Emerson Reliability Solutions

Overview
 Industry Benchmarks Reveal Significant Business Improvement
Opportunities from Average to Top Quartile Performers
Safety Reliability
Recordables Maintenance
3X fewer 4% higher Availability
Process availability
recordables Incidents
and process
incidents
Approximately Half the
ONE TRILLION maintenance
4th Quartiles 1st costs 4th Quartiles 1st
DOLLARS
Production in company value Emissions
lost
is every year
Operating Costs CO2 Emissions
to 30% lower
20% lower Utilization
operating costs suboptimal operating emissions Energy Use
performance
30% less
10% higher energy use
Utilization Rate 4th Quartiles 1st 4th Quartiles 1st

Sources: Refining and Petrochemical Benchmarks,

API, Solomon, OSHA, IHS Markit and Company Reports
 The Plantweb Digital Ecosystem: Enabling Top Quartile Performance With the Industry’s
Broadest Integrated Portfolio of Digital Transformation Solutions

DIGITAL DIGITAL
FOUNDATION TRANSFORMATION

Project, Lifecycle, As-a-

Consulting & Software Connected Services
Services and Educational Shutdowns, Service Cloud-Deployed Asset Expertise and
Implementation Industry Expertise: Digital Strategy Turnarounds, Applications Actionable Insights
Services Projects & Operations & Cybersecurity & Outages
Models

Production
Optimization Personnel Effectiveness Asset Performance Platform Digital Twins
Digitally-Enabled Work Processes Enterprise Analytics & Collaboration Plant & Asset Optimization
Analytics
Operator Platforms
Edge, On-Premise,
and Cloud Performance & Software
Device & Machinery Diagnostics Asset Health Asset Health & Efficiency
Condition-Based Analytics Pre-Configured Analytics Integrated Multi-Asset Analytics
Control & Safety
Systems

Secure Secure First Mile

Data Integration & Cybersecurity
Connectivity SCADA Embedded Security at All Levels
Secure Data Pathways to
Connectivity External Applications and Experts

Measurement Valve Non-Intrusive Radar Pressure Toxic Non-Intrusive

Instrumentation Valves Pneumatics Position Flow Temperature Level Gauge Gas Acoustic Vibration Corrosion Location
Intelligent
Pervasive
Data Field
Devices
Sensing
Reliability Solutions

Machinery Health
Field Device Management
Management
Integrating the Data Chain from Sensors to Collaborative Solutions and
Analytics…
Automation Assets Production Assets

Data
Management
Device Machinery
Manager Manager

6500 ATG 6500 Prediction

Fully Integrated Device Management

Control with DeltaV and DeltaV SIS systems

Trex 2140 9420 EZ1000

Devices /
Instruments
/ Sensors
…that Cover the Plant Ecosystem Better than Anyone Else in the Market
Analytics &
Diagnostics

Plantweb
Optics

Plantweb
Condition Monitoring Advisor
Software

Wireless Vibration Device Management

Transmitters Analyzers Software

Online Monitoring Field

Systems & Sensors Communicators
 optics

Plantweb Optics Software prioritizes information on critical asset health, from multiple
data sources, through the lens of relevant persona - delivering information on only the
most critical situations based on roles and responsibilities so that the right people are
being informed and can act quickly, and with certainty.
 Plantweb Optics Dataflow

CMMS = New functionality

Asset Performance Platform

Enterprise Analytics & Collaboration Plantweb Optics Historian

AMS AMS Emerson

Plantweb Plantweb
Device Machinery Wireless
Advisor Insight
Manager Manager Gateway

Plantweb Optics is an Asset Performance Platform.

It will continue to expand to more data sources and functionality.
Mobile Applications – Collaboration in relevant time
AMS Device Manager Connector
AMS Machinery Manager Connector
 Building on a Track Record of Reliability Recognition
AMS 2140 (CSI 2140)

• 2015 Frost & Sullivan

Global Portable Vibration
Monitoring Product
Innovation Award

• 2014 Plant Engineering

Product of the Year

AMS Device Manager Plantweb Optics

Asset View
• 15 years #1 Reader’s Choice in Control • 2016 Connected World IoT Innovations
Magazine Award • 2017 Control Engineering
Engineer’s Choice
• 2015 Plant Engineering Product of the • 2016 Plant Engineering Product of the Honorable Mention
Year Year Bronze

• 2016 Control Engineering Engineer’s • 2017 Control Engineering Engineer’s

Choice – Honorable Mention Choice Honorable Mention AMS 6500 ATG

• 2017 Control Engineering

Engineer’s Choice
Honorable Mention

• 2017 Reliability Conference Best New

Product
Emerson Confidential 13
Reliability Solutions

Machinery Health
Field Device Management
Management
AMS Device Manager
• Complete management of instruments and valves
– Online Alerting & Diagnostics
– Custom Alerts & Email Notification
– Valve Condition Monitoring
– Meter Verification
– Calibration Management
– Interlock Verification

