System Planning Guide

System Planning Guide
Essential Asset Monitoring Essential Asset Monitoring Suite

Revision P1 – 2014-SEPT-09 – Page 1 of 36
Essential Asset Monitoring

Emerson Process Management 2014 – Confidential and Proprietary

Disclaimer
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. We reserve the right to modify or improve the designs or
specifications of such products at any time without notice. This document is not to be
redistributed without permission from Emerson Process Management.
Copyright and Trademark Information

© Emerson Process Management, 2014. All rights reserved. Printed in the USA.
The Emerson logo is a trademark and service mark of Emerson Electric Co.
AMS, PlantWeb™, SNAP-ON™, DeltaV™, RS3™, PROVOX™, Ovation™, FIELDVUE™,

SmartProcess® and ValveLink™ are marks of one of the Emerson group of companies
HART® and WirelesssHART® are registered trademarks of the HART Communications

Foundation of Austin, Texas, USA
All other marks are property of their respective owners.
Revision History
Rev Status Description Date Developed By Reviewed By
P1 Initial Release For EAM application v.R3 Sept 6, 2014 KSP PS

Table of Contents
1 INTRODUCTION ______________________________________________________ 4
1.1 Intended Audience ............................................................................................................ 4
1.2 Reference Publications ..................................................................................................... 4
1.2.1 EAM Application Documentation ....................................................................................................... 4
1.2.2 Product Data Sheets .......................................................................................................................... 4
1.2.3 White Papers and Sales Information ................................................................................................. 5
1.3 Introduction to EAM Solution ............................................................................................. 5
1.4 Glossary ............................................................................................................................ 7
2 SYSTEM CONSIDERATIONS ____________________________________________8

2.1 EAM Application Overview ................................................................................................ 8
2.1.1 EAM Pump ......................................................................................................................................... 9
2.1.2 EAM Heat Exchanger ....................................................................................................................... 10
2.1.3 Blower ............................................................................................................................................... 11
2.1.4 Compressor ...................................................................................................................................... 12
2.1.5 Air-Cooled Heat Exchanger ............................................................................................................. 13
2.1.6 Cooling Tower .................................................................................................................................. 14
2.2 Architecture Overview ..................................................................................................... 14
2.3 EAM Multiuser Architecture ............................................................................................. 15
2.3.1 Thin Client Approach ........................................................................................................................ 16
2.3.2 Thick Client Approach ...................................................................................................................... 17
2.3.3 Hybrid Approach............................................................................................................................... 17
2.4 EAM Requirement Specifications .................................................................................... 18
2.4.1 AMS Asset Graphics License Specifications ................................................................................... 19
2.4.2 Hardware Specifications .................................................................................................................. 19
2.4.3 System Software Specifications....................................................................................................... 19
2.4.4 EAM Functional Specifications ........................................................................................................ 20
3 Systems Integration ___________________________________________________ 22

3.1 Interface with DeltaV ....................................................................................................... 22
3.2 Interface with Ovation...................................................................................................... 26
3.3 Interface with Historians .................................................................................................. 26
4 OTHER CONSIDERATIONS ____________________________________________ 27

4.1 Application Support ......................................................................................................... 27
4.2 Upgrades and Extensions ............................................................................................... 27
4.3 Backup and Recovery ..................................................................................................... 27
Appendix A - Fault Matrices

Revision P1 – 2014-SEPT-09 –
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1 INTRODUCTION
This document provides guidelines to help users successfully plan, implement, and
use Essential Asset Monitoring applications. This guide also contains information on
application types and their architectures, licensing requirements, and general
planning considerations.
1.1 Intended Audience

This guide is intended for sales and service personnel at Local Business Partners
and Field Sales Offices (LBP/FSO) as well as company personnel of Emerson
Process Management.
The information in this guide should be considered as confidential.
1.2 Reference Publications

1.2.1 EAM Application Documentation
The EAM Application is delivered with the following documentation:
- Installation Guide
- Configuration Guide
- User Manual
Access to the EAM demos and documentation is provided for Emerson or Local
Business Partner employees. Access requires a valid Emerson Active Directory
account. You may request access to these files by sending an email to:
EAM.Support@Emerson.com.
1.2.2 Product Data Sheets

