. 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, required time for installation and integration into the control system, long term results and lessons learned. Adding instrumentation and wiring to a Natural Gas Storage Facility is expensive and poses severe safety hazards to construction personnel. To do so quickly and at minimal cost without disrupting the facility or putting people at risk is difficult. A wireless installation minimizes the installation time and causes no disruption to the facility. It also allows for a compleby safe installation. Using the wireless solution reduced the cost of this project by $25,000 and reduced deployment time by several weeks. The storage facility now has a reliable b for monitoring temperature in the storage tanks and measuring an accurate volume in the tanks. The installation was done in days with no disruption to the facility and no safety hazards exposure to personnel. Rosemount wireless 648 temperature transmitters installed on the natural gas storage tanks eliminated any need for running additional conduit and wire. This minimized the amount of workers, as well as their time in the storage yard. This also reduced cost for the installation. It changed a potentially difficult, expensive, and dangerous installation into a fast and low cost solution. Instrumentation - Temperature Installation Best Practices, Wireless, Safety Oil & Gas Midstream (Pipelines, Terminals) Engineer Workshop Josh Morris Sawtooth NGL Caverns Tony Searle Emerson Automation Solutions - - - - - Instrumentation - - - -
2. Measure & Analyze Approved Wireless Condensate Detection System Improves Steam Delivery Perbance on 1.5 Mile Pipeline "This Workshop will present the CAPEX Savings achieved by Air Liquide during the installation of wireless Rosemount Instruments selected to provide early detection of condensate bation in a pipeline containing superheated steam that runs 1.5 miles on a public right of way along a busy highway.
The presentation will conclude with discussion of the OPEX benefits detection system has provided during its' 2 years of service." "Challenges resolved included:
1. Installation of instruments along a 1.5 mile pipeline that ran under and adjacent to a busy road.
2. Determination of the proper bs for sensor installation to successfully detect condensate bation.
3. Successful meshing of transmitter wireless communications.
4. The integration of detection data into host control system to make required process changes." All sensors were quickly and easily installed, significant savings in time and material (wire and conduit) were realized. Sensors have successfully detected condensate bation and process changes made that prevented catastrophic water hammer development. Air Liquide selected Rosemount Wireless Pressure and Temperature sensors for installation at the base of many pipeline expansion joints, the bs of lowest pipeline pressure. All sensors were wirelessly meshed with the next closest sensor set, their data fed into an Emerson ROC 809 with IEC62591 Gateway Card and distributed to the Power Plant DeltaV for any required process control b. Installation Best Practices Instrumentation - Pressure, Wireless, Reliability Chemicals (Industrial, Specialty) Engineer Workshop Michael Day Air Liquide Brian Cleary Emerson - - Carlos Matos Emerson - Reliability Monitoring - - - -
2. Measure & Analyze Approved BASF Tackles Difficult Issue with Critical Electrical Asset Using InbliSaw System "BASF Manufacturing Plant implements proactive solution to solve humidity issues in Transbers, Bus Ducts, medium voltage Switchgear and MCC lineups. The inherent design of arc rated equipment limits air flow in and out of the gear. This can lead to excess humidity buildup within the gear. This buildup has the potential to cause electrical faults, and can cause significant unscheduled outages.
This paper addresses how BASF implemented InbliSAW technology that continuously monitors one of their critical electrical assets. BASF installed Temperature, Partial Discharge and Humidity sensors in the assets, with data transferred to the DCS. BASF was able to increase reliability, lower maintenance costs, and avoid catastrophic failures due to unforeseen indicators." The problem is the design of the arc rated equipment not allow sufficient air flow and therefore permits excess humidity to buildup. Excess humidity buildup elevates the potential for an arcing fault between conductors to occur. This situation can result in the site stopping production to implement repairs and cause the company to miss deadlines to customers and lost revenue. By monitoring the assets in real time, 24/7, BASF is able to determine if there is excess humidity buildup, temperatures beyond specification, arcing between conductors or a failure of heaters not working properly. This gives operations the same in-depth knowledge of their electrical equipment as they receive from their process via the process control systems. BASF turned to Emerson to proactively monitor the electrical equipment. The project engineer installed Temperature, Humidity and Partial Discharge sensors in two Transbers, associated Bus Ducts, Switchgear and MCC Lineups. BASF is able implement this solution without increasing personnel safety risks or prioritizing limited resources for this task. Wireless Diagnostics, Reliability, Predictive Technology Chemicals (Industrial, Specialty) Engineer, Technician / Analyst / Specialist, Plant or General Manager, Operator Workshop Joel Logue BASF Chris Short Emerson Automation Solutions - Rosemount - - - - - Reliability Monitoring - - - -
2. Measure & Analyze Approved Use Rosemount 8700 Mag Transmitter on NON-Emerson flow tubes to reduce spares and improve capability International Paper's Cellulose Fiber Mill located in Columbus MS, has been systematically upgrading its Honeywell control system which utilizes DE digital protocol and Honeywell instrumentation to Emerson DeltaV. Although newly constructed and converted areas of the Mill are able to integrate new SMART instrumentation devices into the DeltaV DCS, the facility still faced the challenge of upgrading the remainder of its installed Honeywell instrumentation to the new industry HART standard. Purchasing Azbil transmitters that have digital protocol switching capabilities would allow IP to prep areas before system cut-over then simply switch the protocol on the devices during the system cut-over during a scheduled outage. IP's cost saving technique to keep the installed Azbil mag tubes, but purchase Azbil transmitters that feature DE/HART protocol switching capabilities revealed the new Azbil transmitters had a HART addressing issue in addition to an analog output scaling issue. This meant that IP was unable to access the transmitters remoby via AMS and would have to directly configure each device with a 475 HHC Savings of $7k- $25k per installation realized. The 8700 transmitter is capable of additional diagnostics of the Azbil flowtube such as High Process Noise Detection, Ground/Wiring fault detection and even Smart Meter Verification!! All accessible remoby via AMS. Furthermore, this allows IP to reduce storeroom costs as the Rosemount 8700 series can now serve as a spare for both manufacturers. With the Universal capabilities of the Rosemount 8700 series mag transmitter, Emerson and IP were able to install 8712's on the Azbil flowtubes and deliver a dependable and repeatable process flow rate while continuing to save IP the cost of purchasing new flowtubes and associated installation costs. This solution allows IP to interrogate and monitor the asset via AMS Instrumentation - Flow Diagnostics, Optimization, Maintenance All / Cross-Industry Consultant, Engineer Workshop Drek Williams International Paper Mark Antonetti Emerson - - - - - Instrumentation - - - -
2. Measure & Analyze Approved Energy Harvesting Enables Real-Time Monitoring of Fans at BP Refinery The BP Cherry Point refinery in Washington needed to continuously measure and display the speed of turbine-driven fans in bs with no available power wiring. Running new wiring would have been too expensive and disruptive to existing operations, so the BP team turned to Emerson for a wireless solution. All Emerson wireless instruments have power modules, but require battery replacements. BP wanted to avoid this maintenance task, particularly in this situation where replacement would have been more frequent than usual due to the need to continuously power the wireless transmitter and an LCD display. Multiple bs in the plant have similar requirements, making it critical to identify a wireless solution that could be replicated throughout the refinery. Data had to be captured, transmitted and displayed in an area with poor physical access. Four turbine-driven fans are located on the top deck of a heater. The fans fail without warning, and the only way to ascertain status is by manually reading total airflow from another downstream fan. Personnel must routinely climb to the top of the heater to read the speed of this fan. The energy harvester solution powers the speed sensor and wireless transmitter with nearly continuous data capture and LCD operation for preventative maintenance. Project costs were limited to instrumentation (est. $5K), for a 90% savings on installation over a wired solution (est. $50K). The simplified installation used in-house labor, was perbed by a single craft, and all without scaffolding. The plant chose Rosemount 705 wireless transmitters and AI-Tek magnetic speed sensors with LCD's, both powered by Power Puck energy harvesters. The harvesters use the temperature differential from a nearby warm furnace surface to produce power. The alternative was to install a magnetic pickup on the turbine to indicate RPM back to the control system; this would have cost around $50,000 USD. Wireless Reliability, Wireless All / Cross-Industry Engineer, Technician / Analyst / Specialist, Project Manager / Lead, Plant or General Manager, Operator Workshop Bob Stiles BP Cherry Point Refinery Janet Dobbs Perpetua Power - - Stephen Reeves Emerson Automation Solutions - Instrumentation - - - -
2. Measure & Analyze Approved Adopting X-well Technology for Remote Well Surveillance Set to Save Shell Millions in Brunei "Brunei Shell Petroleum (BSP) supplies 350,000 BOEPD to Asia Pacific region. It operates an extensive and complex infrastructure of over 1000 wells. Well surveillance is of utmost importance to them. In 2016, in a technical exchange with Shell PACO in Bengaluru, Emerson introduced Rosemount X-well technology for non intrusive process temperature measurement. Discussions led to a pilot of X-well for well surveillance in BSP.
X-wells are installed on oil well flow lines to solve multiple problems. Both pipe surface and process temperatures are accessed to indicate waxing, well perbance and water break through. Data retrieved is used in wax models and well surveillance dashboards. This saves BSP huge OPEX and improves HSSE.
Session will give application & implementation details." "X-well were installed on oil & gas well flow lines to solve three problems:
1) Provide indication of waxing of oil in the flow lines
2) Provide well status whether flowing, not flowing or shut down
3) Indicate water breakthrough as the temperature rises
Since the technology was wireless and non intrusive from process side too, so cable lying problems did not arise and implementation was easy." "Ready availability of data in the control room safe b has helped to reduce the operator rounds and improved OPEX and HSSE. This saving can amount to millions as we consider avoiding well work overs and avoid pipeline breakdowns due to wax bation.
During wireless implementation phase, the non intrusiveness of the solution resulted in quick easy installation." Shell started a pilot with putting X-well on the Flow lines of the oil wells. X-well has been installed on two types of well: Ones that are remote well with pneumatic or hydraulic control without much instrumentation and another type are instrumented oil wells that were missing flow line temperature data. Both, the pipe surface and process temperature data is accessed. Wireless Instrumentation - Temperature, Reliability, Optimization Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Engineer Workshop Ubaid Ullah Shell PACO Shardula Nogaja Emerson Automation Solutions - - - - - Instrumentation - - - -
2. Measure & Analyze Approved The Customer Rules: Designing next generation Process Radar by working close together with customers Radar is the fastest growing level technology for a reason: In this workshop we will show how to develop radar’s that are flexible enough to fit most application conditions but yet easy to install and to use. We will here listen to Instrument Technicians at a major paper mill in Europe how they worked together with Emerson to develop the next generation Process Radar – and making it possible to increase plant efficiency, improve the safety and decrease the maintenance costs. The first radar for level gauging was a highly complicated device with limited abilities and a rather non-existing user interface, creating a roamer that radar is complicated. Since then engineers have continuously improved both perbance and usability. Today's radars are easy to use and very universal for most applications – very much thanks to customer interbs during the design process. By making radar's simple to understand, install and maintain by using smart design algorithms, the user can focus on revenue rather than on maintenance and inaccurate level readings. The radar design criteria's aiming to always provide the safest, most reliable and cost-efficient level solution. We will have a closer look at the increasing level of complexity at customer sites, such as new regulations, increased automation levels and a generation shift among the instrumentation technicians. We will also understand how new generations of radar’s are developed together with customers and how both application criteria's and demands on ease-of-use comes into play when designing a radar. Instrumentation - Level Design, Installation Best Practices, Engineering All / Cross-Industry Consultant, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, Plant or General Manager, Operator, Engineer Workshop Per-Anders Fasth S?dra Cell Andreas Berndtsson S?dra Cell - - Ingemar Serneby Emerson Process Management - Instrumentation - - - -
2. Measure & Analyze Approved PeakVue - Outside the Box - Its not just for Roller Bearings and Gears In this session we will review case histories and examples of non-traditional PeakVue applications. The cases will include sleeve bearings, broken agitator blades, sliding surfaces and more. We will review the unique requirements of these assets and how we effectively applied PeakVue to the overall monitoring and reliability strategy. When traditional monitoring techniques have proven less effective than desired, applying PeakVue to these applications has resulted in providing additional insight into the potential root causes of failures. We will even provide a case that shows how the PeakVue data responded to and help to identify a broken agitator blade broken agitator blade. In the case of the broken agitator blade the site was able to realize a cost benefit analysis of more than $325,000. The other applications have resulted in significant contributions to root cause analysis investigations for critical assets in many different industries. By changing the mindset that PeakVue can only monitor shock events and understanding the failure processes that result in dynamic frictional loading and stress wave generation we were able to employ PeakVue and its unique data integration to identify faults that had previously not been captured. Predictive Technology Machinery Health Management, Reliability, Predictive Technology Petrochemicals Technician / Analyst / Specialist Workshop Reuben Wunder Emerson Process Management Gary Gardner Tucson Electric Power - - - - - Reliability Monitoring - - - -
2. Measure & Analyze Approved Wireless non-intrusive integrity monitoring system enables refinery to achieve better profitability HMEL Bhatinda refinery is one of the largest refineries in India which has the capability to process 300K bpd. This is a world class facility which is looking maximize refinery margins by processing a large proportion of opportunity crudes which are cheaper to procure. The new project was to process high acid crude in the existing facility. An effective online corrosion monitoring system that is easy to install and maintain is critical to ensure the integrity of the refinery infrastructure while processing high acid crudes. This workshop will show on how Emerson’s non-intrusive corrosion monitoring system over the traditional corrosion monitoring systems and how it helped HMEL to achieve the refinery margins. Traditional inspection does not provide a frequent enough picture of asset integrity to afford early detection. Corrosion probes involves replacement cost and high safety concerns on the replacement procedures. The intrusive probe creates a disturbance in the flow of the fluid that can potentially induce corrosion. Wiring the probes back to the control room can be complex in an existing plant. Real time thickness monitoring provides the ability to process high throughput of cheap high acid crude without compromising the integrity of the plant. Opting for this tighter monitoring system along with chemical inhibition results in a payback that is measured in the order of 2 months for 100 sensors. Easy to install and maintain. Eliminates the need for replacing probes which can be unsafe. Emerson’s non-intrusive integrity monitoring system is readily installed online and measures the wall thickness of the fixed equipment and pipeline using ultrasonic sensors. Data is transmitted wirelessly (WirelessHART) to ensure there is no cabling to be installed. The software suite provides sophisticated data analysis & visualisation that helps better decision making for the production team. Reliability Operations, Predictive Technology, Optimization Chemicals (Industrial, Specialty), Refining, Power & Utilities, Petrochemicals, Oil & Gas Upstream (On-shore, Off-shore, Sub-sea), Oil & Gas Midstream (Pipelines, Terminals) Engineer, Plant or General Manager, Other Workshop Sanjay Thakker HMEL India Srivastava Anupam Emerson Automation Solution - - Jake Davies Emerson Automation Solutions - Reliability Monitoring - - - -
2. Measure & Analyze Approved ASCO Pneumatic Panel CHARMS the hearts of our project team. Cargill Inc. is a Bio Refining Company with multiple facilities. The Fort Dodge facility is in its fourth year of operation. This facility looks forward to the adoption of technologies that enable them to be more efficient, more reliable and to increase production rates. The 580 Charms manifold is one of those product that can make a difference. Traditional implementation of solenoid operated valves has always limited the time frame of project implementation. Solenoid b, wiring, tubing and integration to the control system were a challenge. This implementation resulted in a project that was completed ahead of schedule and on budget with ease. The benefits allowed us to complete a project that may have otherwise been delayed until an outage. The ease allowed us to complete the project with fewer people and significantly reduced our engineering time. The implementation and integration to DeltaV of the 580 CHARMS ASCO Pneumatics Panel which was connected to 28-30 valves. Engineering DeltaV, Engineering, Design Chemicals (Industrial, Specialty) Engineer Workshop Jamie Vickery Cargill Inc Marshal Dreessen Cargill Inc - - John Witte R. S. Stover Company - Communication Protocols - - - -
2. Measure & Analyze Approved Address Tough Measurements to Improve Boiler and Combustion Process Perbance Even though boilers are crucial to plant/mill operation, their perbance is often not ideal. Poor combustion causes higher fuel costs and increased emissions. Lack of reliability and response hurts site production throughput and quality. A root cause of poor boiler operation is often inadequate process measurement, and this is often due to the fact that many combustion process beters are difficult to measure reliably and repeatably. This session will provide guidance on how to overcome tough boiler measurement challenges including where to place devices, preferred technology choices, and installation bs. For ideal operation, boiler process beters must be measured repeatably. But, this is often difficult due to mechanical arrangements and fast changes in the process that result from load swings and fuel variations. Air, fuel, drum level, oxygen, and emissions measurements are critical to combustion control, but can be difficult to accomplish repeatably over the load range. Correctly selecting and installing measurement devices for key boiler process beters provides the foundation for achieving robust, optimal control that simultaneously delivers higher reliability, improved response, lower fuel costs, and reduced emissions. Case histories will be presented of sites that have lowered fuel costs 10-15% and reduced need for manual operator intervention by 80%. Properly designed and located annubar flow devices deliver better air flow measurement. Fuel flow measurement technology can be selected based on the application and its constraints. Guided wave radar provides stable and reliable drum level measurement. Correctly selecting and placing oxygen sensors supports optimal combustion control. Specific gravity meters can detect fuel Btu variations. Engineering Instrumentation - Analytical, Instrumentation - Level, Instrumentation - Flow All / Cross-Industry Consultant, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, Plant or General Manager, Engineer, Director Workshop Bob Sabin Emerson Automation Solutions Joel Lemke Emerson - - Scott Pettigrew Emerson Automation Solutions - Instrumentation - - - -
2. Measure & Analyze Approved Modernization of the electronic ignition system using Emerson Process Management wireless technology "PEMEX APATG – Activo de Producción Aceite Terciario del Golfo"" is part of the Subdirección de Campos no Convencionales.
Safety at the facilities is a matter of great importance for the APATG, one of the most relevant works in 2017 will be the rehabilitation of the 100 mmfcd gas burner (currently damaged) at the Tajin II compression station. In order to perb the rehabilitation works of the gas burner a 20mmpcd alternating burner with a traditional ignition system had to be installed in place to maintain operations running, integrate the new burner variables to the existing DeltaV system to monitor and operate.
? Integrity of the facilities by having a reliable electronic ignition system.
? Continuous monitoring of the burner defogging system.
? Measurement of the fuel gas used." The installation of the 20mmpcd alternating burner in order to rehabilitate the main 100 mmpcd burner required close to 1 km of electrical wiring enclosed in conductors as per project to integrate it to the DeltaV system. There was also risk of facilities robbed and vandalized (cable robbery ) representing risk of signal loss due to frequent cable robbery in the areas. "? Integration of the electronic ignition system variables to the Delta V system of CAB Tajín wirelesly.
? Reduced costs when using the wireless technology for transmission of the variables of the electronic ignition system of the burner of 20 mmfcd of gas.
? Remote start-up and shut-down of liquid transfer pumps.
Personal and facility safety." The solution was re-engineered with wireless technology. By optimizing infrastructure and expanding the existing wireless network all measurement points of the 20mmpcd alternating burner were integrated using native wireless devices and adaptors to the existing gateway and DeltaV, allowing all main measurement points of the burner to be monitored, Wireless proved to be reliable and efficient. Wireless DeltaV, Wireless, Instrumentation - Flow Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Supervisor / Manager / Dept. Head Workshop Eduardo Mena PEMEX Jorge Garay Emerson - - - - - Instrumentation - - - -
2. Measure & Analyze Approved Zinc Nacional S.A. Improves Operations and Personnel Safety with Rosemount Wireless Pressure Gauge Zinc Nacional S.A. is a major producer of Zinc Compounds in the American Continent. Founded in 1952, our company is dedicated to the production of zinc oxide and zinc sulfate, as well as recycled Paperboard. Over the years, Zinc Nacional has established itself as one of the world leaders in the production of zinc compounds. Zinc Nacional S.A. is now required to record measurement data of their supply tanks on a daily basis. Operators are walking through all areas of the facility to manually collect this data from existing mechanical manometers. This task is highly time consuming and time spent by maintenance personnel in this capacity is costly and prevents them from completing preventative maintenance activities. "Rosemount WPG offered the optimum solution for the challenges faced by Zinc Nacional, manual rounds, time and automated measurement recording and with the addition of wireless communication the inbation is reliable and in real time.
