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Refinery Saves Over $700,000 with Smart Wireless

One of the largest petroleum refineries in the world is equipped to refine various types of crude oil and manufacture various grades of fuel from motor gasoline to Aviation Turbine Fuel. Due to wear and tear, eight hydrogen valves in each refinery were leaking, and each cost $1800 per ton of hydrogen vented. The plant also had leakage on nearly 30 flare control hydrocarbon valves. The refinery wanted a continuous, online monitoring system that could catch leaks early, minimize hydrogen and hydrocarbon production losses, and improve safety for maintenance.

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  • SUPPLIER
  • Emerson
    Emerson is a diversified global manufacturing company that brings technology and engineering together to provide innovative solutions to customers in the industrial, commercial and consumer markets through its Process Management, Industrial Automation, Network Power, Climate Technologies, and Commercial & Residential Solutions businesses. ​Year founded: 1890Revenue: $24.5 billion (2014)NYSE: EMR
  • INDUSTRIES
  • Energy
  • FUNCTIONS
  • Maintenance
  • CONNECTIVITY PROTOCOLS
  • USE CASES
  • Machine Condition Monitoring
    Machine condition monitoring is the process of monitoring parameters such as vibration and temperature in order to identify changes that indicate a reduction in performance or impending fault. It is a necessary component of Predictive Maintenance solutions and allows maintenance to be scheduled prior to failure, or other actions to be taken to prevent damages to the machine and loss of production. Condition monitoring also provides value beyond improving maintenance schedules. For example, improved visibility into machine operations can indicate the root causes of product defects and can support optimization of energy consumption.
  • CUSTOMER
  • One of the largest petroleum refineries in the world.

  • SOLUTION
  • Emerson installed 94 Wireless Acoustic Transmitters and 2 Wireless Gateways with one gateway and 47 transmitters in each refinery. 26 acoustic transmitters were installed upstream of the vent and flare valves. Total 22 transmitters were installed upstream of PRVs in the hydrogen unit. The alarms and health indications from the continuous online acoustic monitoring network enabled the refinery to initiate corrective actions when leakage occurred.

  • DATA COLLECTED
  • Alarms For Automated Applications, Facility Health Status, Fault Detection, Leakage
  • SOLUTION TYPE
  • SOLUTION MATURITY
  • Cutting Edge (technology has been on the market for < 2 years)
  • OPERATIONAL IMPACT
  • Impact #1
    [Process Optimization - Predictive Maintenance]
    Employee's safety and health are improved by catching and minimizing the hydrogen leakage early.
    Impact #2
    Impact #3
  • QUANTITATIVE BENEFIT
  • Benefit #1

    The plant has improved revenue by more than $700,000, and is now looking at online acoustic monitoring for some of the 40,000 steam traps in their refineries.

    Benefit #2

    The plant saved $500,000 in lost hydrogen from leaking vent valves and PRVs.

    Benefit #3

    The plant saved $200,000 in lost hydrocarbons from leaking flare valves.

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