A Product Data Sheet for the EAM solution as well as customer flyers for each of the
assets are available on the Emerson Global Sales Portal.
EAM:
https://sales.emersonprocess.com/IndustriesandApplications/IndustrySolutionsPacka
ges/Pages/Essential-Asset-Monitoring.aspx
Pumps:
http://www2.emersonprocess.com/siteadmincenter/PM%20Central%20Web%20Doc
uments/PumpsREF_CustFlyer.pdf
Blowers:

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uments/BlowersREF_CustFlyer.pdf
Heat Exchangers:
uments/HeatExchangersREF_CustFlyer.pdf
Air-Cooled Heat Exchangers:
uments/Ache-REF_CustFlyer.pdf
Compressors:
uments/CompressorsREF_CustFlyer.pdf
Cooling Towers:
uments/CoolingTowersREF_CustFlyer.pdf
1.2.3 White Papers and Sales Information

Many white papers and sales material are available for each of the asset types on
the Global Sales Portal. In particular, there are Application Opportunity Briefs (AOB)
for each asset type that outlines the solution, the benefits to a customer and which
customer roles care.
1.3 Introduction to EAM Solution

Emerson’s EAM solution is a combination of software, hardware, and measurement
devices designed to monitor the performance and ascertain the “health” of particular
types of assets. The solution that Emerson provides to an end customer must be
tailored to the specific requirements and infrastructure available at a plant.
Depending on the level of instrumentation that exists, the types of faults that need
detecting, and the user interface preferences, an EAM project will likely involve
installing new field devices, wireless gateways, a new EAM server hardware and
software and integration with an existing DCS or historian.
Emerson’s EAM software can be delivered as a stand-alone server connected to the

plant LAN and any wireless gateways, providing the database, calculation logic and
user-interface through dedicated monitors and remote sessions. Alternatively, the
EAM Server can be treated as a “black box” for the calculations and logic, and the
user interface is provided on a DeltaV, Ovation or OSI-PI platform. These options
are explained further in Section 2.
EAM software modules are currently available for the following asset types:
- Pumps

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- Blowers
- Heat Exchangers (Shell/Tube)
- Air-Cooled Heat Exchangers
- Compressors (Max 3-stage, Roller Bearings)
- Cooling Towers
Each of the EAM modules uses a common look and feel for the standard User
Interface. Each module is designed for the maximum potential instrumentation
possible, but a user can select which inputs are available (based on which faults
they need to detect) and the system will automatically disable the calculations that
are not required.
It should be noted that Emerson’s EAM applications use a statistical approach to

determining health as opposed to the 1st principles models found in AMS
Performance Advisor and AMS Performance Monitor. The intent is to simplify the
configuration, installation and setup of the EAM modules and use these as indicators
to flag attention when something does not look right. The system can automatically
capture a base-line or a signature and calculate statistical limits for alarming.

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1.4 Glossary
Term Definition
ACHE Air Cooled Heat Exchanger
AMS AG AMS Asset Graphics
DCS Distributed Control System – Could be DeltaV,

Ovation or something else.
EAM EAM – Usually references the EAM software

that performs the algorithm and logic
OPC OLE for Process Control - Standard protocol

use to exchange real-time data between
systems
UI User interface – The application running on

the user’s PC which displays the EAM
variables, calculations and alerts.

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2 SYSTEM CONSIDERATIONS
2.1 EAM Application Overview
EAM applications are designed to continuously monitor the health of industrial
assets by combining both process and equipment data in a patent-pending approach.
The EAM Suite is built on Emerson’s AMS Asset Graphics (AG) platform. AG
typically runs on a dedicated PC or Server with the EAM application engine scanning
the measurements, running the logic and setting alerts and statuses. The AG
platform has been designed to easily integrate with the existing control system at a
customer site using OPC.
Emerson’s wireless technology for the field instruments provides additional

advantage for using the EAM applications in remote, hazardous areas.
Using the built-in OPC client in AMS AG, the EAM applications read the field
instrument data over OPC communication. This data is then processed to generate
alarms, alerts, KPIs and asset Health as indicated in the flowchart below (Figure 2-1).
Statistical Alarms
for Vibration
EAM Functional Flowchart
Static & Dynamic
Record Calculate Process Alarms
Process &
Baselines & Alarm
Vibration Data
Signatures Limits
Process Alerts
Performance Indices
Health Calculation
Data Trending
Data Exporting
Events Logging
Figure 2-1
EAM Functional Flowchart
Presently, the EAM Suite is available for following assets:

