MHM Smart Machinery Technologies
- 1. TM Smart Machinery Health Management Improve Reliability, Availability and Performance ©2007, Emerson Process Management. The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our terms and conditions, which are available on request. We reserve the right to modify or improve the designs or specifications of our products at any time without notice. All rights reserved. AMS, PlantWeb, DeltaV, Ovation, Machinery Health and PeakVue are marks of one of the Emerson Process Management group of companies. The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their respective owners. D351387X012/printed in USA/8-2007 Emerson Process Management - Asset Optimization North/South America Europe Asia Middle East 835 Innovation Drive Interleuvenlaan 50 1 Pandan Crescent PO Box 17033 Knoxville, TN 37932 USA Leuven 3001 Belgium Singapore 128461 Dubai – United Arab Emirates T 1(865) 675-2400 T 32(16) 741-471 T 65 6777 8211 T 971 4 883 5235 F 1(865) 218-1401 F 32(16) 741-419 F 65 6770 8038 F 971 4 883 5312 Online Machinery Health Management powers PlantWeb through condition and performance monitoring of mechanical equipment to improve availability and performance. www.assetweb.com/mhm
- 2. In an increasingly competitive market, organizations are challenged to run their plants more profitably and with greater efficiency. Yet mechanical equipment deteriorates causing a decrease in performance, a reduction in throughput and a rise in operating costs. Or an unplanned shutdown grinds production to a halt, resulting in a large loss in revenue. Deterioration in machinery health Emerson’s combination of ■ Increase throughput, IS YOUR MACHINERY ’ S HEALTH PUT TING and performance is usually best-in-class technologies and availability and reliability YOUR OPERATIONAL GOALS AT RISK? associated with misalignment or services helps increase equipment ■ Improve operating performance imbalance, corrosion and wear, effectiveness, reliability and ■ Reduce maintenance expenditures fouling, sediment build-up performance by allowing you to ■ Avoid unplanned shutdowns or poorly lubricated parts. be proactive in your maintenance. ■ Reduce energy consumption Detecting these underlying With Emerson’s Smart Machinery and costs problems early allows you to correct Health Management solution, issues before they affect your you have a comprehensive view ■ Extend equipment lifespan process, optimizing the performance of every machine, allowing you Turn to Emerson to ensure of your plant. to diagnose problems early – optimal health and performance before they even become an issue. of your mechanical equipment. 2| |3
- 3. CRITIC AL A SSE TS IN A HIG H -STAKES WO RLD Prevent unscheduled downtime. Improve availability and performance. Ensure protection from catastrophic failures. Protect people, facilities, and the environment. In an environment that relies on critical mechanical equipment, any failure can have a dramatic effect. A prolonged process interruption can be the difference between profit and loss. With this much at stake, having the correct protection, prediction, and performance monitoring system in place is essential. With Emerson’s online machinery monitoring technologies, you can monitor mechanical assets and analyze temperature, vibration, efficiency, and deviation data for changing conditions that could result in a shutdown. Emerson offers the most comprehensive protection, plant-wide prediction, and performance monitoring system integrated with process control. PlantWeb® Digital Plant Emerson’s online machinery Combining protection, Architecture monitoring capability prediction, and performance Emerson’s PlantWeb digital plant ■ For American Petroleum Institute capabilities makes the architecture forms an integrated (API) 670 standard and insurance difference in knowing your environment for process automation requirements, PlantWeb’s mechanical equipment is and asset management. Within protection capabilities truly reliable. Emerson PlantWeb, Emerson’s online machinery coordinate asset or plant ensures protection. Delivers prediction. PROVEN RESULTS monitoring extends protection, emergency shutdown with prediction, and process control. Prevents downtime. And brings reliability Emerson’s machinery management and reliability solutions have performance monitoring ■ Continuous online monitoring to your critical assets. been deployed in a variety of sites and processes around the world. capabilities to a plant’s delivers real-time predictive Here are some of the quantifiable results that our customers report: most critical machinery. diagnostics to an asset ■ Protect against Online machinery catastrophic failures ■ Rompetrol Petromidia saved an estimated $10.1M by avoiding management system and monitoring is complemented by an unnecessary shutdown triggers alerts that allow ■ Reduce process disruption PlantWeb Services to ensure successful operations to make informed ■ Premcor increased hydrotreater production by 25% after ■ Improve maintenance implementation and to maximize production decisions. implementing a lubrication program effectiveness investment value. These applications ■ Analysis