AMS Suite

Improve Plant Availability and Performance

 A basic truth applies to every

plant: you are challenged to

maximize profitability and

your assets play a critical

role in achieving that goal.

In the past, you may have

accepted that your plant

was in its best condition

when it was new. When

critical assets broke down,

you reacted, trying to get

your process back to normal

as quickly as possible.

EF F EC T IVELY MANAGE ASSE TS, ACHIE VE FINANCIAL GO

2|
AL S
Now, you don’t have to settle for
getting back to initial standards
of plant performance. World-class
organizations recognize that their
assets are critical to maximizing
financial results.
With Emerson’s combination
of innovative technology and
industry-leading expertise, you
can drive your plant toward
a more predictive environment
that delivers the business benefits
you expect. As you realize the
benefits of improved availability
and performance, know that your
assets are helping you achieve
your financial goals.
With Emerson, you can
continually push back
the boundaries of
what is possible.
|3
 PUSH BACK THE BOUNDARIES
Predict and Optimize
Emerson’s Asset Optimization
technologies and services deliver the
Partnership Taking the First Steps
Toward Change
Emerson knows you can’t get to
a predictive environment with Whether your biggest challenge

power of a predictive environment to technology alone. So, partnering is improving availability, meeting

your plant. AMS® Suite is a family of with Emerson ensures the essential your performance targets, reducing

best-in-class diagnostic software technologies are paired with expertise. maintenance and operations costs

applications, which enable you to Our experience in a wide variety of or dealing with rising fuel costs,

detect plant equipment problems industries and applications translates Emerson works with you to address

before they occur. into an unmatched ability to help your immediate concerns. We

AMS Suite and intelligent you implement a predictive asset provide the combination of

field assets are the core management strategy. technology and services that will

of PlantWeb®’s open get your plant to the next level.

Going Farther Our process is proven, leading to
network of predictive intelligence.
Wherever you are in the plant life real change for sustainable benefits.
From measurement and control
cycle, Emerson can help you push Emerson’s PlantWeb Services
devices to electrical, mechanical,
back the boundaries. Through experts assess your current situation,
and process equipment, AMS Suite
wireless technology, you can reach compare how you match up with
provides you with real-time
new areas of your plant. By sending world-class organizations, and
information to enable effective
diagnostics from smart wireless identify where your greatest
decision support critical to improving
devices to AMS Suite, you gain deeper opportunities lie. We provide
business performance. Whether you
visibility to the health of all your quantification of those opportunities,
are looking at mechanical assets
assets, regardless of where they are including an ROI you can take to
or instruments, whether you are
located. AMS Suite also allows you to management. We work with you to
in operations or in maintenance,
streamline your maintenance process develop a quantified list of prioritized
AMS Suite gets you the right
by automatically generating work assets, which becomes part of
information. Through the PlantWeb
notifications for your most critical a larger roadmap for how your
digital plant architecture, real-time
assets to your enterprise asset organization can achieve its goals.
predictive diagnostics seamlessly
management system. With Emerson, Once you have that roadmap,
communicate with DeltaVTM, Ovation®,
you can ensure your maintenance you can recognize the AMS Suite
and AMS Suite PCs throughout your
resources are focused on the highest technologies that will help you
enterprise. PlantWeb notifies plant
priority assets, making it possible take the next step toward change.
personnel of asset health and
for your staff to be better prepared
performance to empower
and more effective.
decision-making.

4|
IMPROVE AVAILABILITY AND PERFORMANCE
BY GETTING THE MOST FROM YOUR
PEOPLE AND YOUR ASSETS.

|5
 MACHINERY HEALTH MANAGEMENT

Unplanned downtime is
the largest source of lost
revenue. In fact, mechanical
equipment failure is the
single greatest cause of
process interruption.*
How would improving availability
and performance of your critical
mechanical assets impact
your operation?
Operator
Error
21%
Gain the advanced warning you
need to plan and schedule repairs
by monitoring current machinery
health to protect equipment and
to predict when and why the
health begins to deteriorate.
AMS Suite: Machinery Health®
Manager provides knowledge
to predict problems and make
informed decisions prior to any
equipment failure. You have current
health data to know the status of
your critical turbomachinery and
other mechanical assets.
integrated solution. Critical
machinery problems can bring
production to a halt. With a
combination of shutdown
protection and prediction
capabilities integrated with
process control, you can ensure
your machinery will continue
to perform within acceptable
parameters.
AMS Machinery Manager makes
complete machinery health data
available in a single software
application by integrating all your

MECHANICAL Accident/ condition monitoring diagnostics.

