Reference Manual

Emerson’s Smart Wireless Technology Saves Plant €

¤160,000 Euros in Downtime and Maintenance

RESULTS

•Preventedproductionlossesof¤150,000Euros

•Reducedneedtoreplacepumpseverysixmonths

atacostof¤10,000Euros

APPLICATION

Gas-cleaningtowerwithafeedwaterinlet/outletsystem.

CUSTOMER

ChemicalplantinEurope.

Theplantproducestitaniumdioxidetoenhancethewhiteness,

brightness,opacity,anddurabilityofpaints,coatings,plastics,and

otherconsumerproducts.

CHALLENGE

Plantpersonneloperatedthegascleaningtowerwithanoverlldrain

thatonlydumpedwhenthevesselbecamefullofwaterandsand

settledtothebottom.Thewaterwouldbedisplaced,loseproper

dilution,andcleaningefciencywoulddrop,allowingunknownlevels

ofhydrochloricacidtobereleasedtotheatmosphere.Thesand

buildupwouldalsoerodeceramiccomponentsofthecirculating

pump,causinginternalleaksandcompletefailure.Bi-weekly

maintenancetocleanthevesselprovidedminimalimprovementto

cleaningefciency.And,theteamstillhadtoreplacethecirculating

pumpeverysixmonthstopreventaplantshutdown.Processshut

downforonedayforpumpreplacementisestimatedataproduction

lossof¤150,000Euros($194,000USD)and¤10,000Euros($12,886

USD)forpumpreplacement.

Emersonengineerslearnedaboutthegas-cleaningtowerchallenge

andrecommendedtheinstallationofanewdrainvalvewirelessly

controlledusingaSmartWirelesssolutionpoweredbyWirelessHART™

technology.

SOLUTION

Theapplicationrequiredtheinstallationofanewdrainvalveat

thebottomofthecleaningvesselsothatwaterandsandcouldbe

automatedtoushonanas-neededbasis.Todeterminewhenthe

vesselwasfullandreadytobedrained,aRosemount

2160Wireless

VibratingForkLiquidLevelSwitchdetectedwhenwaterlevelsreached

overllconditions.TheDeltaV™controlsystemwouldthensend

CHEMICAL

The ﬁrst use of WirelessHART

devices has virtually eliminated

downtime in this process and

improved the efﬁciency of the

gas-cleaning tower.

PAGE 1
CHEMICAL Emerson’s Smart Wireless Technology Saves Plant € ¤160,000 Euros in Downtime and Maintenance RESULTS • Prevented production losses of ¤150,000 Euros • Reduced need to replace pumps every six months at a cost of ¤10,000 Euros APPLICATION Gas-cleaning tower with a feedwater inlet/outlet system. CUSTOMER Chemical plant in Europe. The plant produces titanium dioxide to enhance the whiteness, brightness, opacity, and durability of paints, coatings, plastics, and other consumer products.
PAGE 2
CHEMICAL a wireless “open” command to the Fisher® 4320 Wireless Position Monitor with On/Off Output Control Option to open the turn drain valve. After 30 seconds, the DeltaV control system would send the “close” command to complete the draining cycle. RESULT Implemented in December 2011, the project has proven to be a positive change for the plant. The first use of WirelessHART devices has virtually eliminated downtime in this process and improved the efficiency of the gas-cleaning tower.