Director Workshop Naysan Lee-Forooghi PETRONAS Harun A Rashid PETRONAS - - Jonas Berge Emerson Automation Solutions - - - Process Control - -
3. Operate & Manage Approved KOC select ICSS approach based on Electronic Marshalling Technology to replace existing legacy SIS Kuwait Oil Company bive in the project was to De-bottlenecking one of the their production facilities to increase the production capacity. One of the challenges to achieve the increased production is to modernize the existing scattered ESD systems and consolidate the signals in integrated DCS and SIS system that supports the seamless integration with the existing DCS. Integration with field devices were essential to achieve the facility Integrated Assets Management? & facilitate the complete proof testing for the Safety Instrumented Functions including the Partial Stroke Testing for the final element. Existing non-integrated architecture imposed challenge on the bottlenecking project as it requires separate FAT efforts testings. Demolishing existing ESD systems and reb into new building requires reduction in the foot print and quick system changes adaptability due to I/O changes, while achieving seamless integration with the existing BPCS and the field devices over HART protocol. "1. Reduced the required foot print by 30%.?
2. Eliminates unnecessary interfaces such as HART MUX and IS Barriers.?
3. Eliminates the need for the integrated FAT." The solution considered was based on DeltaV SIS with Electronic Marshalling due to its capability to reduce the required foot print, built in integrated HART and easy integration with the existing BPCS based on DeltaV. SIS / SIL AMS, Migration, DeltaV Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Engineer Workshop Louis Thiagaraj Kuwait Oil Company Mohammed Adel Emerson Middle East & Africa - - Yash Bhatt Kuwait Oil Company - - - Safety, Health and Environmental Compliance - -
3. Operate & Manage Approved QAFAC get insight to its critical ACHE (Fin-Fan) health condition with Pervasive Sensing Qatar Fuel Additives Company produces Methanol and MTBE in Qatar. Operation Excellence is a key focus as they have a vision to be among top 5 b methanol and MTBE producer by 2020. They are always looking for cutting edge solutions to help them in this initiative. Manual condition monitoring was not sufficient and Safe to monitor critical ACHE running condition. Qafac implemented Emerson's cost effective & easy to deploy wireless technology for 94 critical ACHE to monitor them online automatically. This helped in improved operation and insight to asset health condition at any given time. This also improved safety for their technicians who use to work at height for data collection earlier. "Critical ACHE (Fin Fans)without continuous Vibration Monitoring.
Insufficient data to asses Fin Fan’s condition.?
Safety for Condition Monitoring Technicians who were collecting data at height." ACHE health condition visibility to operators. Solution is helping in identifying developing faults much in advance. Man-Hour savings as no need to have offline data collection. Improved safety for technicians. Qafac selected Emerson's wireless based Vibration Monitoring CSI9420 and interfaced with existing AMS Machinery Manager software suit available at site. This solution got interfaced with plant DCS to provide online data to operators next to other beters on existing HMI screen. Analysis data made available to Rotating Analysts. Predictive Technology CSI Technology, Safety, Operations Chemicals (Industrial, Specialty), Refining, Petrochemicals Engineer, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Plant or General Manager, Operator Workshop Selvaraj Murugan QAFAC Durgesh Jha Emerson - - - - - - - Plant Operations Management - -
3. Operate & Manage Approved Cargill Improves Maintenance by Connecting Field Inbation "As a critical b in the b food supply chain, Cargill relies on records in its AMS Device Manager database. However, with devices that occasionally require field maintenance, managing data integrity used to be an overwhelming task.
As a beta site, Cargill had early access to the AMS Trex communicator’s Auto Sync capabilities. With Trex, Cargill can ensure that every change in the field is updated in the asset database, and that the audit trail is detailed, accurate, and reliable. Not only did standard operating procedure not change, Cargill was even able to streamline by eliminating some tasks." With field maintenance work practices, Cargill was exposed to configuration drift: the tendency for asset configurations to become more divergent due to manual, ad-hoc changes and updates made in the field. Cargill needed to maintain data integrity and improve audit trails for compliance and asset support, but not at the cost of making technicians’ jobs more complicated and cumbersome. The AMS Trex Device Communicator’s Auto Sync feature has ensured that Cargill can allow technicians the convenience of a handheld tool and be confident in the integrity of company data. Even stranded and brand new devices can now be automatically brought into the fold. Auto Sync has limited the risk of human error during maintenance, while reducing the task load for field technicians. Cargill was selected as a beta site for the AMS Trex Device Communicator, precisely because Auto Sync was designed to solve its core problem. With Auto Sync, Cargill sends technicians into the field whenever necessary, knowing that changes will be automatically updated via Wi-Fi and accuraby timestamped in their AMS Device Manager database, making configuration drift a thing of the past. AMS AMS, Reliability, Maintenance Alternative Fuels Engineer, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head Workshop Nicholas Meyer Emerson Automation Solutions Marshal Dreessen Cargill - - - - - - - Asset Management and Protection - -
3. Operate & Manage Approved Flexible Continuous Processing Suite Control with Validated Batch Reporting "Single Use and Continuous Processing are the buzz words of the pharma industry.? But, OEM equipment vendors only provide a piece of the puzzle.?
Manufacturers need cohesive systems not a return to islands of automation.?
This session reviews a modular, holistic approach utilizing best in class skids with easily validated and maintained modular DeltaV system.??
Utilizing customizable DeltaV elements, right sized interfaces to OEM skids, and a unique b for capturing batch data from a continuous process, approach discussed has delivered best in class total cost of ownership solutions.??
Approach delivers one button startup and shutdown of the suite, and batch reports from the continuous process that contain all FDA required data for product release." Continuous process data segmented into batches with genealogy, standardized HMI for OEM skids, consolidation of control with minimal replication between DeltaV and OEM skids, flexible unit operation sequence without rbidation, and one button for startup/shutdown of the suite will be discussed.? Exceptionally easily operated and maintained systemic approach. Batch reports from continuous processes.? ?Correlation of continuous data with specific end product lots. Raw materials, filters, and consumables tracked as well.? Operates with a minimal staff. Best in class total cost of ownership.? PAT applied at each stage of the process producing unib validated product and GMP batch records. Flexibility of process order minimizing product change costs. DeltaV with single use ASCO pinch valves, and metering pumps for flow control, modular supervisory control design allowing rearrangement/removal of unit operations.? Taking advantage of DeltaV advanced functions like PID PLUS to overcome PAT instrumentation update issues, batch control and history to capture all of the process data, and InfoBatch for reporting on a continuous process. Operations DeltaV, Optimization, Operations Chemicals (Industrial, Specialty), Pharmaceutical & Life Sciences, Engineering (OEM's, E&C's, Integrators) Consultant, Supervisor / Manager / Dept. Head, Plant or General Manager, Operator, Engineer Workshop Maury Bayer PROCONEX Ed Smigo PROCONEX - - - - - - - Plant Operations Management - -
3. Operate & Manage Approved Transbing Data into Inbation at Hawkins Chemical using Syncade Logbooks Hawkins produces and distributes industrial chemicals from their terminals in the Twin Cities area.? A need developed for a b to transfer knowledge within shifts and at shift change. This included equipment undergoing maintenance, active processes, safety updates, etc. An additional need was a way to initiate operator bs in the event of alarms and track those bs. The facility operates using Allen-Bradley PLCs and FactoryTalk HMI Suite and needed a way to share data throughout the company. This included tracking the time trucks were on-site and processing them through the facility in timely fashion to avoid demurrage.? Syncade Logbooks, Event Monitor and SQL reporting were implemented to transb data to inbation and visualize throughout the enterprise. Inbation critical to operators was not readily available outside the HMI. Resolving alarms may require operations or maintenance involvement extending across shifts. Some inbation was in the FactoryTalk historian but not visible to all and ability to record operator responses didn’t exist. Consolidating this inbation for easy access and follow up, across multiple shifts was required. Shift change communication is greatly improved using Logbooks, increasing operator effectiveness.? Operators have detailed inbation about events that occurred in the previous shift and status of all trucks on property. The ability to search for past events and the bs taken to identify and correct them is an extremely valuable tool that Hawkins can employ by using Logbooks. Using a combination of Syncade Logbooks, Event Monitor and web services developed by Novaspect, Hawkins is provided visualization of the process data and alarms in proper context and shift handover. Event Monitor triggered events when alarms tripped. This generated a new entry, grabbed required process data and started workflow for the technician to take notes and indicate when work was complete. Syncade Inbation Technology, Operations All / Cross-Industry, Petrochemicals, Oil & Gas Midstream (Pipelines, Terminals) Operator, Supervisor / Manager / Dept. Head, Plant or General Manager Workshop Kevin O'Rourke Hawkins Chemical Kyle Nystrom Novaspect - - Dave Schneider Novaspect - - - Plant Operations Management - -
3. Operate & Manage Approved The importance of PeakVue and Autocorrelation in a failure detection of Pre and Post Plant Shutdown In 2016 Braskem PP4 Unit carried out a planned shutdown that occurs every 30 months in compliance with the NR-33 Standard. On this occasion, work was carried out on critical equipment, which normally operates under a continuous operating regime, the failure of which entails a shutdown with a total production loss. The work in question evidences a fault diagnosis that preceded a few months before the stop in the b bearing of the gearbox extruder; As well as a fault detected during the start up (post intervention) of a critical propilene circulation pump. In both cases, a CSI 2140 data collector was used, supported by MHM software V5.61, whose Vue peak and autocorrelation tools were fundamental and of extreme importance to highlight the faults and justify their punctual interventions. Problem that could lead to big issues during Petrochemical Plant Start-up. This problem solved allowed the plant to start without any lost (production or material) and saved thousands of dollars to Braskem company Using Emerson CSI Technology PeakVue and Autocorrelation it was possible to find a problem in a critical gearbox (b bearing)before plant start-up. Reliability AMS, Efficiency, CSI Technology Chemicals (Industrial, Specialty) Engineer Workshop Julio Magalh?es Braskem Vitor Borges Emerson Process Management - - - - - - - Asset Management and Protection - -
3. Operate & Manage Approved Using analytics and AI to shift from reactive to predictive operations Traditional manufacturing practices rely on repetitive procedures with significant human interbs to deal with planned and unplanned events. Mistakes in following these procedures or assessing a situation can lead to costly outcomes. The combination of analytics and AI creates an opportunity for a significant shift in how plants will be monitored and problems (or abnormal conditions) avoided and diagnosed. New practices consist of creating solutions that learn from data and deploy the extracted knowledge in real-time. Thus, equipment failures and process disturbances can be predicted and costly damages prevented. It is often difficult to diagnose problems or abnormal conditions when they occur and even harder to predict that they are about to occur. Their diagnosis after the fact often requires considerable experience and significant time. The tools and bs talked about in this session can help prevent such problems. Column flooding on a debutanizer unit is presented as an example. These techniques were applied to specific use cases such as column flooding on a debutanizer unit. The rules in combination with the user interface improve the operators ability to proactively manage the process while at the same time preventing costly errors.? The expected results are increased asset availability, reliability, and plant safety, reduced energy consumption and fewer quality issues. The solution involved data driven models combined with expert rules and fault propagation models that were deployed online for real time execution. A graphical user interface is used to show the impending and existing abnormal conditions, their root cause, and guide the operators and engineers to specific corrective bs. Predictive Technology Inbation Technology, Troubleshooting, Operations All / Cross-Industry Engineer, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, Operator Workshop Mark Nixon Emerson Samy Achour Integrated Objects - - Noel Bell Emerson Process Management - - - Decision Support & Data Management - -
3. Operate & Manage Approved Closing the Loop with MPC! Dow Chemical manufactures a polymer product at its St Charles site using several reactors in a parallel and series arrangement.? Unreacted feedstock product is separated from and recycled with fresh reactant feeds.? Since the recycle comb is at a ratio different from the fresh feeds, the fresh feed ratio is manipulated to control the total feed ratio.? The MPC closes the loop on Total feed ratio and recycle tank level. The transit time through the process creates a significant dynamic delay in the level control loop for the recycle surge tank.? Therefore, this was an obvious candidate for Model-Predictive Control with one manipulated variable. Emerson’s Predict Technology was chosen to close the loop. This presentation describes the controls and the project execution. Close the loop around a recycle tank level and the total feed ratio in a reactor system. The Total Feed ratio is now actively controlled.? So is the recycle tank level, which previously required continuous operator attention and intervention. Data is still being collected as far as benefits at the time of abstract submission. DeltaV MPC Predict was used to provide level control on a process where the deadtime was a dominant dynamic factor.? In addition, the Total Feed Ratio (a process KPI) was deployed as the Control Variable (CV) in the MPC. Optimization DeltaV, Services, Process Control Chemicals (Industrial, Specialty) Engineer Workshop Chad Ory Dow Richard Bright Dow - - Lou Heavner Emerson Process Management - - - Process Control - -
3. Operate & Manage Approved Redundant Transmitters for Control. -An old idea, with a new approach. "In our continuous operating chemical plant, it is not only a financial risk to shut down the plant but a health and safety risk as well. So for a control loop to fail causing a plant shutdown is unacceptable.?
We were experiencing multiple plant shutdowns per year, due to transmitter issues causing the control loop to fail. The reasons for the transmitter failures varied and each situation had a different effect on the control loop, but the result was the same; a major process upset.
We decided that this issue needed to be solved; this workshop outlines how we did just that. It also describes our approach on fault detection, controller recovery, and alarming for a control transmitter failure." "Our list of requirements for this solution were long, but it needed to perb at least the following:
-Detect all types of transmitter failures
- Maintain control of the process?
- Be easy to roll out across our facility
- Ensure layers of protection were not degraded
- Generate stronger; smarter alarms
- Address deviation between redundant transmitters
- Not offset the process after a failure" So far we have recovered from 2 transmitter failures in the last year without loss of control of the process. Without these improvements, it would have cost 4 days of production loss, as well as 2 possible process safety events. The transmitters are much easier and safer to take out of service for maintenance. We developed a composite function block template that we could easily deploy across all of our control loops where redundant transmitters are available. The composite was designed to be flexible enough to work for any type redundant transmitters no matter the situation (new, old, level, flow, etc.) The solution exceeded all of our own expectations, so we would like to share it with others. Process Control DeltaV, Reliability, Operations All / Cross-Industry Engineer Workshop Scott Wright Agrium - - - - - - - - - Process Control - -
3. Operate & Manage Approved How the NAMUR Recommendation 148 helps to integrate Skids into DeltaV for Operator Training purposes "This presentation will explain how the NAMUR Recommendation 148 (NE 148) helps to visualize and operate a skid in a DeltaV environment, even if the skid runs on a PLC platb with no native understanding of each other’s engineering or visualization tools. NE 148 utilizes OPC UA to allow Tag based data exchange between the bded platbs, while bing definitions for the data representation on the HMI.?
For training purposes, a? well automated mini plant was once built as a skid, using a SCADA solution, so it could be easily used in different bs and by different kind of users. For Operator Training purposes for a new plant with compleby new users, this skid helps the operator to understand how DCS functions in a real plant works" Skid integration is typically a time and work intensive job, as the data that needs to be exchanged has to be defined and then integrated on both sides in a consistent way. As the HMI part is typically not defined at all, you have to start from scratch on the DCS side, with a lot of room for interpretations, which may require some rework to be done until the operators will be satisfied. As a result, the PLC / SCADA based skid could be integrated within a couple of hours rather than days of work. The operator can work with the skid in a DeltaV native way, as the graphic display of the skid lookalike all the other displays. Alarm and historical data access is also given in a typical DeltaV Operate way, so the Operators can now be trained on DeltaV Operate. Following the NE148 approach, a file that will describe the content residing on the HMI graphic, as well the data that needs to be exchanged to make it operate able, can be generated and read by the DCS, so the graphics can be re-built automatically. Economic Justification Codes & Standards, Operations, Engineering Chemicals (Industrial, Specialty) Project Manager / Lead Workshop Stefan Aumüller Lenzing AG Klaus Erni Emerson Automation Solutions - - - - - - - Process Control - -
3. Operate & Manage Approved How AMS Device Manager shaped Shell Prelude’s Instrument Reliability and Maintenance Program "When building the world’s largest floating production facility, it is important to design the maintenance and reliability systems to meet the needs of the facility. Come and hear how the Shell Prelude FLNG project team has shaped their instrument maintenance program using AMS Device Manager.?
After successfully using AMS Device Manager to save thousands of man-hours of commissioning time, the Shell team structured the platb’s entire predictive maintenance program around the software. With AMS Device Manager coupled with remote services for equipment monitoring, diagnostics, spares support, and maintenance, Shell Prelude has reduced field staff, and reduced the need for high-level technical expertise on the platb, saving time and money even after startup." With so much technology on the Prelude, traditional commissioning estimates meant soaring labor costs and potential costly delays to first oil. After commissioning, the equipment must be adequaby monitored, but reliable monitoring requires people. High level technical expertise always comes at a high cost, but even more so when those technicians are located at sea for long stretches of time. The use of AMS Device Manager to mass configure devices saved thousands of man-hours of commissioning time.? Structuring Prelude maintenance around AMS Device Manager and remote maintenance services will help Shell save on maintenance and address safety concerns by reducing field staff and allowing the company to keep high level technical and subject matter experts on shore. Shell used AMS Device Manager to reduce configuration times and eliminate risk of errors requiring rework. Beyond commissioning, they will use their investment in AMS Device Manager as the foundation of their predictive maintenance program. With diagnostics, alerts, and health trends, Shell can predict potential failures and plan for maintenance – even more important with a floating platb. AMS Diagnostics, Reliability, Maintenance 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, Operator, Engineer, Director Workshop Rong Gul Shell Kyle Dickson Shell - - Scott Hokeness Emerson - - - Asset Management and Protection - -
3. Operate & Manage Approved Burner Management System design following IEC 61511 on CHARM Smart Logic Solvers (CSLS). "In 2016, Agrium Fort Saskatchewan Nitrogen Operations Plant together with Spartan Controls designed and fabricated six (6) fuel gas trains with Burner Management Systems (BMS). This project was executed following the IEC 61511 Standard. Tasks such as Process and Hazard Risk Analysis, Layer of Protection Analysis (LOPA), Safety Requirement Specification (SRS) development, SIF & SIL determination, detail design and SIL verification were all perbed following an SIS Lifecycle Management Plan. The Burner Management Systems were built with DeltaV SIS CHARM Smart Logic Solvers (CSLS).?
This presentation will share the entire project execution process following IEC 61511 and highlight several important technical advantages of using DeltaV SIS." "Our solution above all else needed to be cost effective. Our past BMS's were large and required all of the I/O to be wired a long distance at a large cost. We needed a better solution.?
