Asset Reliability Services
™
Smart Turnarounds and Outages
TURNAROUNDS: A SMART APPROACH
You plan for turnarounds.
Now plan for a better return.
enables you to determine the scope
Turnarounds play a critical role in the
work smarter, more targeted,
plant’s life cycle. It’s a time to repair,
and cost-effectively.
renew, replace, and revitalize your
around costs are high, it’s important
When it comes to
turnarounds, no one is
more qualified to service
your plant than Emerson.
to get the job done right.
Our asset reliability services experts
Poor planning can result in
use predictive diagnostics to assess
unidentified issues with critical
the condition of your electrical,
assets or overlooked processes, while
mechanical, process equipment,
insufficient workmanship can cause
instruments, and valves. With
delayed startup and even worse –
predictive maintenance technologies,
safety and environmental mishaps.
we can know in advance which assets
Poorly executed turnarounds can
will need work, what work should be
cause extended downtime, resulting
done, and in what order we should
in lost production, possible fines, and
do it for maximum efficiency.
decreased profitability – ultimately
With Emerson’s proven turnaround
impacting the longevity of your plant
process, you’ll be assured that the
and the life of your equipment.
planned maintenance is executed
key assets to maximize your plant’s
true potential. And, because turn-
When your available time for
maintenance is short, how can
you be sure to get the most
out of your turnaround?
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of the turnaround and allows you to
smoothly and efficiently, in the
shortest amount of time.
For your next turnaround, make it
a Smart Turnaround with Emerson.
Predictive diagnostics from key
We’ll be there every step of the
production assets are the drivers for
way – in whatever role you need us.
a successful and efficient turnaround.
Together, we’ll plan for a successful
Information obtained about the
turnaround and build long-term life
health and condition of your assets
cycle efficiency for your plant.
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A PROVEN PROCESS FOR RELIABLE RESULTS
Plant turnarounds constitute the
Asset Review
single largest identifiable maintenance
An effective turnaround strategy
expense – and controlling turnaround
begins with effective planning.
Once the scope of work has been
costs and duration represents a
During this step, Emerson will
clearly defined and a schedule has
definite challenge. The most critical
conduct a plant walk-through and
been developed, we’ll create a plan
objectives are:
equipment assessment to identify
for each element of the execution
To complete the turnaround in
the project objectives. We will
and allocate test equipment, parts,
the shortest possible time and
develop a comprehensive inventory
materials, and labor resources.
at the lowest possible cost
of your assets, including nameplate
Turnaround Services Operation
To achieve the best quality
information, service cycles, and
of workmanship
age and criticality of system
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To execute the turnaround
components. This information
provides the foundation for
Resource Planning
& Allocation
When it’s time to execute your
turnaround, we’ll be there with
the right people, processes, and
PREDICT & OPTIMIZE
PARTNERSHIP
CONFIDENCE
NTEGRATE
with the highest possible
safety record
asset planning.
technology to ensure that your
turnaround is done right, on schedule,
Asset Planning
within budget, and to your satisfaction.
has developed a proven process that
Emerson will conduct pre-outage
Turnaround Review
ensures your turnaround is done
online diagnostic testing to assess
right, on schedule, and within budget.
the condition of your assets,
The steps of our turnaround process
determining which assets will
include:
need work and what work is
To meet these objectives, Emerson
required. We’ll establish the
details of the project, prioritize
needs, and examine the impact
on the overall process.
After your turnaround is completed
and your process is successfully
online, we’ll review the turnaround
process with you and provide a
final comprehensive report detailing
the tasks performed, equipment
serviced, and personnel involved.
The report includes testing results
and a summary of recommendations
for future maintenance.
PREDICT & OPTIMIZE
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Infrared inspection findings are
carefully documented in a comprehensive
report that includes high-resolution color
digitized photographs and thermograms,
and recommendations for correction
or repair prior to the next scheduled
maintenance shutdown.
