Emerson Case Studies Refinery Saves Over $700,000 with Smart Wireless

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	Refinery Saves Over $700,000 with Smart Wireless Emerson

Refinery Saves Over $700,000 with Smart Wireless

Emerson

Technology Category	Networks & Connectivity - Gateways Sensors - Acoustic Sensors Sensors - Gas Sensors
Applicable Industries	Oil & Gas
Applicable Functions	Process Manufacturing
Use Cases	Machine Condition Monitoring
Challenge	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. Read More
About Customer	One of the largest petroleum refineries in the world. Read More
Customer Name	Undisclosed Read More
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. Read More Log in to view content
Data Collected	Alarms For Automated Applications, Facility Health Status, Fault Detection, Leakage Read More Log in to view content
Contents

Technology Category

Networks & Connectivity - Gateways

Sensors - Acoustic Sensors

Sensors - Gas Sensors

Applicable Industries

Oil & Gas

Applicable Functions

Process Manufacturing

Use Cases

Machine Condition Monitoring

Challenge

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.

About Customer

One of the largest petroleum refineries in the world.

Customer Name

Undisclosed

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

Impact #1	[Process Optimization - Predictive Maintenance] Employee's safety and health are improved by catching and minimizing the hydrogen leakage early.

Impact #1

[Process Optimization - Predictive Maintenance]
Employee's safety and health are improved by catching and minimizing the hydrogen leakage early.

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.

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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Overview

Refinery Saves Over $700,000 with Smart Wireless

Operational Impact

Quantitative Benefit