Using a documented, proven process to asset management, we develop alignment to common objectives among all stakeholders. We consolidate your data sets from fragmented, unique plant processes and practices into a new system that brings consistency with unparalleled speed and accuracy to deliver the business case to support ongoing asset performance improvements and effectively manage the risk of critical asset failures.
With our Asset Management Tag, you can track your assets with an intrinsically safe (FM, CSA, and ATEX certified), rugged RFID tag. Keep safe distance from hot process conditions and avoid dangerous situations while digitally obtaining critical information to quickly initiate maintenance. Our engineers have been documenting the reliability characteristics of assets like valves, actuators, instruments, and regulators and know the strategies that work and why they work. Our consultants are highly experienced at understanding the rate your asset health deteriorates and then implementing proactive maintenance processes that mitigate impacts to production.
Emerson provides the strategies, proven methodologies, and services to support you using our Reliability Roadmap™ that takes a balanced approach to evaluating all these factors, enabling you to select the path to higher reliability without spending too much to maintain it. Our experts and accelerators demonstrate the value of proactive and predictive reliability practices. In addition, we provide guidance as how to implement tools for sustaining the process through cultural change. So together, we can collaboratively design the transformation that maximizes the effectiveness of your resources bringing them to optimal performance for increased availability and profitability.
This service is available for all valve, actuator, and regulator brands. Contact your local sales office or service center for more information about our service capabilities for your products.
As your dedicated support partner, Emerson recognizes that not all equipment within your plant is of equal importance to the process or its safety. To help you deliver greater operational effectiveness, we can implement an equipment lifecycle strategy that enables you to maximize the period between scheduled maintenance and helps increase reliability of your valves, actuators, instruments, and regulators. We will work with you create complete reliability-based program that compliments your maintenance plan and defines OEM standards and best practices for routine maintenance to achieve the best long-term benefits of your plant’s assets.
In addition, the program will include recommended non-destructive, non-intrusive online and offline diagnostics timing, periodic health checks, application reviews, required parts inventory and ordering strategy, as well as shutdown, turnaround, and outage preparation requirements by unit or application. As an integral part of the equipment lifecycle strategy, we’ll build in proactive obsolescence planning to account for the inevitable asset discontinuation, as old technology is displaced by new, which helps prepare and reduce the impact when a process redesign is necessary to minimize costs incurred for engineering services, testing equipment, and operating capital.
As your experienced and knowledgeable consultative support partner, we recognize that getting the highest reliability and performance out of your automation investments requires identifying your plant’s unrealized potential. The journey to being a sustainable best-cost producer means minimizing variability associated with control strategies, controller algorithms, tuning, field devices, and process design to gain manufacturing efficiency and product quality benefits. Each time there’s variability from the expected production, your result is sub-optimal performance, throughput, and quality product.
Performance degradation happens over time and is typically an accumulation of multiple process issues that have not been addressed holistically. Using Emerson’s EnTech Variability Index (EVI) a clear benchmark for your processes can be established using a combination of data sets from a plant walk-down, asset specifications and serial card information, real-time process data analyzed, and industry standards. Our blend of technology, expertise, and enhanced automation consulting studies identify and quantify plant performance improvements that enhance operating stability to maximize your plant’s availability and profitability. We provide specific data-powered recommendations to optimize controller and instrumentation performance, and define actions for further improvements to instrumentation, process design, and control strategies which deliver a significant economic payback.
Control Performance Audits are designed to benchmark and analyze your existing assets, applications, and processes to identify opportunities and provide sound recommendations for improving safety, performance, energy efficiency, and environmental compliance. Information collection occurs through interviews and discussions with your operational and maintenance staff, plant walk-downs to inspect plant field equipment and control systems, and reviews of process and business data, report logs, control system documentation and alarms. Expert analysis helps determine options for improving your existing processes, such as retrofitting assets and upgrading entire loops and systems.
We work in close partnership with you to document recommendations and best practices based on business goals and objectives for debottlenecking, loop tuning, and optimizing service and maintenance schedules to enable running processes for optimal utilization. To help justify your initial outlay, we provide an evaluation of the return on investment that includes obsolescence planning for both stock and assets, as well as achieving better compliance through reducing emissions. We provide short-term and long-term performance improvements with a step-by-step implementation plan giving you maximum flexibility to reprioritize as your business needs change. We integrate products, technologies, and lifecycle services into an economical and reliable solution while supporting Emerson and non-Emerson products over the lifespan of your plant.
Emerson’s Resident Engineer program is a service designed to place an experienced engineer at your site to assist with a wide range of activities from engineering to start-up to system maintenance. All resident engineers are pre-qualified, experienced engineers that meet Emerson’s rigorous training standards. Based on your unique needs, Emerson selects qualified personnel from the available pool of trained engineers, matching the desired qualifications. You then review the resumes, interview the candidates, and make selections.
Resident engineers are available for short term and long term assignments (a few weeks to a few years). They can participate in project activities including custom configuration, factory acceptance testing, and site acceptance testing. They can also provide staff augmentation during system start-up and can assist with graphics corrections, module configuration changes, loop checks, and resolving hardware and software issues.
Emerson’s Valve Connected Services utilizes the Plantweb™ digital ecosystem features to gather and interpret valve and process information. We can help you move from reactive maintenance to predictive maintenance using many of the tools and smart technology you already have in place for a better return on investment. Then we add agreed upon technology pieces needed, based on business objectives and goals, for a seamless integrated solution.
