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					                                                                                                                                         Emerson Exchange Abstracts from 2004

                                                LAST     FIRST           COMPANY                ABSTRACT TITLE                                                                                     DESCRIPTION                                                                                    TRACK
                                           Lancaster   Dave      Bechtel Corp.            Foundation Fieldbus Alerts and One of the advantages of Foundation Fieldbus is diagnostic alerts and alarms. The industry has been focusing on developing methods and means to                 PlantWeb Asset Optimization
                                                                                          Alarms - Managing the          manage process alarms that sometimes flood the operator with information. Foundation Fieldbus instruments have an enormous amount of information
                                                                                          Information                    that can significantly add to the quantity to be managed. For instance, a digital valve controller may have as many as twenty six (26), alerts or alarms. All
                                                                                                                         of these are in addition to other information available for calibration and diagnostics.
                                                                                                                         The design of control systems now must provide solutions to the potential increase of information to operations and maintenance personnel. This paper
                                                                                                                         offers some of the questions to be considered as well as potential solutions for managing the enormous increase of information available today.


                                           Garon       Joe       CANFOR - Prince George   Online AMS Valvelink Prevents Maximizing the reliability and uptime of the paper machine at Canfor's PG Pulp and Paper mill are key operational objectives. Variability reduction on           PlantWeb Asset Optimization
                                                                 PNP                      Downtime at PG Specialty      critical process control loops is a key factor in meeting these objectives. Utilizing the on-line tools in AMS Valvelink has proved to be an effective means
                                           Murphy      Colin     NORPAC Controls          Paper                         of managing variability on a day-to-day basis. Valvelink is used on the Paper Machine control valves to continually monitor valve performance and make
                                                                                                                        proactive maintenance decisions. Alerts are monitored and any valves that trigger alerts are trended to monitor performance. This site has many
                                                                                                                        documented many instances where online monitoring has detected problems before they became failures. This has allowed maintenance personnel the
                                                                                                                        chance to fix the problems during scheduled area shutdowns and avoid costly downtime. Several success stories will be shared that document
                                                                                                                        operational improvements and cost avoidance.



                                           Noblitt     Mike      Coors Brewing Company     Developing Standards and       During the recent development of company wide DeltaV standards, the Coors team made major efforts to build in Asset Care information. Both by using            PlantWeb Asset Optimization
                                           Beinecke    Craig     Applied Control Equipment Asset Care in Mind             standard DeltaV tools such as DeltaV Inspect as well as creating custom code at the module level to suppliment the standard tools, Coors has developed
                                                                                                                          software standards that not only provide efficient, robust control, but that also monitors the condition of their assets to a level that few others have
                                                                                                                          achieved.




                                           Keuer       Doug      Degussa Chemical         Early Adoption of New           This session will present the implemenation results and lessons learned for the new model 9210 Machinery health Transmitter during the engineering field       PlantWeb Asset Optimization
                                           Rezabek     John      BP Chemical              Machinery Health Monitoring     trial and beta testing phases at Degussa Chemical in Mapleton, IL. The 9210 is a new intelligent field device which delivers health information related to
                                           Reeves      Todd      Emerson Process          Technology at Two Chemical      the condition of motor-pump machinery trains via the FOUNDATION fieldbus communications protocol. The expectations and results of the field testing
                                                                 Management               Plants Leads to Early Lessons   will be presented by the participants at Degussa.
                                                                                          Learned



