Heighten
Operational
Readiness
Thank
You
Emerson Confidential
27-Jun-01, Slide 1
Heighten Operational Readiness for the
Power Industry
Moderator: Sara Larrabee, Marketing & Communications
Specialist, New England Controls
Jim Racca
Kristin Scharf
Greg Witte
Energy Industry
Leader
New England Controls
Reliability Technology
Consultant
New England Controls
Reliability Business
Development Manager
New England Controls
Emerson Confidential
27-Jun-01, Slide 2
Renewable Power and Abundant Natural
Gas Has Changed the Industry…
Challenges
Opportunities
Former baseload plants operate
in load follow  60-80% of plant
failures are related to cycling
Equipment & control
modifications reduce thermal
stresses & associated costs
Reliability is a top industry
concern, yet many plants have
limited reliability programs
Condition monitoring tools &
reliability programs improve
plant availability
About 50% of the industry’s
workforce will retire within 10
years
Productivity improvements
gained from technology,
training & staff support
Emerson Confidential
27-Jun-01, Slide 3
Dispatching Renewables Requires
Flexible Fossil Unit Operations
Increased load following
Lower minimum load
Increased ramp rates
More frequent shutdowns
Emerson Confidential
27-Jun-01, Slide 4
Plant Cycling is Increasing O&M Costs
A major root
cause of
increased O&M
costs for many
fossil units is
cycling
-NREL, Power Plant
Cycling Costs, Apr 2012
Emerson Confidential
27-Jun-01, Slide 5
Gaining Insight into
Equipment Health Raises
Plant Availability
Emerson Confidential
27-Jun-01, Slide 6
• Reduce forced
outages
• Streamline
maintenance
Enabling Predictive Technologies
Raises Plant Availability
Digital valves tell you
about excessive wear,
improper installation
or process variations
that may cause service
interruption…and tell
you how to correct
Vibration sensors
detect early onset
problems well
before any impact
on plant
operations
Digital automation
and asset management
systems let you make
decisions to optimize
production and
availability
Emerson Confidential
27-Jun-01, Slide 7
Measurement
devices
can warn you of
developing
problems…with time
to correct and avoid
a shutdown
Use of Enabling Predictive Technologies
Raises Plant Availability
Reduce plant incidents
Improved reliability of
critical motors/fans
Generate predictive
diagnostics for turbines
Predictive maintenance
of critical machinery
Reduced work orders
Emerson Confidential
27-Jun-01,
01, Slide 8
“We expect this integrated
equipment health
monitoring system to result
in high availability with
lower maintenance costs.”
Jason Bryant,
EDF, West Burton Station
How to Engage in Reliability– Big “R” versus little “r”
Reliability:
Holistic facility-wide
focus driving Top
Quartile Performance
reliability:
Business leaders see Emerson as a preferred reliability
partner in achieving “Top Quartile Performance”
Reliability Consulting • Emerson Confidential • Slide 9
Focus on a single
asset that
contributes to
overall Reliability
Benchmarks for Monitoring Reliability
$2.5 million Savings* - $4 million PER YEAR!
* Per $100 Million CAPEX
$6.5 million
QUARTILE
MAINT$
(% RAV)
STORES$
(% RAV)
% VIB
% IR MECH
% IR ELEC
% OIL ANAL
% OTHER
NDT
% ON PM
% ON BOM
Power Generation
Top 1st
0.9%
0.3%
91.8%
71.0%
100.0%
38.1%
63.9%
21.0%
75.0%
Middle 1st
2.5%
0.6%
82.5%
60.9%
92.0%
35.7%
55.9%
23.0%
69.0%
Top 2nd
3.5%
0.7%
69.5%
51.7%
88.1%
29.8%
49.9%
25.0%
61.0%
56.1%
41.2%
24.3%
41.0%
27.0%
DATA
57.0%
Middle 2nd
COST 1.6%
5.0%
HEALTH
85.1%
Top 3rd
6.5%
2.8%
42.8%
34.6%
79.8%
19.8%
35.9%
