1. Solve & Support Approved Furnace- and boiler-thermocouple debottlenecking: a problem-solving approach "Our new approach to furnace- and boiler-thermocouples provides us with several improvements and possibilities. Most are closely related to the design that relocates the bending of the thermocouple from the MI-cable to an expansion-joint. The results:
- No flexing of MI-cable sheath; reduced cracking, allowing for the use of ceramic coating.
- Larger diameter; better protection and increased reliability of the measurement.
- Larger diameter and no flexing, allowing for online insert replacement or verification during operation.
- Removing skin-thermocouples as a bottleneck for continued operation
- Reduction of cost related to welding, scaffolding, NDA or number of shut-downs.
- Reduction of risk and complete elimination of thermocouple-related early-stage failures." "The issues that were resolved :
- Chemical attack
- Early-stage-failure
- Fatigue in sheath and conductors
- Faulty readings due to irradiation" The benefits that were realized are way beyond the value of the instruments. Actual process continuation bottlenecks were eliminated. Early-stage loss of measuring points was prevented. A true shift from “not taking measurements results seriously” to “actually relying and controlling based on the output” has been achieved. Lives may have been saved. Prevent bending MI-cable for elongation-compensation purposes. It doesn’t like that. At the same time profit from the new construction to allow for ceramic protection that would otherwise crack. Use the increased space to reduce vulnerability and offer on-line replacement possibility. Benefit from increase in reliability even before the massive increase of lifespan begins. Instrumentation - Temperature Instrumentation - Temperature All / Cross-Industry Engineer Workshop Martin Rosmolen Thermo Electric Instrumentation.com - - - - - - - - - - - Consulting Services
1. Solve & Support Approved Smart software validation tools deliver significant cost savings and quality assurance. "This presentation covers the details of smart tools developed and used to validate the DeltaV BPCS and SIS software configuration being built for the Shell Pennsylvania Chemicals site with over 45000 I/O. The project extensively uses Smart Plant Instrumentation(SPI), Alarm Management Database(AMD), standard templates and graphics library.
The project developed Automated smart tools utilizing these structured bs and DeltaV configuration native files for software validation. This is estimated to lead to substantial minimization of tedious manual validation of software configuration and savings of approximaby 2 million USD." "The challenge is to deliver both a cost effective and error free software configuration that meets the acceptance criteria, minimizes customization and ensures use of project standard templates.
The bive is to improve the productivity of the software teams by reducing manual efforts and activities associated with the traditional software testing." "The expected benefits from the smart validation tools are:
- Reduction in man-hours and in duration of the software acceptance testing.
- Quality assurance.
- Helps in maintaining consistency in recording test results.
- Allows tester to focus on the complex logic." "The project developed smart validation tools which automatically extracts DeltaV configuration from native files and compares it against bs from EPCs, i.e. Smart Plant Instrumentation(SPI), Alarm Management Database(AMD) and project standards.
The tool generates reports in excel and flags deviations for further analysis and rectification." Efficiency Compliance, Engineering, DeltaV All / Cross-Industry Consultant, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Sales / Marketing, Project Manager / Lead, Engineer Workshop Prasad Burugupalli Shell Oil Carlos Pereira Emerson - - Darshan Shah Emerson Process Management - - - - - Project Services
1. Solve & Support Approved Mobile Temperature Monitoring of a Pharmaceutical Products Used in Manufacturing Processes Lonza Pharmaceutical utilizes a cryopreserved drug product(CDP)on the second floor of the facility. It must be maintained at a specific temperature to ensure proper application. It is transported via liquid filled Nitrogen dewars of various sizes.? The dewars are stored in a remote area and moved to processing units on different floors via unattended elevators. The temperature must be monitored in real-time once every 30 sec to ensure the CDP does not experience an increase in temperature. The portibility requirement made implementing an wired solution challenging. A wireless network was able to solve the problem. This workshop discusses the problems involved and describes the wireless solution The main problem was trying to cover a multiple-floor installation while maintaining an acceptable update rate. As the distances were great, three remoby-mounted gateways configurated with the same network ID and join key were buated.? This was elimated because the temperature transmitters would have to leave one network and rejoin the neighboring network, causing a gap in readings. The gateway and other required items were supplied as an intergrated solution. Lonza realized shorter installation and startup by utilizing Emerson Service. The multi-floor network provides continous coverage, ensuring the CDP temperature is always monitored, while in storage or being transported. The solution was to use one gateway with multiple antennas strategically located along the travel path. The gateway communicates wirelessly with each temperature transmitter, and is hardwired to their automation system. The temperature transmitter mounted in each dewar never leaves the network thus eliminating any monitoring gaps and keeping the update rate to 16 seconds. Instrumentation - Temperature Design, Wireless, Instrumentation - Temperature Pharmaceutical & Life Sciences Engineer Workshop Rex Polley Lonza Joe Cipriani Emerson Automation Solutions - - Steve Kelliher Emerson Automation Solutions - - - - - Consulting Services
1. Solve & Support Approved How did Qatargas adopt AMS technology to reduce PM cost and improve Maintenance Strategy? Qatargas has large installed base of Emerson smart field devices that are connected to Emerson's Asset Management System. Since the plant startup in 2008 Qatargas was looking to exploit the capabilities of AMS and realize the benefits. After successful startup and stable operation, Qatargas recently bed an internal Maintenance Excellence team to identify key areas of optimization where they envisaged potential scope for cost savings and improved maintenance strategy with better utilization of existing systems and resources. Qatargas identified AMS as the top priority initiative and decided to partner with Emerson to develop a business case with two primary bives; 1. Reduce overall planned maintenance(PM) work load on instrument maintenance team by 10% 2. Avoid incidents through predictive alerts with a target of minimum one trip savings every 5 years. The pilot test proved that Qatargas will be able to save 10% of existing PM work load. They were also able to quantify four credible alerts from the pilot that would have caused production impact if left unattended. Based on the business case and projected ROI, Qatargas awarded Emerson a 3Y contract in Q3 2016 to help integrate AMS into the plant SOP(PM tasks) and started realizing the benefits. Qatargas and Emerson jointly bed a team to develop a charter with bly defined KPI's and b plan.A pilot project was initiated covering 200 tags to observe over 3 months period to capture credible alerts. In addition a motion study was perbed in the field to demonstrate the time savings by utilizing AMS system to carry out the same PM tasks the technicians were doing manually. Optimization AMS, Predictive Technology, Control Valves Oil & Gas Midstream (Pipelines, Terminals) Engineer, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Plant or General Manager Workshop Ramesh K.V Qatargas Arunkumar Ayyalusamy Emerson - - Durgesh Jha Emerson - - - - - Lifecycle Services
1. Solve & Support Approved Competency Development of I&C staff thru training and ensuring implementation thru Capstone Project Companies have invested heavily in technology to make today’s plants safer, reliable and more efficient. These complex plants are run by local engineers and technicians. With Ever increasing emphasis on localization, it is important that they are fully trained to support the maintenance and operations.? They need to be trained in weeks and months, to replace years of experience of expatriate workforce. In designing a training curriculum for competency development developers need to assess the unique needs of the organization, create a plan to address those needs, and identify means to measure the results. The presenters will share their learning from developing the program, from project kick-off to implementation and measuring the results. KOC has identified twelve (12) areas of competency for I&C staff. After training students should work with minimum supervision. The training should explain the basic principles and should have practical hands sessions. There should be a mechanism to measure both proficiency and growth of each students. Monitoring of the student progress in the field after completion of training is a critical must. Competency Development Program enabled the students to achieve desired proficiency. Overall 50-60% improvement in the pre and post test results was observed. On-boarding time was reduced from two years and six months. The graduates of this program are working independently in the field. The program is repeated frequently to improve the competency of incoming I&C staff. A KOC specific program was designed. First the students were given a test to determine the as is state, then students went through a customized classroom program to fill the gaps. At the end they were given the theoretical and practical test to determine the progress. A six months Capstone Project ensured the implementation of learning and monitoring of the student’s progress Training Maintenance, Training, Optimization Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Engineer, Vice President, Supervisor / Manager / Dept. Head, President / Principal, Plant or General Manager Workshop Khaled Al-Juaib Kuwait Oil Company Imran Babar Emerson FZE - - - - - - - - - Educational Services
1. Solve & Support Approved Planning Ahead for Control System Migration and Upgrading "Based on the large Migration program at the Covestro Baytown, TX site this workshop discusses migration approaches, experiences and examines solutions for planning ahead when migrating to new automation and control systems. Also discusses migration justification, project management, budget controls, downtime minimization, and safety and security hazard avoidance.
Covestro is a world-leading manufacturer of high-tech and premium polymer materials for key industries. The Baytown, Texas site is the largest plant in North and Central America. A control system migration program has been implemented at Baytown site to migrate from Emerson legacy Provox to the latest DeltaV Control System and to upgrade the SIS system to the latest safety philosophy." "? Control System obsolescence with focus on Provox?
? Other obsolete systems including APACS, AB PLCs, Quadlog
? Alignment with latest safety philosophy
? Alignment with Covestro’s b configuration and tagging standards, dead code cleanup and IO upgrades??
? Bring up the existing control system documentation to current?
? Minimize unit downtime
? Partial migration risk?
?Safety and security" "? Minimize downtime using “Hot” cutover strategy?
? The phased approach towards control system migration gave maximum availability of control system, high reliability and safe system upgrades.
? Standardization and conbance to b standards.?
? Improved documentation?
? New generation DCS functionality provides framework for enhanced plant reliability and efficiency (e.g. APC, OTS, HPG, CCR)" "? Program approach brings standardization across units
? Code optimization with best engg. practices to improve maintainability?
? Processes and tools to maximize productivity gains
? Standardized DeltaV library, tools/procedures, drawings
? Detailed FEED step involves ‘As-Is’ and ‘to-be’
? Cutover planning and simulation for partial unit migration shortened cutovers
? Hot cutover using CVCS box" Migration DeltaV, PROVOX, Migration Chemicals (Industrial, Specialty) Plant or General Manager Workshop Gerrit Vogel Covestro LLC Venu Rebba Emerson Automation Solutions - - Juan Wu Covestro LLC - - - - - Project Services
1. Solve & Support Approved The Event Chronicle as a 401K - Put Gold Into It Now to Pay Dividends When You Need It Later Something has happened in the facility and you receive a panic phone call to troubleshoot. You can see the alarms that occurred and the bs the operator took, but is that the whole story? Interlocks can occur and b; other logic can command your devices independently of the operators; and transient conditions may prohibit an operator b at just the wrong time. Can you see the culprit when you examine YOUR Event Chronicle? You can put additional inbation (gold) in the Event Chronicle that can make the difference between a half-hour ‘Ok, this is what happened’ and a six-hour ‘What really DID happen?’ Come see use cases, code examples, and do’s and don’ts. Troubleshooting an event in the facility can be a time-sensitive, high pressure, high visibility task for the engineer to provide the answers of ‘what’ and ‘why’. Additional inbation that can drastically shorten the time to get those answers is not always made easily available to the engineer perbing the trouble-shooting. Having a record of control logic bs provided in the context of alarms and operator bs allows the engineer to see a more complete state of the facility and to see time-correlated events that may not have been initially thought to have been connected to the problem. This can reduce trouble-shooting time. Data mining can be used to see when/how often a particular trigger condition occurs. Use LOGEVENTs to record not just that an interlock occurred, but which interlock(s) and when all interlock conditions b. Log when control logic changes controller modes, setpoints, and outputs. Log control logic commands to pumps and valves and what conditions were active that led to those commands. Log batched computation results presented to the operator to allow re-creation of data tables. Troubleshooting DeltaV, Process Control, Engineering All / Cross-Industry Engineer Workshop Stephen Posey Savannah River Remediation - - - - - - - - - - - Project Services
1. Solve & Support Approved How does Praxair Maintain a Secure and Reliable Control System? With the help of Guardian Support! Control systems are the heart of manufacturing and production processes. Keeping them operating at peak efficiency while also keeping them reliable and secure requires time, energy and focus. Managing risk, particularly through managing software patches manually, is labor intensive and has grown over the years into nearly a full-time role. Learn how Praxair has optimized their efforts around patching and overall risk management with the help of Emerson's Guardian Support service. Managing risk, particularly through managing software patches manually, is labor intensive and has grown over the years into nearly a full-time role. Praxair needed help with quick identification of the impact and urgency of new hotfixes and patches to the DeltaV control system. What KBAs, hotfixes, and patches are specifically for my system and how do I prioritize what b needs to be taken? Praxair's DeltaV systems are now kept patched and secure to maximize our reliability and reduce unplanned downtime. The amount of effort to manage and maintain KBAs, hotfixes, and patches is now optimized with reduced manual effort through the help of Guardian Support. Our risk is being better managed and we can track progress by leveraging the system health score indicator. System integrity was maintained by utilizing Emerson's Guardian Support web portal to monitor the security and overall risk of our DeltaV systems. Microsoft patches and DeltaV hotfixes are now kept up to date more regularly and confidently. Utilizing the system health score provided a means to monitor how we were managing the the overall risk of the system over time. DeltaV Maintenance, Security, Reliability Chemicals (Industrial, Specialty) Engineer Workshop Mick Roberts Praxair Bob Cruz Emerson - - Matt James Emerson - - - - - Lifecycle Services
