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

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

3. 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

4. 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 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

5. 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

6. 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

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

8. 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

9. 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.

10. 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

11. Failed?

12. Failed?

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

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

15. 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

16. 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

17. 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)

18. 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.

19. 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

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