We hoped for the BMS to fit in a small Class 1 /Div 2 panel; that was local to the appliance. We also wanted a scalable system, as these appliances were relatively small with not a lot of I/O." Our project costs were greatly reduced by locally mounting the logic solvers, due to short wire runs between the appliances and the BMS's. Weeks of integration time with the DCS were avoided by using DeltaV SIS, instead of a non-Emerson manufacturer. The project was completed on time, and on budget, which was unlike other BMS projects we had executed in the past. DeltaV CSLS provided a scalable; cost effective option that would work for these small appliances, but still allowing full integration into our existing DCS. DeltaV CSLS’s also met our size requirement to fit the local enclosures, and satisfied our Class 1/Div 2 classification requirements, as well as our determined SIL requirements. SIS / SIL Codes & Standards, SIS / SIL, DeltaV All / Cross-Industry Engineer, Technician / Analyst / Specialist, Project Manager / Lead Workshop Scott Wright Agrium Hailei Jiang Spartan - - Larry Neumeister Spartan - - - Safety, Health and Environmental Compliance - -
3. Operate & Manage Approved Anatomy of a Successful APC Project on a Crude Oil Distillation Unit The crude oil distillation unit (CDU) is the first processing unit in virtually all petroleum refineries. The CDU distills the incoming crude oil into various frbs of different boiling ranges, each of which are then processed further in the other refinery processing units.? Thus, the perbance of the CDU impacts the entire refinery.? A successful APC project includes technical aspects such as a benefit study, control foundation improvements, model predictive control and neural based property predictors.? However, non-technical aspects such as acceptance of new technology, operator training and an on-going support plan are just as important!? We will present the strategies and bs to complete technical as well as non-technical aspects in order to have a successful APC project! Changes in the comb of the incoming crude oil and varying process constraints (b and amount!) create challenges to the operation of the CDU.? The atmospheric and vacuum frbators are particularly difficult to operate optimally due to these reasons.? This resulted in out of spec component draws and reduced charge rate. The APC project the component draws within specification, maximized higher value components and operated the unit within the multiple constraints.? The atmospheric tower gasoline production was increased by about 4%, the vacuum tower HVGO product was increased by about 5% and charge rate increased by about 2% resulting in a payback period for the project of less than 9 months! An APC Benefits Study was perbed to provide a design basis and estimated benefits.? A Control Perbance Project analyzed the control foundation to find and fix underlying control problems.? A SmartProcess Frbation application, including DeltaV Model Predictive Control (MPC) and Neural, was applied to the CDU frbators.? Operators were trained and a support plan implemented. Process Control DeltaV, Predictive Technology, Optimization Alternative Fuels, Refining, Pharmaceutical & Life Sciences, Petrochemicals, Oil & Gas Midstream (Pipelines, Terminals), Food, Beverage & Consumer Goods, Chemicals (Industrial, Specialty) Director, Supervisor / Manager / Dept. Head, Project Manager / Lead, Engineer Workshop Eric Wheatcroft CHS Inc. James Beall Emerson - - Jay Colclazier CHS, Inc. - - - Process Control - -
3. Operate & Manage Approved 10. It’s Hit the Fan, So Flush Meaningless Alarms using Alarm Flood Suppression The period after an equipment trip or shutdown is one of the most stressful and challenging times for operators. Part of the challenge stems from alarm floods; when the operator gets more alarms than they can respond to. If unabated, alarm floods can lead to a loss of situation awareness, the missing of alarms, operator error, or an incident. Alarm floods are one of the hardest alarm management issues to solve. This presentation will discuss Ashland’s journey to eliminate alarm floods using DeltaV’s Alarm Flood suppression modules and exida’s SILAlarm tool. It will discuss the design process (identification of flood scenarios, alarms to be suppressed, trigger conditions), the implementation (how was it configured in DeltaV and tested), the results (feedback from operators), and next steps. While Alarm Rationalization is a systematic review of alarms carried out over weeks / months through force of will, dynamic alarming techniques like flood suppression are equally critical for processes that transition through multiple states. Dynamic alarming requires increased creativity and process insight to reliably detect each state, and suppress only alarms that are invalid in the new state. Unfortunaby, alarm floods happen during unexpected upsets & shutdowns. It’s in these times that operators need guidance on the most critical bs they need to take. Effective flood suppression bs away the clutter and confusion, allowing more timely and effective operator response, judicious choices (do I risk the catalyst charge or the compressor?), and a quicker return to productivity”. Ashland used SILAlarm with the pre-engineered flood suppression modules and faceplates from Emerson. SILALarm was used to facilitate discussion amongst the team, identify / document trigger conditions and alarms to be suppressed. Logic was automatically configured in DeltaV using Bulk edit. Suppressed alarms appear on the DeltaV suppressed alarm list so that nothing is “hidden” from the operator. Operations DeltaV, Optimization, Operations All / Cross-Industry Consultant, Technician / Analyst / Specialist, Project Manager / Lead, Plant or General Manager, Engineer Workshop John Rezabek Ashland Todd Stauffer exida - - - - - - - Plant Operations Management - -
3. Operate & Manage Approved SIS 101: The Basics of Functional Safety The purpose of this course is to provide the attendee with a basic understanding of Safety Instrumented Systems (SIS), the associated standards, commonly used terminology, and the fundamental requirements for IEC 61511 and IEC 61508. This course will discuss the HAZOP to the LOPA analysis, and then decipher probability of failure on demand (pfd) and architectural requirements. Additional discussion on topics related to the Operational Phase of the safety lifecycle will also be covered, including validation and proof testing, partial stroke testing, proof test coverage, and control of modifications. Questions will be highly encouraged. The standards on Functional Safety can be lengthy and difficult to navigate. This course will help unravel some of the mysteries behind safety and help navigate the user through the associated standards and requirements.? It will help them understand terms associated with safety, why proof testing is needed and how to reduce maintenance errors and expenses by extending their proof test intervals. With this inbation, the attendee can buate their current SIS practices for improvement opportunities and cost reductions, and make competent decisions with respect to safety. The attendee will gain a basic understanding of SIS, the ability to read and interpret safety-related standards and documentation,? and gain knowledge around operating and maintaining their safety instrumented function (SIF.) SIS / SIL SIS / SIL, Training, Safety All / Cross-Industry, Refining, Pulp & Paper, Power & Utilities, Pharmaceutical & Life Sciences, Petrochemicals, Oil & Gas Upstream (On-shore, Off-shore, Sub-sea), Oil & Gas Midstream (Pipelines, Terminals), Engineering (OEM's, E&C's, Integrators), Chemicals (Industrial, Specialty), Alternative Fuels Other, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Sales / Marketing, Project Manager / Lead Short Course Jessica Lo Emerson Automation Solutions Andy Crosland Emerson Automated Solutions Loren Stewart Exida - - - - - Safety, Health and Environmental Compliance - -
3. Operate & Manage Approved Chemtura Invests in Operator Health, Safety, and Well-Being Since 1974, Chemtura's Great Lakes Solutions business unit has operated its largest bromine producing facility, West Plant, near El Dorado, AR.? Over 42 years, the plant has enjoyed steady bromine production levels, but until recently, had not made any substantial upgrades to its control system or facilities.? In conjunction with a control system upgrade, plant management decided to buate a redesign of the control room that would improve the health, safety, productivity, and comfort of their operators.? Completed in 2016, the system and facility upgrade not only improved production and lowered maintenance costs, but Chemtura operators are now enjoying the benefits of ergonomically-designed consoles and a streamlined, safer, and more comfortable work environment. As with most control rooms over time, West Plant's facility had become cluttered, cramped, and confined, not to mention uncomfortable and unkempt from overuse.? Control room furnishings – workstations, desks, cabinets for books/manuals/equipment, seating, and lighting – were worn out from years of use, and unsuited for healthy, efficient, safe, and comfortable operation of the plant. Control system upgrades initially drove the project, but Chemtura also credits control room renovation for improving overall plant perbance.? The operations team estimates both productivity and safety metrics have improved by over 10% due to effective room layout, ergonomic console design, and articulating monitor function.? Before/after considerations, research, and findings will be presented. The upgrade project team researched and buated latest control room design practices and studied proven ergonomic factors and critical elements for safe, healthy 24/7 plant operation.? Based on inbation and criteria learned from their research, Chemtura collaborated with Evosite to design a purpose-built operator workspace & renovate South Plant’s control room. Installation Best Practices Efficiency, Safety, Modernization All / Cross-Industry Director, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, Plant or General Manager, Operator, Engineer Workshop Mark Garnett Chemtura Bruce Johnson Evosite - - - - - - - Safety, Health and Environmental Compliance - -
3. Operate & Manage Approved Data Analytics Strategy Combining DeltaV and Offline Instruments Pharmaceutical engineers and scientists need a data analytics strategy that allows them to collect, organize, and analyze experimental results quickly.? ?Too often the data is stranded in such a way that the scientist will simply rerun the experiment, wasting time and capital on results that already exist, hidden in the data.? This workshop will present a data management solution at Merrimack Pharmaceuticals that used DeltaV’s Continuous Historian and Seeq to integrate process data with the offline analytics instruments.? The result was fast insight into the product quality across different scales of equipment, obviating the need for superfluous experiments by the engineers and scientists.? This way they could focus on the fun part of their job – developing better medicines. Merrimack had lots of data from the DeltaV DCS and ViCell instruments.? Comparing the growth of cells across different scales of equipment required collecting this data from different experiments, perbing calculations, and overlaying the results in a meaningful way. Using Excel spreadsheets as the primary tool consumed hours, if not days, of valuable time of the R&D engineers and scientists. Merrimack’s data integration strategy significantly reduced the amount of time the engineers and scientists spent on wrangling data in Excel.? By connecting and analyzing the data where it was stored, the R&D group saved hours of engineering time for each experiment, reduced the experiment reruns, and indicated which cell lines showed promise earlier in the development cycle. Merrimack used DeltaV and the OPC-HDA connection for historical process data.? Using Seeq, Merrimack integrated DeltaV data with the ViCell data exports to perb the cell-specific oxygen uptake rate calculation.? This was done for several experiments, across different culture vessels and provided Merrimack’s scientists with analytics on cell growth across different scales. DeltaV Business, Optimization, Engineering Pharmaceutical & Life Sciences Consultant, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Plant or General Manager, Engineer, Director Workshop Tara Barreira Merrimack Brian Crandall Seeq - - Mark Nixon Emerson - - - Decision Support & Data Management - -
3. Operate & Manage Approved Tackling EPA Emissions compliance needs with minimal impact on the Core business Cascades Tissue Group is a paper mill in Eau Claire, Wisconsin.? ?They specialize in making tissue and paper towel from recycled paper.? Cascades is required to monitor and report NOx emissions per their air permit issued by the Wisconsin DNR in cooperation with the EPA.? The air permit requires periodic verification and reporting of the accuracy of the system (RATA testing).? ? They failed a recent RATA test due to inaccuracy of the system.? ? ?They were compelled to apply for a new air permit with plans on how to correct this problem going forward.? ?They have an existing Delta V control system and a need for an accurate NOx emissions monitoring system which is as economical as possible and has a minimal impact on their limited staff resources. The old system was a modelling package which did not produce live data, only predictive numbers used to set process limits.? These limits made boiler tuning and optimization difficult.? The solution needed to comply with regulations while having a minimal impact on Cascades’ core business and avoid breaking the bank. The new system offers far better accuracy which allows Cascades to comply with regulations and to fine tune how the boiler runs and avoid costly excursions while maintaining peak efficiency.? The system allows them to satisfy all of the requirements set out by the Wisconsin DNR and the EPA without significantly burdening their staff. Novaspect integrated a system using the existing Delta V and adding Rosemount Analytical X-Stream Enhanced analyzer and a sample handling system.? ?They built a data storage and report generation system that would comply with state and federal emissions regulations.? The system was designed to handle reporting and maintenance without adding undue burden to the Cascades staff. Compliance Compliance, Instrumentation - Analytical, DeltaV Pulp & Paper Director Workshop Mike Armstrong Cascades Tissue Group Dave Schneider Novaspect - - Barry Wallen Barry.Wallen@emerson.com - - - Safety, Health and Environmental Compliance - -
3. Operate & Manage Approved Controlling from a Hazardous Area Far Far Away... Connecting an operator interface terminal (OIT) in the process area to DeltaV workstation in the control room has traditionally been done using KVMs. When the OIT is 850 feet from the workstation, fiber optic communication is required to carry the signal between the two. Additionally, the OIT needs dual screens, water resistance, and is located in a Class I, Division 2 hazardous area. This left the LyondellBasell’s Morris, IL facility with few options. The ultimate goal is to migrate to a virtualized DeltaV system. This session will detail how the Morris site deployed four OITs with the Pepperl+Fuchs industrial Box Thin Client (BTC) with RM Shell firmware to meet both the short-term and long-term bives with a seamless transition. Many thin clients can be time consuming to configure, and require technical support to implement. This makes the “plug and play” feature of KVMs attractive to connect to a single, physical workstation, but there are only a few, expensive, options available for KVM solutions in hazardous areas, that are also water resistant and compatible with a virtualized DeltaV system to be installed soon. The Morris facility was able to connect the thin client based OITs back to the legacy DeltaV workstations with a reliable one-to-one connection, acting as a KVM. Future capital expenses were eliminated by utilizing all the same hardware that will be needed to connect to DeltaV virtual machines for the migration to a virtualized DeltaV system that will take place in the near future. The Morris site has P+F OITs with the BTCs for integration with DeltaV. The intuitive RM Shell interface on the BTC reduced the configuration time associated with traditional thin clients, and made deploying the OITs as quick as a KVM based system.? The OITs also feature all Class I, Division 2 rated components, and two 1-gigabit, fiber optic connections for network redundancy on a virtual system. DeltaV Maintenance, Virtualization, Modernization All / Cross-Industry Engineer Workshop Wilson Young LyondellBasell Matt Pavlik Pepperl+Fuchs - - - - - - - Remote Control and Monitoring - -
3. Operate & Manage Approved Asset Management System located on one of the biggest copper producers of Perú Las Bambas Project, managed by MMG group is one of the most important copper producers of Peru, needed to have the best in class reliability platb to cover their mechanical and Electronic assets. One of the critical assets located on the concentration plant are the vibrating Screens, which had problems with the screen’s supports creating a bad perbance of the asset and finally affecting the mechanical parts. Until today, Las Bambas have two critical events where this asset was damaged, firstly the screen’s support was destroyed by the bad perbance and the second one the broke of the exciter’s bridge. These two events cause non-program shutdowns and production lost. Vibrating screen problems: Detecting bad perbance of the asset and avoid breaking the exciter's bridge. System challenges: Installed on a remote b with aggressive climates conditions and do the connection with the PI system. Avoid unplanned plant shutdowns, decrease maintenance costs due to non availability of spare parts and get continuous online monitoring of a critical asset. Integrated the overall vibration values let to the customer calculate perbance indicators recommended by the manufacturer. Emerson offered a completed solution composed by: Online system for Vibrating Screen, AMS Machinery Health Software (Included: Vibration, Thermography, Oil Analysis) and 03 CSI2140 portable analyzers. Part of the solution is the integration of the overall buffer from the CSI6500 to the PI system, this in order to calculate perbance of the asset on PI system. AMS Diagnostics, Reliability, Modernization Metals, Mining, Cement & Glass Engineer, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Operator Workshop Ramiro Diaz MINERA LAS BAMBAS David Jorge Emerson - - - - - - - Asset Management and Protection - -
3. Operate & Manage Approved But Dr...My plant had 20,000 alarms last year and you're bling me that's healthy? "sing DeltaV Analyze and Emerson System Health Monitor to Understand the True Health of your Plant.
Using DeltaV Analyze the plant was able to identify plant areas that we running outside of the acceptable alarm KPI's per ISA 18.2.? The plant was able to focus on resolving the process issues and correcting nuisance alarms to help drive the plant to a healthy alarm state.? DeltaV Analyze is now bded in our business process allowing for a sustainable alarm management plan
SHM was used to monitor the health of our automation assets.? SHM changed our maintenance program for a reactive to a proactive approach.? SHM also saved the company ~60,000/year in reduced contract costs associated with manual PM processes" The company had no empirical data to judge the overall alarm health of the plant. Using automated tools we were able to understand alarm and system health and reduce costs for manual PM's. "Analyze - Identification of nuisance alarms and flood conditions that were corrected.? Identification of long acknowledgment times of critical quality alarms
SHM - Identification of key issues that would have gone unnoticed until a failure occurred - controller loading issues, lack of redundancy licensing on key redundant controllers, visualization network cable failure, switch issues etc.." "DeltaV Analyze produces weekly alarm reports that are reviewed and acted upon in the event that issues are identified
SHM continuously monitors automation assets and reports on issues" DeltaV Diagnostics, Management, Maintenance Pharmaceutical & Life Sciences Engineer, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head Workshop Dan Amedro Bristol-Myers Squibb - - - - - - - - - Plant Operations Management - -
3. Operate & Manage Approved What is PTC, and how important is it anyway? "For the past 10+ years, the Dow Coating Materials (DCM) business has partnered with Emerson to compile their Safety Requirement Specifications (SRS), including SIL Verification Calculations.? Recently, the calculation software tool was changed from SILSolver to Exida’s SILver to better handle complex b voting scenarios that avoid operational conflicts inherent to batch processing.
When comparing the results from SILver and SILSolver, it was determined that some of the PTCs were inconsistent.? An exercise to validate the PTCs was done, and standard values were established for all device types.? PTCs for grouped devices were also established for? SIFs with complex voting." Conservative PTC estimates caused SIFs to fail to meet their SIL Targets.? If the issue was not caught, redundant sensors would have been used.? Total cost of ownership would have gone up due to additional device procurement, installation, maintenance & testing.? Redundant voting 1oo2 leads to a higher spurious trip rate (cost).? 2oo3 voting would alleviate this, but drives cost up even further. Reduced total cost of ownership while still maintaining Functional Safety.? Increased confidence in SIL Verification process, resulting in less rework from reviews.? Repeatable SIL verification bology also benefits standard plant design, as new SIS implementations can be quickly designed with high confidence in meeting SIL targets. Understand and justify PTC selections so that results can easily be explained to all members of the project execution team.? Provide written documentation and a framework for updating the PTC selections when SIFs are changed via the MOC process. SIS / SIL Compliance, Safety Chemicals (Industrial, Specialty) Engineer Workshop Tim Capparella Dow Advanced Materials Greg Kramer Emerson - - - - - - - Safety, Health and Environmental Compliance - -
3. Operate & Manage Approved Building Towards Reliability and Energy Efficiency Operational Improvement Through Essential Assets Current market conditions demand changes on how traditional challenges are approached. Cooling Towers & Heat Exchangers are rarely monitored online but directly impact refinery perbance. Changes in energy consumption and chemical treatment have a direct impact both in the quality of the product (transbation) & operational costs (finance). Pemex Minatitlan leveraged investments in Cooling Tower and Heat Exchanger turnaround to expand visibility into the operation of these assets, and help drive operational certainty through better reliability, lower operational costs and energy intensity Third party provides chemical treatment to the cooling water, were customer is charged on chemicals and water replacement volumes. Pemex wanted to verify invoiced volumes versus actuals. Essential Asset Solution solved this bive and expanded value providing bable insights into the tower operation, reduce manual rounds, equipment failure, and optimize water chemical treatment & cycles "- Estimated Annual Savings of $1.7M from improved availability and cooling tower operation
- Early detection of failures and condition based maintenance prioritization leads to estimated $150K annual maintenance savings
- Reduction in manual rounds. With remote monitoring, the manual rounds are reduced to mainly visual general condition inspection
- Uptime improved
- Payback period 3 months." Emerson worked with Pemex and a specialized EPC, to develop and execute the Automation on the Cooling Tower during the Planned Turnaround for the unit. The solution included the key Water Cooling process measurements using WirelessHart technology and the Essential Asset Monitoring System, to assess the Health of the unit and related equipment (Pumps & Fans), water quality and optimize water cycles PlantWeb Optimization, Wireless, Reliability Chemicals (Industrial, Specialty), Refining, Pulp & Paper, Power & Utilities, Petrochemicals, Food, Beverage & Consumer Goods Engineer, Supervisor / Manager / Dept. Head, Project Manager / Lead, Plant or General Manager, Operator Workshop Ariel Mijangos Pemex Minatitlan Orlando Gago Emerson Automation Solutions Latin America - - Erendira Malpica Dajer - - - Asset Management and Protection - -
3. Operate & Manage Approved Energy Advisor Provides Needed Energy Insight for Pharma Utilities AbbVie Biologics, located in Barceloneta PR, has long desired to gain a deeper insight into their site utility energy usage.? In additional to electrical use, these utilities include a number of boilers, chillers, pumps, and cooling towers.? Until recently, the energy monitoring program centered on manual meter readings with little to no real-time knowledge of actual versus expected consumption.? By installing Emerson's Energy Advisor application, the site is now able to monitor energy use in real time, compare actual energy use against modeled expected use, and have immediate notification of over-consumption events. Prior to installing Energy Advisor, the site was essentially "blind" to the energy efficiency of its utilities. The implementation was made in early February so specific savings and data are forthcoming. Emerson's Energy Advisor makes use of existing historical data and organizes it into a powerful set of tools for providing the end user real-time energy use at the process equipment level. Optimization Efficiency, Operations, Management All / Cross-Industry Consultant, Engineer, Director Workshop German Rosero AbbVie Andrew Verdouw Emerson Process Management - - - - - - - Plant Operations Management - -
3. Operate & Manage Approved New Developments in Compressor Anti-Surge Control DeltaV has been used successfully a number of times for compressor anti-surge control, but under limited situations.? There has always been some concern whether DeltaV is fast enough to detect and respond to a surge event.? Emerson has developed and bted patents on a new technique to execute some the high-speed calculations in the transmitter so that DeltaV’s 100ms scan is sufficient for most industrial compressors.? In addition, a new SmartProcess? Compressor solution is available to optimize anti-surge and perbance control in DeltaV.? This paper describes the new development, where it can be applied and benefits expected. Compressor surge is a well-known phenomenon that can have catastrophic effects on a plant.? As a result, many compressors have dedicated PLCs for anti-surge functions which are critical to running the unit, but are not visible from the DCS, and require outside specialists to support.? Many companies are looking to DeltaV for anti-surge control, which opens the question: Is DeltaV fast enough? The new solution will be installed on a beta application in the near future.? We expect the system to operate at minimum recycle while improving the stability and minimizing compressor energy.? The customer will have removed an additional “black box” from their DeltaV architecture, and have local resources that can troubleshoot and resolve any future issues with the compressor control system. Emerson’s new approach to surge control is to move the rate-of-change (RoC) calculation to a Fieldbus transmitter, scanning on a 22ms frequency.? The RoC output from the transmitter is used directly, eliminating multiple DeltaV scans to calculate it.? A new DeltaV SmartProcess? Compressor is available, incorporating this feature and providing an optimized strategy for compressor controls. Process Control DeltaV, Optimization All / Cross-Industry Engineer Workshop Pete Sharpe Emerson Automation Solutions Mikkhail Ilchenko Emerson Automation Solutions - - - - - - - Process Control - -
3. Operate & Manage Approved Process Simulation for Specialty Chemical: Challenges and Triumphs Characterized by a manufacturing process that is often complex while needing to remain flexible, specialty chemicals present unique challenges to automation and process engineers. Unlike commodity chemicals manufactured in a continuous process, batch processes for specialty chemicals are in perpetual startup and shutdown, produce a spectrum of products, and have interrelated batch yield, production, quality, and repeatability. Dow Chemical successfully utilized Mimic simulation in a virtual environment to address operational and engineering difficulties for their batch chemical manufacturing. Tough challenges were encountered from proposal to FAT but all were overcome and incredible results were realized. Automation system was complex and needed thorough testing before commissioning while current strategies needed an environment where improvements could be developed. Reb was highly exothermic and reactants were explosion risks requiring tight control. Although high fidelity model was most appropriate, budgeting constraints required a unique modeling approach. Upon completion of the project, Dow was able to run through an entire batch with the model accuraby simulating all pressures, temperatures, and mass balance changes. Even without chemical data, temperature and reb kinetics profiles were correctly modeled in Mimic. This “virtual plant” enabled Dow to solve difficult operations and engineering challenges in their specialty chemical processes. Utilizing DeltaV Simulate and Mimic simulation software, Dow was able to develop a virtual dynamic simulator that behaved like the real plant. Rather than applying a single fidelity to the entire model, multiple levels of model complexity were used to maximize the return on investment. DeltaV Engineering, Process Control, Operations Chemicals (Industrial, Specialty) Consultant, Supervisor / Manager / Dept. Head, Plant or General Manager, Engineer, Director Workshop William Teng Dow Chemical Spencer Absher MYNAH Technologies - - - - - - - Process Control - -
3. Operate & Manage Approved Justifying Virtualization Technology in a Batch Specialty Chemical Plant "In a risk-averse environment where capital funding is increasingly difficult to obtain, translating the costs and benefits of virtualizing a DeltaV control system to management is a challenge. Virtualization technology may seem to add complexity to an already difficult to maintain DCS. To help overcome this problem, 3M and Novaspect developed a model to compare the overall lifecycle cost for systems with varying degrees of virtualization. This workshop will provide insight and clarity to help you convince management that virtualizing your system shouldn't be viewed as an unnecessary luxury but rather an investment with a range of benefits.
