Reduce Shutdowns and Fulll Production Goals

Compressor Health Monitoring

Keep compressors from causing unplanned downtime
Cost has long been the main barrier to installing
automated monitoring on essential (non-critical)
compressors. This continues to be the case despite
the many times a compressor failure caused missed
production targets and repairs led to costs that
outweighed the expense of automated monitoring.
Compressor failure accounts for 0.6 percent of all lost
production. Many essential compressors go unmonitored,
but the fact that power consumption alone represents 65
percent of compressed air costs in plants shows that there
are opportunities for savings from automation.
A seemingly insignicant essential compressor failure can
become a costly environmental incident. Hydrocarbon
vapor releases or an unforeseen leak not only cost your
staff time with paperwork and meetings, but it could also
put you on the evening news.
What often plays out in plants is that the pressure of
emergencies can overwhelm even the most skilled
operatorassuming they arent already overextended
amid short stafngand then cause more damage,
compelling operations to ask why couldnt this have
been prevented before we even had to go x it?
Anatomy of Compressor Failure
Common Threats to Compressor Health
Root Cause
Equipment
Impact
Process
Impact
Environmental
Impact
Business
Impact
Undetected
Conditions
Avoidable
Consequences
Abnormal
Situations
Leaks
Toxic release/fires
Flaring
Reportables
incidents
Fines
Evening news
Rebuild costs
Health/safety
issues
Excess vibration
Compressor trip
Seal failure
Compressor
mechanical
damage
Shaft misalignment
Cracked shaft
Coupling failure p g
Resonance
frequency
Low suction
pressure
Surge
Compressor
instability
Fluctuations of
flow and pressure
Unit slowdown/
shutdown
Reduced unit
throughput
Increased
maintenance costs
Blade fouling
Mispositioned
control vane
Restriction in
suction or discharge
Sudden load change Suddenloadchange
Significant changes
in gas composition
g
Instrument/control
malfunction
Bl d f li
Bearing oil
leak/failure
Bearing failure
Blade imbalance
RESTRICTIONS
Restrictions on the compressors suction or discharge
lead to low suction pressure which can result in
compressor surge. Root causes include a plugged
suction lter, control valve issues, or a poorly
positioned control vane.
HYDROCARBON VAPOR RELEASES
Process gas seal failure can be caused by excessive vibration resulting in possible
aring, toxic releases, and res leading to reportable incidents and nes.
LUBE OIL LEAK/FAILURE
Inadequate lubrication can result in bearing failure, which causes excessive
vibration and leads to mechanical damage of the compressor.
FLUCTUATIONS IN GAS FLOW
Fluctuations in gas ow and pressure result
in instability that can lead to surge, causing
mechanical damage and/or compressor
trip. Root causes include instrumentation
malfunction and sudden changes in gas
composition and compressor load.
TEMPERATURE RISK
Temperature spikes can result in damaged compressor
internals and seal failure.
SURGE
Surge occurs when ow in the compressor is
too low in relation to its speed. Sudden changes
in composition, ow, or suction pressure can
trigger surge, which, if uncontrolled, could
cause catastrophic consequences.
HIGH VIBRATION
Increasing vibration indicates blade,
bearing, shaft, or coupling issues that can
lead to compressor failure and a potential
unit shutdown. This reduces throughput,
increases maintenance costs, and generates
environmental issues. Root causes include blade
fouling, lubrication and coupling failure, shaft
misalignment, or operating near resonance
frequency.
What if a compressor didnt fail unexpectedly and didnt mean lost
production and sudden, costly repairs?
With the proper insight that comes with automated monitoring, you can reduce unplanned
slowdowns and shutdowns, along with the lost production and frustrations that accompany dealing
with the unexpected.
Reduce Unplanned Shutdowns
Automated and trendable asset health data will allow your reliability engineer to run root-cause and
failure analysis. If compressor failure is approaching, there may be time to perform life-extending
repairs. If repairs arent enough, operations can at least anticipate production changes and prepare
a timely and effective response.
Increase Asset Reliability
Increasing asset reliability does not have to be an unachievable goal. With early warnings and
algorithms that detect when a compressor operates outside of required operating parameters, your
maintenance staff will know when a compressor is not operating the way it should be. Your operator
can then make preventive adjustments before the asset falls prey to a bad actor and becomes an
unreliable piece of equipment that keeps you from required production.
Mitigate Safety and Environmental Risk
Imagine that your operators had sufcient warning prior to abnormal operation or imminent failure
of a compressor. An operator could then perform a controlled shutdown or switch to a backup
compressor, if available. A controlled shutdown reduces your plants exposure to environmental
and safety risks, and takes the control and puts it into your operators hands. An effective controlled
shutdown starts with timely and accurate information, which Emersons automated monitoring
provides.
Protecting your prot
Industry experts suggest that compressor failure and shutdowns are responsible for 0.6 percent of
production capacity loss. Care to get that back?
INPUT
Renery capacity in barrels per day 250,000
Renery net margin per barrel rened $5
Renery total annual maintenance spend, excluding turnarounds $50,000,000
Renery total annual maintenance attributable to compressors 8%
Anticipated reduction in compressor maintenance cost with diagnostics 20%
Anticipated reduction in lost production with compressor monitoring 30%
OPERATIONAL BENEFITS
a. Renery capacity in barrels per day 250,000
b. Renery net margin per barrel dened $5
c. Production capacity lost due to compressor failures 0.6%
d. Reduction in lost production with compressor monitoring 30%
Annual Net Prot Improvement (=a x b x c x 365 x d) $821,250
MAINTENANCE BENEFITS
e. Annual maintenance budget $50,000,000
f. Renery total annual maintenance (e.) attributable to compressors 8%
g. Reduction in average cost to repair if compressors didnt fail unexpectedly 20%
Annual Maintenance Cost Reduction (=e x f x g) $800,000
TOTAL ANNUAL PROFIT IMPROVEMENT $1,621,250
Value calculation notes
The 0.6 percent production capacity loss is based on all compressors (critical and essential)
Percent of planned capacity loss; assume renery can sell recovered capacity
Compressor maintenance budget excludes turnarounds
Cost avoidance of more severe damage versus just beginning to fail
Straight-time work versus overtime
Cost avoidance of doing too much maintenance when not required to ensure reliability (preventive maintenance resulting in no problem found)
Get Started Today at
EmersonProcess.com/
Compressors
Compressors
Emersons integrated solutions
for compressor monitoring
allows your operators and
engineers to detect conditions
that can cause compressor
failure. With that knowledge,
you can prevent potentially
dangerous situations. Integration
means that not only will there
be fewer installation headaches,
but also much less confusion
in using and maintaining
equipment. The clarity will
allow personnel to focus their
attention on the key priorities
of increasing efciency, asset
planning, stopping unplanned
shutdowns, and reducing the
risk of environmental and safety
incidents.
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Compressors
Emerson Compressor Monitoring Products
Emerson Process Management
1100 W. Louis Henna Blvd.
Building One
Round Rock, Texas 78681-7430
www.EmersonProcess.com
2012 Emerson Process Management. All rights reserved.
The Emerson logo is a trademark and service mark of Emerson Electric Co. Rosemount is a mark of one of the
Emerson Process Management family of companies. All other marks are the property of their respective owners.
The contents of this publication are presented for information purposes only, and while effort has been made
to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding
the products or services described herein or their use or applicability. All sales are governed by our terms and
conditions, which are available on request. We reserve the right to modify or improve the designs or specications
of our products at any time without notice.
D352133X012 / Printed in USA / 12-12
SOFTWARE INTERFACE
NETWORK INTERFACE
DEVICES
AMS SUITE: ASSET GRAPHICS FOR OPERATIONS
Provides online graphical displays that indicate abnormal operation, including compressor instability, control vane defect, low differential
pressure, high differential temperature, plugged suction lter, and overall compressor health. A pre-engineered algorithm delivers
diagnostic information for alarms, process analysis, trending, historization, and key performance indicators.
SMART WIRELESS GATEWAY
Connects IEC 62591 (WirelessHART

