Maximize Reliability and Reduce Maintenance Costs Blower Health Monitoring

Maximize Reliability and Reduce Maintenance Costs Blower Health Monitoring
Maximize Reliability and Reduce Maintenance Costs
Blower Health Monitoring
Want to stop being blindsided by blower failure?
Industry-wide estimates show that 48 percent of unplanned
downtime occurs due to equipment failure. Small variations
and changes that prompt sudden shutdowns and repairs
often blindside operations personnel, but missed availability,
production targets and rising maintenance budgets always
get noticed. The cost of downtime and repair are often
not considered when automated monitoring for blowers
is deemed cost prohibitive.
Many developing equipment issues—which often go
­unnoticed during manual spot checks—can be prevented or
mitigated with automated monitoring that provides timely
information about abnormal operation and imminent failure.
Cost and other barriers that prevented plants from using
continuous monitoring have fallen, making continuous
monitoring more of a possibility and also more cost effective.
Equipment
Impact
Bad/loose support
Environmental
Impact
Fired heater/
boiler trip
Cracked
C
k d foundation
f
d i
Normall wear
N
and tear
Process
Impact
Increased vibration
and bearing
temperature
Business
Impact
Unit slowdown/
shutdown
Forced
Draft Fan
Root Cause
Piping
p g stress
Belt/coupling
failure
Fan/blower trip
Induced
draft fan
Resonance
frequency
Claus
blower
Many plants typically provide online monitoring and
­protection for critical rotating equipment, but only
­manually monitor less critical equipment like blowers.
Blowers can still have an adverse impact on the plant;
for example, a forced-draft blower on a fired heater
can cause units to slowdown or shutdown, creating
production issues and piling up ­expenses.
Anatomy of Blower Failure
Bent louver arm
Stuck louver
Faulty louver
position
Broken linkage
FCC
blower
Every plant is trying to prevent unplanned downtime.
Whether the cause is equipment failure or recurring “bad
actors”, unplanned downtime adds up to an estimated
five percent of lost production.
Increased
energy cost
Fired heater/
boiler heat
limited
Reduced
sulfur
recovery
No catalyst
regeneration
Reduced unit
throughput
SOx emissions
If long term
Reportable
incident & fines
Severe reduction on
gasoline production
Bent louver arm
Trash in
suction grate
g
Restricted air flow
Plugged
suction strainer
Undetected
Conditions
Heater turndown
to match
available air
Abnormal
Situations
Avoidable
Consequences
Common Threats to Forced-Draft Blower Health
BAD INSTALLATION
Improper installation can lead to
shaft misalignment and excessive
vibration, causing blower
damage and possible failure.
BLOWER MALFUNCTION
Low discharge pressure indicates
a problem with the blower itself.
It could be dust buildup on the
blades or the fan running at a
lower speed than designed. This
will lead to low flow and reduced
capacity.
LOUVER MECHANICAL
DEFECTS
Faulty louver position can result
in restricted air flow, which causes
reduction in heater capacity.
Root causes include bent or
broken louver arm, stuck louver,
or broken linkage.
HIGH VIBRATION AND BEARING TEMPERATURE
RESTRICTION
Increasing motor or fan vibration and bearing temperature
can result in belt and coupling failure leading forced-draft
blowers to trip, which can cause unit shutdowns, increased
energy costs, reduced throughput, and environmental
issues. Root causes include bad support of frame, piping
stress, cracked foundations, and normal wear and tear.
Low suction pressure is an indication of restriction in the inlet air ducts. This
could be caused by trash in the grates, a plugged suction strainer, or faulty
louver positions. Inlet restrictions will lead to reduced air flow which potentially
causes a reduction in the available heater capacity and can even result in a
blower tripping, leading to unit shutdowns, increased energy costs, reduced
throughput, and environmental issues such as flaring.
What if you could foresee a blower’s breakdown before it actually fails
and creates ripples across the plant?
Equipment failure can interrupt an efficient and effective operation, eroding profit margins and
potentially a safety record in the process. It’s not the cost of equipment repair itself that creates
the problem. It’s the unplanned downtime where minutes, hours and days become missed
production goals, lost profit, and an inability to meet contract commitments.
Get Started Today at
EmersonProcess.com/
Blowers
Reduce unplanned shutdowns
Minimize unplanned shutdowns and slowdowns by using Emerson’s automated solutions to put
your most inexperienced operators on par with your best and by automatically comparing current
conditions to your baseline. Personnel—experienced or not—can make an intelligent call about a
­developing situation before it becomes more serious.