 EAM Pump
 EAM Heat Exchanger
 EAM Blower

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 EAM Multistage Compressor

 EAM Air Cooled Heat Exchanger
 EAM Cooling Tower
These modules are licensed on a per-asset basis with volume discounts starting at 5
of more. A description of each is provided below. Further material can be found on
the Emerson Global Sales Portal.
2.1.1 EAM Pump
Figure 2-2
EAM Pump Process Overview
This module is designed to monitor the health of centrifugal pumps, in essentially any
type of service. It uses vibration sensors on the pump and motor, combined with
process data on the flow, suction and discharge pressures and seal flush system to
detect when one of the parameters is outside it’s expected operating range and
detects faults like bearing or alignment issues, cavitation, plugged suction strainers,
hydrocarbon leaks and seal flush problems.
For more information, see this site:
ges/Pages/Pump-Health-Monitoring.aspx

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2.1.2 EAM Heat Exchanger
Figure 2-3
EAM Heat Exchanger Process Overview
EAM for heat exchangers is designed primarily for shell-and-tube heat exchangers,
although other types (e.g. plate, seawater) have been considered. The application
utilizes the process flows, inlet and outlet temperatures to calculate exchanger duty,
fouling factor and degradation cost. In addition the application utilizes differential
pressure to assist with predicting when the exchanger will need cleaning.
ges/Pages/Essential-Asset-Monitoring---Heat-Exchangers.aspx

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2.1.3 Blower
Figure 2-4
EAM Blower Process Overview
The EAM module for blowers uses vibration sensors on the fan and motor as well as
air pressure and louver positions to detect fan blade imbalance, bearing defects,
lubrication issues, resonance speed, and malfunctioning louver drive. Health is
derived from the active alerts and distance from maximum vibration limits.
ges/Pages/Essential-Asset-Monitoring---Blowers.aspx

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2.1.4 Compressor
Figure 2-5
EAM Compressor Process Overview
EAM for compressors is designed for single-, dual- or 3-stage centrifugal

compressors and calculates health from vibration and process parameters. The
Compressor module monitors for rotor alignment, lubrication and bearing issues on
each stage. The wireless CSI9420 is designed for rolling-element bearings. While
some customers have applied the CSI9420 vibration sensors on sleeve-type
bearings, the recommendation would be a CSI6500. The vibration signals from the
6500 can be used as EAM inputs. Additional faults include low flow, low stage
pressure ratio, and compressor instability.
ges/Pages/Essential-Asset-Monitoring---Compressor.aspx

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2.1.5 Air-Cooled Heat Exchanger
Figure 2-6
EAM ACHE Process Overview
The Air-Cooled Heat Exchanger (ACHE) module of the EAM suite monitors both the
fan and the thermodynamic performance of these assets. For ACHE, the system
monitors for fan imbalance, louver defects, resonance speeds, bearing, lubrication
and alignment issues, exchanger fouling, and damaged heat exchanger surfaces.
For more information see:
ges/Pages/Essential-Asset-Monitoring-Air-Cooled-Heat-Exchangers.aspx

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2.1.6 Cooling Tower
Figure 2-7
EAM Cooling Tower Process Overview
EAM for cooling towers provides integrated monitoring and determination of a

combined health status for each cooling tower cell, including supply and circulation
pumps, fans, makeup and blow-down water, basin, chemical use and water
chemistry.
ges/Pages/Essential-Asset-Monitoring---Cooling-Towers.aspx
2.2 Architecture Overview

The EAM Software is designed to allow customers to easily bring in real-time data
either through wireless or existing wired infrastructure via OPC. Emerson delivers a
pre-configured EAM solution which only needs to be mapped to the appropriate OPC
points. The system is typically run on a dedicated server and the user interface can
be either through remote sessions or integrated into the existing DCS or historian
user screens. Refer to Section 3 for more details.

