Case Studies
Customer case studies
Browse fault detections and equipment-performance investigations by industry and asset type. Each case describes the finding, the site response and the reported outcome.
Showing 36 of 36 results
Industry
Asset Type
Fault Type
Metals & Mining
Early warning of failing heated godet roll prevents $90k in production loss
SAM4 picked up motor overloading on the godet roll early enough for maintenance to be planned, before the fault could stop the production line.
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Water & Wastewater
Hydraulically rerating an existing booster pump station to reduce energy cost by €99k a year
Two identical booster pumps ran the same duty. Rerating one to match actual demand cut energy cost while keeping full backup capacity.
View case study Metals & Mining
16x early alerts to degrading rollers save €650k in lost production
Roller conveyor faults were caught well before failure, letting the mill book each repair into scheduled downtime instead of losing production.
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Water & Wastewater
Control change would reduce aeration blowers’ energy cost by 5% overnight
The blower station was running more capacity than the process needed. Changing the control strategy saves €120k a year with no capital spend.
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Metals & Mining
How ArcelorMittal prevented 31 hours of downtime by detecting 27 failures ahead of time
SAM4 detected each fault far enough ahead that the repair could be scheduled into planned maintenance, rather than stopping production without warning.
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Water & Wastewater
Rightsizing booster pumps to save €121k a year in wasted energy
SAM4 Energy identified a classic mismatch between pump size and system flow that was annually consuming 813 MWh more than it needed to.
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Water & Wastewater
Early alerts on a degrading oxidation ditch rotor prevent two pollution events and up to €900k in costs
Twice, SAM4 Health provided early warning of gearbox degradation though the vibration system had not yet alerted the customer to a problem.
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Water & Wastewater
Detecting a burst rising main in Southern Water’s wastewater network
SAM4 flagged a burst rising main from the pumps' electrical signature, red alert at 01:41, main isolated within 20 hours. See how early detection works.
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Metals & Mining
9x common faults detected in steel manufacturing
Nine detections drawn from anonymised SAM4 data across steel plants, each shown with the signal that triggered it so engineers can judge the evidence.
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Water & Wastewater
Preventing downtime on borehole pumps
Borehole pumps sit far underground, out of reach of vibration sensors. SAM4 reads their condition from the motor control cabinet at the surface.
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Water & Wastewater
Preventing failure in wastewater inlet screws
Preventing failures in wastewater inlet screws holds significant importance on the agenda for water companies as it helps avert breakdowns and pollution events.
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Water & Wastewater
Yorkshire Water clears two blocked sewage pumps
When a second pump began to block, Yorkshire Water sent a team to clear both pumps. The client verified €190,000 in estimated avoided costs.
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