Industry estimates suggest that approximately 5% of production capacity is lost each year to unplanned downtime, much of it caused by equipment failure. Emerson Process Management’s new integrated Pump Health Monitoring solution enables users to detect and predict problems, greatly reducing the risk of unexpected pump failures that can cause lost production and expensive repairs, as well as safety and environmental incidents.
“It is not unusual for plants to invest in expensive online monitoring systems only for their most critical or expensive pumps,” says Tim Olsen, refining consultant at Emerson Process Management. “The rest may be checked occasionally during technician walkabouts, but as many as two-thirds of essential pumps are ‘running blind’ most of the time, at risk of problems that can lead to unexpected downtime, leaks, fires, or other situations that threaten safety and profitability.”
Emerson’s scalable Pump Health Monitoring solution can detect several conditions, including:
* Cavitation.
* Excessive temperature.
* Vibration.
* Process leakage.
* Differential pressure imbalance.
These conditions can independently or jointly bring about pump damage, failure, and several otherwise avoidable consequences.
The integrated solution includes intelligent Rosemount and CSI instruments that let users monitor continuously for conditions that are of most concern. A user-friendly asset management interface gives maintenance technicians, operators and managers an at-a-glance view of all conditions with alerts for situations requiring attention. Smart Wireless technology makes implementing the solution easy and affordable, even on existing pumps, without expensive engineering, trenching, and cabling that discouraged more-extensive monitoring in the past.
“Detecting and predicting equipment problems while there is still time to take corrective action can significantly reduce costs and help avoid slowdowns or shutdowns due to pump failure,” says Olsen. “That is why the Pump Health Monitoring solution is only the first of several asset-monitoring packages we are developing to help users improve the safety, reliability and profitability of their operations.”
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