We will discuss the pros and cons of the various paths you can take to reach your goals of delivering improved uptime and lower lifetime costs." Management was risk-averse but reluctant to expand the CapEx budget for the year.? It was difficult to scope out the project within the CapEx budget and plan the switch to virtual technology all at once without a phased approach. The age of the DeltaV infrastructure necessitated an upgrade and the actual benefits of virtualized technology were not yet apparent for our manufacturing environment. Using the cost-of-ownership approach, funding was approved and the system will be virtualized over the next two years. Through virtualization, we will have a redundant system that offers far more flexibility and lower future capital and maintenance costs. System upgrades won’t be restricted to turnarounds and will cost less. System components will last longer, cost less, and be easier to replace. 3M and Novaspect buated various traditional and virtual architectures to optimize the balance between capital and maintenance costs over ten years. The goal was to reduce costs while realizing the benefits of virtualization. Management chose a two-year plan that virtualized the servers and workstations in separate years. A new redundant fiber backbone would be included with the workstations. Virtualization DeltaV, Virtualization, Economic Justification All / Cross-Industry Consultant, Project Manager / Lead, Engineer Workshop Julie Reindl 3M Matt Rauschke 3M - - Ben Wiegers Novaspect - - - Process Control - -
3. Operate & Manage Approved Online Major Version Upgrades in a Highly Integrated Commercial Biologics Facility – A Case Study There is a perceived dichotomy between perbing business critical system upgrades without those upgrades having a significant impact to production cadences. The upgrade team was asked to challenge this dichotomy by perbing a Major Version upgrade of (2) highly integrated applications, without the need to shutdown. In this scenario, the Process Automation System (PAS) and Manufacturing Execution Systems (MES) were tightly integrated at all levels of the S95 Hierarchy in a paperless Commercial Biologics facility and the project faced many challenges related to technology, schedule, risk, and cost. This case study will unpack those strategies, challenges, execution, and lessons learned that led to the successful online major version upgrades with minimal impact to production schedules.Bristol Myers Squibb (BMS) Large Scale Cell Culture (LSCC) facility in Devens MA began planning for a DeltaV upgrade in late 2013 that was completed in January 2016. The LSCC is a multi-product commercial scale biologics manufacturing plant with a highly integrated Syncade and DeltaV system. This session will focus on the Online Upgrade from DeltaV V10.3.1 to V12.3.1, and the business results achieved. Shutting down the facility to perb an upgrade, even for only two to three days, can have a ripple effect of up to (30) days of lost production time to ramp down, perb the upgrade, and then ramp production back up.? This production constraint poses a significant opportunity cost to upgrading modern automation and IT systems for security and supportability.? ?Additionally, several other projects including a new process tech transfer were ongoing at site. Significant planning and coordination was required to ensure there was no delay to those projects during the upgrade. The online DeltaV upgrade of (21) Servers, and (68) controllers was completed in (20) hours. This allowed the site to maintain production cadences and smoothly transition from one product to another. This strategy had a significant positive impact to production at the facility, and was an industry benchmark upgrade. In addition, the redundant infrastructure added to support this upgrade enables the site to perb online maintenance and upgrades in the future resulting in lower risk and higher future system availability while maintaining increased production rates. Several pre-upgrade activities were critical if the upgrade was to be perbed online. These included the addition of redundant controllers for quick and seamless flashing of hardware while equipment was running; extensive testing to verify the migration and integration points; extensive planning to ensure that the cutover duration was as short as possible and that manufacturing/quality could maintain and verify product was in a controlled state during the cutover; and the building of parallel environments to ensure no impact to the in-flight projects. DeltaV Maintenance, Syncade, Reliability Pharmaceutical & Life Sciences Engineer Workshop Scott Clark Bristol-Myers Squibb Glenn Gregg Emerson Automation Solutions - - - - - - - Process Control - -
3. Operate & Manage Approved Leveraging Existing Investments to Improve Asset Reliability and Achieve Operational Certainty "Current market conditions demand changes on how traditional challenges are approached.
The evolution of IIoT applications allows producers to capture efficiently the value of the data generated on the field, and translate it into benefits through value adding bs. Plantweb Health Advisor is a great example of how to integrate new tools with existing infrastructure to drive insights and decision making to improve reliability across the organization. Explore how to help you make the business case to add analytics to your existing capabilities and drive success with condition based maintenance" Often the main cause for inefficiencies in maintenance and reliability is bed to inability to identify developing issues, that lead to reactive maintenance. Also, it usually takes time to diagnose and decide on an b plan. Wouldn’t it be better to send people to the field with the right tools & parts to address the actual issue? Or take b when there is time to prevent a shutdown? "Among the main direct benefits of this solutions, we find:
? Enable Real Condition Based Maintenance
? Optimizes Repair time and costs
? Reduces production disruption from failure
? Increases maintenance and reliability team productivity through prioritizing activities on those assets that require immediate attention
? Extends life of assets through reduced wear from run to failure" Plantweb Health Advisor leverages existing measurements in the plant, to visualize in a consolidated dashboard, the condition and health index of plant assets, summarized at an enterprise level or detailed individual asset. It enables easy identification of selected failure modes, for quick and simple diagnostics and decision making, and overlaying process data for root cause analysis PlantWeb Predictive Technology, Wireless, Reliability All / Cross-Industry Engineer, Supervisor / Manager / Dept. Head, Project Manager / Lead, Plant or General Manager, Operator Workshop Orlando Gago Emerson Automation Solutions Latin America - - - - - - - - - Plant Operations Management - -
3. Operate & Manage Approved Modernization of Liquid Terminals: SOL Petroleum case "SOL Petroleum bought Terminal business from ESSO International.? As a result of it, SOL inherited Emerson legacy terminal automation system, DANTAS, and legacy Daniel preset, Danload 6000s.? The terminals have legacy software and hardware for 10+ years and it was the time to modernize the terminals.
Working closely with Emerson, SOL has successfully migrated to the latest Emerson Terminal Automation system and latest Emerson presets.? SOL has successfully modernized its terminals using Emerson’s technology without any data loss and changing the work flow.? The modernization enable SOL to keep up with the latest technology; hence avoiding long manual process and expensive repair cost for obsolete hardware.? It also helps SOL to shorten the loading time and improve terminal efficiency." Obsolete hardware costs a lot of money to repair. Sometimes it is hard to find replacement parts.? Old software technology always slow down the operation and billing process.? SOL Petroleum was able to resolve those issues using latest Emerson hardware and software. With modernization, SOL Petroleum Terminals were able to cut down the cost of operations.? It also cut down the time for loading process; hence improving order to cash process.? Terminals have improved in efficiency and safety. In modernization process, legacy Terminal Automation system replaced with the latest Emerson Terminal Automation System with no data loss.? Danload 6000 presets were replaced with DL8000 presets with little downtime.? Some of the Meter Pulsars were replaced on the old meters to give better meter readings. Migration Engineering, Project Management, Modernization Oil & Gas Midstream (Pipelines, Terminals) Engineer Workshop Scott Child SOL Petroleum Gabriel Prieto Emerson - - Myo Thane Emerson - - - Decision Support & Data Management - -
3. Operate & Manage Approved AXION Energy's Terminal Operations streamlined at 3 sites in Argentina Even after the acquisition AXION has continued to operate their terminals with Emerson's DANTAS system.? With change in technology and difficulty in maintaining system it became evident a need to migrate.? AXION went through a extensive buation process before selecting a vendor that could migrate their existing DANTAS system to a system that can help maintain increase in throughput and be easily supported.? Emerson's Truck Loading System was selected as their system of choice. AXION Energy's guideline was to make sure that during the migration process terminal operation to not be impacted in terms of loading products into trucks.? Also provide higher efficiency in moving the trucks in and out of the terminal. System and access security standards to be met within the new system. Communication with AXION's SAP business system to be established. AXION Energy now migrated to new technology that would provide better support both internally and to their customers.? Terminal throughput to increase with efficient and streamlined operations and normalized across all 3 sites. Emerson generated an assessment that enabled to define the upgrade path. Migration required updating existing system servers and replacement of communication switches. This was achieved with close collaboration between Emerson and AXION's project teams. Emerson helped in redefining business processes that were more efficient but still maintaining operating procedures. would not Migration Efficiency, Security, Operations Oil & Gas Midstream (Pipelines, Terminals) Director Workshop Martin Guernik AXION Energy Shoyeb Hasanali Emerson Process Management - - Myo Thane Emerson - - - Decision Support & Data Management - -
3. Operate & Manage Approved Eliminating the Bad Day with DeltaV Alarm Help "Flint Hills Resources, Pine Bend, like many facilities has been challenged with an aging operations workforce resulting in new operators being trained for DCS board operator bs.? By leveraging DeltaV Alarm Help and knowledge captured during alarm rbidation meetings FHR is able to help the board operators to effectively respond to DCS alarms.
The DeltaV Alarm Help installation at FHR is unique in that they were able to efficiently integrate their existing alarm validation data on over 15,000 points into DeltaV Alarm Help.? Otherwise, this valuable data would continue to be inaccessible to the operators.
DeltaV Alarm Help is proving to be an effective training tool for the new operators and is helping the refinery prevent the bad day." "- The refinery's experienced DCS board operators are getting closer to retirement age and the next generation are being trained to fill these roles.? Tribal knowledge needs to be documented and accessible to the newer operators.
- Potential for unplanned events.
- The refinery wasn't making full use of their alarm rationalization data." "- Alarm Help provides the DCS Board Operators easy access to alarm inbation (consequences and responses) allowing them to respond properly to process alarms.
- Great training tool for new DCS board operators giving them confidence when flying solo.
- Preventing unplanned events (and the bad day).
- Makes full use of existing alarm re-validation data." "- DeltaV Alarm help was installed on nine operator consoles in the Central Control Room.
- Existing alarm rationalization data was imported into the DeltaV Alarm Help database using a Novaspect engineered bulk import solution.
- Operator training on DeltaV Alarm Help was perbed to ensure this tool is utilized and maintained." DeltaV Operations, Training, Safety Refining Engineer Workshop Mike Rierson Flint Hills Resources Jason Stafne Novaspect - - Dave Strobhar Beville Engineering - - - Safety, Health and Environmental Compliance - -
3. Operate & Manage Approved Procedural Automation for Continuous Processes – ISA 106 The automation of a process allows every start up to be the same. This eliminates potential errors and overshoots which preserves the integrity of the process and eliminates most recycle, purges, safety trips and lost production.? Using procedural automation cuts average start-up time by as much as 50% or more. This is accomplished by streamlining the process and using the logic tools for automation. Automated start-up improves profitability and enhances flexibility of the process. Project ROI estimates show that the project typically pays for itself in 3 months.? Examples of state logic and typicals of control modules will be illustrated.? Controller loading, how to plan and best practices for state based control on a DeltaV will be discussed as well as how to avoid pitfalls. The modern industrial facility is being pushed in the direction of lower risk, better safety, with less experienced personnel and more frequent turnover. This has an impact on all business operations, especially the process control system as more is required for automation. Using Procedural Automation, you can reduce exposure rates, improve process operations and manage abnormal situations better. Reduce exposure rates, improve process operations and manage abnormal situations better. Much of the value is provided by leveraging your existing investment in the control system. Also capture process knowledge from experienced personnel so it's not lost by retirement/employee turnover. It eases operator training and improves process safety and adapts to the changing role of the board operator. A holistic approach is used to define, justify, document and automate the control system. This allows for one approach that encompasses many of the complexities of the control system and simplifies the end solution. This allows the modern plant to achieve its bives without creating a complicated control system configuration that is difficult to maintain and impossible to document. Safety Operations, Process Control Chemicals (Industrial, Specialty) Engineer, Supervisor / Manager / Dept. Head, Plant or General Manager, Operator Workshop Dustin Beebe ProSys - - - - - - - - - Process Control - -
3. Operate & Manage Approved Paving the Way for Improved Operations at Midwest Asphalt Midwest Asphalt operates a terminal in LaCrosse, WI. They receive product by barge, rail and truck, blend bulations and ship via truck to regional contractors. Truckers had set manual switches to line out the valves and entered quantity into preset controllers based on instructions given at the scale house. MA looked for a solution that would reduce costly errors when incorrect products were shipped, eliminate overfills and provide improved workflow. DeltaV has been implemented to generate a barcoded BOL that is scanned at the loadout rack. Valve alignment and load amounts are set automatically eliminating the possibility of operator error. Auto-sampling systems were installed to collect required retention sample. Complete documentation of delivery is generated and stored in the system. Scale house operator handed the driver instructions on tank selection. Driver was responsible to set a matrix of switches and enter load amount into a preset controller. Delivery of the wrong product bulation could result in the terminal operator covering the cost of ripping and replacing miles of roadway. Retained samples were not always collected or documented creating risk if audited by DOT. Cost of returned or off-spec product is eliminated and risk of product liability claims significantly reduced.? Parameters of each load including product source, additives and delivery temperature are stored automatically, before there was no confirmation that drivers had selected the correct product. Operators and drivers now have real time visibility to each load out bay and operating status. Load data is entered into DeltaV SQL database which generates bar coded load ticket and sample labels. Driver scans ticket at the rack and DeltaV control aligns valves, pump and meter trains. Auto-samplers collect samples and driver applies preprinted labels. Amount delivered, temperature, source tanks and sample reference are logged in the database to comply with record retention requirements. DeltaV Inbation Technology, Process Control, Operations Oil & Gas Midstream (Pipelines, Terminals) Engineer, Supervisor / Manager / Dept. Head, Plant or General Manager, Operator Workshop Drew Frederixon Midwest Industrial Asphalt Jeff Pingeon Novaspect - - Dave Schneider Novaspect - - - Plant Operations Management - -
3. Operate & Manage Approved DeltaV Virtual Studio – Planning For Success "Virtualization with DeltaV Virtual Studio can provide significant improvements in reliability and flexibility for your DCS system.? However, proper preparation and implementation require considering areas that are often unfamiliar to control system engineers.
This workshop will look at several different items that should be planned out to ensure the smooth implementation of a virtual system.? From networking to load balancing, time synchronization to patching, we will discuss many different areas that are needed to make a DeltaV Virtual Studio deployment smooth and successful." Virtualization is a new and unfamiliar concept to most DeltaV users, with terms and requirements a physical system doesn’t have.? When considering things like the number of different networks needed, the b of virtual machines for failover, the consequences of clock drift, and the need to patch both physical and virtual systems, virtualizing a DeltaV system may seem complex and overwhelming. Implementing a virtual environment can be faster and more flexible than a traditional computer system, if design details are carefully planned up front.? This approach can make future changes or troubleshooting much easier to accomplish as well. With careful planning before the start of a DeltaV Virtual Studio deployment, many of the issues that could slow down implementation can be prevented.? These plans include deciding the many different networks’ IP ranges, identifying networks by using different cable colors, arranging virtual machines to maximize failure protection, and synchronizing systems’ clocks to a single source. Virtualization Design, Installation Best Practices, Inbation Technology All / Cross-Industry Consultant, Technician / Analyst / Specialist, Project Manager / Lead, Engineer Workshop Nathaniel Miller Eastman Chemical - - - - - - - - - Plant Operations Management - -
3. Operate & Manage Approved Find and Fix Unhealthy Devices Fast With a focus on device alert reduction, Monsanto was able to reduce smart device generated spam by over 70%. But that still wasn’t enough to fully move our maintenance to planned. Once we rid our system of redundant alerts, we began using the new device health based analytics in AMS Device Manager to turn our optimized alerts into b. With the new graphical overview of device health, we are able to plan and prioritize our maintenance more effectively. With a more planned approach to maintenance, Monsanto continues to strengthen our strong reliability culture. Inbligent devices often generate multiple alerts for the same root cause cluttering up your Alert Monitor and filling your Audit Trail with thousands events.? This often makes finding the real device issue much more difficult. Even with predictive diagnostics, maintenance is still reactive when you can’t pull bable inbation out of your device diagnostics. We will present detailed quantitative analysis comparing how smart devices drove our work process before and after the new device health based analytics. We will show how this has saved time and money by finding issues much faster and perbing less maintenance. We will also look at how we have prioritized our maintenance activities and improved overall maintenance effectiveness. Emerson worked closely with device manufacturers to create default alert definitions for their devices. This greatly reduced the volume of alerts and focused attention on the actual problem. Then the streamlined inbation is shown graphically in the new AMS Device Manager. The new AMS Device Manager is a thin client, so we can look at the device health inbation wherever we are in the plant. AMS Diagnostics, Reliability, Maintenance 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 Joel Holmes Monsanto Mike Fredericks Emerson - - Scott Hokeness Emerson - - - Asset Management and Protection - -
3. Operate & Manage Approved Are Your Plants Cybersecure? - Attend This Workshop Before You Answer Attacks on Industrial Control Systems (ICS) at manufacturing plants can cause unsafe conditions and disruption to manufacturing processes.? The number of cyber attacks is increasing exponentially.? Manufacturing companies need a pragmatic approach to manage the implementation and maintenance of the required safeguards to protect their significant control system investments and ensure continuity of their operations.? How would you like to go to your CEO and bl them that your DCS is being held hostage by 'ransomware'?? It may be a career-limiting message!? Join this engaging discussion about how to make sure this doesn't happen to you. Ashland was facing a situation where they had control systems deployed bly without a consistent program to ensure implementation of the latest safeguards recommended for effective cybersecurity.? There was a need to manage risk by improving the overall security of their control systems, policies and practices. Through a risk-based, practical approach, a solid process was established to reduce the likelihood of cyber attacks.? A program was developed to continue the buation process and help Ashland adapt to the ever-changing threats facing all who operate manufacturing facilities utilizing technology. A cross-functional team was assembled to address the problem.? Thorough assessments were completed of the current state of cybersecurity across the company and a b path forward were established. Security Codes & Standards, Safety, Compliance Chemicals (Industrial, Specialty) Consultant, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, President / Principal, Plant or General Manager, Engineer, Director Workshop Gary Lipson Ashland LLC - - - - - - - - - Asset Management and Protection - -
3. Operate & Manage Approved Implementing a small historian for limited amount of data "The Trans Anatolian Pipeline, TANAP, is a 1150-mile natural gas pipeline system. Several gas quality readings along the pipeline need to be stored in a timely manner. The stored inbation has to be accessible by control room personnel as well as other personnel outside of the control room environment.
