Asset Management Blog

Integrated Asset Performance Management for Reliable Operations

Jim Cahill — Thu, 30 Oct 2025 13:00:01 GMT

This 1:50 YouTube video, titled “AI-Powered Asset Performance Management (APM) | Emerson and AspenTech” shows the power of this architecture to drive greater performance in reliability.

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Maximize Instrumentation Management with AMS Device Manager and AMS Trex

Jim Cahill — Mon, 14 Jul 2025 13:00:09 GMT

Emerson’s Anna Velena, Tinh Phan, and Eric Snyder collaborated to present “Maximize Field Device Management using AMS Device Manager and AMS Trex” at the Emerson Exchange 2025 Conference. Here is their presentation abstract.

Field Device Management (FDM) plays a critical role in optimizing industrial operations by enabling efficient monitoring, configuration, and maintenance of instruments and valves. Explore how FDM enhances operational reliability by ensuring devices are correctly calibrated and functioning, reducing downtime through predictive maintenance. Learn how to streamline data management, offer real-time insights into device performance, and proactive decision-making. Improve compliance with industry standards by maintaining accurate device records and audit trails. Hear how your peers are using AMS Device Manager and AMS Trex to achieve best-in-class FDM by taking advantage of the full functionality available.

Eric opened by noting that studies point to reliability as the most significant opportunity for improvement in manufacturing and production operations. Assets will inevitably fail. But the earlier you can detect that it is on the path to failure, the less costly the fix will be.

Failures follow predictable patterns, including infant mortality, random break-in, fatigue, wear-out, and the bathtub curve. The level of asset failures varies significantly between the first and fourth quartiles in terms of reliability performance.

AMS Device Manager can manage all registered HART or Foundation Fieldbus devices from any automation supplier. It can manage up to 30,000 devices and connects to 20+ control systems, safety instrumented systems, PLCs, gateway interfaces, modems, and field communicators.

AMS Device Manager is a single system that can seamlessly integrate devices from multiple standalone systems, providing a unified interface, database, user security, and a single environment for comprehensive device management, predictive diagnostics and documentation.

AMS Device Manager helps with start-up, commissioning, configuration, monitoring, and diagnostics. It can also help streamline shutdowns, turnarounds, and outages in the performance verification of the measurement and final control devices.

It performs numerous functions to help drive reliability and productivity improvements. Here are some categories and work functions where it can help.

AMS Trex Device Communicator

The AMS Trex Device Communicator can commission, provision, configure, diagnose, and troubleshoot any HART or Foundation Fieldbus devices. It is intrinsically safe, certified to ATEX, CSA, FISCO, and IECEx standards. Apps include Loop Diagnostics, Fieldbus Diagnostics, ValveLink Mobile, WirelessHART Provisioning, and Radar Master.

Changes made by AMS Trex can be auto-synced with AMS Device Manager in the field via Wi-Fi or USB.

You can find numerous customer success case studies in the document “How Real Users Benefited from Effective Asset Management” and reach out to the AskPSS team for more.

Visit the AMS section on Emerson.com for more information on device monitoring and health analysis solutions that help you proactively manage devices to drive reliability and performance.

The post Maximize Instrumentation Management with AMS Device Manager and AMS Trex appeared first on the Emerson Automation Experts blog.

Upgrade or Get Left Behind: The Hidden Risks of Old Wireless Field Gateways

Jim Cahill — Tue, 06 May 2025 09:00:01 GMT

In a world where field operations depend on fast, reliable, and secure data transmission, sticking with outdated wireless field gateways can silently sabotage your performance. Legacy devices will still in operation, but they’re often the weak point — exposing systems to cybersecurity threats, limiting your ability to scale or integrate new digital services, sensors and assets monitoring solutions. This note highlights the often-overlooked dangers of clinging to old hardware, from increased maintenance costs to operational blind spots, and lays out the compelling reasons why upgrading to the latest wireless gateway technology is not just a smart move—it’s a necessary one to stay competitive and future-ready.