                                           Eryurek     Evren     Emerson Process          Abnormal Situation Prevention Detection and characterization of anomalies in an industrial plant provide improved plant availability and plant efficiency thus yielding increased economic     PlantWeb Asset Optimization
                                           Karschnia   Bob       Management               Enabled by Intelligent Field    efficiency. Traditionally, historian based systems have been used to deliver a process anomaly detection. The main drawback of these methods has
                                           Peluso      Marcos                             Devices                         been the lacking granularity of the data which is used in process anomaly detection. In addition these conventional centralized approaches suffer from
                                                                                                                          their dependence on detailed mathematical models of the processes which have not become a main stream solution especially in the refining, chemical
                                                                                                                          and oil & gas industries. The premise of the field centric abnormal situation prevention (ASP) is making use of the capabilities of the new generation field
                                                                                                                          instruments and digital communication methods such as Foundation Fieldbus integrated under DeltaV. One of the challenges we have been asked to
                                                                                                                          address by the end users is providing ASP to installed legacy systems. In order to address this issue a new platform, Rosemount’s 3420, is being
                                                                                                                          architected with analytical tools and rule-based systems for users to take advantage of the state of the art technologies in their plants. This new
                                           Thompson    Tim       Emerson Process          Rapidly Growing City            Despite a large growth in demand, equipment approaching end of life, and increasing production costs, the water utility had to maintain a reliable and         PlantWeb Asset Optimization
                                           Granger     Mark      Management               Increases Potable Water         affordable supply of water to its customers. This meant doing the right maintenance tasks and at the right time with the existing resources and budget.
                                                                                          Production While Maintaining Emergency maintenance had to be reduced while expanding the maintenance coverage to new pumping stations. To reduce emergency maintenance,
                                                                                          Current Budget and Staffing     the utility first implemented a predictive maintenance (PdM) program. The PdM program monitors critical equipment to determine machinery health and
                                                                                                                          identify problems prior to failure. By relying on Emerson expertise for the initial program setup, training, and operation, a rapid startup and immediate
                                                                                                                          benefits were achieved. The utility deployed Emerson’s AMS Suite: Machinery Health Manager and multiple diagnostics technologies such as vibration
                                                                                                                          and ultrasonic analysis. The reduction of emergency maintenance resulted in increased reliability, reduced repair costs, and fewer scheduling disruptions.
                                                                                                                          With emergency maintenance under control, the utility focused on optimizing all scheduled maintenance tasks to free up resources to provide
                                           Gonzalez    Hermes    Emerson Process          Using Information-Rich Coriolis Coriolis meters have historically been known as information-rich devices. Their multi-variable measurement capability (Mass Flow, Density, Temperature,        PlantWeb Asset Optimization
                                                                 Management - Micro       in PlantWeb Applications        and Volumetric Flow) has contributed greatly in the technological differentiation and associated preference by countless customers in the various industry
                                                                 Motion, Inc.                                             segments. This technology is now ready to deliver significant incremental value to our customers. This presentation will discuss in detail how Micro
                                                                                                                          Motion will enhance its Coriolis Solutions portfolio by providing much more descriptive, meaningful and actionable information via Emerson’s PlantWeb
                                                                                                                          platform. Topics such as PlantWeb Alerts & Health Indices and how these sets of information will be channeled through the Intelligent Device Manager
                                                                                                                          from Emerson’s AMS Suite will provide the discussion framework. Specific examples will focus in the areas of Meter Health and Process Intelligence.

                                           Day         Roger     Enpower Management       Energy Producer Uses            Operating process equipment at optimum efficiency is a goal for many companies, including those in the power industry. Some of the key areas of             PlantWeb Asset Optimization
                                           Zeren       Kim       Emerson Process          Performance Monitoring          information required to make decisions on operating practices include current equipment performance and the effect of maintenance. Gas Turbines in the
                                                                 Management               Technology                      power industry are often affected by deterioration in equipment performance. As performance declines, operating costs rise and power production can
                                                                                                                          decrease, as well as the turbine availability. To improve performance and prevent lost revenue, accurate and reliable information is required to understand
                                                                                                                          optimal equipment operation. Emerson's AMS Suite: Equipment Performance Monitor is a tool that provides comprehensive knowledge into the
                                                                                                                          performance of process, mechanical and rotating equipment, tracking degradation and providing detailed intelligence into specific key performance
                                           Ehrhardt    David     ExxonMobil               Protection and Monitoring       Emerson provides a proven Turbine shutdown system installed on two ExxonMobil off-shore platform Solar Turbines – one turbine has sleeve bearings           PlantWeb Asset Optimization
                                           Horn        Deane     Emerson Process          Technology Installed on Off-    the other turbine has roller element bearings – and has had no false trips. ExxonMobil has avoided some trips completely by using Emerson’s Machinery
                                                                 Management               Shore Platform Turbines         Health Monitoring solutions to successfully provide alerts of impending failures.