A reduced set of instrument readings is required to be constantly updated and retained for up to 2 years.
PipelineManager has been deployed to provide robust historian capabilities in a dual redundant solution. SCADA and field bemetry data are stored for remote access and visual presentation.
PipelineManager database has proven to be a cost effective alternative to a full blown SCADA historian." "A existing SCADA and Historian applications provide massive data storage. However, not all the required bemetry is stored in the SCADA database and therefore additional readings are required.
The challenge was to provide an application that could meet the requirements of (a) long term retention for a small number of instrument readings (b) distributed access and (c) data access security." "The package provided, based on PipelineManager meets the requirements and has the benefits of providing ancillary features such as alarm and event handling.
The simple historian implemented is ‘light’ compared to typical historian solutions. Furthermore, the package includes a feature rich HMI that supports drag and drop trend visualization and the ability to export data to Excel." "Chromatographs and other gas process variables are accessed by PipelineManager via OPC protocol.
A dual redundant data administration system based on PipelineManager provides measurement storage, on-line access to the inbation and an attractive HMI." Operations Engineering, Services All / Cross-Industry Operator Workshop Rafael Noguerol Emerson - - - - - - - - - Remote Control and Monitoring - -
3. Operate & Manage Approved THE LUCKY 13:CRISA LIBBEY Improves Solids Inventory & Personnel Safety With Scanners 5708 & Wireless "HOW CRISA LIBBEY WILL IMPROVE YOUR RAW MATERIAL INVENTORY IN 13 SILOS TROUGH CONTINOUS AND RELIABLE AVERAGE LEVEL MEASUREMENT AND HOW PERSONNEL SAFETY WILL BE INCREMENTED AVOID OR REDUCING THE MANUAL MEASUREMENT IN THE TOP OF THE SILOS
ACUSTIC AND WIRELESS ARE? EMERSON FRIENDLY TECHNOLOGIES THAT WILL BOOST MEASUREMENTS AND WILL REDUCE THE EXECUTION TIME MAKING A FASTER IMPLEMENTATION OF PROJECTS" FIRST CHALLENGE TO SOLVE WAS THE SOLID MEASUREMENT DUE TO DIFFICULTIES TROUGH OTHER LEVEL TECHNOLOGIES LIKE DUSTY ENVIROMENTS AND IRREGULAR SURFACE IN THE SILOS, IN CONSECUENCE OTHER CHALLENGES WILL BE SOLVED LIKE HOW AVOID PERSONNEL RISK EXPOSITION DUE TO MANUAL MEASUREMENTS IN HEIGHTS, A BETTER MEASUREMENTS FOR FINANCIAL REPORTS AND PRODUCTION INVENTORIES TROUGH A REAL TIME MONITORING "PERSONNEL RISK EXPOSITION WILL BE REDUCED.
BETTER FINANCIAL REPORT DUE TO IMPROVE INVENTORY OF RAW MATERIAL FOR PRODUCTION
REAL TIME MONITORING OF SILOS TO TAKE A BETTER AND FASTER DECISIONS" SOLIDS MEASUREMENT IN SILOS WAS SOLVED TROUGH ROSEMOUNT 5708 ACOUSTIC SCANNER, THE AVERAGE LEVEL SOLVE THE UNCERTAINTY WITH PUNTUAL MEASUREMENTS, WIRELESS TECHNOLOGY HELPS TO REDUCE THE INFRAESTRUCTURE AND TIME OF INSTALLATION IMPROVING THE COST OF THE PROJECT Optimization Instrumentation - Level, Wireless, Reliability Metals, Mining, Cement & Glass Plant or General Manager Workshop RICARDO MARTINEZ CRISSA LIBBEY RENE GONZALEZ EMERSON - - ADRIAN SANCHEZ EMERSON - - - Plant Operations Management - -
3. Operate & Manage Approved Refinery Upgrades Terminal Automation System for Improved Operations Ceylon Petroleum Corporation (CPC) has a petroleum products distribution terminal at Sapugaskanda adjacent to the Sapugaskanda Oil Refinery which is about 17 km from Colombo, Sri Lanka. The terminal has an installed capacity of 12 storage tanks and 18 number of gantries to distribute Auto Diesel, Motor Gasoline, Kerosene and different grades of fuel oil. CPC has been operating this terminal for more than 15 years. In 2015, CPC decided to automate the terminal for improving the operational efficiency, replace the obsoleted installed products and systems with the latest technology solutions. It will be implemented in two phases. The first phase is to replace the existing Terminal Automation System (TAS) and the second phase is to upgrade the existing tank gauging system. Some of the obsoleted products were replaced with new products. So, spare parts issue, hardware and software support issues from vendors and existing operational bottlenecks were compleby eliminated with improved functionalities of Emerson's Terminal Automation System (TAS).It becomes now easier and flexible for the terminal operators to manage the terminal operations efficiently. Better terminal operations will be achieved. Obsoleted products and software are replaced with latest products, software and services from Emerson and it will help to achieve the entire Terminal Management System to be the latest in Sri Lanka. Faster loading operations will enable more trucks to be loaded in a day. This will result in an increase of about 15% profitability. CPC came out with a Terminal Automation System (TAS) architecture that will replace all the obsolescence TAS hardware, software, provide latest TAS hardware, software, 3rd party products and installation. It will also provide better integration with multiple vendor systems while retaining some of the key components. The terminal is fully automated now. Migration DeltaV, Operations, Modernization Oil & Gas Midstream (Pipelines, Terminals) Plant or General Manager Workshop Rajitha Perera Ceylon Pegtroleum Corporation Murali Krishnan Thiagarajan Emerson Automation Solutions - - - - - - - Plant Operations Management - -
3. Operate & Manage Approved Shell Improves HSE Perbance by Automating Product Transfers with Emerson Piggable Manifolds Traditionally, blending operations required extensive downtime and operator involvement in order to eliminate contamination by flushing lines or transfer products from tanks to filling stations via manual hoses. These manual operations often resulted in product spills, contamination,additional material handling of slop, and safety hazards. Shell faced similar operational challenges and consulted Emerson to help improve their HSE perbance. Shell utilized Emerson’s automated piggable manifolds to drastically reduce these HSE risks. Shell will share the impact the automated piggable manifold solution has had on? HSE perbance as well as highlight additional economic benefits that come with piggable manifolds such as eliminating flush costs, reducing piping, and/or increasing throughput. Shell Lubricants used manual hoses connections to route products from 140 storage tanks to 9 filling and packaging lines. This resulted in over 1,000 possible connection options. These manual changeovers conducted by the operators posed threats both to personnel safety and the environment due to potential operator errors that could result in spills, contamination, leaks, or wrong connections. The solution drastically reduced Shell's HSE risk and increased throughput by eliminating manual hose boards in product transfers. Furthermore, Shell reduced contamination that resulted due to operator error by automating the control of lining up and transferring products as well as by utilizing piggable lines to automatically clean lines. Blending and Transfer Solutions conducted a FEED study to replace the manual operations with a more efficient and safer solution. Blending and Transfer Solutions implemented a compact, automated piggable manifold capable of handling 32 inlets and 16 outlets. The piggable lines enabled Shell to automatically transfer multiple products through one line with minimal contamination. Process Control Installation Best Practices, Operations, Modernization All / Cross-Industry Director, Plant or General Manager, Operator, Engineer Workshop Frank Lafuente Shell Balaji Athimoolam Emerson - - - - - - - Process Control - -
3. Operate & Manage Approved Keep Your Process in the Pipe – Non-Intrusive Corrosion Monitoring with Permasense P66 has been inheriting tough challenges with utilizing opportunity crudes; one of them being accelerated corrosion throughout the refinery.? With the use of opportunity crudes detecting where corrosion is taking place and having a certainty that the pipes were thick enough to continue to run has been a real challenge.? They came to Emerson to get a real time monitoring solution utilizing Permasense technology to help determine the effects of the chemical injections to neutralize the crude. P66 has seen an accelerated corrosion rate in their distilling units due to opportunity crudes that they’re processing in the refinery.? They were taking manual readings once a week to determine the pipe thickness, hoping they were getting an accurate measurement.? This data was collected and entered into spread sheets to try and analyze the effects of the inhibitors of the chemical injections. By deploying Permasense corrosion transmitters, P66 has increased the safety of the refinery by knowing the thickness of pipes and vessels. The reliability team will be able to determine the correct chemical balance to neutralize the opportunity crudes in the refinery to deter corrosion. This will also allow them to increase run rates and not have to come down as often to do manual inspections. The reliability team is deploying a WiHART network with 25 non-intrusive sensors in each distilling unit to get real time data. This data is going to be pulled back into the Permasense software to analyze the wall thickness and be able to trend corrosion rates over time. This will allow P66 to make a correlation between the inhibitors to see what needs to be added to lessen the corrosion rates. Wireless Diagnostics, Safety, Reliability Chemicals (Industrial, Specialty), Refining, Petrochemicals, Oil & Gas Upstream (On-shore, Off-shore, Sub-sea), Oil & Gas Midstream (Pipelines, Terminals) Director, Supervisor / Manager / Dept. Head, Plant or General Manager, Engineer Workshop Brad Livergood P66 Wood River Refinery Chris Short Emerson Automation Solutions - Rosemount - - - - - - - Remote Control and Monitoring - -
3. Operate & Manage Approved ABB 800xA to DeltaV migration at a large mining operation - the 10-minute cut-over "An ABB 800xA system at a large mining operation in central Africa was migrated to DeltaV in a series of warm cut-overs. The ABB system was installed in 2008 using Profibus for motor and analog I/O. However due to operational and optimization problems DeltaV was selected as a replacement. The b and local conditions required a well-organized solution to minimize both cut-over time and risk.
Logic from the ABB system was exported in xml bat and used to bulk-generate 80% of the DeltaV configuration. DeltaV was installed in parallel and cut over during normal plant maintenance. Profibus networks and hardwired I/O were reused. In this way, each cutover took less than 10 minutes and gave the security of a fall-back to the original system in case of problems. Optimization has started." A distinct challenge was finding an efficient b to generate DeltaV logic for 3000 hardwired I/O and 2100 Profibus devices, including 500 motors and 290 drives without compromising safety or integrity. Another challenge was finding a hardware cutover b that would be fast and provide a backup procedure.? Space was constrained, and the migration plan needed to take this into account. Downtime costs and risk are the biggest obstacles to migrations. Bulk software conversion and reusing I/O racks saved $1M of project costs. The rapid hardware cut-over reduced downtime from 8-10 hours for a re-termination to 10 min and provided a fall-back option to minimize risk. As production is worth over $100,000/hr, downtime savings were at least $1.5M. Staff can now focus on optimization. Basic DeltaV modules were generated programmatically using data from the ABB system. Careful design and management of templates allowed each processor to be converted close to the cutover date. For the hardware, all existing Profibus networks were connected directly onto DeltaV cards. All existing I/O racks were connected to DeltaV as Profibus devices so there was no rewiring and a low DST count. Migration DeltaV, Engineering Metals, Mining, Cement & Glass Engineer Workshop Rob Perry MinPro Solutions Ltd. Eddy Lam E.H.Lam Inc. - - Don Umbach Spartan Controls - - - Plant Operations Management - -
3. Operate & Manage Approved Optimize BP Trinidad and Tobago offshore flow assurance with active chemical injection rate control Offshore chemical injection is a major component of OpEx funding.? By implementing a real-time Active Control solution, the BP Trinidad & Tobago site was able to eliminate manually bypassing their chemical injection skids that were plugging up within 2 hours of startup. Combining the TESCOM ER5000, pressure regulator, and Micro Motion coriolis flow meter eliminated the manual bypass and system downtime, reduced chemical usage and waste of over-injection, and provided the control room with feedback on the status of the chemical flow, saving BP over $300,000/year in chemicals. More than 10% of an offshore Opex budget is spent on chemicals. It is difficult to precisely control the flow rate of the chemical injected. 5% over injection can cost up to $90K/well/chemical.? Under injecting can cause hydrate bation or corrosion that can damage infrastructure or halt production costing $1M/day. Most flow rate control devices are difficult to repair offshore. Active Control Solution enabled BP to keep their chemical injections skids running problem free. BP no longer needs an operator dedicated to manually controlling flow rates. The chemical flow rate was accuraby controlled and tied to well production, allowing BP to reduce their chemical usage by over $300K/year. Start up and shut down no longer an issue with the increased reliability. The TESCOM ER5000 controls a TESCOM pressure regulator to accuraby control the flow rate of the chemical regardless of changes in temperature, inlet pressure, well pressure, or well flow.? The signal to the ER5000 is provided by a Micro Motion coriolis meter to ensure high accuracy. This control is real-time and automatic. Instrumentation - Flow Optimization, Reliability, Regulators Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Operator Workshop Anthony Hartman Emerson Dania Pariag BP - - - - - - - Process Control - -
3. Operate & Manage Approved Batch Analytics - Putting Emerson to the Test "This presentation describes a user's experience with Batch Analytics.? Topics covered will include the process of selecting a use case, organizing a pilot project, installing & configuring the software, and finally building and deploying models.?
Two main bives were considered.? The first was to determine if the product actually works.? Are the models generated accurate enough to make decisions as well as to learn what kind of decisions can be supported from the product.
The next bive was to test the user's (a typical process control / plant engineer) ability to implement and support Batch Analytics.
Described will be effort required to install and configure the software, comments on ease of use, and comments on effectiveness of the product." "Producing on-spec batches of product is of high importance.? As a result, some batch processes may be run conservatively to ensure final quality.??
The more conservative process comes with the cost of time - an extremely valuable utility!
Tools to support better decision making are needed.? These tools need to be supportable by a typical plant / process control engineer - not a specialist." "We sought to test two claims by Emerson on Batch Analytics:? Ability to predict end batch quality and simple enough for the average engineer to build models.
Accuracy of end batch quality predictions are still being buated.
However, the product met the claims for a typical engineer to install, configure, build models and deploy were met." "After seeing presentations on Batch Analytics, several of our batch plants in NA were interested.
It was decided to pilot the product on a specific plant at a site that already had the infrastructure in place to support.??
Based on results - ability to generate valid models and ease of use - recommendations on its use would be made to the other sites." Optimization DeltaV, Process Control Chemicals (Industrial, Specialty) Engineer Workshop Michael Moody BASF Corporation - - - - - - - - - Process Control - -
3. Operate & Manage Approved Every journey begins with the first step - Realizing the vision for a better operations environment The City of Calgary’s Water Resources Division CSS Supervisor wanted to create an integrated operations environment in five separate control rooms, beginning with the operator's console. To convince Operations, he needed to demo the integration of multiple source bs into a single workspace, and show how it would help operators be more effective in their role, while reducing the strain from having to operate from multiple workstations. This story is about the process and the people he worked with to get the first console in place, and begin the transbation to integrated operations. The challenge was convincing Operations stakeholders to allow installation of new technology in the facility’s control rooms. The “integration-at-the-glass” visualization technology for operator workspaces was new and few people had actually seen it work. The idea champion knew it would transb the operations environment but he needed to convince others by bringing the technology to them. Greater awareness of and hands-on experience with integrated operations has set the City of Calgary on a new path toward increased operational efficiency, reduced operator stress and strain, and a more collaborative working environment. The project champion called upon his LBP account manager, who also enlisted help from Emerson and partners, to come up with a solution for his challenge. Together they worked to get an early version of the integrated operations console placed in the automation manager’s office, and design the software solution for the specific set of source bs that would be displayed on the single workspace. Operations Economic Justification, Services, Efficiency Power & Utilities Supervisor / Manager / Dept. Head Workshop Sheldon Araki Spartan Controls Todd Brase Emerson Automation Solutions - - Shariq Zia Spartan Controls - - - Plant Operations Management - -
3. Operate & Manage Approved Trip the Operator Training Simulator, not the plant. In 2011 we installed an operator training simulator (OTS); it consisted of a high fidelity plant model tied to an offline replica of our DeltaV DCS using OPC as the connector. At the time, the purpose was only to train our operators, but has since become a critical and integral part of our running plant. In 2014, our process control engineers decided to start making modifications to control logic on the OTS before making the same changes on the live plant DCS. It was such a minor philosophy change, but has since made a major impact on the way we do things. We needed to make it easier for our control engineers to use the OTS as a tool to implement and test configuration. We needed an easy and secure way to transfer files between OTS and DCS. We also needed to make sure the OTS stayed up to date, and stay synchronized to our plant. Our plant operators also needed to be trained on control changes before the changes were made on the plant DCS. Prior to this philosophy, we struggled to keep our OTS up to date with all of the changes we were making; now our OTS is always 1 step ahead of the DCS. We now train our operators on changes before they happen, and get a lot more operator feedback, before the change is made a reality.? We have prevented 4 plant shutdowns in the last 3 years, because the errors in DCS changes were found on the OTS. We gave control engineers access to the OTS from their offices, control room, board rooms, etc. We utilized the Avocent Matrix KVM to allow engineers to have access to both the DCS and the OTS, from the same terminals.? We setup a file transfer service through a firewall between the OTS and DCS, so the engineers could easily move imports/export back and forth. DeltaV DeltaV, Process Control, Operations All / Cross-Industry Engineer, Technician / Analyst / Specialist, Plant or General Manager, Operator Workshop Scott Wright Agrium - - - - - - - - - Process Control - -
3. Operate & Manage Approved Changing Controls and working collaboratively saves $180K/yr American Crystal Sugar’s migration project from RS3 to DeltaV included extensive meetings between maintenance and operations to redesign the sequencing of the heaters to reduce the maintenance cost. The new agreed upon sequence still allowed operations to do the cleanout phases but limited them from getting into a situation where the plates could be damaged.? This paper will go through the programing changes and in detail on how to work collaboratively with operations and maintenance. The inflexibility of the legacy reverse flow sequence presented operational issues requiring manual intervention by operators that often resulted in damage to heater plates. When this area come up for migration from RS3 to DeltaV there were additional meetings between maintenance and operations to find a better way to control these heaters. The final solution ended up being a rare case where the result added both a safer and more flexible system. After starting up on DeltaV the results were immediate and after the first year there was a reduction of 90% in the amount of plates there were replaced.? This provides a yearly payback of ~$180K.? Which paid for the project in one year. During the design time of the migration project, operations was heavily involved to help redesign the sequencing of these heaters.? Operations still required the ability to sequence the heaters during the cleaning phase without damaging the plates.? During numerous meetings, a new sequence was agreed upon and implemented during the conversion from RS3 to DeltaV. Optimization DeltaV, Reliability, Process Control Food, Beverage & Consumer Goods Operator Workshop Zachary Bullinger American Crystal Sugar - - - - - - - - - Process Control - -
3. Operate & Manage Approved Achieving a Step Change in Biomass Boiler Perbance A power plant in Australia uses a biomass fired boiler to be one of the country’s largest renewable energy base load generators. To improve plant perbance, it was desired to increase thermal efficiency, reduce emissions, and improve the overall reliability of the power boiler. A multi-disciplined effort was needed to accomplish this improvement, including mechanical adjustments, improvements to the combustion control strategy, and modifications to standard operating procedures. Emerson’s Industrial Energy Solutions Group worked collaboratively with the plant engineering and operations teams to implement the changes needed to obtain a step change improvement in boiler perbance. When power plants can produce steam through burning of sustainable biomass fuels, a clean renewable electric energy source is achieved.? The challenge is that renewable fuels such as bagasse and waste wood are more difficult to handle and burn in a power boiler and this often results in thermal efficiency loss and reduced generation. An overall improvement in boiler perbance of 18% was achieved through the control strategy and operating b adjustments.? This resulted from adjustments in boiler air splits, total air management, biomass firing strategy modification, and real-time compensation in the controls for changes in fuel quality.? Thermal efficiency was raised while reducing carbon in ash and emissions output. Leveraging extensive expertise in biomass firing, Emerson initially conducted a comprehensive survey of the power boiler.? This reviewed the process mechanical situation, controls, and operating practices.? A combustion trial then followed.? The initial activities highlighted a need to adjust mechanical settings and make improvements to the control strategy.? These changes were then implemented. Optimization Efficiency, Optimization, Operations Alternative Fuels, Pulp & Paper, Power & Utilities Consultant, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, Plant or General Manager, Engineer, Director Workshop - - Grant Hudson Cape Byron Management Pty Ltd - - Scott Pettigrew Emerson Automation Solutions - - - Process Control - -
3. Operate & Manage Approved Replacing a GE3300 at a 250MW Combined Cycle Power Plant "This workshop will discuss the replacement of a GE3300 shutdown system with an AMS 6500? on a Gas Turbine and related Steam Turbine.??