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Figure 2-8
Typical EAM Architecture at site
Figure 2-8 shows the basic architecture of a typical EAM application. As shown, the
source of OPC data for the EAM application could be the wireless gateway or the
OPC server in the local DCS, PLC or historian. The Blue line indicates the data flow
from the wired transmitters and the Green line indicates data flow for the wireless
transmitters.
The EAM application is designed to read data from DA (Data Access) type OPC
server which can feed a continuous stream of data. The application also reads
instrument health status of the individual data point along with its process value. The
health status is then indicated on the user interface of the EAM application and used
in the fault detection logic and asset health.
Using the built in OPC client in AMS AG, it is possible to read data from multiple OPC
servers simultaneously.
2.3 EAM Multiuser Architecture

The EAM application could be used in multiuser environments using the following
approaches
1. Thin Client (Remote Desktop) approach.
2. Thick Client (Dedicated Station) approach.

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3. Hybrid approach (Remote Desktop and Dedicated stations)
2.3.1 Thin Client Approach

In case of thin client approach, there is only one Master station running the EAM
application. The client machines can connect to the Master station using Microsoft
Windows remote desktop application (RDP). There could be up to 31 such thin
clients concurrently accessing the EAM Master station. A multi-user system is
licensed based on the number of concurrent sessions allowed. The following
diagram provides an example network diagram for this approach.
Figure 2-9
EAM Architecture for Thin Client Multiuser Approach
2.3.1.1 Prerequisites
1. AMS AG platform needs to be installed on the Master station only with a

multiuser license. (The thin clients do not require any additional software
prerequisites).
2. The Master station must be a server-grade machine with MS Windows Server

operating system installed along with terminal server license with required
number of concurrent users.
3. The machine specifications of the Master station should ensure performance

capability to serve the required number of multiple RDP connections concurrently.
4. The thin clients must be able to connect to the master station through a remote
desktop connection.

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2.3.2 Thick Client Approach

In this approach, as the name suggests, the clients would be user PC’s connected to
the Master station through a physical or wireless network. Each client station needs
the AG client software to be installed. This approach eliminates the need of a server
grade machine for the EAM master station. Also, no terminal server license is
required in this case. The machine specifications for the Master station could be as
simple as that of the thick client machine.
Similar to the previous approach, the number of clients that could be connected to
Master station is limited to 31.
Figure 2-10
EAM Architecture for Thick Client Multiuser Approach
2.3.2.1 Prerequisites
1. AMS AG platform needs to be installed on the Master station as well as all the
client stations.
2. The client PC’s need to have direct network access to the Master station through
the firewall.
2.3.3 Hybrid Approach

This is special case of thin client approach wherein some thick clients are connected
to the Master station through physical network (as in case of thick client approach)
thereby offering advantages of both the approaches into one.

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The total number of clients (thick and thin) is licensed by concurrent user and is
limited to 31.
Figure 2-11
EAM Architecture for Hybrid Multiuser Approach
Note: When it comes to selecting one of the above mentioned approaches, following
factors are to be considered
1. Need for running the EAM application remotely (from the plant LAN or higher
level LANs)
2. Investment cost on the EAM stations
With thin client approach, the EAM application could be run on lower grade machines
(not need of workstation grade machines). However the customer needs to put more
investment in the EAM master station (terminal server license, Server grade OS etc)
In case of thick client approach, the Master station could be as simple as the thick
client (workstation grade machine), however the client machines should satisfy the
minimum specifications mentioned in Section 2.4.2.
2.4 EAM Requirement Specifications

The following sections outline EAM requirements in terms of following aspects
 AMS Asset Graphics Licenses
 Hardware
 System Software

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 Configuration
2.4.1 AMS Asset Graphics License Specifications