WirelessHART has gone from strength to strength with many customers benefitting from the value it brings. However, it might be time to take a closer look at your aging wireless infrastructure. Our latest gateways, 1410S, support two remote access points, each one of which can support a network of up to 500 devices. Of course, our new gateways come with the latest firmware and offer improve cyber-security protection, compliant with the current security framework, i.e. IEC62443. Why not upgrade your old gateway today and benefit from an increase in capacity to support new solutions and improved cyber-security protection.

Learn more – https://www.emerson.com/documents/automation/flyer-flyer-wirelesshart-gateway-upgrade-en-11430652.pdf

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Micro Motion™︎ Coriolis Flow Meters are now Easier to Select and Install, Providing Even More Value to Chemical Industry End Users

Jim Cahill — Wed, 11 Dec 2024 20:01:02 GMT

One aspect of consumer electronics that we all appreciate is how designers have worked to make things easier to use. It wasn’t that long ago when adding some peripheral device to a computer called for fiddling with drivers and configuration, whereas today many devices are plug and play. The same also happens with industrial equipment, and we can use Micro Motion Coriolis mass flow meters as an example.

Coriolis flow meters have some very strategic and unique capabilities that make them ideal for a variety of complex measurement applications, but taking advantage of all these features can be challenging. Emerson has worked to ease these issues, as explained in this recent article in Chemical Engineering, Coriolis Flowmeters: Insights for Selection and Upgrade.

Coriolis meters are one of the few flow meter types that can directly measure the mass flow of either gases, liquids, or slurries. They also simultaneously directly measure density and temperature, providing three vitally important measurements within a single meter. Most importantly, the mass-flow measurement remains accurate despite process variation, allowing production units to consistently close the loop on process mass balances and optimize production.

These capabilities are all needed, and even more features are now available. For starters, the range of sensor designs has increased to reduce size, and to support specialized application and configuration options. A great option for chemical manufacturers is the recently released Micro Motion G-Series Coriolis Flow and Density Meter Micro Motion™ G-Series Compact, Drainable Coriolis Flow and Density Meters, an ultracompact and lightweight solution offering simple installation and integration. Additionally, a range of Micro Motion Coriolis sensors is available with characteristics that cater to different needs and applications. Micro Motion Flow Meters

Transmitters also have new, valuable options for the chemical industry. For instance, the Micro Motion 4700 Coriolis Transmitter offers a compact C1D1 (Zone 1) housing, scalability from 1-3 output channels, Bluetooth® Technology, and retrofitting to existing Micro Motion sensors.

The article goes into more detail on Coriolis additional new features, but a chat with one of our application engineers will be very informative.

If faced with the need to specify a new Coriolis flow meter or upgrade an existing sensor, users should fully understand the assortment of sensor and transmitter options that have recently become available. Coriolis meters have always been a premier flow-measurement device, but the latest technological advances make these meters even more capable and affordable.

You can also connect and interact with other engineers in the Downstream Hydrocarbon and Chemical Processing Groups at the Emerson Exchange 365 community.

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AMS Device Manager for More Reliable Operations

Jim Cahill — Wed, 31 Jul 2024 17:50:36 GMT

At the 2024 Ovation Users Group meeting, Emerson’s Tinh Phan presented Back the Basics: Software-Based Instrument & Valve Management. Here is his presentation abstract.

Explore how AMS Device Manager can provide real-time, online access to intelligent instrument and valve diagnostics and alerts, delivering a view of device health and troubleshooting information when an issue is found. By viewing easy-to-understand, intuitive interfaces and dashboards infused with real-time condition data, maintenance and operations personnel can respond quickly and make informed decisions. Once a strong foundation is established with your instrument and valve programs using AMS Device Manager, you can then take Digital Transformation and Asset Management a step further — injecting powerful diagnostic data into other operational systems and workflows using AMS Device Manager Data Server and AMS Optics. Topics include: Ovation Configuration Setup, Diagnostics and Actionable Recommendation Capabilities, Alerts Optimization, and Digital Transformation Options, and more.

Tinh opened by asking if people are missing areas of instrument diagnostics, such as process conditions, process connections, device health, data integrity, and loop integrity.

Intelligent field devices can detect power, wiring, and device connection issues. These capabilities enable proactive maintenance and easy troubleshooting to prevent on-scale failures and provide early warning of wiring termination corrosion and power supply issues.