The workshop will discuss what was learned from this rack swap out including:
1)improved inbation to Ovation,?
2)the good and bad of re-using the existing probes and sensors
3)comparison of data taken from the front panel with a 2140
4)the AMS 6500 tripped the turbine… now what ???
5)we could do it again, what would we do differently?" The challenge was an aging GE 3300 system on our Westinghouse/Siemens Gas Turbine and accompanying HRSG – Heat Recovery Steam Generator A startup condition that in the past was overlooked by the GE 3300 system was detected and the Gas Turbine was tripped and protected with the new AMS 6500, thus avoiding a potentially very bad day! An AMS 6500 protection rack fully integrated to our control system Reliability CSI Technology, Modernization, Machinery Health Management Power & Utilities Plant or General Manager Workshop Nick Dingman LS Power Cottage Grove Chris Hince Novaspect - - Craig Truempi Novaspect - - - Asset Management and Protection - -
3. Operate & Manage Approved Industrial IOT, bded cellular wireless, PeakVue, Text Messaging, and a subbion service "This workshop will discuss the Industrial Internet of Things the value chain from measurement, to domain expertise, to bded cellular wireless, and finally the easy deployment through a monthly subbion service.
The workshop will discuss real world applications and how to navigate the obstacles of IT, systems integration, and capital funding.? The session will include a discussion around electronic notification, and delivering the right inbation to the right people at the right time.? Learnings from weal world applications in the power and paper industries will be presented." "Two challenges will be discussed:
1)Condition monitoring of distributed, intermittently operated assets were being overlooked due to difficulty coordinating a route based inspection.? Also, the b separate from the main plant made it prohibitive to wire or use WiHart.??
2)In plant assets with intermittent issues related to load conditions were being missed by the monthly route." Increased frequency and visibility of machinery conditions allowed resolution to otherwise missed? failures Using the AMS9330 PeakVue transmitter bded in a cellular wireless device was simple and easy.? The PeakVue, overall vibration, and bearing temperature were captured, trended, and text notifications delivered, resulting in the intermittent issues being captured, quantified, and ultimaby resolved. Inbation Technology Predictive Technology, Wireless, Reliability All / Cross-Industry Supervisor / Manager / Dept. Head Workshop Dan Yarmoluk Atec Companies Chris Hince Novaspect - - Craig Truempi Novaspect - - - Decision Support & Data Management - -
3. Operate & Manage Approved RF200 - Wireless Natural Gas Regulator Flow and Pressure Solution SaskEnergy is a Western Canada natural gas utility which needed the ability to remoby measure and monitor flow and pressure data at natural gas regulation sites. Spartan Controls along with Emerson Process Management Regulator Technologies developed the RF200 solution to provide remote flow and pressure inbation from their Fisher EZR regulators directly to SaskEnergy’s web browser. The RF200 program was developed to use existing field proven Emerson hardware for pressure measurement and communication while adding remote monitoring and flow estimation capabilities to the pressure regulators. The RF200 solution also allows for alarming, remote set point changes, valve trips, and other additional features. Previous to the gas utility having flow and pressure monitoring on their Fisher EZR regulators, they had to rely on flow modelling to predict this inbation on a number of stations.? This proved to be inaccurate and at times caused potential customer service disruptions.? The gas utility can now quickly respond to changes in demand and pressure requirements. The gas utility can now make more inbed system decisions to ensure they meet their customers’ requirements by having access to the EZR Regulator flow data at their town border pressure regulating stations. Without the solution, gas pressures within the utilities network were at risk due to unknown flow volumes that could lead to costly operational shutdowns and customer supply interruptions. The RF200 solution includes; Fisher EZR Regulator travel b (Fisher 4320 Wireless HART), Pressure Transmitters (Rosemount 2051S Wireless HART), Emerson Floboss 107 c/w Wireless IEC 62951 card.? The RF200 software provides the natural gas flow and pressure inbation that is sent via CloudGate cell communications to DeviceLynk Cloud for web access to the complete data for the gas utility. Efficiency Design, Instrumentation - Pressure, Instrumentation - Flow Engineering (OEM's, E&C's, Integrators), Refining, Power & Utilities, Oil & Gas Upstream (On-shore, Off-shore, Sub-sea), Oil & Gas Midstream (Pipelines, Terminals), Metals, Mining, Cement & Glass Consultant, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, President / Principal, Plant or General Manager, Operator, Engineer, Director Workshop Brad Shotton SaskEnergy Brian Burkowsky Spartan Controls - - Doug Scheffler Emerson - - - Remote Control and Monitoring - -
3. Operate & Manage Approved 400 MW Steam Turbine gets a new AMS 6500 Full Prediction and Protection System This workshop will discuss installation of a new 6500 prediction/protection combination rack on a 400MW Steam Turbine at the Dairyland Power JP Madgett Station located in Alma, WI. The turbo machinery tools including transient and 3D shaft centerline will be discussed.? Additional, successes/saves will be discussed using the 2140 vibration analyzer on our coal conveyor bearings.? Lastly, our plans to migrate our 4500 systems on our? Boiler feedwater pumps, ID Fans, FD Fans, Primary Air Fans , and Coal conveyor gearboxes will be reviewed. The challenge was aging vibration monitoring systems on our critical and essential plant assets, and a desire to have one common analysis platb for all tiers of our rotating assets. Improved equipment health data was realized in a single platb for all tiers of our rotating assets.? Specific cases will be presented that include early detection of bearing defects on our coal conveyor, as well as, a rotor bar failure on our 5000 HP FD Fan, AMS 6500 prediction and protection racks fully integrated to the Ovation system were deployed to leverage our existing Machinery Health Manager platb.? Upgrades to the 2140 with a Triax sensor and blue tooth headphones were also implemented Reliability CSI Technology, Modernization, Machinery Health Management Power & Utilities Technician / Analyst / Specialist Workshop Steve Richter Dairyland Power Chris Hince Novaspect - - Craig Truempi Novaspect - - - Asset Management and Protection - -
3. Operate & Manage Approved Migration to DeltaV while maintaining existing GeniusBus Field I/O The main driver of this project was to replace end of life control system hardware in an existing pharmaceutical batch manufacturing facility.? Continuing to utilize the GeniusBus I/O provided a cost benefit in that field wiring/marshalling was not required.? The existing control system was comprised of a GE PLC(and associated GeniusBus I/O) and iFix SCADA.? This was replaced with a DeltaV version 12.3 system employing S-Series Controllers and VIM2, utilizing the OVDA interface to communicate with Genius Bus I/O via a ProSoft Ethernet IP to GeniusBus Gateway. "-Mapping I/O references to landing modules, employed a database to manage changes and updates as they occurred.?
-Controller Loading and scan rates?
-Limited documentation on existing bus configuration and wiring?
-Managing existing wiring concepts in the field. Open loop detection was utilized on the GeniusBus as a way to limit I/O required on the bus(Single channel was both b and output)." "Replaced End of Life GE PLC and iFix SCADA.
Limited the cost of upgrading all I/O and field wiring.?
Platb that can be flexibly expanded using CHARMS I/O and interfaced to other packaged systems.
Enhanced data collection with Advanced Continuous Historian." DeltaV version 12.3 with S-Series Controllers and VIM2 utilizing the OVDA interface to communicate with Genius Bus I/O via a ProSoft Ethernet IP to GeniusBus Gateway. Migration DeltaV, Process Control, Modernization All / Cross-Industry, Pharmaceutical & Life Sciences Consultant, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Sales / Marketing, Project Manager / Lead, Plant or General Manager, Engineer, Director Workshop Christopher Vales Control Associates Inc. Joseph Soltys Merck - - - - - - - Process Control - -
3. Operate & Manage Approved Killing the Green Dinosaur: How a Major Oil Terminal is Using DeltaV Logbooks to Replace Paper "The Buckeye Bahamas Hub, in Freeport, Bahamas, is one of the largest marine terminals for petroleum products in the Western Hemisphere. Decades of manual processes have evolved into numerous departmental and inter-departmental processes that have served the needs of the Company. This presentation will cover:
?An overview of the day to day operations conducted at Buckeye Bahamas Hub
?A summary of the types of processes and reports that traditionally were recorded manually
?A debion of the process by which Buckeye and Control Southern buated and prioritized the various candidates for conversion to DeltaV Logbooks
?A brief overview of the Logbooks architecture?
?Challenges encountered during the implementation process
?Benefits and future plans" The existing manual processes for recordkeeping at Buckeye Bahamas Hub were time consuming and highly prone to mistakes. It was next to impossible to trend or benefit from the data in a timely manner. Additionally, coordination and planning of Maintenance activities and Projects required acknowledgment and cooperation of each shift and at least 2 departments. "Buckeye is now able to track, coordinate, and trend inbation across multiple departments. This results in increased efficiency, accuracy, and productivity, as well as more timely review by supervisors and deeper involvement of Maintenance and Operations planning.
Logbooks is expected to drive the company into a competitive arena that was unattainable with the existing manual processes." "A pilot installation of DeltaV Logbooks was implemented to replace the manual logbook (“Green Dinosaur”) used by the land-side head operator. This included a new server outside the existing DeltaV network and a number of templates to replicate paper entries.
There are plans to expand this installation up to almost 100 total users. (This project is in progress and will be completed mid-2017.)" Syncade Maintenance, Operations Chemicals (Industrial, Specialty), Pulp & Paper, Oil & Gas Midstream (Pipelines, Terminals) Engineer, Supervisor / Manager / Dept. Head, Operator Workshop Dexter Pinder Buckeye Bahamas Hub Alvord Smith Buckeye Bahamas Hub - - Bill Tinley Control Southern - - - Plant Operations Management - -
3. Operate & Manage Approved Using Version Control and Procedures to Easily Manage SIS Changes and Downloads "Cargill has over 25 burners, 40 centrifuges and several high hazard reactors running on DeltaV SIS. Validating a system after a small logic change, a trip point change for example, would typically require a full functional check. This would mean keeping the unit down for an extended period while a team of engineers and operators ran through every possible trip and permissive condition.
Using VCAT and a robust Management of Change document, the team can isolate which item changed and only retest that change. This translates into shorter downtime and less plant personnel tied up in functional checks. This bology also maintains control of SIL2 and SIL3 rated SIFs by only authorizing certain safety resources to approve downloads of these functions." Previously, changing any logic in a BMS or ESD would require a functional check of the entire unit due to not being able to ascertain what was changed from the CRC values alone. This would result in a large amount of resources being tied up and a unit being down longer than was desired by the plant. Additionally, policy required higher level signatures on downloads on high hazard processes. Much shorter downtimes were possible. What originally took shifts to functionally check became mere hours to identify, configure, and download the change, including the proper review cycles called out in the MOC document. DeltaV VCAT allows engineers to identify exactly which beter was changed. This, along with a bent MOC document for any SIS change, meant retesting was held to a minimum. Allowing only the high level safety personnel the authorization to approve SIL2 and SIL3 application downloads satisfied their requirements as well. SIS / SIL Efficiency, Safety, Operations Chemicals (Industrial, Specialty) Engineer, Project Manager / Lead, Operator Workshop Zach Brooks Emerson Process Management - - Devin De Weerd Cargill - - - - - Plant Operations Management - -
3. Operate & Manage Approved How Evonik used Plantweb to Enable Corporate IIoT Strategy & Improve KPIs Evonik's corporate IIoT initiative is for their IT and OT operations to be centralized allowing for enterprise-wide visibility into KPIs for asset management, supply chain, process perbance, etc.? An Assessment of Evonik's largest site identified key projects with the best ROI resulted in a handful of essential asset monitoring projects perfectly suited to leverage Pervasive Sensing technologies and Emerson's Plantweb Digital Ecosystem.? This workshop details how Evonik leveraged Plantweb to begin their path to enterprise-wide collaboration to ultimaby improve operational efficiency and exceed KPI bives. With 33 sites across North America, each with their own independent projects and infrastructure, Evonik felt there must be a better way to measure and monitor operational perbance.? Evonik recognized an opportunity to leverage IIoT bologies to improve enterprise-wide operational efficiency. Evonik's first phase of their corporate IIoT strategy in Mobile, AL has been a complete success.? A number of essential assets have been repaired and optimized as a result of the new IIoT infrastructure.? There are also improvements in multi-site collaboration and visibility as well as in the way in which KPIs are being tracked. Plantweb, built upon secure open-standard protocols & bologies, greatly simplified the IIoT implementation. They leveraged infrastructure investments in DeltaV, IP21, Predix, Survalent & CMMS while preserving a secure first mile. WirelessHART transmitters enabled visibility into essential asset operation. Insight was used to analyze & monitor steam traps & pumps. ARES monitored vibration. PlantWeb Operations, Wireless, Predictive Technology All / Cross-Industry, Chemicals (Industrial, Specialty) Consultant, Vice President, Supervisor / Manager / Dept. Head, Project Manager / Lead, Plant or General Manager, Director Workshop Michael Sowell Evonik Richie Graham Emerson - - David Gustafson Emerson Automation Solutions - - - Asset Management and Protection - -
3. Operate & Manage Approved Smart Innovative Operations: A New Approach for Remote Support, Diagnostics, and Control Existing plant assets and their aging technology have a limited ability to contribute to growth in profitability unless a new philosophy is adopted.? In order to remain competitive and uphold our commitment to our customers and the environment, we must radically transb.? The Smart Innovative Operations (SIO) initiative leverages digitization, predictive analytics, and our existing expertise and competencies to create new value from existing assets. "The projects, technology, and work processes that Air Liquide has relied upon to build its reputation in the Large Industries business have run?
their course.? Without change, they have a limited capability to continue contributing to our operational excellence." Once successfully implemented, the SIO initiative will create a compleby new digital environment, with a wide range of new possibilities and opportunities, for all in the organization.? Experts will be leveraged across the organization.? Combining their expertise with the intensive use of digital and predictive techniques will maintain Air Liquide's b as a world leader. Digital and predictive technologies of today are affordable, easy to put in place, user friendly and extremely powerful. They allow an expert anywhere in the world to predict an event, spot trends, anomalies or recurring patterns on geographically distributed assets. They save time and provide the largest amount of value with little effort. Operations Diagnostics, Reliability, Predictive Technology Chemicals (Industrial, Specialty) Consultant, Vice President, Supervisor / Manager / Dept. Head, President / Principal, Plant or General Manager, Director Workshop Charles Harper Air Liquide Ben Bishop Emerson - - - - - - - Plant Operations Management - -
3. Operate & Manage Approved Implmentation of APC to Optimize Crude Oil Stabilization Process Abqaiq Plants completed the implementation of Advanced Process Control (APC) techniques in South Stabilizer plant columns 12 and 13. The APC continuously optimize operating conditions of stabilization columns to increase steam savings and crude oil revenue. The project utilized highly sophisticated tools with complex bulas to accuraby perb required calculations and directly adjust multiple operating conditions for superior control and optimization. In addition to APC , Abqaiq Plants developed innovative soft sensor model to predict H2S levels as an b to APC with no need for lab sample or costly online analyzers. "The below challenges were faced:
1) Unavailability of hardware analyzers to predict H2S level which forced the team to look for alteratives to develop fully automated system." "1) Enhance steam saving through the control of stabilization heat set point based on required H2S level.?
2) Increase crude oil revenue by avoiding the use of excessive heat in the stabilization columns.
3) Increase safety during shipping of product through accurate control of H2S levels.
4) Deliver $950,000/year cost reduction from steam savings." The solution was done by implementing soft sensor to compute real-time stabilized crude’s H2S, RVP, TVP values. DeltaV DeltaV, Operations, Efficiency Oil & Gas Midstream (Pipelines, Terminals), Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Engineer Workshop Mohammed Batouk Saudi Aramco Omar Al-Mohisin Saudi Aramco - - Mohammed Al-SAEED Saudi Aramco - - - Process Control - -
3. Operate & Manage Approved The Challenges and Benefits of Wireless Evolution at a Specialty Chemical Plant "For a 70-year-old batch chemical operation, maintaining safe, high quality manufacturing provides many challenges. 3M Cottage Grove has utilized wireless technology as a strategy to solve these problems. Starting small, 3M has gradually expanded its wireless capabilities and worked through the challenges of WIOC vs. Gateway.
Projects include temperature and level monitoring, limit switches to eliminate valving errors, and remote flow measurement for leak detection.
Each production building will have fully redundant wireless I/O. This enables many new capabilities.? ?An example is a project is that will collect data in order to monitor equipment health.
3M views wireless technology as a key component in its strategic vision, and is realizing many benefits in operation and maintenance." The 3M Cottage Grove Chemical Factory faces challenges to maintain a productive operation with an aging infrastructure and the loss of experience on the production floor. With fewer technical resources, these challenges increase the need for automation. Many areas are Class 1, Division 1 and are expensive to wire devices, which limits the feasibility of projects. "Benefits include:
? Extended life of existing equipment;
? More process control leading to fewer human errors that impact product quality or safety
? More engineering time for proactive improvement projects (rather than reactive); and
? Completion of projects that were previously infeasible due to high cost of hard wiring.?
Management has approved future projects to expand the wireless program." A solution is a growing infrastructure of wireless technology using WIOCs and gateways. It started small – temperature monitoring of a water line for freeze protection. Since then, 3M has increased the scope of its wireless program. For example, 3M recently integrated wireless flow and valve b in the solvent tank farm. These successes led to further plans to incorporate wireless technology. Wireless Economic Justification, Operations, Modernization Chemicals (Industrial, Specialty) Engineer Workshop Matt Peters 3M - - - - - - - - - Remote Control and Monitoring - -
3. Operate & Manage Approved Race Car Tire Mfr Uses Connected Services to Improve Perbance, Emissions, & Profitability Steam is an important component in the process of making tires. Steam trap failures can waste steam, impact process perbance, or worse, damage equipment and upset availability. These conditions can have a major impact on profitability and product quality. A North American Tire Plant decided to invest in Emerson's Steam Trap Health Monitoring Connected Service to monitor their most critical steam traps. This workshop will describe the use case and results achieved from the remote monitoring service. Usually, a technician is sent out to test each trap manually each year but it hadn't been done in 2+ years. The test must be done while the trap is in operation with live steam present so batch operations make it difficult. Often these traps are out of reach or located in hazardous areas. If failures occur, they may not be identified until the next round leaving traps in a failed state for months. 194 traps are being remoby monitored, 43 of which failed & were repaired. By repairing these traps in a timely manner, the tire mfr improved throughput & assured product quality.? Additionally, they realized over $60,000 in energy savings & reduced emissions by 225 tons.? The total identified opportunity for energy savings has exceeded the service cost by $20,000 resulting in positive cash flow. A Steam Trap Health Monitoring Service provided the complete infrastructure to monitor traps in near real-time & delivers reports to maintenance & executive stakeholders.? The connected service contract required no capital investment upfront but instead is a subbion contract.? This allows for energy savings to cover most, if not all, of the service cost & contribute to the bottom line. Services PlantWeb, Wireless, Reliability All / Cross-Industry, Chemicals (Industrial, Specialty) Consultant, Vice President, Supervisor / Manager / Dept. Head, Project Manager / Lead, Plant or General Manager, Director Workshop Rick Ainscough Goodyear David Gustafson Emerson Automation Solutions - - Paul Kapur Emerson Automation Solutions - - - Remote Control and Monitoring - -
3. Operate & Manage Approved Improvements in the perbance of the system gain loss across Colonial Pipeline Presentation to demonstrate how Colonial Pipeline narrowed our gain losses by? +0.025% (12 p rolling average) through training, updates to instrumentation and improvements in procedures. How we undid what was considered normal and reset our goals and metrics to become a top quartile perbing operator. A general acceptance of what was consider normal and not really looking at what should be considered acceptable perbance. General losses across our system that we are responsible for as a third party shipper. Overall tightening of our gains and losses for better accountability. We have improved our net gain and loss by +0.025%, which equates to around ~20k bbls month. These improvements on the tank side of our operation have help gain better control on the pipeline movement side of the business system wide. Implemented vendor training on the proper calibration and use of our tank gauging equipment. Operator training on proper verification of net volume in the tanks in order to reconcile against the pipeline receipts. Optimization Instrumentation - Level, Training, Operations Oil & Gas Midstream (Pipelines, Terminals) Director, Vice President, Supervisor / Manager / Dept. Head, Plant or General Manager, Operator, Engineer Workshop Leonel Nava Colonial Pipeline Lance Berry Emerson - - - - - - - Plant Operations Management - -
3. Operate & Manage Approved Ovation System upgrade Saudi Aramco- Abqaiq Plants completed successfully an online upgrade of Ovation system software to the latest release. This upgrade was perbed online with no plant shutdown. The upgrade was planned carefully utilizing several techniques including establishing dedicated networks for old and new systems and establishing an OPC soft b to transfer data between systems to tackle the issue of dependency between systems controllers. A total of 60 controllers were successfully migrated to the new software in two weeks with no single operation interruption. "1) Segregated the primary and secondary systems network into two networks where one was utilized for the controllers not yet migrated and the other one for migrated controllers.
