Emerson Overhead Air Cooled Heat Exchanger Monitoring Products
SOFTWARE INTERFACE
AMS SUITE: ASSET GRAPHICS FOR OPERATIONS
Provides real-time graphical displays that indicate abnormal operation, including resonance frequency detection, louver defects, exchanger fouling detection, and overall exchanger health. A pre-engineered algorithm delivers diagnostic information for alarms, process analysis, trending, historization, and key performance indicators. Reduce Slowdowns and Fulfill Your Production Goals Air Cooled Heat Exchanger Health Monitoring NETWORK INTERFACE DEVICES
SMART WIRELESS CSI WIRELESS ROSEMOUNT WIRELESS
GATEWAY VIBRATION TRANSMITTER TEMPERATURE TRANSMITTER Connects IEC 62591 Provides early warning of excessive Enables temperature measurements (WirelessHART) vibration in heat exchangers. to determine heat transfer efficiency self-organizing networks Helps determine root cause and on exchangers. Ideal for this high with any host system. guides corrective action. Optional performance application to enable functionality can identify premature optimization of exchangers at a low bearing wear and predict failure. cost.
ADDITIONAL OPTIONS
FISHER WIRELESS ROSEMOUNT WIRELESS AMS SUITE FOR MAINTENANCE
POSITION MONITOR TEMPERATURE TRANSMITTER Aids early identification of asset Indicates equipment position Enables (high density) temperature problems using p redictive diagnostics, with a percent of span plus measurements to determine heat allowing maintenance to schedule on/off indication. Monitors transfer efficiency on exchangers. repairs while reducing cost and louver position for mechanical Ideal for this high performance downtime. defect detection. application to enable optimization of exchangers at a low cost.
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The Emerson logo is a trademark and service mark of Emerson Electric Co. CSI, Fisher, and Rosemount are marks of one of the Emerson Process Management family of companies. All other marks are the property of their respective owners. Emerson Process Management The contents of this publication are presented for information purposes only, and while effort has been made 1100 W. Louis Henna Blvd. to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding Building One the products or services described herein or their use or applicability. All sales are governed by our terms and Round Rock, Texas 78681-7430 conditions, which are available on request. We reserve the right to modify or improve the designs or specifications www.EmersonProcess.com/Chemical of our products at any time without notice.
D352152X012 / Printed in USA / 10-14
With hundreds of fans, need to know where to focus? Overhead air cooled heat exchanger failure puts plant Anatomy of an Overhead Air Cooled Exchanger Failure What if you could... operators face to face with an industry-wide enemy: Reduce Unplanned Shutdowns Get Started Today at unscheduled slowdowns and process disruption. An Root Cause Equipment Impact Process Impact Environmental Impact Business Impact Keep a closer eye on fan vibration, bearing temperature and overall asset health without having EmersonProcess.com/ exchanger problem can cause lost production, reduced to increase manual maintenance checks. Discover abnormal situations or subtle variations such as Chemical margins, overextended maintenance budgets, and Bearing normal Increased wear and tear vibration Reduced unit temperature changes before they cause problems, slowdowns, or shutdowns. recordable incidentsincluding the possibility of a and bearing Cooling reduced throughput R Resonance government audit. frequency temperature Increase Asset Reliability Uncover the root causes behind bad actor equipment. Perform maintenance on your exchangers In a cooling-limited operation, losing one fan can lead Belt/coupling normal wear Belt/coupling Distillation Reportable only when required and in time to prevent failure. Reduce the costs incurred by repeat failures and to a recordable incident if the fan affects a distillation and tear failure fines column Flare Evening news unnecessary preventive maintenance. columns overhead receiver and causes the relief valve over-pressure Rebuild costs relief valve lift to lift. Should the relief valve fail to reseat, then not only Fan blades stop Human impact Mitigate Safety and Environmental Risks will this constitute another recordable incident, but a Dust