P4 Emerson Overview
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Overview
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Emerson Overview Willy Vinckx
Emerson Global Presence 2002 Headquartered in St. Louis, MO (USA) Founded in 1890 FY 2002 Sales of $13.8B Over 109,000 employees and 320 plants worldwide
Europe North America Sales: $8.8 billion Employees: 63,000
Sales: $2.8 billion Employees: 23,000 Locations: 83
Asia Sales: $1.6 billion
Emerson Growth Through Technology Leadership $530
$600
$400
40%
30%
$354
33% 26%
20%
$200 10%
$0
0%
1995
2002
Engineering & Development Investment ($M)
1995
2002
New Products as a Percent of Sales
The Emerson Brands
Emerson: $13.8 Billion In Revenues With Over 60 Divisions
The Emerson Brands
Emerson Process Management Overview
Measurement & Analytical
• Rosemount • Saab Rosemount • Micro Motion • Brooks • Rosemount Analytical • Daniel
Final Control Elements
• Fisher • Bettis • El-O-Matic • Shafer
Emerson Process Management Overview Revised 02, Dec. 2003, Slide 8
Systems & Solutions
• Delta V • Ovation • Industry Centers • • • • • • • • •
Asset Optimization
• AMS Suite • Services & Technologies
• Mechanical Chemical Equipment Oil & Gas • Electrical Refining Systems Power & Water • Process Life Sciences Equipment Metals & Mining • Instruments Pulp & Paper & Valves Food & Beverage Educational Services
Asset Optimization Mission Deliver World-Class Services, Innovative Technologies and Expertise to Increase the Availability and Performance of Production Assets for Improved Bottom Line Results
Mechanical Equipment
Electrical Equipment
Process Equipment
Instruments & Valves
PlantWeb Branding Strategy
PlantWeb Architecture DeltaV / Ovation
Intelligent Field Devices
AMS Suite
The AMS Suite of software applications enables predictive and proactive maintenance of mechanical equipment, electrical systems, process equipment, instruments and valves
PlantWeb Services Process Automation
Asset Optimization
PlantWeb Services for Asset Optimization ensure successful implementation of the AMS Suite and maximize the value realized by users
What are PlantWeb Services for Asset Optimization?
Services Are Critical To Help Customer’s Gain Full Value From Technology
Asset Management Best Practices
Plant assessment: -Business Objectives Work Process -Spider chart People & Skills
8.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.0
Management & Culture
Technologies
Program Design: Opportunities Identification Cost & ROI calculation
Implementation
• Define/optimize Work Processes • Apply Diagnostic AO Technologies • SRCM (criticality + FDP) • RCFA • Education / Certification
On-Going Execution
• Diagnostics Services • Monitoring & Analysis • Program Management
Spider chart Work Process
Work Identification
People & Skills
Spider
8.0 Qualification
Inter-Departmental Communication
7.0 6.0
Work Execution (Daily-Running Maintenance) Work Execution Scheduled) Work Close-out
5.0 4.0
Utilisation
3.0 2.0
Training
Work Management Systems
1.0 0.0 Maint. & Diagnostics Technologies
Goal
Benchmarking
Information Integration Tools
Technologies
Setting Goals Communication Mechanisms Global Metrics Leadership
Management & Culture
Continuous Improvement Accountability Organisation
Equipment description : Reactor pump Failure Mode &Effects Analysis MPI Equipment number : 50 P 101 Functional Failure 97 System Name: Polyols Reactor Heavy seal leak, Hot chemical product coming out pump Failure Effect Reactor must be stopped. Empty reactor. Product/Time loss. Polyols
LI
Heat Exchanger
TI/TT
Steam
Failure Mode Carbon seal ring of single mechanical seal was broken. Failure Cause Due to an unbalance of the pump seal ring has broken.