• Based on open standards

– HART, FOUNDATION Fieldbus, OPC, XML,
Web Services, WirelessHART and More

• Supports devices from all vendors

Pillars of AMS Device Manager
Configuration
Management
➢ Smart Commissioning
➢ Remote Configuration
➢ User Security
➢ Connects to a variety of
DCS
➢ Device Dashboards
Project Certainty
Paperless Calibration Diagnostics and
Documentation Management Monitoring
➢ Paperless Configuration ➢ Calibration Connections ➢ Secure First Mile to
Management to Beamex, Fluke, etc Assets
➢ Paperless Calibration ➢ Create Test Schemes ➢ Online Asset Monitoring
Management
➢ Create Calibration ➢ SNAP-ON Applications
➢ Audit Trail Routes
➢ Device Site Health with
➢ Paperless Drawings and ➢ Calibration Reporting Thin Client Dashboards
Notes
Operational Certainty
Diagnostics and Monitoring:
Progressive Disclosure into Problems

Intuitive User Streamline Device Accessible

Interface Maintenance From Anywhere
 “I can get rid of the paper and avoid a lot of potential
AMS Trex Device Communicator errors. It creates a lot more efficiency for me.”

Rugged IP 54 Rated
Communication Modules
Housing

I.S. Hazardous Area

approved Device Communicator Plus
• HART
• HART + Power
• FOUNDATION Fieldbus
• FF + Power
Long Life Power Module • Ammeter

Device Communicator
• HART

• FOUNDATION Fieldbus

5.7” Touch-screen
Applications

• Field Communicator App

• Loop Diagnostics App*

• Fieldbus Diagnostic App*

• ValveLink Mobile App*

• WirelessHART® Provisioning App**

• Trex Help
And more to come!

*After Activation
**Purchase Separately
AMS Inspection Rounds
• A digital solution to track and monitor facility
status and asset condition accurately and in
real-time to:
– Improve data accuracy
– Identify and resolve safety issues early
– Integrate information to make better decisions
– Gain deeper insight into the conditions of the plant

Hot Spot
(Auto Sync)
Reliability Solutions

Machinery Health
Field Device Management
Management
Asset Criticality and Machinery Health Monitoring

Turbines, Compressors, Generators

Motors, Gearboxes, Pumps, Fans, Blowers

Spared Equipment

Run to failure, Low Maintenance

AMS 6500 Prediction
Features:
• Built from 12-2-2 channel I/O modules
– PeakVue Option
– Modbus option
– Transient Option
• Up to 192 channels per cabinet
– Large channel count using multiple servers

AMS 6500 AMS 6500MS

Up to 48 Channels Compact Rack
 AMS 6500 ATG – API 670 compliant protection with prediction
Built on a decade of proven in use AMS 6500

Certifications:
Class 1 Div 2
ATEX Zone 2
DMV Marine

SIL 2 Certified

“The flexibility and configurability of

ATG has allowed us to implement
Communication Monitor Process Input Relay
advanced diagnostic algorithms – thus
simplifying installation”
Embedded Prediction in a Protection System

CH1 CH2

Time wave form

FFT-Amplitude

FFT-Phase
Easy Upgrade to Advanced Prediction

Advanced Prediction
(prediction license)
Standard Modbus
Prediction
✓ Up to 96 kHz sampling rate

✓ Up to 37.5 kHz Fmax

✓ On Demand “Transient GRAB”

✓ On Event “Transient GRAB”

✓ On Schedule “Transient GRAB”

✓ Spectrum, Waveform plots

Advanced Transient
✓ Multivariable trends GRAB
✓ Orbit plot

✓ Waterfall plot
AMS 6500 ATG Form Factors
Standard Rack
A6500-SR
• 3U height (one rack) / 6U (two racks)
• 19 inch wide (84 HP)
• 240mm depth (+100mm installation
space)
• Rear termination
• Each rack chassis (3U) for:
– Up to two communication cards
(A6500-CC)
– One single relay card (A6500-RC)
– Up to 11 UM or TP cards (A6500-UM
and/or A6500-TP)
• Hazardous (ATEX & CSA) and Marine
DNV rated
Redundant Relay
A6500-RR
• 3U height (one rack) / 6U (two racks)
• 19 inch wide (84 HP)
• 240mm depth (+100mm installation
space)
• Rear termination
• Each rack chassis (3U) for:
– Up to two communication cards
(A6500-CC)
– Up to two relay cards (A6500-RC)
– Up to 9 UM or TP cards (A6500-UM
and/or A6500-TP)
• Hazardous (ATEX & CSA) and Marine
DNV rated
Front Term Mini Rack
A6500-FR
• 6U height
• 12.25 inch wide (50HP)
• 240mm depth
• Front termination
• Compact rack chassis for:
– One communication card (A6500-
CC)
– One single relay card (A6500-RC)
– Up to 6 UM or TP cards (A6500-
UM and/or A6500-TP)
• Hazardous (ATEX & CSA) and
Marine DNV rated
AMS EZ 1000