From a measurement integrity standpoint, the AMS Device Manager can identify and help prevent on-scale failures, proactive maintenance, and maximize process uptime. Here are some examples.

Device diagnostic information can help you improve productivity. AMS Device Manager helps you avoid the “No Problem Found” cases where technicians are manually sent to the field to troubleshoot.

AMS Device Manager:

Helps avoid unnecessary downtime with a window into the health of intelligent field devices
Fully implements predictive diagnostics to improve plant availability and reduce maintenance costs
Uses real-time condition data from your intelligent field devices to identify, troubleshoot, and resolve device issues remotely and efficiently
Configures and calibrates all your devices using one software application

During the projects/start-up phase, users can reduce time and cost using AMS Device Manager configuration tools. Users can do their work remotely as they can access the devices from AMS Device Manager clients. This doesn’t just enable plant personnel to work smarter and safer since it reduces the time they need to be exposed to hazardous locations.

The Maintenance team can use the diagnostics and monitoring tools to respond faster and make informed decisions based on the health of the field devices. This results in operational improvements, as unnecessary slowdowns or downtimes are prevented.

The software also has Calibration Management. It can streamline calibration work processes with automated and paperless documentation. Connectivity is available to document calibrators (Beamex and APM) and allows users to create test schemes, calibration routes, and print reports.

At these stages, the AMS Device Manager has an audit trail that automatically logs events related to the system and the devices. Several reports are also available to document actions taken on the devices.

This software makes configuration easy. With an online AMS Device Manager system, a user can access a configuration screen by simply double-clicking on the device. From there, they can make configuration changes, save them, and exit in just a few minutes. All changes are automatically logged in the Audit Trail and saved for the life of the device in the AMS Device Manager system. All this is done without having to leave the control room or maintenance shop.

It provides complete management of field instruments and valves, including online alerting and diagnostics, valve condition monitoring, meter verification, and calibration management. SNAP-ON applications can give your AMS Device Manager advanced diagnostic functionality. The seven major SNAP-ON applications are AlertTrack, ValveLink, DCMlink, Wireless, Calibration Assistant, Micro Motion Meter Verification, QuickCheck, and Rosemount Engineering Assistant.

AMS Device Manager is a FULL asset management software that supports instrument and valve maintenance activities for preventive, predictive, and proactive maintenance. It accomplishes this through these key solutions for our customers: a complete configuration management solution, the ability to monitor their instruments online for proactive diagnostics, and a complete calibration management solution—all with reporting functionality enabling information to be electronically documented.

Visit the AMS Device Manager section on Emerson.com for more on how it can help drive reliability improvements.

The post AMS Device Manager for More Reliable Operations appeared first on the Emerson Automation Experts blog.

AMS Device Manager for More Reliable Operations

Jim Cahill — Wed, 31 Jul 2024 17:50:36 GMT

At the 2024 Ovation Users Group meeting, Emerson’s Tinh Phan presented Back the Basics: Software-Based Instrument & Valve Management. Here is his presentation abstract.

Explore how AMS Device Manager can provide real-time, online access to intelligent instrument and valve diagnostics and alerts, delivering a view of device health and troubleshooting information when an issue is found. By viewing easy-to-understand, intuitive interfaces and dashboards infused with real-time condition data, maintenance and operations personnel can respond quickly and make informed decisions. Once a strong foundation is established with your instrument and valve programs using AMS Device Manager, you can then take Digital Transformation and Asset Management a step further — injecting powerful diagnostic data into other operational systems and workflows using AMS Device Manager Data Server and AMS Optics. Topics include: Ovation Configuration Setup, Diagnostics and Actionable Recommendation Capabilities, Alerts Optimization, and Digital Transformation Options, and more.

Tinh opened by asking if people are missing areas of instrument diagnostics, such as process conditions, process connections, device health, data integrity, and loop integrity.

From a measurement integrity standpoint, the AMS Device Manager can identify and help prevent on-scale failures, proactive maintenance, and maximize process uptime. Here are some examples.

Device diagnostic information can help you improve productivity. AMS Device Manager helps you avoid the “No Problem Found” cases where technicians are manually sent to the field to troubleshoot.