1. Solve & Support Approved Control Modernization, Unique Staging with Wireless Checkout and Many Unplanned Benefits American Crystal Sugar completed a controls modernization project with DeltaV in the Molasses Desugarization plant.? They used a detailed cutover plan with pre-staging of the whole system and field device tagging before the outage.? This minimized the time spent on the project by electricians and operators, respectively.? MDS operators utilized the DeltaV mobile worker to complete the checkout under the scheduled time, while still completing their process outage tasks as well.? Several unexpected benefits resulted from the mobile worker, after the project was completed. American Crystal Sugar had a short b to migrate the Molasses Desugarization plant from RS3 to DeltaV.? Over 1900 I/O to be cut over in less than 3 weeks. Migration was during inter-campaign, resulting in minimum number of people available for checkout and startup.? The cutover plan had to make the best use of the available people. The careful planning with detailed staging enabled ACS to reduce the installation time required, and shortened downtime by 4 days.? The mobile worker with the tagging structure cut the checkout time in half, saving resources on commissioning. Today the mobile worker enables the operators to swap resin filters, run the water treatment facility, and test instrumentation more efficiently than before. ACS implemented DeltaV with mobile worker, and used a tagging system on each transmitter to track checkout to the device, reducing checkout time.? They setup a staging room to assemble and test the system before installation.? There were unique mounting systems that allowed for all of the CHARMs I/O to be pre-mounted on DIN rails and marked, reducing the electricians’ installation time. Optimization Efficiency, Modernization, Migration Chemicals (Industrial, Specialty) Engineer Workshop Amy Timian American Crystal Sugar Company Robin Brophy American Crystal Sugar Company - - Nick Elliott American Crystal Sugar Company - - - - - Lifecycle Services
1. Solve & Support Approved From Paper to Electronic Procedures – How to Capture Knowledge and Standardize Work Using Syncade What is the impact of an error in your facility?? In a nub facility, it can be devastating.? Engineers at the Savannah River Site switched from paper procedures to electronic procedures.? Imagine moving from a paper map to using a GPS.? A GPS provides b instructions to reach your destination.? Similarly, electronic procedures provide a structure to perb work in compliance with safety and quality assurance. Operators are more susceptible to human error when handling paper procedures.? The risk of misreading data and possessing physical bs can be cumbersome. Emerson’s Syncade provides user-friendly, efficient tools so that the specifications, responsibilities, and best practices are enforceable and traceable. The Code of Federal Regulations mandates that there be 75 year retention on all nub documents.? Prior to the switch to electronic procedures, paper documents were improperly handled, lost, and illegible.? Continued use of paper procedures holds more risks to potentially violating this regulation. The new electronic procedures once implemented will direct the operator by enforcing tasks from a centralized b. All tasks can be configured to be completed chronologically before proceeding to the next task, minimizing error and ensuring safety.? Electronic procedures also give the ability to override business rules in special circumstances. Emerson’s Syncade is the software that allows developers to b the electronic procedures and once implemented prepares an electronic copy that can be sent to our Document Control Repository. Syncade perbs in parallel with the DeltaV Distributed Control System to equip the operator with the means necessary to execute and succeed. Syncade has been the resolution we’ve been waiting on. Personal Improvement Codes & Standards, Syncade, DeltaV All / Cross-Industry Engineer Workshop Jennifer Turner Savannah River Nub Solutions Dale Nicosia Savannah River Nub Solutions - - - - - - - - - Lifecycle Services
1. Solve & Support Approved Help Wanted:? Building a Customized Help Utility on a DeltaV system Savannah River Site Engineers will share their successful deployment of a simple yet powerful Help Utility customized for operations personnel and integrated into the DeltaV workstation.? This session will show how the Tritium Process Controls Group at Savannah River Nub Solutions integrated an off the shelf product into the DeltaV to show work instructions, procedures, network drawings, troubleshooting and maintenance guides and even training videos that can be accessed on demand from any DeltaV workstation.? The tool is based on the existing Microsoft Help framework, is easily customizable and editable, and has applications beyond the control room. The Tritium area is in the process of a multi-year conversion to DeltaV as the DCS standard.? Prior to this conversion, the facility had used a legacy DCS for over 30 years.? Despite multiple training sessions, the operations personnel were still asking questions about how to perb various tasks, but the current tools (such as DeltaV Books Online) were not sufficient to answer their questions. The new Help Utility has been implemented in the Production area and the response has been positive.? Now when operators have questions, they can quickly look in the utility instead of needing to leave their workstation or calling engineering.? Because the content within the utility was suggested by operations, they feel involved in the development process, leading to stronger collaboration. The Tritium Process Control group used the Microsoft HTML Help Workshop to develop a customized Help utility.? The utility allows the group to create a set of instructions and guides that are specific to the process area and tailored to the end user.? Training videos have also been created and bed for those who learn visually. Training DeltaV, Troubleshooting, Engineering All / Cross-Industry Engineer Workshop Kaitlyn Allport Savannah River Nub Solutions, LLC Tommy Patterson RE Mason Co. - - - - - - - - - Lifecycle Services
1. Solve & Support Approved Need to Transition an Old Control System to DeltaV? Think Outside the Box to Reduce Costs and Time If you are struggling with shrinking budgets and accelerated installation schedules to replace obsolete control systems then Savannah River Site Engineers will share creative solutions they have developed by Thinking Outside the Box.? In today’s ultra-competitive world of manufacturing, budgets to upgrade are tight and schedules even tighter.? Analysis of how to minimize the labor and time needed to upgrade the system requires new approaches and different thinking.? The old rip it all out and start from scratch approach is not always an option anymore.? Engineers at the Savannah River Site have switched to Thinking Outside the Box and will discuss the planning, decision processes, and lessons learned used to upgrade several obsolete control systems to DeltaV. The problems of limited budgets and facility outage constraints can be overcome when upgrading obsolete control systems. Labor costs associated with design documentation and component installation were controlled in addition to having the facility outage time reduced to acceptable periods by using pre-tested, pre-staged, and modular replacement components. A combination of innovative bs to connect existing field terminations to Delta V along with careful planning of resources and pre-staging of equipment allowed needed upgrades to be implemented. Installation Best Practices Engineering, Project Management, Modernization All / Cross-Industry Engineer Workshop Ray Walker Savannah River Nub Solutions, LLC Robert Fogle Savannah River Nub Solutions, LLC - - - - - - - - - Project Services
1. Solve & Support Approved Wireless Valve Monitoring On Drilling Rig Promotes Environmental Stewardship Manual Valves are a critical, yet overlooked piece of mechanical equipment within most processes. Most companies do not even think to automate, or try to gain transparency regarding their b. However, one drilling company found that not having visibility regarding the b of their more than 60 manual valves can prove costly. On the North Slope of Alaska, sensitive environmental conditions do not give drillers and producers much room for error. One of the key tenents for all of these companies is Environmental Stewardship. Because of this, Alaska's Northslope Producers and Drillers are increasingly concerned about the monitoring and control off all of their assets, even the ones that are not automated. Find out how this driller broke the mold using wireless technology to improve Nabors Drilling was having issues regarding spills during their drilling activities on the North Slope. Their Automation Engineer found the root cause to be a lack of visibility and transparency of the b of their manual valves that drain to the tanks causing overflow of produced water. Nabors reached out to Emerson and PCE to help engineer them a solution for this issue. Nabors realized a payback of $50,000 per drill site for an ROI of 20%. It is estimated that if the wireless system prevents all spills for (5) different drill sites, this wireless project will have paid for itself PCE and Emerson utilized the Topworx/Fisher 4310 and 4320 wireless valve b monitor and controller for 60 of their manual valves and 10 of their automated block valves that drain to the tanks. Included in this solution, PCE bundled (3) Rosemount Gateways, (20) Rosemount 702 Discrete Switches, (10) Emerson Bettis Actuated Block Valves, and a 60" Screen Monitor for HMI. Also included services Wireless Economic Justification, Modernization, Isolation Valves Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Engineer Workshop - - Kenneth Davis Nabors Drilling - - Kevin Hayward PCE Pacific Inc - - - - - Project Services
1. Solve & Support Approved How Air Products implemented a multi-site turnaround program with Emerson Life Cycle Services With more than 40+ sites in North America and reduced staffing for turnaround planning and execution, Air Products turned to team Emerson to design a turnaround program.? The program consists of program management, development of scopes of work, planning, scheduling, and execution of the turnaround for all automation assets including valves and instrumentation for each site. Team Emerson consists of Fisher Valve services, Rosemount Instrumentation Services, and Local Business Partners (LBP) Services. The program has been successfully implemented on several sites in 2016 with many more sites scheduled for program execution over the next couple of years.? As of the end of December 2016, Air Products has realized savings of nearly $400k with turnarounds completed on time and within budget. In an effort to reduce costs, Air Products reduced turnaround staffing but still had the necessary requirement for executing site turnarounds at more than 40 sites throughout North America. Air Products turned to Emerson Life Cycle Services to supply the necessary program management, planning, scheduling, and skilled turnaround execution resources to implement a successful multi-site program. As of December 2016, Air Products has realized nearly $400k of savings from the implementation of the multi-site turnaround program.? For the sites on which Team Emerson has executed a turnaround, Air Products has realized the on-time and within budget completion of the turnarounds executed. Due to staff reduction, Air Products lost significant skills and expertise in turnaround planning and execution. Team Emerson in partnership with Air Products, provided the necessary program management, planning, scheduling, and turnaround execution resources for a multi-site program. In addition team Emerson provided the necessary replacement and repair parts needed for each site turnaround Services Maintenance, Reliability, Project Management Chemicals (Industrial, Specialty) Operator Workshop Augie DiGiovanni Emerson Jake Pittman John H. Carter - - Clay Roccaforte Air Products - - - - - Lifecycle Services
1. Solve & Support Approved Journey to upgrade the fuel oil feed pipeline in a Mexico Refinery while protecting the environment Pemex is the National Oil Company in Mexico and has six Refineries . The Salina Cruz Refinery decided to switch the consumption of Fuel Oil into Natural Gas in all its heaters and boilers in order to reduce the high pollution levels and to reduce operation and maintenance costs. By utilizing the Emerson MAC approach and bing Automation, Control, Monitoring, Regulation & Metering Systems to the existing National SCADA system, Pemex was able to reduce the high fuel costs, eliminate some bottlenecks and reduce pollution around 42% with overall total savings over $400MUSD/year. The refinery used to burn fuel oil that was affecting the local community with high pollution levels. At the same time the price of fuel oil was much more expensive than the Natural Gas. Pemex planned transport gas in a 272 Km? distance away from the refinery.? but they had no compression stations or any infrastructure to receive and distribute the new fuel into the refinery. Estimated savings to switch from oil to gas fuel of around $201MUSD/Year. Reduction of emissions to atmosphere 1,233 KTon/year. Cost Savings by reducing steam consumption $138MUSD/year. Savings for reduction of LPG consumption $52MUSD. Savings for reducing chemical cleaning of about $3MUSD/year and finally a $6MUSD/year Carbon Credit was assigned according to the Kyoto Program. Emerson was able to tailor an integral solution to convert the 12" LPG pipeline and to implement three new compression stations with Emerson Actuators, On-Off valves, field devices, MLV, RTU, MOV's, Metering & Regulation system, DCS, F&G and ESD systems, as well as Custody Transfer & Quality Systems to be interconnected to the National SCADA System. All implementation under a MAC model. Project Management - Refining Consultant, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Sales / Marketing, Project Manager / Lead, President / Principal, Plant or General Manager, Operator, Engineer, Director Workshop ISRAEL GERMAN RAMOS TAPIA PEMEX Fernando Mirafuentes Emerson - - Raul Olivera Emerson - - - - - Project Services
1. Solve & Support Approved Emerson's Digital Plant Helps Customer Achieve Objectives "Japan Canada Oil Sands (JACOS) is a 20000 bpd SAGD technology based process. The plant choose to automate and secure its operations using latest Emerson products and solutions starting with DeltaV PCS and subsequently solutions for data management using Emerson IEH, disaster recovery using the Automated Backup and Recovery solution and finally cyber security based on the Automated Patch Management. The plant also used Emerson's latest automation products and technologies like CHARMS, AMS, DeltaV Switches etc. Considering the highest level of automation JACOS can be categorized as a smart plant that is? operational in the region.
Human Centric Design (HCD) based intuitive graphics are designed with most effective and easy navigation bs to improve operator effectiveness and efficiency." "1) AMS popular snap-on applications such as quick check and valve b have immensely helped the completions team to achieve faster commissioning
2) Effective use of AMS for Config changes, troubleshooting & Maintenance.
3) Managed frequent design changes via effective gap analysis tools and tracking bology.
4) Inconsistent Third party interfaces handled via simple techniques." "1) Addressed the manpower needs using AMS tools.
2)Human Centric Design (HCD) based intuitive graphics are designed with most effective and easy navigation bs to improve operator effectiveness and efficiency. Helped new operators to learn quickly and work independently.
3) Addressed manpower needs for system maintenance using Auto Back/Recovery and Auto patch management solution." "1) Customer focused library
2) The intuitive and yet powerful plant graphics design.
3) Extensive use of AMS for Config changes, troubleshooting & Maintenance.
4) Use of Auto Backup/Recovery & Patch Management Solution to solve & support system maintenance needs.
5) Thanks to CHARMS for several last minute changes in design.
6) Saved serial DST count aligning the modbus registers using SIXNET RTU." DeltaV AMS, Efficiency, DeltaV Oil & Gas Upstream (On-shore, Off-shore, Sub-sea), Other - Oil Sands (SAGD) Engineer, Project Manager / Lead, Operator Workshop Girish Mahajan Emerson Process Management Nagesh Subramaniam Japan Canada Oil Sands, Canada - - - - - - - - - Project Services
1. Solve & Support Approved CTO Stands for Challenging Traditional Options "Everyone has heard for the last few years about Delt V CTO cabinets benefiting your site.? We can talk all about the features, options, and the theory behind CTO benefits, but what users really want to hear is if it really works, and who are the folks who have used it successfully.