ROI is around 1.5 years for the whole project
Economical benefits:
Operations Personnel time saving representing
43 KUSD savings in manual rounds to the site." Zinc Nacional S.A uses mostly manometer technology for their measurement needs. This solution will upgrade existing manometers to the WPG on each tank and measurement point, install flow transmitters and wireless level transmitters as needed around the plant. Adding wireless gateways and integrating them to the existing PLCs made wireless a perfect fit with a minimum investment. Wireless Instrumentation - Pressure, Wireless, Modernization Metals, Mining, Cement & Glass Supervisor / Manager / Dept. Head Workshop Dan Ibis Zinc Nacional Jorge Garay Emerson - - Eduardo Godinez Emerson - Instrumentation - - - -
2. Measure & Analyze Approved ERS – Providing a New View into Fermentation – What a Gas! "With the use of ERS on a series of existing fermenters, MillerCoors Milwaukee was able to improve CO2 collection through vessel headspace monitoring and increase fermenter throughput by monitoring the changing fluid density masquerading as changing tank level.
All told, these process insights will provide a tremendous savings to the brewery in terms of capital avoidance, additional throughput, CO2 savings and labor savings. In rough numbers, this would total $1 million on an annual basis resulting in a three month ROI for the project.
This was a true win in terms of improving the sustainability of the brewery as well as helping reduce a production bottleneck." "The ERS installation was to address two items
? Protect rupture discs from overpressure
? Prevent unnecessary loss of CO2 upon disc failure
Three unexpected benefits were discovered post-installation
? “Seeing” into the fermenter and detect fermentation activity to accuraby trigger CO2 collection
? Realizing that dropping tank level is due to changing liquid density associated with fermentation" "Have a b “view” into the tank headspace pressure allowing for
? Accurate determination of when to turn on foam control -Throughput
? Immediate annunciation of a burst rupture disc -Sustainability
? Gain improved insight into process-driven CO2 collection triggers -Sustainability
Determine when fermentation is complete through the stagnation of bottom tank level (specific gravity) -Throughput" The project used an ERS Level Transmitter System to provide a true measure of fermenter level and to monitor the fermenter head space pressure. Each ERS was installed to existing fermenters and the HART signal was brought into a tri-loop with the corresponding 4-20mA signals sent out to analog I/O in the field for integration into the brewery DCS. Instrumentation - Pressure Instrumentation - Level, Sustainability, Optimization Engineering (OEM's, E&C's, Integrators), Pharmaceutical & Life Sciences, Food, Beverage & Consumer Goods Consultant, Sales / Marketing, Project Manager / Lead, Plant or General Manager, Engineer, Director Workshop Andrew Klosinski MillerCoors Larry Wavrunek Rosemount Measurement - - - - - Instrumentation - - - -
2. Measure & Analyze Approved Vibration monitoring and control in conveyor belts ensure perfect operation in Peru "Minera Las Bambas is an open-pit copper mining complex located equipa, Peru.
The Minera Las Bambas operation includes a 140,000 metric tons concentrator plant. The ore is transported along the operation with conveyors belts. These belts are in the production critical path and any issue will impact supply chain and production. This is the story of a successful development that allowed maximizing the conveyors reliability and operation conditions." At Minera Las Bambas conveyor belts are in charge of transporting the ore to the several crushing areas and then to the plant for process and copper extrb. Due to the criticality of the task, the belt has to ensure work continuity 24 hours a day, 365 days a year, without no failure or unexpected shutdowns. Additionally, the mine needed to reduce manual round to improve operators safety. The solution installed in Long Belt Conveyors guarantees a more reliable perbance and optimizes product quality. The acoustinc monitoring system allows pre-checking the conveyor belt to detect equipment failure in an early stage, avoid process interruptions and increase process reliability. Minera Las Bambas avoided losses in production for over $500k a day for process interruption. Emerson proposed the implementation of acoustic technology to monitor the conveyor belts structure, monitoring in real time bearing temperature and acoustic signal to detect abnormal conditions. The system, coupled with regular safety conditions compliment and the control systems present in the conveyors, ensures very high reliability and control on the equipment. Wireless Modernization, Reliability, Optimization Metals, Mining, Cement & Glass Engineer, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Operator Workshop Ramiro Diaz MINERA LAS BAMBAS Abraham Lopez Emerson - - - - - Diagnostics - - - -
2. Measure & Analyze Approved Relative Accuracy Test Audit (RATA) Using Hybrid QCL/TDL Spectrometer for Emissions Monitoring BP Cherry Point has tested a Rosemount CT5400 Hybrid QCL/TDL Analyzer to measure analytes O2, CO2 and NOx. Traditionally, BP and many other sites have used CEMS configured from multiple analyzers, each measuring specific analytes: NOx measured with Chemiluminescent analyzers, O2 with Paramagnetic, and CO2 with Non-Dispersive Infrared (NDIR) analyzers. BP and Rosemount Analytical worked together to install, run and perb a RATA with the CT5400 alongside the legacy analyzers. US EPA regulations in 40 CFR Part 60 along with local regulatory agencies require routine measurement of specific pollutants plus the testing of analyzer systems, such as the Relative Accuracy Test Audit (RATA), and maintaining analyzer availability rates above 95%. Violations can lead to substantial fines. The Rosemount CT5400 was quickly installed and started. It perbed as well or better than existing analyzers and passed a third party Relative Accuracy Test Audit as required by the EPA. Rosemount CT5000 series analyzers use up to six Quantum Cascade Laser and/or Tunable Diode Lasers in one analyzer to measure all CEMS analytes in one system. QCL and TDL based analyzers are extremely stable, do not drift and have no moving parts to maintain. The cost savings due to reduced maintenance and avoided fines can be substantial. Instrumentation - Analytical Compliance, Reliability, Modernization Chemicals (Industrial, Specialty), Refining, Pulp & Paper, Power & Utilities, 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) Consultant, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, Plant or General Manager, Operator, Engineer, Director Workshop Ryan Holgate BP Refining Dave McMillen Emerson Automation Solutions - - - - - Analysis Methods - - - -
2. Measure & Analyze Approved Brewing Insights – Craft brewery gains unprecedented insight into its award-winning beer production "Badger Hill Brewing is a quality-focused craft brewery passionate about producing attention-getting and award-winning beer. Most of its brewing processes are controlled manually by its experienced brewers. Badger Hill is expanding and we are always looking for ways to improve the quality of our beer and make our lives easier.
This workshop shares how adding key automation equipment enabled 1) big improvements in consistency and quality; 2) simplified processes, saving time and significant cost; and 3) prototyping self-documentation procedures." We were able to approach two of the key problems that challenge craft brewers: ascertaining the actual volume of liquid in a sealed, opaque tank and measuring the flow and totalized volume for the entire range of our product constituents, from thick yeast slurry to bittered wort to clarified beer. Traditional bs are either non-sanitary, expensive to install or inaccurate. This unprecedented inbation gives us accurate and repeatable tank volume determination coupled with accurate b and output accounting of trub, yeast slurry and beer. This improves yield and yeast quality and reduces uncertainty in the volume of taxable beer, which positively affect customer satisfb and profitability. A Rosemount Wireless Pressure Transmitter and Hygienic Magnetic Flowmeter with Wireless Adapter were deployed in the brewery. They provide instantaneous access to the measurements on local displays and wirelessly via the Emerson Gateway. The ModBus protocol allows continuous logging and plotting of the inbation to see trends and comparisons and enable future automation. Process Control Engineering, Instrumentation - Pressure, Instrumentation - Flow Food, Beverage & Consumer Goods Plant or General Manager Workshop Michael Koppelman Badger Hill Brewing - - - - - - - Instrumentation - - - -
2. Measure & Analyze Approved BP Refinery Uses Wireless, Non-Intrusive Instrument to Accuraby Measure Temperature Emerson’s non-intrusive X-well temperature measurement technology was deployed with great success at the BP Cherry Point Refinery on a diesel stripper tower feed line. The installation was on an 8” standard schedule carbon steel line, with a traditional thermowell installation immediaby upstream of the X-well. The resulting X-well temperature measurement closely tracked the existing thermowell measurement, yielding high confidence level in deploying more X-wells in similar situations. The advantages of using X-well are no required process penetrations because the instrument clamps on to the outside of a pipe. Unlike other clamp on solutions, X-well delivers very high accuracy due to proprietary imbedded calculation algorithms. X-well uses standard thermocouple and RTD sensors. While temperature measurement is a well understood technology, there are very few options available for non-intrusive measurements. Typical thermowell installations require scaffolding, welding and mechanical installation. Brownfield costs for a single thermowell can run up to $20k. Using a non-intrusive technology that can be installed online by a single craft cuts cost substantially. X-well technology can be quickly installed, and can be applied without welding, cutting or shutdown. This allows refineries and other process plants to install needed temperature monitoring points now, instead of waiting years for the next planned shutdown. The combination of wireless and non-intrusive technology makes this an exceptionally high-value rapid deployment option. The refinery installed a wireless X-well temperature transmitter on a diesel stripper tower feed line. The installation required minimal pipe surface preparation and basic tools. Engineering resources for thermowell design calculations were not required, resulting in further savings. The temperature reading from the X-well is much more accurate than other clamp on temperature instruments. Wireless Diagnostics, Reliability, Economic Justification All / Cross-Industry Director, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Plant or General Manager, Operator, Engineer Workshop Bob Stiles BP Cherry Point Refinery Marcio Donnangelo Emerson Automation Solutions - - Stephen Reeves Emerson Automation Solutions - Reliability Monitoring - - - -
2. Measure & Analyze Approved Inventory Management of Bulk Solids (Frac Sand) Halliburton has drilling sites throughout west Texas which require frac sand on a regular basis. They have large storage silos to store their frac sand and were losing about $600,000 worth of sand per year due to differences in their volume measurements and what they were paying for. This also impacted their operations as they had less sand on hand then expected. Halliburton wanted to have better control of operations and improve logistics of delivery of frac sand to their drilling sites. They were able to achieve more accurate volumetric measurement of bulk solids (frac sand) and will be saving $360,000 per year in costs for frac sand, in addition to improving control of their operations. Halliburton has many large silos they use to store frac sand which is a very dusty product making it difficult to measure during the filling process. It also tends to bridge and rat hole. They were using guided wave radar, but measurements were not reliable during filling and they were only getting single point measurements which did not provide the desired accuracy for volume measurements. Halliburton is able to measure frac sand by volume as it is loaded into large silos for storage. The accurate volume measurement allows Halliburton to have better control of operations and improve logistics of delivery of frac sand to oil drilling sites through out west TX. They will be able to save $360,000 of spending on frac sand per year. Halliburton installed 5708 3D Solids Scanner Systems on frac sand silos at four of their frac sand distribution sites in west TX. These systems cut through the dust during the filling process and provide an accurate volumetric measurement that takes into account bridging and rat holes. It has allowed them to increase the accuracy by 60%. Instrumentation - Level Operations Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Operator, Supervisor / Manager / Dept. Head Workshop David Penny Emerson Kyle Hall Emerson - - Brandon McDaniel Halliburton - Instrumentation - - - -
2. Measure & Analyze Approved Keep it Cool: Measuring Temperature on the lid of an 80 Megawatt Arc Furnace Measuring the cooling water temperature is critical to operating a furnace designed to melt shredded scrap steel. Three 24 inch diameter electric rods are lowered as 80 Megawatts of DC current liquifies everything in the furnace. Avalanches of soon to be recycled particles splash molten steel and shoot hot gases at extreme temperatures all around the process. This harsh environment is difficult to control, and frequent rebuilding of the instruments on the furnace lid is required due to heat failure of many components. Designing a system that can monitor the health of the process and live for any length of time is a challenge. The process of rebuilding the furnace regularly is a major operational cost. Temperature sensors previously failed due to sensor wires being knocked loose by falling debris or burned from irregular hot gas or liquid eruptions. Losing cooling water monitoring of the furnace means the furnace must be shutdown. We designed a more reliable temperature measurement system which allowed for the furnace to be more easily monitored, removed and rebuilt. This system decreased operating costs while increasing critical measurement reliability. Costs associated with rewiring temperature measurements due to heat failed wiring were greatly reduced, and the duration of time between rebuilds can not be extended. By using wireless Temperature Transmitters, we were able to remote mount the sensor with high temperature cable and put the transmitter in a better b for longer life. Instrumentation - Temperature Economic Justification, Reliability, Operations Metals, Mining, Cement & Glass Consultant, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Sales / Marketing, Project Manager / Lead, President / Principal, Plant or General Manager, Other, Operator, Engineer, Director Workshop Sam Matson CMC Steel Jared Edwards Emerson Automation Solutions - - Eric Farmer CMC Steel - Instrumentation - - - -
2. Measure & Analyze Approved Finally! Now you can KNOW that your GWR measurement is valid! With the release of API 18.2 and BLM 43 CFR 3174, an onshore Oil & Gas producer was looking to optimize the way they sold and accounted for their oil. The new regulations allow for Automated Tank Gauging instead of manual hand gauging. However, per the updated regulations you must be able to verify that your equipment is working properly and accuraby. Emerson introduced a new service utilizing a GWR Verification Box, also called a Vericase for short. The Vericase will verify that the GWR electronics are interpreting the signals appropriaby and more importantly, accuraby. By utilizing this service, the production company was able to minimize the number of ticket discrepancies as well as increase the safety of their operations. Traditional verification bs for GWR can only verify one half of the system. Manual hand gauging will verify the level in the tank, and then one would have to program the electronics to match the result. This only verifies one specific level in the tank, and one would have to assume that the electronics were interpreting the signal properly throughout the entire measurement range. By moving to an ATG system with Verification Services they will have better accuracy AND repeatability with their data. The company could realize ~$50K - $150K savings vs going with a LACT system by being able to design the facilities smarter. Finally, ATG will keep their facilities safer by nearly eliminating the need to climb tanks. Utilizing the Emerson Verification Services, the production company was able to verifiy that the electronics of several older GWR's on 3 different bs were still operating within the manufacturer's specifications. This allowed the company to show the BLM that their ATG is in compliance with the new regulations. Services Codes & Standards, Safety, Compliance Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Director, Supervisor / Manager / Dept. Head, Plant or General Manager, Engineer Workshop Richard Swimm O&G Consultant Anders Willberg Emerson - - - - - Instrumentation - - - -
2. Measure & Analyze Approved Fast and Easy Calibration Verification of Non-Contacting Radars Level measurements in the chemical industry are critical. Periodically, it is important to confirm accurate perbance and know that the measurements are reliable and any potential problems detected. Safety and minimizing effects on operations are extremely important. Given the modular design of the Rosemount 5400, a verification station for non-contacting radars was built to easily and safely remove and test the 5400 transmitter without violating the integrity of the vessel or disconnecting any wiring. A solution was provided to solve the requirement for annual calibration verification and documentation of non-contacting radars. This inbation is required for both safety and operations departments. It is also required for customers who audit Grace's process control and calibration procedures. The radar calibration verification documentation is required for safety and production. This inbation can be collected quickly and safely with the verification station. It is important that safety and production maintain records of the 5400 perbance verification. In addition, Grace's customers may audit their processes and this documentation supports the audit. The 5400 is designed so that the electronics can be separated from the flanged antenna and the integrity of the vessel is maintained. Mounting the 5400 electronics on the verification station with a target at a known distance allows for a fast and safe means of verifying the 5400's calibration, and checking to ensure that there are no issues with the 5400 non-contacting radar. Instrumentation - Level Compliance, Reliability, Maintenance Chemicals (Industrial, Specialty) Supervisor / Manager / Dept. Head Workshop Doug Isaac Grace Tim Lekie Emerson - - - - - Instrumentation - - - -
2. Measure & Analyze Approved Unilever Increases Production Efficiency and Improves Dosing Control with Wireless Pressure Gauges Unilever Food Solutions Costa Rica produces salsitas, beans and Lizano sauce. The plant has replaced its mechanical gauges with Wireless Pressure Gauges to locally indicate and wirelessly track both hopper and pump outlet pressures. These processes have tight tolerances, so measuring these pressures is critical as any variation could cause a safety or quality issue. Using WPG's Unilever can remoby monitor pressures allowing for the detection of possible process issues and increased production output. Operators are now able to focus on proactive improvement activities and their surroundings Mechanical gauges used to indicate hopper and pump outlet pressures provided inaccurate data causing improper pressure on the dosing machine. This negatively impacted production output. Manually data collection is time consuming for operators and decreased time for proactive maintenance, so pumps were running to failure. Lack of real-time data prevented possibility of improvement opportunities. Readings shifted from once an hour once a minute. It provides richer data and freeing operators to focus on other tasks. Data reliability has improved, as it goes from the gauges to the database. Preventive maintenance can be implemented to avoid pumps run to failure. Higher production is possible by increasing pressure in the hoppers since strict track is possible. nilever installed 31 Rosemount Wireless Pressure Gauges with a tri-clamp for hygienic fittings on each of the hoppers and each of the pumps moving material from the hoppers to the dosing machines. Because WPG is wireless, each gauge now communicates with a centralized data acquisition unit, where pressure readings are recorded and safety limits have been established. Instrumentation - Pressure Maintenance, Optimization, Modernization Food, Beverage & Consumer Goods Engineer, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head Workshop Mauricio Salazar UNILEVER Jorge Espinoza Emerson - - Ariel Vega Elvatron - Instrumentation - - - -
2. Measure & Analyze Approved Building API 18.2: How Accurate Radar Level and the new VeriCase makes Selling Oil Safer All crude oil producers hand gauge to sell oil, its just a matter of whether hand gauging is the primary b, or if its a fall back. Add high H2S Eagle Ford crude into the mix, and safety becomes a serious issue. Even though operators like ConocoPhillips rely on Coriolis measurement for liquid custody measurement, they were interested in developing a safe and reliable back up plan that prevented H2S exposure when hand gauging was necessary as well. If this back-up plan could be more safe and improve time during LACT outages; then all the better! Prevent H2S exposure from crude tanks in the Eagle Ford Shale, and other oil assets across the US. Be an industry leader by pushing for both new standards and new technology for safer and more efficient measurement bs. Save time over manually gauging oil tanks when API 18.1 and 3.1B could both be considered in the same cost-effective solution. Thousands of man hours have already been saved over open hatch manual measurement. This greatly reduces both temporary hydrocarbon releases, and exposure to high H2S by Field Techs. When a LACT unit goes down, or a new remote well that has to sell by manual gauging starts producing, ConocoPhillips now has an approved b to sell based on safe, fast, and approved automation bs. Helping API write 18.2 in a way that allowed for the use of existing level technologies, specifically Guided Wave Radar, to be proven in a way that meets both 18.1 and 3.1B in an economical way. The VeriCase plus proven acceptable accuracy equals a safer and more timely solution. Instrumentation - Level Codes & Standards, Services, Safety Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Consultant, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Sales / Marketing, Project Manager / Lead, President / Principal, Plant or General Manager, Other, Operator, Engineer, Director Workshop Hilary Gleitz ConocoPhillips Jared Edwards Emerson Automation Solutions - - Tyson Kennedy Emerson - Instrumentation - - - -
2. Measure & Analyze Approved Flow Measurement in Erosive Services. Flow measurement in erosive slurry services can be complex and lead to leakage, inaccurate results, and cleaning/maintenance difficulties. To channel this problem a fully fabricated wedge meter assembly with external epoxy coating due to environmental erosion was engineered. Results have shown the wedge meter is able to maintain accuracy in the erosive services vs. more traditional flow technology. To counter the leakage issues a fabricated assembly was established allowing for easy instillation, commissioning and maintenance. By using Rosemount transmitters with flushing ring remote seal the required flow communication was achieved and fit client standards. When working in a erosive slurry service the ability to use traditional flow meters is challenging. Traditional meters such as the orifice plate have been known to read 2.5-3.5% inaccurate due to damage caused by erosive services. This led us to finding a flow measurement that could handle the process beters as well as the erosion difficulties. The wedge meter was shown to have higher accuracy than other flow measurement when exposed to the erosive process. A fabricated package with epoxy coating was designed to minimize the leakage requirements combined with Rosemount Transmitters to fulfill the required communication protocol. Lastly using the wedge meter allowed for the necessary upstream and downstream pipe diameter requirements. A complete assembled wedge meter package that was equipped with Rosemount transmitters, flanged diaphragm seals with flushing ring, pressure tap flanged with purged isolation valves to the flanged tap wedge meter. By buying the entire fabricated package we are able to ensure no leakage of the erosive service, simplified installation, and the required communication details. Efficiency Instrumentation - Flow, Safety, Maintenance All / Cross-Industry Director, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Plant or General Manager, Other, Operator, Engineer Workshop Spencer Drake Wood Group Joel Lemke Emerson - - Panthini Pab Emerson - Instrumentation - - - -