Nature With Emerson’s online machinery
FAILURE 16% By delivering the right information
43 % monitoring, you can combine
Other/ to the right people when they
Unknown predictive diagnostics with
2O% need it, you empower them
machinery protection for an

In an independent study, it was determined

that mechanical failure is the biggest
source of unplanned outages.

*Marsh & McLennan Protection Consultants

6|

to make critical decisions with
confidence and accuracy; your
team will know when to bring
down the line and when to keep
the process moving. These are
the decisions that impact your
business’ bottom line.
■ Avoid unexpected shutdowns
■ Protect critical machinery
and personnel
■ Reduce maintenance costs
P R E D I C T & O P T I MI Z E
FINE PAPER PRODUCER
Results:
■ Saved $180,000 by avoiding lost production
■ Saved $120,000 on machine clothing
■ Discovered critical equipment fault during commissioning
Challenge:
Vibration route monitoring in the fine paper mill was scheduled
monthly, but often that was not enough to avoid unplanned
equipment failure caused by the hot, wet, dusty environment.
Careful route-based monitoring was too infrequent to detect the
rapid deterioration of the paper machines’ high-speed bearings.
Solution:
The mill decided to implement an online continuous monitoring
solution using the CSI 4500 Machinery Health Monitor. The CSI 4500
identified an inner race bearing fault on a breast roll during
commissioning, helping the mill to avoid $180,000 in lost
production. The mill now uses 46 CSI 4500s to monitor 600 sensors.
“You can’t walk around the continuously monitor. It takes me 30 days
to walk all the routes. The beauty of Emerson’s online monitoring
solution is that it’s on all the time.”
– Vibration Analyst
www.assetweb.com/amssuite
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 PROCESS EQUIPMENT MONITORING
Process equipment
is a source of ongoing
deterioration and sudden
upset. As the performance
of the equipment
deteriorates, efficiency
decreases; throughput
declines; operating costs
rise; and profits fall.
Improving throughput gives
you a competitive advantage
without requiring major capital
investment. Take advantage of
the full capacity of your plant by
avoiding unplanned downtime
and identifying less-than-
optimum performance in
equipment. Control losses
and protect your investment
in critical process equipment.
Process equipment performance
monitoring applications in
AMS Suite provide comprehensive
8|
insight into your assets. With In addition, combining performance
these tools, you can know the monitoring with online protection
efficiency of your key assets so and prediction allows you to ensure
you can schedule maintenance the health and safety of both your
for optimal cost benefit. equipment and personnel.
Performance monitoring makes
predictive data accessible, so you
$1 Million
don’t need to rely on intuition
SAVINGS $/ YEAR
to know when to schedule
maintenance. You have the data
$200K
500MW
you need to decide when to wash $160K
100MW
compressors, change air filters $10K
80MW
on gas turbines, to perform soot
10MW
blowing on boilers, or to clean
fouling from heat exchangers. SITE ENERGY USE & PRODUCTION (MW )
Per Percent of Performance
Or you can evaluate process and
Cogeneration Site Single Asset
asset performance to evaluate how Oil Platform Small Utilities
to maximize power generation See what recovering a 1% performance loss
from gas turbines, to select means across a variety of applications.
What could it mean to your plant?
extraction or admission flows
from stem turbines, or to reduce
fuel costs from boilers.

