Embed Size (px)
Citation preview
708 Acoustic
Wireless
Sensors
Engineered Polymer Housing
• Light weight
• Temperature range -40 to 85ºC
• Intrinsically Safe
• Chemical resistant
• Weather-proof
Power Module
701PGNKF
10+ year life at 1 min update
Use for new generation of engineered polymer devices
Internal Antenna
• 200m range
• No extended range
Acoustic Waveguide
Acoustic Sensor
Temperature Sensor
Wireless Acoustic Transmitter
Emerson Confidential
Page 3 0
50
100
150
200
250
300
Co
un
ts
How does it Work? Ultrasonic Acoustic Event Detection
– During event, liquid or gas moves from a high pressure to a low pressure. As it passes through the leak site, a turbulent flow is generated. This turbulence has strong ultrasonic components which can be detected with specialised detection equipment.
Ultrasonic Acoustics can be used to detect leaks on following equipments/system
– Lifted Safety Valves
– Leaking process Valves
– Condensers
– Steam Traps
– ………….
– ………….
Sensor sensitive to a broad range of spectral frequencies
Sensor is calibrated against a white noise with a broad range of frequencies.
– White noise is similar to the background noise that will be typical in these applications.
Sensor is calibrated among different noise level points
– broad range of frequencies, to give different “counts”, or an average
frequency.
Calibration curve is a relative measurement as the actual noise level is dependent on the environment and installation
Alerting
– similar to a discrete device
– looking for a large change in noise level that is made during a leak or release
High Counts Low Counts
Easy To Install
Stainless Steel
Mounting
Bands
Easy, Fast, Flexible to Install
Install without cutting into pipes or modifying valves
Install without special training
Mount devices easily with supplied stainless steel mounting bands
Place devices anywhere
Emerson Confidential
Page 5
Acoustic Transmitter Installation
Emerson Confidential
Slide 6
1 Minute
Relief Valve Steam Header
Relief opening 10 times an
hour
Emerson Confidential
Page 7
Real-Life Issues
“We know that if we don’t take care of our steam traps on some routine basis, after a few years we could have anywhere between 25% and 35% in some failed condition… We would impact our fuel bill by anywhere between 8% and 10% a year.”
– Dan Dvorak, DuPont Engineering Technology
In steam systems that have not been maintained for 3 to 5 years, between 15% to 30% of the installed steam traps may have failed.
– Energy Tips – Steam, U.S. Department of Energy
A large pharmaceutical company recently experienced four plugged traps causing severe hammering and shock waves for hours, resulting in a 6-hour site shut-down and more than €200K in repairs.
– Emerson Process Management customer
Emerson Confidential
Page 8
Overview of Plant
..\..\..\..\Station Management\PR Material\Images for Presentations\MJP_Scans\Image1\TIFF\Image1_5904x4683.tif
Emerson Confidential
Page 9
Key Goals of Using Wireless Technology
Improve Efficiency
Reduce Effluent discharge
Visibility to Potential hidden issues
Flexibility / portability of the measurement
– Rapid re-deployment where necessary
– Ease of configuration/re-configuration
– Low cost of installation
Expandability without additional cabling costs
= INCREASED PROFITABILITY
Emerson Confidential
Page 10
Challenges
Detecting low-volume steam leaks without impinging on the integrity of pressure systems
Detecting Boiler tube failures
Non-intrusive detection of Blockages
Instant visibility of potential issues
Emerson Confidential
Page 11
Real-time Visibility to Critical Steam Traps
Smart Wireless system
Monitor traps throughout their plant, even in remote and hard-to-reach locations
Works with their existing WirelessHART® network
Emerson Confidential
Page 12
HP Superheater Drain Pot / Steam-trap
Impact to Process
Lost steam when running.
Lost pressure when in standby.
Lost nitrogen when shutdown.
Lost revenue.
Approx £1400 every 24 Hours of operation.
Emerson Confidential
Page 13
Mounting Arrangement of LP Drain Pot TX
Emerson Confidential
Page 14
Real-time Visibility to Critical Steam Traps
Know the
state of
each steam
trap
Know what to fix
before you go
Differentiate between trap
and device failure
Emerson Confidential
Page 15
Information to Make Good Decisions
Know where to focus your
attention first to prioritize
your steam traps
Emerson Confidential
Page 16
Boiler Tubes
Failed Boiler tubes can mean difference between running and not running = Thousands of pounds of lost revenue
Emerson Confidential
Page 17
CW Pump Auto Vent
Emerson Confidential
Page 18
CW Pump Auto Vent
Issue
– Vent fails to close if blocked by debris in sea water.
Impact
– Flooding of the CW pit
– disposal as trade effluent.
1 operator is tied up to manually check the valve isn’t leaking for 1hr per shift
Emerson Confidential
Page 19
Other Applications – Other Industries?
Leaking Flare Stack
Blocked Powder flow
Leaking process valves
………
………
………
Chemical
Power
Refining
Paper
Pharma
………
………
Emerson Confidential
Slide 20
Any Questions?
