Monitoring Software enhances heat exchanger performance.

Press Release Summary:

As pre-engineered, integrated solution, Heat Exchanger Monitoring Solution embeds process and exchanger best practices into software using wired and wireless instrument applications for automated, 24/7 monitoring. Maintenance personnel can schedule optimal time to clean to sustain optimal heat transfer, helping facilities reduce energy and capacity loss due to fouling by up to 10%. Also, additional emissions from heater operation are avoided due to improved heat recovery in process.

Original Press Release:

Emerson Introduces Pre-Engineered Heat Exchanger Monitoring Solution That Significantly Enhances Operations Performance and Decreases Energy Costs

New integrated application solution detects accelerated fouling and identifies best cleaning time to optimize facility’s energy usage, capacity, maintenance cost, carbon footprint, and safety

AUSTIN, TEXAS -- Emerson Process Management has announced the release of an integrated Heat Exchanger Monitoring Solution. The solution is part of Emerson’s new suite of Essential Asset Monitoring applications. The pre-engineered heat exchanger solution embeds process and exchanger best practices into software using existing wired and new wireless instrument applications for cost-effective automated 24/7 monitoring enabling operations improvements and reduced energy costs.

Emerson’s Heat Exchanger Monitoring Solution allows maintenance personnel to schedule optimal time to clean to sustain optimal heat transfer. As a result, facilities can reduce energy and capacity loss due to fouling by up to 10 percent. For a 250,000-barrel-per-day refinery, that could mean a savings of as much as $3.5 million or more annually across all process units.

The environmental footprint is lessened by avoiding additional emissions from heater operation because of improved heat recovery in the process. And safety is improved as wireless data transfer reduces hazardous information-gathering trips to the field amongst exchangers that can be difficult to access, stacked, and filled with hot flammable fluids

"Typical world-class process facilities use hundreds of heat exchangers, which foul over time resulting in missed operating targets," commented Pete Sharpe, Emerson’s director of applications development. "Fouling typically occurs slowly but can be accelerated by inlet stream impurities or incompatible crude blends."

"Energy costs rise when fouling forces downstream process heaters to supply more energy because of heat transfer degradation in pre-heat exchangers," continued Sharpe. "Increased demand on downstream fired heaters can also diminish throughput as operating temperature limits are reached, and can increase emissions and potential fines. Avoiding these issues requires an effective cleaning program that enhances operations, and eliminates costs and time lost due to unnecessary schedule-driven cleaning or manual exchanger surveys."

The Heat Exchanger Monitoring Solution is scalable. Users simply choose the number and type of monitoring applications and instruments that are needed for their facility. Dynamic temperature and pressure measurements are trended, historized, and analyzed, delivering alerts of accelerated fouling and optimal time to clean.  Heat transfer, exchanger heat-transfer coefficient, fouling factors and cost of degradation can be calculated. Operations personnel can get valuable insight into operations that can be adversely affected by exchanger fouling.

The monitoring instruments are easily installed and commissioned to form a wireless field network for automatic online measurements. The Heat Exchanger Monitoring Solution uses AMS Suite operator graphics and maintenance screens to communicate continuous online diagnostics and application data to user host systems, control systems, and historians.

"The new automated monitoring solutions reduce costs through pre-engineering savings and wireless efficiency," said Sharpe. "Whereas wired continuous monitoring is traditionally afforded for only the most expensive and critical heat exchangers, the lower costs of Essential Asset Monitoring Solutions enable expanded asset oversight."

To learn more about ways to optimize energy utilization and lower emissions, go to the Industrial Energy section on Emerson's website.

About Emerson Process Management

Emerson Process Management (, an Emerson business, is a leader in helping businesses automate their production, processing and distribution in the chemical, oil and gas, refining, pulp and paper, power, water and wastewater treatment, mining and metals, food and beverage, life sciences and other industries. The company combines superior products and technology with industry-specific engineering, consulting, project management and maintenance services. Its brands include PlantWeb™, Syncade™, DeltaV™, Fisher®, Micro Motion®, Rosemount®, Daniel™, Ovation™, and AMS Suite.

About Emerson

Emerson (NYSE: EMR), based in St. Louis, Missouri (USA), is a global leader in bringing technology and engineering together to provide innovative solutions for customers in industrial, commercial, and consumer markets around the world.  The company is comprised of five business segments: Process Management, Industrial Automation, Network Power, Climate Technologies, and Commercial & Residential Solutions.  Sales in fiscal 2011 were $24.2 billion.  For more information, visit


David Holmes

Emerson Process Management

1 (512) 418-7536

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