Emerson Digitally Modernizes Aging Facilities to Create Smart, Efficient and Competitive Chemical Plants


PlantWeb® technologies increase yield, availability, and make plants easier to operate and maintain

New York, NY (October 30, 2007). At Chem Show 2007, Emerson Process Management is displaying its automation solutions for modernizing and improving operational excellence of existing/aging chemical facilities that must compete in a global economy. Emerson combines knowledge and technology to help customers migrate from traditional and legacy systems to Smart digital plants that increase yield and plant availability while being easy to operate and maintain.

Emerson engineers, designs, and implements modernization of Smart chemical facilities using the PlantWeb® digital plant architecture technologies, including the easy-to-use DeltaV(TM) digital automation system, AMS(TM) Suite predictive maintenance software, and digitally networked instruments, valves, and equipment.

Continued innovation has expanded PlantWeb architecture to Safety Instrumented Systems that are integrated for operational advantages while isolated for safety. The most recent PlantWeb innovation is Smart Wireless Solutions that cut the installed cost of measurement points by up to 90 percent, and enable access to performance-boosting data that was previously out of physical or economic reach.

DeltaV software includes a library of pre-engineered SmartProcess Advanced Process Control tools for optimizing units like distillation columns, heaters, boilers, fractionators, and more. A suite of embedded Advanced Process Control applications help identify control performance problems and enable optimizing of throughput.

Control system modernization can proceed at the pace needed to satisfy the customer's strategy and budget. For example, one of Emerson's chemical plant modernization projects has proceeded step by step through utilities and processing units over a three-year span. Hot cutover during key stages avoided production shutdown. The resulting digital infrastructure is a platform for continued growth with advanced process control and asset optimization, enabling efficient operations and a predictive maintenance approach. Production has increased, and maintenance costs have been reduced.

Another example involves Biovet, a manufacturer of food additives and pharmaceuticals for farm animals and pets. Replacing the legacy control and instrumentation system with PlantWeb architecture reduced operator walk-around monitoring and manual adjustments, and replaced an outdated paper-based system at the plant. The digital upgrade used FOUNDATION fieldbus networking which centralized operations resulting in 30 percent increase in yield, operating cost reduction of 20 percent, capacity increase of 60 percent, and elimination of unplanned shutdowns.

The innovative new Smart Wireless Solutions from Emerson will be a major boost to modernization and operational excellence improvement. Consider the early application by PPG Industries, who installed and commissioned Smart Wireless instruments at their Chemical Division facility in Lake Charles, Louisiana.

The PPG plant's Smart Wireless network uses ten wireless Rosemount® transmitters for pipeline and steam header temperature measurement, which enables operators to watch for cold spots and adjust steam throughput. PPG also plans to use the Smart Wireless solutions to do temperature profiling of the entire plant, enabling load sharing and balancing to maintain superheated steam plant-wide.

PPG has also commissioned eight wireless Rosemount transmitters on the self-organizing mesh for tank level measurements to provide backup of primary radar level measurements, helping ensure level control.

Wireless transmitters allow PPG to install instrumentation that would normally be cost-prohibitive in the plant that covers approximately 765 acres and is dense with pipes, buildings and equipment. PPG estimates installation costs for wired instruments would include near $20 per foot for wiring and conduit. Wireless measurements have the potential to increase process reliability and provide low-cost redundant measurement.

PlantWeb architecture is ideal for modernization; it is an open, standards-based digital automation solution that networks smart instrumentation throughout facilities and uses continuous process and diagnostic information from devices to manage production and health of devices themselves. Wireless capability extends the information collection to the far reaches of the plant or even remote facilities, enabling elimination of any operating blind spots, and leading to improvement of efficiency, throughput and business results.

About Emerson Process Management

Emerson Process Management (www.emersonprocess.com), an Emerson business, is a leader in helping businesses automate their production, processing and distribution in the chemical, oil and gas, refining, pulp and paper, power, water and wastewater treatment, food and beverage, pharmaceutical and other industries. The company combines superior products and technology with industry-specific engineering, consulting, project management and maintenance services. Its brands include PlantWeb®, DeltaV(TM), Fisher®, Micro Motion®, Rosemount®, Mobrey®, Bristol®, Daniel®, Ovation®, and AMS(TM) Suite.

About Emerson

Emerson (NYSE: EMR), based in St. Louis, is a global leader in bringing technology and engineering together to provide innovative solutions to customers through its network power, process management, industrial automation, climate technologies, and appliance and tools businesses. Sales in fiscal 2006 were $20.1 billion. For more information, visit www.emerson.com.

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