of deterioration in ■ Entergy saved nearly $1M by minimizing loading on a boiler ■ Start-up safely use the power of predictive intelligence performance identifies the root through performance monitoring to improve plant performance and ■ Increase plant profitability cause of equipment inefficiencies ■ Voridian Chemical saved $350,000 through vibration monitoring provide greater operational benefits. ■ Reduce operating costs so maintenance can be You improve throughput and ■ SITA UK reduced steam leakage in a superheater by 50%, saving $70,000 proactively planned. availability and sustain the resulting ■ Amerada Hess increased gas export by 10% following the performance gains. identification of an under-performing compressor ■ Johns Manville reduced mechanical emergency maintenance by 43% ■ Belgian Navy saved $2M by applying predictive maintenance technologies aboard ships www.assetweb.com/customerproven 4| |5
- 4. B E S T- I N - C L A S S D I AG N OS T I C S P RO M OT E O P E R AT I O N A L E X C E L L E N C E Infrared Thermography Machinery Health Ultrasonic From API 670 machinery Transmitter Testing protection to real-time analysis of critical machines, Emerson is the single Performance source for optimizing Monitoring your mechanical assets. Lubrication With a proven track record of Analysis implementing plant-wide predictive Machinery Health diagnostic solutions, you can Management count on Emerson to unlock the maximum potential in your Electric Motor machinery. Emerson’s AMS™ Suite Diagnostics predictive diagnostic software integrates information from Online Machinery robust diagnostic technologies. Monitoring Alignment and This powerful combination of Balancing software, online technologies, and portable technologies Vibration builds a predictive diagnostic Analysis foundation for your machinery management program leading to improved productivity. SOFTWARE ONLINE TECHNOLOGIES PORTABLE TECHNOLOGIES ■ Electric Motor Diagnostics – ■ Ultrasonic Detection – ■ Machinery Health Transmitter – ■ Machinery Health Management – ■ Online Machinery Monitoring – ■ Vibration Analysis – locate defects caused by heat scan for leaks in plant air, vacuum receive alerts and diagnose multi-technology integration, a complete protection, prediction conclusive condition information and fatigue in electric motors. seals and pressurized systems problems in motor-pump analysis and reporting tools and performance monitoring about bearings, gears and other ■ Lubrication Analysis – or lack of lubrication. machine trains. allowing enterprise-wide system integrated with rotating components; implement determine that lubricants and ■ Infrared Thermography – predictive maintenance planning. process control. on a periodic basis. fluids are clean and moisture- thermal imaging detects ■ Performance Monitoring – ■ Alignment and Balancing – free; detect particle in oil after mechanical and electrical analyze and obtain peak ensure precise alignment and onset of wear. anomalies. performance of critical mechanical balance of rotating machinery. and process equipment. 6| |7
- 5. THE SOF T WARE TOOLS FO R ASSET MANAGEMENT AND PREDIC TIVE DIAGNOSTICS The performance and health of mechanical equipment will deteriorate over time. Early detection is vital. Ensure gradual deterioration doesn’t strip away performance or your peace of mind. Knowing the health and performance of your mechanical equipment allows you to be proactive with your maintenance planning instead of reacting to unexpected events. When your maintenance and operations staff are alerted to degrading asset health, critical production decisions can be made to eliminate outages and improve the bottom line. The PlantWeb Advantage Performance Monitoring ■ Develop a planned PlantWeb empowers your organization AMS Suite provides thermodynamic- maintenance approach with predictive intelligence. based performance diagnostics, ■ Prioritize and plan AMS Suite distributes this intelligence allowing you to improve the maintenance activities to the right people at the right time efficiency of your critical machinery – ■ Achieve and maintain optimum so accurate, timely decisions can be turbines, compressors, boilers and equipment performance made. The integrated family of other assets. By analyzing machinery ■ Quantify thermodynamic AMS Suite predictive maintenance performance, you can run your efficiency losses applications brings together process more efficiently, track ■ Evaluate the effectiveness information from critical production operating performance against of maintenance on production assets, including mechanical targets, schedule maintenance and equipment condition equipment, process equipment, activities, and determine the root instruments and valves. cause of equipment inefficiencies. ■ Track key performance indicators against targets Equipped with health and Machinery Health performance diagnostics information ■ Determine the root cause of Management OUR CUSTOMERS SAY IT BEST and backed by a team of Emerson production inefficiencies AMS Suite integrates Emerson’s engineers, you can move from “We have reaped rich savings in fuel costs. AMS Suite has provided