buildup on tubes or corrosion Exchanger fouling Receive early warning of potential fan failures and resulting safety hazards before they become Air Cooled shutdown will also be required to fix the unseated valve. plant-wide problems. Reduce reportable incidents through early detection. Limit the number Bent louver arm Heat Exchanger Solution Products to of trips into potentially hazardous plant areas for maintenance or data collection related to fan Other factors such as freezing temperatures, dust or Misaligned louver Faulty louver storage tanks Emersons overhead air cooled Vapor release vibration and bearing temperature. oil fouling the heat transfer areas, and an inability to positioner position too hot-tank heat exchanger health monitoring over-pressure cool hot chemicals can cause maintenance woes and Stuck St k llouver solution gives operators greater environmental incidents. These common issues can Ambient b conditions d confidence and control over asset (freezing Freezing within increase costs and make it difficult to meet production temperatures) finned tubes Process leak planning by replacing manual, goals, particularly if a repair requires overtime pay and Increasing your profit periodic reading with automated Replacement of Unit shutdown Increasing monitoring that indicates expedited parts. The situation only becomes worse if ruptured/leaking maintenance Unscheduled shutdowns and slowdowns are a leading cause of lost profit opportunities. What root causes are undetected and repeat failures occur. finned tubes costs assets are contributing to this number at your plant? abnormal operation and allows for alarm, analysis, trending, Undetected Abnormal Avoidable Conditions Situations Consequences INPUT and historization. A utomated Plant capacity in tons per day 1,700 monitoring will allow you to know Plant net margin per ton $200 about and respond to real-time Plant total annual maintenance spend, excluding turnarounds $50,000,000 condition changes such as % of plant total annual maintenance attributable to air cooled heat exchangers 1.5% fluctuations in vibration and % anticipated reduction in air cooled heat exchanger maintenance cost with diagnostics 30% Common Threats to Air Cooled Heat Exchanger Health bearing temperature, which can OPERATIONAL BENEFITS cause exchanger failure, fouling, a. Plant capacity in tons per day 1,700 and damage. Wireless installation BAD INSTALLATION and monitoring r educes your b. Plant net margin per ton $200 Improper installation can lead c. Production capacity lost due to process fan failures 0.2% installation-related costs and to shaft misalignment and Annual Net Profit Improvement (=a x b x c x 365) $248,200 frees personnel from manual excessive vibration, resulting in fan damage and possible failure. trips to hazardous plant areas, MAINTENANCE BENEFITS allowing them to focus their EXCHANGER FOULING d. Annual maintenance budget per air cooled heat exchanger $5,000 energies on other vital areas. Limited cooling is an indication e. Process exchangers not currently monitored 50 of exchanger fouling. This can f. Reduction in average cost to repair if air cooled heat exchangers werent run to failure 10% reduce the cooling capacity Annual Maintenance Cost Reduction (=d x e x f) $225,000 of the exchanger, leading to diminished unit throughput. TOTAL ANNUAL PROFIT IMPROVEMENT $273,200 In addition to other process Notes impacts, fouling can cause This is an example for an olefin plant. products heading to storage tanks to become too hot, Request Information resulting in possible environ- Use our simple online form to mental or health and safety issues. Root causes can include select the options most important dust buildup on tubes or to you. An Emerson specialist corrosion. will contact you shortly.
HIGH VIBRATION AND BEARING TEMPERATURE LOUVER/PITCH ACTUATOR MECHANICAL DEFECTS
Increasing motor or fan vibration and bearing temperature can result in Faulty louver or pitch actuator position can r estrict belt and coupling failure or can cause fan blades to stop. Root causes can airflow and reduce cooling capacity, leading to include bearing normal wear and tear, operation at resonance frequency, and diminished unit throughput. Root causes can include mechanical support failures. broken or bent louver arms, a misaligned louver positioner, and stuck louvers. Scan this code or visit EmersonProcess.com/Chemical