                                                                                                                           This paper describes new technologies that reduce false trips. This paper also describes how Machinery Protection and Machinery Health Monitoring are
                                                                                                                           the first two parts of the right solution for your plant’s most critical assets. The final part of the paper describes how a PlantWeb of open, smart
                                                                                                                           technologies can provide even more value than the individual technologies. The end result is actionable information, PlantWeb Alerts, provided to the
                                                                                                                           right people.
                                           Woda        Dean      International Paper      Multiplexed AMS HART at          During implementation of a Dryer Drainage Project at International Paper’s Pineville, Louisiana Mill in 2000, a decision was made to add Emerson’s Asset      PlantWeb Asset Optimization
                                           Elkins      Tommy     John H. Carter           International Paper - Pineville, Management Software [AMS] and Fisher DVC HART FieldVue valve controllers to the project. IP purchased the Moore APACS expansion system with
                                                                                          Louisiana Dryer Drainage         HART capable Field Termination Assemblies [FTA’s] and added AMS with Multiplexers. Over the last 3 years the results of having live on-line diagnostics
                                                                                          Project                          using AMS have been impressive. Results from using AMS include:
                                                                                                                           A.
                                           Randle      Perry     Johns Manville           Johns Manville Cuts              Johns Manville Engineered Products plant in Etowah Tennessee manufactures commercial/industrial roofing products and fiber glass insulation.                  PlantWeb Asset Optimization
                                           Granger     Mark      Emerson Process          Emergency Maintenance Costs Mechanical failures and unscheduled outages were threatening the company’s status as the industry’s “low cost supplier” and resulted in expensive
                                                                 Management               and Increases Equipment          emergency maintenance and loss of production. Key business objectives were to decrease emergency maintenance to less than 10%, increase
                                                                                          Availability with Machinery      throughput by means of greater machine availability and reduce maintenance costs. Johns Manville partnered with Emerson to implement a customized
                                                                                          Health Management                Machinery Health Management program.
                                                                                                                           This paper reviews the program implementation and expansion strategy and results. The program, which was initiated with no new headcount and no
                                                                                                                           large expenditures, has become an essential strategy to meeting business objectives. The program results include:
                                                                                                                           5% increase in machine availability
                                                                                                                           50% decrease in emergency maintenance costs
                                                                                                                           50% reduction in meant time between failures (MTBF)
                                                                                                                           19% overall vibration reduction to extend machinery life.


                                           Seitz       Dave      Lyondell                 Startup and Operational         Lyondell, a global petrochemical producer, uses Emerson's AMS Suite: Intelligent Device Manager in our recently completed Netherlands facility. The            PlantWeb Asset Optimization
                                                                                          befefits of AMS Suite:          entire E&I maintenance philosophy, procedures and work instructions of this site are based around the AMS Device Manager application and our location
                                                                                          Intelligent Device Manager      is setting the benchmark in our global system for the way in which we have changed our work processes to realize cost savings. This presentation will
                                                                                                                          focus on real world examples that demonstrate the realized benefits during the commissioning and start-up phase as well as the first six months of
                                                                                                                          operation. In addition to utilizing AMS in our routine maintenance, we are actively pursuing the capabilities of AMS to enable predictive maintenance on
                                                                                                                          certain types of equipment. We are tracking "as new" and "with age" signatures of all the relevant equipment and are working in close cooperation and
                                                                                                                          partnering with select vendors to collect and analyze this information.




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                                                                                                                                                 Emerson Exchange Abstracts from 2004

                                                 LAST      FIRST            COMPANY                   ABSTRACT TITLE                                                                                    DESCRIPTION                                                                               TRACK
                                           Skelton      Rik          NorskeCanada - Alberni     Using Diagnostics from AMS         Valve diagnostics have proven their value in determining the health of an old or rebuilt control valve. To assist shutdown maintenance activity, work PlantWeb Asset Optimization
                                                                     PNP                        ValveLink During Planned           practices have been enhanced such that diagnostics are now performed during each paper machine shutdown. Some valves require immediate attention,
                                           Murphy       Colin        NORPAC Controls            Shutdowns is A Now Routine         whereas others have problems that can wait until the next scheduled shutdown and can be planned for properly. The laptop based diagnostics have
                                                                                                Part of Monthly Paper Machine      worked well enough that MUX's will now be installed to go online.
                                                                                                Maintenance