Table 1 shows the required AMS AG licenses that should appear in a typical AMS
AG license document for the EAM applications. These are all bundled into one EAM
Solution part number and sold as an EAM system from Emerson’s AO office in
Knoxville.
Table 1
AMS AG License Specifications
License Specification
Sets the database element size to accommodate all the
System Size
assets to be monitored
Number of concurrent users supported in case of
Simultaneous Users
multiuser environment. (Refer to Section 2.3)
Runtime Program
Multilanguage Required for Multilanguage texts on the user interface
Required only in case of Multiuser environment. (Refer to
Floating License
Section 2.3 for details)
Required only in case of Multiuser environment. (Refer to
Network
Section 2.3 for details)
Required for sharing the EAM data with DCS/PLC. E.g.
OPC Server
EAM alerts in DeltaV (Refer to Section 3.1 for details)
OPC Editor Required for editing/creating OPC client tables
2.4.2 Hardware Specifications

The EAM runtime is usually executed on a dedicated computer, either a workstation
for single user or a server-class machine for multi-user systems. The main criteria
that will affect the hardware specification are the number of simultaneous users and
number of assets to be monitored. The following Table 2 lists the minimum
specification required by the EAM servers.
Table 2
Machine Specifications
Machine Specifications Related EAM Feature

EAM v.R3 (AMS AG v.6.0.2.0)
Processor : Intel Xeon Maximum 40 assets
Processor Speed : 2.4 GHz
RAM : 4 GB
Screen Resolution:
1680 X 1050 OR
1280 X 1024
2.4.3 System Software Specifications

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Table 3 lists the software prerequisites that need to be installed on the EAM Master
station.
Table 3
Software Prerequisites for EAM Master Station
Software Prerequisites Related EAM Feature

Operating System:
- Win 7 - For single user environment
- Win Server 2008 - For multiuser environment
AMS Asset Graphics A maximum of 100 assets can be supported on one
- Version 6.0.2.0 license.
EAM Project Software EAM v.R3 or later
- EAM-PUMPS - Pump Health Monitoring
- EAM-HX - Heat Exchanger Monitoring
- EAM-BLWR - Blower Monitoring
- EAM-ACHE - Air-Cooled Heat Exchanger Monitoring
- EAM-CMPR - Compressor Monitoring
- EAM-CT - Cooling Tower Monitoring
Microsoft Excel 7 Required only in case of EAM Heat Exchange application
OPC DCOM Configuration To enable OPC communication on the Master station
and on the thick clients. See Installation Guide for more
information
Table 4 shows software prerequisites for EAM thick clients.
Table 4
Software Prerequisites for EAM Thick clients
Software Prerequisites Related EAM Feature

Operating System:
- Win 7
AMS Asset Graphics
- Version 6.0.2.0
Microsoft Excel 7 Required only in case of EAM Heat Exchange application
There are no separate prerequisites required for the EAM thin clients except the
ability to connect remotely to the master station.
2.4.4 EAM Functional Specifications

The EAM modules come pre-configured from the factory based on the set of inputs
defined by the customer with the assistance of the local Emerson representative.
Each asset type has a specification form that must accompany the order. These
specification forms define the process inputs that are available, input tag names,
units of measure and valid ranges. In addition, some assets require physical
property constants and equipment information. This data is used to configure the

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project software that is delivered to an Emerson service representative to install and

commission.
NOTE: As mentioned above, the EAM modules have been designed to allow
the maximum level of instrumentation that might ever be needed to detect a
fault or health condition for that type of asset. We recognize that not all assets
will have (or need) all the measurements that are possible. Each asset has a
“Fault Matrix” that is reflected in the Bill of Material tool on their respective
Emerson Sales Portal Page. These fault matrices define which inputs are
required to detect which faults. Using this tool, an Emerson representative can
work with customers to define which faults are important and, therefore, the
required measurements to support them.
For reference, the fault matrix and specification form for each asset is provided in
Appendix A. The reader is recommended to get the latest versions from the
referenced websites above.

