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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.

2014 Emerson Process Management. All rights reserved.


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.
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