With AMS Suite, you gain key
performance indicators based
on the comparison of current
equipment performance to
performance at design conditions.
You have actionable information
right at your fingertips. Efficiency
increases. Throughput improves.
Costs fall. Profits rise.
■ Optimize operating
performance
■ Protect critical assets
and personnel
■ Improve availability
and throughput
P R E D I C T & O P T I MI Z E
ENTERGY CORPORATION
Results:
■ 66% reduction in ramping time of boiler
■ $950,000 fuel cost savings from minimum loading
within 8 months
■ $240,000 in savings from repair to the air heater,
following identification
Challenge:
The Little Gypsy plant is part of Entergy’s five core utility businesses
that produce and distribute electricity to 2.6 million customers.
Entergy required a tool to help determine the cause of slow load
changes and measure future load changes.
Solution:
AMS Performance Monitor provided operational cost savings by
diagnosing which equipment was at fault as well as determining
the effects of performance changes in operation.
“AMS Performance Monitor has provided the information to minimize
the effect of loading on each steam boiler. This has reaped rich savings
in fuel costs.”
– Craig Hopkins,
Maintenance Manager
www.assetweb.com/amssuite
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 INSTRUMENT AND VALVE MANAGEMENT
You suspect some of the
thousands of valves in
your facility are operating
suboptimally. The issue
is not so severe that
it threatens to stop
production, but throughput
isn’t what it should be.
Where is the problem?
Accessing device-based diagnostic
information is key to detecting
potential issues before they
become serious problems
and critical to increasing the
effectiveness of your staff.
AMS Suite: Intelligent Device
Manager gives your maintenance
and operations personnel the
ability to work smarter. Based
on real-time condition data from
your intelligent field devices, plant
staff can respond fast and make
10 |
informed decisions on whether to
maintain or replace field devices.
With the advancement of wireless
technology, you can now see even
farther into your plant for a more
comprehensive view of asset
health. AMS Device Manager allows
you to view diagnostics from both
your wired and wireless devices in
a single application. Combining
AMS Device Manager with wireless
technology extends the power
of predictive maintenance to all
areas of your plant.
With AMS Device Manager, you
have an application to commission
and configure instruments
and valves, monitor status and
alerts, troubleshooting from the
control room, perform advanced
diagnostics, manage calibration,
and automatically document
these activities.
Increasing availability and
streamlining maintenance tasks
will significantly impact your
bottom line. AMS Device Manager
helps you resolve small issues
before they become major
disruptions. And you keep your
staff safe without compromising
production by reducing staff
exposure to hazardous locations.
AMS Device Manager is rated
number one in Control magazine’s
Readers’ Choice awards and
declared the de facto standard
by the ARC Advisory Group, a
manufacturing and supply chain
information and analysis service.

■ Improve maintenance
effectiveness and productivity
■ Extend reach of predictive
maintenance by easily managing
wired and wireless devices
■ Strengthen safety, health,
and environmental compliance
■ Integrate with DeltaV
and Ovation digital
automation systems
P R E D I C T & O P T I MI Z E
CHEVRON ORONITE
Results:
■ Critical valve availability increased to 99%
■ Turnaround time reduced by 60%
Challenge:
Chevron Oronite was experiencing an increase in maintenance costs
due to the amount of reactive maintenance performed. With more than
20,000 instruments, this approach was no long effective. The plant
wanted to make a change to a more predictive approach to maintenance.
Solution:
Chevron Oronite initially focused on the critical valves in their H2S unit
and implemented AMS Device Manager. Using AMS Device Manager with
the unit valves, availability has increased by almost 5% – greatly improv-
ing the plant’s productivity. AMS Device Manager has already
been expanded to 5 units and the plant has reduced its turnaround
time for valve maintenance by 60%.
“Before, equipment would break down and then we would act.
Since the installation of AMS Device Manager, no device issue has
affected the production of the factory.”
– Franck Flour y,
Maintenance Super visor
www.assetweb.com/amssuite
| 11
 ENTERPRISE-WIDE DIAGNOSTICS

As you survey your facility, In a single web dashboard, you AMS Suite: Asset Graphics provides
do you know where the gain key performance indicators of a graphical aggregation of your
greatest threats to your
the health of your entire enterprise. predictive diagnostics and asset
processes lie? Plants
make money when their With AMS Asset Portal, you can health. With AMS Asset Graphics,
assets operate properly, also define alerts and events to maintenance and reliability personnel
so information on how automatically generate work have the same plant view as
well critical assets are notifications in your enterprise operations – only with the
performing is essential.
asset management system. information that is relevant to them.
In order to focus your resources,
you need quick access to
information on active alerts and
events, and where your greatest
risks to availability are. And you
need this information in a way
that is actionable and easy
to understand.

AMS Suite: Asset PortalTM makes

predictive diagnostics more
relevant. It securely collects,
consolidates, and distributes
valuable real-time asset
information for the assets in the
entire plant or multiple plants.

12 |
 P R E D I C T & O P T I MI Z E

ELECTRICAL EQUIPMENT MONITORING

With AMS Asset Portal and The operational efficiency of any plant is only as good as the quality
AMS Asset Graphics, you give your of uninterrupted power being delivered to all of its critical assets.
personnel the information they Your plant’s power distribution system is the vital backbone that
need to run your facility optimally. supports the success of all components.
You strengthen your process and
An unplanned power outage could have consequences that resonate
empower your people by providing
throughout your plant. Intelligent systems that monitor electrical
the diagnostic information they
delivery can provide protection against the loss of power and
need, no matter where they are.
efficiency, as well as improve the safety of your facility. Real-time
Your entire team will have real-time
data can be imported into AMS Suite, allowing a critical overview
data to work on the right problems
of your electrical components.
at the right time – collaboratively.
In the past, you had to inspect each electrical component to retrieve
■ Empower enterprise-wide
detailed analysis and records of performance. AMS Suite is a new
team resources and
frontier in predictive electrical diagnostics that enables superior
improve operations
monitoring capabilities and increased safety when evaluating
■ Increase production and electrical components within your plant.
reduce costs

■ Drive operational excellence

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 OUR USERS SAY IT BEST
Choosing the right technology is
integral to getting the benefits of
a predictive environment. Users
around the world are achieving
benchmark results with the
predictive diagnostics available
from the AMS Suite family of
software applications. More than
13,000 AMS Suite installations are
delivering proven, quantified
results for mechanical and process
equipment, instruments and valves.