2. Measure & Analyze Approved Hot Process DP-Level Solved with Cool Thermal Range Expander! Marathon Petroleum was searching for a solution to their critical crude tower overfill protection problem that had previously used DP technology with heat-traced capillaries. Additionally they had a similar need on their steam drum condensate levels. Very high process temperatures of 665 and 500 degrees F, respectively, had dictated high-temperature silicon fill fluids be used with remote seals. This required the entire capillary lengths to be heat traced which was expensive and presented reliability issues in itself. By collaborating with their local Rosemount account manager, they discovered a brand new product along with another proven technology would provide the perfect solution and meet their need for SIL 2/3 approval. Crude levels in the tower can rise rapidly with catastrophic results, requiring a fast level measurement to the SIS system. Traditional high temperature fill fluids are simply too slow in low ambient temperatures. Also, the steam drums, had previously used site glasses and switches, but changing policies dictate no site glasses are allowed and a continuous level is now required. Business results of higher reliability in both critical measurements, reduced down-time, improved safety, reduced environmental impact (crude towers vent to the flair), ease of troubleshooting, preservation of crude product and expensive chemically-treated water, and lower maintenance costs were all achieved. Six heat trace circuits on the crude unit, and one on the steam drum were eliminated. Marathon applied Rosemount’s new Thermal Range Expander (T-REX) with SIL 2/3 certification, along with ERS to measure the 80’ span on the crude tower in a 2-out-of-3 voting scheme, providing fast DP level measurements where no other technology would fit. Similarly, the T-REX solution on the steam drums eliminated the need for adding bridal assemblies and heat tracing. Instrumentation - Level Instrumentation - Pressure, SIS / SIL, Reliability Refining Project Manager / Lead Workshop Xi Lin Marathon Petroleum Douglas Carlson Emerson - - Tom Garry Emerson Automation Solutions - Instrumentation - - - -
2. Measure & Analyze Approved Online Prediction of Claus Combustion Temperatures Hydrogen sulfide is a staple gas processing desulfurization intermediate. Hydrogen sulfide is combusted to b sulfur dioxide, which reacts with excess hydrogen sulfide to b elemental sulfur and water – the Claus process. Temperature is a critical process variable, ensuring safe operating conditions and low salt bation rates in the presence of ammonia. Infrared pyrometers and shielded thermocouples are the main sensory bs, each subject to external forces (e.g., flame transparency, purge rates). An analytical model was developed for real-time temperature estimation within a control system, a low-cost supplement to existing control strategies. After one year, environmental deviations were significantly reduced across four sulfur recovery units. The E2T temperature measurement was inconsistent and was contributing to environmental deviations. When the SRU was running with oxygen enrichment, the temperature measurement was indicating a drop in temperature when in actuality the temperature was rising. This reduced the life the SRU equipment running at temperature higher than the desired operating temperature. Significant reduction in environmental deviations. Improved equipment life of the SRU. Improved controls and better situational awareness for the operator. We developed an analytical model for real-time temperature estimation. This allowed for the override control to divert feed from the SRU to other SRUs when temperature constraints were reached. Temperature estimation can be applied quickly to additional SRUs with operational inbation. Efficiency Economic Justification, Process Control, Engineering Refining Engineer, Operator Workshop Dustin Beebe ProSys - - - - - - - Efficiency - - - -
2. Measure & Analyze Approved Innovative level measurement solution at a cementing plant helps to improve operation planning UNICON is a Company dedicated to the elaboration of construction concrete. UNICON has an extensive silos area to stock cement. Level measurement is vital to plan for operation capacity and efficiency; up to now measurements were perbed with wired technology. This paper describes the implementation of 3D solid scanner and the business results UNICON obtained from it. UNICON has an extensive silos area to stock cement. Level measurement is vital to plan for operation capacity and efficiency; up to now measurements were perbed with wired technology and accounted up to 20% measurement uncertainty. Additionally, personal safety was in risk due to manual maintenance and calibration tasks. After the implementation of wireless 3D level measurements and the incorporation of the volume 3D software, UNICON has now access to more accurate stock data, allowing a more accurate production planning and lower product waste. In addition, personnel safety was improved. Emerson proposed a comprehensive Wireless level measurement solution implementing 3D solid scanners. The signals collected by the scanner are visualized in the volume 3D software from the safety of the control room, which provides accurate volume calculations and protects personnel from hazardous areas. Wireless Modernization, Safety, Optimization Metals, Mining, Cement & Glass Engineer, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Operator Workshop Percy Rosillo UNICON Abraham Lopez Emerson - - - - - Instrumentation - - - -
2. Measure & Analyze Approved Reciprocating compressor monitoring with a 2140 and a dynamic pressure sensor This workshop will outline the process for reducing unnecessary unplanned reciprocating compressor downtime through portable route condition monitoring using vibration, as well as, dynamic pressure of the cylinder head.. Innovative use of MHM analysis tools including circular wavebs and PeakVue for recip valve monitoring will also be discussed. Condition monitoring of reciprocating compressors were being conducted every 4 months, and there was a need to have more frequent monitoring, especially, when a suspect issue was noticed. Increased frequency of monitoring of a suspect reciprocating compressor was conducted in house and avoided contract services of $30,000 trip. Additionally, the historical data is saved in the MHM database for a better historical view and comparison of the vibration and dynamic pressure data, allowing for more inbed diagnosis of the assets operating condition. Using the 2140 and a dynamic pressure sensor, along with vibration monitoring was used in this reciprocating compressor application to quickly and easily bring new useful inbation to the reliability and operations group. The PeakVue, overall vibration, and head pressure curve was captured to provide comparison views of the equipment issues to the operations and engineering groups. Reliability CSI Technology, Predictive Technology, Machinery Health Management Refining Technician / Analyst / Specialist Workshop Brennan Wickman Flint Hills Resources Nick Jude Flint Hills Resources - - Craig Truempi Novaspect - Reliability Monitoring - - - -
2. Measure & Analyze Approved Level Based Production Reporting: Automating the Most Common Way Upstream Producers Measure Oil Hand gauging crude tanks is how the majority of upstream oil producers regularly check their production. Automating this habit has a huge hurdle: why increase the cost of surface equipment to get inbation that our 'boots on the ground' are already measuring? Implementing Abraxas' first real-time wellhead production reporting system in the Bakken has provided an opportunity for this San Antonio based company to move faster, react smarter, and operate safer. Field support in the Bakken is hard to find. Budgets don't allow for unlimited spending; new equipment must be well justified. Waiting a few days for production numbers is annoying but expected. Multiple invoices are too difficult to manage. Immediate updates of both production volumes and gauge pressures of each well allows Abraxas to solve many problems. Now they always have production numbers to compare against contractors' liquid custody transfer tickets, or even for real time production updates to upper management to help them make the critical business decisions as fast as possible. Tank manager even has fans on the wellhead! Through a lean installation using WiHART 3308 Guided Wave Radars and Wireless Pressure Gauges, an Instrument & Valve Services turn-key solution was drafted to address all of Abraxas' needs in a simple and effective way. RAS Tank Manager software inside a ROC paired with a radio allows for data to be managed effectively and automatically with less human error and much less turn around time. Instrumentation - Level Instrumentation - Pressure, Wireless, Services Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Consultant, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Sales / Marketing, Project Manager / Lead, President / Principal, Plant or General Manager, Other, Operator, Engineer, Director Workshop Colby Cline Abraxas Petroleum Corp. Jared Edwards Emerson Automation Solutions - - Ross Ready Emerson - Instrumentation - - - -
2. Measure & Analyze Approved Energy Harvesting Application- Anything is Possible Wireless instrumentation allows companies to add points of measurement quickly and inexpensively, but battery-powered wireless transmitters present problems. Fast data rates deplete battery life and cold weather cuts battery life, and replacing batteries in hazardous areas is difficult. Energy harvesting devices address these issues by generating sufficient power to keep wireless transmitters running, even at high data rates in cold climes. This session shows how energy harvesting devices have helped several companies, and provides inbation for others looking to implement similar solutions. The challenges resolved by companies through the use of energy harvesting devices included: installing 4-20mA flow meters in areas that lacked wiring; monitoring equipment at fast rates without impacting battery life; managing hundreds of transmitters without increasing maintenance budgets; and operating wellhead instrumentation in areas with days too short for a complete solar solution. Energy harvesting solutions removed what seemed to be insurmountable barriers including accelerated battery depletion, lack of existing wiring, and high maintenance costs. Energy harvesting solutions overcame these obstacles and were deployed with significant cost savings realized in each scenario. New applications were also discovered for wireless deployments by some of these companies. The common factor for these applications was a source of heat near the wireless instrument points of installation. These heat sources included steam pipes, pumps, motors, production oil lines, and wellhead equipment. Temperature differences between the heat sources and ambient air allowed the deployment of energy harvesting solutions including Power Pucks and Power Tiles. Wireless Economic Justification, Reliability, Efficiency All / Cross-Industry Engineer, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, President / Principal, Plant or General Manager Workshop Elizabeth Reierson Emerson Automation Solutions Andy Zaremba Perpetua Power - - - - - Instrumentation - - - -
2. Measure & Analyze Approved ChemTreat and Emerson collaborate to build a new model for Monitoring Heat Exchangers ChemTreat provides heat exchanger services to end users, but is challenged to collect complete data to properly notify end users of heat exchanger conditions. System integration is challenging, so manual data collection is common. Emerson and ChemTreat are working to ensure that heat exchangers are properly instrumented with WirelessHART instrumentation so that data collection is easy and complete. When ChemTreat approaches a customer about heat exchanger services, their main option for data collection is manual routes. This can be a costly and time-consuming process. ChemTreat and Emerson are working together to install WirelessHART instrumentation to automatically collect complete inbation from the heat exchangers. WirelessHART technology allows Emerson to build a compleby isolated monitoring network for the heat exchangers, providing ChemTreat with complete and consistent inbation. This solution helps ChemTreat provide a higher level of service to their end users and minimizes their capital investment necessary to provide their service. Emerson and ChemTreat are working on a pilot site, where Emerson owns and maintains the WirelessHART Infrastructure and provides Secure First Mile connectivity, enabling heat exchanger data to be made available for ChemTreat. Services PlantWeb, Wireless, Reliability Engineering (OEM's, E&C's, Integrators) Consultant, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, Engineer Workshop Kevin Boudreaux ChemTreat David Gustafson Emerson Automation Solutions - - Joe Johnson Emerson Automation Solutions - Reliability Monitoring - - - -
2. Measure & Analyze Approved A Stroll to Save Thousands: Timely Walk Downs During Construction Saves Thousands in Project Costs Appropriaby scheduled walk downs by properly trained investigators for instruments and valves during a capital project saved thousands of dollars by eliminating device failures, process shut downs, exposing workers to hazardous situations and facilitating an on-time start-up. Through proper scheduling by qualified individuals, failures and reworks can be kept to a minimum. This session will cover beters to help define the schedule, as well as many of the common and not so common issues that should be looked for will be discussed. Most capital projects start with an outstanding design and details, but as deadlines loom, and changes are made, some details are overlooked. Valves installed backwards, conduit not buttoned up, flow meters installed upside down. All these things delay start-up. If caught early, the cost to rework is less and the impact on start-up is eliminated Start-up for the project was timely with minimal impact by missing process b or outputs. Workers were not exposed to hazardous situations due to field device replacement. With a proper walk-down schedule by trained investigators, rework can be perbed before exposure to process, and while proper resources are available. The schedule should be set to interface with the construction and commissioning timelines Installation Best Practices Project Management, Troubleshooting, Safety All / Cross-Industry Project Manager / Lead Workshop Brandon Wilson BAE Systems Steven Moore Emerson Automation Solutions - - - - - Instrumentation - - - -
2. Measure & Analyze Approved Thank You For Not Smoking - Measuring Steam Flow to Flare Steam is injected into flares to reduce visible smoke emissions and is governed by EPA 40 CFR Part 60. LCY Elastomers had regular orifice meters on their steam flow to flare lines that were not meeting expectations or in compliance with the regulation. Most steam flows to flare have very wide ranges and it is not possible to accuraby measure them in one line. By using the Conditioning Orifice and Integral Orifice Meters exceptional accuracy was obtained over a wide flow range as well as savings in installed costs, future maintenance, calibration, and operational expenditures. LCY had to meet the EPA regulation over extremely wide flow ranges. There were two main steam lines going to the flare. A 3 in line with 60:1 turn down ratio and a 1 in line with 16:1 turn down. Meters had to be easy to maintain and verify. Pressure and temperature compensation were required to meet the regulation and accuracy requirements. Multiple meters were needed in parallel with each other. The installed meters have lower installed cost and maintenance cost compared to regular orifice plates. The meters can be calibrated in place without sending out and shutting down processes. We achieved compliance with EPA regulation while improving process control, energy tracking, and lowered maintenance costs. Meters were selected that enabled a parallel metering solution with minimum piping changes. Control valves were placed downstream of the meters. As the flow rate changes the steam can be transferred to the other parallel line. The Multivariable transmitter was used with ultra for flow accuracy to achieve mass flow accuracy of +/- 1.0%. Instrumentation - Flow Compliance, Process Control, Instrumentation - Flow Chemicals (Industrial, Specialty) Engineer, Technician / Analyst / Specialist, Project Manager / Lead, Plant or General Manager Workshop David Baldwin LCY Elastomers Alyssa Bartholomew Emerson - - Joel Lemke Emerson - Instrumentation - - - -
2. Measure & Analyze Approved “Over-Process No More”–using liquid Conductivity Tech. to Eliminate Processing of Zero Value Liquids A Specialty Alloy and Components manufacturer had a project to install a new tank storage system to house and process liquids generated from their chemical operations. An element of the design focused on storage capacity. It was discovered as part of modeling the new system design that not all liquids coming to the storage system would require processing, as some of the liquids historically being sent to storage had zero value. The zero value liquids, being berm and sump “water”, had historically been mixed with all other liquids and sent to storage. The calculated volume of zero value liquids was sizeable enough to impact the initial project costs. Due to the potential for project and long-term processing savings, the decision was made to engineer a solution to remove zero value liquids. The project scope established that the new storage facility would store only liquids that required processing and remove liquids from the system that provided zero value. To do this, a process needed to be established where a “real-time” measurement of liquids in the berms and sumps could be obtained and analyzed to insure the material was within established acceptable limits. The major benefit was not processing liquids that provide zero value and that only add cost to the bottom line. A side benefit of these devices is the Environmental benefit. Based on the successful trials and cost savings (<6 month ROI) in Operations, we are currently looking to expand the use of these devices on other sumps and bermed areas, for both cost savings and environmental benefit. A conductivity probe was selected to measure the liquid streams, based on a standard that was developed from Rain, City, and Industrial Water measurements. The device was then placed in a process line with some programming that allows for the sample of the liquid, comparison of the measurement, and then discharge of the liquid to one of two destinations based on a set of pre-defined limits. Optimization Instrumentation - Analytical, Sustainability, Optimization All / Cross-Industry Project Manager / Lead Workshop Stephen Adams ATI - Specialty Alloys and Components Frank Spevak Emerson Process Management - - - - - Analysis Methods - - - -
2. Measure & Analyze Approved Lessons learned – How to optimize gas turbine perbance in a power generation plant in Mexico Mexico is a net importer of natural gas, mostly via pipeline from the United States, and its natural gas demand is rising because of expanding power generation capacity. Many of Mexico’s newer power plants are highly efficient, gas-fired, combined cycle plants which integrate gas and steam turbines. Each power plant that use natural gas has to be strictly controlled in the quality and flow rate to improve the Turbine perbance. For this reason, Grupo Avanzia was looking to develop a project for a reliable system to measure, regulate and analyze the quality of gas for a power turbine. Grupo Avanzia is a worldwide leader that build and operate industrial infrastructures based on excellence in integration and technological innovation. "? Excessive CAPEX costs
? High content of moisture on gas before going into turbine.
? Poor quality of gas." "? Correct separation of moisture through a reliable gas filtration.
? Protection of the Turbine - avoided 60 hours per month of maintenance costs
? Accurate flow rate measurement at process conditions
? Increase of turbine capacity in 5%." Emerson was able to provide the perfect solution for the customer - One Integrated Measurement Skid System comprised of one (1) liquid separator, one (1) coalescing filter w/ condensate tank, one (1) gas regulating skid, one (1) gas metering skid and one (1) natural gas analyzer skid. This skid-mounted equipment is compleby piped, instrumented, wired, and assembled, ready for use. Instrumentation - Flow Diagnostics, Optimization, Efficiency Power & Utilities Consultant, Supervisor / Manager / Dept. Head, Project Manager / Lead, Operator, Engineer Workshop Ivan Go?i Conde GRUPO AVANZIA Raul Olivera Emerson - - Ignacio Ramirez Emerson - Instrumentation - - - -
2. Measure & Analyze Approved Challenges of Processing Opportunity Crudes "As refiners target improved operating margins, one of the likely bs to accomplish this is through the processing of opportunity crudes. Opportunity crudes may command a discounted price due to known processing issues, or they may be new crudes with unknown or poorly understood properties and processing challenges. At stake is higher unit availability, reliability, and run length between major turnarounds.
P66 is one of the many refiners trying to take advantage of processing these crudes while at the same time trying to find a balance of high unit availability. One of the main issues hindering high availability is the unknown corrosion effects of the crudes on the plant infrastructure. To try to slow these effects P66 has implemented various corrosion inhibiting chemicals" Considering the many different opportunity crudes available it’s difficult to determine which corrosion inhibiting chemicals will work best with each slate. The Permasense probes continuously monitor the corrosion rates and help determine what corrosion inhibiting chemicals works best for the different crude slates. When P66 first implemented the Permasense monitoring solution they discovered that one corrosion inhibiting chemical was no longer needed and realized a $375k in savings that first year. 64 Permasense wireless HART probes were installed in highly corrosive applications to continuously monitor the corrosion rates. The wireless data is sent back every 12 hours to the Emerson WiHART Gateway which transfers the data to the Permasense data manager to show corrosion rates over time. Wireless Economic Justification, Reliability, Maintenance Refining Plant or General Manager Workshop - - Ryan Jacobs Emerson Automation Solutions - - Spencer Rex P66 - Reliability Monitoring - - - -
2. Measure & Analyze Approved Increasing Fuel Ethanol Fermentor Capacity with Advanced Guided Wave Radar A 100MMGPY ethanol plant in the Midwest has increased ethanol production by nearly 5% - an estimated $8 million per year in revenue by installing guided wave radar gauges in their fermentors. Variable fluid density and foam had presented an insurmountable challenge to other level technologies. High signal strength and advanced features of the Rosemount 5300 proved to be reliable and allowed higher fill levels and eliminated risk of overfilling. Best practices for installation and commissioning, how features within the 5300 that allow it to make this specialized and difficult measurement, and business impacts will be discussed. Variable fill density and foam caused by CO2 production challenged DP level measurement. Overfill resulted in foam exhausting through PRV or being drawn into vapor scrubber. EPA reportable spills could also result. To prevent this the plant was filling vessels 3-6 feet lower than maximum capacity with resulting loss of production capacity. Raising the fill height of the fermentors will result in an estimated $8 million of annual revenue from ethanol sales; 4,400 gallons per batch, or 5.5 million gallons per year, production increase has resulted. Reliable level measurement allowed operations to top off fermentor during batch to optimize capacity without risk. Environmental incidents and foam venting have been eliminated. Rosemount 5301 Guided Wave Radar gauges were installed on each vessel. High signal strength penetrated foam layer producing high signal to noise. Variable foam level and density was a challenge to repeatability of measurement. Threshold level crossing detection function enabled top of foam to be tracked as measured level independently of amount or density of foam. Instrumentation - Level Compliance, Instrumentation - Level, Economic Justification Alternative Fuels Engineer, Plant or General Manager Workshop Ben Stover Guardian Energy Zachary Bauer Emerson - - - - - Instrumentation - - - -
2. Measure & Analyze Approved Simplicity Meets Flexibility - Reliable flow measurement system for LPG Underground Storage "The LPG is the most used hydrocarbon in Mexico specific for living places, around 80% of houses are using it that means if there is a problem in the supply chain it impact directly to the basics needs of the population. One way to mitigate this risk is to count with a properly storage system.
