measurement, were able to modify their production parameters to achieve a 0.7% higher yield, representing an increase in contribution of around $2m p.a. (from an investment of around $70,000).

    •  

      Malvern Panalytical help leading agricultural company, Syngenta, to improve productivity 

      In 2016, we worked closely with Syngenta, a leading agricultural company, in the move to a new Malvern Instruments system.

      Syngenta manufactures a wide range of agrochemicals including pesticides, fungicides and herbicides. Consistency of the ingredients is essential for overall product quality control and Syngenta needed a system to confirm that all the ingredients in a formulation were in suspension and in the correct concentrations.

      Syngenta decided to purchase an OMNISEC system, consisting of systems, detectors and software, for this particular application. It measures absolute molecular weight, molecular size, and other parameters and is a powerful tool for controlling the performance, quality and value of the ingredients.

      One of the key benefits was the ease of changeover in a lab that handles many different samples.

      The new software was also a key selling point as it made it easy to gather more sensitive data and produce closely customised reports, thus enhancing both efficiency and ability to support decisions around different suppliers and troubleshooting. Improving productivity also freed up time for higher value work.

      “Since we purchased OMNISEC, we’re able to deliver more sensitive data, so our ability to support decisions has been directly enhanced. In an analytical lab like ours that operates so many techniques with relatively few people, improving productivity is a major gain.“ said Dr Kirt Durand, Senior Analytical Chemist at Syngenta

    •  

      Brüel & Kjær Sound & Vibration’s system helps gas turbine testers to increase test efficiency, significantly shortening test times

      Background

      Aircraft manufacturers are required to meet strict regulations on noise and emissions whilst at the same time seeking to reduce fuel consumption. French company Snecma, part of international group Safran, which supplies engines to companies such as Boeing and Airbus, has developed a new engine called LEAP. This features some of the industry’s most advanced technology to make it quieter and more fuel efficient, helping the aviation industry meet its environmental protection objectives.

      The challenge

      Snecma has optimised the aerodynamic design of the engine turbine blades, using woven carbon fibre composite fan blades to achieve greater performance. However, the gas turbine is a highly complex machine that needs comprehensive testing and analysis during development in order to optimise its dynamic behaviour. Each test is a major operation which requires detailed planning: test systems must be scalable and capable of handling large amounts of data from parameters such as
      strain, vibration, pressure and speed.

      The solution

      In order to speed up testing and certification of the LEAP engine, which will power the next generation of single-aisle commercial jets, Snecma selected a Brüel & Kjær Sound & Vibration gas turbine testing system. This is based on LAN-XI data acquisition hardware and PULSE Reflex data processing software, which together provide dynamic data recording, real-time monitoring and post-test analysis, with the flexibility and portability that Snecma required.

      Benefit to the customer

      Brüel & Kjær’s system helps gas turbine testers to increase test efficiency and flexibility and improve data integrity. The system can be set up quickly, which significantly shortens test times. Real-time instant feedback is provided through multiple networked monitoring stations to ensure the validity of the test data and eliminate the need for a re-test.

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