Well, here it is.? During this session we'll talk about the Eastman Chemical CTO journey in Kingsport, TN.? We'll outline the project details, the process to get to the right CTO solution, and review of the standard designs that led to the ultimate production and delivery.? We'll share our takeaways from the experience from the perspective of the owner, the LBP, and the Emerson iCenter.? We'll also have a CTO Factory rep available to answer questions about CTO, and a brief update of new CTO offerings." Like any process expansion, time is the enemy.? Not only does it cost money in the b of design effort, but it always fights against you to get to first production.? The CTO execution for this project led to a successful and rapid selection of required options, leading directly into a design review almost immediaby after kickoff, into an order on Emerson to build, test, and ship the cabinets. Eastman was not faced with a protracted design effort and review cycle due to the nature of the CTO program.? They received their cabinets fully tested and ready for install well within the schedule limits of their project requirements without ever having to worry about details outside of their site prep.? This was a significant departure from their traditional execution b for DCS projects. Using the existing CTO base model lineup and configurable option list, Control Southern was able to help Eastman build the right CTO solution for their expansion.? Emerson was able to support a b design review of the solution with Eastman prior to order of the CTO cabinets. DeltaV Design, Engineering, Economic Justification All / Cross-Industry, Refining, Pulp & Paper, Power & Utilities, Pharmaceutical & Life Sciences, Petrochemicals, Oil & Gas Upstream (On-shore, Off-shore, Sub-sea), Oil & Gas Midstream (Pipelines, Terminals), Metals, Mining, Cement & Glass, Food, Beverage & Consumer Goods, Engineering (OEM's, E&C's, Integrators), Chemicals (Industrial, Specialty), Alternative Fuels Engineer, Supervisor / Manager / Dept. Head, Project Manager / Lead, Plant or General Manager Workshop David McBride Eastman Chemical John Heideman Control Southern - - Mike Knitb Emerson - - - - - Project Services
1. Solve & Support Approved DeltaV SIS Logic Configuration, Done With a Click of a Button! "The conceptual design of a SIF/SIS and the associated SRS define the requirements for the application program logic for a DeltaV SIS system. Manually interpreting and converting the requirements is time consuming and can be error prone. In many cases, logic creation starts prior to requirements completion due to schedule needs. Subsequent rework provides another opportunity for fault introduction. Automating the logic creation ensures consistency, allows a start once all requirements are finalized, and generates the logic with a click of a button.
This workshop will describe how the DeltaV SIS Configurator was used on a project to generate the application program logic, reviewing the project steps, and providing an overview of the time saved by automatically configuring DeltaV SIS logic." Interpreting and manually converting conceptual SIF designs into an application program can be error prone, time consuming, and usually requires rework as requirements are finalized after logic creation has started. By automatically generating the DeltaV SIS logic, conversion errors are avoided, project schedule is reduced, and logic creation can be delayed until all requirements are defined. Use of already defined inbation reduced project execution time. Application program logic was created consistently and in an easy repeatable approach. Conversion of conceptual design and SRS into logic was delayed until requirements were completed. The workshop will share overall project cost savings and schedule time reduction estimates. Configuring DeltaV SIS with a click of a button. This workshop will review how the DeltaV SIS Configurator was used on a project to automatically convert a SIF/SIS conceptual design into application logic. An overview will be provided of the common steps in a functional safety project and how these steps prepare for the application logic creation, showing how use of already available inbation can shorten a project timeline. Engineering DeltaV, SIS / SIL, Design All / Cross-Industry, Engineering (OEM's, E&C's, Integrators) Engineer, Project Manager / Lead, Other Workshop Greg Kramer Emerson Kate Hildenbrandt exida - - Iwan van Beurden exida - - - - - Project Services
1. Solve & Support Approved Graduate Development Program for Engineers of Petroleum Development Oman Localization of skilled technical resources in the one of the major drives in Middle East region. This becomes even more important in the current economic environment of Oil & Gas industry. Companies have invested heavily in technology to make today’s plants safer, reliable and more efficient. The need is to design a program that take a fresh graduate out of the university with little and no experience and provide him a broad knowledge in I&C domain to make him productively quickly.? This presentation will discuss how Petroleum Development Oman (PDO) has worked with Emerson in designing a curriculum for its Instrument & Control Engineers.The presenters will share the experience from developing the program, from project kick-off to implementation and success. PDO wanted their graduate engineers to acquire competency in specific technical areas of? ? ? ? ? Process Automation & Systems, Production Measurement & Tank Management, Field Instrumentation & Earthing system. The desired competency level is for them to be able to understand the application of these subjects without being specific to any vendor or product model. Graduate Development Program enabled engineers to achieve the desired proficiency level while meeting their schedule, venue, and budget requirements. Currently PDO is running batches for Graduate Engineers regularly while continuously improving the program. PDO worked closely with Emerson in designing a comprehensive curriculum for fresh graduates in each of the above areas. Topics of each session chosen carefully and the course material thoroughly reviewed to ensure that it met PDO specific needs. Six weeks intensive training program is designed and executed in Emerson Middle East Educational Services Centre in Dubai and PDO Training center in Oman Training Leadership, Training, Sustainability Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Consultant, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, President / Principal, Plant or General Manager, Engineer, Director Workshop Salim Al Hinai Petroleum Development Oman Imran Babar Emerson FZE - - - - - - - - - Educational Services
1. Solve & Support Approved Results Achieved Using an Offline Development Platb with Process Simulation Updating control strategies is a necessity for the maintenance and improvement of a control system over the lifecycle of any plant. However, implementing these changes requires thorough testing in an offline test platb prior to commissioning. In support of their multi-product facility in Fremont, CA, Boehringer-Ingelheim moved control system development and acceptance testing to a virtual platb. Through the use of Mimic Simulation Software and Virtual IO Modules, this platb included a non-intrusive, real-time simulation integrated to an unaltered copy of the production control system. The use of a simulation with complete material and energy balances allowed for changes to batch control strategies to be validated and transferred to the production environment without downtime. Many strategies exist for control system testing and IO checkout; however, many require changes to be made in the DeltaV configuration or have insufficient modeling to test complex control strategies. For this reason, many of these strategies require additional configuration and validation of the controls on the production system requiring in additional downtime for testing. The non-intrusive and parallel nature of this solution means that conversions or changes are not required when transitioning between the simulation and production systems allowing for both the control strategies and system configuration to be tested. This decreased the time needed for testing and validation and allows for control system updates to be applied without any downtime. The use of Mimic Simulation Software and Virtual IO Modules an unaltered copy of the production DeltaV control system to be used for testing, including IO and commissioning of simulated field devices. The inclusion of Advanced Modeling Objects to provide a full material and energy balance in the simulation allowed for comprehensive testing of batch control strategies. Engineering Foundation Fieldbus, Optimization, Operations Pharmaceutical & Life Sciences Consultant, Supervisor / Manager / Dept. Head, Sales / Marketing, Project Manager / Lead, Plant or General Manager, Engineer, Director Workshop Chris Issacs Boehringer-Ingelheim Zachary Sample MYNAH Technologies - - - - - - - - - Lifecycle Services
1. Solve & Support Approved DeltaV Virtualization Benefits with an off-site Cluster American Crystal Sugar implemented a DeltaV virtualized system. This improved general system maintenance efficiency, while improving the ability to monitor the systems health. This upgrade simplified and streamlined the backup process with the replication feature. The configuration was able to handle a couple of server failures without causing any overall downtime. To add more network bandb and resilience, NIC teaming was introduced. Workstations are created in 1/4 the time using templates.? New nodes are less expensive since no hardware is required. Thin clients have a filter to block settings changes for better security at the remote stations. Node resources are independent to each cluster and provide flexibility for normal operation versus failover. American Crystal Sugar converted over to a Virtual System. The amount of time needed to maintain workstation computers, lack of redundancy on key components, and the necessary skill set needed to address these issues in a timely and efficient way. The system minimizes downtime and improves reliability. The replication feature ensures two identical copies of each VM on each cluster. A server failure automatically switches to another server on that cluster to minimize operator disruption. The update process is quicker with desktop access to all workstation from one b. More node resources are a quick add. ACS implemented DeltaV onto a virtual platb consisting of two clusters: one on-site and another in a remote building on the grounds.? They utilized a SAN storage configuration to store the virtual machines. Thin clients were used to replace all of the workstations in the control rooms.? New fiber optic cable was installed between the plant and the remote building Virtualization Design, Reliability, Inbation Technology All / Cross-Industry Engineer Workshop William Harris American Crystal Sugar - - - - - - - - - - - Project Services
1. Solve & Support Approved WDM as a WMD (Wyse Device Manager as a Widget for Manipulating Domains) The Shire plant in Georgia utilizes DeltaV Remote Terminal Servers (RTS) set up on the Virtual Host for connecting the operator interface terminal (OIT) thin clients to the system rather than physical PCs.? The site has more than 120 OITs in 3 different product areas and maintenance area.? WDM has been implemented to provide enhanced remote support for users, manipulate configurations and easily track assets.? There are both ISO9 and ISO8 classified areas within the plant and WDM allows remote maintenance and configuration access to OITs, saving an least $150 in labor and gowning materials There are over 120 thin clients in the production areas of the plant.? Any simple configuration change would require going to each b in the clean areas.? Thin clients in a single production cell are all connected to different RTS, so if there is associated RTS changes, you would need to go and log out all on that RTS, make the RTS change, then go back into each area and log back in. A daily check can be made to see if all the thin clients are talking to the DeltaV system.? Reports can be generated for the thin clients.? The biggest benefit is there is no need to gown to work on the thin clients.? Some activities that have been done would have caused 4 gowning events for one set of thin client changes, now it can be done remoby to save tens of thousands a year. WDM allows any software changes to be made remoby.? You can log into each unit, do the required work, and then log back in.? It also has the MAC address and other inbation for each thin client.? You can see the status of each in the manager also. DeltaV Efficiency, Virtualization, Maintenance Pharmaceutical & Life Sciences Engineer Workshop Todd White Shire Byron Thomas Control Southern - - - - - - - - - Project Services
1. Solve & Support Approved Active Flow Path Dynamic Alarming-Effective Alarm Management for Chemical Injection System on FPSO "How to improve alarming perbance on a system consisting of multiple flowlines with complex valve alignment and multiple pump-heads grouping under different operation modes? This presentation describes a dynamic alarming application based on the Active Flow Path of complex topside & subsea chemical injection systems on FPSO. It eliminates unwanted and/or false alarms generated during the normal operation, and highlights the primary alarms (the first or shutdown alarms) and suppresses consequential alarms in abnormal events. It helps operator to identify root cause quickly and respond to alarms effectively.
The dynamic alarming management strategies were successfully implemented under process on-line condition without interrupting operation" Nuisance alarms generated during the normal injection line switchover operation and alarm floods occurred in a shutdown event. The system consists of multiple flowlines with complex valve alignment and multiple pump heads supporting various operation modes with subsea operation. Such complicity makes it impossible to condition alarms simply based on a single factor such as pump running status Eliminated unwanted/false alarms during the normal operation and prevent an alarm flood in shutdown events; Highlighted the primary alarms and suppressed consequential alarms helps operator response more effectively. Improved operation efficiency and safety Dynamic alarming uses a combination of multiple conditions based on systematical study of operational ‘Active Flow Path’ elements derived from pump group, valve alignment, control and shutdown logics. The dynamic control of primary and consequential alarms comprehended various process operation scenarios from manually start-up, normal operation, process upset to system shutdown events Engineering Efficiency, Process Control, Operations Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Engineer Workshop Peng Wang Canada Engineering Center, Emerson Automation Solutions June M Kobayashi ExxonMobil - - - - - - - - - Project Services
1. Solve & Support Approved Reducing Cost and Going Green – Using DeltaV with a PLC to Control and Monitor an Ice Storage HVAC Looking for a way to reduce the high costs of operating your facility’s HVAC? Savannah River Nub Solutions Engineers will share their experience interfacing a DeltaV controller to an ice storage based HVAC system capable of providing precise environmental controls without the full time use of a mechanical chiller system.? VIMs interfaced to a remoby located Allen-Bradley PLC provide the capability to monitor, control, and display environmental real-time data from a centralized b eliminating the need for facility personnel to perb equipment manipulations and check of status at the HVAC skids. The HVAC vendor would only provide system controls using Allen Bradley PLCs and a local HMI mounted at the remoby located equipment skids.? The costs of having the vendor switch their design to the Savannah River Site standard PLC vendor or using DCS controls were cost prohibitive.? The project required close interfacing with the vendor to allow them to still use their standard control approach. Besides the significant cost savings realized from using stored ice during peak power rates and generating ice during lower power rates, connecting the normally standalone PLC based HVAC system to the DeltaV DCS eliminates the need for physically monitoring remoby located equipment. This provides the additional benefit of reducing manpower costs and improving facility safety. The remote HVAC system was interfaced to the DeltaV DCS via VIMS using Ethernet IP protocol.? This provided monitoring and control functions from one of several possible control rooms while eliminating the need for personnel to perb equipment checks during off-shifts and inclement weather conditions. Economic Justification Efficiency, Safety, Engineering All / Cross-Industry Engineer Workshop Milton Sanders Savannah River Nub Solutions, LLC Kaitlyn Allport Savannah River Nub Solutions, LLC - - - - - - - - - Lifecycle Services
1. Solve & Support Approved Integrated cybersecurity monitoring: from the Plant to the SOC Security monitoring is an essential (but often missing) piece for every cybersecurity strategy. But plant-level resources lack the time and expertise to monitor security events 24/7. Consequently, events and logs from control system endpoints are left unchecked. Fortunaby, corporate IT Security Operations Centers (SOC) already have the expertise and resources for security monitoring. Valero recognized this opportunity to integrate security events from its downstream facilities using Security Inbation and Event Management (SIEM) technology. With support from their executives, Valero was able to realize a strategy to integrate security events from b operating facilities, even across control system vendors, achieving 24/7 security monitoring for their critical infrastructure. Valero’s team was challenged with collecting events from control system endpoints, without affecting operations, and securely forwarding them up through multiple layers of networks to a Security Operations Center. Their strategy was to integrate Windows events and network device logs from multiple control system vendors across their b downstream operations. Valero’s corporate IT cybersecurity team has gained visibility into the control system layer to monitor for threats in their critical infrastructure. An integrated cybersecurity strategy provides the security inbligence they need to proactively respond. Locally, operations can focus on production and safety, effectively gaining the security monitoring productivity of six full-time resources. Events are collected on each DeltaV System, and aggregated locally into a plant-level virtual Security Inbation and Event Management (SIEM), using McAfee technology tailored for DeltaV. Events are then forwarded through the De-Militarized Zone (DMZ) using a Syslog Relay, and finally integrated into IT at the corporate SOC where they are monitored and analyzed by threat hunters 24/7. Security DeltaV, Services, Inbation Technology All / Cross-Industry Consultant, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Sales / Marketing, Project Manager / Lead, President / Principal, Plant or General Manager, Other, Engineer, Director Workshop Jason Bottjen Valero Ben Jackman Emerson - - - - - - - - - Lifecycle Services
1. Solve & Support Approved Exemplary Cybersecurity Improvements: Applying DHS Seven Strategies to Defend ICS Many times, cybersecurity is treated as optional and solutions are reactively selected without a b strategy. When in fact, applying a few select cybersecurity solutions proactively can significantly improve your system defenses. What’s more, many cybersecurity improvements require little investment, sometimes capitalizing on available features and integrating them into your operational culture. We will review MarkWest’s exemplary cybersecurity strategy through the lens of the Department of Homeland Security publication “Seven Strategies to Defend ICS." Using a novel approach and innovative solutions, MarkWest has created a consistent and defendable b across several facilities, yielding a reduced attack surface. MarkWest was motivated to improve their cybersecurity protections, but didn’t want to apply solutions without a bology or consideration for the human element. Cybersecurity options and offerings can be overwhelming, but a strategic approach will show where you can achieve the highest returns. MarkWest has created a cybersecurity posture and culture that is both defendable and consistent across their critical infrastructure. These exemplary cybersecurity improvements mitigate over 90% of the incidents reported to ICS-CERT. Furthermore, automation of patching and backups has helped alleviate manual effort, effectively gaining the productivity of a full-time resource. Antivirus and Whibisting solutions combine to provide a complete malware protection and detection strategy. Automated Patch Management closes known security vulnerabilities, with tested and approved updates from Emerson. Third, Backup and Recovery provides consistent backups and a restoration plan to recover from an incident. Security DeltaV, Services, Management All / Cross-Industry Consultant, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Sales / Marketing, Project Manager / Lead, President / Principal, Plant or General Manager, Other, Engineer, Director Workshop Ron Sprengeler MarkWest Energy Partners Ben Jackman Emerson - - Richard Paton Equipment & Controls, Inc. - - - - - Lifecycle Services
1. Solve & Support Approved Migrating Storage Field ROCs from Wonderware to DeltaV using OPC An NGL facility has an underground storage cavern network with Fisher ROCs at each cavern to provide monitoring and control. The Wonderware HMI system that provided the interface to the caverns was past its end of life date. As a component of a total facility migration to DeltaV, the cavern network would be integrated into the existing DeltaV DCS. The caverns communicate over an existing, but aging, radio network and new architecture components needed to be added to bring the data into DeltaV. Utilizing the power of OPC and the flexibility of DeltaV, all of the cavern controls and displays were integrated seamlessly to be indistinguishable from any other equipment at the facility. The 75 ROCs transfer a large amount of data over the existing radio network via MODBUS TCP. Given the facility’s low tolerance for communication disruptions, reliability, redundancy, and simplicity of the communications b and hardware were priorities. Data must be stored in a SQL database for daily and quarterly reporting. Reporting tools must function reliably. The critical infrastructure is no longer reliant on a system that is past its end of life; failure of the system would shut down the facility and the pipeline. This meets the facility goal of integrating control of all systems into DeltaV, reduces control system complexity, and provides higher fault-tolerance with built-in redundancy. This presents Operations with a unified and unib interface. A redundant DeltaV OPC server was deployed along with a set of redundant KepServer communications servers to facilitate communications between the ROCs, DeltaV and SQL Server. SCADA-like control modules were developed to facilitate the seamless interface into DeltaV Operate. A series of SQL Server stored procedures and Sytech XLReporter were deployed to handle the reporting requirements. Migration DeltaV, Services, Design Oil & Gas Midstream (Pipelines, Terminals) Consultant, Engineer Workshop Nathan Asberry ONEOK Hydrocarbon Dave Marshall Experitec, Inc - - - - - - - - - Project Services
1. Solve & Support Approved Selection of DeltaV Virtualization using VLANs at Shire Covington "A virtualized project has a range of obstacles from Sizing & Tech Selection to Network Design & domain management.? To realize the practical and economic benefits of DeltaV Virtualization, the planning of every aspect cannot be ignored.? This Workshop will cover the process of what happens after deciding to go virtual on a large project.
