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. Papers/Workshops/Short Courses Committee Page 1 of 3 84cf86e5-35ef-43e2-8aa8-fe5754731fd1.xls 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. Papers/Workshops/Short Courses Committee Page 2 of 3 84cf86e5-35ef-43e2-8aa8-fe5754731fd1.xls 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 - Papers/Workshops/Short Courses Committee Page 3 of 3 84cf86e5-35ef-43e2-8aa8-fe5754731fd1.xls
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