AMS Device Manager:

Helps avoid unnecessary downtime with a window into the health of intelligent field devices
Fully implements predictive diagnostics to improve plant availability and reduce maintenance costs
Uses real-time condition data from your intelligent field devices to identify, troubleshoot, and resolve device issues remotely and efficiently
Configures and calibrates all your devices using one software application

Visit the AMS Device Manager section on Emerson.com for more on how it can help drive reliability improvements.

The post AMS Device Manager for More Reliable Operations appeared first on the Emerson Automation Experts blog.

Driving Reliability Improvements Across the Enterprise

Jim Cahill — Mon, 15 Jul 2024 13:00:58 GMT

Emerson and AspenTech have advanced technologies on numerous fronts to help solve many challenges that manufacturers and producers face. One key area is in asset performance management to improve reliability. In an OPTIMIZE 24 Conference presentation, Enterprise Reliability Solution with Aspen Mtell and Emerson AMS, Emerson’s Greg Rome, and AspenTech’s Nithiya Parameswaran discussed ways to drive performance, resiliency, and sustainability improvements.

A significant challenge for organizations is a lack of skilled resources to improve maintenance practices. Skilled labor recruitment has become significantly more difficult as experienced practitioners leave the workforce. One way companies are addressing this shortage is to use cloud-enabled practices to enable experts to have a broader geographic reach.

Many manufacturers and producers seek to increase overall equipment reliability through IT/OT integration. Here’s a look at how these Emerson and AspenTech applications fit into the OT and IT integration architecture.

Click to enlarge

Greg described how AMS Machine Works delivers health data for rotating assets and their associated monitoring devices. AMS Device Manager provides real-time access to the health of a wide range of intelligent instruments and valves. Together, these feed their data streams to AMS Optics, enabling enterprise-level visibility & mobility to drive operational performance and workflow efficiency independent of location.

AMS Optics

AMS Optics can also receive analytics from the numerous Plantweb Insight applications and Aspen Mtell. The Plantweb Insight data analytics software provides visibility into the health of key plant assets, and Mtell provides advanced pattern recognition using statistical and machine learning techniques to identify asset degradation. These applications help organizations move from traditional manual condition monitoring to automated asset monitoring.

Wireless intelligent field devices, such as the AMS wireless vibration monitor, play an essential role in providing the data for the analytics to turn into actionable information. The AMS Asset Monitor is an edge-based analytics solution with embedded prescriptive analytics to detect common issues associated with rotating machinery automatically. It can connect with AMS Machine Works and AMS Optics.

Aspen Mtell monitors asset health using a combination of monitoring technologies and artificial intelligence/machine learning (AI/ML) to detect early failure indicators. This enables predictive and prescriptive maintenance, boosting efficiency, reliability, and productivity.

Aspen Mtell

Aspen Mtell provides early and precise warning with several monitoring methods—rules-based, conditions-based, first principle-based, AI/ML-based, and the ability to create custom monitoring algorithms. Data from IT sources such as Enterprise Asset Management (EAM) applications, process historians, and other OT sources are ingested and cleansed, analyzed by the appropriate monitoring algorithms, and turned into alerts, key performance indicators, and dashboards.

Boundless Automation is our vision for an industrial architecture built on a consistent, cohesive software ecosystem from intelligent field devices to the edge and the cloud—integrating operations to make all data instantly accessible, understandable, and usable for analytics, innovation, and performance improvement.

The AspenTech Inmation centralized data management solution combines the wealth of data and analytics from the asset performance and reliability domain with information and contextualization from other domains, such as production, safety, and sustainability. Optimizing operations requires insights across these multiple domains, powered by unified data access across the intelligent field, edge, and cloud.

Visit the links above for more information on these solutions to drive improved reliability and decision-making.

The post Driving Reliability Improvements Across the Enterprise appeared first on the Emerson Automation Experts blog.

Driving Reliability Improvements Across the Enterprise

Jim Cahill — Mon, 15 Jul 2024 13:00:58 GMT

Click to enlarge

AMS Optics

Aspen Mtell

Visit the links above for more information on these solutions to drive improved reliability and decision-making.