                                           Lashta       Don          NorskeCanada - Elk Falls   DeltaV Inspect Identifies High The #4 Paper Machine at the Elk Falls mill was recently upgraded with DeltaV and Foundation Fieldbus. DVC positioners were installed onto existing              PlantWeb Asset Optimization
                                                                     PNP                        Variablity Loops, then Valvelink Fisher control valves in order to take advantage of on-line diagnostics and improve the mill's maintenance troubleshooting capabilties. During the monthly
                                           Sheehan      Carl         NORPAC Controls            Finds the Problem                1-day shutdowns on the papermachine, AMS ValveLink is routinely used to perform valve diagnostics and document control performance. With well over
                                                                                                                                 100 control loops operating on the machine, DeltaV's Inspect was incorporated into this maintenance program as a higher level tool to benchmark and
                                                                                                                                 identify process variability. Control loop performance indexes are monitored and excessive variability is identified by Inspect. AMS ValveLink diagnostics
                                                                                                                                 are then utilized to find the root cause of any potential control valve issues. As a result of this enhanced toolset, the mill has been able to isolate valve
                                                                                                                                 problems faster and optimize their maintenance time during shutdowns.


                                           Dahlan       Shah Rizal   Petronas Ammonia Sdn       Petronas Ammonia experience        This paper will be focusing on how Emerson Asset Management Solution with ValveLink Snap-on together with Fisher FIELDVUE PD, has helped                    PlantWeb Asset Optimization
                                           Daud         Shariman     Bhd                        in utilising Emerson Asset         Petronas Ammonia Sdn Bhd not only in optimizing its control valves spares inventories and in providing a good basis for its maintenance planning and
                                                                                                Management Solution with           scheduling but also in significantly reducing its control valve repair cost during its latest plant turnaround. The presentation would share our experience
                                                                                                ValveLink Snap-on together         taking advantage of the capability of DVC 5000 & 6000 in 2 stages. The initial stage involves offline diagnostics performed during plant turnaround. All of
                                                                                                with Fisher FIELDVUE PD to         control valves fitted with Fisher DVC were put through signature test. Step response and performance tuning were performed on selective control valves
                                                                                                provide a good basis for its       based on the findings and also the process demand for accuracy. The second stage would involve our first step of moving towards predictive
                                           Breese       Trevor       Pope & Talbot Ltd -        DVC Valve Position and Alerts      Valvelink has been monitoring control valves on the Kamyr digester for several years. Several benefits have been logged, however, system visabilty          PlantWeb Asset Optimization
                                                                     Harmac PNP                 Displayed on Foxboro               needed improvement. When it came time to go on-line in the steam plant, this plant wanted to get information all the way to the operator consoles. Tri-
                                           Sollitt      Glenn        NORPAC Controls            Consoles Via AMS Valvelink         loop converters were limiting and costly and OPC was not an option. Using Valvelink's Modbus capability, actual valve position and travel deviation alerts
                                                                                                and Modbus                         are now displayed on operator consoles beside each control valve and damper drive. Operators can determine immediately whether a valve is actually
                                                                                                                                   stuck before summoning the instrument department. Other information may be added as the familiarity grows.