Emerson provides the control valve expertise and resources necessary to implement the service, including asset criticality analysis, configuration confirmation using valve serial information, and inventorying plant diagnostic capabilities. Best of all, our subject matter experts will remotely monitor your assets, interpret the results, and provide an actionable summary supported by information from your plant floor. You can make informed maintenance decisions that are aligned with maintenance and operational objectives to improve the output of your existing assets, systems, and applications. Regardless of your current conditions and your starting point, Emerson can work with you to develop monitoring plans that support your operational goals using one, two, or all three tiers of customizable monitoring services to match your plant’s unique needs.
Emerson’s scheduled on-site support service makes it easier to keep your hardware and software maintenance requirements up-to-date while providing a flexible path to adopting new technology. Regularly scheduled maintenance ensures the dependability and longevity of your system, and minimizes the chance of unexpected emergency service calls and costly equipment failures.
Proactively maintain your system and protect your automation investment by scheduling planned maintenance visits. Emerson experts will work with you to define the frequency and duration of service visits, the specific services to be performed, and which equipment is to be serviced. A highly-trained service specialist will perform a prescribed set of maintenance tasks using a factory-standard, proven procedure. After each service visit, our experts will recommend an action plan that identifies ways to improve the health and maintenance needs of your control system, allowing you to proactively address shortcomings that can impact operational reliability and availability.
Scheduled On-Site Support services include careful inspection and maintenance performed by trained and certified specialists on a prescribed schedule, customized maintenance programs designed to reduce long-term equipment deterioration and may prevent premature equipment failure or damage, and priority access to site services specialists with deep knowledge of proven solutions that can help reduce risk.
Existing plant facilities face the need to install, update, and upgrade their industrial equipment in order to comply with applicable laws and safety regulations. In addition, plant owners and operators continually seek to optimize process efficiency and contrast obsolescence. We provide the most advanced automation solutions that include new installations or retrofitting existing valves, sourcing of actuator and automation products, and modification of products to mount the package until assembly of the fully automated package.
Initially defining the customer’s needs and scope of supply, we assess existing valves and determine appropriate actuator sizing. We then supply, install, and commission all equipment and proficiently manage the entire project from start to finish. We offer you numerous benefits including process control and optimization, improved safety levels and efficiencies, reduced personnel costs, and compliance with new regulations and standards. As a leading manufacturer of valves, instruments, and actuators, we have the proven expertise to identify and discuss the optimal solutions for each customer’s unique needs. By offering and managing the best turnkey valve automation solutions, we can expedite execution and reduce plant downtime.
Managing operational costs, minimizing downtime, and assuring regulatory compliance is an ongoing challenge when replacing assets in your process plant. Emerson’s Advanced Repair & Replace service can create a single pull, repair, and install service order to simplify having a replacement valve, actuator, instrument, or regulator on–site, before removing your deteriorating asset; saving you time and money by significantly shortening the repair timeline and reducing your overall maintenance costs.
An instant repair can leverage a new or refurbished unit if you’re replacing obsolete, non–stock, or typically hard–to–locate assets and parts, helping you keep costs down while assuring full regulatory compliance. No other support partner tests and guarantees that their refurbished assets will meet the original OEM specs, offering you cost-effective performance without the wait. In some situations, Emerson can ship your instant repair asset the same day you order. Using our fast delivery service to send it to you same–day or next–day delivery service 24/7/365 to minimize downtime.
With our Advanced Repair & Replace service, you’ll be able to complete assembly and installation ahead of turnarounds, eliminate risk of removing units, transportation, and inadvertent damage, avoid change orders, save extra time and expense, and reduce installation costs.
Online and offline preventive diagnostics, available through Fisher™ FIELDVUE™ instruments and ValveLink™ software, along with alarms from AMS Suite and DeltaV™ systems provide consolidated digital intelligence to indicate component health. Similarly, Emerson’s technicians perform diagnostics on valves with analog positioners using FlowScanner technology. Diagnostics, can be used to optimize and preserve your asset reliability for shorter shutdowns, earlier start-ups, and higher production with less variability for greater availability.
Matching your equipment lifecycle strategy, preventive diagnostics, and asset criticality with your maintenance processes creates greater alignment with your production goals; setting you up for continuous improvement, risk reduction, and best-in-class performance that gives you a competitive advantage.
Plantweb™ digital plant architecture links your plant’s computer maintenance management system and smart field devices allow the asset monitoring system to effectively achieve monitoring and data collection for analysis. Together, these technologies play a vital role in helping create a sustainable and predictive maintenance model and optimization plan.
Leverage the extracted data from your intelligent automation assets to detect and diagnose problems before they occur, helping minimize variability and rework for higher first pass yields of product. Plantweb digital plant architecture efficiently gathers and manages a wealth of predictive intelligence, including equipment health and diagnostics from a broad range of field devices and other process equipment. It provides you better process control, asset optimization, and integration with other plant and business systems. This frees up your maintenance staff to focus on executing repairs that are going to have an impact on the reliability of your plant’s assets, minimizing downtime and lowering your operational costs.
Proper maintenance helps to keep your process equipment operating optimally, extending essential asset life and performance while ensuring your plant operates safely, reliably, and economically. As a dedicated support partner, Emerson can assist you in developing a sustainable, proactive maintenance plan that impacts business goals and asset reliability based on criticality ratings of process equipment and best practices.
Emerson helps you develop sound foundational maintenance data through online and offline diagnostics, centralized asset documentation, application reviews, obsolescence planning, parts and spares management, and expert technical support from certified technicians to maximize the period between scheduled maintenance, reduce operating costs, and ensure process availability.