A Pervasive Sensing ™ Strategy Steam Trap Monitoring A Pervasive Sensing ™ Strategy

Overview Steam System Management Challenges Achieving Top Quartile Performance with Pervasive Sensing™ Strategies Real-time Steam Trap Monitoring Proven Results Getting Started

Steam System Management Challenges Poor Steam System Management Affects Operational Efficiency Process Quality and Throughput Water Hammer and Impingement Corrosion and Erosion Energy Loss Increased Emissions Traditional Manual Approach Has Limitations Puts people in hazardous areas Personnel can be better utilized Manual audits are consistently inaccurate “Temperature testing alone can identify leaking or blow-through failures up to 44% of the time.” – Swagelok® Energy Advisors

Steam Affects the Entire Plant Send personnel to the trap only when necessary and better prepared Safety Reliability Energy Process Environment Productivity Prevent damage to equipment caused by water hammer, water impingement, erosion, corrosion, and freezing Take action when failures occur. Don’t wait weeks, months, or years. High value traps can fail open costing $10,000-$100,000/year Focus plant resources on core competencies and less time performing manual steam trap audits Improve yield and product quality by assuring steam quality, resulting in better temperature control and transfer of steam enthalpy Reduce the environmental impact from failed open steam traps, which can waste 50-500 tons of CO2 annually when using natural gas boiler fuel improve personnel safety by reducing water hammer incidents, manual rounds, and foot traffic in higher risk areas improve reliability by reducing damage to equipment caused by water hammer, impingement, corrosion, and freezing improve yield and product quality by assuring temperature control and optimal transfer of steam enthalpy improve energy efficiency by expediently addressing leaks and blow-through failures improve environmental impact by reducing greenhouse gas emissions and water usage improve productivity by allowing plant resources to focus on more critical activities and core competencies

Achieving Top Quartile Performance Pervasive Sensing™ Strategies Reliability Process HSSE Energy See your production through a new lens Non-intrusive Wireless Maintenance Free Analytics based on decades of process experience Information that allows you to predict, respond, and optimize

Now’s the Time Previous Challenges Today’s Solutions INFORMATION COST Cost of data access was high Often immeasurable Complex installations Time consuming and maintenance intensive Information benefit was low Data was raw Required experts to create value Today’s Solutions Innovative sensors Wireless communications Exponential power improvements Non-intrusive installation Advanced analytics Embedded expertise Mobile and location accessibility HIGH Process Safety Reliability HSSE Process Control Energy INFORMATION COST LOW INFORMATION BENEFIT LOW HIGH

Real-Time Steam Trap Monitoring Acoustic & Temperature Sensing Steam Trap Failures SteamLogic™ Analytics

Innovative Sensing Sensor CCA Sensor Cap Acoustic Spring Non-intrusive, application based technology Acoustic = Piezoelectric crystal converts ultrasonic sound to electric charge Temperature = Type T Thermocouple Designed for fast and simple installation and maintenance No training required; no calibration Non-intrusive steel band mounting No downtime or risk to the process Set and forget (10+ year power module) Thermocouple

Pervasive Sensing™ Analytics Platform A single, lightweight, web-based analytics platform for all your Pervasive Sensing™ solutions Applications: Steam Traps Pump Health Heat Exchangers Air-cooled Heat exchangers Cooling Towers Safety Showers Safety Pressure Relief Devices Network Management Energy Management Battery Life Valve Health Hydrocarbon Leak Detection Navigator Mass flow More… Secure. Scalable. Reliable. Open- architecture. Cloud-ready.

Remote Monitoring Service Emerson™ installs and maintains infrastructure Emerson assures service reliability Actionable information provided in customized reports to be integrated into your workflow to optimize personnel and material inventory Monthly service agreement No upfront investment Clear and concise recommended actions For maintenance organization Delivered weekly or within 24 hours of failure Key Performance Indicators (KPIs) Delivered monthly as Executive Summary Complete wireless sensing infrastructure as a service delivers actionable information *Available in North America, Europe, Singapore

Failed?

Failed?

Trap Failure Example – Thermodynamic Disc ~5 Months Failure Detected Failure Verified Normal Operation Beginning Failure Early Stage Failure Advanced Failure

Real-Time Monitoring Can Save Thousands Early Detection & Remediation Thousands of Dollars! Annual Audit Cycle

Capacity Critical Steam Traps Identify Critical Traps Top 20% account for 80% of potential steam loss Located on larger, higher pressure steam lines Protect essential assets Large impact on process should they fail closed Known higher failure rate Inlet Pressure

Realize Energy Savings for 1-2 Year Payback Recommended Practice Start monitoring 5% most valuable Energy loss >$10k/year/failure 15% annual failure rate Realize six months of savings if performing annual audits Example: 100 Critical Steam Traps 15 failures/year >$5k/failure (6-mo savings) >$75k savings/year ROI payback ~1 year

Success Stories Avoid lost batches of tires by assuring proper heat transfer in vulcanization process Specialty chemical company reduced steam usage by 8% ($153k/yr) Assure high quality cigarettes with valuable clean steam Steam jacket froze crushing feedstock line slowed production from 2 to 8 hours $120k in repairs Assure high quality potato chips with valuable clean steam Coffee bean production increased by 5,000 tons/year Biotech company lost 4 heating coils due to condensate freezing $72k in repairs Prevent condensate backup in refinery reboiler for increased throughput $1.2M/yr Refinery experienced steam line rupture from water hammer injuring two & shut down plant for 151 days $1.1B in lost production & lawsuits Prevent perfume line from plugging (steam tracing)

Steam Trap Monitoring… The Start of Your Pervasive Sensing™ Strategy Application Real Time Insight Annual Savings ($M) Implementation Cost ($M) ROI (Months) Relief Valve Monitoring Emissions and leaks $2.4 - $3.2 $ 1.59 6 months Pump Monitoring Cavitation, pump health $0.5 - $0.6 $ 0.55 11 months Heat Exchanger Monitoring Fouling and efficiency $2.7 - $3.6 $ 0.62 3 months Cooling Tower Monitoring Efficiency and health $0.3 - $0.5 $ 0.16 4 months Steam Trap Monitoring Energy waste and water hammer risks $0.4 – $0.6 $ 0.30 7 months Air Cooled Heat Exchanger Monitoring Fan health and fouling $0.9 - $1.1 $ 1.20 13 months Mobile Workforce Startup and turnaround efficiency $1.6 - $2.1 $ 0.40 1 Startup or Turnaround Safety Shower & Eye Wash Monitoring Instant, Trigger indication Per incident $ 0.39 Safety TOTAL $8.8M - $11.7M per year $5.2M one time * based on a 250,000 bpd refinery analysis Per site cost savings are significant. Expand across enterprise to multiply.

Getting Started Past Steam Trap Audit Provide Steam Trap Info 1. Steam Cost 2. Steam Trap Count 3. Line Pressures 4. Line Sizes OR Personalized Economic Value Study 1. Complete ROI and cost-benefit analysis. 3. Prioritize traps by potential steam/energy loss. 2. Estimate energy and emissions savings. 4. Outline trap management plan options. 5. Identify opportunities to improve. Trial 90 days 25 or more traps

Real-time Steam Trap Monitoring for Steam System Optimization A Pervasive Sensing™ Strategy Thank you!