From the beginning at Shire we asked “Where is the breakeven point for integrated solutions like the VRTX vs a SAN & Servers?” and “Who owns the shared networks?”.? We managed unknowns by thorough preparation build plans with early in the process. For instance, by properly gauging the difficulty of redesign, we saved over $150,000 using VLANs that simply can’t be justified in a critical system without skilled 24hr IT support." The challenge experienced at Shire Covington was the boring, tedious task making milestone dates while engineering a large, physically distributed DeltaV System. Following the plans seems simple enough, but only through attention to detail and dedication to planning will it go seamlessly. The results of the planning and implementation over the course of two years was the deployment of a 16000 DST site with no delays to schedule or significant changes to scope.? Any scheduling gains were rolled into other areas, allowing for more flexible staffing and support.? There were immediate dollar savings in reduced cable runs and avoiding panel redesigns due to early design choices. The solution was an understanding of the scale and scope of the virtualized build early in the process. The plan developed was flexible enough to change with requirements, but comprehensive of all the needs unique to virtualized builds, such as preplanning IP addresses and switch bs. Virtualization Business, Design, DeltaV Pharmaceutical & Life Sciences Engineer, Supervisor / Manager / Dept. Head, Project Manager / Lead Workshop Marcos Feliciano Shire George Goodyear Control Southern, Inc - - - - - - - - - Project Services
1. Solve & Support Approved Inventory Optimization Enabled by Best-in-Class Field Service Technology Emerson has created an application utilizing mobile work flow technology to improve customer asset data collection and buation of the asset heath while improving field service productivity.? This tool simplifies and streamlines data collection that allows our service teams and LBPs to quickly take asset data and work with Customers to generate inventory recommendations to maximize their plant’s availability and reliability while minimizing inventory investment.? The session will show what a customer can expect in terms how Emerson will collect data and how they will collaborate with Emerson to build a parts stocking strategy. A customer will co-present to speak to their experience. Prior to the Walk Down App, customer asset data collection was a very manual process.? Often data was recorded and re-entered into various systems and worksheets to generate inventory and maintenance recommendations.? A consistent work flow for data collection and a standard customer experience when creating a spare parts stocking strategy were time-consuming to produce. The technology implemented by Emerson improves walk down process efficiency by increasing speed and accuracy validating assets in-line. Use of the Walk Down App can cut the data collection time in half, meaning that our technicians spend less time on site. It also facilitates data-driven decisions on maintenance, inventory, reliability and perbance services. Having collected the proper data digitally, Emerson and our LBPs work with the customer to drive parts stocking strategies that ensure better risk mitigation for critical assets. This also allows a structured process to take that inbation and help the Customer keep the right parts on the shelf based the criticality of a given valve. Maintenance Control Valves, Reliability, Maintenance All / Cross-Industry Engineer, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, Operator Workshop Clinton Schneider Emerson - Final Control Jim Toyne RS Stover - - - - - - - - - Lifecycle Services
1. Solve & Support Approved Control System Hot Cutover Tool - Saves Time and Money "Suncor Energy is Canada’s leading integrated energy company, with an oil sands development and upgrading business unit located in the Athabasca oil sands, one of the world’s largest petroleum resource basins, producing an average of 433,000 bbl/d. Since starting Base plant operations in 1967, we are continuously expanding our operations, which results in many legacy controls systems.
With the continuous aging of our control systems, many modernization projects are regularly executed. We are always looking for faster, cost saving ways to modernize our controls systems while maintaining production. When we find new tools that allow us to modernize our control systems and keep the plant running we are keen to implement it, as flowing production provides best value to our shareholders." Secondary Extrb Plant 4 has multiple centrifuges of various ages and manufacturers. Some legacy control systems had been migrated to a central DeltaV system. Due to its complexity, runtime requirements and overall logistical challenges with a traditional offline cutover, one 500 HP centrifuge had not been migrated.? Our preference was to find a hot cutover solution for this equipment. The benefits Suncor realized using the TEMPUS tools include a cost saving execution strategy, no process unit downtime, no loss of production, and a much shorter cutover period. We migrated over 10 signals per hour during the hot cutover. Instead of moving individual signals one at a time, they were done on a system level aligned with the process. Using the CIMA+ TEMPUS tool enabled migrating to DeltaV with no downtime while maintaining control of all I/O on both old and new control systems during the migration process. This solution offers a new approach to the traditional hot cutover which instead of moving single I/O at a time we can cutover a full system as a unit allowing for online commissioning and minimizing impact to operations. Migration Efficiency, Modernization, Migration All / Cross-Industry Consultant, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, President / Principal, Plant or General Manager, Engineer Workshop Vineet Saxena Suncor Energy Inc. David Findlay CIMA+ - - - - - - - - - Lifecycle Services
1. Solve & Support Approved Power plant modernization to digital and Wireless technlogy "AES Gener Ventanas is a 340MW power plant located in Valparaiso, Chile. This project implementation main challenge was to update and modernize pneumatic technology from the 60s and manual operating workstations. There was a lack of updated documentation of control logics, P&ID and wiring.?
?
The modernization project implemented Ovation DCS and WirelessHART technology transbing the plant into the largest and more modern generation plant in the region." Pneumatic control was manual and there was a lack of optimization on the control loops. The documentation of the plant was obsolete. The implementation schedule was very tight for cabling tasks. The pneumatic technology was obsolete and several parts of the process were not monitored, generating all sorts of production, efficiency and availability problems. Control loops optimization after the incorporation of wireless technology. Burner optimization with HRSGs standards. Mounting and commissioning time decrease, and AMS implementation to get devices diagnostics and alarms. New and updated documentation which allowed to decease the commissioning time and accelerating plant start up. Pneumatic controllers were migrated to Ovation state of the art technology. Emerson made an exhaustive survey of all the plant to make reverse engineering to developed control logics and detailed engineering for over 380 digital instruments and actuators and integrated them to the system. 200 wireless measurement points were added, increasing process visibility. Burner management optimization. Migration Migration, Optimization, Modernization Power & Utilities Engineer, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Operator Workshop Ariel Oyola AES GENER David Mu?oz Emerson - - - - - - - - - Project Services
1. Solve & Support Approved A never been done Virtualization for a robust solution on large multiple DeltaV zones system "Minera Los Pelambres is a mine located in Coquimbo, north of Santiago. The plant produces 355.000 ton /year of copper. The plant had 15k DST distributed on 4 DeltaV zones implemented with 80 workstation / serves? on DeltaV 10.3.1.?
?
This is the story of a challenging project, involving the virtualization of 95% of the physical computers and upgrade to DeltaV 12.3.1 in an online enviroment. This is the first virtualization project executed by the Mining Center of Excellence in Chile." Minera Los Pelambres was facing an obsolescence of the workstations: lack of support of Win XP and Sever 2003 from Microsoft. Management of spare parts of the workstations was an issue. In addition, the company was affected by high insurance costs regarding to lack of Disaster Recovery Plan and high time on a disaster recovery. As a result of the virtualization, there was an improvement on the spare parts management, decreasing operations and insurance costs. The decrease on workstations generated important savings on energy costs and time reduction on hardware maintenance and replacement. Footprint reduction on datacenter cabinets. Virtualization of all DeltaV zones and upgrade to DeltaV 12.3.1. The solution designed implements a pair of VRTX per zone, an each one handling at least 15 VM. We implemented this solution in an online environment (except of the Zone 1) without waiting a shutdown of the Zone. Virtualization Engineering, Optimization, Operations Metals, Mining, Cement & Glass Engineer, Supervisor / Manager / Dept. Head, Project Manager / Lead, Operator Workshop Carlos Collado MINERA LOS PELAMBRES Carlos Jaure Emerson - - David Mu?oz Emerson - - - - - Project Services
1. Solve & Support Approved Deny malicious activity on your system with Whibisting A virus on a DeltaV production system could lead to downtime and product loss.? ? To minimize risk of a cyber attack, Fuji implemented? Automated Patch Management? with McAfee antivirus and whibisting.? Automated Patch Management has been around for several years.? The addition of whibisting adds an extra layer of protection.? Even if a virus did make it's way onto a workstation or server, the virus couldn't run with whibisting enabled. Even well trained operators have the potential to accidentally invite a virus by clicking on a malicious b or loading a tainted memory stick.? Whibisting prevents this concern by blocking all applications that are not pre approved. Fuji is confident their systems are more secure than ever.? The risk of an accidental virus due to user error or malicious intent is miniscule. Whibisting offers protection from unwanted applications including executable files, libraries, drivers, Java apps, ActiveX controls, bs, and specialty code. The goal of whibisting is to protect computers and networks from potentially harmful applications.? Only approved applications can run on servers and workstations with whibisting enabled.? Fuji implemented whibisting as an extra layer of protection. Security DeltaV, Services, Process Control All / Cross-Industry Consultant, Supervisor / Manager / Dept. Head, Sales / Marketing, Project Manager / Lead, Plant or General Manager, Engineer, Director Workshop Jon Ellis Fuji Film Shelli Callender Emerson Automation Solutions - - - - - - - - - Lifecycle Services
1. Solve & Support Approved Exxon Partners with Emerson to Build First Modular, Smart Blending Plant in Asia Specialty Chemical producers face a dynamic market full of increasing product variations, variable volumes, and shorter lead times. Producers need to be quick to respond to customer needs to remain competitive. Emerson helps manufacturers evolve their operations to meet demand by designing blending processes, utilizing leading edge technologies, and building turnkey solutions to enable quick start up. Exxon partnered with Emerson on a joint venture to design and build their first modular, fully automated blending plant featuring smart instrumentation. The process is proprietary, but Exxon will be sharing why they selected Emerson as their design and instrumentation partner as well as highlighting the benefits of Emerson's modular design approach and smart instrumentation utilization. To meet growing market demand for a specialty chemical product in Asia, Exxon partnered with Emerson's Blending and Transfer Solutions to help them design and construct their first ever production plant of its kind in Southeast Asia. Exxon's design requirements were that the plant be flexible and scalable to manufacture multiple types and volumes of product while being fully automated. Due to the modular design approach and implementation, Blending and Transfer minimized project risk and complexity while delivering a turnkey solution for easy start up and commissioning. The use of Smart instrumentation also aided in a quick start up and configuration. Exxon also operationally benefited from the use of Smart instrumentation enabling automatic, quality control of their blending. Blending and Transfer designed the blending plant in 5 modules allowing for simplified project execution and easy site implementation. Furthermore, the Smart instrumentation incorporated into the blend unit allowed for quick start up and configuration, as well as providing real time measurement which Exxon viewed as critical for quality control of their blending. Design Economic Justification, Installation Best Practices, Engineering Chemicals (Industrial, Specialty) Director, Technician / Analyst / Specialist, Project Manager / Lead, Plant or General Manager, Operator, Engineer Workshop Paul Grives Exxon Mobil Balaji Athimoolam Emerson - - Edward Barth Emerson - - - - - Project Services
1. Solve & Support Approved Leveraging Emerson’s Virtual Development Solution to support a “Many Mini” plant architecture model "Supporting many small plants across the country with DeltaV systems that are not all at the same revision level poses a challenge for centrally managed Engineering technical center. Being able to quickly and efficiently switch between plants on a single, multi-user development system allows our engineers to spend more time on value added support and development activities instead of time consuming system setup/re-setup time.
