Industry estimates suggest that approximately 5 percent 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’s not unusual for plants to invest in expensive online monitoring systems for only their most critical or expensive pumps,” said Tim Olsen, refining consultant at Emerson Process Management. “The rest may be checked occasionally during technician walkarounds, but as many as two-thirds of essential pumps are ‘running blind’ most of the time – and 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:
- Excessive temperature
- Process leakage
- Seal pot level
- Differential pressure imbalance.
These conditions can independently and jointly bring about pump damage, failure, and several otherwise avoidable consequences.
The integrated solution includes intelligent Rosemount® and CSI instruments that let users continuously monitor for conditions they are most concerned about. 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. And 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.
Emerson is currently offering a special Pump Health Monitoring Starter Kit that makes it even easier to take advantage of the solution’s flexible options, easy configuration, and seamless integration with existing control and asset management networks.
“Detecting and predicting equipment problems while there’s still time to take corrective action can significantly reduce costs and help avoid unplanned slowdowns or shutdowns due to pump failure,” said Olsen. “That’s 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.”