2) Established an OPC b to transfer needed data between old and new systems to avoid operation interruption during the cutover period." "1) Completed the upgrade with no single interruption to Abqaiq Plants operation
2) The upgrade was completed timely in two weeks with no need for any equipment shutdown." "1) Segregated the primary and secondary systems network into two networks where one was utilized for the controllers not yet migrated and the other one for migrated controllers.
2) Established an OPC b to transfer needed data between old and new systems to avoid operation interruption during the cutover period." Ovation Modernization, Ovation, Operations Power & Utilities Engineer Workshop Mohammed Batouk Saudi Aramco Omar Al-Mohisin Saudi Aramco - - Mohammed Al-SAEED Saudi Aramco - - - Process Control - -
3. Operate & Manage Approved Energy Efficiency Improvement on a Black Liquor Concentrator Zellstoff Celgar is a large pulp manufacturer in North America and recently completed an energy efficiency improvement project on an Evaporator used to increase the solids content of weak black liquor (WBL) from ~15% to heavy black liquor with a solids content of ~75%.? There is an interim Evaporator process step where the liquor solids content is ~45%, known as sweet black liquor (SBL).? The project involved modifying the Evaporator's concentrator rinse circuit to use SBL in lieu of WBL during the rinse cycle.? Less total energy is now used with the Evaporator.? This was achieved with the installation of two 6" and one 8" V150 Fisher on/off valves along with a 4" Micromotion coriolis meter needed for accurate process measurement of black liquor flow and specific gravity. Black liquor is a caustic and erosive process fluid that's a by-product of the pulping process? ?It contains organic solids and the fluid density varies (depending on the solids content) from near-that of water up to a solids content of 75% - where the viscosity is equivalent to that of thick molasses.? The Micromotion coriolis meter can accuraby measure specific gravity and flow of black liquor This project had an energy efficiency improvement with a 4 month payback.? In addition, there has been a process stability improvement which now allows for the implementation of a model-predictive control solution. The Micromotion Coriolis meter is ideally suited to handle black liquor and avoids any corrosion/erosion issues that can be found with other specific gravity measurement technologies.? ?Accurate specific gravity and flow measurement has provided a number of process improvements including the ability to now know when the circuit rinse cycle has been completed. Operations Economic Justification, Optimization, Efficiency Pulp & Paper Plant or General Manager Workshop Robert Zwick Automan Controls Inc. Max Bell Zellstoff Celgar - - Dave Paulson Zellstoff Celgar - - - Plant Operations Management - -
4. Final Control & Regulate Approved Marathon Petroleum Improves Refinery-Wide Control Valve Reliability Processing crude oil in refineries is tough on control valves, especially at Marathon Petroleum’s Garyville refinery, since it is built to handle the heaviest dirtiest crude available at market.? During this presentation several examples of those tough control valve applications will be shared, from failure definition to solution implementation.? Issues to be discussed include plugging, cavitation, actuation insufficiencies, vibration, and thermal shock. Due to the nature of the crude oil processed at Garyville, a wide range of challenging control valve applications is present. It’s never just one problem – cavitation with particulate in sour service at elevated temperatures is just one example. Garyville works closely with their local business partner, John H. Carter, and Emerson engineers when these challenging applications arise. The solutions to each of these applications are currently implemented and proven effective.? Some of these solutions took more than one iteration to arrive at the current valve installation.? Refinery reliability has improved with the failures eliminated as a result of the proven empowered collaboration. Depending on the nature of the application, a range of Fisher? control valve solutions are implemented, including:? retrofitting valve trim from Cavitrol III to DST, changing valve trim construction materials, reviewing Bettis actuator sizing, and modifying actuator spring selection. Reliability Control Valves, Maintenance, Installation Best Practices Alternative Fuels, Refining, Pulp & Paper, Power & Utilities, Pharmaceutical & Life Sciences, Petrochemicals, Oil & Gas Midstream (Pipelines, Terminals), Metals, Mining, Cement & Glass, Food, Beverage & Consumer Goods, Chemicals (Industrial, Specialty) Engineer, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Plant or General Manager, Operator Workshop Randy Firmin Marathon Petroleum Rebecca Turner Emerson - - - - - - - - Control Valves -
4. Final Control & Regulate Approved Bridging the Knowledge Gap - Blended Learning Lessons Learned with Lucite International Emerson Blended Learning combines conventional classroom training with video, eLearning, and workshops in order to keep customers at their plant as much as possible while still delivering high quality education to them when needed.? Our customers have trouble getting away from their plants for a long duration, add tot hat the cost of overtime and travel expenses and it becomes almost impossible for some of our customers to attend an instructor led week long course.? The solution is Emerson's Blended Learning approach which allows students to meet on their time, often 2 hours 2-3 times a week over a 2-3 week period to still achieve the training they need when they need it. Kevin Wright needed training on control valve engineering yet could not spend time away from work in a conventional classroom.? The expense of travelling on overtime and other travel expenses can often not be paid for by all student's companies each time they want to attend a course. Kevin Wright was able to stay at his plant providing a critical role to his fellow employees while still training on control valve engineering leading up to a scheduled shutdown of his plant.? ?This allowed Kevin to benefit from knowing the signs of a miss-sized valve and how to troubleshoot it with his Local Business Partner leading to a more effective communications channel as well. Kevin was able to attend Control Valve Engineering I & II with us via Emerson Blended Learning which allowed him to stay at his site yet attend the courses he needed. Engineering Control Valves, Training, Engineering Chemicals (Industrial, Specialty) Engineer, Technician / Analyst / Specialist, Plant or General Manager Workshop Richard Ritter III Emerson Process Management Kevin Wright Lucite International - - - - - - - - Control Valves -
4. Final Control & Regulate Approved 10 Years Later: Did the Fisher? Severe Service Valve Survive in Flint Hills Resources’ Hydrotreater? In 2007, Flint Hills Resources (FHR) Pine Bend refinery executed a project in their Gas Oil Hydrotreater (GOHT). They replaced four separator letdown valves with Fisher? severe service valves. The original valves required maintenance intervals between 6 and 18 months, and were often the unit reliability constraints. Fisher’s solution was a high pressure angle valve with engineered-to-order trim for separator letdown service, where a phenomenon known as outgassing is common. Valve selection for these applications required up front collaboration between FHR, Novaspect, and Emerson. This DST-G design (Dirty Service Trim for Gassing) was a new Fisher product and was the first of its kind at the Pine Bend refinery. This Fisher valve solution was included in a workshop at the 2008 Emerson Exchange.? At the time of the presentation, the valves had about a year of runtime.? Looking back now, with 10 years of runtime, we’ll discuss the repair history on the valves and their perbance over the last 10 years. The answer is yes, the valves have survived and continue to perb well. Prior to the installation of the Fisher DST-Gs, failure rate data on the 4 applications showed regular maintenance. Since their installation, the Fisher DST-G solution has shown significant reliability improvements. These valves were sized and selected utilizing accurate process data gathered in a coordinated effort between FHR, Novaspect, and Emerson. With access to that data, the selection of the DST-G in these applications has provided long term reliability in these challenging applications, outlasting the previous valves’ repair cycle many times over. Control Valves Maintenance, Severe Service, Reliability All / Cross-Industry, Refining, Power & Utilities, Petrochemicals, Oil & Gas Upstream (On-shore, Off-shore, Sub-sea), Metals, Mining, Cement & Glass, Engineering (OEM's, E&C's, Integrators), Chemicals (Industrial, Specialty), Alternative Fuels Director, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Operator, Engineer Workshop Pat O'Connor Flint Hills Resources Kim Barron Emerson - - Ryan Enockson Novaspect - - - - Control Valves -
4. Final Control & Regulate Approved “VERIFICATION AND VALIDATION PROCESS FOR FINAL ELEMENT OF SAFETY LOOP” Safety shutdown valves or emergency shutdown valves (“Final Element) are critical component of Safety Instrumented Function (SIF) Loop. Major accidents worldwide have raised awareness in improved plant safety, especially in the chemical refinery, oil & gas industries. Growing concerns with Safety Instrumented System and enforcing of governing industry standard is creating a significant demand for a device that can provide a b for testing safety valve operation without disturbing the process and providing diagnostics inbation about the final control element. The typical failure includes being stuck in last b and not operating when needed. This could result in a dangerous condition leading to an explosion, fire, or a leak of lethal chemical and gases into the environment. To ensure the needed reliability of this safety shut down valves, they need frequent testing during normal plant operation. The presentation will discuss use of Digital Valve Controller for verification and Validation of “Final Element” integrity during operation phase of safety life cycle. It will also provide current examples and technique used by Wood Group for partial stroking shut down valves. It will also discuss on various field issues and work practice used by Wood Group for validation of safety loop. Unfortunaby, the traditional b of testing these safety valves does not provide any internal valve diagnostics, whereas microprocessor based Digital Valve Controller not only provide diagnostics capabilities but can dramatically hike the reliability of these safety system, and at the same time reduce the risk of spurious trip, unscheduled maintenance, manual laborious test procedures etc. Safety FIELDVUE, SIS / SIL, Reliability All / Cross-Industry Consultant Workshop Mahendra Shah Woodgroup, Houston riyaz Ali Emerson Process Management - - - - - - - - Valve Instrumentation -
4. Final Control & Regulate Approved Gas Distribution Station Design – Better Safety/Integrity and Reduced Operational/Financial Risks FortisBC, a natural gas distribution company, provides service to over 1 million customers across British Columbia with an integrated transmission and distribution network. The distribution pressure control station includes below-grade, compact, safe, tamper-resistant stations for the densley populated areas it serves to provide gas to residential customers and the growing industrial and CNG loads in the area. This means safety, perbance, noise, and emissions are all critical requirements to protect the public.? Utilizing the Fisher FL regulators, FortisBC created an extremely safe, reliable, high perbing station that including the Fisher regulator’s no-bleed and noise abating technologies for a complete low impact design for urban areas for the below grade, pit style installation. In a Risk Assessment study, capacity issues identified at FortisBC’s Rosedale station mandated a new larger station.? Due to space, the new b was a quiet residential area, requiring a low impact to the neighborhood (below-grade, very small space, no bleed, and very low noise) while also providing the over-pressure protection, control accuracy and extra flow capacity required. This new station design has the capacity required to serve the growing area, while addressing the safety, control perbance, and unique low-impact urban considerations. It was tested, installed and commissioned on-time and on budget.? The result is a reduction in operation risks associated with service outages, public safety and social license and is adopted as the company standard design. The Fisher FL regulator with SRII noise abating trim was used in a parallel Main/Monitor configuration for over pressure protection.? The PRX no-bleed piloting system in a control box allows for above-grade set-point and tuning avoiding confined space entry for employee safety.? These devices have improved 2-path perbance, extra capacity, safety and reliability needed for this critical station. Regulators Design, Safety, Engineering Power & Utilities Consultant, Project Manager / Lead, Plant or General Manager, Operator, Engineer Workshop Niko Boskovic FortisBC Randy Gomez FortisBC - - Julie MacLennan Spartan Controls - - - - Pressure Regulators -
4. Final Control & Regulate Approved Valero Gains Short and Long Term Savings by Using Full Scope of Fisher Lifecycle Services Outages are a part of everyday life in a refinery. During a scheduled outage, end users can use a variety of service providers to perb valve repairs, however, Valero has learned that not all service providers are equal. Utilizing Original Equipment Manufacturers (OEM) to repair valves results in fewer unknowns. In this case, Fisher Lifecycle Services was hired to perb service work on Fisher valves. Their certified repairs use OEM parts, resulting in high quality repairs completed on time. During the 2016 outage, Valero learned about another service Fisher provides-leak detection to estimate leakage through valves, which can reveal whether a valve should be repaired during the next outage. Fisher perbed this for 10 butterfly valves, resulting in a reduced repair scope and savings. Like many end users, Valero has historically used a variety of service providers to perb repairs on their control valves and instrumentation. Utilizing Fisher Lifecycle Services to execute certified repair services is not always the lowest cost option. However, a single incident resulting from a non-OEM repair can quickly eliminate the cost savings. By exclusively using Fisher to repair Fisher valves, Valero is assured that the correct parts are used, equipment is repaired back to factory standards, and Fisher will stand confidently behind their products. While a huge costs savings may not have been realized during the outage, they see the long term savings and an immediate benefit of the leak detection services of $400K for their 2017 outage Valero selected Fisher for valve repairs during their 2016 first quarter outage. Fisher technicians worked on a total of 72 valves, including 45 repairs, 9 Field diagnostic scans, 7 new valve assemblies, and 11 spare valve repairs after the outage was complete. In addition, they were back for a smaller 3rd quarter outage and perbed leakage tests on butterfly valves in preparation for 2017. Maintenance Control Valves, Services, Reliability All / Cross-Industry, Refining, Pulp & Paper, Power & Utilities, Pharmaceutical & Life Sciences, Petrochemicals, Oil & Gas Upstream (On-shore, Off-shore, Sub-sea), Oil & Gas Midstream (Pipelines, Terminals), Metals, Mining, Cement & Glass, Chemicals (Industrial, Specialty), Alternative Fuels Consultant, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Plant or General Manager, Operator, Engineer Workshop Dom Toledo Valero Dave Kandel Caltrol - - - - - - - - Control Valves -
4. Final Control & Regulate Approved Equate Petrochemicals' Predictive Maintenance using Emerson AMS and Digital Valve bers Equate lose millions of dollar every year on account of unplanned shutdown, major cause due to valve failures and resultant plant trip. Emerson AMS, Snap-on software along with Inbligent field devices like Emerson DVC6200 help perb online and offline valve diagnostics, which helps Equate to pin point the issues in Valves well ahead of any major breakdown, thereby eliminate unplanned shutdown, reduce shutdown cost on valve repairs and improve process availability Conventional b of valve selection for maintenance lead to long list of valves during shutdown and most of the time valves don’t need any internal change or repair, but by then considerable amount spent on spares and service. Offline diagnostics and valve signature analysis helped Equate know the valve internal conditions which helps engineers pick the right valves for shutdown. Emerson offline diagnostics solutions help Equate chose right valves for shutdown, thereby saves considerable time and cost associated with Valve maintenance during shutdown. Emerson Online diagnostics help to predict the health status of the valves and helps perb predictive valve diagnostics and help eliminate unwanted plant trips. Emerson DVC6200 digital valve controllers provide Online and Offline diagnostics capabilities. It has onboard flash memory which captures events like black box of an aircraft.? By connecting the DVC with ValveLink software helps engineers to download data to their AMS server or directly to DCS Maintenance station. Analysis of the data helps predict the valve health and plan for any maintenance. Maintenance AMS, Predictive Technology, Maintenance Petrochemicals Engineer Workshop Bala Elamaran Equate Petrochemicals Rajeev Nair Emerson Automation Solutions - - - - - - - - Control Valves -
4. Final Control & Regulate Approved Is there such thing as a SIL rated valve? Can a valve alone be SIL (Safety Integrity Level) rated for use in a Safety Instrumented System (SIS)?? Many users face the challenge of selecting a valve that is suitable for use in a SIS, meets SIL targets with an overall SIL verification, and operates as required. This workshop explores the topics of SIL rating, SIL certification and SIL capability as well as outlines challenges and considerations required to properly select a valve engineered and built for use in a SIS. There are many challenges faced in selecting a valve suitable for use in a SIS, including meeting the intention of the IEC61508 and 61511 requirements as well as ensuring the valve, actuator and accessories are designed and integrated to perb under required conditions over the product lifetime. Utilizing a supplier such as Emerson who has the entire breadth of product capability as well as knowledge to support you with the product over each phase of its lifecycle provides users with the confidence that their SIL verification has been done correctly, the valve has been engineered to operate as one, and that the product will be supported by a single accountable source. These challenges can be overcome by selecting a valve considering SIL verification of the valve and overall SIS loop as well as utilizing and maximizing diagnostic coverage and pairing with a supplier who can assist and provide entire lifecycle support. SIS / SIL FIELDVUE, Safety, Isolation Valves Alternative Fuels, Refining, Pulp & Paper, Power & Utilities, Petrochemicals, Oil & Gas Upstream (On-shore, Off-shore, Sub-sea), Oil & Gas Midstream (Pipelines, Terminals), Metals, Mining, Cement & Glass, Engineering (OEM's, E&C's, Integrators), Chemicals (Industrial, Specialty) Consultant, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Sales / Marketing, Project Manager / Lead, Plant or General Manager, Engineer, Director Workshop Afton Coleman Emerson Carsten Thoegersen Emerson - - - - - - - - Isolation Valves -
4. Final Control & Regulate Approved Are Your Control Valves Gold Plated? How to Reduce Unnecessary Cost & Lead-time from Over Specifying With the competitive markets in nearly all industries it is critical that control valve specifications be standardized. By standardizing technical specifications, we can reduce the cost of control valves instead of inflating the price and lead-time. Reviewing technical specifications upfront for gold plated (over specified) items helps gain alignment to industry standards. This reduces the cost of control valves, engineering hours, and often delivery lead-times needed on a project. Many end users have added in requirements over the years in efforts to be more risk adverse or avoid a situation that happened, sometimes on compleby different products. Having an in-depth understanding and knowledge of end user specifications and aligning them with EPC specifications and standards, along with standards Emerson procures and manufactures control valves to can be difficult. By utilizing early design collaborations and reducing specifications to industry standard for control valves we are able to reduce the cost of the control valve package by 61%. Engineering hours were shortened and the overall project schedule was reduced by 25%. The end user is left with an understanding of industry standard specifications they can use moving forward for future projects. Aligning end users and EPCs with products that meet their needs versus using over specified control valves in an everyday application reduces overall project cost and delivery schedules. Being involved upfront in a technical specification review and vendor data requirements will allow for understanding and see a reduction in engineering hours or lead-time adding to an overall project cost savings. Control Valves Codes & Standards, Efficiency, Design All / Cross-Industry, Engineering (OEM's, E&C's, Integrators) Consultant, Technician / Analyst / Specialist, Project Manager / Lead, Plant or General Manager, Operator, Engineer, Director Workshop Vince Mezzano Fluor John Dressel Fluor - - Janelle Prusha Emerson - - - - Control Valves -
4. Final Control & Regulate Approved Digester Bump Testing Results in Improved Plant Perbance and Reliability "Bump testing of all the critical control valves on the digester about 4 months before scheduled major turnarounds finds the bad actors and allows for replacement during the shutdown. This results in fewer urgent rush orders during the shutdown and allows for better planning prior to the shutdown. Following up with valve diagnostics in the early part of the turnaround will catch the problems that developed since the bump testing. Diagnostics can also be run at this time on valves that were unable to be bumped for various reasons while the plant was running.?
This practice has resulted in much smoother start ups, reduced process variability, reduced downtime due to control valve issues between turnarounds, and a reduction of rush orders and associated costs." "The first time we did this, John Lowsley, a Control Loop Reliability(CLR)Manager with PCE Pacific was asked to do the bump testing 3 weeks prior to the shutdown. He found a lot of problem valves that needed replacing and it was very difficult to source the large valves in 3 weeks.