29.0%
55.0%
Middle 3rd
7.8%
3.9%
35.2%
21.2%
74.5%
15.4%
28.9%
32.0%
49.0%
Top 4th
9.1%
4.7%
26.1%
15.0%
68.7%
10.8%
22.1%
34.0%
46.0%
Middle 4th
13.7%
6.7%
13.2%
3.6%
60.9%
5.1%
15.9%
35.0%
39.0%
Bottom 4th
16.2%
10.2%
5.1%
0.0%
52.1%
1.0%
9.8%
39.0%
33.0%
© 2009 Management Resources Group, Inc.
Reliability
Consulting
• Emerson Confidential • Slide 10
Proprietary
and Confidential
Better maintenance performers
depend on more asset health information
Emerson’s Reliability Portfolio
Reliability
Consulting
Machinery
Health Management
•
•
•
•
•
Maintenance and reliability consulting
Machinery protection and diagnostics
Reliability engineering and project delivery
Vibration monitoring, analysis and prediction
Foundational data services and management
• Online, wireless, and portables solutions
Machinery Health Management
• Integrated equipment health monitoring and performance
analysis
• Asset
Performance
Management services
Plant
Asset
Management
Smart field
sensor health
and control
element
management
•• Integrated
equipment
monitoring
and performance
analysis
• Asset Performance Management services
• Smart field sensor and control element management
Lifecycle Services
• Asset monitoring
and performance improvement services
Lifecycle
Services
••
••
•
System
maintenance
and optimization
Asset
monitoring
and performance
improvement services
Training,
repair and
field
services
System
maintenance
and
optimization
Training, repair and field services
Reliability Consulting • Emerson Confidential • Slide 11
Project Services
• Machinery protection and diagnostics
Asset
Management
•Plant
Vibration
monitoring,
analysis and prediction
• Online, wireless, and portables solutions
NIPSCO Sugar Creek Power Generation Station
Reliability
Consulting Value
$168K
565 Megawatt, 2X1 Combined Cycle Facility
Indiana, USA
Solution
Vibration
Pressure
$270K
Flow
17 assets including pumps and
cooling towers instrumented for
predictive maintenance
$240K
Analytical
Level
$131K
2012 Pacesetter
Plant Award
Combined Cycle Journal
Reliability Consulting • Emerson Confidential • Slide 12
$70K
$64K
$97K
Temperature
Installation Services
Emerson’s Reliability Portfolio
Reliability
Consulting
Machinery
Health Management
•
•
•
•
•
Maintenance and reliability consulting
Machinery protection and diagnostics
Reliability engineering and project delivery
Vibration monitoring, analysis and prediction
Foundational data services and management
• Online, wireless, and portables solutions
Machinery Health
Machinery
Health Management
Management
• Integrated equipment health monitoring and performance
analysis
• Asset
Performance
Management services
Plant
Plant
Asset
Asset
Management
Management
Smart field
sensor health
and control
element
management
•• Integrated
equipment
monitoring
and performance
analysis
• Asset Performance Management services
• Smart field sensor and control element management
Lifecycle Services
• Asset monitoring
and performance improvement services
Lifecycle
Lifecycle
Services
Services
••
••
•
System
maintenance
and optimization
Asset
monitoring
and performance
improvement services
Training,
repair and
field
services
System
maintenance
and
optimization
Training, repair and field services
Reliability Consulting • Emerson Confidential • Slide 13
Project Services
Project
Services
• Machinery protection and diagnostics
Asset
Management
•Plant
Vibration
monitoring,
analysis and prediction
• Online, wireless, and portables solutions
Prediction for Condition Monitoring
PeakVue Detects Problems Sooner