The current storage capacity in Mexico is 2.64MMb which leads to an average of 2.37 days of storage in the areas with a big consumption and there is a limited infrastructure to deal with contingencies.
The project scope is regarding a 20-yr leasing contract of underground storage using salt caverns with a capacity of 1.8MMb. This is a “take-or-pay type of agreement”. As part of the scope a Metering Skid System was included." "? Limited LPG supply for the high demand season
? Have the proper storage capacity in case of contingencies as hurricanes, social events, etc.
? Frequent delays caused by LPG Ships offloading time
? High operational and maintenance costs from cryogenic storage tanks from main supplier which is the PEMEX Pajaritos Terminal." "1. 8% Reduction on energy costs instead of using cryogenic tanks.
2. Increase the offloading Ship time - 10 day reduction in delay
3. 30 days increase the storage capacity in to prevent LPG supply contingency.
4. Capability to offloading in each moment directly to underground storage.
5. Improve LPG availability on winter
6. savings in LGP imports
7. Decrease the overall costs in 12%." Emerson was able to provide the perfect solution for the customer – an LPG Custody Transfer Metering System comprised of (3) 8” ANSI 600 Coriolis meter runs, 16” ANSI inlet and outlet with 12” ANSI 600 headers, an 8” inlet and outlet prover and a control panel with Flow Computers and accessories. The design considers that (2) meter runs will be in operation and (1) will be a spare run. Instrumentation - Flow Modernization, Safety, Optimization Oil & Gas Midstream (Pipelines, Terminals) Engineer, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, Operator Workshop Carlos Fernandez ENTREPOSE Raul Olivera Emerson - - Ignacio Ramirez Emerson - Instrumentation - - - -
2. Measure & Analyze Approved Wireless instruments provide asphalt terminal with accurate,cost-effective process/inventory control An asphalt terminal in the Midwest supplies liquid asphalt for road paving operations throughout the region. Different customers have varying specs they must adhere to and rework due to incorrect mixes is costly. Wireless level and flow instruments were added throughout the facility to replace aging/ inaccurate measurements, manage inventory levels, and verify the right components go into each batch. Ease of implementation of wireless instruments enabled them to quickly and cost-effectively gain insight into their processes. Tighter batch quality control removes risk of shipping bad mixes which can cost in the millions of dollars and having real time inventory allows for instant notification if a tank level changes when it isn’t supposed to, leading to safer and more profitable operations. The terminal was using traditional float and tape level measurements on large asphalt tanks and having difficulty keeping accurate inventory. The old gauges often gave false readings. Poor level monitoring also allowed for incorrect mixtures getting to loadout due to operator error. Incorrect road mixes applied before being caught had previously cost the company millions in rework expenses. Installation of this system allows for tighter batch control and inventory accuracy has improved from +/-5% per month to 4 in 45000 Tons in some cases! Wiring costs to implement this solution would have cost over $100K and adding instruments for new tanks is a cinch. Use of this system recently prevented the potential release of 1.5MM gallons of asphalt due to a valve that broke over a weekend. Wireless RMT 2051L transmitters were added to 30+ storage and mix tanks while THUM adapters were installed on Coriolis meters. A Wireless gateway with Ethernet IP collects the data and connects into an PLC which runs the inventory system, allowing accurate tracking of where product is being sent for batch and mixing operations and provides instant visibility to abnormal changes. Wireless Instrumentation - Level, Process Control, Instrumentation - Pressure Oil & Gas Midstream (Pipelines, Terminals) Engineer, Plant or General Manager, Operator Workshop Drew Frederixon Midwest Industrial Asphalt Zachary Bauer Emerson - - - - - Instrumentation - - - -
2. Measure & Analyze Approved Continuous steam trap monitoring improves cogen plant efficiency, reduces risk of equipment damage ADM’s cogen plant supplies steam and power to crush and refinery operations in the facility. ADM was looking for ways to increase energy efficiency and steam trap maintenance was identified as an area for improvement. An online steam trap monitoring system was installed using Rosemount’s wireless 708 acoustic transmitters and SteamLogics software to catch failed or leaky traps when they occur rather than on an annual audit basis. Implementation took only 6 hours and showed an almost immediate payback by identifying 3 leaking traps that had gone undetected. Annual steam trap audits are only snapshots in time. One can’t bl at the time of the audit whether the trap is sticking or leaking intermittently and when a trap is found to be failed there is no way to know at what point between audits it failed – making it impossible to quantify the amount of losses. Old audit practices were inadequate for ADM’s drive to improve energy efficiency. At startup three traps were immediaby identified to be leaking. It had been over a year since the last audit. Assuming those traps had been leaking for half that time, estimated preventable steam losses were nearly $20K! Knowing the health of all high-value traps will allow ADM to actively maintain their steam system, reducing lost money due to failed steam traps and increasing plant efficiency. ADM and Emerson collaborated to implement continuous steam trap monitoring on 26 of their most critical steam traps in the Mankato cogen plant. Rosemount 708 transmitters and SteamLogics software were installed to give the plant real-time accurate data on the perbance of these assets. A newly designed high-temperature bracket was used with the 708 to monitor a handful of 1500# steam traps. Wireless Maintenance, Reliability, Predictive Technology Alternative Fuels Engineer, Operator Workshop Dana Ziegler Archer Daniels Midland Zachary Bauer Emerson - - - - - Reliability Monitoring - - - -
2. Measure & Analyze Approved APC USES WIRELESS TO AUTOMATE OPERATOR ROUNDS AND ADD PREDICTIVE MAINTENANCE Anadarko Petroleum Corp needed to a way to remoby monitor head pressure coming off their 70K barrel oil tanks going to compression pumps at a South Texas Midstream facility. Existing manual gauges required routine rounds to determine required maintenance of the inline screens above the compressor pumps. The Wireless Pressure Gauge provided a quick, cost efficient installation with no disruption to operations. The elimination of traditional wired installation bs and wiring costs resulted in CapEx savings of $60,000 and 320 labor hours. Wireless pressure monitoring and automated shut-downs are allowing APC to prevent pump damage and extend pump life by using predictive maintenance. Manual gauges did not allow for 24/7 remote monitoring of pressure. The inability to remoby monitor pressure resulted in clogged screens causing pump cavitation and damage. Pump repair cost $7,000 per failure. A lack of predictive maintenance insight would lead to additional maintenance cost and reduced throughput. Increased operator availability by 360 hrs per year. Traditional wired installation costs and disruptions were eliminated. Wired installation costs were estimated at $71K compared to wireless at $11K resulting in $60K savings. Pump maintenance cost of $7,000 per failure will be eliminated and pump life extended by a preventative maintenance schedule and automated shut down. Rosemount Wireless Pressure Gauges were installed downstream of the inline screen on 9 pumps for detection of screen clogging. A 1410 Gateway was utilized to get the data back to the control room. The pressure readings are being used for scheduled maintenance and automated pump shut down when the screen is clogged. Wireless Instrumentation - Pressure, Process Control, Predictive Technology Oil & Gas Midstream (Pipelines, Terminals) Plant or General Manager Workshop GEORGE CRAIN ANADARKO TERRY FOLSOM EMERSON - - David Penny Emerson - Instrumentation - - - -
2. Measure & Analyze Approved Improving Energy Efficiency Through Heat Exchanger Monitoring Constant failure and accelerated deterioration of the Packinox Heat Exchanger condition led to frequent process slowdown and subsequent shutdown. To mitigate this, the refinery installed a tube shell heat exchanger on standby to jump into operation when failure occurred. Pemex Minatitlan leveraged investments planned for the Heat Exchanger turnaround to expand visibility into the operation of this asset, and help drive operational certainty through proper condition and efficiency monitoring Lack of experience and operation expertise led to accelerated fouling and deterioration of the exchanger condition, resulting in frequent slowdown and shutdowns that translate into losses of up to $600K per year in lost capacity. Internal corrosion and fouling being the main drivers, leading to product contamination and an increase in 10% in fuel consumption in the unit’s fired heaters "- 15% reduced fuel consumption on unit’s fired heaters
- $600K annual savings from avoided production loses.
- Reduction in manual rounds.
- Improved maintenance planning and scheduling
- Payback period under 1 months" Emerson worked with Pemex and a specialized EPC, to develop and execute the Automation on the Packinox Heat Exchanger, introducing pressure, temperature and flow measurements, and EAM software as an analytics tool, to inb decision making on alternating loads and maintenance scheduling of the heat exchangers (Packinox and Standby) based on condition, and reducing impact on production volume Efficiency Predictive Technology, Wireless, Reliability All / Cross-Industry Consultant, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Operator, Engineer Workshop Ariel Mijangos Pemex Minatitlan Orlando Gago Emerson Automation Solutions Latin America - - Erendira Malpica Dajer - Reliability Monitoring - - - -
2. Measure & Analyze Approved Bridging Reliability and Capital Projects Bridging Reliability and capital projects has it challenges in today’s Industry. Many customers see enhances to Reliability as increased capital expense and do not think of Reliability as a business strategy.? Executives require business cases for implementing any program, and it can be difficult for maintenance and reliability practitioners to build one.? Designing for Maintenance and Reliability Readiness (M&RR) during capital projects can increase profitability, reduce safety exposure, lower maintenance cost. ?This presentation builds the business case for including M&RR during capital projects and shows actual customer results or the benefits of integrating Reliability into the project during the Capital FEED process. The nature of some processes prevents personnel of interacting with the equipment in a close, intimate way that experienced mechanical professions are used to. Thought-out pervasive sensing allows the complex mechanical health indicators to be used as a real-time feedback loop. In this case, online predictive vibration monitoring was combined with asset health tools (ARES, AMS Device Manager, AMS Machinery Manager, and PlantWeb Advisor Suite) which identified incipient mechanical issues. This inbation was easy to interpret, such as green / yellow / red. Operations were immediate inbed that a defect was found, while Engineering was able to perb a deep-dive into the complexity of high resolution vibration analysis and identify which component was defected. An online AMS 6500 prediction system was installed on a lethal service centrifuge. DCS bs were sent to the 6500 to compare loaded vs. unloaded conditions. The Online Watch inbation revealed a defect, where a banded frequency alarm changed from green to yellow. Engineering and Monsanto’s vibration group analyzed real time data to determine that the main shaft bearing had developed an outer race defect. The organization all understood the condition at hand, long before it developed into an obvious equipment problem that could have developed into an LOPC, or worse a PSM incident. By understanding the increase profitability opportunity, reduce safety exposure, lower maintenance cost values drivers to M&RR the project was able to implement the proper Reliability Strategies and add additional Capex expense early for the required Products and Software needed to achieve the project Initiatives. Reliability AMS, Predictive Technology, PlantWeb Chemicals (Industrial, Specialty) Engineer Workshop Derek Taravella Monsanto Gary Adams John H. Carter Company - - Ellis Sampson Monsanto - Reliability Monitoring - - - -
2. Measure & Analyze Approved Asset Insight on Your Cell Phone and Desktop – AMS Device Works & AMS ARES "Learn how the new asset alerts templates worked at UT JJ Pickle Research Facility (fieldbus and HART)
And how the new AMS Device Works revealed asset health in the new thin client.
How this was pushed to Operations Management cell phones via AMS ARES
And how this enhanced their fiscal operations
And finally how easy or hard this was to do.?" "Operation and maintenance are getting flooded with Nuisance Alerts coming from Smart Devices through DeltaV Alarm list and process historian as well as AMS Alert Monitors consuming the heavy load of the alerts and making it unusual. Unable to see Vibration and process issues due to these nuisance alerts cause other important applications slowness.
With this nuisance alerts situation, Operation and maintenance is turning off the all of the alerts and uninstalling AMS Device Manager which defeat the purpose of acquiring Smart Instrumentation and AMS Device Manager to proactive and quick maintenance activities." "From these significant improvements, AMS Insight and AMS ARES platb, user will be able to capture critical alerts on their cell phone/tablet. Drill down to import needed b to remedy the issue.
Pilot trial at JJ Pickle will demonstrate Before and After Alerts visualization and how AMS Insight and ARES platb help and improve daily research operation for the UT JJ Pickle Research facility." With new improve Enhance Device Debors and Alerts reduction effort from DeltaV 13.3.1 and AMS Device Manager 13.5, they can finally be able to capture these smart alerts coming from Smart Instrumentations. Coupling with AMS Insight and AMS ARES Platb, they can obtain specific root process problem. Instrumentation - Analytical AMS, Predictive Technology, Foundation Fieldbus Other - Not indicated Engineer Workshop Robert Montgomery University of Texas at Austin Tinh Phan Emerson Automation Solutions - - Duncan Schleiss Emerson Automation Solutions - Diagnostics - - - -
3. Operate & Manage Approved Oilsands project saves Millions through asset consolidation and optimization best practices Large green field projects that require specification and procurement of thousands of instruments across multiple EPC scopes can present bidable challenges. When projects are driven mainly by cost it can be extremely difficult to coordinate and standardize asset selection for overall capital efficiency. Suncor recognized the need for standardization and recognized potential to improve on cost and coverage efficiencies. Suncor and Spartan worked together on a systematic analysis of the Fort Hills asset database. Suncor and Spartan found that with proper model analysis we could significantly reduce sparing requirements by consolidating recommended spares. The project was executed by six different EPC's around the world which led to multiple instrument models scoped for similar applications. It was determined that in many cases one standard model could be used in place of multiple models. Potential to save millions existed if we could consolidate and analyze the disparate data in order to optimize instrument sparing. "Required inventory reduction results were as follows:
Control Valves- 34%Reduction.
Regulators- 46% Reduction.
Pressure Tx's- 60% Reduction.
GWR Tx's- 91% Reduction.
Non-Contacting Radar Tx's- 61% Reduction.
Micro Motion Tx- 75% Reduction.
Vortex Tx's- 57% Reduction.
Temp Tx's- 79% Reduction.
Mag Tx's- 96% Reduction.
Overall inventory reduction quantified at $7,132,433." "The solution was executed in four phases;
1. Validation of given inbation through communication between EPC’s, Spartan Controls, and Emerson.
2. Standardization for maximum coverage through process application reviews.
3. Consolidation on Suncor approved recommended Spares to cover all critical assets.
4. Rationalization of program accessibility, maintainability and future opportunity." Optimization Management, Project Management, Optimization All / Cross-Industry Project Manager / Lead Workshop Jesus Hernandez Suncor Rob Gray Spartan Controls Ltd. - - Adnan Zaheer Suncor - - - Plant Operations Management - -
3. Operate & Manage Approved Maximizing the Value of HART Outputs in DeltaV without Shooting Yourself in the Foot This workshop is a continuation of the very well received 2016 presentation that was focused on the HART Analog Input. There is tremendous value in the inbation available with the HART protocol within DeltaV. However, taking advantage of this value without unintended consequences is more difficult that it seems. This workshop will guide the user through the various aspects of configuring HART within DeltaV and setting up the field device correctly to prevent making common mistakes that lead to undesirable behavior. Users will learn how to generate maximum value from the inbation available in today's HART instruments. Improper configuration of the HART protocol in DeltaV can cause alert floods, bad channel status, and other undesirable behaviors. Improper alignment between the HART output and the HART Field device can lock up the output (IMAN). Users will learn how to manage the engineering unit range synchronization that takes place with HART and prevent unexpected and undesirable behaviors. Users will learn how to deliver incremental value by taking full advantage of the multi-variable and diagnostic inbation available in todays HART devices. Feeding back the actual valve b to the operator can greatly improve safety during abnormal situations. Understanding the perbance of the final control element can greatly improve the operation of the plant. Users will learn how to properly setup a HART I/O channel, how to properly configure AI and AO function blocks to take advantage of both analog and digital inbation. Users will also learn how to configure important channel and function block beters to maximize value without creating unintended problems. HART DeltaV, Engineering All / Cross-Industry Engineer Workshop Jay Colclazier CHS, Inc. Calvin Burnett Experitec - - - - - - - Process Control - -
3. Operate & Manage Approved Replacement of Legacy ESD system with DeltaV SIS and Integration to Existing DeltaV "Abqaiq Plants is Saudi ARAMCO biggest oil processing and crude stabilization facility in Saudi ARABIA, With a capacity of 7 million barrels per day, the facility is the primary oil processing site for Arabian extra light and Arabian light crude oils.
ABQAIQ crude oil stabilization columns (C-10 and C-11) were connected to centralized and obsolete legacy ESD system, Interfacing to existing DeltaV DCS system was through standard MODBUS RTU interface and no provision of field instruments diagnosis for predictive inbligence, This poses ABQAIQ plant to safety and availability risks, maintenance and troubleshooting complexities
The presentation will address how replacement of the legacy ESD system in ABQAIQ with DeltaV SIS has addressed those issues" "1- Obsolescence of ESD system
2- No visibility to SOE
3- Difficult maintenance and troubleshooting
4- High risk of loosing the 2 columns due to centralized ESD system" "1- Simplified spare parts (One module only)
2- Increasing availability by process area segregation
3- Using DeltaV SIS certified function blocks reduced the engineering and maintenance effort" By Installing DeltaV SIS ABQAIQ - SLS1508 and Implementing DeltaV SIS Function blocks SIS / SIL Maintenance, Safety, SIS / SIL Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Engineer, Supervisor / Manager / Dept. Head, Project Manager / Lead Workshop Majed ALKhalis Saudi ARAMCO Mahmoud ElSohaymi Emerson - - - - - - - Safety, Health and Environmental Compliance - -
3. Operate & Manage Approved Finally be able to pump slurry - without the operator b At Red Chris Mine the concentrate de-watering system experienced frequent downtime due to the inability to pump slurry from the stock tank. The density of the copper/gold slurry was too low to be pumped up to the filter press. A more advanced approach using multiple b variables and MPC helped solve the problem permanently and increased efficiency. The level measurement of the thickener tank was not repeatable, a new sensor and transmitter had to be installed. The operator had to watch the density and compare to manual samples. The pump speed had to be constantly adjusted manually. The operator does not have to pay any attention to the density of the stock tank. The product is consistent all the time and can be used from the stock tank at any time. "The pump speed was controlled by a PID with b from the density gauge only. A MPC with bs from flow, pressure, level, torque and density was deployed and a model has been developed to insure constant density.
A new level sensor has been installed and the inline density measurement repeatability has been improved." DeltaV Operations, Process Control, Optimization Metals, Mining, Cement & Glass Consultant, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Plant or General Manager, Operator, Engineer, Director Workshop Thomas Gross Red Chris Mines - - - - - - - - - Process Control - -
3. Operate & Manage Approved EVERYTHING IS ALARMING! Implementing Alarm Management at McClean Lake "AREVA set a goal to improve the safety and reliability of the milling process by proper utilization of alarming from their DeltaV DCS at their Uranium Mill in Northern Saskatchewan. This presentation includes the process of developing alarm design criteria, utilization of tools for analysis, the rationalization process, implementation of change and early results.