This presentation focuses on how Air Liquide is able to utilize the advantages of the Emerson virtual DCS development system to support not only the “many mini” plants running DeltaV, but how easy it is to switch between plants that are not on the same revision level. The Emerson virtual world has allowed us to consolidate to a more manageable and flexible solution." We were able to consolidate several hardware systems and ad hoc virtual machines running outside of the supported platb to a single, multi-user system that takes advantage of the strengths of Emerson virtualization development system. Since going to a more streamlined development system, the Air Liquide corporate engineering department was able to reduce the number of engineers needed to maintain the development systems, provide an environment that was easier to understand for new comers to the group and provide a much needed understanding of Emerson virtualization prior to committing this technology to our operating plants. Our solution includes a DeltaV Hyper-V host server with licensing for the ProPlus multi-node (PPN), operator station networked (OSN) and virtual S & M series controllers.? The architecture includes a folder hierarchy that allows for quick and easy transition between plants. Snapshots are utilized to capture system states at the plant level to maximize support and development flexibility. Virtualization Engineering, Virtualization, Troubleshooting Chemicals (Industrial, Specialty) Consultant, Technician / Analyst / Specialist, Engineer Workshop Arnold Martin Air Liquide USA Tony Daigle Air Liquide USA - - - - - - - - - Lifecycle Services
1. Solve & Support Approved Implementation of a Gas Leak Detection System for Sacramento Municipal Utility District "Sacramento Municipal Utility District, SMUD has a network comprising segmented and interconnected gas pipelines, approximaby 75-mile in length, diameters between 20-24 inch, handling flow rates of up to 6 MMSCFH.
California energy regulations require that gas-liquid pipeline systems have Leak Detection Systems, LDS SMUD installed a Gas LDS, GLDS, years ago. However, due to limited system support, the GLDS had started to generate false alarms and inaccurate leak bs during leak tests. SMUD took the decision to replace the old system with a solution with fast response time, high sensitivity and b accuracy.
Emerson offered its proprietary PipelineManager application, with a Real-Time-Transient-Model, RTTM based LDS, with redundancy capability and interfaced with a PI historian" The new GLDS had to replace the incumbent system and achieve a better perbance in terms of sensitivity, response time and accuracy over several operating scenarios in an environment in which the instrumentation installed on the pipelines have a variety of different resolutions and accuracies. "PLM and VPL outperbed the previous solution. The solution provided SMUD with a reliable graphical tool to monitor for leaks in real time on their gas pipeline system and meet California regulatory requirements.
PLS allows SMUD to support operational and maintenance activities by conducting offline simulations.
This project is major step for LD on gas pipeline systems." "Using the PipelineManager application, a RTTM based LDS was implemented in a dual redundant environment. To deliver a complete solution, PipelineStudio, an offline simulation tool, was also provided in order to perb calculations to support maintenance activities.?
VisualPipeline GUI, was also implemented to enable real time monitoring of system variable trends, hydraulic profiles and alarms." Operations Engineering, Services, Operations Oil & Gas Midstream (Pipelines, Terminals) Engineer Workshop Alberto Acevedo 571755 2944 Jaime Bermudez Emerson - - - - - - - - - Project Services
1. Solve & Support Approved Online diagnosis and health monitoring of a compressors valves Valve failures can be attributed 50% of reciprocating compressor issues, and as critical equipment, the main pain is the ability to determine the moment when a failure starts and when it will result in catastrophic damage. Emerson helped Enap Bío-Bío to drastically improve their key perbance indicators such as availability and reliability improving the perbance of their compressors through the implementation of PeakVue ? Fault Pattern Recognition to measure the Mean Time Between Failures, and how to optimize it. This paper will describe how the use of the PeakVue ? Fault Pattern Recognition allowed Enap to increase the Availability and Perbance of the reciprocating compressor, what is its impact on key perbance indicators, Reliability and Maintenance, and the economic impact. Thermography only allows detecting when a component is failing, this make it impossible determine the mode of failure and at what time and what condition the fault was generated; this was perbed every 30 days. After the temperature increase the compressor heads are forced cooled, making it difficult to take thermographs because water ingress to internal components of the compressor. The stimated results are between a 5% and 7% increase in Ri. more exact results will be obtained in the next few months and before the October presentation. Once the need was identified, Emerson proposed a solution for the implementation of online monitoring system AMS 6500 with PeakVue technology, and the validation of the solution is started by manually retrieving the data using the AMS MHM software and AMSI 2140 hardware for the generation of the valve failure recognition pattern. Reliability Modernization, Reliability, Optimization Refining Engineer, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head Workshop Tomás Ignacio Stüven Piedra ENAP BIO BIO Cesar Roa Emerson - - - - - - - - - Lifecycle Services
1. Solve & Support Approved Online Virtualization of A Biologics Manufacturing Facility In the early 2017, Amgen Rhode Island (ARI) biologics manufacturing facility completed the migration of existing Upstream and Downstream production DeltaV server infrastructure from physical architecture to Virtual Machines (VM) using the Dell PowerEdge VRTX environment using DeltaV Virtual Studio. The primary design constraints were that running process could not be interrupted, and no data could be lost. This session describes the design and implementation of a multi-failover clustered virtual environment with an online cutover, the immediaby-realized business benefits, as well as unanticipated benefits of the new architecture. The main challenge and success of this conversion was to complete the cutover during full production with zero impact to the manufacturing process.? To meet this requirement, the migration process was divided into two phases consisting of converting all non-critical production servers in early 2017, followed by the conversion of critical servers during a future planned production outage. "The main business driver was to reduce risks from hardware obsolescence.? Additional benefits included:
? Increased availability and reduced risk through VM failover and cluster redundancy.
? Promoted “Always On” software concept, supporting periodic server maintenance activities.
? Optimized data center utilization by reducing server sprawl, and reducing power, heat-load, and cooling requirements" The design includes two VRTX failover clusters, centrally managed by two DVS Domain Controllers. Each VRTX includes four hosts, giving the total system a capacity of 40 VMs, with replication. This added capacity, in 50% of the previous rack space, the solution was extended to include 18 new Terminal Servers. This permitted retirement of 60 operator workstations, which were replaced by ThinClients. Virtualization Business, Sustainability, Modernization Pharmaceutical & Life Sciences Engineer, Plant or General Manager Workshop Serge Saakov Amgen Ray Emerson New England Controls - - - - - - - - - Project Services
1. Solve & Support Approved Have you considered one DeltaV Library across multiple sites? – You should! Cargill embarked on a 10 year program to modernize their legacy control systems to DeltaV.? When the program was started, Cargill and Emerson worked jointly together to develop a library that would meet their specific needs.? Five years into the program, requirements have changed slightly and DeltaV has added some new features and function blocks.? Cargill wanted to incorporate some of these into their library for future projects, but also needed to keep in mind the migration path of the already completed projects.? This session will also take a look at some considerations and best practices to keep a DeltaV library updated and consistent across multiple sites. In DeltaV, new function blocks have been added that provide added flexibility and less controller loading than in the past.? Cargill wanted to take advantage of these new features, but already has a large installed base of DeltaV that had to be dealt with. By using the new DeltaV function blocks, approximaby 10-15% less controllers will be required per project.? All plants use the same library which allows for consistency and the ability for any Engineer to go to another site and understand their system.? Finally, by keeping a standardized library, less mistakes are likely to be made. Since Cargill and Emerson have been working on a program together, Emerson worked to develop an updated version of the library.? This consisted of some new graphics and updated control module classes to keep up with the evolving needs of the business.? In addition, a procedure was developed to help each existing DeltaV system take advantage of the new library. DeltaV Engineering, Process Control, Optimization Food, Beverage & Consumer Goods Engineer Workshop Mark Long Cargill Matt Forbis Emerson - - - - - - - - - Consulting Services
1. Solve & Support Approved Retrofit Lime Kiln BMS with DeltaV CSLS to step up integration (and retain needed independence). Experitec was engaged at International Paper’s cellulose fiber mill in Columbus, MS in 2016 to engineer the controls in the recausticizing area. ?One of the systems that was upgraded was the lime kiln Burner Management System (BMS). ?Rather than replacing it with a newer PLC, the best solution was to deploy a DeltaV CHARMs Safety Logic Solver.? With this approach, we covered this important safety function and provided a better, more integrated solution.? The revamp also included a review against relevant industrial standards and several changes were made to bring it up to current practice. Burner operation is all done at the burner deck using pushbuttons and pilot lights. During the project review, Experitec reviewed the relevant standards for a fired kiln (FM and NFPA) to see how well the instrumentation and implementation would meet current standards. These standards were reviewed line by line. Several safety bs were moved from soft bs to direct CSLS bs. Integration using DeltaV safety system greatly sped up the project execution, startup, and troubleshooting of the BMS.? Integrated through the safety gateway controller, the BMS maintain it independence but allows inbation to flow back to the DeltaV operator graphics, continuous and event history.? This setup greatly sped up the checks as the lime kiln was started up on the new controls. The CSLS and the CIOC were installed where the field wires came back from the lime kiln burner deck. ?Once termination was complete, it was simple to run through BMS device checkout early in the longer outage.? We utilized mobile worker WIFI access points to speed up the checkout of both the field IO and the panel lights (on a CIOC). SIS / SIL Design, Services, Migration All / Cross-Industry, Pulp & Paper, Engineering (OEM's, E&C's, Integrators), Chemicals (Industrial, Specialty) Engineer, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, Plant or General Manager Workshop Dwayne Robbins International Paper Ryan Bosio Experitec - - - - - - - - - Project Services
1. Solve & Support Approved Using a streamlining analysis workflow to explore and visualize your data The University of Texas at Austin is involved in a wide range of research initiatives including separations research, CO2 removal and reuse, and Divided Wall Column Technology (DWC). As part of the research data is carefully collected and analyzed. Considerable time is spent preparing data, looking for patterns and anomalies and generating analyses and reports for clients. Most of this analysis is perbed after-the-fact. In this workshop bs and tools used for monitoring and analyzing data at the separations research center are presented. Any new tools and procedures must augment existing ones. The research center collects a lot of data. This data is used for reporting, analysis, and to back up conclusions. Finding patterns and key contributing factors requires significant time and effort along with teams of experts. Sharing work-in-progress for collaboration with other team members and clients, or even with the person doing the work across multiple sessions, has been too difficult. These techniques have been applied to a number of projects. The new tools and bs are now being used to not only monitor the researcher’s projects, but also to monitor the systems and equipment used for the studies. Since all work is captured on-line in projects, the researchers have been able to go back to review and utilize results from previous projects. The solution was to add additional tools and work practices. To aid in the data cleansing, refactoring, analysis, reporting, and collaboration Seeq is being used. Seeq allows users to interactively set up workspaces for visualizing data, marking patterns, and reporting. All interbs and collaborations are done interactively. Inbation Technology Operations, Troubleshooting, Optimization All / Cross-Industry Consultant Workshop Robert Montgomery University of Texas at Austin Brian Crandall Seeq - - Mark Nixon Emerson - - - - - Consulting Services
2. Measure & Analyze Approved ADNOC (ADCO) biggest oil-field, Path for becoming Top QUARTILE Perbing COMPANY ADCO, ADNOC group of company, biggest oil field in Buhasa is facing Challenging Oil and Gas Prices that put pressure to improve the perbance of their existing assets. They are looking for Partners who have one b solution for improving Assets Reliability, have single Platb for multi technology Condition Monitoring and give real time perbance of their assets to take timely decision making for improving efficiency, increasing productivity and achieve excellence to be in list of top Quartile perbance company. "Obsolete System/ Spare Management
Real time Perbance Evaluation
Single Platb for all of their major Perbance Monitoring Assets.?
Improved Maintainability and Reliability Index" "Corrective Maintenance / Preventive Maintenance Ratio improved 20/80
Online Perbance Monitoring helps to improve operational efficiency by 10% and reduced energy consumption by 15% and buate perbance on ASME standards.
Breakdown and turnaround equipment time improve by 12% due to ease of maintenance and spare parts availability.