protection and prediction reactive to targeted predictive and the information to minimize the effect of loading on each maintenance technologies. You proactive maintenance programs. steam boiler.” – Mill Maintenance Engineer gain a comprehensive view of each AMS Suite helps you focus on the machine so you can accurately “Using AMS Suite helps us determine the events that caused a loss in assets that impact your bottom line, diagnose developing problems. performance across each of the trains, allowing us to push our operating bringing improved performance Unsurpassed analytical capabilities boundaries to generate greater throughput.” – Vibration Analyst and restoring your peace of mind. through automated diagnostics, “AMS Suite allows us to improve operational performance, by applying plotting, and reporting help determine best-in-class technology, to maintain production and reduce the possibility machinery health. Through of downtime.” – Reliability Technician AMS Suite, you can document, www.assetweb.com/customerproven trend and communicate all details of machinery health. 8| |9
- 6. CONTINUOUS ONLINE MONITORING FOR PROTECTION AND PREDIC TION Critical machinery problems can bring production to a halt. A combination of shutdown protection and prediction capabilities ensure your machinery will continue to perform within acceptable parameters. Machinery Protection Prediction Monitoring ■ Automated, continuous, Today’s plants require machinery Visibility to machinery health before predictive machinery protection systems for the most the protection system engages is health monitoring critical rotating machinery. The considered the critical missing ■ PeakVue® technology provides CSI 6000 Machinery Health Monitor component of today’s machinery bearing fault detection meets API 670 requirements and protection solutions. Operations ■ Record, view and replay provides PlantWeb protection and maintenance personnel are no transient data during startup, integrated with process control longer looking for just a protection shutdown and trips systems. The modularity of design capability when replacing an gives the CSI 6000 flexibility outdated protection system. They Empowering Decisions in retrofit applications for are requiring a complete protection, As part of Emerson’s PlantWeb existing cabinets. prediction, and performance digital plant architecture, real-time When safety is key, Emerson monitoring capability integrated machinery health information provides two additional systems – with process control. moves throughout the enterprise a SIL 3-rated overspeed protection The CSI 4500 Machinery Health to the right people so the right system as certified by TÜV and a Monitor provides machinery decisions can be made. thrust monitoring system built on prediction integrated with the When this information is delivered the same SIL3 platform. The CSI 6000 CSI 6000 or it can complement through the Ovation® or DeltaV TM protection system provides vital an existing protection system. It OUR CUSTOMERS SAY IT BEST digital automation system and shutdown protection to prevent delivers real-time feedback to both AMS Suite predictive maintenance catastrophic failure. maintenance and operations, so “After the CSI 4500 was installed, we operated for 8 months without a single trip; software, you empower operations plant personnel can make informed in the 5 months prior, we had 9 ‘ghost’ trips.” – Coke Plant Engineer ■ Continuous online monitoring and maintenance with the full for machinery protection decisions well ahead of a shutdown. value of PlantWeb’s predictive “We’ve been able to trend data from the CSI 4500 and compare that to process With prediction, a machine can intelligence. trends. We’ve been able to correlate spikes in vibration to operations and reduce ■ Compliant with API 670 standard continue performing as long as it those spikes … anything you can do to reduce vibration is good.” – Plant Engineer ■ Integrated with process is within acceptable parameters. “A fault missed by our current monitoring system only became visible once we control systems Repairs can be made when they employed Emerson’s PeakVue technology.” – Reliability Analyst are economically convenient. www.assetweb.com/customerproven 10 | | 11
- 7. PORTABLE DATA CO LLEC TION: THE FO UNDATION OF YO UR RELIABILIT Y PROG RAM By improving machine reliability, you can maximize output and significantly lower production costs. Experience savings by employing predictive and proactive maintenance strategies. Vibration Analysis Alignment and Balancing Electric Motor Diagnostics Unattended, 32-Channel In an environment where you cannot Alignment and balancing can extend After bearing problems, the most Portable Analysis afford to constantly chase the next the life of your rotating machinery. common motor problem is electrical Some critical plant assets require breakdown, you need to quickly and The CSI 2130 is used to precision failure. Heat and fatigue, associated more than the data collected as part accurately identify developing faults balance or laser align machine trains with excessive motor starts or of a route-based vibration analysis and, ultimately, the