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3 SYSTEMS INTEGRATION
In a typical scenario, EAM application users might include operators, maintenance
technicians and reliability personnel as well as process engineers and operations
managers. As a result, the EAM solution is designed to be easily integrated with an
existing DCS or process historian using the built-in OPC server. The AMS AG
system can be treated as a “black box”, performing the calculations and writing the
results back to the customer’s DCS and historian. Using this approach, EAM
graphics and displays can be replicated in the same User Interface (UI) environment
already in use at the site separately. In many systems, including DeltaV, Ovation
and PI, the UI can be setup to launch a remote session on the AMS AG Master
server, giving the user direct access to the EAM displays, trends and functions. It
should be recognized that integration with an external system requires additional
engineering to develop, install and commission. For Emerson platforms, we make
the job easier using an EAM integration library that is provided with the EAM project
software. Further description is provided below.
3.1 Interface with DeltaV

The EAM suite offers additional advantages for interfacing with Emerson’s DeltaV
system using a standard library of DeltaV modules, graphics and faceplates delivered
with the EAM Project software. This library provides a standard landing module to
minimize the efforts required to set up and use the interface. The communication
between the EAM applications and DeltaV is based on OPC. The built in OPC client
in AMS AG sends the EAM alerts to the DeltaV OPC server.
Each of the assets will have its own class module and graphic that goes with it. A
user guide provides step-by-step instruction on how to clone, configure and setup the
EAM functions in a DeltaV environment. The EAM outputs are simply mapped to the
DeltaV landing modules, and linked to the graphic templates and faceplates provided
with the software. The EAM Class Library and an example landing module is shown
in Figure 3-1 and Figure 3-2.

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Figure 3-1
DeltaV Interface Module Library

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Figure 3-2
EAM Blower Interface Module
An example DeltaV graphic that is delivered with the EAM-Blower module is provided
in Figure 3-3.

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Figure 3-3
EAM Process Graphic in DeltaV
The DeltaV software library also includes a custom faceplate to acknowledge alerts,
open the standard process graphic display and launch a remote window into the
EAM AG Server. An example architecture diagram for this scenario is provided in
Figure 3-4.

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Figure 3-4
Integrating EAM with DeltaV
As shown in the Figure 3-4, the EAM data is sent to DeltaV using the OPC
communication. This data is displayed on operator consoles using the standard
DeltaV graphics designed for EAM applications. In this environment, the DeltaV
operator can monitor the health and asset KPI’s from the EAM application in a read-
only mode.
To get more detail on a particular asset, a DeltaV operator connects to the EAM
station through a remote desktop connection. Access to the EAM application is
required to take some actions such as capturing a baseline, acknowledging EAM
alerts, setting the asset in/out of service, etc.
3.2 Interface with Ovation

The plan is to provide a similar integration library for Ovation that we have for DeltaV.
Feedback from the field on the DeltaV interface and user requirements will drive the
next generation of platform interfaces.
3.3 Interface with Historians

The interface to a process historian, such as OSI-PI, AspenTech’s InfoPlus.21 or
GE’s i-Historian can be accomplished in much the same way as the DCS interfaces
using their OPC servers. In this case, custom displays for each asset would need to
be built in their user environment (e.g. PI ProcessBook, OSI-Web parts, or
AspenTech’s Process Explorer) to accommodate the available measurements and
alerts.

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4 OTHER CONSIDERATIONS
4.1 Application Support
The EAM Suite and the AMS AG platform is supported after the sale through the
Emerson Global Service Center (GSC). Sales support questions can be directed to
AskAO@Emerson.com. Technical questions can be directed to
EAM.Support@Emerson.com.
4.2 Upgrades and Extensions

In order to upgrade versions or add new assets to an existing installation, the end
user or Emerson representative must contact the EAM support team on
EAM.Support@emerson.com. The process will involve exporting the project
database, making the necessary modifications and delivering a new installation.
Service fees will apply.
4.3 Backup and Recovery

There is no automated tool available to backup/recover the EAM application in case
of failure of the EAM station. It is expected that the end user will have necessary
backup procedures in place which would include the EAM Server and Project folders.
This folder can be found in the AMS Asset Graphics folder located on the main drive.
The EAM application preserves all the user configured data in the Project folder and
reloads when the application is restarted. If the system is compromised, reinstall
AMS AG, copy the backup Project folder to the AMS AG folder and the system can
be restarted as normal.