PREDICT & OPTIMIZE
THE POWER OF PREDIC TIVE DIAGNOSTICS
PARTNERSHIP
CONFIDENCE
NTEGRATE
Production assets today
are more sophisticated
than ever before.
AMS® Suite, a family of best-in-class
With AMS Suite, you can:
predictive maintenance applications,
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helps you detect equipment problems
diagnostics from field devices
It is impossible to fully optimize
before they occur. Before, during,
to improve plant availability
your assets without an advanced
or after a turnaround, AMS Suite
and reduce maintenance costs
predictive maintenance program that
can help you save time and money
enables an efficient maintenance
by delivering valuable diagnostic
strategy and continuous
information already contained in
performance improvement.
your smart devices. At any time
Emerson’s Smart Turnaround program
in your plant life cycle, online
utilizes advanced technologies to
diagnostics can be utilized for
diagnose, monitor, and protect
control valves and field instruments.
PREDICT & OPTIMIZE
your most critical assets.
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Fully implement predictive
Identify, troubleshoot, and
resolve device issues remotely
and efficiently
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Streamline calibration procedures
and permanently store the
calibration records
FlowScanner diagnostic
reports detail valve assets that
need repair or replacement.
This results in a 20% - 40%
reduction in valve pulls,
depending on the
condition of the valves.
Emerson’s FlowScannerTM 6000
information on all assets included
for the areas that require the
is a valve diagnostic system that
in the work scope. Once the
most attention.
conducts inline testing of valves,
turnaround begins, QC3 enables
With predictive diagnostics, you will
eliminating the need to remove
project status updates, including
know in advance which assets need
and reinstall, to save you time
percent of completion, man-hours
attention so you can optimize your
and money. Valves are tested to
worked, and asset discrepancies.
maintenance plan for maximum
manufacturing specifications,
Emerson’s advanced partial
efficiency during your turnaround.
ensuring maximum performance
discharge testing technology plays
and efficiency.
a critical role in determining the
Efficient data collection is
health of your electrical assets and
made possible with Emerson’s
ensuring maximum uptime. It also
QC3 Outage Tracking Tool.
provides asset managers with
Before your turnaround, Emerson
critical information needed to
technicians electronically capture
target maintenance resources
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EMERSON’S SERVICE E XPERTS PROVIDE
THE SUPPORT YOU NEED
When it’s turnaround time,
take advantage of Emerson’s
range of industry-leading
services and expertise.
your site. Equipped with lathes,
assets to ensure their efficient,
mills, welders, workbenches, and
reliable and safe operation. Our
parts, we’re prepared to diagnose,
expert technicians will clean, inspect,
calibrate, remove, repair, and replace
and test your entire electrical
Predictive Diagnostics
your instruments and valves onsite –
distribution system and identify areas
Assess the condition of your aging
saving time and money. Our
for improvement. Our life-extension
assets prior to your next turnaround
“workbench on wheels” provides
services provide repair, retrofit, and/or
with Emerson’s predictive diagnostic
24/7 availability throughout the
replacement for obsolete and defective
services and technologies. Emerson’s
duration of your turnaround.
equipment in order to maximize the
advanced diagnostics for valves
Encore® Program for Valves
value of your existing equipment while
improving overall system performance.
include valve leak testing and leak
Repair or replace obsolete and hard to
PREDICT & OPTIMIZE
PARTNERSHIP
CONFIDENCE
NTEGRATE
detection using AMS Suite and
FlowScanner.
find valves in a matter of hours with
Emerson’s Encore program. Encore
For your electrical assets, we’ll
conduct partial discharge testing,
oil analysis, infrared inspections,
and ultrasonic testing. Conducting
diagnostic testing in advance of
your next turnaround will assist in
prioritizing those assets that need
products are units remanufactured
Asset Planning and Management
to original factory specifications
Services provide daily technical and
and assembled by expert valve
around-the-clock emergency support
technicians. Our strict quality
for your electrical, valve, and instrument
control process ensures that every
applications and maintenance. Our
Encore part meets industry and
asset managers deliver best-practice
factory standards – guaranteed.
solutions during your turnarounds
immediate repair – making the best
use of your maintenance work.