                                           Arceneaux    Robbie       PPG Industries             PPG Lake Charles: A case       PPG Industries is a global supplier of coatings, glass, fiber glass and chemicals. PPG's Chlor-Alkali facility in Lake Charles, LA, makes a variety of            PlantWeb Asset Optimization
                                           Bushnell     Jimmy        Emerson Process            study on using AMS Device      chemicals, such as chlorine, caustic, hydrogen, ethyl chloride, etc. Over the past four years, the Silica Products plant at this site has implemented the
                                                                     Management                 Manager and AMS Device         PlantWeb® architecture, including AMS Suite: Intelligent Device Manager used online with multiplexers, a distributed system network, roving stations, and
                                                                                                Manager Web for Instrument     the AMS Device Manager Web capability. PPG has been able to streamline typical maintenance tasks, such as troubleshooting and reconfiguring
                                                                                                Documentation and              devices as well as replacing devices. The calibration management and documentation features allow for easy access to historical data for ISO audits.
                                                                                                Maintenance                    For the past year, the Critical metering department has increased its use of the system to track calibrations on custody transfer meters. The rest of the
                                                                                                                               plant has begun documenting its process critical smart transmitters as well. And, the Web capability allows employees around the plant to share and view
                                                                                                                               the information. Years of experience and use of the technologies have allowed PPG to define more efficient work processes
                                                                                                                               and reap benefits from the system. This paper will explain the benefits this site has realized
                                                                                                                               using the software with both HART and conventional devices throughout the plant, how AMS
                                           Smigo        Ed           PROCONEX                   Using the AMS QuickChek        AMS provides the infrastructure for gaining access to SMART field devices. The challenge is to align the features to how an SOP is executed in a plant.           PlantWeb Asset Optimization
                                                                                                Snap-on for Interlock Checkout Regulatory agencies or insurance carriers often dictate a procedure for the health and safety of a plant and its employees. To that end some processes
                                                                                                                               require strict compliance to regulations that require interlock verification or validation as well as instrumentation conformance to a defined installation
                                                                                                                               practice such as instrument protection, loop testing or service state. QuickChek reduces significantly the time required to test interlocks as well as to
                                                                                                                               provide verification, via reporting, as to the protection state as well as other parameters within the field instrumentation. This workshop will explain how to
                                                                                                                               reduce outage time during a turnaround through the QuickChek snap-on.




                                           Skoncey      Michael      Reliant Energy, Elrama     Utilizing AMS's OPC Server to       Many control systems do not have the ability to perform predictive or preventative maintenance. Mainly because the associated costs of providing the         PlantWeb Asset Optimization
                                                                     Power Plant                Provide HART Information to a      additional process and sensor inputs required to perform diagnostics and maintenance management to a legacy control system is not only expensive but
                                                                                                Legacy Boiler Control System       in many cases impossible to add. Smart field devices currently have most of the diagnostic data required stored within, but until an OPC server for AMS
                                                                                                Network for the Purpose of         6.0 was developed the information could not be made economically available to multiple open system network . Elrama's initial installation of AMS
                                                                                                Improving the Plant's              included boiler related data from units 3 & 4 utilizing two 32 point multiplexing cards which are wired to 40 Fisher digital valve positioners and 20 smart
                                                                                                Availability, Reliability and      Rosemount transmitters. Next we installed an OPC server so that we could utilize more of the data being stored in the smart devices. Also, the data
                                                                                                Maintenance Practices              retreived includes valve positions which are transmitted to the Bailey Controls without any additional wiring. All data is being stored in OSI's PI historian
                                                                                                                                   every 60 seconds and the valve position are available to the boiler
                                                                                                                                   operators graphically. Plans are to have this data being available to NeuCo's optimization neural software for optimizing plant operation and maintenance.


                                           Storey       Herman       Shell Global Solutions     A Development Study on Using       During the last year’s Exchange meeting a joint field study with ExxonMobil and Emerson was presented around FCC operation. The study had shown                 PlantWeb Asset Optimization
                                           Eryurek      Evren        Emerson Process            Field Driven Statistical Process   the advantages of using field driven statistical data, namely using Rosemount’s Advanced Diagnostics Block (ADB) and its Statistical Process Monitoring
                                                                     Management                 Data for Process and Unit          (SPM) to detect at least 30 min in advance some of the developing process anomalies within the riser operation. Parallel to this work, Shell has been
                                                                                                Monitoring                         identifying some opportunities to explore the power of the SPM. Late last year PlantWeb Technology and Shell global Solutions team have been working
                                                                                                                                   on improving the flexibility and scope of coverage for these PlantWeb tools. Joint team has identified some modifications to these tools that will support
                                                                                                                                   these extensions. Once the tools are prototyped, several field trial opportunities have been identified and these new tools will be placed in an operating
                                                                                                                                   refinery to further test the capabilities and identify improvements. This is a true joint development effort to help succeed an end user achieve its goals with
                                                                                                                                   enhanced PlantWeb technology. Benefits of this development program will be applicable not only to refining industry, but also to chemical, oil and gas as
                                                                                                                                   well as others.