) self-organizing
networks with any host system.
ADDITIONAL OPTIONS
AMS SUITE FOR MAINTENANCE
Aids early identication of asset problems using
predictive diagnostics, allowing maintenance to
schedule repairs while reducing cost and downtime.
FISHER WIRELESS POSITION MONITOR
Indicates equipment position with a percent of
span plus on/off indication. Monitors position of
mechanical control vanes for mechanical defect
detection.
ROSEMOUNT GUIDED WAVE RADAR with
Smart Wireless THUM Adapter/Wireless
Vibrating Fork Level Switches
Enables level measurements to monitor lube oil tank
level on compressors. Guided Wave is a suitable
technology for continuous level monitoring. For high/
low level indications, vibrating fork switches may be
more suitable.
MICRO MOTION
GAS SPECIFIC GRAVITY METER
Provides gas molecular weight measurement
for detection of instability conditions. Responds
quickly and dynamically to process changes,
with self compensation for gas composition and
compressibility variations, reducing uctuations in
measured gas ow.
SMART WIRELESS THUM ADAPTER
Allows devices compliant with Hart 5 (and later
revisions) to wirelessly transmit measurement and
diagnostic data that was previously unavailable.
ROSEMOUNT WIRELESS
TEMPERATURE TRANSMITTER
Enables temperature measurements to monitor
compressor suction and discharge temperature limits
and optimize compressor performance.
CSI WIRELESS VIBRATION TRANSMITTER
Provides early warning of excessive vibration in
compressors. Helps determine root cause and guides
corrective action. Optional functionality can identify
premature bearing wear and predict failure.
ROSEMOUNT WIRELESS
PRESSURE TRANSMITTER
Detects compressor instability conditions from a
statistical analysis of discharge and suction pressure.
Provides early warning of plugged suction lter and
enables monitoring of lube oil pressure.
ROSEMOUNT WIRELESS DP FLOWMETER
Provides high performance ow measurements, to
give valuable insight into compressor operation.
Signicant increases in gas ow can indicate
compressor instability problems.