Chemicals

Canned pumps are vital in the Petrochemical industry for transferring hazardous liquids, with enclosed bearings that don’t require regular lubrication. Continuous monitoring is essential, as journal bearings can fail within 48 hours, making monthly inspections inadequate.

• Capital expenditure (parts): $90,000 on average
• Labor: $10,000 16-24 hours downtime

Blowers are crucial in the Acid Regeneration process, and maintaining assets like Turbo Blowers is essential but challenging. Downtime can halt production, with failure modes varying by process configuration.

• Unplanned downtime can cost up to $100,000/day
• Repairing & replacing parts can take multiple days

Cooling towers pose challenges for accessibility and monitoring, causing many maintenance professionals to overlook critical signs of impending failure. Such failures can disrupt various production processes downstream.

• $1,000/hour downtime cost
• $50,000 in equipment costs per failure
• $100,000+ cost savings per avoided failure

Dryer blowers are vital in the chemical industry for removing moisture from products. Induced and forced draft fans provide a steady flow of hot air, facing challenges like blade corrosion and imbalance from material buildup, leading to premature bearing or asset failure.

• $5,000/hour Downtime Cost
• 4-8 hours Downtime
• Asset Cost $50,000

Screw compressors are essential for air supply and gas storage. Failures, often due to bearing issues, shaft misalignment, or lubrication problems, halt operations by losing high-pressure fluid. Optimizing running speeds is key to minimizing downtime.

• Compressor rebuild: $80,000 4-6 weeks downtime
• Compressor replacement: $240,000 15-17 weeks downtime

Air compressors in a plant can cause significant energy waste and costly downtime due to unexpected failures. Air leaks increase demand, leading to higher energy use and more wear on compressor components.

• $60,000 Per year/ compressor