As a problem worsens,
PeakVue value increases
PeakVue
0
10
20
40

Machine Condition
Good
Have maintenance check
Action plan must be in place
Machine will fail
Detects bearing faults,
defects, misalignments,etc.
on fans, pumps, motors,
and gearboxes
Emerson Confidential
27-Jun-01, Slide 14
Methods for Detecting
Machine Problems
Critical Assets - CSI 6500 ATG
Introducing Flexible I/O
Single card concept,
Nothing additional in the back
Communication
Emerson Confidential
27-Jun-01, Slide 15
Universal
Monitor
Process Input
Relay
What about an Upgrade from GE Bently
to CSI 6500 ATG?



Yes, you can
upgrade
Yes, you can
use the installed
GE BN sensors
Yes, it will have
the integrated
predictive
features as well
with GE BN
sensors
Emerson Confidential
27-Jun-01, Slide 16
CSI 6500 ATG
Information Availability
Information at your finger tip,
wherever you are in your facility
Emerson Confidential
27-Jun-01, Slide 17
CSI 6500 ATG
Simplify the Configuration





Emerson Confidential
27-Jun-01, Slide 18
MicroSoft Office oriented
Easy and intuitive
Real time analytical tools
Ability to store templates
You want more, graduate to
AMS Machinery Manager
CSI 6500 ATG
Simplify the Configuration
In addition to the online
predictive capability,
the measurement cards
store the last
• run up or
• coast down
Speed over time and
the main value for both
channels are available
as Bode diagram
Time wave form
FFT-Amplitude
Emerson Confidential
27-Jun-01, Slide 19
FFT-Phase
Emerson Confidential
27-Jun-01, Slide 20
Essential Assets – Wireless Monitoring
• Online continuous vibration
trend for early warning,
maintenance planning
Major Pumps
Compressors
• Temperature monitoring of
thermal cycle loss due to
leakages to increase megawatt
generation and lower emissions
• Online control valve diagnostics
for early warning, outage
planning
Cooling Towers
Emerson Confidential
27-Jun-01, Slide 21
FD & ID Fans,
Ammonia Blowers
• Add continuous online
measurements without adding
cable, conduit, and I/O
infrastructure
Tracking Bearing Failure on a Fan
Overall Vibration vs. PeakVue Impacting
0.15 / 3.7
Minimal Warning
Minimal
Warning
Good
0.4
FAULT
7.5
0.2
ALERT
5.0
Good
0.15 / 3.8
Good
0.16 / 4.0
Good?
0.18 / 4.5
OK?
0.30 / 7.5
Failure occurs!!!
PeakVue
Early Warning with Severity
50
0
Good
40
10
Alert – Notify maintenance
20
Problem getting serious.
30
Near end of life
40
Take action! Bearing failure
imminent
Emerson Confidential50
27-Jun-01, Slide 22
Failure occurs!!!
0.1
2.5
0.0
0.0
Onset of
Fault
PeakVue (g’s)
9.0
0.3
0.15 / 3.7
g’s
No
Warning!
FAULT
30
20
10
0
ALERT
After
Repair
mm/s
Bearing
Failure
in/s
Vibration
Vibration
Vibration
12.5
0.5
Robust and Tolerant to All Types of
Interference

Based on IEEE 802.15.4 radio standard
–
–
–
–

Channel hopping
DSSS modulation
Clear channel assessment
Channel black listing
Coexistence
Technical
White
Paper
Available
Non-interfering
– Low transmit power
– Very short messages bursts

Coexists with other wireless 2.4 GHz
networks such as IEEE 802.11b/g Wi-Fi
Emerson Confidential
27-Jun-01, Slide 23
WirelessHART
+
Wi-Fi
Unique ‘Always-On’ Security
Protection
Support
Description
Encryption
√
Scrambled, message is kept secret (AES-128)
Authentication
√
Login/Password (Network ID / Join key) to join network. Not over the air
Verification
√
Data integrity checksum: Not tampered with
Anti-Jamming
√
Channel hopping
Key Management
√
Encryption keys rotate automatically (hard to crack), access control list (ACL)
Sequence Number
√
Messages cannot be replayed later
Security
Technical
White
Paper
Available