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Appendix A
EAM
Fault Matrices

Revision P1 – 2014-SEPT-09 – Page
29 of 36
Pump Fault Matrix

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Heat Exchanger Fault Matrix

Hot
Cold Side Cold Side Hot Side Hot Side Cold Side Cold Hot Side
Fault Condition Side Notes
Inlet Temp Outlet Temp Inlet Temp Outlet Temp Flow Side dP dP
Flow
Fouling Factor Option 1     
Fouling Factor Option 2     
Heat Duty Option 1   
Heat Duty Option 2   
Duty Error      
If both Hot and Cold side flow exist, duty error can be calculated.
Hot or cold side flow can be used to calculate the fouling factor
Cost of Degradation and subequently the cost of degradation. If both hot and cold
    
Option 1 side flow are known, the average heat duty will be used to
calculate cost of degradation.
Hot or cold side flow can be used to calculate the fouling factor
Cost of Degradation and subequently the cost of degradation. If both hot and cold
    
Option 2 side flow are known, the average heat duty will be used to
calculate cost of degradation.
HX Cleaning Required Exchanger cleaning is determined by a high fouling factor and
     
Option 1 either hot or cold side high DP.
HX Cleaning Required Exchanger cleaning is determined by a high fouling factor and
     
Option 2 either hot or cold side high DP.
Exchanger cleaning can be determined using high fouling factor
HX Cleaning Required
     AND high cost of degradation. Cost can be calculated using Hot or
Option 3
Cold side flow.
Exchanger cleaning can be determined using high fouling factor
HX Cleaning Required
     AND high cost of degradation. Cost can be calculated using Hot or
Option 4
Cold side flow.

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Blower Fault Matrix

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Air-Cooled Heat Exchanger Fault Matrix

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Compressor Fault Matrix
Motor Stage/Interstage Vibration Stage Specific Parameters Compressor Parameters

Motor Motor
Stage Stage Stage Stage Spill K
Outboard Inboard Intake Lube Lube Lube
Fault Condition VFD Vibration Vibration Vibration Vibration Bearing Suct Disch Suct Disch Back Vane
Vibration Vibration Filter Flow dP Oil Oil Oil SG/MW
Speed (OV3, (OV4, (OV5, (OV6, Temp Press Press Temp Temp Valve Position
(OV1, (OV2, dP Press Temp Level
PKV3) PKV4) PKV5) PKV6) Position
PKV1) PKV2)
Resonance Freq Detection Option 1  
High Vibration Option 1       
High Vibration Option 2   
High Vibration Option 3    
Bearing Fault Option 1        
Bearing Fault Option 2   
Bearing Fault Option 3     
Plugged Intake Filter 
Process Instability Option 1 
Process Instability Option 4   
Low dP Option 1  
Low dP Option 2 
High dT  
Spill Back Valve Defect 
Lube Oil Monitoring   
Control Vane Defect 
Gas Comp Change 
Low/High Knock Out Drum Level

34 of 36
Cooling Tower Fault Matrix – Page 1
Cooling Tower Fans
XXX CSI 9420's - Accelerometers and Bearing Temps

Fault Condition
Motor OB Gearbox HS
Motor IB Gearbox LS
Vibr Vibr
VFD Speed Vibr Vibr
(OV, PKV, (OV, PKV,
(OV, PKV, T) (OV, PKV, T)
T) T)
Resonance Freq Band (Option 1)  

Resonance Freq Band (Option 5)     
High Vibration Fans (Option 1)  
High Vibration Fans (Option 5)     
Bearing Fault Fans (Option 1)  
Bearing Fault Fans (Option 5)     

35 of 36
Cooling Water Pumps

RMT RMT RMT
XXX CSI 9420
3051S 3051S 3051S
Fault Condition
VFD Speed Pump Motor 2 Pump Motor
Disch Suct Strainer
(if Vibr Vibr Bearing Bearing
Press Press dP
applicable) (OV, PKV) (OV, PKV) Temp 1 Temp 2
Bearing Fault Pump (Option 1)  