Get more from your maintenance budget
Reactive maintenance, such as repairing failed equipment, is estimated to cost up to 50 percent
more than preventive maintenance which could have stopped the failure from happening in the
first place. With up-to-date, online health information on your blowers, you can use maintenance
to ­prevent failure, track alert data to analyze “bad actors”, and determine root causes to improve
asset reliability.
Protect your people and lower environmental risks
Your personnel and your equipment need quality care. Reduce risk by minimizing time in
hazardous areas with Emerson’s automated and wireless solutions. By providing your personnel
with timely i­ nformation on impending problems, you’re allowing them to avoid the equipment
failure and ­potential safety hazards that accompany emergency shutdowns.
Protecting your profit
Industry experts suggest that blower failure and shutdowns are responsible for 0.25% of lost
production capacity. Care to get that back?
INPUT
Refinery capacity in barrels per day
Refinery net margin per barrel refined
Refinery total annual maintenance spend, excluding turnarounds
% of refinery total annual maintenance attributable to process blowers
% anticipated reduction in process blower lost production capacity with diagnostics
% anticipated reduction in process blower maintenance cost with diagnostics
OPERATIONAL BENEFITS
a. Refinery capacity in barrels per day
b.Net margin per barrel
c. Production capacity lost due to process blower failures
d.Reduction in lost production with blower monitoring
e. Operating time in days per year
Annual Net Profit Improvement (=a x b x c x d x e)
MAINTENANCE BENEFITS
f. Annual maintenance budget per blower
g.Process blowers not currently monitored
h.Reduction in average cost to repair if blowers weren’t run to failure
Annual Maintenance Cost Reduction (=f x g x h)
TOTAL ANNUAL PROFIT IMPROVEMENT
Blowers Solution
Emerson’s Blower Monitoring
­integrated solution allows you to
avoid unit slowdowns, shutdowns
and potential safety incidents by
giving you the ability to wirelessly
monitor and detect deteriorating
conditions before a unit trip o
­ ccurs.
Automated, online measurements
and alerts provide you with
­confidence that changes will not
be missed, as could occur with
infrequent or periodic manual
readings. Wireless deployment
saves time and costs from the
headaches of wiring diagrams
and complex installations, and
reduces costs from engineering,
labor, trenching and scaffolding.
250,000
$5
$50,000,000
0.18%
30%
30%
250,000
$5
0.25%
30%
365
$342,188
Request Information
Use our simple online form to
select the options most important
to you. An Emerson specialist will
contact you shortly.
$7,500
12
30%
$27,000
$369,188
Scan this code or visit
EmersonProcess.com/
Blowers
Emerson’s Blower Monitoring Products
SOFTWARE INTERFACE
AMS SUITE: ASSET GRAPHICS FOR OPERATIONS
Provides real-time graphical displays that indicate abnormal operation, including low differential pressure, resonance frequency detection,
louver defects, plugged suction filter and overall blower health. A pre-engineered algorithm delivers diagnostic information for alarms,
process analysis, trending, historization, and key performance indicators.
NETWORK INTERFACE
DEVICES
SMART WIRELESS GATEWAY
Connects IEC 62591 (WirelessHART®)
self-organizing ­networks with any host system.
CSI WIRELESS VIBRATION TRANSMITTER
Provides early warning of excessive vibration in blowers.
Helps determine root cause and corrective action. Optional
functionality can identify premature bearing wear and predict
failure.
ADDITIONAL OPTIONS
FISHER WIRELESS
POSITION MONITOR
Indicates equipment position
with a percent of span plus on/off
indication. Monitors louver position
for mechanical defect detection.
AMS SUITE FOR MAINTENANCE
Aids early identification of asset problems
using predictive diagnostics, allowing
maintenance to schedule repairs while
reducing cost and downtime.
ROSEMOUNT WIRELESS
PRESSURE TRANSMITTER
Enables pressure measurements, to
monitor blower suction,discharge
and differential pressures and
optimize blower performance.
Provides early warning of impending
plugged suction filter.
ROSEMOUNT WIRELESS
DP FLOWMETER
Provides high performance flow
measurements to give valuable
insight into blower operation.
Decreases in gas flow can be caused
by restrictions on inlet ducts.
ROSEMOUNT WIRELESS TEMPERATURE TRANSMITTER
Enables temperature measurements to monitor blower suction,
discharge temperature limits, and optimize blower performance.
©2015 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
1100 W. Louis Henna Blvd.
Building One
Round Rock, Texas 78681-7430
www.EmersonProcess.com
D352132X012 / Printed in USA / 2-15
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