Failure Defence Task M Reactor pump
1. Balancing/Vibration analysis every 3 months 2. Improve seal design. 3. On-line monitoring
Implementation Approaches
Transition from Design to Machinery Health Operation Program Effort and Cost (€)
Implementation Approaches
Reliability and Availability
Contract Cost $ Labor, Training, and Technology Cost $ In-house
Implementation Time
Partnership
Outsourced
PlantWeb Includes Asset Optimization Technologies and Services
PlantWeb Architecture DeltaV / Ovation
Intelligent FieldDevices
AMS Suite
The AMS Suite of software applications enables predictive and proactive maintenance of mechanical equipment, electrical systems, process equipment, instruments and valves
PlantWeb Services Process Automation
Asset Optimization
PlantWeb Services for Asset Optimization ensure successful implementation of the AMS Suite and maximize the value realized by users
Applications in the AMS Suite Asset Portal
Intelligent Device Manager
Machinery Health Manager
Equipment Performance Monitor
Real-Time Optimizer
Decision-support, reporting and analysis on the health and performance of production assets Predictive and proactive maintenance of instruments and valves Predictive and proactive maintenance of mechanical equipment Predictive and proactive maintenance of process and mechanical equipment Real-time economic optimization of units, plant or multiple facilities based on changing conditions and business constraints
AMS Suite Enables Broad Diagnostics Coverage in PlantWeb
Valves Sticking
Mechanical Equipment
Process Equipment
Safety Valve Stuck
Loose Mounting
Boiler Sooting
Not Fully Seating
Misaligned & Unbalanced
Turbine Blade Wear
Plugged Air Supply
Gear Defects
Capacity Reductions
Instruments
Bearing Wear
Hourly Cost Increase
Impulse Lines Plugged
Cavitation
Increased Energy Use
Sensor Drifting
Motor Defects
Pump Efficiency Dropping
Probe Aging or Fouling
Efficiency Dropping
Equipment Efficiency Drop
Sensor Failed
Lubricant Contaminated
Heat Exchanger Fouling
Transmitter Installed Wrong
Belts Loose
Cumulative Cost Increase Maintenance Effectiveness
AMS Suite in the PlantWeb Architecture Asset Portal
Intelligent Device Manager
HART
Equipment Performance Monitor
Real-Time RealOptimizer
Machinery Health Manager
Fieldbus
Future Instruments & Valves
Process Equipment
Mechanical Equipment
Electrical Equipment
Quick Look at Asset Portal Summary Views
User configurable Tree
Data Sources
Summary of equipment from multiple data sources
Asset Details Select the asset to view details such as current configuration, calibration status, efficiency, etc..
Active Alerts Select the Active Alerts tab to view assets that currently have a problem.
Alert Details Select the alert to view the details of the current problem.
Link Relevant Information Embed links to other sources of information
Asset Portal Dashboard Graphical Dashboard highlights assets that need attention and speeds navigation
Asset Portal Supports Output
Asset Portal increases the efficiency of maintenance organizations by making on-line asset information available in a common format to technicians. Quickly and easily view all your plant asset information in real-time from anywhere. Make asset information available to all levels of the organization, so people can work more efficiently and make better decisions. Asset Portal enables people to see opportunities for improvement and companies to excel
Emerson Global Presence 2002 Headquartered in St. Louis, MO (USA) Founded in 1890 FY 2002 Sales of $13.8B Over 109,000 employees and 320 plants worldwide
Europe North America Sales: $8.8 billion Employees: 63,000
Sales: $2.8 billion Employees: 23,000 Locations: 83
Asia Sales: $1.6 billion
Emerson Growth Through Technology Leadership $530
$600
$400
40%
30%
$354
33% 26%
20%
$200 10%
$0
0%
1995
2002
Engineering & Development Investment ($M)
1995
2002
New Products as a Percent of Sales
The Emerson Brands
Emerson: $13.8 Billion In Revenues With Over 60 Divisions
The Emerson Brands
Emerson Process Management Overview
Measurement & Analytical
• Rosemount • Saab Rosemount • Micro Motion • Brooks • Rosemount Analytical • Daniel
Final Control Elements
• Fisher • Bettis • El-O-Matic • Shafer
Emerson Process Management Overview Revised 02, Dec. 2003, Slide 8
Systems & Solutions
• Delta V • Ovation • Industry Centers • • • • • • • • •
Asset Optimization
• AMS Suite • Services & Technologies
• Mechanical Chemical Equipment Oil & Gas • Electrical Refining Systems Power & Water • Process Life Sciences Equipment Metals & Mining • Instruments Pulp & Paper & Valves Food & Beverage Educational Services
Asset Optimization Mission Deliver World-Class Services, Innovative Technologies and Expertise to Increase the Availability and Performance of Production Assets for Improved Bottom Line Results
Mechanical Equipment
Electrical Equipment
Process Equipment
Instruments & Valves
PlantWeb Branding Strategy
PlantWeb Architecture DeltaV / Ovation
Intelligent Field Devices
AMS Suite
The AMS Suite of software applications enables predictive and proactive maintenance of mechanical equipment, electrical systems, process equipment, instruments and valves
PlantWeb Services Process Automation
Asset Optimization
PlantWeb Services for Asset Optimization ensure successful implementation of the AMS Suite and maximize the value realized by users
What are PlantWeb Services for Asset Optimization?