The post Driving Reliability Improvements Across the Enterprise appeared first on the Emerson Automation Experts blog.

Digitally Transforming Plant Asset Health Monitoring

Jim Cahill — Fri, 28 Jun 2024 16:34:11 GMT

Boundless Automation enables the liberation of trapped or hidden data to drive significant performance improvements. One great example is asset health monitoring throughout your production process. Wired and wireless sensors across your process not only provide real-time readings for the automation systems but also continuously diagnose themselves and the surrounding process.

By enabling access to this wealth of data, operational analytics software can provide actionable information to plant staff for early recognition of issues or improvement opportunities in the process. This 2-minute YouTube video, Digitally Transform Asset Health Monitoring with Plantweb Insight Software, provides a high-level overview of the Plantweb Insight suite of operational analytics software to help you proactively monitor the assets across your facility.

Visit the Plantweb Insight section on Emerson.com for more information on the applications that can help you drive safer, more efficient, and more reliable operations.

The post Digitally Transforming Plant Asset Health Monitoring appeared first on the Emerson Automation Experts blog.

Digitally Transforming Plant Asset Health Monitoring

Jim Cahill — Fri, 28 Jun 2024 16:34:11 GMT

Visit the Plantweb Insight section on Emerson.com for more information on the applications that can help you drive safer, more efficient, and more reliable operations.

The post Digitally Transforming Plant Asset Health Monitoring appeared first on the Emerson Automation Experts blog.

How Data-Driven Reliability Improvements Can Streamline Maintenance And Cut Costs

Jim Cahill — Tue, 28 May 2024 12:18:15 GMT

Advanced monitoring solutions provide real-time information and actionable insights that empower predictive maintenance strategies that lead to reduced downtime and help prevent quality issues.

For manufacturers, the ultimate aim is to have no unexpected machinery failures and ensure production equipment is always available. They also want to prevent underperforming machines from impacting product quality. As I explained in a Controls, Drives & Automation article, `Advanced Solutions Simplify Condition Monitoring’, to achieve these outcomes, companies are digitally transforming their operations and applying advanced monitoring solutions to enable greater access and visibility to machinery and equipment health data.

The article starts by looking at solutions for monitoring the health of valves used to control compressed air in pneumatic systems. Previously, these valves would be run to failure, creating the possibility of downtime and interruptions to production. However, as I describe in the article:

…diagnostic functionality provided by advanced fieldbus valve system technology now enables valve performance to be continuously monitored, so that developing problems can be identified earlier. If the system detects that the travel time of a valve is increasing, this may indicate valve wear.

Vibration monitoring and analysis have been used for many years for online condition monitoring of critical rotating machinery. Significant vibration analysis expertise has been required to understand the data and identify issues and root causes. As I explain in the article, the reliance on experts has been removed by modern software solutions that analyse the data, alert maintenance teams to issues, outline causes and even suggest necessary repairs.

…the latest asset management software also makes it easy for users, by providing a single location where all the various condition monitoring data come together to identify `troublemakers’ quickly and efficiently. The software collates data from a wide range of monitoring technologies and then predictive maintenance techniques and analysis tools provide accurate assessment of the health of each machine.

Wireless vibration monitors can be installed on the equipment being monitored. Data is transmitted to an asset management system, where prescriptive analytics provide accurate diagnostics to maintenance teams.

Wireless and edge technologies, less expensive sensors and advanced software are helping to overcome cost barriers and resource restraints. Manufacturers are able to deploy condition monitoring technology on a much broader range of equipment. The article explains that condition monitoring data is also being moved into the cloud to allow stakeholders to view the information and make informed decisions.

…edge computing technology helps to provide greater visualisation at the factory floor level…built-in web service software interfaces mean access to asset health is simple via any browser-enabled device. Cloud-based infrastructure simplifies the sharing of information and provides the opportunity for wider collaboration.

Intelligent field devices, such as measurement instrumentation and digital valve controllers, have become crucial to the smooth running of a plant. These present a wealth of diagnostic data that can be utilised to drive improvements. But more devices being monitored means more data being collected that needs to be processed and analysed. As I explain in the article, with hundreds of control valves in a typical process plant, tracking the condition of each manually is time-consuming. It also requires a lot of expertise to ascertain valve health and follow-up action. A solution is at hand:

…Emerson’s Plantweb InSight Valve Health software tool simplifies this monitoring task by providing plant personnel with a fleetwide valve health index along with recommended maintenance actions and recommended timeframes to act. This allows users to prioritise repair and maintenance activities.