Culture and ownership are the major driving forces behind an alarm management project. This presentation will delve into how the project was justified and the importance of commitment to continuous improvement. There are currently 11,600 alarms configured in the plant and AREVA has rationalized 3,000 to date." Historically at the JEB Uranium Mill at McClean Lake, control system alarms were implemented without the basis of an bive design criteria other than priority levels. The resulting state of alarming overwhelmed the operator and results in the operator becoming numb to alarms in general. During incident cause map investigations, a frequent root cause identified is inb to alarms. "Early results include an experienced Alarm Rate that is meeting Industry Standards after a first pass rationalization for the process areas that were first rationalized.
The company is rallying behind the initiative which is of utmost importance to success." AREVA was able to develop a alarm design criteria and deploy tools for analysis. AREVA is currently completing rationalization of all existing alarms in the mill area by area, implementing those changes and subsequently monitoring the changes. Optimization DeltaV, Safety, Operations Metals, Mining, Cement & Glass Engineer, Operator Workshop Chad Sewell AREVA Resources Canada - - - - - - - - - Plant Operations Management - -
3. Operate & Manage Approved Solve Level Control Loop Problems To Smooth Your Plant Operation Liquid level controls may appear to be “just tank controls” but actually function in key areas such as column feed, column bottoms, inlet separators, reactor volume, or boiler drums. Level loops often have a surprising impact on plant stability and operator effectiveness. Properly designed and maintained level loops can absorb variability. However, many plants encounter level loops that generate variability (by self-cycling), propagate the variability to other vessels, or regularly cause alarms. We present 10 never-published examples from the oil & gas, LNG, refining, agrichem, and power industries in context of the plant operations. This presentation will show instrument engineers, process control engineers, and commissioning teams how to rapidly isolate, diagnose, and fix problems. First we need to isolate the problem to a component of the loop, preferably without going to the field for time-consuming (and possibly hazardous) inspection. Root cause could be in the final control element, control logic, filtering, controller tuning, control strategy, or interbs with other loops. Level processes have integrating dynamics, so controller tuning may be counter-intuitive. The level loops now perb much better, with less oscillation, reduced disturbance to key flow rates, and greatly diminished alarms. Benefits include tighter control of product quality, faster startup of units, reduced operator distrb with loops staying in AUTO/CAS, enabling of APC projects, reduced wear on control valves. The results shown here are typical of all process industries. Measuring the process dynamics with DeltaV Insight, EnTech Toolkit or other b helps to isolate the problem. For problems in the controller, Lambda Tuning gives non-oscillatory response; details of that are in the Short Course. For surge vessels, the tuning philosophy is “How slow can we go?”. Problems in other loop components can be recognized from our symptom-to-diagnosis-to-cure examples. Process Control Operations, Troubleshooting, Optimization All / Cross-Industry Consultant, Operator, Engineer Workshop mark coughran Emerson - - - - - - - - - Process Control - -
3. Operate & Manage Approved Automating Fertilizer Crystallization Process using Remote I/O, Delta V batch-like Logic AZOMURES fertilizers factory, an Ameropa company, in order to improve reliability and product variance, it revamped NPK crystallizing plant composed of 20 units - 102 remote operated valves in a cycle of seven hours. Low reliable, old automation based on hundreds electromagnetic relays, operated for years only in remote manual mode, it has been replaced by a new one integrated in Delta V DCS. Field interface is made by Profibus DP network of SIEMENS remote I/O modules: ET200X. Logic has been created in Delta V to solve the interlocks and the operation of units in automatic mode, manual mode and out of service/ test mode. Units work synchronized between them during crystallizing phase and synchronized with filling/collecting units after attaching them during filling/dumping phases. Including all process phases: filling, crystallizing, dumping, operation is now full automatic, crystallization units are synchronized in ring even some of them are out of service or in manual mode. Start-up of crystallization plant has been perbed without to stop the fertilizer production during site works: the revamped units has been operated in ring together with not revamped ones. Now, the NPK crystallization plant is operating almost 99% in full automatic mode. Manual mode is used only for equipment failure situation. Operational costs have decreased: 10% for pumps mechanical maintenance and 30% for instrumentation maintenance. Plant throughput in crystallization phase has increased with 3-5 %. Product quality has increased due to strictly temperature operation As the crystallization process involves only one recipe, Delta V Batch executive and advanced unit modules have not been used; these has been replaced in Control Studio strategies by independent working equipment modules based on advanced classes and synchronized between them by messages, with dynamic references and using limiting alb beters for common units like in Delta V Batch logic. Operations DeltaV, Reliability, Migration Engineering (OEM's, E&C's, Integrators), Food, Beverage & Consumer Goods Engineer Workshop Lucia Giurascu SC Ludan Engineering SRL Ion Paidiu SC Ludan Engineering SRL - - - - - - - Process Control - -
3. Operate & Manage Approved Do you know if your system is healthy? System Health Monitoring dashboard has the answer! Even a small DeltaV System has hundreds of diagnostic beters relating to individual components, software and hardware. Additionally, these diagnostics come from disparate sources and require various applications and interfaces. Imagine driving a car with hundreds of speedometers! Consolidating these diagnostics into a single dashboard allows the DeltaV System administrator to "keep his eyes on the road." This session details how Pfizer's batch manufacturing facility in Sanford, NC, utilizes IIoT technology to centralize system diagnostics and enable Connected Services to drive proactive system maintenance. A novel approach was implemented, leveraging virtualization and blending Emerson solutions and custom tools to proactively monitor, trend and stay alert in real-time. Historically, monitoring DeltaV components has been resource intensive, requiring detailed system knowledge. Additionally, there has been no centralized dashboard for monitoring system components and security functions. By deploying virtual SHM, the Sanford site consolidated monitoring into one dashboard that automatically analyzes system health, eliminating the manual monitoring process. System components are continuously monitored using virtualized servers, gaining the productivity of a full-time resource. Diagnostics are locally presented in a centralized dashboard. Data is trended and can be exported into custom graphs for tracking and reporting. Emerson’s Connected Services has provided several proactive alerts, enabling local response to prevent a system disruption. To reduce resources needed for manual system monitoring, the Sanford site implemented virtual SHM. The service was installed on all four production systems and configured to automatically notify the system administrator and Emerson when system beters reached a defined alert limit. A centralized dashboard was implemented to consolidate all system data into one b. DeltaV Operations, Virtualization, Troubleshooting All / Cross-Industry Engineer Workshop Richard Dedzins Pfizer Inc. Josh Cloninger RE Mason - - Ben Jackman Emerson - - - Remote Control and Monitoring - -
3. Operate & Manage Approved Implementing ValveLink and Asset Management Solutions on a non-AMS Platb "Instrumentation asset management is continuing to gain momentum in many industries. A major challenge is to integrate the device inbation via the control system into an asset management platb. This is especially challenging when HART has not always been embraced as the control systems main communication protocol.
This workshop will detail steps taken to launch device monitoring/asset management on a non-AMS platb at the CHS Refinery at McPherson. The primary focus will be monitoring the Fisher control valve asset via ValveLink but also other Emerson/Non-Emerson devices via DD’s and DTM’s." Previous to ValveLink no predictive maintenance activities were in place for Fisher control valves at the refinery. Through the use of ValveLink a b into the process and the health of field devices has been accessed. Early results are good. Work orders have been generated against problem devices. It is difficult at this point to put a monetary value on the success but this will be buated. Staring up a non-AMS asset management platb and implementing ValveLink. ValveLink Diagnostics, Reliability, HART All / Cross-Industry Consultant, Technician / Analyst / Specialist, Engineer Workshop Mark Isom CHS Ken Hall Emerson - - - - - - - Asset Management and Protection - -
3. Operate & Manage Approved Gas Lift Optimization Application Increases Crude Oil Production Gas lift is a common b of artificial lift for crude production and deliquification of gas wells. The optimization of the process in order to minimize lift costs versus production gains is an ever present concern to all operators. Automated applications can achieve significant improvements by offering injection alternatives, and by placing the equivalent of a seasoned lease operator, at every wellhead, 24/7 in order to make lift gas adjustments. Due to the relatively low price received for produced natural gas relative to a much greater return for crude oil, there is a tendency for an operator to inject as much gas as possible with the idea to obtain the most oil possible. This is not always the most optimal approach. In addition, manual operations are inherently slow to react to production changes. One producer perbed a 22 well pilot. The total investment was approximaby $45,000.00 per site to add additional equipment. The resulting crude production increased by 40% with a 50% reduction of injection gas required. Economic analysis indicated an average three day payback period, and an overall project ROI greater than 300%. A flow computer/controller installed at the wellhead running a SmartProcess application continually adjusts PID loop beters in order to optimize the amount gas injection versus liquid production. Optimization Efficiency, Operations, Instrumentation - Flow Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Director, Supervisor / Manager / Dept. Head, Operator, Engineer Workshop Scott Mease Vinson Process Controls Al Majek Emerson - - - - - - - Remote Control and Monitoring - -
3. Operate & Manage Approved A strategic guide to advanced control in your plant for the “cautiously interested” Many industrial users are keen to try advanced controls, but are unfamiliar with the tools and technology or just not sure how it fits in their facility. This presentation will outline an approach to the implementation of advanced controls for the “cautiously interested”. By starting with a high-level opportunity audit that looks for key indicators to identify high-value applications, the most promising advanced control applications can be identified and bed into an bable plan to deliver meaningful results. The presentation will also cover best-practices to achieve successful commissioning and long-term solution sustainability. Over $20M to date in case studies and observations from the perspective of an end user will be provided by Potash Corp. Industrial users liked the idea of advanced process control (APC) but did not know where to start. They did not want to miss out on the benefits of APC, but were unsure of what potential applications they had on site due to a lack of expert knowledge of available tools and technologies. This gap and uncertainty added risk, and they were not able to justify capital spending on an APC project. Given a b path forward for APC opportunities on site, the customer was able to proceed with strategic implementation of the highest value opportunities with a b understanding of the project costs and payback. At Potash Corp, this has resulted in the implementation of 3 major APC projects to date with a combined realized benefit of $20M. By bringing in an APC expert to conduct an opportunity audit of the process, the user was able to identify potential applications, estimate potential benefits/costs/risks of implementation, and present those benefits in terms of bottom line profitability to the user. This provided a basis for an APC implementation strategy, which was used to kick off the first of many APC projects. Process Control Economic Justification, Sustainability, Optimization All / Cross-Industry, Metals, Mining, Cement & Glass Consultant, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, Plant or General Manager, Engineer, Director Workshop Kenton Peterson Potash Corp Devin Marshman Spartan Controls - - - - - - - Process Control - -
3. Operate & Manage Approved Virtual Instruments? Big $$$ from 1’s and 0’s. A “virtual” instrument is a computed value, based on a collection of actual measurements, to measure something as if an actual instrument were there. These virtual instruments can be as simple as inferring a tank’s outlet flow by computing the change in level or as complex as inferring a flow via mass balance. Come see how our plant uses a variety of these virtual sensors to corroborate actual measurements, provide real time ‘calibration’ of actual sensors, or perb the function of a primary instrument. The why's are addressed, but the focus is on the implementation of these sensors. We have fielded over 2 dozen virtual instruments and will discuss the pain and the payoff. How does one take the derivate of a noisy signal? Can you specify when the virtual sensor is valid vs. giving bogus data? How long until the virtual sensor computes the correct value and is that duration acceptable? The DeadTime block (DT) does not compute long dead times as desired. How was this determined and what is the work around? These and other issues will be discussed. The first group of virtual instruments were ‘fielded’ 9 years ago and they have proven very effective in enhancing both function and reliability without the exorbitant cost of installing real sensors in radiation environments that have already gone hot. Based on their success, many more virtual sensors have been installed throughout the facility. There’s no rocket science in this presentation, just a little physics and solid coding suggestions for using the power for which you have already paid, in purchasing DeltaV, to address some real plant measurement problems. Process Control DeltaV, Optimization, Instrumentation - Flow All / Cross-Industry Engineer, Project Manager / Lead Workshop Jim Coleman Savannah River Remediation - - - - - - - - - Process Control - -
3. Operate & Manage Approved Fulfilling the iOPS Vision - The Future of Plant Operations made ready NOW Significant cost, schedule delays, and inefficiencies are incurred on customers who have Operating facilities in remote bs. A Remote iOps was designed as a solution to monitor and control these remote bs from more accessible centers (e.g. Calgary). A combination of technology and network infrastructure allow for a single consolidated center of Operation hosted at the head office. Making this happen involves an integration of the latest technologies available including video conferencing technology, CCTV, VOIP, reliability software, virtualization and analytics software in a state of the art facility that features smart glass, lighting and acoustics. The iOps solution allows collaboration of experts, projects, and operations to view shared data, resources, and tools. Traditionally plant users including operators, maintenance and engineering are located locally in a plant. Some of those plants are in geographically dispersed bs which causes logistical difficulties and staffing costs. Also, bringing the company or contractor consultants to site for troubleshooting or for standardization efforts across plants is extremely time consuming and expensive. There are tremendous cost savings due to locating traditionally plant staff in the head office bs (e.g. Calgary) instead of in expensive remote bs (e.g. Fort McMurray). In addition, plants benefit from having shared resources in the IOPs which removes the silos and improves collaboration and access to tools that improve reliability, safety and efficiency within the plants. Integrated Operations Center in the owner's b of choice where the shared staff can monitor and/or operate multiple plants, troubleshoot issues and standardize operations. A vision of the solution that was designed for a customer in Alberta. Process Control DeltaV, Process Control, Optimization All / Cross-Industry Consultant, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, President / Principal, Plant or General Manager, Other, Operator, Engineer, Director Workshop Samer El Issa Emerson Automation Solutions - - - - - - - - - Remote Control and Monitoring - -
3. Operate & Manage Approved Automation of Crude Oil Processing Facility Level Control System using Guided Wave Radar Transmitter Due to the dare need for Midwestern Oil & Gas Company Limited to achieve steady state process, reliable end product and cost effectiveness, the Automated Central Crude Oil Processing facility which had been using level controller having float cages for level measurement was replaced with one of Emerson's technology in Level Measurement. This is the Guided Wave Radar Level and Interface Level Transmitters currently in use. The output from these transmitters in the field are transmitted to an Allen Bradley Control Logix5000 PLC, feedback is fed to the final control element(control valve). The result over the period has helped the organization to achieve better efficiency in term of process, output and cost. This has eliminated enormous process upset that would have been caused by operator's intervention to achieve a steady process and saved the organization yearly maintenance cost if manual level control system was used. The results of using Emerson Guided Wave Radar and Interface Level Transmitters compared to the analog level measurement controllers are too wide a margin as it eliminates constant operator intervention due to process upset and maintenance cost due to controller wear and tear. It saved Midwestern over $3000 yearly in procurement and shipping cost. Emerson technology is adopted Guided Wave Radar Level & Interface Transmitters are used in Level measurement of different liquids of different densities ranging from water, crude oil etc. The outputs of the measurements using dielectric are routed to remote monitoring and control systems. A HART communicator or inbligent device Instrumentation - Level HART, Operations, Instrumentation - Level Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Supervisor / Manager / Dept. Head Workshop ThankGod Innocent Isaac Midwestern Oil & Gas Company Limited Adeniyi Majekodunmi Midwestern Oil & Gas Company Limited - - - - - - - Process Control - -
3. Operate & Manage Approved New Coriolis Wet Gas Applications and Development By using an algorithm that leverages a Coriolis meter’s diagnostics to identify single-phase and two-phase conditions within the sensor, a flow computer is able to allocate mass flow measurement as dry gas or liquid and create two-single phase measurements in a single-stream, two-phase process. The original goal of the algorithm was to improve the dry gas measurement and ignore the liquid - which the algorithm is able to do well - but it was also found that by looking at the difference in the dry gas measurement and the bulk two-phase measurement, that a reasonable indication of liquid flow can also be obtained. Additional process insight creates a number of possibilities for managing wells of various artificial lift types more efficiently. The customer wanted to eliminate expensive equipment, like separators at each well pad and monitor lift perbance. This paper will present field data and discuss how the algorithm functions on a gas well with plunger lift and a liquid-producing well with downhole separation and an electric submersible pump (ESP), measuring the gas from the annulus and the liquid that are carried up with the gas. Having accurate annulus gas measurement on the ESP well allows the model of the well and reservoir to be updated to accuraby reflect actual conditions and take that data and high-fidelity model into account when sizing and operating the ESP. Assessing the perbance of downhole separation is also critical to protecting assets. On the plunger lift separators can be eliminated and pumps monitored Implementing Advanced Phase Measurement for wet gas on Mirco Motion's 5700 Coriolis transmitter gave real-time, high speed data and accurate, affordable wet gas measurement. Further improvements to wet gas capabilities are anticipated, as Micro Motion develops in-house wet gas testing capabilities this year. Instrumentation - Flow Efficiency, Optimization Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Engineer, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, Operator Workshop Justin Hollingsworth Micro Motion - - - - - - - - - Asset Management and Protection - -
3. Operate & Manage Approved Going for the Gold! Advanced Control in an Ore Grinding Circuit In the mining industry, advanced control usually means expert systems or fuzzy logic. These have been used in the past with mixed results at Barrick Nevada’s Cortez Mine. Barrick recently migrated the existing controls on the SABC circuit to Emerson's DeltaV. The PredictPro (MPCPlus) multivariable, model-predictive control technology bded within Delta V was selected for the optimization bive of maintaining consistent operations from shift to shift. The MPCPlus applied in the grinding circuit enforces consistent operations from crew to crew. This presentation will describe the three MPCPlus's configurations, designs, interfaces, implementation, commissioning, and perbance reporting for the SAG, Ball Mill, and Thickener circuits at Barrick Nevada’s Cortez Mine. The need to optimize throughput in grinding and obtain consistent grind operations shift-to-shift by standardizing the overall operating strategy in grinding through use of MPCPlus Improved throughput was graphically illustrated before/after applying MPC. Final benefits are still being determined at the time of abstract submission, but utilization has been good at 90+%. DeltaV PredictPro (MPCPlus) and Control Perbance Services were used to redefine the control problems around the SAG Mill, Ball Mill, and Thickener in the Grind Circuit. A custom operator interface was developed to simplify the transition for operators and to feed data forward to plant data management systems. Optimization DeltaV, Services, Process Control Other - Mining Engineer Workshop Jim Bosch Barrick Lou Heavner Emerson Process Management - - - - - - - Process Control - -
3. Operate & Manage Approved Ultrasonic vs. Peakvue: Comparision on slow, noisy critical assets. And the winner is.... The goal of this session will be to compare and contrast the value of Ultrasonic inspection vs. PeakVue on Slow Speed Critical Assets in the Mining industry. Both technologies have been utilized in the past with mixed results. Our goal is to determine best practices on selected assets with these complementary inspection techniques. In potash mining, compactors are critical machines that play a vital role in assuring final product meets customer specifications. They are slow moving, noisy, and very expensive machines to maintain. Common failure points are in the gear box and main gear. Their size and slow moving nature have made effective condition monitoring difficult. A b difference between the technologies has been discovered resulting in a corporate wide best practice that is in the process of being implemented. This has reduced the amount of off spec product produced at the facilities. Additional savings in maintenance cost, spare parts inventory, and inspection time will be detailed in the presentation. Over the past months we have conducted a comparison across two mine sites and 20 compactors. Applying Ultrasonic Inspection and PeakVue analysis to identify which of the technologies best fits and creates confidence with inspection teams. Reliability Machinery Health Management, Reliability, Maintenance Metals, Mining, Cement & Glass Director, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, President / Principal, Plant or General Manager, Operator, Engineer Workshop Greg Frondall Potash Corp Matt Chaplin Spartan Controls - - - - - - - Asset Management and Protection - -
3. Operate & Manage Approved Best Practices for SIS configuration DeltaV SIS provides great out-of-the-box functionality that sometimes is unnecessarily replicated due to lack of knowledge. In other instances, certain configuration practices leads to either poor perbance or complicated solutions which are difficult to maintain. In this short course, most of the SIS function blocks are explained from a practical perspective with examples from real projects. The course covers recently added functionality such as Global Safety Network, always from a real-life perspective. The course is delivered by unique combination: a experienced SIS lead, the Emerson Chief Technologist behind most of the DeltaV SIS, and an end-user. Attendees can understand why something was implemented, how it is implemented in real projects and why it is important. All the different configuration options within SIS function blocks could be a little daunting for the novice users. Seasoned SIS engineers accustom to legacy safety systems could attempt to replicate configuration practices from older safety PLCs and unnecessary creating code already provided by standard functionality. Unexperience SIS engineers could create configuration difficult to maintain. "While having SIS configurations that are simple to troubleshoot and maintain is a good benefit by itself. The real benefit is the avoidance of systematic errors which means increased safety and availability.
