Plant Services - July 2008 - (Page 32)

Condition Monitoring RELIABILITY Sensors predict their own demise Smart-transmitting sensors installed in real-time process control systems can not only transmit self-diagnostic data, they also can play an important role in multivariable condition-monitoring efforts. The Ingold line of pH and dissolved oxygen sensors from Mettler-Toledo (www.mettlertoledo.com) adds a smart chip in the sensor tip itself, not just the transmitter, and this year went all digital to reduce wiring complexity. As part of a process plant’s distributed control system (DCS), it can send pH and dissolved oxygen data as well as indications of signal quality based on real-time impedance measurements, and comparisons of calibration trends to spot sensor degradation. Some plants, such as wastewater, are likely to use pH sensors in run-to-fail mode. But in a refinery, loss of pH control can damage process pipes; in biotech, off-spec can kill active cells and reduce productivity. The sensor-and-software solution includes a “dynamic life indicator” based on actual conditions, “so you go into a predictive cycle, where the sensor tells you it’s time to recalibrate or replace,” says Roger Goavert, engineering, procurement and construction projects manager with Mettler-Toledo Ingold. CRCIndAnnivAd_x4.875:2 dition-based predictive tracking of its hybrid continuous, batch and discrete paper-making and converting facilities, which include wind power generation. The system can factor multiple runtime, calculated kilowatt usage down to the asset level, and other indicators to compare design specifications or other benchmarks with actual performance data. The system isn’t yet installed, but one demonstration considers two pieces of refrigeration equipment (chillers) (Figure 2). They’re identical except that one uses a different filter, which costs $150 less. Both filters are changed every four months. Running this routine for 18 months might show both chillers to be in top working condition when viewed from a traditional maintenance mode, and the less-expensive part would prevail. 1/23/08 2:50 PM Page 2 But, by monitoring energy use, the demonstration shows that the asset with the more expensive filter is running at nearpeak efficiency, while the asset with the less-expensive filter degrades to 60% efficiency. Instead of saving roughly $400 annually with a less-expensive filter, the maintenance department finds that the higher-priced filter can save them nearly $5,000 in reduced energy costs. These benefits point to the great potential for real-time CBM, and how CMMS/EAM system designers are beginning to capitalize on it. Math in the middle ARC’s Chin names Ivara (www.ivara.com), Meridium (www. meridium.com) and SmartSignal (www.smartsignal.com) as After 50 years, our performance still shines. Thank you for making CRC the brand of choice for industrial maintenance chemicals. As a trusted leader since 1958, we are proud to have reached this milestone by constantly innovating, leading and listening. We always remember that our customers are crucial to our success. We appreciate your trust in us and in our products. CRC Industries, Inc. 885 Louis Drive Warminster, PA 18974 (800) 272-4620 www.crcindustries.com A WORLD OF SOLUTIONS SINCE 1958 32 www.PLANTSERVICES.com July 2008 http://www.mettlertoledo.com http://www.meridium.com http://www.meridium.com http://www.smartsignal.com http://www.crcindustries.com http://www.crcindustries.com http://www.PLANTSERVICES.com

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Plant Services - July 2008

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