ISA99 / IEC 62443 security
Security always on, can’t be turned off
No direct TCP/IP addressing
Emerson Confidential
27-Jun-01, Slide 24
Wireless Online Continuous Vibration
Monitoring System Architecture
Control System or Plant Historian
AMS Machinery
Manager
1.
2.
3.
4.
5.
Easy to install
Self-configuring
Self-healing
Fully scalable
Open standard
Emerson Confidential
27-Jun-01, Slide 25
AMS Device
Manager
Wireless
Gateway
Wireless Online Continuous Vibration
Monitoring System Architecture
Control System or Plant Historian
AMS Machinery
Manager
AMS Device
Manager
Optimum
Path
1.
2.
3.
4.
5.
Easy to install
Self-configuring
Self-healing
Fully scalable
Open standard
Emerson Confidential
27-Jun-01, Slide 26
Wireless
Gateway
New
Path
Obstacle
CSI 9420 Wireless Vibration Transmitter
Mount transmitter
away from machine
Most Equipment
Most
Equipment Types
Types
Most Applications
Applications
Most
Up to 100 ft / 30 m
Accel
Accel
)
This image cannot currently be displayed.
)
Wireless Vibration
Wireless
Vibration Transmitter
Transmitter
Outputs (scalar
Outputs
(scalar values)
values)
1.
Overall Vibration
2.
PeakVue® Vibration Units:
Range:
Comment:
G’s Peak
1,000 Hz – 20,000 Hz
Quantify early bearing & gearbox defects, need for
lubrication, pump cavitation
3.
Temperature
-30 to +250 F / -34 to +120 C
If applicable
Emerson Confidential
27-Jun-01, Slide 27
Range:
Comment:
Serial (Modbus RTU)
750 ft / 228 m
CSI 9420
CSI
9420
Units:
Range:
Comment:
)
OPC, Modbus TCP, or
Ethernet IP
Velocity (in/sec or mm/sec)
2 Hz – 1000 Hz (per ISO 10816 standard).
Identifies problems like imbalance, looseness,
misalignment
1420
Smart Wireless Gateway
Cooling Tower Fans Diagnosing Faults Using Vibration
Bearing
Bearing
Defects
Looseness
AMS Suite
Coupling
Issue
Control
System
Smart
Wireless
Gateway
CSI 9420
Wireless Vibration
Transmitters
Imbalance
Emerson Confidential
27-Jun-01, Slide 28
Shaft
Misalignment
Lubrication
Broken / Chipped /
Worn Tooth
Online Vibration Case History –
Monitor 9420 alerts and watch trends in order to prevent failures
4 days
before failure
9 days
before failure
30 days
before failure
Overall Vibration
PeakVue
Emerson Confidential
27-Jun-01, Slide 29
Bearing G’s PeakVue
Overall Vibration (In/Sec)
Belt Driven Fan - Inboard Bearing
Smart Valves Allow In-Service, Predictive
Diagnostics
Plugging of I/P
Travel Deviation
Insufficient Air Supply
Failed Diaphragm
Diaphragm Leaks
O-ring Failures in Actuators
Friction and Deadband
External Leaks
Many others
Emerson Confidential
27-Jun-01, Slide 30
Performance Diagnostics: Run On-Line Diagnostics
Tests for Troubleshooting or Prior to an Outage