“The commissioning was
extremely successful. By using
AMS Suite, we were able to cut
22 days off of our commissioning
time. And the first batch was
within specification.”
– Adrian Moody,
Synthomer Sdn Bhd
“AMS Suite is being used to
determine the events that cause
a loss of performance across
each of the trains, allowing us to
push our operating boundaries
to generate greater throughput.”
– Kevin Harper,
Atlantic LNG
“Before, equipment would
breakdown and then we would
act. Since the installation of
AMS Suite, no device issue has
affected the production of
the factory.”
– Franck Flour y,
Chevron Oronite

14 |
“AMS Suite is an important tool in
providing information about the
condition of rotating equipment
throughout the plant, enabling
us to effectively reduce costs
through predictive maintenance.”
– Ahmed M. Ibrahim,
Arabian Cement Co.
“AMS Suite allows us to improve
operational performance by
applying best-in-class technology
to maintain production and
reduce the possibility of
downtime. Compression train
performance increased more
than 10 percent. We’ve had
an $800/hour increased gas
export production following
identification of a faulty
compression train recycle valve.”
– David Stewar t,
Amerada Hess
“AMS Suite predictive
maintenance software has
dramatically reduced the time
required to identify and rectify
a wide range of faults.
Efficiencies have improved
and unplanned shutdowns
have been reduced by 10%.”
– Peter Montfor ts,
Akzo Chemical
| 15
 YOUR PARTNER FOR ASSET OPTIMIZATION
iEmerson’s technologies and services
expertise deliver proven business
results. You won’t have to spend
hours each day reacting to every
problem that crosses your desk.
You’ll have the visibility to your most
critical assets and know where to
direct your energies and resources.
PlantWeb Services helps you extract
the full value of AMS Suite and make
tangible improvements to your plant.
Our experts help you identify your
most critical assets and equip you
with an actionable plan of how to
optimize your work practices around
those assets. Achieve operational
16 |
excellence from a predictive
maintenance environment that
makes the best use of your resources.
Or bring us in at the beginning stages
of your planning for a new facility.
We will help you design a plant
asset management strategy that will
optimize predictive maintenance
procedures before ever starting
the cycle of reactive maintenance.
All the support you need.
Your staff is changing and sometimes
valuable knowledge is lost. So,
training and support are more
important than ever. Every business
day, all over the world, our service
professionals train and mentor
plant personnel to make sure new
processes and tools are understood
and implemented. With our global
training capabilities, we offer training
programs onsite and at one of our
locations to meet your specific needs.
Emerson delivers the support you
need. Our worldwide response
centers offer troubleshooting,
remote monitoring, diagnostics
interpretation, and emergency site
services to keep your process running
smoothly. Make the most of your
resources with experienced people
when and where you need them.
 EMPOWER YOUR PEOPLE TO MAKE
SOLID DECISIONS BY GIVING THEM
THE SKILLS AND SUPPORT THEY NEED.

| 17
 Realize the true potential

of your plant assets.

Turn to Emerson as

your technology and

expertise partner to:

■ Identify the health

and performance of
your assets
■ Develop a blueprint
so you know where to
invest your resources

EF F EC T IVELY MANAGE ASSE TS, ACHIE VE FINANCIAL GO

18 |
ALS

Pushing back your boundaries You get increased availability,

with Emerson means lower maintenance and operating
experiencing the benefits of a costs, and better plant performance.
more predictive environment: You realize the potential of your

■ Meeting production targets assets to keep you profitable.

■ Selecting the most economic Move beyond what

fuels and equipment you think is possible.
Call your local Emerson
■ Evaluating the impact of process Process Management
changes on total performance sales representative
or visit us at
■ Minimizing energy costs
www.assetweb.com.
■ Diagnosing the root cause of
performance degradation

■ Streamlining maintenance tasks

| 19
©2009, 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, Asset Portal, Machinery Health and ValveLink 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.
D351324X012 /00803-0100-6124, rev CA/printed in USA /3-2009

Emerson Process Management – Asset Optimization

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AMS Suite powers

PlantWeb by using
predictive intelligence
to improve availability
and performance of
production assets.

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