Subsequent bump tests were done 3-4 months ahead of the scheduled shutdown which has worked well and reduced costs." Reduced process variability, ability to run more loops in automatic, reduced unscheduled downs and upsets to replace or repair bad valves and/or bers. Reduced storeroom inventory as the Fisher 2052, V-ball, and DVC6200 were already the mill standard. Ease of troubleshooting control valves with ValveLink and the ability to run diagnostics on a lot of valves in a short period of time. Most of the valves replaced were blue non-Fisher ball valves with piston actuators. Whenever possible, a Fisher V-ball with a spring and diaphragm actuator and FIELDVUE DVC6200 digital valve controller with PD diagnostics was used which allows for quick valve diagnostics during operation and shutdowns. This is laying the groundwork for an online monitoring system in the future. Optimization Diagnostics, ValveLink, FIELDVUE Pulp & Paper Engineer, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Plant or General Manager Workshop Frank Ramirez KapStone Paper and Packaging John Lowsley PCE Pacific - - - - - - - - Control Valves -
4. Final Control & Regulate Approved Flint Hills Resources Follows New Fisher Valve Selection Guide for Hydrofluoric Acid Alkylation In 2009, Fisher faced an interesting problem. A refinery was following the valve selection guidelines for hydrofluoric acid alkylation (HF Alky) & ordered an impossible valve construction. While working with the licensor on a valid construction, Fisher revolutionized their valve selection in HF Alky. Traditional control valves in HF Alky are limited to post or stem guided sliding stem valves-either Fisher EZ or A-body valves. While both of these valves are still available options, the A-body is a legacy Fisher product that is not frequently manufactured. The new valve selection of a Fisher Vee-Ball valve provides a proven, reliable valve that is more economical & available. In this presentation Flint Hills Resources will share their successful utilization of Fisher Vee-Balls in HF Service. When refiners are asked about the most challenging process units, often the HF Alky unit is mentioned because of the hazards associated with the process operation and fluid. Accordingly, caution is taken when instruments are selected for HF Alky units. However, the selection of a Fisher A-body does not always meet project budgets and schedules. The Vee-Ball at FHR’s Corpus Christi refinery has been operating for 3 years without incident. In addition to the capital savings achieved by selecting a Vee-Ball instead of the traditional A-body, time and cost for repairs will be reduced.? By utilizing a standard (and current Fisher product, operators are more familiar with the valve construction, leading to a safer facility. FHR was one of the early adopters of modernizing control valve selection by using a Fisher Vee-Ball in their HF Alky unit. Prior to approval of the valve, Fisher worked directly with the process licensor to carefully select the valve body and trim components that were acceptable for this service, which was shared in a 2012 Emerson Exchange Workshop. Control Valves Codes & Standards, Sustainability, Compliance Chemicals (Industrial, Specialty), Refining, Petrochemicals, Engineering (OEM's, E&C's, Integrators) Engineer, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, Operator Workshop Taylor Beamer Flint Hills Resources Jerry Cross Puffer-Sweiven - - Andrew Prusha Emerson - - - - Control Valves -
4. Final Control & Regulate Approved Saving your Bacon & Summer Shandy in Wisconsin – Valve Diagnostics to Keep the Electricity Flowing Alliant Columbia is a 1200 MW coal fired power plant that provides electricity to many industrial companies in central Wisconsin.? This session is for individuals who want to benefit from incorporating control valve diagnostic capabilities available with their smart bers into their maintenance & reliability efforts.? Methods and case studies will be shared pertaining to the online diagnostic program at the Alliant Columbia power plant.? We will walk through our bology step by step starting with the AMS Alert Monitor, diagnosing the problem, and the eventual repair. Our goal is to help you identify problems before operations is aware of an issue. Due to early detection, you may prevent unscheduled shutdowns or reductions in your plants output. BFP Recirc. valve - We kept receiving travel deviation alerts for this valve. With further troubleshooting, we were able to correlate the problem to plant operating conditions and logic. Soot Blowers – From the alert monitor, observed high drive signal alert. We discovered a worn I/P and leak in actuator diaphragm. Turbine oil cooler valve - Alerted to relay problem using the PD one button sweep A unexpected plant shut down at critical times can cost us $50,000 in start-up costs, not including lost generation revenue. A damaged Soot Blower valve can cost up to $16,000 to replace if it becomes damaged beyond repair. Keeping our critical assets perbing at optimal levels allows us to deliver electricity to our meat packing plants, breweries, and other electrical customers on the grid. We have assigned a weekly work order to charge time for control valve diagnostics. This provides the time allotment to look at the diagnostic tools that we already had in place.? When a new valve or ber is installed in the plant all of the alerts are set, spec sheets are filled out and other critical diagnostic criteria are completed. This allows an easier path to diagnostics and analysis Diagnostics AMS, ValveLink, Reliability Power & Utilities Technician / Analyst / Specialist Workshop Jake Janssen Alliant Energy Steve Hagen Emerson Automation Solutions - - Steve Zinda Novaspect - - - - Control Valves -
4. Final Control & Regulate Approved Chevron and Emerson Journey to Successful Partial Stoke Testing "Chevron presented their Safety Instrumented System vision and laid out the instrument that will support their vision during a technical exchange session with Emerson.?
Emerson incorporated these requirements into various valve instrumentation development projects and has been working with Chevron to validate that the development is in line with their requirements at various key stages in the project.?
This workshop will discuss the reasons behind the vision, the development challenges and the solutions." "Reduce the number of accessories connected to the final control elements that perb the safety function.?
Requirements:
1. SIL 1 rated b transmitter.
2. Increased venting capacity 0.35, 1.5, 3.5 & 6.0 Cv.
3. Simplify configuration and programming.
4. Full integration to PST Manager.
5. Diagnostics to include Pass, Fault and Fail criteria that are configurable.
6. Operator trust and use." The b process industry is benefiting from Chevron's vision and leadership in the area of Safety Instrumented Systems. The product improvements made to support the Chevron vision have increased the adoption of Partial Stroke Testing, increasing the interval between full stroke test or shutdown thereby increasing the industries availability. "Fisher responded by addressing these requirements in various product releases
1. A SIL2 certified b transmitter in every DVC6200 SIS.??
2. A DVC6200 with high capacity (CV 1.2, 3.2 and 6.4) scheduled for release in June 2017.
3. Simplifying Configuration - Work in progress? .
4. Integration with PST Manager - Available since 2012
5.? ?Configurable Pass, Fail and Fault - Available in FW7." SIS / SIL FIELDVUE, Safety, Isolation Valves Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Engineer Workshop Joe Pittman Chevron Stanley Amirthasamy Emerson Automation Solutions - - - - - - - - Valve Instrumentation -
4. Final Control & Regulate Approved Partial Stroke and Valve Signature Test Data for On/Off Valves "Clients and end users are spending more money today to ensure they are operating a safe and efficient plant. What are users doing today to ensure they are maximizing their ROI.What data will they use to compare when the first PVST and valve signature tests are initiated at site??
Are you prepared and ready to capture partial stroke and valve signature test data for on/off valves? More importantly what inbation needs to be captured and how do you plan on documenting and using the data captured during FAT. During this short course we will explain the procedures we have implemented for pneumatic on/off valves, critical data that should be captured, how to properly capture the data, describe what the inbation is used for, and discuss why it is important to you the user." "PVST and obtaining signatures for on/off valves are becoming more prbent in today’s marketplace
?What inbation is available during the test?
?How will the inbation be captured, stored and transferred?
?How do you know what inbation you need?
?What are some potential pitfalls when executing the tests?
?What are the drivers for collection and maintenance of the data?" By collaborating with our customer and identifying their requirements, we were able to bulate a defined procedure. Since there currently is no procedure in the industry, we felt it was critical for our success to develop this. The benefit to our end user is that we capture all of the data, save it, then load to the plant maintenance tool when the customer is ready, which eliminates delays. The Isolation Valve team has developed a standardized process which is followed for any valves that require PVST and/or valve signatures. This ensures consistency during the FAT and reduces any delays during start-up. Diagnostics Diagnostics, SIS / SIL, Isolation Valves Petrochemicals Engineer Workshop Jose Breton Puffer Sweiven Kerry McFee Fluor - - - - - - - - Isolation Valves -
4. Final Control & Regulate Approved Koch Pipeline Links Reliability of Fisher Valve with Efficiency of VFD for Optimal Pipeline Control Pipeline energy usage, which includes either using a control valve to throttle pressure or a variable frequency drive (VFD) to control the speed of pumps, can be optimized for a wide range of operating scenarios.? Koch Pipeline (KPL) learned that by using a control valve to throttle pressure can sometimes be more efficient than using a VFD to control the speed of a pump, considering energy losses and associated costs of isolation transbers, HVAC, etc.? However, the inverse is also true in certain scenarios.? In the scenario that will be discussed, using a Fisher? V250 control valve in conjunction with a VFD provided better energy efficiency and greater reliability for the pump by ensuring that it operates within its design curve limits. Pipelines are notorious for requiring final control equipment to function through a wide range of operating scenarios. KPL desired an optimized solution that would lower energy costs, improve pump reliability, and lengthen the mean time between failure (MTBF). After reviewing the complete range of operating scenarios and available solutions, KPL was able to choose the solution that provided the lowest possible energy costs, highest pump reliability, and broadest range of operating scenarios. The selected solution combined the precision and reliability of the Fisher V250 with the efficiency of a VFD. The key to optimizing the control scheme is to use all available data associated with the equipment energy losses. By utilizing utility rates and understanding that there are costs associated with throttling pressure, HVAC and transber losses, and operating equipment outside of its design limits, KPL and their LBP Novaspect developed a cost effective and reliable control scheme. Optimization Efficiency, Process Control, Optimization Oil & Gas Midstream (Pipelines, Terminals) Engineer Workshop Chuck Swanson Koch Pipeline Ken Hillman Koch Pipeline - - Eben Spencer Koch Pipeline - - - - Control Valves -
4. Final Control & Regulate Approved Flint Hills & Emerson Collaborate to Increase Production Uptime by Using Fisher High Alloy Valve When a valve has a standing preventative maintenance (PM) order for complete trim replacement, there might be a better option available. In the production of Purified Isophthalic Acid (PIA), there are unique vessel-mounted valves that are required to handle three phase flow-gas, liquid, and solid crystals. At Flint Hills Resources (FHR) Joliet plant, an existing valve required frequent (planned and unplanned) maintenance due to regular sticking issues and packing leaks. After learning from their LBP, Novaspect, that Fisher had a unique valve design for this application, FHR worked closely with Emerson and Novaspect to select a Fisher replacement. Since installation, FHR has increased PM cycles to at least 18 months. The application challenges and Fisher valve solution will be discussed. While the existing valve did not throttle regularly once the PIA unit was operational, FHR was concerned that in the event it needed to move, the valve would be stuck in place, which can damage the very expensive catalyst. It was noted that the valve rarely went over 20% open, but there was no documentation indicating a need for a higher flowrate. Since installation of the new Fisher SS-83, FHR has seen significant savings associated with the reduced maintenance and production downtime. Between 2010-15, the valve required maintenance 2-4 times annually, but after installing the new valve in late 2015, no work orders have been required and Fisher Lifecycle Services has developed a cost effective plan in place to refurbish the titanium trim. It was evident that FHR needed a more dependable valve. Working off the current process data instead of a dated spec sheet, Emerson engineers and the Novaspect team were able to size and select a unique severe service SS-83 valve that fit the operating conditions into a wider control range using a smaller port size, provide low emission packing, and include a lubrication option to reduce sticking. Severe Service Control Valves, Reliability, Maintenance Chemicals (Industrial, Specialty), Refining, Petrochemicals, Engineering (OEM's, E&C's, Integrators) Engineer, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, Operator Workshop Angel Arias Flint Hills Resources Dave Goode Emerson - - Mike Leinhauser Novaspect - - - - Control Valves -
4. Final Control & Regulate Approved Critical Applications in the Pulp and Paper Industry The pulp and paper industry has twelve critical applications known as the “dirty dozen” which are usually problem valves for customers. Spartan Controls worked with Harmac Pacific to provide Fisher valve solutions for these applications to improve reliability, efficiency, and the lifespan of the control valves. Each application is unique and must be reviewed carefully in order to select the proper valve solution. It is important to match application requirements with available control valve designs and options to provide for a more optimal and profitable process operation. When a valve is properly selected for an application, it can last in service for many years even in the most challenging applications. There are different problems and challenges faced in the dirty dozen applications that are specific to each application. Problems for applications in the bleach plant are usually erosion and corrosion due to the chemicals used in these processes while applications in the power house deal with high pressure and temperature making them more susceptible to problems like cavitation and noise. The Fisher valve solutions provided Harmac Pacific with better control perbance, reduced variability, and increased reliability. Problems such as cavitation and noise were also alleviated. Overall, plant efficiency increased and waste was reduced leading to a more profitable operation. In the pulp and paper mill side, the most common solutions are rotary valves (Fisher V150/V300 and Fisher 8580/8532) in stainless steel constructions to withstand the process media. In the power house, the most common solutions are the Fisher easy-e or the Fisher HP/EH depending on the pressure and temperature with anti-cavitation trim or noise attenuating trim. Process Control Control Valves, Reliability, Optimization Pulp & Paper Engineer, Sales / Marketing, Plant or General Manager, Operator Workshop Greg Rivett Harmac Pacific Mary Barker Emerson Process Management - - Dirk Feenstra Spartan Controls - - - - Control Valves -
4. Final Control & Regulate Approved DVC6200 Digital Valve Controller Zero Point Calibration Presentation on the DVC6200 Digital Valve Controller ability to be quickly replaced in a "Hot Swap" situation without the need to conduct a full travel calibration. This is a unique quality that the DVC6200 has giving it an advantage to be quickly replaced in the field under active process conditions and function effectively until an auto-calibration of travel can be completed. In active process conditions a failing or crippled instrument directly impacts plant operations. Often no bypass exist and stroking the valve is not possible as this would upset the process. This drives the necessity for a instrument to be "Hot Swapped" while process is active at the valve without the need to complete a full travel calibration. The DVC6200 allows a "Hot Swap" procedure without having to fully stroke the valve assembly that would cause a process upset but still provides excellent control and valve b accuracy. This reduces time spent on replacement, quickly restores plant efficiency, and removes the possibility of a costly plant or unit trip. All DVC6200 instruments are pre-calibrated at the factory. All magnetic arrays used for travel b feedback have the same magnetic field regardless of shape or size. This allows the DVC6200 to be replaced with another unit and maintain good control without a full travel calibration conducted in the field. Installation Best Practices Control Valves, Troubleshooting, FIELDVUE All / Cross-Industry Technician / Analyst / Specialist Workshop Ron Hager Emeron Automation Solutions Steve Hagen Emerson Automation Solutions - - - - - - - - Valve Instrumentation -
4. Final Control & Regulate Approved Improving the efficiency of natural draft burner for oil and gas production An upstream oil and gas production company, in the Marcellus and Utica shale bation, has implemented a new fuel gas control system and burner design on their gas production units (GPU). The new system is a combination of Emerson’s Fisher Regulators and ASCO Solenoid Valves united with Millstream’s natural draft burner design. Using this new fuel gas system delivers more consistent heat throughout the firetube, reduces fuel gas usage and emissions, and decreases unplanned downtime. In addition to the above this new system has increased safety for their employees by keeping them from manually lighting burners. "1.Fuel gas supply to the burner needs to be accurate, reliable and connect to a burner management system (BMS).
2.Burners need a reduced supply of fuel during startup to ensure ignition.
3.Cost associated with running burners in a low commodity price environment.
4.Temperature in the firetube were not unib and fluctuate.
5.Burners were manually lit exposing employees to risk of burns or worse." "1. Reduced fuel gas usage up to 40% resulting in about $1.5 million/yr in fuel gas savings.
2. Decrease unplanned downtime resulting in increased production of over $2 million/yr.
3. Improved safety for employees with Fisher 119EZ and ASCO solenoids connected to automated ignition system.
4. Reduce gas emissions by monitoring flame presence and shutting down fuel system when flame is not present." "1. Emerson’s Fisher Regulators and ASCO Solenoid Valves are accurate, extremely reliable and connect to any BMS control system.
2. Emerson’s Fisher 119EZ has an adjustable opening speed to tune it to the burner startup requirements.
3. Millstream’s unique burner design is highly efficient and reduces fuel gas usage.
4. Millstream’s design distributes heat evenly throughout the firetube." Process Control Optimization, Reliability, Regulators Oil & Gas Upstream (On-shore, Off-shore, Sub-sea) Director, Sales / Marketing, Plant or General Manager, Operator, Engineer Workshop Greg Nuk Millstream Thomas Weyer Regulator Technologies - - - - - - - - Pressure Regulators -
4. Final Control & Regulate Approved Improving Severe Service Valves Applications in New Tula Delayed Coke Utilizing Fisher Technology "Pemex Tula Refinery did acquire one of the largest DCU units in the world with a 166-thousand BPD total capacity to achieve its goal of expanding the refinery’s capabilities. Comprehensive long-term care of control valves has been a crucial directive to achieve expected perbance meeting production schedules, maintaining product quality while taking full advantage of the waste from the primary units of the refinery.?
Utilizing Fisher specific and special severe service control valves as well as FIELDVUE technology for common delayed coker valve selection issues will represent long lasting and cost effective valve solutions, savings in maintenances and unexpected shutdowns." Common delayed coker valve selection issues include high temperatures, large particulate, material compatibility, viscous fluids, corrosive environments, environmental compliance, experiencing coke buildup, cavitation, trim plugging, flashing, outgassing and high aero and hydrodynamic noise levels, resulting in disturbances in process, unsuitable control and low perbance of control valves. Acquisition of these valves with Fisher technology will represent long lasting and cost effective valve solution, savings in maintenances and unexpected shutdowns. Improved control and high mechanical perbance against erosion, cavitation with particulate as well as flashing and some outgassing issues. Several applications to beat any problem related with dirty fluids and any severe serviceas mentioned with Fisher V500 FFD Special Valve for furnace feed in coker units, 461, NotchFlo DST and E series with DST (Dirty Service Trim) trim, V500, Whisper Trim. FIELDVUE DVC6200f @ FD & AD. Severe Service Control Valves, Severe Service, Optimization Refining Consultant, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Operator, Engineer Workshop Daniel Cano Emerson Process Management S.A. de C.V. Fernando Parga PEMEX - - - - - - - - Control Valves -
4. Final Control & Regulate Approved How many revisions to get it RIGHT? Selecting Severe Service valves for ExxonMobil’s RAHC expansion In 2016, ExxonMobil’s Rotterdam refinery built a new Advanced Hydrocracker at their existing refinery site. The project required several Fisher Severe Service valves. Primary solution was a high pressure angle valve with engineered-to-order trim for hydrocracker service, where a phenomenon known as outgassing is common. Selection for one control valve with a DST-G design (Dirty Service Trim for Out-Gassing) is challenging, let alone for multiple applications. Working together and challenging each other, Fisher, the EPC, and ExxonMobil successfully engineered solutions for the difficult applications. Once specification sheet and process data is clarified and missing data resolved, correct interpretation is bount. All-inclusive, commercially available software packages can fall short for correctly determining control valve requirements. Third party results from such programs conflicted with Fisher IEC 60534-2-1 based sizing calculations and special techniques used for out-gassing services. The team successfully worked together to size, select, and deliver eleven Severe Service control valves. Getting more process perbance data and its appropriate implementation is key for control valves to operate as intended the first time while minimizing change orders and overall project costs on the deployment of Rotterdam’s $1.2-billion brownfield project. Conflicts between Fisher sizing calculation and third party results were first discovered at a preliminary meeting to discuss the project.? Due to the different world areas involved, several Webcasts were held between all parties to determine the appropriate sizing model and valve selection b, as well as to implement on-going changes in process beters. Severe Service Control Valves Engineering (OEM's, E&C's, Integrators), Refining Consultant, Technician / Analyst / Specialist, Project Manager / Lead, Engineer Workshop Ernie Shikles ExxonMobil Chris Hammond Emerson - - Janelle Prusha Emerson - - - - Control Valves -
4. Final Control & Regulate Approved Future of Tank Management Wireless Monitoring Control "Vale is amongst the largest mining companies in the world. Located North of Brazil, Carajas is one of the most significant iron reserves for Vale. Trucks are used as the main product transportation mean at this site, leading to considerable Diesel consumption. Vale consumes 2.5% of Brazilian Diesel. Following API 2000 standards, atmospheric tanks strategically store the flammable liquid, meeting the high demand at this remote b.?