No Alert
Valve Friction
–
High
Friction Alert

Supply Pressure
–

Air
Leak
Alert
Emerson Confidential
27-Jun-01, Slide 31

Ensure that the supply pressure
to the actuator is adequate;
detect and quantify droop in the
air supply during large travel
excursions
Air Mass Flow
–
Supply
Pressure
Alert
Determine valve friction & dead
band on a valve while it is online, in-service
Detect leaks downstream of the
relay (in the actuator or tubing
to the actuator)
I/P and Relay Integrity
–
Incorrect relay adjustment
–
I/P nozzle starting to plug
Advanced Diagnostics: Run Out of Service
Diagnostics at Valve During a Shutdown
50
Valve Signature 11LAB30AA101 14 Jul 2003 08:09:32
1st
2nd
Best Fit
1st 11LAB30AA101 22 Apr 2003 09:23:13
2nd 11LAB30AA101 22 Apr 2003 09:23:13
30
20
Closed
Actuator Pressure (psi)
Actuator
Pressure
(psi)
Actuator Pressure
(psi)
40
• Aqua & magenta shows valve signature
“as found” with badly damaged trim
• Red & blue shows valve signature with
new valve internals (verify operation
before putting valve back in service)
10
X: 3.12
0
Y: 40.18
Valve Travel (in.)
-10
-0.5
0
0.5
1.0
1.5
Travel (in)
Valve Travel (in.)
Emerson Confidential
27-Jun-01, Slide 32
2.0
2.5
3.0
Essential Control Valves
Typical Combined Cycle Plant (2 Units)
CT #1
IP to Cold
Reheat
2nd Stage Outlet
Temp Control
3rd Stage Outlet
Temp Control
4th Stage Outlet
Temp Control
Steam Cooling
Inlet
Steam Cooling
Outlet
Seal Oil H2 Side
TE Pressure Diff
Seal Oil H2 Side
CE Pressure Diff
Emerson Confidential
27-Jun-01, Slide 33
CT #2
IP to Cold
Reheat
2nd Stage
Outlet Temp
Control
3rd Stage Outlet
Temp Control
4th Stage Outlet
Temp Control
Steam Cooling
Inlet
Steam Cooling
Outlet
Seal Oil H2 Side
TE Pressure Diff
Seal Oil H2 Side
CE Pressure Diff
HRSG #1
LP Drum
Feedwater
HRSG #2
LP Drum
Feedwater
IP Drum
Feedwater
IP Drum
Feedwater
HP Drum
Feedwater
HP
Attemperator
HRH
Attemperator
HP Drum
Feedwater
HP
Attemperator
HRH
Attemperator
HP Sky Vent
HP Sky Vent
HRH Bypass
HRH Bypass
HP Bypass
HP Bypass
LP Bypass
LP Bypass
Steam
Turbine/BOP
HP to Aux Steam
CRH to Aux Steam
HP Aux Steam
Attemperator
Gland Seal Steam
Inlet
Gland Seal Steam
to Condenser
Seal Oil H2 Side
Temperature
Seal Oil H2 Side TE
Pressure Diff
Seal Oil H2 Side CE
Pressure Diff
Balance of Plant Assets – Route Based
Analysis Tools

Colored parameter
alarms provide
immediate indication of
Machinery Health
M1H - RPM
May 2007 – July 2007
A
A
A
A
B
Fault
Next
Freq
Trend

Ampl: 1713.47
Fault Frequencies help
identify the source of
the vibration

Trends provide
historical reference for
immediate evaluation
of current status
Fault Frequencies
Emerson Confidential
27-Jun-01, Slide 34
June 12 2007
Trend
Parameter Alarms
B
B
Prev
Trend
See what parameter is
in alarm and its severity
immediately at the
point of data collection