Other benefits are: simpler compliance with standards and better utilization of CPU capacity" The proper combination of out-of-the-box functionality, sound configuration practices, and standardization lead to a robust, simple and lean SIS configuration that simplify the SIS life-cycle. SIS / SIL Engineering All / Cross-Industry Engineer, Project Manager / Lead, Operator Short Course Rafael Lachmann Emerson Jay Colclazier CHS, Inc. Gary Law Emerson - - - - - Safety, Health and Environmental Compliance - -
3. Operate & Manage Approved Motivations for new approaches in the pharma industry – From vertical slices to modularization "This presentation will cover the needs, as well the challenges the pharmaceutical industry is facing today and how they can be overcome by following new approaches. A key to success is the modularization of large scale production plants, while doing the same with the automation systems. We will explain how a project as well the system architecture can be splitted in packages to be able to be executed in a more parallel rather than a serial way. By following this new approach, for an example - technology transfer steps - can be reduced from 3 to 2 !
This modularized approach was realized recently with a DeltaV System, with the CHARMs residing on the modules. The full flexibility of the Electronic Marshalling Architecture could be utilized and played beneficially to the bottom line results" With an traditional approach, a project will be divided into an electromechanical/processpart and the Automation package. One independent system integrator is then responsible for configuring the Software for the Automation package. The scope of the system integrator is mainly defined by process technology, so process changes are typically big time and cost drivers "Complete scope of supply in one hand, one supplier from design to implementation.
Eliminating unnecessary interfaces between process and software engineering
Integrated system from DCS down to remote I/Os, sensors and valves..
One quality assurance for the complete package incl. documentation
All hardware and software components are qualified from one supplier." Following the modularization approach, the automation packages can now be configured and adjusted while process changes may accrue. As all can be done now by the vendor in-house and in line with the rest of the organization, the typical time and cost drivers are eliminated and more faster project execution is possible. Project Management Codes & Standards, Operations, Engineering Pharmaceutical & Life Sciences Project Manager / Lead Workshop Gerald Dollberger ZETA Automation Klaus Erni Emerson Automation Solutions - - - - - - - Process Control - -
3. Operate & Manage Approved DeltaV Offline Systems Mega Cluster - Part II (The Odyssey) "This is second part of a presentation that was first given in 2015 and was awaiting the v13.3.1 release of DeltaV.
Virtualization brings a new era of DeltaV system design. A portion of the offline DeltaV systems at Eli Lilly and Company are being centralized. With help from Cornerstone Controls we set forth to capitalize on the aspects of virtualization that can be leveraged from clustering a large number of offline systems together into a single geographical b. Design aspect pro’s and con’s will be discussed and analysis for tradeoffs will be included. Now beyond the conceptual phase this behemoth is still being fed existing physical systems as they are upgraded to virtual systems." As we breathe life into our large virtualization off-line environment, did we design an infrastructure with increased flexibility without increasing risk? Have we incorporated Emerson system applications and services for robustness and reliability? Have we made a system that can truly be maintained and supported? Mission goals include increased reliability and robustness, greater flexibility, decreased footprint, and ease of support and maintainability when compared to its physical system predecessor. Among the design elements are multiple pairs of Dell VRTX servers and numerous host servers with portions of common network infrastructure. Ability to interconnect to physical control and simulation hardware as well as their virtual counterparts was incorporated. A single centralized Virtual Studio instance for host/machine interfaces was created. Virtualization DeltaV, Inbation Technology, Design Pharmaceutical & Life Sciences Engineer Workshop Kurt Russell Eli Lilly and Company August Behling Cornerstone Controls - - - - - - - Decision Support & Data Management - -
3. Operate & Manage Approved Lubrizol’s Chicago-area grease production glides into automation with a slick Emerson team The Polyurea project is an automation project with almost 500 I/O and complex configuration requirements designed to increase Lubrizol’s existing Polyurea production by about 30%. As an old-school, labor-intensive, grimy fluid delivery system has been used over many years on-site, a new capital project presented the Emerson team with an opportunity to implement a cost effective automation solution to expand the Chemtool (Rockton IL) manufacturing plant’s production capabilities that increases operator efficiency and safety. The problem Chemtool faced was the laborious task of supplying the correct raw material process fluid through a complex hose to pipe fluid manifold system. This Emerson/Chemtool collaboration allowed for consistent raw material feed to maintain batch integrity and eliminate costly overflow situations by minimizing the potential for human error by the on-site operators. The implementation of the Emerson Polyurea automation project has provided Lubrizol with an efficient Polyurea production capacity that is scalable for the future. The real time operator interfaces provide operators with finite control of the automation system to safely respond to upset conditions and provide optimized set points to hit quality requirements and decrease costly batch errors. A full Emerson solution was engaged to automate three new Polyurea reactors, seven finishing tanks, and one slurry tank in the Chemtool Polyurea project. In order to maximize batch efficiency, the Delta V process automation system provided monitoring and control of Fisher Control Valves, Rosemount Micromotion and Magnetic flow meters as well as Emerson’s vibration monitoring technologies. DeltaV Control Valves, Process Control, Machinery Health Management Chemicals (Industrial, Specialty) Engineer Workshop Toby Brown Chemtool Austin Barber Chemtool - - Taylor Hines Novaspect - - - Process Control - -
3. Operate & Manage Approved Utilizing the ControlWave Micro as a Data Gateway. "Upgrading or implementing system solutions usually requires interfacing to technologies with specific hardware interfaces, data interface restrictions and/or support for custom protocols. Each implementation can provide its own specific challenges with hardware and custom protocol requirements.
Implementing the custom or specialized interfaces on a standard host based Supervisory Control and Data Acquisition systems can be difficult and generally require specialized host based application knowledge. Levering the RAS (Remote Automation Solution) CWM (ControlWave Micro) as data and/or protocol gateways is one way to address the interface challenges." "Three interface challenges:
1. Providing a replacement RTU when a vendor discontinued its RTU product. The RTU supported a custom protocol to an in-house SCADA system.
2. A large number of serial Modbus devices required interfacing to a DeltaV EIOC (Ethernet IO Controller) Modbus solution.
3. Interfacing to a Mauell serial display controllers as part of the RAS Open Enterprise SCADA project." "Providing the CWM as a replacement RTU with custom protocol enabled customer to continue deploy field equipment without immediate disruption to the in-house developed SCADA system. As a result the customer was able to meet its regulatory RTU deployment commitment.
Utilizing the CWM on the DeltaV and OE SCADA projects enabled the respective host SCADA systems to use the standard data interfaces." The RAS CWM was utilized to address data interface challenges. The CWM’s robust and flexible software platb with a range of communication hardware interfaces has proven to be an effective platb in providing a solution for a range of custom interfaces. In all three interface challenges, a CWM application was developed to address the specific custom interface requirement. Process Control DeltaV, Sustainability, Reliability All / Cross-Industry Engineer Workshop Nerino Persic Control Associates Inc. - - - - - - - - - Process Control - -
3. Operate & Manage Approved How Pascuales-Cuenca project save space, time and cost in greenfield project (Pipeline - Terminals) "Pascuales-Cuenca projects has 134 miles of pipeline to transport refined products such as Gasoline, Diesel and LPG, also has 2 storage Terminals. The pipeline goes across the Andes mountains and required 5 pumping stations, 19 segmentation valves between the 2 Terminals.
The project need to reduce cost and fast implementation to meet local need and quick product distribution to the cities of Pascuales and Cuenca." The size of the system will require 2 main cabinets for BPCS and 2 for SIS and 3 JB for Remote IO's plus engineering and space. Emerson help to reduce half the size of the physical space required, time and implementation cost reduction "The solution required only 1 cabinet per control system leaving space for future expansion.
No need for new control room reduce cost by 200K usd and 1 month of construction" Electronic Marshalling for BPCS and Electronic Marshalling IS for SIS were the solution implemented to help the customer to meet the space requirement, also to keep the project on time and budget DeltaV Design, Project Management, Engineering Oil & Gas Midstream (Pipelines, Terminals) Engineer Workshop Miguel Arreaga EP Petroecuador Jose Luis Amaquina SEIN - - Manuel Arroyo Emerson Automation Solution - - - Plant Operations Management - -
3. Operate & Manage Approved PEMEX Standardize Loading Racks for LPG with mass measurement saving up to $300K "PEMEX is the National Oil Company with presence in the complete O&G value chain, including LPG storage and distribution.
This paper describes the story of a standard loading solution implementation which solved measurement uncertainty challenges, contributed to increase terminal availability and helped to save installation and commissioning costs." This terminal presented three main operational challenges: increase loading capacity, improve process visibility and a tight budget, which demanded a serious reduction in installation costs. "Implementing a proven solution allowed the standardization of the loading racks
generated a decrease on the installation costs and to reduce the spare parts inventory. Calculated savings go up to $300K, impacting directly the operations bottom line. With this level of automation they can reduce dramatically the Trucks Turnaround during the loading process." Emerson proposed the implementation of a standardized comprehensive solution that included: batch control software, mass flow meters, valves and transmitters. The combination of this technologies under a proven solution allowed Marsori to significantly reduce installation and commissioning costs. Installation Best Practices Economic Justification, Project Management, Instrumentation - Flow Oil & Gas Midstream (Pipelines, Terminals) Engineer Workshop Claudia Arroyo PEMEX Manuel Arroyo Emerson Automation Solution - - Fernando Mirafuentes Emerson - - - Plant Operations Management - -
3. Operate & Manage Approved What to do when your operator can’t see the forest for the trees – COSA graphics The loss of operator situation awareness has been identified as a contributor in several major process incidents. Effective graphics, and specifically overview displays, have been identified as one important solution to improve situation awareness. However, users have struggled in creating overview displays. This is often due to the lack of inbation on what is required for this type of display. The Center for Operator Perbance investigated industry best practices for overview displays, developing rules, guidelines, and examples for creation of effective displays to maintain an operator’s situation awareness. Overview displays based on this process are called Console Operator Situation Awareness (COSA) displays. With the introduction of operator DCS consoles, operators lost the “big picture” of the process that they had previously with the panel boards, a phenomenon known as loss of situation awareness. Many plants have accepted this result of unavoidable, believing that the “big picture” cannot be presented for a unit with several thousand I/O on a handful of monitors. Attendees will have an improved understanding of what is required to create COSA graphics. Operators are provided with the “big picture” of the process, providing them with improved situation awareness for their span of control. This allows them to more quickly recognize and react to process upsets. Situation awareness can be maintained using a single display when the data are chosen and batted correctly. Developing effective COSA graphics re-creates the process overview for operators. The key aspects and process to design COSA graphics will be discussed. Workshop participants will be asked to describe processes that they have and the framework for COSA graphics will be developed. Operations DeltaV, Process Control, Engineering Alternative Fuels, 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, Chemicals (Industrial, Specialty) Engineer, Operator Workshop Ike Brackin Flint Hills cindy scott Emerson Process Management - - Dave Strobhar Beville Engineering - - - Plant Operations Management - -
3. Operate & Manage Approved Unique solution for electrical AC motors diagnostics - MotorView Gold with CSI 2140 and FluxCoil Wide machine diagnostic platb based on Emerson technology developed by PKN Orlen consists of various diagnostic equipment with common network AMS MHM. Since almost last three years diagnostics of AC electrical motors has become a one of the key diagnostic activities executed by diagnostic team. Portable analyzers AMS 2130/2140 and dedicated MotorView Gold software package is a very unique solution. Data analysis collected during standard diagnostic routes allows detection of early stage of rotor failures, stator failures (winding breakage, winding short-circuit, voltage imbalance, winding looseness) and mechanical failures. Conclusions allow scheduling of installation/machine train outages protecting continuous production process and increasing business results. "Problem1 – early diagnostics of electrical conditions of AC motors during standard operation to support the decision of planned machine/installation outage not to influence/lose production (case)
Problem2 – advantages and weaknesses of FluxCoil analysis, diagnostic results repeatability (case)
Problem3 – recommendations of diagnostic platb development (customer’s expectations)" "Fast and easy electrical machine diagnostics – detection of machines failure/degradation on early stage.
Less amount of unplanned installations outages (finance results)
Extension of machines diagnostic capabilities thanks to MotorView Gold package integrated with common AMS MHM platb." AMS 2130/2140 + FluxCoil – unique diagnostic solution for electrical AC motors diagnostics (Emerson differentiator), integrated part of the plant-wide AMS MHM diagnostic platb. Predictive Technology CSI Technology, Predictive Technology, Diagnostics Petrochemicals Plant or General Manager, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head Workshop Pawel Goralski PKN ORLEN Jacek Stec Emerson - - - - - - - Asset Management and Protection - -
3. Operate & Manage Approved Rompetrol Saves Millions with Emerson In-Line Fuel Blending Solution Fuel Blending operations around the world today are faced with stricter environmental regulations, increasing product requirements,and tighter product specifications. Remaining competitive and compliant in today's market requires plant modifications, modern blending technology, and advanced controls so you can blend your product right the first time,every time. Emerson can help you produce repeatable on-spec blends, improve tank utilization, and increase profitability by designing blending operations and providing integrated, turnkey blending systems and controls. This session will highlight how Emerson helped solve Rompetrol's fuel blending challenges and save them more than $10 million a year in re-blends and product downgrades by implementing an in-line, optimized blending solution. Rompetrol was utilizing tank blending and as a result they were experiencing difficulty in meeting the required specifications for their gasoline and diesel blends. This resulted in re-blends, property giveaway, and operational inefficiencies for most of their blends. This solution enabled Rompetrol to move from tank blending to in-line blending. This resulted in more effective tank utilization, labor savings, and optimized component utilization in an annual savings of $14 million and a ROI in excess of 60%. Blending and transfer conducted a FEED study to analyze the current process to design a blending solution to cost effectively utilize the blend components and tighten quality control. Blending and Transfer Solutions installed in-line blending systems for gasoline and diesel. These were turnkey, integrated solutions that featured Coriolis meters, on-line analyzers, and optimization controls. Process Control Economic Justification, Process Control, Instrumentation - Flow Engineering (OEM's, E&C's, Integrators), Refining, Oil & Gas Midstream (Pipelines, Terminals) Director, Plant or General Manager, Operator, Engineer Workshop Alexander Kovelesky Rompetorl Christian Bolohan Rompetrol - - Arnie Josefson Emerson - - - Process Control - -
3. Operate & Manage Approved Migration DCS Patache Port ( Mining Collahuasi) Minera Collahuasi needed to modernize its current control system in ABB Plant to a new platb that allows them to integrate new technologies and develop the concept of CRRC (Copper Remote Reliability Center). "AC450 system is in complete obsolescence. ABB dos not sell spare parts and support for this system
Controller AC450 is running under maximum capabilities and is not possible to run fieldbus technology
Process Portal A v2.1 and Control Builder 3.2/16 with no actualizations and support
Operative System Windows 2000 with not support
Fault diagnostic is complex…take to much time." The DCS modernization project estimates an increase of 1% in Confidence in Filters & Thickeners (Process), in the case of rotary equipment this continues in process since the original project will integrate a new project 24 Cells project under development. A Full Solution with DeltaV platb integrated with CHARMS / H1 / EIOC Cards is implemented, all enabled to natively integrate the process equipment under FF / HART & Conditions Monitoring equipment via CSI predictive inbation to be deployed in HMI DeltaV. PlantWeb AMS, DeltaV, CSI Technology Metals, Mining, Cement & Glass Plant or General Manager Workshop Marcelo Jara Minera Collahuasi Victor Pe?a Emerson - - - - - - - Plant Operations Management - -
3. Operate & Manage Approved Lean and Mean – Optimizing the PCSD Library This workshop will discuss techniques to optimize the processing speed of the PCSD library as well as to minimize processing requirements based on the needs of the user. Optimizations will be discussed that can be implemented during design to reduce controller utilization and the number of required controllers without sacrificing features important to the user. Also, code structure can be customized to speed execution resulting in faster responses of final control elements. : During commissioning, it was discovered that the response time for valves and pumps in some applications was too slow. Through investigation, it was determined that the problem was the amount of time between an equipment module was commanded to the time the respective valve or pump actually received a command to act. It was also determined that, at times, the controller utilization was high. The optimization of PCSD saved the need for purchasing additional controllers to handle the extra memory usage. It was not necessary to purchase different equipment to account for slower reb time. The savings would be at least $25000 per instance as the purchase and commissioning of a new device was avoided. Also, as 5 extra controllers were no longer required, $400,000 was saved. The PCSD library was modified to consolidate steps such that total process time was reduced prior to executing commands to final control elements. Also, features that were not necessary functions were removed to avoid superfluous memory usage. As this was purely a software exercise, the costs were minimal. DeltaV Operations, Process Control, Optimization All / Cross-Industry Consultant, Engineer, Director Workshop Vincent Wojtaszek Shire Matt Sarcopski Control Southern - - - - - - - Process Control - -
3. Operate & Manage Approved Financially Justifying Plant Reliability Improvements It is well accepted that improving equipment reliability and the associated increased plant availability has a positive operational impact in refineries, chemical and petrochemical plants. Enhanced online real time measurements and use of predictive reliability analytic models based on these enhanced measurements can result in significant reliability and availability improvements. But how can these enhancements be financially justified? Maintenance cost reductions are seldom sufficient. We have to look further at operational impacts. There are many possible investments to improve reliability - improved real time measurements and predictive techniques must compete for funds with all of these. However, it is often difficult to provide a complete quantitative economic analysis of the expected benefits in the reliability area since the improvements impact multiple cost and revenue components – not just maintenance costs A case study based on predictive reliability analytics in the refining industry is used to provide a realistic example of the benefits estimation procedure. This bology can be applied to potential new investments in “smart” field devices including wireless devices and digital networks, DCS upgrades, advanced control applications, plant inbation technology and asset management systems In the presentation a bology for developing reliable, accurate, and consistent estimates of financial return on investment for these technologies is covered. Benefit areas examined include reductions in scheduled and unscheduled maintenance costs, increased overall unit availability and production, reduced cost of unplanned shutdowns and major incidents, and operational efficiency impacts. Economic Justification Modernization, Reliability, Predictive Technology Alternative Fuels, Refining, Pulp & Paper, Petrochemicals, Metals, Mining, Cement & Glass, Engineering (OEM's, E&C's, Integrators), Chemicals (Industrial, Specialty) Consultant, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, Operator, Engineer Workshop Douglas White Emerson Automation Solutions - - - - - - - - - Asset Management and Protection - -
3. Operate & Manage Approved How a Centralized Control Room (CCR) study could influence a 3rd party DCS migration? MOL Petchem had more than 25 years old TDC 2000 Honeywell system at MTBE Plant. MOL devoted to integrate this Unit into one Centralized Control Room (CCR) with ergonomic study for Operator Consoles, by using High Perbance HMI philosophy as well. Unit integration without interrupting other running Main production technologies. MTBE Unit shutdown time was 2 weeks for migration. "- Eliminate 3 km-s ESD multicore cabling for Remote Push Buttons (ESD, POS, MOS etc), with cable trays installation.
- High Perbance HMI design
- CCR concept for all monitor walls and operator consoles.
- Avoid any shut-downs at the main technology unit" "- 25 + % cost saving by implementing SIS ring.
- First high Perbance HMI operator graphics in use.
- No Production loss due to the migration at the main process.
- First phase of CCR implementation." "Expansion of the existing DeltaV system with the MTBE HW and SW elements. Upgrading existing DeltaV system from 12.3 to 13.3. version with hot cut-over.
Customer engineering center leaded by Emerson Senior Lead Engineer.