The ability to monitor the health of more equipment, machines and devices is helping increase availability and productivity, but has created the challenge of managing the increasing amount and types of data required to analyse and support decisions. As I put it in the article:

…having access to more data is important, but if all an organisation does is dump it into a centralised repository, then positive outcomes are unlikely.

Overcoming this issue is at the heart of Emerson’s Boundless Automation™ vision, which focuses on implementing next-generation technologies to seamlessly connect intelligent devices and sensors to the edge and into the cloud to drive innovation across all aspects of plant operations. One of those technologies is Emerson’s AMS Device Manager Data Server, which supports a broad range of communication protocols to prevent data silos and ensure access to device information. I explain in the article that by utilising this solution:

…consolidated data can be shared with other software applications beyond the process control system, such as the plant historian, visualisation and dashboard application and advanced analytics software. Analysis of this data can provide more insights and help identify trends, such as the most common alerts or issues with specific device types.

Myself and other Emerson reliability experts will be available to discuss your own condition monitoring application at Maintec/Manufacturing & Engineering Week 2024, 5-6 June, NEC, Birmingham, UK, Hall 4, Stand E50. Or if you are unable to attend that event, visit here to learn more about how Emerson’s asset performance management solutions enhance the availability and performance of equipment.

The post How Data-Driven Reliability Improvements Can Streamline Maintenance And Cut Costs appeared first on the Emerson Automation Experts blog.

How Data-Driven Reliability Improvements Can Streamline Maintenance And Cut Costs

Jim Cahill — Tue, 28 May 2024 12:18:15 GMT

Advanced monitoring solutions provide real-time information and actionable insights that empower predictive maintenance strategies that lead to reduced downtime and help prevent quality issues.

…having access to more data is important, but if all an organisation does is dump it into a centralised repository, then positive outcomes are unlikely.

The post How Data-Driven Reliability Improvements Can Streamline Maintenance And Cut Costs appeared first on the Emerson Automation Experts blog.

Time Sensitive Data From Anywhere, Anytime – Tereos Case Study

Jim Cahill — Tue, 14 May 2024 15:00:14 GMT

Like many food production companies around the globe, each growing season is very limited, and every machine needs to be monitored to be kept in perfect health to make the most of each window in time. And since time is the enemy of a successful production season it’s also why it’s so important to have clear visibility to all remotely located assets in the field, over countries, and across oceans. Knowing exactly what is or is not happening in the field can be from literally – anywhere and at any time can make or break your season.

Imagine being able to monitor your critical machines from anywhere in the world, even from four countries and two oceans away. This level of access could be the key to maintaining your profit margins and saving your season. The right technology can provide this level of control and insight.

But getting started can seem overwhelming and even impossible when thinking of all the other, far more pressing issues you deal with day-to-day just to keep things going. You have lots of ‘fires’ to put out every day, and although you realize the right tech in place could, of course, help with all that, just finding the time to investigate your digital options doesn’t exactly feel like an option. Instead, it gets quickly put on your back burner for some other time; maybe next off-season when you can catch up on all the other lists of things to do you always have rolling, or maybe not.

>When you do make the time, probably the most important factor to consider is the partner you choose to work with; sure, you need the latest and greatest technology to be able to grow into the future company you are dreaming about becoming, and of course, you need to have all the most secure measures in place for your data, and you also need to be sure all that data is able to be utilized because you of all people certainly know too much data doesn’t really mean anything at all if the right people, in the right roles, aren’t getting only what they need to make faster, more accurate and stronger business decisions; Afterall, that is the whole point of technology – to enable your people to help you, while spending less, producing more and setting your company up for years of sustainable growth.

Read this Case Study about how we helped Tereos with improved visibility and security to critical machine health with monitoring through data analytics.