B
Essential/BOP Rotating Assets
Typical Combined Cycle Plant (2 Units)
CT #1
CT #2
Steam Turbine
ACC
CLCW Fans
Fire Pump House (BOP)
#1 AC L.O. Pump
#1 AC L.O. Pump
#1 AC L.O. Pump
K11 Fan Motor
CLCW HE Fan Motor #11
Cond Make Pump Motor #1
#2 AC L.O. Pump
#2 AC L.O. Pump
#2 AC L.O. Pump
K12 Fan Motor
CLCW HE Fan Motor #12
Cond Make Pump Motor #2
DC L.O. Pump
DC L.O. Pump
DC L.O. Pump
D1 Fan Motor
CLCW HE Fan Motor #21
Back Wash Motor Pump #1
DC Seal Oil Pump
DC Seal Oil Pump
DC Seal Oil Pump
K13 Fan Motor
CLCW HE Fan Motor #22
Back Wash Motor Pump #2
#1 Vapor Extractor
#1 Vapor Extractor
#1 Vapor Extractor
CLCW HE Fan Motor #31
Raw Water Pump Motor #1
#2 Vapor Extractor
#2 Vapor Extractor
#2 Vapor Extractor
K21 Fan Motor
CLCW HE Fan Motor #32
Raw Water Pump Motor #2
Rotor Air Cooling Fan Mtr
Rotor Air Cooling Fan Mtr
Generator Casing Inlet
K22 Fan Motor
CLCW HE Fan Motor #41
Service Water Pump Motor #1
Enclosure Fan #1
Enclosure Fan #1
Generator Casing Aft-end
D2 Fan Motor
CLCW HE Fan Motor #42
Service Water Pump Motor #2
Enclosure Fan #2
Enclosure Fan #2
Bently Nevada
K23 Fan Motor
Enclosure Fan #3
Enclosure Fan #3
Turning Gear Motor
Enclosure Fan #4
Enclosure Fan #4
#1 Gland Steam Exhaust Fan Mtr
Enclosure Fan #5
Enclosure Fan #5
Enclosure Fan #6
Diesel Fire Pump
T-HALL Roof & HRSG Fans
Electric Fire Pump
K31 Fan Motor
Main Turbine Hall Fan #1
Jockey Pump
#2 Gland Steam Exhaust Fan Mtr
K32 Fan Motor
Main Turbine Hall Fan #2
Enclosure Fan #6
Clean Drains Pump Motor #1
D3 Fan Motor
Main Turbine Hall Fan #3
Fuel Oil / Well Water / WTB
Starting Motor
Starting Motor
Clean Drains Pump Motor #2
K33 Fan Motor
Main Turbine Hall Fan #4
Surge Raw Water Pump # 1
Generator Casing Inlet
Generator Casing Inlet
EH Pump Motor #1
Main Turbine Hall Fan #5
Surge Raw Water Pump # 2
Generator Casing Aft-end
Generator Casing Aft-end
EH Pump Motor #2
K41 Fan Motor
Main Turbine Hall Fan #6
Fuel Forwarding Pump Motor #1
Bently Nevada
Bently Nevada
K42 Fan Motor
Main Turbine Hall Fan #7
Fuel Forwarding Pump Motor #2
Main Fuel Oil Pump
Main Fuel Oil Pump
BOP
D4 Fan Motor
Main Turbine Hall Fan #8
Well Water Pump Motor #1
Turning Gear Motor
Turning Gear Motor
Main Condensate Pmp Mtr #1
K43 Fan Motor
Well Water Pump Motor #2
Main Condensate Pmp Mtr #2
Well Water Pump Motor #3
HRSG Bldg Lower Roof
HRSG Bldg Upper Roof
Boiler Feed Pump Motor #1
Separator Lift Pump Motor #1
HRSG Exhaust Fan #6
HRSG Exhaust Fan #1
Boiler Feed Pump Motor #2
Separator Lift Pump Motor #2
HRSG Exhaust Fan #7
HRSG Exhaust Fan #2
CLCW Pump Motor #1
Back Wash Sump Pump Motor #1
HRSG Exhaust Fan #8
HRSG Exhaust Fan #3
CLCW Pump Motor #2
Back Wash Sump Pump Motor #2
HRSG AHU #1
HRSG AHU #2
HRSG Exhaust Fan #4
HRSG Exhaust Fan #5
Int Blowdown Tank Pmp Mtr #1
Int Blowdown Tank Pmp Mtr #2
Back Wash Filt Feed Pmp Motor #1
Back Wash Filt Feed Pmp Motor #2
Oily Waste Sump Pmp Mtr #1
Fuel Oil Off Loading Pump #1
Oily Waste Sump Pmp Mtr #2
Fuel Oil Off Loading Pump #2
Chemical Sump Pump Motor #1
Fuel Oil Off Loading Pump #3
Chemical Sump Pump Motor #2
Intrument Air Cooling Fan # 1
Intrument Air Cooling Fan # 2
Emerson Confidential
27-Jun-01, Slide 35
Demographic Shifts
Require the Preservation
of Skills & Experience
Emerson Confidential
27-Jun-01, Slide 36
• Retain critical
knowledge
• Keep your staff
trained
• Supplement
your workforce
The Growing Labor Imbalance
Approximately
half of the work
force in the
electric utility
sector will retire
in the next 10
years.
- US Bureau of Labor
and Statistics
An estimated 31% of employers worldwide find it difficult to fill
positions because of talent shortages in their markets.
- Emerson
Ernst Confidential
& Young, Six Global Trends Shaping the World
27 Jun 01, Slide 37
27-Jun-01,
Technology Will Help Supplement
Staffing and Knowledge Shortfalls
Remote Collaboration &
Supplemental Staffing
Embedded Expertise
Simulation &
Analytics
Emerson Confidential
27-Jun-01, Slide 38
Embedded Expertise Informs Plant
Before Operations is Impacted
Business
(ERP)
Operations
Emerson Confidential
27-Jun-01, Slide 39
Maintenance
& Reliability
Meaningful Information, Like Advice
From a Senior Staff Member



