Emerson AMS 6500 ATG Machinery Protection System

Emerson AMS 6500 ATG Machinery Protection System

In process industries such as electricity, petrochemicals, and metallurgy, the health status of rotating machinery such as steam turbines, compressors, and fans is directly related to production continuity and safety. According to statistics, up to 90% of mechanical failures are predictable, and half of them are induced by process reasons. Although traditional mechanical protection systems (TSI) can provide basic safety interlocks, they cannot provide early warning of faults. Emerson's AMS 6500 ATG (Asset Tagging and Prediction) system combines API 670 compliant protection features with embedded predictive diagnostic technology to provide an integrated health management solution for critical rotating assets.

Product Overview and Core Advantages

AMS 6500 ATG is an independent mechanical protection system that complies with the API 670 standard, designed specifically for critical equipment such as steam turbines, gas turbines, and compressors. Its core value lies in:

Integrated protection and prediction: The system provides standard TSI measurements such as vibration, displacement, and speed, while also incorporating PeakVue based technology ™ The predictive and diagnostic capabilities of technology. PeakVue technology focuses on capturing impact signals generated by bearing and gear failures, and can detect signs of equipment degradation earlier than traditional vibration analysis.

High reliability and redundancy design: The system adopts external redundant power supply, supports module hot plugging, and minimizes the impact of maintenance operations on operating equipment. Each measurement module has only two channels, which meets the requirements of API 670 for the range of fault impact. The 2003 logical voting function can effectively prevent false tripping. Redundant communication ensures that the operation station can always obtain the device status.

Open communication architecture: Built in OPC UA technology, achieving seamless integration with upper level control systems (DCS, SIS) and third-party software. Simultaneously supporting Modbus TCP/IP and Modbus RTU protocols to meet the connection requirements of different industrial networks.

Durable industrial design: All components comply with ISA-S71.04 standard G3 level and can operate reliably in high concentration industrial pollution environments. The 42 month product warranty period reflects its excellent reliability.

System Components and Flexible Architecture

The AMS 6500 ATG adopts a modular rack design, with the main components including:

Universal Measurement Card (A6500-UM): As the core measurement unit, it can be configured with multiple measurement modes such as shaft vibration, shaft displacement, casing vibration, velocity, acceleration, eccentricity, speed, and pole position difference. Support dynamic signal analysis, such as peak to peak value, RMS, Smax and other characteristic value calculations.

Temperature/Process Card (A6500-TP): Used to connect temperature sensors or other process quantity signals (such as pressure and flow) to expand monitoring range.

Relay Card (A6500-RC): Provides 16 SPDT relay outputs, built-in graphical logic engine, and allows users to drag and drop define complex interlocking logic (such as voting, delay, etc.).

Communication card (A6500-CC): realizes communication between the system and the outside world, including USB local interface, TCP/IP network interface, Modbus RTU/TCP protocol, OPC UA server. Built in 32GB SD card for data storage.

The system provides multiple rack options to accommodate different application scales:

A6500-SR (standard rack): 19 inches 3U height, supports 11 measurement cards, 1 relay card, 2 communication cards (redundant).

A6500-RR (Redundant Relay Rack): 19 inches 3U height, optimized for redundant configuration, supports 9 measurement cards, 2 relay cards, and 2 communication cards.

A6500-FR (Front End Wiring Rack): 12.25 inches 6U height, using front end wiring method for easy on-site installation, supporting 6 measurement cards, 1 relay card, and 1 communication card.

PeakVue Predictive Diagnostic Technology

PeakVue is the core prediction technology of AMS 6500 ATG. Traditional vibration monitoring mainly focuses on synchronous vibrations caused by rotor imbalance and misalignment, while PeakVue uses a unique signal processing method to filter out these conventional vibration components, focusing on capturing brief, high-energy impact pulses generated by bearing damage, gear meshing faults, etc. By monitoring the impact trend, users can obtain a "single value" indicator of the device's health status and clearly determine the degree of fault development. The system also supports advanced diagnostic tools such as order analysis, frequency band analysis, and energy band analysis. In addition, the Transient GRAB function can synchronously record the dynamic waveforms of all channels at a sampling rate of up to 96kHz, providing detailed data for start stop process analysis and fault root tracing.

Software and Mobile Applications

Machine Studio configuration software: provides a graphical interface based on human factors design, simplifying system configuration, module function definition, and interlocking logic configuration. Users can intuitively configure predictive parameters and view diagnostic results in real-time.

ATG View mobile application: By scanning the QR code on the cabinet, maintenance personnel can directly access rack data using their mobile phones or tablets, view real-time trends, alarm status, module health information, etc., without returning to the control room or plugging in buffer outputs, avoiding the risk of accidental tripping.

Full lifecycle service guarantee

Emerson provides end-to-end product support and services through the Guardian digital platform, including:

Technical support and spare parts management: covering normal wear and tear repairs, priority exchanges, spare parts discounts, etc.

Planned system maintenance: Professional engineers perform maintenance tasks for six core categories on site, generate standardized reports, and provide improvement suggestions to enhance process availability.

Spare parts optimization tool: Based on statistical data and availability goals, collaborate with customers to calculate the optimal spare parts list, balance inventory costs and equipment availability.

Summary of Technical Specifications

Simulation channels: up to 44 (two fully equipped racks)

Sampling rate: 48 kHz (standard), 96 kHz (transient recording)

ADC resolution: 24 bits

Analysis functions: PeakVue, order analysis, frequency band analysis

Communication protocols: OPC UA, Modbus TCP/IP, Modbus RTU

Time synchronization: SNTP

Order Information

The main models include:

A6500-UM: Universal Measurement Card

A6500-TP: Temperature/Process Card

A6500-RC: System Relay Card

A6500-CC: System Communication Card

A6500-PE: Predictive Extended Authorization

A6500-SR/RR/FR: racks of different specifications