1) Emerson offers online machinery health management to improve reliability, availability, and performance of mechanical equipment through condition and performance monitoring. 2) The system provides continuous monitoring of critical machines to detect problems early before they cause an outage through technologies like vibration analysis, infrared thermography, and ultrasonic testing. 3) By gaining a comprehensive view of machinery health across an entire plant, operations can make informed decisions to proactively plan maintenance and avoid unexpected downtime.

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.
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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
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