Equipment Availability index improve by 5%." Emerson provides CSI 6500 protection with Prediction capabilities that enable them to provide safety of their critical assets and also providing insight to machine with state of art technologies like 100+ hours transient records, 3D shaft animation, PeakVue technologies. Provide single platb of MHM Software for multi-technolgies like Vibration, Thermo and Oil analysis with Perbance advisor Predictive Technology CSI Technology, Predictive Technology, Migration All / Cross-Industry, Refining, Petrochemicals, Oil & Gas Upstream (On-shore, Off-shore, Sub-sea), Oil & Gas Midstream (Pipelines, Terminals), Engineering (OEM's, E&C's, Integrators) Consultant, Supervisor / Manager / Dept. Head, Plant or General Manager, Director Workshop Muhammad U Ddin Kalhoro Abu Dhabi Company for Onshore Petroleum Operations Ltd Jawad Sherwani Emerson Automation Solutions - - - - - Reliability Monitoring - - - -
2. Measure & Analyze Approved Integration of a Boiler Drum Water Level Measurement System to Improve Safety and Operator Control A project was initiated to improve water level measurements on process boilers for an industrial application. The boilers have been in operation for over 20 years with frequent startups and shutdowns. During the startup phase of operations, water levels were difficult to monitor via the sight glass and there were limitations on using DP measurements. Inaccurate water level measurements can damage boiler systems and increase safety hazards. A Rosemount Dual Chamber Guided Wave Radar/MLI System was added to the system to enhance safety and to reduce boiler system life-cycle costs. The boiler systems are essential plant assets and impact plant operations. During frequent boiler startups, the water levels were difficult to monitor due to discoloration of the sight glass and do to limitations with DP measurements because of water and steam density changes. Low water levels in the boilers can cause damage to various systems and increase safety hazards during operations. Improved safety and an optimized thermal cycle can be achieved with advanced boiler water level measurement systems. A guided wave radar system with dynamic vapor compensation (DVC) has been deployed along with a magnetic level indicator. This advanced measurement system can enhance measurement capabilities during frequent boiler startups and improve boiler perbance. A defense-in-depth approach was taken by adding an additional layer of safety to the existing boiler controls system.? A Dual Chamber Guided Wave Radar/ magnetic level indicator was integrated into their system while maintaining existing controls and ASME requirements. Instrumentation - Level Instrumentation - Level, Process Control, Operations All / Cross-Industry Engineer, Plant or General Manager, Operator Workshop Eric Daggett eric.daggett@emerson.com Don Shulock Arcelormittal - - Matthew Stignani Emerson - Instrumentation - - - -
2. Measure & Analyze Approved Generating Safety With Concentration One of the most efficient electric generators is hydrogen-cooled. Prior to generator maintenance the H2 gas in the generator must be purged with CO2 then purged with air to avoid an explosion. The Micro Motion Gas Specific Gravity Meter (SGM) is used to constantly monitor the H2 purity in air, CO2 purity in H2, and air purity in CO2. The SGM accuraby indicates when the generator is free of H2 or CO2 and safe to work on. To operate more efficiently, the SGM provides an additional 1% accuracy of H2 purity compared to the previous system allowing for approximaby $90,000 annual operational cost savings. Purity of hydrogen gas is critical to the generator efficiency and operational safety. The generator needs to operate with above 95% H2 purity in air (below which is potentially explosive). Prior to generator maintenance the H2 gas in the generator must be purged with CO2 then purged with air to avoid an explosion. In addition to employee safety, the SGM provides an additional 1-2% accuracy compared to the previous system. A 1% loss in H2 purity will result in 250kW loss. For a plant with 8,000 operating hours a year, the SGM allows for approximaby $90,000 annual operational cost savings. The SGM allows the generator to operate efficiently and safely by constantly monitoring the H2 purity in air from a b very close to the generator. The SGM also monitors CO2 purity in H2, and air purity in CO2. When the user is transitioning between gases in the generator, the SGM gives an accurate indication of when the generator is free of H2 or CO2 and safe to work on. Safety Efficiency, Optimization, Operations Power & Utilities Engineer, Plant or General Manager, Operator Workshop Keith Blendowski GE Energy Hans Loewenheath Micro Motion Inc - - David Taplin Micro Motion Inc - Safety Monitoring, SIS / SIL - - - -
2. Measure & Analyze Approved India's largest Lube Producer uses Wireless Tank Farm Management to improve Efficiency and Safety Hindustan Petroleum Corporation Limited (HPCL), India's largest Lube manufacturer owns a Lube Refinery and 6 Lube Plants across India. They had concerns over utilizing the limited storage capacity to the full potential. Also, the Pollution Control Board imposed Environmental safety regulations for overspill. Wireless, SIL2 certified, Tank gauging systems combined with Vibrating Fork Level switches improved the capacity utilization of the tanks to 95%, while complying with the Safety Regulations. Usable capacity increased by 5000KL equivalent to 5.5%, thereby increasing the revenue by 15M US$ per year. High Accuracy Radar Level Gauges increased the utilization to 95% of total capacity. Wireless Solution reduced the Overall Project Cost by over 20%. The Instrumentation ensured compliance to Indian Pollution Control Board, OISD and AP12350 standards. The Pollution Control Board allowed to resume the use of Pipelines for Oil Transfer, which had been banned due to a recent overspill. SIS systems ensured compliance to Local Environmental Committee guidelines and OISD standards. Usable capacity increased by 5000KL and revenues increased by 117K US$ per day. Overall capacity of the plants increased by 5.5% or 14.25 TMT. 123 SIL2 Certified, Wireless Raptor Systems have been commissioned. The System consists of 5900S Radars for level measurement, 565 Multi point temperature sensors with 2240S Multi b Temperature transmitters, 3051S Pressure Transmitters for online density measurement and SIL2 Fork Level Switches for Hi-Hi Alarms. Efficiency Efficiency, Wireless, Safety Oil & Gas Midstream (Pipelines, Terminals) Operator, Plant or General Manager Workshop Rahul Narayan Hindustan Petroleum Corporation Limited Sumant Juvekar Emerson Automation Solutions - - - - - Efficiency - - - -
2. Measure & Analyze Approved Micro Motion Saving the World by Getting Rid of Nukes.? Density Measurement Without a Gamma Source "Most plants running Flue Gas Desulfurization (FGD) systems use nub densitometers to measure lime slurry density/concentration. Nub densitometers are typically a single point calibration and may have to be calibrated frequently to adjust for process changes. Requirements for nub devices can be rigorous.? These range from state requirements to federal, Nub Regulatory Commission (NRC), documentation and testing to specific training and long-term disposal plans.
This workshop will investigate alternatives to nub densitometers including vibrating element densitometers.? In addition to highlighting the safety benefits, this paper will illustrate the operational benefits. Finally, this session will buate the capital cost and on-going operational costs of this approach." Nub densitometers are typically a single point calibration but the process is constantly changing. What may be accurate one day, isn't the next. Stringent NRC & State requirements drive the cost of ownership for nucleonic devices to astronomical numbers.? Also, record keeping, ongoing financial constraints & constant training add to the requirements of utilizing a nub densitometer. No mandated inspections, ongoing training and endless record keeping associated with nub densitometers. Easy, direct, simple, low costs installation – reducing instrumentation costs by approximaby 90% per meter. Eliminates operators going to the device to recalibrate equipment to match the process ?uid, reducing trips into the plant to a minimum, increasing the safety of employees. Micro Motion? Fork Density Meters (FDM) measure concentration of a wide range of process fluids without a gamma source.? The FDM is an inline device for density and concentration monitoring plus it enhances the interface detection, concentration control and blending operations of process ?uids. Customers chose the FDM for not only lower operating costs but for improved accuracy and operations. Instrumentation - Flow Efficiency, Modernization, Instrumentation - Flow All / Cross-Industry, Power & Utilities Consultant, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Plant or General Manager, Operator, Engineer Workshop Brent Pankonien Emerson Mark Head Emerson - - - - - Instrumentation - - - -
2. Measure & Analyze Approved Huadong Pharmaceuticals improved Process Control through a Plant Modernization Program Huadong Pharmaceuticals, since its inception in 1993, has been growing significantly. In 2015, they were notably ranked as No.4 among the top 100 pharmaceutical companies in China. For one of their projects called the Bailing, Emerson was entrusted to supply the total solution that included the System, Valves, Instrumentation from Rosemount, Engineering and Validation Services. To increase the degree of automation and ease of commissioning, Emerson’s Wireless technologies provided a new dimension that helped to accelerate the project cycle, with reduced time and costs. The Key Pain Point resided in the Plant Cabling Infrastructure around the fermentation tanks. The existing layout, with running cables and trays all around the tanks, posed an Environmental Safety risk for the technicians at the plant. Additionally, there was an increased tendency of Process Contamination caused by the running cables and threatened to halt down the Process Operations anytime. They improved the Safety at the tanks by minimizing risk of Overfills and optimized operations through Remote Monitoring, while keeping technicians off the tank roofs. Eliminating Cables reduced the risk of contamination. Increased Automation was recognized as a long-term, sustainable solution and simplified verification of Wireless instrumentation by third parties accelerated the Project Cycle. Huadong Pharmaceuticals replaced 96 traditional Capacitance level meters with Emerson’s 3308 Wireless Guided Wave Radar to monitor the levels in their fermentation tanks. The Digital Communication and the Ease of Configuration helped them to gain reliable, accurate measurements with no cables and trays. Wireless Modernization, Safety, Process Control Pharmaceutical & Life Sciences Consultant, Plant or General Manager Workshop Shuijin Yuan Huadong Pharmaceuticals David Ji Emerson Automation Solutions - - Charles Wan Emerson Automation Solutions - Instrumentation - - - -
2. Measure & Analyze Approved Rethinking Diagnostic Functions in Pressure Transmitters MOL Petchem conducted a study utilizing Emerson pressure instrumentation to determine if the technology could help improve operations by examining the relationship between installed equipment and the technology supplied by Emerson to monitor for impulse line plugging. The historical solution was to monitor for impulse line using periodic reactive maintenance when an alert was received by the maintenance department. In the analysis, we examined the long-term correlation between various measurement values provided, along with plugged line detection. The end goal was to determine whether there was a way to combine all of this data to help proactively plan maintenance or cleaning and also give a warning to the operator of inefficient chemical dosing. The plant initially had no way to monitor and proactively detect issues with technology equipment, such as plugged impulse lines, that could lead to contamination of the process. "The result was that we were able to improve b and reduce downtime by implementing this solution.
-Prevent unplanned shutdown duration 2 weeks, estimated cost : min. 5 million USD)
-Early planning of the cleaning shutdown
-Optimization of the chemical dosing
-Saving Turbo machinery energy (steam consumption)1000USD/day
-Prevent unexpected major machine failure) – 1 million USD" We perbed an analysis of the historical measurements (i.e. pressure, flow, and temperature) compared to the diagnostic data available in Emerson pressure transmitters to determine ways to proactively detect process and equipement issues. The analysis of the data received and implementation of the diagnostics allowed us to monitor for contamination inside of our equipment. Diagnostics AMS, Troubleshooting, Diagnostics Petrochemicals Engineer Workshop István Bognár MOL Petrolkemia (MPK) Erik Mathiason Emerson - - Norbert Nagy Emerson - Efficiency - - - -
2. Measure & Analyze Approved APM Software virtually eliminates mass errors, improves prod spec., in high viscosity chem app. Dow Corning, a b leader in silicon-based technology and innovation, had an extremely high viscosity production line that created process difficulties for engineers over the years due to air entrainment in the product. Operational efficiency and profitability had been reduced due to frequent, unplanned shut-downs and inventory control errors. Most process challenges were the result of air bubbles passing through a flow meter, causing their system to interpret an erratic flow condition and interrupted the process. Dow Corning implemented the innovative Advanced Phase Measurement software, and was able to remediate the flow rate going to the controls. Their improvement in process up-time, product quality and extended batch runs is also a noticeable improvement to their profitability. Intermittent and sizeable gas bubbles moving through an extremely viscous fluid (>50,000Cp) were causing large discrepancies in the mass flow rate readings from a Coriolis meter. Not only did the flow fluctuations sometimes cause shut-downs, but the flow rate inaccuracies ultimaby created downstream blending quality complications as well as inventory control problems. Improved quality control allowed Dow Corning to run longer without shut-downs and could produce larger batches because of the confidence in the measurement. In addition to the increased process efficiency, Dow Corning reduced scrap and waste produced by the shut-down events at an estimated savings of $20,000/ yr. The return on investment (ROI) is calculated to be 3-4 months. Dow Corning upgraded to new transmitter technology with Advanced Phase Measurement (APM) software.? The software first uses an output from the meter to detect multiphase conditions in the meter and then uses inbation from a more stable time period in the process to adjust flow outputs for estimated gas content. The remediated measurement improves the overall flow accuracy of the process. Operations Instrumentation - Flow, Troubleshooting, Optimization Chemicals (Industrial, Specialty) Engineer Workshop Mike Hoon Dow Corning Corp Joe Lawson Emerson Automaiton Solution - - - - - Diagnostics - - - -
2. Measure & Analyze Approved THE X-WELL X-FACTOR: HOW APC REDUCED SAFETY RISK, CAPEX AND OPEX Anadarko Petroleum Mainline Facility in Catarina, Texas needed to measure temperature at multiple points along their gas line. Liquid drop due to temperature variance was identified as the cause for $800K in unexpected maintenance costs to clean solidified carbon pellets in six sulphur treaters. The facility was designed without these temperature measurement points and lacked adequate I/O for expansion. Wireless technology and X-well temperature transmitters provided a quick, cost efficient installation with no disruption of operations. The elimination of traditional hot tap installation and wiring costs resulted in CapEx savings of $45,000 and 230 labor hours. Temperature monitoring will prevent future OpEx? costs associated with the solid bation build-up in the sulphur treaters. A lack of temperature measurement in the original facility design did not allow for monitoring incoming gas line temperature. The inability to monitor facility line temperatures resulted in liquid drop within the sulphur treaters. This caused the carbon charcoal pellets inside the sulphur treater to harden into a solid bation resulting in excessive maintenance costs and reduced production. Traditional hot tap and wired installation costs were eliminated. Safety risks associated with hot tap installation were eliminated. Disruption of facility operations was eliminated. Wired installation costs were estimated at $60K compared to wireless at $15K resulting in $45K savings. The $800K in maintenance cost will be eliminated with facility temperature monitoring. Rosemount Wireless X-Well temperature transmitters and 1410 Gateway provided temperature monitoring on the incoming gas line as well as upstream and downstream of the sulphur treaters. This allows adjustments upstream to prevent liquid drop within the facility and subsequent maintenance costs. Wireless Instrumentation - Temperature, Safety Oil & Gas Midstream (Pipelines, Terminals) Engineer Workshop TODD HOOVER ANADARKO PETROLEUM CORPORATION TERRY FOLSOM EMERSON - - DAVID PENNY EMERSON - Instrumentation - - - -
2. Measure & Analyze Approved Micro Motion Coriolis Meters Improve Combustion Control in Natural Gas Condensate Plant Fired heaters are used in MarkWest Energy's condensate plant in the frbation process of natural gas liquids (NGL's).? The fuel supply for those heaters comes from off-gas from various processes within the plant.? The process control challenge is to maintain stable operation of the burners in the fired heater when the comb and therefore the BTU content changes suddenly.? MarkWest installed a Coriolis Meter and a Specific Gravity Meter on the fuel gas to the burner to better control the BTU's feeding the burner.? They were able to achieve much tighter control of their combustion, reduced heater upsets and the associated flaring events, saving an estimated $200,000/yr. This paper will discuss the process challenges, project implementation and the results achieved. The problem was unstable fired heater operations due to comb changes in the fuel feeding the burners. The benefits were tighter control of the combustion, fewer furnace trips and the associated flaring events.? The savings were estimated to be $200,000/yr. The solution was to install a Micro Motion Coriolis meter to measure and control the mass flow rate of the fuel gas and an SGM to measure the specific gravity of the gas feeding the burners. Process Control Economic Justification, Instrumentation - Flow, Efficiency Oil & Gas Midstream (Pipelines, Terminals), Refining Engineer Workshop Julie Valentine Emerson Rick Kline MarkWest Energy - - Michael Sylvester Emerson Automation Solutions - Instrumentation - - - -
2. Measure & Analyze Approved Increase 0,42% availability of Stream Cracker with diagnostic of instruments,wireless technology&AMS "MOL Petrochemical (MPC), a Hungarian Petrochemical company (berly TVK) introduced a plant wide campaign after the successfully implemented pilot in order to increase the reliability, availability and the up-time of it’s Olefin 2 plant.