The Tereos cooperative group, a union of 11,200 cooperative members, has recognized know-how in the processing of beet, sugarcane, alfalfa, and cereals. Through 43 industrial sites, a presence in 15 countries, and the commitment of its 15,800 employees, Tereos supports its customers close to their markets with a broad and complementary range of products.

Or Contact us for more information.

The post Time Sensitive Data From Anywhere, Anytime – Tereos Case Study appeared first on the Emerson Automation Experts blog.

Time Sensitive Data From Anywhere, Anytime – Tereos Case Study

Jim Cahill — Tue, 14 May 2024 15:00:14 GMT

Read this Case Study about how we helped Tereos with improved visibility and security to critical machine health with monitoring through data analytics.

Or Contact us for more information.

The post Time Sensitive Data From Anywhere, Anytime – Tereos Case Study appeared first on the Emerson Automation Experts blog.

BASF and Teva Increase Energy Efficiency by Monitoring Steam Traps

Jim Cahill — Thu, 21 Mar 2024 09:49:56 GMT

Optimizing energy use helps industrial organizations to increase their profitability while also achieving their environmental sustainability targets. However, identifying and addressing causes of energy inefficiency can be challenging without the right tools and expertise. Emerson provides a broad portfolio of measurement and monitoring solutions and services to help companies establish where energy inefficiency is occurring at their plants, so that they can take measures to reduce their energy use and greenhouse gas emissions.

One area in which major energy efficiency improvements can be achieved is by optimizing the performance of steam traps. At Emerson Exchange EMEA 2024 in Düsseldorf, delegates heard presentations from two companies who have implemented an Emerson solution to help them improve their steam trap monitoring, leading to significant benefits.

Chemical giant BASF is committed to achieving a 25% global emissions reduction by 2030. Miguel Angel Alvarez, reliability engineer at BASF Mexicana, told delegates how monitoring steam traps has enabled the company to reduce CO2 emissions at its Altamira plant in Mexico.

Alvarez explained that steam trap inspections at the plant were previously performed visually and sporadically, which meant that their impact on energy consumption and emissions was unknown. Visual inspections are an ineffective way of detecting open-failed traps, and there is no way of identifying condensate accumulation within the lines when traps fail to close. This situation posed a risk to both the energy efficiency and integrity of the pipeline system.

BASF addressed the situation by implementing an online, real-time steam trap monitoring solution from Emerson. Utilizing Rosemount™ 708 Wireless Acoustic Transmitters, it is possible to detect trap failures and gather real-time data on trap conditions and temperature, thereby enabling prompt action to reduce energy consumption and emissions.

Critical steam traps are now monitored in real-time

Real-time monitoring facilitated by Emerson’s Plantweb Insight™ Steam Trap Application has provided BASF with a baseline for energy usage and emissions related to its steam traps. This serves as a benchmark when enhancing maintenance and operational practices. Since the Emerson solution was implemented, BASF has achieved a 25% reduction in steam costs, a 15% reduction in CO₂ emissions, and a 10% reduction in maintenance costs by shifting from preventive to data-driven maintenance.

Delegates also heard from Levente Szuros of Teva Pharmaceuticals in Hungary. Szuros explained that as part of its greening mission, the company had undertaken a study to determine the biggest energy-consuming assets and processes at its major manufacturing site in Debrecen, and that based on the results, it had formulated a strategy to increase energy efficiency and reduce emissions.

The study identified the plant’s steam distribution line as a major source of energy inefficiency, and therefore also of energy saving possibilities. The steam system includes more than 520 steam traps, which were being checked only once a year. To address the situation, Teva chose Emerson’s steam trap monitoring solution, which is quick to implement and configure, and would achieve a fast return on investment. Continuous, real-time monitoring of 40 critical steam traps revealed that eight of them had issues with leaking, blocking or bleeding. Having been alerted to these problems, Teva was able to address them within two days, whereas previously the faults may have gone unnoticed for months and resulted in significant energy losses.

Szuros concluded by revealing that as a result of implementing the Emerson solution, the company was significantly reducing its energy usage and its emissions. It now plans to install steam trap monitoring on 375 steam traps.

The post BASF and Teva Increase Energy Efficiency by Monitoring Steam Traps appeared first on the Emerson Automation Experts blog.