Emerson Confidential
27-Jun-01, Slide 40
This valve has a
maintenance issue
that needs
investigation
A click of a button
reveals a travel
deviation with clear
guidelines to fix the
problem
Simple action taken
today can avoid a
problem that reduces
unit availability
Remote Rotating Machinery Condition
Monitoring Process
2. Emerson Remote Monitoring Service
Reports via
Email or WWW
Data Export
Expert Analysis of Export Data
1. Customer Site
AMS Machinery Health Manager collects data from
machinery via CSI online hardware.
Emerson Confidential
27-Jun-01, Slide 41
3. Customer Site
Emerson Local Service Providers work with
customer to interpret the information provided by
the monitoring service.
Service Implementation
• New England Controls Reliability Engineer travels to site to
implement the below process
• Time estimate: 50 machines per day
Machinery
data
provided
Emerson Confidential
27-Jun-01, Slide 42
Database
build
Data
collection
training
Data transfer
process
implemented
Remote Monitoring Process
Sense

Acquire
Transfer
Analyze
Act
Service leverages batch or continuous data collection
– Routes are collected monthly by customer with CSI
2130/CSI 2140 handheld vibration analyzers
(analyzers can be leased from Emerson as part of
program)
– CSI 9420 or CSI 6500 online monitoring systems
continuously collect data on specific intervals or when
alarm levels are reached
Emerson Confidential
27-Jun-01, Slide 43
Remote Monitoring Process
Sense
Acquire
Transfer
Analyze
Act

Vibration data is transferred to Emerson analysts via
secure FTP or Secure Remote Desktop

Data is stored in secure Emerson servers
Emerson Confidential
27-Jun-01, Slide 44
Remote Monitoring Process
Sense
Acquire
Transfer
Analyze
Act

Vibration data is reviewed by ISO 18436-2 Level 3
analysts

Analysts generate monthly reports based on machinery
conditions

Reports include problem identified, recommended
actions and potential root cause
Emerson Confidential
27-Jun-01, Slide 45
Remote Monitoring Process
Sense
Acquire
Transfer
Analyze
Act

New England Controls to lead follow up meeting to
ensure appropriate corrective maintenance actions are
taken

Customer or New England Controls performs corrective
maintenance
Emerson Confidential
27-Jun-01, Slide 46
Remote Rotating Machinery Condition
Monitoring Process - Sample Report
Customer XYZ
Example Report
Alarm Summary
Overview matrix
showing machine
condition
Emerson Confidential
27-Jun-01, Slide 47
Detailed Analysis
Remote Control Valve Condition
Monitoring Process – Sample Report
High Level Health
Values and Monthly
Valve Data
Emerson Confidential
27-Jun-01, Slide 48
Remote Control Valve Condition
Monitoring Process – Sample Report
Control Valve
Specific Data
Raw Data from Valve
Diagnostic Tests
Expert Analysis and
Recommendations
Emerson Confidential
27-Jun-01, Slide 49
Emerson Confidential Proprietary
Emerson Can Help You Improve Plant and
Fleet Performance
Raise Plant
Reliability
Emerson Confidential
27-Jun-01, Slide 50
Enhance Staff
Effectiveness
Improve unit and fleet
availability with online
condition monitoring
Use technology to
supplement retirements
and skill shortages
Gain earliest possible
insight into developing
problems with enabling
technologies
Leverage 3rd party
partners to optimize and
shorten outages
Enhanced training will
elevate staff performance
Thank You
Thank
You
Emerson Confidential
27-Jun-01, Slide 51
Heighten Operational Readiness
for the Power Industry
Jim Racca
Energy Industry Leader, New England Controls
(508) 339-5522
Jim.Racca@newenglandcontrols.com
Kristin Scharf
Reliability Technology Consultant, New England Controls
Kristin.Scharf@newenglandcontrols.com
Greg Witte
Reliability Business Development Manager, New England Controls
Greg.Witte@newenglandcontrols.com