MPK has identified the following bottlenecks in its Stream Cracker 2 facility where the availability are critical and needs to be improved:
?- uncertainty of the main technology stream line?
- availability of the cooling water system?
- reduce pump failure by using diagnostics
- operator activity Beside the increased reliability the Customer targeted less maintenance cost and increased operation efficiency, too." -Technology uncertainty lead cavitation at pumps.MPC did unplanned maintenance at 8 pumps last year. -Due to none appropriate cooling water treatment MPC had to shut down the plant 2 times and replaced the heat exchangers last year. -Operators are overloaded with inefficient activities.They should monitor visually the supply system of the stem of pumps.They experienced 12 breakdown last year. -Due to early detection of cavitation MPC can avoid unnecessary maintenance at pumps(save 20-70k$/unit). -MPC uses ClO2 application,monitors the status of water treatment and adjust the dosing of chemicals online.Beside the shutdown (1M$/event) MPC saves the cost of heat exchanger(~70k$). -Operator can avoid unnecessary activities/rounds, increase the availability of stem and save 15k$/breakdown. -MPC implemented Pump health monitoring system for 17pumps.MPK installed 3051S+THUM to get early cavitation warning and wireless temperature units to detect overheats at the bearings. -MPK implement wireless corrosion monitoring system to follow online the status of the heat exchangers. -MPC replaced the manometers by wireless pressure gauges to monitor the pressure of supply system of the stem. Diagnostics Maintenance, Wireless, Reliability Petrochemicals Plant or General Manager Workshop Tibor Poór MOL Petrolkemia (MPK) István Bognár MOL Petrolkemia (MPK) - - Norbert Nagy Emerson - Diagnostics - - - -
2. Measure & Analyze Approved STRUGGLING WITH INACCURATE FLOW RATIO CALCULATIONS? LEARN HOW TO GET SAVINGS BY USING CORIOLIS 5700 "Lyondellbasell is a b leader in manufacturing of Chemicals and Polymers materials for a wide range of industrial applications. In their Pasadena facility they have a reactor measuring EO Flow Ratio using four differential pressure transmitters sharing one orifice plate; they are SIL 3 rated included in a SIS with 2oo3 voting system.
High or Low ratio will trip Rx Feed Valves and Block Valves.
Consequences of inaccurate Reactor Flow Ratio are as follows
? Runaway Reb
? High Pressure
? Level 3 environmental Release of EO to atmosphere.
The impulse lines of the orifice plates were plugged with EO polymer on average of 6 times a year, averaging more than 300 deviations alarms per month.
Every product changes the dP transmitters range needs to be changed." "1. Level 3 environmental Release of EO to atmosphere avoided.
2. Potential exposure to EO to I/E technicians and field Operators avoided.
3. Preventive Maintenance cost reduction ($85K per year before MMI meters installation).
4. Frequency in calibration intervals changed from six months to three years.
5. Re-Range of the differential pressure transmitters every product change avoided." "1. Level 3 environmental release of EO to atmosphere avoided
2. No risk exposure to EO to I/E technicians and field Operators?
3. Calibration interval is now 36 months as per SIL calculations. This means savings of $85K per year
4. Reduce Deviation alarms - No deviations have been shown since MMI Coriolis meters installation.
5. No Range changes needed using the MMI Coriolis meters" "A solution implementing 2 Micro Motion (MMI) 5700 Coriolis meters with CMFS150M was considered to address the problem.
Two MMI 5700 Coriolis electronics installed with CMFS150M mass flow meters with two output channels each, three channels connected to SIS with 2oo3 voting system and one channel connected to DCS for control" Instrumentation - Flow Instrumentation - Flow, SIS / SIL, Reliability Chemicals (Industrial, Specialty) Engineer Workshop SERGIO VICENCIO LYONDELLBASELL Woody Rogers Emerson - - - - - Reliability Monitoring - - - -
2. Measure & Analyze Approved Kuwait Oil Company optimizes safety standards with Emerson’s Wireless Emergency Door Solution Safety is never compromised in Kuwait Oil Company; it is a commitment that KOC adhere to and forces throughout its operations. KOC Gas team, specifically booster station team met with Emerson in order to increase the Safety measures at their facility and understand how automation can play a major role in achieving the highest safety standards. Accordingly, KOC/Emerson proposed & came up with a quick, easy to install solution around Emergency doors which not only enhance safety standards but also reduces cost from current working practices KOC Team has issues in monitoring status of Emergency Doors (total No. 10.There are no monitoring solution to understand which Emergency Door is used, which would prevent them from assessing any safety related issue.Those doors are being used when there is no emergency and they would not know about it until they visit the area. Thus, KOC team has explore the solution with Emerson With Emerson Wireless solution, KOC needs not to spend extra amount on Physical efforts for cable laying & in future any addition of Physical beter or I/O e.g.Pressure/ Temp./Flow/level will be monitored quickly in DCS by utilizing existing Installed Wireless Network. KOC has now real time continuous monitoring for their doors which is a major safety improvement.Thus meeting KOC bive Emerson supported KOC team by supplying 1No. 1420 Gateway, 10 No. of 702 TopWorks GO switch to monitor the Emergency Doors along with 3 No. 702 Repeaters for contingency/Better line of sight with good network strength and KOC team has integrate the Gateway Data to the existing DCS system. Wireless Economic Justification, Security, Safety Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Engineer Workshop Jatin Ponda Kuwait Oil Company Eman Wagdy Emerson Automation Solutions - - - - - Instrumentation - - - -
2. Measure & Analyze Approved Tank Gauging System Migration uses Redundancy to Improve Reliability and Reduce Operational Costs Koch Pipeline's tank gauging system migration and expansion in Clearbrook, MN was executed efficiently and enhanced the terminal's tank automation system in several ways.? The project included upgrading tank gauging system hardware and software for 9 crude tanks and addition of 4 new crude tanks.? The upgrade leveraged the existing bus network and the Foundation Fieldbus device network to reduce installation costs and meet aggressive project commissioning deadlines. The new tank gauging system improved accuracy of tank measurements, reliability and safety of the system, achieved API 2350 category 3 status, and reduced overall operations costs.? In addition, the WiHart communication infrastructure created a network for easy integration of future measurements across the terminal. The existing TRL/2 system was in service for XX years and had reached retired phase of its product life cycle.? Although the system worked reliably for many years its accuracy was degrading and instrument failures were difficult to resolve due to parts shortages.? The new system was able to eliminate drift and improve reliability and thus reducing maintenance costs and improve safety. The solution provides greater reliability to best serve its refining customers as well as reduces operational costs.? Savings in ops are achieved in reduced frequency of hand gauging and man hours to repair obsolete parts and mechanical floats.? Greater accuracy has helped with inventory control and improvement of safe fill levels.? System redundancy improves safety and addresses API regulations. Each tank included 5900S with 2-in-1 design communicating to 2 separate tank hubs.? The redundancy of this design eliminates failure-prone float switches and enables them to meet API2350 category 3.? FFB multi-spot TTs and PTs also integrate into the hub for greater accuracy and gravity measurements. The tank hub utilized Wireless Thums for redundant communication transmission. QBR avail by pres. Instrumentation - Level Codes & Standards, Wireless, Installation Best Practices Oil & Gas Midstream (Pipelines, Terminals) Engineer Workshop Travis Falk Koch Pipeline Company Scott Baruch Emerson - - - - - Instrumentation - - - -
2. Measure & Analyze Approved Rosemount GWR Level Design for High Pressure Separator This session is to discuss the level design approach that was taken on an existing high pressure separator in a refinery for a new safety function to protect a downstream equipment from a gas blow through scenario that could cause a catastrophic failure of low pressure equipment. The new safety function was a SIL 2 with an RRF of 250. This requires the SIS level design to be very reliable to provide the required RRF and a low spurious trip rate.? ?The unit had a history of unreliable level measurements due to challenging process conditions and technology misapplication and was less than five years old. Site preference was to use external chambers for GWR’s for maintenance convenience rather than consider alternative level designs for best reliability and perbance. The first challenge was to consider what measurement technology could operate at 2200 psig. At this high pressure only GWR’s and floats were possible solutions. Another challenge was to minimize the amount of new process connections. With a vessel wall of over four inches, welding new nozzles for the new level devices becomes a technical welding challenge especially during a short outage. All three GWR’s perbed flawlessly right from startup and measured within 0.5% of each other. Typically with external chambers readings are 3-5% apart. By designing direct vessel connections, SIS trip point could be made 10% lower compared to external chamber design making it more operations friendly. No regular probe maintenance is expected. Operations quickly trusted these new levels. The final solution was to use three Rosemount 5302 GWR’s with a segmented rigid high pressure probe in a stilling well design for separators as shown in Rosemount best practices manual. GWR’s would be installed directly in the vessel, minimizing nozzle connections, for best perbance and reliability and avoiding external chamber issues forcing regular maintenance. Instrumentation - Level Design, SIS / SIL, Installation Best Practices Refining Engineer, Operator Workshop Robert Ancrum Consulting Engineer Len Laskowski Emerson - - Christopher Trino Emerson - Instrumentation - - - -
2. Measure & Analyze Approved Installation Synopsis: ERS and Thermal Range Expander for Vacuum Bottoms Level This discussion focuses on the challenges of level measurement in the vacuum tower bottoms level measurement application. Inherent characteristics include high process temperature, vacuum service, build-up/plugging, and wide ambient temperature of Minnesota climate. Typically this application is approached with nub level technology but it has proven unreliable due to background X-ray events. To accommodate the vacuum bottom process demands and deliver a more reliable measurement a triple redundant ERS and Thermal Range Expander system was installed. The workshop discusses challenges faced during commissioning and what was done to address those challenges, and how the system is perbing today. The Emerson solution provided better pump asset reliability and overfill protection. This application is widely recognized as one of the most challenging in an oil refinery as it is defined by its high temperature (645F) and nozzle plugging due to its inherent viscosity in cold ambient climates.? The DP level solution addresses these. Installed nub technology was not reliable/accurate due to background X-ray events disabling nub transmitters. The redundant level indication allowed Flint Hills Resources to better determine actual liquid level. The benefits of measurement reliability provided protection from vacuum tower pump cavitation. The solution also provided better protection from liquid overfill scenarios including capital equipment exposure and environmental, health, and safety risk. QBR data will be acquired and incld in wrkshp. Flint Hills Resources installed (3) Electronic Remote Seals with Thermal Range Expander seal systems on the Vacuum tower for measurement reliability.? The vacuum levels of the column enabled use of ERS and elimination of reference leg remote seals.? Thermal Range Expander allowed for direct mount solution to? minimize heat tracing to nozzle.? A gas purge was installed to further limit plugging. Instrumentation - Level Engineering, Instrumentation - Pressure, Installation Best Practices Refining Engineer Workshop John Zimmerman Flint Hills Resources Scott Baruch Emerson - - - - - Instrumentation - - - -
2. Measure & Analyze Approved ONGC set to recover $3M Annually by reducing gas custody transfer uncertainty ONGC Gas plant at Uran, India supplies over 353 MMSCFD gas to various consumers. They had custody transfer systems based on orifice metering with uncertainty of 0.9%. ONGC wanted improvement in the system. Emerson proposed, designed & implemented Daniel Ultrasonic gas flow custody transfer systems to reduce measurement uncertainty to 0.3%. Emerson India manufactured the skid locally to reduce the project cost & schedule. The new system pays for itself in an year and will help ONGC to recover $3M annually from their custody transfers. Paper discusses project details & savings calculation. ONGC Gas Processing plant at Uran, India was supplying nearly 353 MMSCFD gas to various consumers based on orifice metering with uncertainty of 0.9%. ONGC was seeking alternatives to lower down the uncertainty of their metering system and increase the reliability of flow measurement. They were also looking at increasing their revenue by more accurate custody transfer metering. By implementing Daniel Custody transfer solution with ultrasonic flow technology ONGC is set to realize extra revenue of nearly $3Million per annum because of reduced uncertainty of the new systems. The new systems require lesser maintenance. This will help ONGC to recover project cost within a year. Emerson modified ONGC custody transfer by using Daniel Ultrasonic gas flow meters with a low measurement uncertainty of 0.3%. The skids were fabricated and integrated locally and to ensure reliability and better control. Modular design reduced engineering efforts and improved fabrication schedule. Emerson India was awarded this $2.5million job on a single source basis. Instrumentation - Flow Design, Optimization, Economic Justification Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Consultant Workshop Bhupendra Shringi ONGC Uran Shardula Nogaja Emerson Automation Solutions - - Sanjay Patil Emerson Automation Solutions - Instrumentation - - - -
2. Measure & Analyze Approved Pump up the volume: how pervasive corrosion monitoring can help increase production Like many refineries in today's market, Citgo-Lemont is being pressed to hit increasing throughput numbers while minimizing downtime in production. The site refines many different high-TAN count crude slates, meaning the material they are processing is inherently harmful to their refining infrastructure. Market pressure to produce more gasoline and diesel is forcing the site to push limitations on their production units. One area of specific concern is in their diesel production stream. The high TAN crude source pushes production numbers down in order to protect against corrosion issues such as napthenic acid attack. By deploying a pervasive corrosion monitoring solution, process technologists have the confidence to increase throughput by understanding real-time corrosion values. Issues inherent with processing high-TAN crude slates at high temperatures and velocities can cause headaches for process engineers and hinder production targets. By monitoring the effects these high-TAN slates have on the production system, refiners can properly monitor their infrastructure's integrity, as well as ensure their preventative measures (upstream dosing) are dialed in properly. Depending on the crude slate used, the site dials back production values by 5,000 barrels per day in their diesel system in order to ensure asset integrity and unit reliability. By deploying the PermaSense system, the site plans to increase production to average throughput values and capture additional production numbers. The quarterly impact is estimated at $500,000 in increased production. PermaSense's non-intrusive, wireless corrosion system allows for fast, comprehensive deployment in areas of specific concern. PermaSense provides real-time data which monitors for unib and spot corrosion issues, which are detrimental to achieving production targets. Over time, proper analysis of the data collected can change process behavior and allow for more run-time between outages. Wireless Operations, Wireless, Reliability Refining Engineer, Plant or General Manager, Other, Operator Workshop Pedro Lopes Citgo Lemont Christiane Lederer PermaSense - - Christopher Trino Emerson - Instrumentation - - - -