Remote ESD push buttons are using SIS ring with SIL-3." Migration DeltaV, SIS / SIL, Modernization Petrochemicals Engineer Workshop Tibor Poór MOL Petrolkemia (MPK) Zoltán Máthe Emerson - - Norbert Nagy Emerson - - - Remote Control and Monitoring - -
3. Operate & Manage Approved Difficult Process Control - EnTech & Model Predictive Control In Practice. "The company ZT Kruszwica SA owned by BUNGE, is a leading producer of edible oils and margarines in Poland. Company decided to use modern techniques of Process Analysis and Control for a nonlinear, very noisy process with a long dead time.
Considered process has a significant impact on a plant efficiency and product quality. Due to a process complexity it was not possible to control it by a classic PID. A manipulated variable was undetermined before an analysis. Process was controlled manually, based on operators’ knowledge and experience.
Workshop will present:
- process transfer functions buation;
- process analysis (EnTech) results with real screenshots;
- MPC function block with trends before and after tuning;
Workshop will not reveal process details (proprietary inbation)." Considered process is difficult to control due to dynamic beters and is not possible to be stabilized by a classic PID. The process manipulated variable is unknown. In analyzed case a process dead time is greater than a process time constant, so control by PID is slow and with poor quality. Due to significant impact on final product beters – it was not possible to proceed a bump test. Using Emerson modern techniques of process analysis it was possible to determine a manipulated variable and to identify a process dynamic model – without a bump test. Today DeltaV MPC block stabilizes a process controlled value. Process controlled value deviation is reduced from 2% to 0.3%, what brings a significant operational savings. Operators are released from a duty of manual control. "Company decided to use EnTech and APC.
Instead of a classic bump test execution, a process was analyzed with Emerson tools:
- EnTech Analyse to determine and select a manipulated variable (cross-correlation and FFT);
- EnTech Tuner to determine a process beters and settings for MPC;
- DeltaV MPC block to manage a process with significant dead time." Process Control DeltaV, Optimization, Operations Food, Beverage & Consumer Goods Engineer Workshop Jacek Brauer ZT Kruszwica SA - BUNGE Ryszard Boron Emerson Process Menagement Sp z o o, Poland - - - - - - - Process Control - -
3. Operate & Manage Approved Cold Water Storage = $2.5M Savings in Electricity! With ever increasing electricity costs, a novel approach to energy storage was used to save the University of Guelph millions of dollars in electricity costs and reduce their carbon foot print dramatically. For users with large cooling requirements, such as a university, large scale cold water storage offers many unique benefits; namely, the ability to produce and store thermal energy when electricity costs are at their off-peak rates. This allowed the University to shave 7MW of electrical load during peak periods and save $2.5M in electrical charges b the local utility provider. The University needed a way to put a cap on their ever increasing electrical costs and achieve their Greenhouse reduction targets. A unique approach was used to solve this problem by the use of a very large scale Cold/Chilled Water Storage Facility. The University of Guelph Campus was able to reduce their on-peak daily electrical usage by 7MW! In the short time the system has been running they have reduced their electrical costs by $2.5M. Producing their chilled water at night has also reduced their carbon foot print by removing natural gas electricity production off the grid during peak demand times. An extra-large storage tank (100 foot wide by 100 foot tall), plus an assortment of mechanical equipment, control systems, and complex third party interfaces were used for the complete solution. The DeltaV control system was interfaced to the existing Trane Chilled water production system via BACnet along with a unique use of the Rosemount 2410 Tank Hub to determine the tank temperature profile. Economic Justification Economic Justification, Optimization, Efficiency Power & Utilities Plant or General Manager, Vice President, Supervisor / Manager / Dept. Head Workshop John Kuri MCW Consultants Steve Sullivan Lakeside Process Controls - - - - - - - Safety, Health and Environmental Compliance - -
3. Operate & Manage Approved CIP One–A Modular Story:How Emergent collaborated to implement S88, Delta V CHARMs I/O & ASCO 580 "Emergent chose to take a progressive approach when it came to replacing an existing and outdated CIP system. Their utilization of the DeltaV modular hardware / software combined with the new modular ASCO 580 CHARM manifold reduced their construction, commissioning and validation costs by a combined ~50%.
Is this session we will examine the WHY and the HOW did they achieve this success along with displacing existing competing plant automation and pneumatic standards." "? Increased Flexibility for automation changes after FAT
? Maintaining Plant Standards while producing a custom piece of equipment
? Quick system commissioning and turnaround from old CIP system to new CIP system
? Limited budget
? Providing an automation solution for a 3rd skid manufacturer in another country" "? Fast Cycle Development
? All programming for flow paths (valves) is now done compleby natively on DeltaV (use of ASCO)
? Reuse of existing cycle programming without additional validation
? Consistent cleaning results
? Minimal Operator Training
? Significant reduction in overall project cost (validation / programming)
? The CIP System functions exactly like an existing C" "The solution consisted of both hardware and software
Software
? Reused existing classed based which reduced development, commissioning and validation time
o Control Modules
o Equipment Modules
o Phase Modules
o Operations
o Unit Procedures
o Dynamo Sets
Hardware
? S-Series CHARM architecture
? Custom built panels
? ASCO 580 manifolds (CHARM integration)" Compliance Compliance, Engineering, DeltaV Pharmaceutical & Life Sciences Engineer, Project Manager / Lead Workshop Neil Stephenson Emergent BioSolutions Adam Troeller Lakeside Process Controls Ltd - - - - - - - Safety, Health and Environmental Compliance - -
3. Operate & Manage Approved Dual Level for Process Towers with Guided Wave Radar & ERS In 2013 the refinery started the process of removing outdated pneumatic displacer level control on their process towers. Through an approved MOC a tee connection was added allowing us to install dual levels. During the testing phase we kept one pneumatic level and added either guided wave radar or ERS. At first the new level instrumentation was only used to monitor until the operations people saw how much better the device actually reported true level. Once they became confident in the newer technology we then replaced the displacer with guided wave radar allowing us to set up for either instrument to control or monitor tower level. We have since added this instrumentation scheme to several other towers in the refinery and plan on making this combination a standard for our level control. One of the main problems we solved with dual levels was reliability and the need for constant maintenance. Installing the newer instrumentation has allowed our process downstream to line out much better and faster than ever before during an upset. A comparison of trends on charts or trending bly shows more precise control of the tower. No moving parts means less maintenance or downtime. "From the start it was b that we were going to give operators better level control of their towers by installing these level control instruments. We also achieved a significant safety benefit by providing redundancy where there had not been any before.
This has allowed us much tighter and better control of our process and reduced overall maintenance costs and increasing profits." The solution for us was to hedge our bets by having two level measurement instruments that used different technologies to provide stable control and monitoring of our process towers. This was accomplished by installing one guided wave radar and one ERS onto our towers. Through careful engineering and study of level trends these two instruments have become our staple for level measurement. Instrumentation - Level DeltaV, Maintenance, Instrumentation - Level Refining Supervisor / Manager / Dept. Head Short Course craig kalkhof United Refining Company Richard Zachrobski ECI - - - - - - - Process Control - -
3. Operate & Manage Approved Repsol PLC Modernization - A tight time line approach for risk mitigation and operational success "Lower Natural Gas prices these days mean any unplanned outage can have lasting economic impact on profitability. At the Bigstone gas processing facility Repsol staff recognized a significant risk in their aging/obsolete PLC processors and I/O. The original PLC5 installation from 1994 was still functioning but there were no new replacement parts available and used ones on ebay were in very short supply.
Unacceptable risk in terms of mean time to repair led to a plan to migrate 600 i/o from PLC5 to the DeltaV based plant control system. The trick was figuring a way to do this during a narrow 5 day turnaround b. Good planning would obviously be the key to success here.
This paper discusses strategies, planning, configuration, execution and results of a highly successful project." "The Bigstone gas plant has run for several years with a split architecture system. DeltaV for regulatory control, PLC5 for logic/shutdowns. Moving to one system across the entire plant would benefit operations and fix the obsolescence risk. The challenge in this case was how to fit this switch into a 5 day turnaround b.
Planning pre-work and configuration testing were absoluby essential" The cut-over went smoothly and finished one day early. Operations now has one control platb with Redundancy, eliminating the single point of failure. The obsolescence issue was removed while providing the means for the plant to be run more efficiently with lower complexity. The final presentation will include economic results and impact on plant production, uptime and annual targets. Electronic Marshalling was an obvious fit since we had physical space constraints. Replacing marshalling with CHARMS gave flexibility while respecting density constraints.DeltaV logic templates reduced configuration time which was important since we had to reverse engineer the PLC logic. This afforded more time for testing which lowered risk posed by the narrow shutdown b. DeltaV Migration, Reliability, Modernization Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Plant or General Manager Workshop Troy Williams Repsol Oil and Gas Canada Brett Stiles Repsol Oil And Gas Canada Inc - - - - - - - Process Control - -
3. Operate & Manage Approved Making Big Rocks Into Litte Rocks with DeltaV Freeport-McMoRan Sierrita's Crushing Operations was experiencing difficulty breaking in Sandvik Secondary and Tertiary Crushers after a liner change or overhaul. Sierrita’s Automation team worked with Operations and Maintenance to develop a control scheme using DeltaV to take over the role of the Operator during the break-in process. A control scheme in DeltaV was developed which eliminated unsuccessful break-ins and reduced the break-in time from a week to 8 to 48 hours. Freeport-McMoRan Sierrita's Crushing Operations was experiencing difficulty breaking in Sandvik Secondary and Tertiary Crushers after a liner change or overhaul. The break-in process was being done manually by Operators which resulted in a lack of precision, accuracy and repeatability. Due to the complex requirements, it was common to have length break-in periods or failures. The break-in SFC eliminated unsuccessful break-ins and reduced the break-in time from a week to 8 to 48 hours. The break-in program provided a solution by continuously monitoring the operating health of the Crusher while making adjustments to the mantle. This also reduces stress on Crusher Operators who were required to manually break-in crushers over 14 12 hour shifts. Sierrita’s Automation team worked with Operations and Maintenance to develop a control scheme using DeltaV to take over the role of the Operator during the break-in process. This solution would have been provided by a Vendor in the ber of APC software else known as an Expert System. Phase 1 solution was to utilize DeltaV via a SFC; Phase 2 is to enhance the break-in control scheme with MPC. DeltaV Efficiency, Operations, Maintenance Metals, Mining, Cement & Glass Engineer, Technician / Analyst / Specialist, Plant or General Manager Workshop Sam Del Rey Freeport-McMoRan David Miscisin Caltrol, Inc. - - - - - - - Process Control - -
3. Operate & Manage Approved DeltaV and Simulation Insure Successful New Plant Start-Up Novita Nutrition, an animal nutrition company, produces two branded products through its innovative process, including NovaMeal?, a highly digestible bypass protein for the dairy market and NovaOil?, a renewable oil used in animal feed, at its green field plant in Aurora, South Dakota. Novita Nutrition sources Dried Distillers Grains with Solubles (DDGS), as the beginning feedstock and through a patented process extracts most of the unsaturated fat resulting in the two branded products. CHARMS I/O allowed late design changes without negatively impacting budgets. MYNAH Mimic simulation allowed for testing of control system functions and operator interfaces. Operator training on the simulation allowed for a safe start-up of the plant and reduced time to reach full production. New plant and highly integrated process presented challenges in project execution and construction. New inbation from vendors, process modifications based on trials at a pilot facility resulted in design changes well into construction. Operators had to be familiar with plant controls and processes on day one though there was no plant running this process where they could be fully trained. Control system design and implementation met budget expectations and provided flexibility required by late changes in the project. Operators were familiar with the system operation on the first day of production and had practiced emergency procedures in the control system environment. Result was reduced start up time for this new process allowing plant to reach production goals ahead of schedule. Mimic Simulation allowed engineers and plant staff to complete design, test operating procedures and make changes independent of hardware changes. Plant operators had access to the simulation before start-up which provided training on procedures and emergency sequences. CHARMS allowed hardware changes at the last minute with minimal impact on costs or schedule. DeltaV Management, Training, Operations All / Cross-Industry Consultant, Project Manager / Lead, Plant or General Manager, Engineer Workshop Kurt Swenson Novita Nutrition Jeff Pingeon Novaspect - - Dave Schneider Novaspect - - - Process Control - -
3. Operate & Manage Approved MPC Applications in Pulp Mills that Save Money The pulp and paper process has many complex unit operations with highly coupled bs, challenging dynamics, uncertain measurements, and unmeasured disturbances. Advanced control techniques provide a way to effectively address these challenges where conventional control falls short, resulting in reduced costs, increased throughput, and improved quality. This presentation will focus on case studies highlighting the successful application of model predictive control (MPC) to several pulp mill applications with savings ranging from $50,000/y to $1,000,000/y. The pulp and paper process has many complex unit operations with highly coupled bs, challenging dynamics, uncertain measurements, and unmeasured disturbances. Due to these challenges, conventional control techniques fall short and the mill relies heavily on experienced operators to maintain stability. The presentation will include multiple case studies for MPC solutions on the above applications. For each applications, savings realized at various pulp mills ranging from $50,000/y to $1,000,000/y will be presented. Advanced control techniques provide a way to effectively address these challenges throughout the pulp mill and optimize operations to reduce costs, increase throughput, and improve quality. This presentation will focus on the successful application of model predictive control (MPC) to several pulp mill applications including brownstock washing, evaporators, boilers, causticizers, kilns, and more. Optimization Economic Justification, Process Control, Engineering Pulp & Paper Consultant, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Sales / Marketing, Project Manager / Lead, President / Principal, Plant or General Manager, Operator, Engineer, Director Workshop Devin Marshman Spartan Controls TBD TBD TBD - - - - - - - Process Control - -
3. Operate & Manage Approved DeltaV SIS with Electronic marshaling proved best fit for standalone F&G offshore platb upgrade Dubai Petroleum Establishment (DPE) is an offshore Oil production facility in UAE established in 1963. As per the initial design of platb there was no F&G system implemented. Over the period and aging of some pipes/instruments there was a need to measure gas leaks and fire protection. DPE had central processing and operation facilities (CCR) with remote production wells. DPE adopted remote IO solution to reduce the multicore cable run from platb to CCR. Remote I/O and logic solving capability of the CHARMs SLS provides higher safety and availability in case of communication loss between the platbs compared to the traditional remote I/O solutions. Interface with existing plant DCS and modular design with expansion capability made CSLS most suitable for DPE's requirement. New F&G detectors at platb connected to F&G system in CCR b increased cable and laying cost. Central facility had space constraints for new cabinets. DPE preferred remote IO solution but knew communication loss to central controller could cripple the system functionality. Further they expected seamless communication of the F&G system with existing plant DCS system at CCR. DPE were able to save close to $100K cost associated to multicore cable, cable laying, reduced cabinet footprint. DPE used the OPC interface from DeltaV F&G system to existing plant DCS. Further DPE were able to get all the diagnostic bs from the F&G detectors which would avoid any spurious alarms or trips. DeltaV SIS electronic Marshalling system design with CSLS in field not only solved the multicore cable issue but also overcome the communication loss issues compared to traditional remote IO design. High IO handling capability of Charms meant 50% less cabinet. Inherent serial and OPC communication helped seamless interface with plant DCS. DeltaV Operations, Safety, SIS / SIL All / Cross-Industry Consultant, Plant or General Manager, Operator, Engineer Workshop David Easthope Dubai Petroleum Swarup Gokhale Emerson - - Sachin Sethuram Emerson - - - Safety, Health and Environmental Compliance - -
3. Operate & Manage Approved Connecting the Dots: How Safety Impacts Operational Excellence Often organizations use the common metric of total recordable rate to measure safety success. Even extendable metrics, like severity rates and incident counts, are directly tied to safety. However, safety has a broader impact well beyond an employees’ well-being. During this session, cases will be shared exemplifying how safety perbance is both an indicator and driver of increased operational excellence. Links will be made to improved operational discipline, decreased downtime, increased maintenance and reliability perbance, and more efficient operations. Participants will see how to b operations to HSE while building the case for safety as a driver of operational excellence. Many organizations face the challenge of building a comprehensive business case for safety. Lagging indicators such as total recordable rates and severity rates are used, but the positive impact a strong safety culture has on operational excellence is often missed. Organizations can achieve improved safety and operational perbance through an integrated approach that includes technical models, processes, mindsets & behaviors and capability building. In this workshop, participants will learn, through examples from other organizations, how improved safety perbance can lead to improved operational excellence. Safety Maintenance, Reliability, Operations All / Cross-Industry Consultant, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Sales / Marketing, Project Manager / Lead, President / Principal, Plant or General Manager, Operator, Engineer, Director Workshop Rich Eagles Dupont Sustainable Solutions Will Goetz Emerson Automation Solutions - - - - - - - Safety, Health and Environmental Compliance - -
3. Operate & Manage Approved Electronic Marshalling the right choice for legacy system migration Dubai Petroleum Establishment (DPE) is an offshore Oil production facility in UAE established in 1963. DPE has been using Emerson's RS3 control system for more than 20+ years at their Water Flood platb associated to Fateh offshore complex. RS3 system had reached its end of life in 2013. Since then it was challenging for DPE to maintain this system and decided to replace it with latest control system. In addition the existing relay based safety system also needed to be replaced by smart Logic solver based ESD system. Main bives under this project was flawless migration to new system with minimal complexity, cost and cabinet footprint. DPE analyzed various systems available in current market. DPE selected Emerson's Electronic Marshalling solution which met all of bives. Current challenging market forced DPE to use inhouse expertise and avoid any 3rd party consultants for this revamp project. They wanted to achieve flawless migration of their obsolete RS3 and relay based ESDsystem. Outdated cabinet wiring data were added challenge. DPE expected the selected vendor to do have RS3 migration experience, provide flexible system with reduced cost & cabinet foot print. DPE where able to migrate from a separate DCS + Safety system to an integrated smart DeltaV ICSS solution. Charms solution provided Opex savings of 20% compared to traditional approach, it also provided flexibility in cabinet wiring which reduce the cutover period. The migration tool minimize reverse engg efforts. Integrated HART capability of the selected solution diagnose field fault faster. Electronic marshaling solution had 20% less cabinet footprint compared to RS3 system. The flexibility of the charms solution helped quick wiring changeover from existing marshaling to Electronic marshaling. CIOC + CSLS helped to achieve a truly integrated solution. Charms along with migration tools provided all the confidence in DPE to overcome challenges with less OPEX expense. DeltaV Modernization, PlantWeb, Operations All / Cross-Industry Consultant, Supervisor / Manager / Dept. Head, Plant or General Manager, Operator, Engineer Workshop Simon Keyes Dubai Petroleum Swarup Gokhale Emerson - - Sachin Sethuram Emerson - - - Process Control - -
3. Operate & Manage Approved Maximizing SAGD Production with MPC-PLUS "In steam assisted gravity drainage (SAGD), it is efficient to withdraw the bitumen/water emulsion from a reservoir as fast as possible to minimize heat loss to its surroundings. By maximizing steam utilization, production is maximized. However, a small emulsion layer is required to prevent the steam from entering the wellbore which is inferred from a subcool measurement.