Services Are Critical To Help Customer’s Gain Full Value From Technology
Asset Management Best Practices
Plant assessment: -Business Objectives Work Process -Spider chart People & Skills
8.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.0
Management & Culture
Technologies
Program Design: Opportunities Identification Cost & ROI calculation
Implementation
• Define/optimize Work Processes • Apply Diagnostic AO Technologies • SRCM (criticality + FDP) • RCFA • Education / Certification
On-Going Execution
• Diagnostics Services • Monitoring & Analysis • Program Management
Spider chart Work Process
Work Identification
People & Skills
Spider
8.0 Qualification
Inter-Departmental Communication
7.0 6.0
Work Execution (Daily-Running Maintenance) Work Execution Scheduled) Work Close-out
5.0 4.0
Utilisation
3.0 2.0
Training
Work Management Systems
1.0 0.0 Maint. & Diagnostics Technologies
Goal
Benchmarking
Information Integration Tools
Technologies
Setting Goals Communication Mechanisms Global Metrics Leadership
Management & Culture
Continuous Improvement Accountability Organisation
Equipment description : Reactor pump Failure Mode &Effects Analysis MPI Equipment number : 50 P 101 Functional Failure 97 System Name: Polyols Reactor Heavy seal leak, Hot chemical product coming out pump Failure Effect Reactor must be stopped. Empty reactor. Product/Time loss. Polyols
LI
Heat Exchanger
TI/TT
Steam
Failure Mode Carbon seal ring of single mechanical seal was broken. Failure Cause Due to an unbalance of the pump seal ring has broken.
Failure Defence Task M Reactor pump
1. Balancing/Vibration analysis every 3 months 2. Improve seal design. 3. On-line monitoring
Implementation Approaches
Transition from Design to Machinery Health Operation Program Effort and Cost (€)
Implementation Approaches
Reliability and Availability
Contract Cost $ Labor, Training, and Technology Cost $ In-house
Implementation Time
Partnership
Outsourced
PlantWeb Includes Asset Optimization Technologies and Services
PlantWeb Architecture DeltaV / Ovation
Intelligent FieldDevices
AMS Suite
The AMS Suite of software applications enables predictive and proactive maintenance of mechanical equipment, electrical systems, process equipment, instruments and valves
PlantWeb Services Process Automation
Asset Optimization
PlantWeb Services for Asset Optimization ensure successful implementation of the AMS Suite and maximize the value realized by users
Applications in the AMS Suite Asset Portal
Intelligent Device Manager
Machinery Health Manager
Equipment Performance Monitor
Real-Time Optimizer
Decision-support, reporting and analysis on the health and performance of production assets Predictive and proactive maintenance of instruments and valves Predictive and proactive maintenance of mechanical equipment Predictive and proactive maintenance of process and mechanical equipment Real-time economic optimization of units, plant or multiple facilities based on changing conditions and business constraints
AMS Suite Enables Broad Diagnostics Coverage in PlantWeb
Valves Sticking
Mechanical Equipment
Process Equipment
Safety Valve Stuck
Loose Mounting
Boiler Sooting
Not Fully Seating
Misaligned & Unbalanced
Turbine Blade Wear
Plugged Air Supply
Gear Defects
Capacity Reductions
Instruments
Bearing Wear
Hourly Cost Increase
Impulse Lines Plugged
Cavitation
Increased Energy Use
Sensor Drifting
Motor Defects
Pump Efficiency Dropping
Probe Aging or Fouling
Efficiency Dropping
Equipment Efficiency Drop
Sensor Failed
Lubricant Contaminated
Heat Exchanger Fouling
Transmitter Installed Wrong
Belts Loose
Cumulative Cost Increase Maintenance Effectiveness
AMS Suite in the PlantWeb Architecture Asset Portal
Intelligent Device Manager
HART
Equipment Performance Monitor
Real-Time RealOptimizer
Machinery Health Manager
Fieldbus
Future Instruments & Valves
Process Equipment
Mechanical Equipment
Electrical Equipment
Quick Look at Asset Portal Summary Views
User configurable Tree
Data Sources
Summary of equipment from multiple data sources
Asset Details Select the asset to view details such as current configuration, calibration status, efficiency, etc..
Active Alerts Select the Active Alerts tab to view assets that currently have a problem.
Alert Details Select the alert to view the details of the current problem.
Link Relevant Information Embed links to other sources of information
Asset Portal Dashboard Graphical Dashboard highlights assets that need attention and speeds navigation
Asset Portal Supports Output
Asset Portal increases the efficiency of maintenance organizations by making on-line asset information available in a common format to technicians. Quickly and easily view all your plant asset information in real-time from anywhere. Make asset information available to all levels of the organization, so people can work more efficiently and make better decisions. Asset Portal enables people to see opportunities for improvement and companies to excel
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