2. Measure & Analyze Approved Ten Most Difficult Flow Applications in a Pulp & Paper Mill There are many challenging flow measurements in a Pulp and Paper mill, from noisy stock flows, expensive additives, aggressive chemicals, abrasive materials, and high process temperatures, to varying steam quality and fuels. Selecting and installing the right technology and configuration is critical for effective flow and density measurement in any typical paper mill. Black liquor is one of the most aggressive applications in the mill as the combination of high temperature and harsh chemicals can drive permeation in magnetic meter liners.? New, engineered liner solutions address the premature failure rate of traditional mag meters. Utilizing unique flow technologies to dose expensive additives and coatings for paper are critical to optimize ratio control. Each of the ten targeted flow solutions provide significant economic impact.? For example, by tracking percent solids through evaporators, concentrators, and into the firing line, the efficiency of the recovery process was optimized. Calculations show that increasing solids levels by 2% for a recovery boiler firing 300 GPM of black liquor yielded $160,000 in annual savings. Magnetic flowmeters are the primary flow technology in the mill and effectively address difficult black liquor flows around the Digester and critical Basis Weight measurement on pulp stock flows, other technologies including vortex meters, DP and Coriolis are also frequently used to measure steam flow (Vortex and DP,) fuel flows (Coriolis,) and high value chemicals and coatings (Coriolis) Instrumentation - Flow Diagnostics, Optimization, Engineering Pulp & Paper Engineer Workshop - - Larry Hammett International Paper - - Vince Miller Emerson Automation Solutions - Instrumentation - - - -
2. Measure & Analyze Approved Outdoor Piping Leak Detection - Tough Terrain Challenges & Wireless Solutions Are you designing a system for outdoor piping leak detection?? Is it in a challenging and tough terrain?? If so, this workshop is for you!? ?This workshop will discuss the topographical challenges of Red Chris mine’s tailings pipeline leak detection project and how they were addressed through careful planning and radio audits, utilization of WirelessHART technology and installation best practices.? The project was successfully commissioned with 23 pressure and rupture disk transmitters along 4 tailings pipeline choke stations located in a challenging mountainous and forested terrain in northern Canada. The terrain was extremely challenging as the pipeline snaked down a sloped mountainous terrain that was densely forested in northern Canada.? In addition, the tailings pipeline did not have any I/O or power infrastructure along its 5km length except for a high voltage 25 kVa transmission line. By eliminating the infrastructure around traditional wired I/O, the project was able to realize over 75% cost savings by eliminating costly power transbers, field I/O cabinets and fiber optic cabling and trenching.? Installation was simple and low cost and provided successful and robust communications due to the well planned communications design. A preliminary radio site audit was conducted using WirelessHART devices to determine the ideal GPS coordinates and bs to install the wireless transmitters along the pipeline.? WirelessHART was chosen as it did not require any external power or wired I/O infrastructure which was not available in the area. Wireless Engineering, Wireless, Installation Best Practices All / Cross-Industry Engineer, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, Plant or General Manager Workshop Thomas Gross Red Chris Mines TBD TBD TBD - - - - - Communication Protocols - - - -
2. Measure & Analyze Approved Are you on the level? How Rosemount technology provided reliable level measurement at BP Whiting Light ends distillation presents a wide variety of application concerns for traditional level technologies. The T-201D primary gas oil (PGO) stripper at BP Whiting was notoriously one of the most difficult level measurements made on site. A nasty combination of low material reflection (dK), high temperature/pressure, reliance on external measurement chamber and wide range of product density all contributed to the difficulty. A low level alarm designed to protect unit infrastructure from catastrophic failure and potential fire relied on this measurement. Prior to leveraging Rosemount's Probe End Projection technology, the measurement was a top 5 bad actor on site. PEP mode provided an immediaby reliable level measurement, and resulted in throughput increase in the crude unit. Primary gas oil has a variety of application concerns (high temperature/pressure, turbulent surface, low material reflective properties and varying product density) which guided wave radar traditionally struggles measure reliably. Probe End Projection leverages an internal algorithm to directly infer level as a result of probe length and time of flight reflection. The PGO level went from a site-wide top 5 bad actor measurement to something that has not alarmed in over 12 months. The resulting reliability allowed the crude unit PGO stripper to provide increased throughput, decreased downtime and improved the speed of response for operators. BP Whiting gained improved operation for the entire PGO stream, which contributed to achieving unit rates. "Rosemount's probe end projection uses the probe end echo as reference, in case the surface echo is lost, to calculate
the surface echo b. BP Whiting used PEP to address PGO level's surface turbulence and low dielectric (dK) reflection concerns, which resulted in the 5300 GWR measurement to track accuraby regardless of inherent application difficulties." Instrumentation - Level Instrumentation - Level, Reliability, Maintenance All / Cross-Industry Consultant, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Sales / Marketing, Operator, Engineer Workshop Hardy Adjunta BP Whiting Daniel Lucey Emerson Rosemount - - Christopher Trino Emerson - Instrumentation - - - -
2. Measure & Analyze Approved Electronic Remote Sensor-Increasing Reliability and Reducing Maintenance in a Chemical Plant Dakota Gasification Company owns and operates Great Plains Synfuels Plant. This is a unique facility that specializes in the manufacturing of natural gas and is the only commercial scale coal gasification plant in the United States. DGC utilizes DP level for many of their applications. Over the years their legacy capillary systems were starting to become a reliability and maintenance issue. With ERS, DGC was able to reduce callouts,0 to any ERS that was installed in the last year, reduce inventory, increase reliability and throughput, and ease of install was a big benefit. With all of these factors taken into consideration the customer has realized about 20K in savings over the last year of eight systems installed on tar oil, seal oil tanks, and chilled methanol. With the legacy capillary systems installed reliability and maintenance were a problem. Leaking capillaries needed to be re-pumped up and calibrated, cold weather caused slow reb time, unreliable, two techs two install, and stock items for each system. With ERS this eliminated all of that. Callouts have went to zero on installed ERS over a years time and they have reduced stock by half. Once a number ERS were installed and running for a period of time DGC realized the cost of ownership was very low.? Callouts on the installed ERS over the last year have been zero. Operators rely on the value given to them and able are able run the process efficiently. Stock has been reduced by half. Due to lack of maintenance, increased reliability, reduced stock DGC has realized a savings of 20K The solution for DGC was to install ERS on the repeat problem areas in the facility. We started with a few non-critical areas to make everyone comfortable with the technology and the measurement. Once ERS proved itself DGC installed ten systems on tar oil, seal oil tanks, and one on chilled methanol with a probability of ten more. The reliability and lack of maintenance has sold DGC on using ERS. Instrumentation - Level HART, Reliability, Maintenance Chemicals (Industrial, Specialty) Consultant, Technician / Analyst / Specialist, Plant or General Manager, Operator, Engineer Workshop Trevor Harris Rosemount Inc Nick Ahlschlager Dakota Gasification Company - - - - - Instrumentation - - - -
2. Measure & Analyze Approved Coriolis Direct Well Head Measurement of Wet Gas- Part II Last year we demonstrated proof of concept that this producer was able to directly measure wet gas from a well head using only a Micro Motion Coriolis meter, a pressure transmitter, and ROC 809 flow computer. The data showed the meter is able to measure the gas to within 3% of a separator.? Part II data will show results of upper end loading and that this is an economic solution for future sites. Part I results showed the lower end of liquid loading spectrum and this new group of data will show the higher end loading and how it compares. The other problem which is overcome here is the automatic determination of meter factors that are based on sensor diagnostics. Best practices for success will also be reviewed. Not having heated separators and tanks at each wellhead, this operator can complete future well pads with this metering system & connect it to gathering pipelines that transport gas & liquid to a central processing station. Savings at each pad is ~$250k in capital and $50k in maintenance. Operational efficiencies of central vs well-pad processing for an entire field could be $1M or more per year. Total dry gas is measured with a Micro Motion ELITE sensor used with the new 5700 Advanced Field-Mount Transmitter, an Emerson ROC 809 gas flow computer, and a pressure transmitter. The Coriolis meter measures mass flow, density, and diagnostic beters. These are sent via Modbus to the ROC 809 to calculate the dry gas density from AGA 9, via the pressure transmitter, and Coriolis temperature. Instrumentation - Flow Economic Justification, Optimization, Operations Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Project Manager / Lead Workshop Todd Williams Talisman/Repsol Robin Dutton Micro Motion - - Ted Reppi Micro Motion - Instrumentation - - - -
2. Measure & Analyze Approved Recovering Partially Calcined Clay from Scrubber Water KaMin Perbance Minerals mines and processes kaolin clay at three plants in Georgia.? A slurry waste stream from the calcination process at one of the plants contained unmeasured amounts of kaolin clay. A system was designed to detect, recover and reuse the clay, utilizing outputs from Coriolis meters integrated into a process control system. The recovered clay will reduce? waste accumulation in KaMin’s impound by as much as 8000 tons annually and result in substantial product savings.? Additionally, 45 million gallons of clarified waste water can now be reused at the plant, contributing toward our goal of a 30% water use reduction by 2020. A scrubber was used to clean exhaust from the calciner before it was released to the atmosphere. Good control of the scrubber resulted in consistent environmental compliance, but created a waste stream containing kaolin clay that was then directed to a waste impound with unknown environmental impact. The quality of the clay was unknown and low concentration categorized it waste material. Reuse of the scrubber clay results in a 27% reduction in mined clay usage for the product.? Flocculent usage is reduced by 10#/ton. Waste disposed in the impound is reduced by 8000 tons annually and water usage at the plant is reduced by 7%. Manual samples were collected to determine the properties of the clay and its potential for reuse. From there, a dewatering process and economical reuse plan were developed. The outputs from three Micro Motion Coriolis meters were integrated into our process control system. These measurements are instrumental in controlling the dewatering and reuse process. Instrumentation - Flow Engineering, Sustainability, Process Control Metals, Mining, Cement & Glass Engineer Workshop Jeanine Maxwell KaMin Perbance Minerals - - - - - - - Instrumentation - - - -
2. Measure & Analyze Approved How Wireless Improved Flare System Management to Comply with the EPA Refining Sector Rule At Marathon Petroleum’s refinery, faulty relief valves (PRVs) were leaking too much product to flare stacks for burning, but operators could not easily identify which of 500 PRVs were releasing product. It could take weeks or even months to pinpoint a problem. Marathon installed wireless acoustic sensors on 40 critical PRVs, enabling them to quickly identify failed valves. Marathon had unexpected process benefits as well. By reducing product loss and the unexpected benefit of improving process unit efficiency, the monitoring system paid for itself in five months. Faulty PRVs released too much isobutene and propane to flare stacks, costing the refinery millions a year in lost product. Manual rounds took too long to identify problems, were expensive, and exposed workers to hazards. PRVs needed to be remoby monitored so operators could immediaby identify releases and offending PRVs. But, installing standard wired transmitters was prohibitively expensive. Marathon now identifies & corrects PRV problems quickly. Releases are detected & reported within 10 seconds, diagnosed & pinpointed within an hour. Using 4 second update rates, wireless trend data helps to “l(fā)ine out” process units and run them closer to limits, increasing throughput without compromising safety. Payback was achieved in 5 months with total annual savings estimated at $2 million. In one month, acoustic wireless transmitters were installed on 40 PRVs to monitor releases. Transmitters use acoustics to detect lifts, leaks, releases and blockage. Each transmitter sends a Wireless HART signal to a nearby gateway, and the gateway transmits a signal to the refinery’s DeltaV process control system. DeltaV’s AMS asset management system analyzes the signals and diagnoses problems. Wireless Economic Justification, Safety, Efficiency Petrochemicals, Refining Director, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, Plant or General Manager, Operator, Engineer Workshop Don Cramer Marathon Petroleum Marcio Donnangelo Emerson Automation Solutions - - Tom Garry Emerson Automation Solutions - Safety Monitoring, SIS / SIL - - - -
2. Measure & Analyze Approved Temperature monitoring in Natural Gas Storage Tanks - done wirelessly Sawtooth NGL Caverns, a natural gas storage facility located in Delta Utah needed to monitor the temperature in their natural gas storage tanks in order to accuraby calculate the volume of gas in the storage tanks. They also needed to easily get this inbation into their control system. The tanks are located in a large controlled yard, NGL wanted to minimize cost, and maximize safety during the installation. They did not want to use heavy equipment for trenching and pulling wires and they wanted to install the temperature sensors as fast and easy as possible. This workshop will show the cost analysis for wireless vs wired installation,?