We demonstrate that MPC-PLUS inherently manages the long process dynamics of SAGD production/subcool. We also show that process dynamics can vary up to a factor of 10 along a well’s length. To quickly model the well, we use Matlab to automatically create 60 process models per well along its length, and MPC-PLUS was easily configured to switch to the correct model when the controlling wellbore subcool b changed." The existing PID controller was difficult to tune given the long process dynamics, and it was unable to compensate for variations in dynamics down the length of a well. Moreover, it was not designed failsafe to manage the unreliable wellbore instrumentation, thus an inferior subcool measurement was used. Throughput was sacrificed, and controller maintenance and pump speed variability was high. The controls work the pump less hard than PID subcool control, yet tighter subcool control is achieved leading to significant steam savings by permitting closer operation to the subcool constraint. Wellbore subcool variability decreased by ~73%, pump speed variability decreased ~50%, and production increased an estimated 5%+ per well due to less steam heat loss to the reservoirs’ surroundings. DeltaV MPC-PLUS was utilized to manage the long process dynamics of SAGD production. Matlab quickly and automatically generated 60 process models per well for each temperature point down the length of the wellbore, and MPC allowed for easy model switching when the controlling subcool b changed. Moreover, MPC switches over to redundant measurements for control upon instrumentation failure. Optimization DeltaV, Process Control, Predictive Technology Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Engineer Workshop Greg Myhill Athabasca Oil Corporation Ken McClure Spartan Controls - - - - - - - Process Control - -
3. Operate & Manage Approved A Program Approach to Achieve 30% Efficiency Gains Cargill Corn Milling has 5 separate plants undergoing upgrades from obsolete control systems to DeltaV and/or adding new DeltaV infrastructure to interface with existing control system technology. A central program approach was implemented to manage all of the projects consistently across all sites as well as to execute to the developed program standards. This presentation will provide an overview of the program approach including a deep dive into the perbance metric data, achievements, continued challenges, and continuous improvements using Project Certainty elements. A major challenge presented at the onset of the program was to achieve consistency on hardware and software and to insert best practices across each of the bs undergoing the upgrade to DeltaV. Executing a migration program approach allowed us to implement the developed standards, track perbance, achieve continuous improvement, and realize efficiency gains. 14 of 30 individual projects have been completed across all sites, and 7 other projects are currently in different execution phases. The program has made significant increases in cut-over efficiency from one project installation to the next, as well as a decrease in project cost and configuration time. This presentation will analyze the program approach and efficiency gains achieved. A program approach using a core team of Cargill and Emerson personnel to manage and guide individual project teams to achieve continuous improvement. Standards were developed for the project teams with common project tracking and reporting tools along with audit functions to ensure consistency. Program bives with Project Certainty elements enabled efficiency gains. Efficiency Codes & Standards, Migration, Management Chemicals (Industrial, Specialty) Engineer, Project Manager / Lead, Plant or General Manager Workshop John Krueger Cargill Tom Canterberry Emerson Automation Solutions - - Nancy Shoup Emerson Automation Solutions - - - Process Control - -
3. Operate & Manage Approved Cracking Furnace Operation Optimization with Wireless Monitoring Furnace temperature and pressure monitoring has been done with traditional wired transmitters in the past, but identifying exactly which set of tubes was fouling and to what degree was difficult. By the time a serious issue was identified, it was often too late. With the introduction of the low cost of wireless pressure/temperature transmitters, a plant can now monitor every set of tubes, starting with clean status and trending from there. This allows operation personnel to clean tubing when needed in a timely manner, reducing fuel costs and keeping efficiency at a maximum level. Unscheduled major outages due to tube fouling from excessive buildup of coke residue caused an average of 30 to 45 days of furnace downtime a year and $125K/day in production losses. Due to adverse conditions, the cleaning process required 24 hours. During this time, plant output was reduced by 12%. In response, the plant was pigging tubes annually, a very expensive and time-consuming activity. Each bundle is monitored, so production continues until maintenance is required. With daily trending of tube fouling, segmented cleaning is perbed without shutting down the entire furnace, saving $4M/year. Reduced downtime increased efficiency by 2% for a 4-month ROI. Additional revenue from fewer shutdowns covered the cost of the 96 wireless transmitters and installation after only one year. The Cracking Furnace is composed of 12 bundles of feed tubes, and each bundle has 8 heat exchangers. A total of 96 Wireless 3051S Pressure Transmitter units were installed to monitor the heat exchangers within each tubing bundle, giving the plant visibility regarding coke buildup. This allowed the plant to optimize control by balancing flow among the bundles for best furnace yield. Wireless Economic Justification, Reliability, Predictive Technology Petrochemicals, Refining Director, Supervisor / Manager / Dept. Head, Plant or General Manager, Operator, Engineer Workshop Robert Boyer Flint Hills Resources Marcio Donnangelo Emerson Automation Solutions - - James Raymond Emerson Automation Solutions - - - Asset Management and Protection - -
3. Operate & Manage Approved Native Control of Pressure Swing Adsorption (PSA) Units with DeltaV Pressure Swing Adsorption Units are commonly used in Refining and other industries for the purification of hydrogen, oxygen and other gases. The processes are typically licensed and controls are usually done in vendor supplied equipment. The controls are complex and required relatively high speed processing. This workshop will provide a case history of multiple installations across multiple refineries where PSA control was done natively in DeltaV. The workshop will provide an overview of the process, control and sequencing requirements and implementation details. A native DeltaV solution eliminates the need to maintain multiple hardware platbs and eliminates the need for special communications between systems. The solution improves reliability by providing access to advanced valve and instrument diagnostics available through AMS Device Manager. Multiple PSA units are currently in operation at multiple refineries using native DeltaV with both classic I/O and CHARMS. With the collaboration of Emerson Engineering Center, PSA Consultant & the customer, Emerson developed a specific library of module Classes, Templates & composites that met the bent functional requirements if the process technology vendor. Process Control DeltaV, Process Control, PlantWeb Alternative Fuels, Refining, Petrochemicals, Engineering (OEM's, E&C's, Integrators), Chemicals (Industrial, Specialty) Consultant, Technician / Analyst / Specialist, Sales / Marketing, Project Manager / Lead, Operator, Engineer Workshop Mike Fornshell Phillips66 Jay Colclazier CHS, Inc. - - Phillip McGough Emerson Automation Solutions - - - Process Control - -
3. Operate & Manage Approved Device Alerts - Finally! An Emerson Solution for Installed Base Users "Many users have experienced the negative consequences of improper device alert configuration defaults in DeltaV. High volumes of confusing, non-bable device alerts fill up the Event Chronicle and flood operators with meaningless alarms. This workshop will discuss the Emerson developed solution to improve the device alert experience for installed base users.
This workshop will show users how to get the new Emerson solution and how to use it to improve the device alert experience." Users have resorted to a variety of solutions to eliminate unwanted device alerts, including turning off the alerts or disabling HART communications. Many of these solutions also diminish the benefits of HART devices and eliminate useful bable alerts. This workshop will show you how to turn device alerts back on and get useful, bable inbation. Benchmarking has shown that device alert volumes can be decreased by 60% - 80%. With the new Emerson solution, Device alert records will be automatically eliminated from the DeltaV Event Chronicle view and device alarms will no longer appear on Operator Workstations by default. Emerson has redefined the alerts in a high majority of current and previous generation Emerson HART devices. In addition, new enhancements to current and previous release of DeltaV greatly simplify the process of updating existing system configurations. DeltaV AMS, Maintenance, Engineering All / Cross-Industry Engineer Workshop Jay Colclazier CHS, Inc. Duane Toavs Enmerson - - - - - - - Asset Management and Protection - -
3. Operate & Manage Approved The Slope of a Line Kept Our Plant Alive: Measuring Flow Using Linear Regression Measuring flowrate is usually an uneventful task, right? You just install the flowmeter, hook it up to the DCS, and you’re good to go. Sometimes, however, installing a flowmeter is prohibitive or downright impossible. On paper, the slope of tank level readings over time can be used to compute flow. In practice, computing slope in the DCS, accounting for disturbances in the tank, and dealing with noise make this task more challenging. Come see how we applied a least squares regression in DeltaV to measure flowrate without using a flowmeter. How does one obtain slope in the presence of noise? How should previous tank levels and the time be recorded and stored? How can you differentiate valid data from bad data? How do you dynamically alarm for flowrate discrepancies? DeltaV can only store up to single precision floating points. What are the limitations of this? We will present different bs of tackling these challenges. We met a DOE requirement to provide ‘redundant’ flow measurement for a critical system. Installing a second actual flow meter was not economically possible due to radiation hazards. However, the addition of this ‘virtual’ instrument has allowed us to continue to operate safely, efficiently, and economically. Understanding the process, a little bit of ingenuity, and analyzing historical data proved to be beneficial. Utilizing techniques to filter out noise and disturbances, we obtained flowrate by monitoring the rate of tank depletion. Process Control DeltaV, Optimization, Instrumentation - Flow All / Cross-Industry Engineer, Technician / Analyst / Specialist, Plant or General Manager, Operator Workshop Sterling Bash Savannah River Remediation Adam Samet Savannah River Remediation - - - - - - - Process Control - -
3. Operate & Manage Approved Notre Dame scores again by simplifying their process control with 580 CHARM and DeltaV Emerson’s 2009 introduction of Electronic Marshalling (EM) for DeltaV revolutionized many aspects of plant control, and not coincidentally of system implementation. ASCO has extended EM — and for the first time allows integrated control of pneumatic valve manifolds on one network. Notre Dame recently employed this new technology for control of a water system on campus which simplified the process of valve control and made a cleaner more manageable installation using ASCO's 580 CHARMS Node, 500 series valves, and Panel Mount Kit. Notre Dame used to control valve piloting via discrete wiring. This was a costly labor intensive way to setup valve control on a DeltaV network. The ASCO 580 CHARMs manifold allowed direct connection to DeltaV through the CHARMS I/O architecture, offered redundant control,and feedback on valve status. It significantly simplifies configuration, wiring, and it empowers the full, native diagnostic capabilities of DeltaV. It requires one communication cable, in simplex configurations, to be connected from the CIOC to the Controller while maintaining redundant power and communication to the valves. It also allows for diagnostic feedback to the DCS. Using the Emerson CHARMs architecture ASCO Numatics manifolds are connected directly through the backplane to the DeltaV controller via the CHARMs I/O Card (CIOC). Now what use to be a panel full of wires and bulkhead fittings became a two-wire manifold control with a single panel connection for pneumatic outputs. Actuation DeltaV, Process Control, Optimization Power & Utilities Engineer Workshop Thomas Cole Notre Dame University Bill Farmer Novaspect - - Don Launder ASCO - - - Process Control - -
3. Operate & Manage Approved Improving PEMEX Safety level in Offshore Facilities Improving safety was Pemex’s primary concern after a fatal explosion at an offshore Abkatun platb in the Gulf of Mexico. ASCO took this challenge very seriously and came up with a great safety control panel for the Emergency Shutdown Valves (ESDV's) and Bettis spring-return pneumatic actuator assembly. The safety control panel, along with various other Emerson solutions, enabled the company to improve their confidence in their safety level and also the reliability of the facilities. PEMEX previously installed double-acting actuators controlled by an electro-hydraulic control panel which was sometimes not SIL certified. With the ASCO Control Panel Solution complementing the spring-return Bettis actuator, the reliability to get the most safety in last b for the ESDV increased. Availability in the Safety Instrumented System with solenoid valves in redundancy and on-line maintenance; feedback of the behavior of the components such as solenoid valves and pressure switches with on-line tests; avoid spurious trips in the ESDV; improved reliability and safety with a SIL 3 system and leakage and failure points reduced by its compact design. Design a control panel for the ESDV featuring the ASCO RCS (Redundant Control System), along with additional components, inside a cabinet in order to guarantee the safest operation. Reliability Isolation Valves, Safety, SIS / SIL Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Engineer, Plant or General Manager, Operator Workshop ROBERTO CARRASQUEDO PEMEX HECTOR ANIBAL MARTINEZ ASCOMATICA SA DE CV - - - - - - - Plant Operations Management - -
3. Operate & Manage Approved Techniques for Remote Monitors in Hazardous Areas "Three general technical solutions are available today to deploy and operate a remote monitor in a hazardous b:
1. KVMs with a suitably rated remote monitor
2. Purge-Pressurized enclosure with remote monitor
3. Industrial Thin Client remote monitor
A remote monitor in any process area, especially a hazardous area, must be industrial, rugged, and suitable for use in that area, including wide-temperature ranges." A commercially available workstation or a commercially available thin client cannot be installed directly in a hazardous b; protection must be provided. And, often the unit must be able to support wider temperature than commercially available products. Using an integrated industrial Thin Client remote monitor solution can save cost both in hardware cost and installation time. A typical application of 10 remote monitors, plant located in Class I Div 2, an integrated solution can save $2,000/remote monitor relative to KVM solutions, plus save 40-60 hours of installation time. An industrial Thin Client remote monitor can provide a much better solution for deploying and operating as remote monitor in a hazardous b. If multiple remote monitors are required, it may make sense to utilize the Virtualization architecture. DeltaV Installation Best Practices, Virtualization, Operations All / Cross-Industry Consultant, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, Operator, Engineer Workshop Marc Seissler Pepperl+Fuchs, Inc. Bruce Greenwald Emerson - - Aaron Severa Pepperl+Fuchs - - - Plant Operations Management - -
3. Operate & Manage Approved Tackling Critical Transportation Capacity Requirements for the National Gas Pipeline Network "Following significant rebs in the Mexico energy sector, the single role that Pemex once had over the industry has changed, and a new player, CENAGAS, is now part of the management, administration and supervision of operations, transportation, and storage of natural gas on a national level. CENAGAS, which has a more corporate structure than other state owned entities, has also inherited the responsibility of overseeing the bidding process through which private enterprises can invest in the energy sector, a role that CFE, the national utilities company was previously in charge of.
CENAGAS is responsible for Mexico’s gas provision and distribution coordination in the most secure, efficient, and reliable way possible and uses specific tools/applications to ensure gas availability." CENAGAS is a new entitity that took over the operations of the existing PEMEX +9,000 km gas network, as well as the supervision of private transmission lines. This operation and supervision requires operational systems, which are currently projects under development, reason for which CENAGAS temporarily outsources these services, along with specific maintenance needs, to PEMEX. PiplineStudio has allowed the operations and commercial CENAGAS teams to reliably validate and oversee safety, efficiency, operational, capacity and infrastructure related inbation provided by their temporary +9,000 km gas network operator, PEMEX, and the private transmission companies, by providing fast and detailed hydraulic analysis, operations scenarios and operations data compatability. The outsourcing of these operational and commercial requirements to PEMEX, as well as the supervision of private transmission lines, make inbation validation critical. These operational/commercial validations are currently possible via the offline gas hydraulic modeling capabilities provided by PipelineStudio to the CENAGAS operational and commercial areas responsible for gas availability. Operations Modernization, Process Control, Optimization Oil & Gas Midstream (Pipelines, Terminals) Consultant, Operator, Engineer, Director Workshop Nestor Gonzalez CENAGAS Daniel Rubinestein Emerson - - - - - - - Decision Support & Data Management - -
3. Operate & Manage Approved DeltaV Logbooks streamline an internal communication in organization The company ZT Kruszwica SA, owned by BUNGE, is a leading producer of edible oils and margarines in Poland. Almost the whole process is controlled by DeltaV DCS. The system architecture is widely distributed over ten local control rooms. Shift and operation managers work in different, remote offices. A lack of consistent and efficient communication between operators and shift mangers happened to be a reason of some misunderstanding and various interpretations of past events. Issues were reported to automation manager who decided to implement a DeltaV Logbook solution. Since years of process modernizations and extensions, more and more tasks were assigned to shift and operation managers. It reduced a time available for a direct discussion and meetings. Operators spend a considerable part of work time on installation, out of control room. A lack of consistent and efficient communication built up to the main problem in organization. A successful DeltaV Logbooks implementation streamlined internal communication and reduced a risk of misunderstanding during shift handovers. Examination of past events is b, all needed data and operator entries are easy accessible for shift and operation managers also from office PC. A shift scheduler is available for every user, all work instructions and procedures are easy accessible. There was a market research made to find the best solution to resolve issues and streamline internal communication. DeltaV Logbooks was chosen as it offered the whole needed functionality. After Logbooks implementation, operators can create log entries, manage tasks, and collaborate directly with shift managers from a DeltaV operator station. All raports are legible and unambiguous. Operations Business, Maintenance, DeltaV Food, Beverage & Consumer Goods Engineer, Supervisor / Manager / Dept. Head, Operator Workshop Marcin Palacz ZT Kruszwica SA Ryszard Boron Emerson Process Menagement Sp z o o, Poland - - - - - - - Plant Operations Management - -
3. Operate & Manage Approved Kuwait Oil Company Increase Production Capacity Building New Facilities using CHARMS Technology. Kuwait Oil Company recently has constructed 4 new facilities through various EPCs with a total of 21,000 IOs (DCS+SIS) in different bs and overcame space constraint and challenging project schedule using DeltaV CHARMS based Electronic Marshalling technology as an approved ICSS solution "? Challenging Project Schedule with late engineering Inputs
? Highly reduced Footprint helped in early completion of shelters/Instrumentation related civil works drastically reducing project lead time.
? High Flexibility in incorporating late changes, IO type Change without space/timeline extension." "? Overcame challenging project timeline
? Faster hassle-free commissioning with DeltaV AMS and Mobile Worker
? Diagnostics and Monitoring of plant assets with DeltaV AMS
? Greater than 1M$ opportunity loss prevented per facility with faster startup time" Emerson has provided the assigned EPCs CHARMS based Electronic Marshalling technology and DeltaV AMS in line with KOC specifications and guidelines where it has overcome the schedule constraint providing KOC the aimed space saving. Also provided system is being designed on wireless ready concept where KOC can expand and deploy Plantwide various wireless solution in future. DeltaV AMS, Wireless, DeltaV Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Engineer Workshop Ali Al-Kandari Kuwait Oil Company Yash Bhatt Kuwait Oil Company - - Shailesh Wattamwar Emerson Process Managment Qatar W.L.L - - - Process Control - -
3. Operate & Manage Approved Continuous manufacturing for pharmaceutical products Eli Lilly’s work with continuous process and Process Analytical Technology (PAT) is changing the production bs used for pharmaceutical products. Traditionally, the products were manufactured in a batch process that was time consuming and included several different unit operations. These operations typically included dispensing, blending, blend laboratory analysis, granulation (if needed), tablet compression, and tablet laboratory analysis. The Continuous Direct Compression process utilizes advances in PAT and combines dispensing, blending, tablet compression and analysis, into a single process In the batch model, scaling up from small development batches to production batches had always been a challenge, primarily due to differences in the size of equipment between the development and production facilities. Additionally, in the batch process, if laboratory sampling determined that material was out of spec, the entire batch would have to be rejected. There is no scale-up for production because the continuous process utilizes the same equipment in both development and production environments, with difference in batch sizes only being a function of how long the process is run. The integration of the PAT enhances process understanding and allows the process to reject only the tablets that are out of spec rather than the whole batch. A Continuous Direct Compression process centered around a DeltaV control system was developed. The development of this process relied on expertise from industry leaders in each of the ber unit operations with DeltaV integrating these operations into a single process. Additionally, DeltaV provides a single operator interface and recipe management to run the process. DeltaV DeltaV, Process Control, Operations Pharmaceutical & Life Sciences Engineer Workshop Ronald Ruff Eli Lilly Companyh Steve Dyer Eli Lilly - - Alan Mohr Cornerstone Controls - - - Process Control - -
3. Operate & Manage Approved World’s first FLNG project on the fast-track with project certainty, for operational certainty PETRONAS, Malaysia’s national oil & gas company, set out to build a floating LNG (FLNG) plant in record time. As the world’s first FLNG vessel, changes could be expected as the design was not yet fully mature. Moreover, the b is remote and staff is limited. Vessel weight and space requirements had to be considered. System I/O was installed indoors. 584 transmitters were replaced with only 73. The architecture has flexibility to add devices and signals with little or no wiring. Device and wiring cost savings were achieved. There were many changes after FAT but they were easily handled allowing project to stay on the fast track with confidence. Already in the first few months device diagnostics saved several man-days of investigation. PETRONAS FLNG is the world’s first floating LNG plant to operate so no prior FLNG experience existed anywhere. Changes could be expected as the design was not yet fully mature so automation project needed flexibility to adapt to changes to move fast with confidence. Moreover, remote b with limited staff onboard requires automation letting them operate with confidence. Device and wiring cost savings were achieved. There were many changes after FAT but the flexibility of the architecture made these easy to handle to stay on the fast track with confidence. The floating plant has been in production since December 2016. Device diagnostics already saved several man-days of investigation for two level issues. Operators have greater confidence in digital readings. System I/O was installed indoors with bus power integral to H1 card. 73 multi-b temperature transmitters took the place of 584 single, no wiring or I/O needed for valve b feedback, flexibility to add devices without running long cables, and simply turn on more device I/O. Virtual remote seals instead of capillaries. Field indicators used extensively. Centralized device firmware update. DeltaV Engineering, PlantWeb, Foundation Fieldbus All / Cross-Industry Consultant, Project Manager / Lead, President / Principal, Plant or General Manager, Engineer,