Onsite Repair Center
Our mobile service trailers provide
a portable maintenance facility at
PREDICT & OPTIMIZE
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Asset Planning and
Management Services
Electrical Testing
and Maintenance
Conduct electrical testing and
maintenance on all your electrical
and throughout your plant’s life cycle.
When it’s turnaround time, turn to
Emerson for proven technologies and
services to help your plant succeed
today, tomorrow, and beyond.
TECHNOLOGY ALONE DOESN’T
GET THE JOB DONE – PEOPLE DO
From the moment they arrive onsite
safety, including training in more
from one of our conveniently-located
than 60 Environment, Safety, and
service centers in North America,
Health (ESH) procedures.
our technicians and engineers
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Our technicians are trained and
offer you the highest standards
certified by the PHMSA (US
of professionalism and safety.
Department of Transportation
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Emerson’s Asset Reliability
Pipeline and Hazardous Materials
Services team is comprised of
Safety Administration) to work
more than 700 of the industry’s
on pipelines.
premier engineers, PEs, technicians,
Emerson has a history of working
safely. Our Experience Modifier
the InterNational Electrical Testing
Rate (EMR) is one of the lowest
Association (NETA), Instrument
in the industry.
Society of America (ISA) CCST
Certification, and Emerson’s
Rosemount®, Fisher®, and Micro
Motion® Certification programs,
our technicians have the expertise
and experience to accomplish
the most complex projects safely
and reliably.
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and support professionals. Through
Finally, when the job is complete,
our technicians leave something
valuable behind – expertise.
Through our training programs,
your in-house personnel learn
about operation, troubleshooting,
diagnosis, and resolution. As a result,
your plant staff can benefit from
Every technician is trained to
Emerson’s expertise long after
Occupational Safety and Health
the turnaround is over.
Administration (OSHA) standards
for personal and environmental
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PREDICT & OPTIMIZE
TURNAROUNDS ARE JUST THE BEGINNING
PARTNERSHIP
CONFIDENCE
NTEGRATE
Leverage Emerson’s services
Our AMS Suite predictive
to create and run a more
maintenance software is a core
backed by people who are committed
profitable plant.
component of the PlantWeb
to meeting your needs and exceeding
Emerson project managers are
digital plant architecture, improving
your expectations. Maybe that’s why
available to deliver valuable insight
availability and performance of
Emerson’s technologies and services
during turnarounds and startups.
mechanical equipment, electrical
are routinely recognized as superior
Between turnarounds, keep your
systems, process equipment,
by both customers and industry peers.
processes running at peak efficiency
instruments, and valves. Through
So, the next time you schedule a
through scheduled maintenance
asset optimization, customers have
turnaround, call Emerson’s Asset
of your electrical systems, valves,
increased production from 2%-5%
Reliability Services team. We can
and instrumentation.
and decreased their energy costs
be there before, during, and after
by 15%-20%.
your next turnaround to help you
PREDICT & OPTIMIZE
Emerson’s asset optimization
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Every Emerson product and service is
®
technology can help raise the
maximize the potential of every
productivity of aging plants.
asset in your plant.
www.assetweb.com
©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, Smart Turnarounds, Fisher, Micro Motion, Rosemount, FlowScanner and Encore 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.
D351034X012/MT-01-0209/printed in USA /7-2009
Emerson Process Management – Asset Optimization – Asset Reliability Services
Instrument & Valve Services
Electrical Reliability Services
Machinery Health Management
205 South Center Street
8760 Orion Place, Suite 110
835 Innovation Drive
Marshalltown, IA 50158
Columbus, OH 43240
Knoxville, TN 37932
www.assetweb.com