underlying root before returning them to service. overloading, can lead to broken program. Turbomachinery and other cause of the machinery problem. It balances machines in up to 4 rotor bars in electric motors. complex machines may require Vibration analysis offers the most planes and at multiple speeds, and The CSI 2130 non-intrusively collects temporary, but continuous information about the condition can automatically detect and alert current, flux, and temperature data monitoring across a machine of rotating machinery. you to secondary structural faults while the motors remain online. or multiple machines. The CSI 2130 Machinery Health Analyzer that might complicate the balancing This motor analysis technology The CSI XP32 Machinery Health simplifies the task of vibration analysis job. Unique laser heads include dual can diagnose electrical problems, Expert is a temporary continuous by monitoring virtually every high-speed angle sensors that providing information on rotor- monitoring and analysis system. It machine in the plant. Onboard measure the exact rotational related electrical faults such as records data for hours or weeks at a analysis for advanced trouble- position of laser heads, reducing broken rotor bars, high-resistance time, and makes use of the advanced shooting is available at the push of a sweep time and providing an joints and cracked rotor end rings. PeakVue technology for rolling element button, providing an instantaneous accurate alignment solution. bearings and gearboxes. Real-time ■ Early detection of rotor machinery health assessment. ■ User-friendly display for faster and stator faults transient events can be viewed and OUR CUSTOMERS SAY IT BEST ■ Unmatched data collection speed balance and alignment jobs replayed for further analysis with ■ Collect motor analysis data ■ Balance four planes and animated machine and structure ■ Powerful in-field alerts and while the motor is online “We could have suffered over 12 hours of paper machine downtime. The backside multiple speeds views for advanced diagnosis of analysis for guided, machine-side ■ Trend motor condition over dryer bearing fault was invisible in the regular spectra and waveform, but the most difficult reoccurring testing and troubleshooting ■ Alignment within one quarter time to plan and prioritize we found it thanks to the CSI 2130’s simultaneous PeakVue measurement machinery problems. ■ PeakVue technology for turn of shaft rotation maintenance action point capability.” – Mill Maintenance Engineer ■ Monitoring and troubleshooting advanced bearing and “This is the new wave of maintenance, the new paradigm. We now have for turbomachinery startup, gear fault detection nearly zero unplanned downtime with production because of our coast down, and production state reliability program.” – Vibration Analyst ■ Record 50 hours of simultaneous, continuous time waveform “The simple fact is that the CSI 2130 can take consecutive measurements across 32 channels and definitely speeds up the process tremendously.” – Reliability Technician ■ Live oscilloscope and www.assetweb.com/customerproven FFT analyzer 12 | | 13
- 8. ADDITIONAL SOLU TIONS FO R COMPLE TE MACHINERY HE ALTH MANAG EMENT While vibration analysis is the core technology for predictive maintenance, additional technologies are necessary to complete the picture of machinery health. Oil and lubrication analysis often provide the earliest indication of machine degradation, while infrared thermography and ultrasonic testing provide critical pieces of the information puzzle. Each test complements the other, confirming potential diagnosis or eliminating suspected causes of failure. Lubrication Analysis Ultrasonic Testing Infrared Thermography Oil and lubrication analysis are widely- Ultrasonic testing identifies various Emerging faults are frequently accepted tools for determining the fault types by analyzing noise accompanied by excessive heat or health of machinery. The CSI 5200 patterns within specific sonic and heat loss. The CSI 9800 Machinery Machinery Health Oil Analyzer tests ultrasonic frequency ranges. Beyond Health Imager is a handheld, oil for machine wear, lube system simply locating faults within these route-based infrared detector contamination, and chemistry specific frequency ranges, the CSI that captures thermal images changes of the oil that are indicative 7100 Machinery Health Scanner is of potential problems, and can of machinery health degradation. unique in its ability to provide an upload them to AMS Suite for Results provide a warning of unseen indication of the problem severity further analysis and reporting. corrosion, contaminates, improper and a calibrated reading of the ■ Diagnose anomalies in lubrication, and machine wear, signal level as a measurement electrical systems MOTO R-PUMP CO MBINATIONS: and can eliminate the root cause of asset health. ■ Scan mechanical equipment THE BACKBONE OF YO UR PROCESS of equipment failure. ■ Scan for bearing faults for heat-related problems ■ Accurate onsite analysis of Over half of the equipment in process facilities consists of motor-pump machines trains. ■ Detect gas emission leaks ■ Detect