Bearing Fault Pump (Option 2)  
Bearing Fault Pump (Option 3)   
Motor Bearing Lubrication Fault 
Pump Bearing Lubrication Fault 
High Vibration Pumps (Option 1)  
High Vibration Pumps (Option 2)  
High Vibration Pumps (Option 3)   
Low Head (Option 1)  
Low Head (Option 2) 
Low Head (Option 3) 
Low Discharge 
Low Suction 
Strainer Plugging 

36 of 36
Cooling Tower Basin

702 RMT dP
RMT 648 RMT 649 RMT 650 RMT 651 RMT 6081C RMT 6081P RMT 3051S RMT 3051S
TraceTek Level
Fault Condition
Air Out
CW
H2O In H2O Out Air Temp Wireless Wirelesss CW Makeup HC Leak
Blowdown Basin Level
Temp Temp In Temp (1 per Conductivity pH Flow Detection
Flow
Fan)
High Water Temp    

Low Water Temp    
Fouling (Option 1)      
Fouling (Option 2)    
Fouling (Option 3) 
Fouling (Option 4) 
Corrosion (Option 1)  
Corrosion (Option 2) 
Corrosion (Option 3) 
High pH 
Low pH 
Low Flow  
HC Leak in Basin 
Excessive Windage/Water Loss   

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Essential Asset Monitoring Essential Asset Monitoring Suite

Essential Asset Monitoring

Emerson Process Management 2014 – Confidential and Proprietary

Copyright and Trademark Information

AMS, PlantWeb™, SNAP-ON™, DeltaV™, RS3™, PROVOX™, Ovation™, FIELDVUE™,

HART® and WirelesssHART® are registered trademarks of the HART Communications

All other marks are property of their respective owners.

Emerson Process Management 2014 – Confidential and Proprietary

2 SYSTEM CONSIDERATIONS ____________________________________________8

3 Systems Integration ___________________________________________________ 22

4 OTHER CONSIDERATIONS ____________________________________________ 27

Appendix A - Fault Matrices

Emerson Process Management 2014 – Confidential and Proprietary

1.1 Intended Audience

The information in this guide should be considered as confidential.

1.2 Reference Publications

1.2.2 Product Data Sheets

Emerson Process Management 2014 – Confidential and Proprietary

Air-Cooled Heat Exchangers:

1.2.3 White Papers and Sales Information

1.3 Introduction to EAM Solution

Emerson’s EAM software can be delivered as a stand-alone server connected to the

Emerson Process Management 2014 – Confidential and Proprietary

- Heat Exchangers (Shell/Tube)

- Air-Cooled Heat Exchangers

- Compressors (Max 3-stage, Roller Bearings)

It should be noted that Emerson’s EAM applications use a statistical approach to

Emerson Process Management 2014 – Confidential and Proprietary

ACHE Air Cooled Heat Exchanger

AMS AG AMS Asset Graphics

DCS Distributed Control System – Could be DeltaV,

EAM EAM – Usually references the EAM software

OPC OLE for Process Control - Standard protocol

UI User interface – The application running on

Emerson Process Management 2014 – Confidential and Proprietary

Emerson’s wireless technology for the field instruments provides additional

Presently, the EAM Suite is available for following assets:

Emerson Process Management 2014 – Confidential and Proprietary

 EAM Multistage Compressor

2.1.1 EAM Pump

For more information, see this site:

Emerson Process Management 2014 – Confidential and Proprietary

2.1.2 EAM Heat Exchanger

For more information, see this site:

Emerson Process Management 2014 – Confidential and Proprietary

For more information, see this site:

Emerson Process Management 2014 – Confidential and Proprietary

EAM for compressors is designed for single-, dual- or 3-stage centrifugal

For more information, see this site:

Emerson Process Management 2014 – Confidential and Proprietary

2.1.5 Air-Cooled Heat Exchanger

For more information see:

Emerson Process Management 2014 – Confidential and Proprietary

2.1.6 Cooling Tower

EAM for cooling towers provides integrated monitoring and determination of a

For more information, see this site:

2.2 Architecture Overview

Emerson Process Management 2014 – Confidential and Proprietary

2.3 EAM Multiuser Architecture

1. Thin Client (Remote Desktop) approach.

2. Thick Client (Dedicated Station) approach.

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3. Hybrid approach (Remote Desktop and Dedicated stations)