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 The contents of this publication are presented for information purposes only, and while effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our terms and conditions, which are available on request. We reserve the right to modify or improve the designs or specifications of our products at any time without notice.
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