One Convertor for ALL Sensors

Digital convertor for all sensor chain combinations

3rd Party Ready

Always have the right convertor – EZ 1000 works
with any sensors, Emerson or 3rd party

Field Calibratable
Calibrate in the field to work with the right sensor,
extension cable, target material

Critical Asset Monitoring Lower TCO

Flexible Eddy Current Sensor Chain Free software, faster engineering, flexible to
changes

Fewer Spare Parts

One convertor part number works with all sensors
AMS 6300 SIS Overspeed Protection
• SIL-rated Safety Functions
– Overspeed
– Rotational Direction
– Overspeed + Rotational Direction
• SIL 3 Overspeed Protection (IEC 61508:2010)
– When using pulse wheels / teeth wheels / involute
• SIL 2 Rotational Direction (IEC 61508:2010)
– When using a pulse wheel
• Key Features
– Integrated Front Panel Display
– Options for VOTED <or> NON-VOTED Backplane
– Shaft speed acceleration measurement
AMS 9420 Wireless Vibration Transmitter
Mount transmitter
away from machine

Most Equipment Types

Most Applications
Up to 100 ft / 30 m
) ) )
750 ft / 228 m

1420
Smart Wireless Gateway

AMS 9420
Wireless Vibration Transmitter
• Measurement processing
• Radio communication
• Power Module

Outputs (scalar values)

1. Overall Vibration Units: Velocity (in/sec or mm/sec) Battery Powered

Range: 2 Hz – 1000 Hz (per ISO 10816 standard).
Comment: Identifies problems like imbalance and looseness

2. PeakVue® Vibration Units: G’s Peak

Range: 1,000 Hz – 20,000 Hz
Comment: Quantify early bearing & gearbox defects

3. Temperature Range: -30 to +250 F / -34 to +120 C

Comment: When sensor with embedded temperature used Line Powered
Flint Hills Refinery Case Study
• Project installed 110 pumps with wireless monitoring technology
– Velocity: inches/sec

– Peakvue Acceleration: G’s

– Oil Pressure (Sundyne gearboxes)

– Bearing Temperature (sleeve bearing applications)

• Redundant System, sends High Select to PI every 30 minutes.

• High and High High alarm. Operators encouraged to switch to

spare pump.

• Alarm also sends out automatic email to vibe techs to check

equipment with 2130 for further evaluation.

• Project Objectives were to prevent catastrophic failure which

could lead to vapor cloud release.
“Technology has proven to be
• FHR Pine Bend has gone 5+ years without a pump fire
successful in early failure warning
and meets our project vision.”
AMS 2140 Machinery Health Analyzer

✓ Vibration Analyzer
✓ Laser Alignment
✓ Faster Data Collection
✓ Powerful 4-Channel Analysis
✓ Large, bright screen
✓ Easy Touchscreen Navigation
✓ Wireless Communications
✓ Ergonomic Design
✓ Full Shift Battery
AMS Machinery Manager - Multi-Technology Suite

Analytical Tools for Decision Making

– Vibration Analysis
• One platform for all EMR vibration hardware
• FFT, waveform, & phase analysis
• Automated diagnostics expertise
– Lubrication Analysis
• Trivector wear, chemistry, & contamination
analysis
– Electric Motor Monitoring
• Automated rotor & stator diagnostics, using
current & flux
– Infrared Thermography
• Palette & plot annotation tools
• Temp profile & histogram analysis
– Alignment & Balancing
• Tolerance plots by the job
Vibration Analysis Toolset
Advanced PeakVue Analysis Live Waveform Multi Technology
Plotting Tools Support Playback Reporting

➢ Waterfall plots ➢ Earliest warning of fault ➢ Real time data plots ➢ One tool for all vibration
plus severity data collection hardware
➢ Orbits ➢ Make real time
➢ Rule of 10’s decisions starting or ➢ One tool for all
➢ 3D Shaft Centerline stopping critical assets mechanical reliability
Animation ➢ PeakVue
Single is unrivaled in mechanical fault prediction
operator technologies
parameter for asset ➢ Review fault events to
➢ Waveform health determine
Best diagnostics tools for a vibration failure
power root
user ➢ Capture all historical
autocorrelation cause information around an
➢ PeakVue Waveform asset
Educational Services – Training Courses

Over 40 Courses Available on Reliability

Emerson Confidential 36