                                           Weaver       Ed           Tarrant Regional Water     Tarrant Regional Water District    An existing SCADA system controls and monitors the entire water system. Tarrant’s SCADA Operations Manager, Boyd Miller, believed that vibration           PlantWeb Asset Optimization
                                                                     District                   Satisfies Growing Production       monitoring be more effective and performed more efficiently if integrated into the SCADA. Therefore, Tarrant partnered with Emerson to implement a
                                           Granger      Mark         Emerson Process            Demands Using Advanced             centralized online vibration monitoring system for all high-capital equipment. Emerson engineers provided a customized solution using the AMS Suite:
                                                                     Management                 Reliability                        Machinery Health Manager and CSI 4500 Machinery Health Monitor with advanced network fault tolerance to assure continuous data integrity. If the
                                                                                                                                   network fails, machinery condition data is automatically stored on local servers and then updated to the central server when the network is restored. All
                                                                                                                                   vibration data as well as oil predictive data is integrated and managed using the AMS Machinery Manager software. For early problem identification,
                                                                                                                                   Emerson’s Analysis Services Team remotely provides detailed monthly analysis and trending of the vibration data. The monitoring system provides
                                                                                                                                   SCADA operators with real time vibration alarms and status. Vibration is now used as a process variable along with pressure and flow to determine
                                                                                                                                   optimum pump efficiency. With the system, manpower is now available to perform predictive monitoring on other critical equipment such as exhaust fans.
                                                                                                                                   Using the online system, equipment is monitored during startup and testing. Pump and motor defects have been detected on four different occasions. This
                                           Ramber       Andy         Valero Refining            Using AMS Device Manager           Valero Energy Corporation, a Fortune 500 company based in San Antonio, TX, is one of the top U.S. refining companies with a throughput capacity of 2.4 PlantWeb Asset Optimization
                                           Zieba        John         Puffer-Sweiven             with Ethernet Architecture for     million barrels per day. The Valero Texas City Refinery makes a variety of products including gasoline, low-sulfur diesel, kerosene, home heating oil, and
                                                                                                Refinery Savings                   jet fuel. In 2000, the Texas City Refinery implemented a small 100-tag AMS Device Manager system to leverage the information in the HART transmitters
                                                                                                                                   and digital valve controllers (DVC's) in the heavy ends unit of the refinery. In 2002 and 2003 we expanded the AMS Device Manager system to
                                                                                                                                   incorporate several other units in the refinery that have now recognized significant savings by shortening the turnaround time by as much as 8 days.
                                                                                                                                   Attend this session to learn about the architecture of the Valero AMS Device Manager system that leverages ethernet connectivity. This session will also
                                                                                                                                   discuss how the AMS Device Manager was used to reduce time and cost during instrument commissioning and start-up. Also learn how Valero uses
                                                                                                                                   AMS Device Manager on a daily basis to check instrument information.




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                                                                                                                                Emerson Exchange Abstracts from 2004

                                                LAST     FIRST         COMPANY           ABSTRACT TITLE                                                                                  DESCRIPTION                                                                                      TRACK
                                           Gordon      Todd      We Energies     Integration of AMS Suite:        Most existing plants are not able to introduce new technolgies all at once. This presentation will discuss the introduction of "smart" technologies from the   PlantWeb Asset Optimization
                                           Vigansky    Bob       We Energies     Intelligent Device Manager and   mid-1980's to the present at the Valley Power Plant in Milwaukee, Wisconsin, with emphasis on the AMS Device Manager software and the capabilities
                                                                                 "Smart" Electronics              that it brings to the end-user. Equipment that has been upgraded to "smart" electronics include Rosemount transmitters, Rosemount World Class 3000
                                                                                 Technology into Existing Plant   O2 probes, Rosemount pH transmitters and Fisher FIELDVUE positioners. AMS Device Manager was initially introduced as a stand-alone version on a
                                                                                 Environments                     laptop computer. Hand-held Model 275 Communicators, recently upgraded to Model 375's, were also utilized. This year it was decided to upgrade to an
                                                                                                                  online multiplexer system during our 2004 maintenance outage. The decision was driven by the introduction of PD diagnostic capabilities of the Fisher
                                                                                                                  FIELDVUE positioners (both DVC-5000's and DVC-6000's). FIELDVUE positioners have been retrofitted on several different brands of valves at the
                                                                                                                  Valley plant. Examples of two of these valves were included in a Novaspect applications brochure on DVC positioners ("Asset Management Services -




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