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Installs on any machine within seconds Immediate feedback through visual Monitor remotely and wirelessly, to
1 through a magnetic connection. 2 fault-detecting indicators. 3 mirror notifications and record data.
IMPORTANCE OF CHEMICAL INDUSTRY
✔Refining is the first process in most of the chemical plants and mandatory in Food,
Pharmaceutical, and Petrochemical industry.
✔A refinery is a plant in which crude oil is transformed and refined into useful products such
as petroleum naphtha, gasoline, diesel fuel, asphalt base, heating oil, kerosene, LPG, jet
fuel, and fuel oils.
✔90% of refineries perform Predictive Maintenance (cleaning heat exchangers, servicing and
maintenance of exhaust fans).
✔Breakdown in a refinery invites at least 21 days of production loss and repairs and spares
amounting to USD 350,000.
✔Generally, Extractors with different types of rollers (Cylindrical, Spherical, Taper Rollers)
are used to extract one constituent from a solid or liquid by using a liquid solvent.
✔Bearings are monitored for typical defects (Imbalance, misalignment, and looseness).
✔Ores are normally crushed into finely ground tailings and the target minerals are extracted
using crushers (powered by motors).
✔Sometimes Smelting, a process of applying heat to ores to extract a base metal is used.
Motor-driven heaters or fan heaters are used in this process.
CHEMICAL INJECTION
Polluted water, impure (less concentrated) chemicals damage the equipment (pipes,
pumps, and seals) and hence filtration is essential.
Typically filtering media like filter papers, filter-bags, filter-drums, sieves, belt filters,
rotary vacuum filters, filter presses and pressure (vacuum) filters are used.
Filter–bags powered by motor measure the concentration of the pure air in the plant.
Vibrations on the sieves are monitored to ensure the size of granules in the solidified
chemicals. As the size of the granules increases, vibrations decrease.
FILTRATION
Belt filters are used for dewatering of sludge and slurry and wastewater treatment.
A rotary drum filter is designed for the separation of solids from liquids using pressure
or partial vacuum. Compressors are generally monitored as they are used to generate
vacuum.
The filter presses are operated by compressing several filter plates together through a
tube down the center of the plates. For maximum filtrate recovery, the air is blown at
high pressures through the filter press with the help of a blower or exhaust fan. Filter
presses are used in the chemical manufacturing, pharmaceutical, and oil industries.
Vacuum filters operate continuously. contain a conveyor belt to move filter media from a
roll through the machine. The belt is usually powered by a motor and needs monitoring as
it is usually an automatic process and the user needs only replace the roll of filter media
to continue the process.
COOLING TOWERS
Cooling towers are specialized heat exchangers that cool down water heated up by industrial equipment and
processes. In a chemical plant they are huge (at least 6 feet tall and 330ft in diameters) making them difficult
to monitor.
Catastrophic failure of a cooling tower can bring serious consequences to plant business operations, such as
failure of other equipment, safety hazards, downtime, lost production revenue, expensive repairs, and
health issues.
Common causes of failure in cooling tower components can often be linked to either the misalignment or
imbalance of components (motor (60%), the gearbox (30%), the fan (2%), others (8%)).
The failures of a motor can be caused by motor imbalance, rotor bar defects, output shaft alignment, bearing
defects, and improper bolting to foundations.
Because of the force applied to bearings in a cooling tower, defects often progress quickly and lead to
friction, bearing damage, and gearbox failure.
The structure of a cooling tower makes collecting vibration data on the gearbox difficult and dangerous
without permanently installed vibration sensors.
Gearbox failure causes include the result of stress that the gearbox experiences from being in the airflow of
the cooling tower, misalignment of the gear with the motor, added stress to the gear teeth, and bearing
failures.
COOLING TOWERS
A double cone blender has low maintenance, costs Rs. 1 Lakhs per kg
and has the capability of blending dry powders. It has stainless steel
blades governed by the motor that moves the blades.
DRYING
Rotary dryers, drum dryers, kiln dryers, flash dryers, tunnel dryers,
fluid-bed dryers, spray dryers, tray dryers are the various types of
dryers used in chemical industries.
Tray dryers are hot chambers with fans that blow hot air. The moist
air is extracted and replaced by a pipe with hot air, used to dry the
ingredients poured in the tray. If the fans are not monitored the
proportion of moist air in the chamber increases causing the decay of
the ingredients.
25% of the piping failures, 14% of breakdown of reactors and storage tanks,
10% Leakages issues of process vessels and about 51% of the equipment failure
contribute to the shutdown of the chemical plant. Hence monitoring the
equipment is crucial.
Blowers are used in production process to clean the acids and residues obtained
in the manufacturing of chemicals. High pressure of the blower can cause
excessive contamination and fluttering of chemicals and explosive reactions
causing fatal accidents.
Heavy materials like Mercury, Nickel, Cobalt get accumulated in the pipes
blocking and corroding the pipes and pumps. Hence, they need to be
monitored.
Condition monitoring of an equipment sequentially ensures the streamlining of a chemical process. Multiple chemical processes
safeguard operation of the Chemical plant. However, Sometimes equipment are over-maintained.
HOW DOES IDE WORK?
CASE STUDY
MONITORING FD FAN IN A COOLING TOWER PRESERVES
THE CIRCULATION OF COOLING WATER; AND SAVES USD 17 THOUSAND
THE NEED
per
Refining of petroleum cannot take place without cooling towers. day.
The loss of cooling water circulation within a refinery can lead to
unstable and dangerous operating conditions requiring an immediate shut down of processing units. The efficiency and production rate
of a cooling tower is heavily dependent upon the efficiency of the fan and the fan drive system. An efficient and reliable fan drive system
is required to maintain a relatively high cooling efficiency and prevent interruptions in production. Hence monitoring the fan to ensure
its efficient working subsequently resulting in coherent purification of petroleum is extremely essential.
IDE DEPLOYMENT
The main function of the large FD fan is to provide ambient air. Drive systems are used to drive and rotate the fans. The fan is enclosed
within a fan cylinder that is located on the fan deck of the cooling tower. IDE was installed on the fan bearing to monitor its operation. At
the instance of installation, vibrations on the bearing and acoustics were captured and under normal operating conditions threshold
limits for vibrations and noise were set. Any deviation from the threshold generated an alarm and also sent a notification in the form of
SMS and email to registered authorities.
IDE OUTCOME
After 45 days, the IDE detected a rise in the vibrations. The trend was analyzed. Subsequently, alarms were generated and notification
was sent to the registered maintenance team through SMS and emails.
The notification invoked a physical inspection of the fan.
The duty cycle required of the fan drive system in a cooling tower environment was extreme due to intense humidity and corrosive
water treatment chemicals. These chemicals were noticed in the form of fine depositions on the blades resulting in unbalance.
CASE STUDY
MONITORING FD FAN IN A COOLING TOWER PRESERVES
THE CIRCULATION OF COOLING WATER; AND SAVES USD 17 THOUSAND
per day. A remedial action of cleaning the deposition
balanced the fan and the vibrations
Rise in vibrations normalized.