hot spots oil health information Careful monitoring of these assets can prevent lost profit due to unplanned downtime. ■ Identify unsafe high voltage ■ Early indication of machine arcing problems wear and fatigue The CSI 9210 Machinery Health pressure, level and flow, and the ■ Detection of problems in AC ■ Ensure correct valve and Transmitter uses various sensor immediate impact they can have on induction motor-pump trains ■ Verifies correct oil usage steam trap operation inputs to assess the health of the production assets. Problems such as ■ Analysis of vibration, motor by screening oil supplies motor-pump machine train. This pump cavitation, motor overheating flux, temperature and speed assessment is based on an analysis or overloading, imbalance, shaft ■ Alert notification to maximize engine that has been specifically misalignment, and rolling element machinery uptime optimized and embedded into bearing degradation can be the device for motor-pump identified in the early stages before machine trains. the machine fails. Reduce the factors that lead to unplanned The CSI 9210 offers operations and downtime and improve plant maintenance personnel the ability to availability and performance. understand the interaction between process variables such as temperature, 14 | | 15
- 9. RE ALIZE FULL VALUE FROM YO UR MACHINERY MANAG EMENT SOLU TION When you consider a ■ Identify and quantify your largest ■ Implement a structured approach to critical technology and most significant opportunities technology implementation, based investment, you cannot for improvement through an on proven experience, to ensure afford to overlook service. opportunity assessment to your reliability program starts right Emerson understands the uncover performance gaps and and endures over the years. requirements for comprehensive potential opportunities in your ■ Assess the skill sets of your workforce expertise to ensure start-up success current maintenance plan. and deliver training programs with and long-term support. We are fully ■ Develop a roadmap for asset an emphasis on implementing committed to supporting you prioritization that allows you to maintenance practices that take full through all of the installation steps focus PlantWeb technologies on the advantage of new technologies. and to keep your system running assets with the highest benefit. ■ Extend the predictive power smoothly and reliably. of PlantWeb to help reach your plant’s true performance and availability levels. A CO MPLE TE PI C TURE OF MACHINERY HE ALTH From online monitoring with protection, prediction, and performance to portables for vibration analysis and more, Emerson’s integrated Smart Machinery Health Management solution delivers critical predictive diagnostic information on your high-stakes assets in AMS Suite. You get a holistic view that allows you to make informed decisions about your PlantWeb Services for Asset Optimization is a structured approach to implementing PlantWeb technology, operation. Depend on the innovation and expertise of Emerson for a complete picture of designed to address specific business barriers that move you from a reactive plant to a best-cost producer. machinery health. Emerson's expertise enables you to streamline daily maintenance procedures, implement predictive maintenance, enhance planning time, and operate with your maintenance resources fully optimized. 16| | 17
- 10. EMERSON – YO UR PARTNER FOR ASSE T OPTIMIZATION Realize the true potential Emerson is your single source for and the combined power of of your plant. reliability technology. Since the Emerson’s PlantWeb digital plant When you partner with Emerson, introduction of our first portable architecture with PlantWeb Services you achieve optimal health and vibration analyzer in 1986, expertise, we provide real-time performance while experiencing the Emerson has led the market in the predictive diagnostics on all your value of a predictive environment: development of advanced vibration key production assets to drive technologies. With an annual operational excellence within ■ Prevent catastrophic failures investment in machinery health your facility. and unplanned shutdowns research and development that With Emerson, you have the ■ Meet production targets exceeds the sales revenue of many complete portfolio of machinery ■ Diagnose the root cause of reliability suppliers, Emerson health management technologies, performance degradation continues to lead the industry software and services ensuring ■ Reduce maintenance in the release of new products for your mechanical equipment is and repair costs monitoring the health and performance maintained correctly for optimal of your mechanical equipment. ■ Reduce inventory and overtime health and performance. ■ Achieve predictive or In addition to our expertise in Turn to Emerson as proactive maintenance mechanical equipment, no one your critical machinery knows instruments, valves, electrical management partner to systems and process control like manage and realize your Emerson. With a view to the machinery’s potential complete manufacturing process to achieve your operational goals. www.assetweb.com/mhm 18 |