Unmonitored from the Control Room, Storage Tanks are essential assets that directly impact operational efficiency. Managing the vapor space inside the tank improves Safety, Product Quality and the Environment. In addition, fine tuning and live monitoring reduces costs related to tank management" The restricted access and under developed conditions at this site elevate difficulties to manage pressure and protect the tanks. The unmonitored aspect increase the risk of failure related to the vapor space pressure inside each of the 24 diesel tanks, exposing the fixed assets to implosion and explosion situations. The remote b jeopardizes the speed of response in case of emergencies "$150K annual maintenance savings. Solution allows for abnormal condition detection, anticipating production problems;
$400K reduction of insurance premiums;
Flame Arrestor capacity monitoring;
Reduction of employee exposure to hazardous situations during inspection;?
Improved reliability & reduction of unscheduled stops;
Improvement of operational safety & risk management;
Payback under 12 months;" Monitor pressure remoby as it oscillates with temperature and level. The wireless solution includes a GO Switch installed at the PVRV pallets, reporting open and close bs from overpressure and Vacuum; a temperature transmitter at the flame arrestors, monitoring the system against potential fire hazards; A pressure differential transmitter at the Flame arrestor indicating maintenance needs Reliability Regulators, Wireless, Safety Alternative Fuels, Refining, Petrochemicals, Oil & Gas Upstream (On-shore, Off-shore, Sub-sea), Oil & Gas Midstream (Pipelines, Terminals), Metals, Mining, Cement & Glass, Food, Beverage & Consumer Goods, Engineering (OEM's, E&C's, Integrators), Chemicals (Industrial, Specialty) Engineer, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Sales / Marketing, Project Manager / Lead, Plant or General Manager, Operator Workshop Marcelo Valandro Vale Diego Cruz Emerson - - Victor Oliveira Emerson - - - - Pressure Regulators -
4. Final Control & Regulate Approved ENI Petroleum Improves Control Valve Reliability with Emerson Connected Services "ENI Petroleum is a 20K BPD refinery on the North Slope of Alaska. Critical control valves play a major role in the reliability of the refinery.? A process upset due to a failure of a critical control valve can be extremely costly to ENI's bottom line.? ENI needed to standardize their control valve reliability program in order to avoid unplanned events.??
Developing a control valve expert was not a realistic solution in their remote b, so ENI turned to Emerson's Connected Services experts to gain the control valve expertise they needed to support the planned maintenance of critical valves." Developing an expert in valve diagnostics was not realistic at ENI.? The site is in remote Alaska and is minimally staffed with maintenance personnel.? The maintenance team relies on support from Emerson experts to analyze diagnostic data, deliver recommendations, support the planned maintenance of control valves at the refinery. One unplanned shutdown of the refinery for 30 minutes will pay for the service for one year, so the most import bive is to keep the plant running.? ENI and Emerson are doing this by identifying conditions as they appear on control valves and collaborating on recommended repairs using ENI's work order management tools.? This has been a major improvement for work order management for ENI. ENI Petroleum subscribed to Emerson's Control Valve Connected Services to monitor their critical control valves.? Emerson collects and analyzes data from ENI's valves on a weekly basis and reports any problematic conditions to ENI for repair. This allows ENI's limited staff to focus their maintenance efforts on urgent issues and eliminates the need for an onsite valve expert. Services Diagnostics, Reliability, PlantWeb Refining Consultant, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, President / Principal, Plant or General Manager, Operator, Engineer Workshop Robin Bogard ENI Petroleum Todd Bell PCE Pacific - - Joe Johnson Emerson Automation Solutions - - - - Control Valves -
4. Final Control & Regulate Approved Emerson & Fluor use SmartPlant Instrumentation to keep ExxonMobil’s RAHC expansion on track As industry moves toward a data centric engineering environment, a critical element are control valves which are complex to specify, have critical lead times, and impact piping design. Emerson, Puffer-Sweiven and Fluor have combined their expertise to automate the work process from specification to piping design using Intergraph SmartPlant Instrumentation (SPI) and Fisher tools. By transferring data electronically rather than using paper documents, the work content, schedule lead time and data entry errors are significantly reduced. The current process when sizing, selecting, and delivering vendor data for control valves is manual handling of specifications and drawings for dimensional data for building valves in the 3D model. This is labor intensive and prone to data entry errors throughout the supply chain. This manual process impacts engineering schedules causing project delays and increasing project cost. Emerson and Fluor executed Rotterdam’s 16,000 tag project using SPI and were able to reduce engineering lead-time by 5 weeks, introduced a seamless work process, removed data entry errors, and management of change was smoother with revision tracking capability within SPI. Overall Control Systems Engineering and Piping Design cost was reduced 20% by implementing electronic data transfer. Emerson partnered with Intergraph to introduce functionality between Emerson’s Fisher FIRST 2 tool and Intergraph’s SPI to simplify the electronic transfer of control valve specification data and Dimensional Data for Piping. The imported data populates into SPI and is available to Intergraph’s Smart 3D for piping designers to quickly insert control valve 3D shapes into the 3D piping design model. Optimization Control Valves, Optimization, Design All / Cross-Industry, Engineering (OEM's, E&C's, Integrators) Consultant, Vice President, Sales / Marketing, Project Manager / Lead, President / Principal, Plant or General Manager, Engineer, Director Workshop John Dressel Fluor Luis Angelo Bonito Fluor - - Janelle Prusha Emerson - - - - Control Valves -
4. Final Control & Regulate Approved Valve Connected Services Offer Early Value to Shell Shell in Deer Park, TX decided to subscribe to Emerson's Valve Connected Services for support in analyzing control valve diagnostic data.? This this workshop will discuss the early findings from the service and outline plans for using those findings at an upcoming Turnaround. Shell has been challenged with a lack or resources necessary to get the full value out of their technology investment in diagnostics.? We need help analyzing tour valve diagnostic data so that we always know the status of our control valves and can ensure appropriate maintenance activities based on the diagnostic analysis. The service has only been in place for 3 months, but we have identified some early benefits.? The service implementation identified some valve conditions that needed to be addressed.? Subsequent reports identified a common condition on control valves located around a heater.? All of this data has helped us to identify service work to be done at an upcoming turnaround. Shell subscribed to Emerson Valve Connected Services to improve control valve reliability.? Having a better understanding of the health of our control valves while we are operating will help to avoid unplanned outages and develop accurate plans for an upcoming refinery turnaround. Services Control Valves, Reliability, PlantWeb Refining Consultant, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, President / Principal, Plant or General Manager, Operator, Engineer Workshop Scott Miller Shell Craig Jeane Puffer Sweiven - - Joe Johnson Emerson Automation Solutions - - - - Control Valves -
4. Final Control & Regulate Approved Optimizing Ball Valve Seals to Meet Stringent Fugitive Emission Requirements Industry requirements are becoming more and more bent with Fugitive Emission Testing (FET) requirements; this is one of the biggest challenges facing the valve industry moving forward. According the US Environmental Protection Agency, “60% of all fugitive emissions come from valve stem packing.” Many EPCs and end users struggle to meet these requirements while keeping valve cost under control. Being able to adhere bent requirements for Fugitive Emission Testing per ISO 15848-1 & Type Acceptance Testing as per Shell MESC at a reasonable cost takes special engineering effort. This workshop will cover how Emerson engineers used a combination of design tools and industry experience to successful meet the requirements and keep cost in control for our customers. A major challenge with meeting FET with a bottom entry stem ball valve design is being able to accommodate stem seals. A valve designer has to balance the use of space for the seal while meeting the industry envelope requirements for the valve. Emerson engineers explored various options to meet the requirements including the use of special grade O-rings, lipseals, and several pack materials. The project resulted in being able to successfully achieve FET tightness Class A / B with endurance class CO1 for a temperature range of -50° to +232° C. These results were certified by Third Party Inspectors. This solution will help to reduce the fugitive emissions that come from valve stem packings to better our environment and help our customers lower their emissions, a win all around. Emerson engineers were able to design a series of Virgo valves that met FET per ISO 15848-1, Class A / B, endurance class- CO1, while also accommodating a wide range of customer seal requirements.? This solution required a combination of engineering, appropriate geometric dimensioning and tolerancing, as well as, manufacturing process improvements to achieve the desired results. Compliance Codes & Standards, Isolation Valves, Engineering Chemicals (Industrial, Specialty), Refining, Petrochemicals, Oil & Gas Upstream (On-shore, Off-shore, Sub-sea), Oil & Gas Midstream (Pipelines, Terminals), Engineering (OEM's, E&C's, Integrators) 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 Tony Foster Emerson Narayan Patil Emerson - - - - - - - - Isolation Valves -
4. Final Control & Regulate Approved Creating a Smart Gas Lift Control Valve!? Getting Creative with Fisher easy-Drive Solutions The Internet of Things focuses on the interconnectivity of products, services and people. Emerson and Fisher are consistently pushing the boundaries on smart technology and communication efficiency.? With the recent release of the Fisher Generation 2 easy-Drive controller came a microprocessor and an extra set of Digital Input/Output terminals.? These allow endless customizations to a customer's well pad and other process control applications.? We will discuss how you can leverage the power of smart electronics to maximize operational insight of processes like Gas Lift, Plunger Lift, Separators, Heater Treaters and much more! Gas lift plays an important role for most oil producers.? As fields and wells mature, the production units require the ability to handle increasing gas and water.? Optimization of this process helps ensure maximum oil production and maximum profits.? Gaining process insight with smart technology can exponentially increase the factor of success for these operations. Fisher's easy-Drive Electric Actuator provides the missing piece in valve health monitoring.? Receive real-time data over existing Modbus networks, allowing 24/ monitoring capabilities without sending personnel to site.? Implementing smart technology can unlock the true automation potential. Customers worldwide have begun to use the flexibility of the easy-Drive to their benefit.? New digital b / output terminals can be used as a b feedback, high/low level interlocks and many more.? The new microprocessor allows application style programs to be written to the board for agile enhancements Optimization Actuation, Instrumentation - Analytical, Control Valves All / Cross-Industry Operator Workshop Shawn Fagen Emerson Automation Solutions Thomas Pesek Fisher - - - - - - - - Actuation -
4. Final Control & Regulate Approved Celanese and Emerson work through challenges to implement Valve Connected Services Celanese and Emerson identified a number of IT security and operational challenges when they implemented a Valve Connected Services contract.? Working through those challenges has given both companies a better understanding of how this service will be executed now and in the future. "Celanese has strict protocols on our process control network that made it difficult for the diagnostic tests to run.? We had to build a workaround for that process.??
We also had concerns about diagnostic tests heavily loading our DeltaV DCS.? Emerson worked with Celanese operations to ensure that diagnostic tests would not interrupt our process." The collaboration with Emerson has allowed us to begin the Connected Services monitoring process, which we are looking forward to, but we have already gone through the implementation of the service and during that process, we have identified preliminary reliability issues on 2 critical valves.? We are looking forward to more insight into the health of our valves as the service progresses. We ended up installing a ValveLink client station on our mobile network.? This allowed us to operate in a secure enviornment, but avoid the strict policies of the process control network. We also worked with Emerson to ensure that the ValveLink tests would not cause unnecessary load on our DeltaV DCS. Troubleshooting Diagnostics, ValveLink, PlantWeb Chemicals (Industrial, Specialty) Consultant, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Project Manager / Lead, President / Principal, Operator, Engineer, Director Workshop Greg Gattis Celanese Joe Johnson Emerson Automation Solutions - - Carla Pruneda Puffer Sweiven - - - - Control Valves -
4. Final Control & Regulate Approved Improving Turbine Bypass Reliability through Actuation Retrofits "The Wisconsin Public Service Fox Energy Center is a 620MW 2x1 Combined Cycle Power Plant that began operation in 2005.? The facility is located just outside of Kaukauna, Wisconsin, about 20 miles Southwest of Green Bay.??
This session will discuss the challenges that Fox Energy Center faced since 2005 with their turbine bypass valves during startup and operation.? It will dive into how? Plant Fox was able to improve perbance and reliability by retrofitting their actuation package with a Fisher actuator, volume boosters, and a Fisher DVC6200 onto competitor valves.? The presentation will finally discuss the benefits to that Fox Energy Center has seen since the retrofit." Fox was built with CCI turbine bypass valves.? Since construction, the plant was continually challenged by valve and actuator perbance.? Up to six times per year they missed scheduled start times due to poor actuation perbance during winter months. The plant also struggled to get qualified support from the manufacturer due to the lack of local support for CCI valves in Wisconsin. Since installation the plant has undergone every possible sequence of start-ups events.? In every case the actuators perbed.? For the first time since the plant was built in 2005, Fox did not miss a scheduled start. The plant is now able to perb their own diagnostic condition monitoring through the DVC ber and the AMS system and receive local support through Novaspect. "In October, 2015 six new actuator packages were purchased.? The Fisher actuator packages included:
? Type 585C piston actuators and yoke adaptation
? Remote Mounted type 6200 DVC bers with ODV diagnostic tier
? 377 Trip Valve
? Volume Tank
? Solenoid Valve
? 4 Type 2625 Volume Boosters
? Parker Filter/Regulator
? On-site installation and start-up calibration" Actuation Control Valves, Reliability, Operations Power & Utilities Engineer, Technician / Analyst / Specialist, Plant or General Manager, Operator Workshop Marc Puyleart Novaspect Keith Nehring Emerson Process Management - - - - - - - - Actuation -
4. Final Control & Regulate Approved No Emissions? No Problem! A Solar Powered Wellpad Solution; The Future of Upstream Oil & Gas SM Energy wanted to get rid of pneumatics on their wellpad, due to perbance and reliability issues.? Puffer-Sweiven’s Fisher and RAS engaged the customer on an electric wellpad solution, using all Emerson equipment.? One problem was that the pad had to run on solar, so low power equipment was a must. Due to the complexity of the design, it was necessary for Puffer to provide not only the equipment, but also RAS commissioning services.? SM’s Houston office doesn’t have a purchasing department, so they requested that Puffer bundle all the Emerson equipment together, thereby reducing purchasing complexity for the customer. A great team Effort between the Local Business Partner and other Emerson Business units to provide a full electric wellpad solution; the future of Upstream Oil & Gas. With increasing EPA regulations on the upstream Oil & Gas Industry, customers need to be looking for alternate wellpad solutions from traditional pneumatics. A full electric automated wellpad solution powered by solar gives the customer greater reliability & perbance. Not only is it emission free (except for the ESD), but they have more insight into their process than they've ever had before. Electric, no bleed solution; Visibility into process which they hadn't had before with traditional pneumatic products. Reliability & Precision/Perbance is greater with Emerson's electric solutions. We are currently commissioning the first pad this week, and expect to startup mid-March.? By the end of FY17, we expect to have some run-time data on the equipment. The electric wellpad solution encompasses many Emerson Business Units. Fisher's easy-Drive dump valves & L2e / 2100E level control technology. Remote Automation ROC's and Rosemount products. Puffer-Sweiven provided the additional services of bundling the package & start-up/commissioning services; thereby reducing purchasing & start-up complexity for the customer. Design Compliance, Wireless, Reliability 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, Operator, Engineer, Director Workshop Reid Youngdahl Emerson Fisher Jeff Cassidy Puffer-Sweiven - - - - - - - - Actuation -
4. Final Control & Regulate Approved How we leveraged Emerson's actuation technology and service network to increase plant reliability Emerson Fisher was approached by Lyondell to improve compressor anti-surge valve reliability.? The installed competitor valve had caused plant shutdowns on several occasions.? After a few discussions, it was collaboratively determined that the best path forward to meet budget and obtain desired perbance would be to retrofit a Fisher actuator and accessory package onto the competitor valve.? Given the high criticality and history of this valve on site, we took a deep look at every detail during preparation, engineering, and execution to create a compleby custom solution which was delivered on site and on time.? Now, five months after installation, Lyondell is very pleased with the valve’s enhanced perbance and we are looking to share this success with other Emerson users. Lyondell was experiencing several issues with the operation of a competitor valve. The valve is installed upside down and water had collected in the actuator yoke and handwheel, rendering the handwheel inoperable.? Actuation and accessory failure caused this valve to fail twice with a multimillion-dollar operational impact. Lyondell is very satisfied with not only the implemented solution, but the service and support Emerson has offered and will continue to offer throughout this assembly’s lifecycle.? The upgraded actuation and accessory package has made compressor startup smoother and has not resulted in any unexpected plant shutdowns. Emerson engineered a special optimized digital valve (ODV) accessory package fitted on a custom model 685 actuator.? Due to valve orientation and prior water collection issues, Emerson implemented actuator specials such as room temperature vulcanization (RTV) silicone sealing, a protective piston rod bellows/boot, and a hydraulic override to eliminate any potential manual override gear corrosion. Reliability Actuation, Services, Control Valves Chemicals (Industrial, Specialty), Petrochemicals, Oil & Gas Midstream (Pipelines, Terminals) Engineer, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Plant or General Manager Workshop Will Sjobeck Fisher Controls International LLC Dino Desalvo Lyondell - - Mike Leinhauser Novaspect - - - - Actuation -
4. Final Control & Regulate Approved Poet Increases Product Throughput and Improves Unit Reliability Through Mole Sieve Bottle Upgrade In 2014, Poet Big Stone was struggling with reliability and efficiency within their distillation process. This presentation will show how Poet, in collaboration with Emerson and their Local Business Partner, has turned their maintenance-prone Molecular Sieve Bottles into a dependable and efficient process unit. Emerson’s Molecular Sieve Solution uses proven Fisher? technology that has been tested to withstand the rigorous demands of high cycle applications. The upgrade captured in this presentation has helped Poet achieve both a significant increase in throughput and a reduction in maintenance costs within the distillation unit. The valves used in Molecular Sieve applications cycle 10-15 times per hour. Valves, actuators, and instrumentation that are not designed for high cycle applications suffer due to mechanical failures, leading to downtime and inefficiency. Poet has a total of 24 valves and their existing solution had a typical lifespan of only 3-4 months. This reduced lifespan was severely limiting plant throughput. Since the installation, Poet Big Stone has realized significant results. In addition to increasing maintenance intervals by a factor of 8, the Emerson solution has improved the vacuum perbance of the bottles through increased shutoff. The throughput improvement achieved, by means of enhanced vacuum perbance, was sufficient to provide a 2 month payback on the solution. Emerson’s Molecular Sieve Solution consists of a Fisher 8580 High Perbance Butterfly Valve, FieldQ Rack and Pinion actuator and an Asco Solenoid. Each bottle also includes a control valve fitted with a FIELDVUE DVC6200 valve controller. The Fisher 8580 High Perbance Butterfly Valve has been tested, using the 136,000-square-foot Emerson Innovation Center, to withstand over 1 million cycles. Reliability Control Valves, Maintenance, Efficiency Alternative Fuels Engineer, Plant or General Manager, Operator Workshop DJ Haggerty Poet Ryan Enockson Novaspect - - Jonathan Vance Emerson - - - - Control Valves -
4. Final Control & Regulate Approved How additive manufacturing supported Lubrizol’s valve trim needs Lubrizol’s hydrogen sulfide unit is critical to site operations. The unit includes multiple control points that must operate with a high level of accuracy to ensure smooth operations. One of these points is pressure control with a low flow rate and erosive service. Due to these application conditions, a very specific trim set was required in erosion resistant material. This workshop discusses how Emerson’s Additive manufacturing technology was utilized to meet Lubrizol’s specific trim set needs. Due to the criticality of the application, the valve must be continually monitored for any perbance changes. The erosive nature of the process continually wears on trim components and requires replacement.? A specific low-flow trim set was required to meet perbance requirements.? When traditionally manufactured, this trim set can pose challenges due to extremely close tolerances required. Where perbance is critical for tight control for low flow control valves, customers need vendors with flexible manufacturing needs.? Emerson Additive Technology provided Lubrizol with a solution meeting their expectations for execution and quality. Micro-flute trim was selected to meet the low flow requirements in Alloy 6 material due to its erosion resistant properties.? Where perbance is critical for tight control for low flow control valves, customers need vendors with flexible manufacturing needs.? Emerson Additive Technology provided Lubrizol with a solution meeting their expectations for execution and quality. Control Valves Design, Severe Service, Engineering All / Cross-Industry Engineer, Supervisor / Manager / Dept. Head, Operator Workshop Blake Coleman Emerson Pete Engler Equipment & Controls, Inc. - - Melissa Westbrook Lubrizol - - - - Control Valves -
4. Final Control & Regulate Approved Material Compatibility Question? Keep Calm and Collaborate Material selection is a crucial and often times misunderstood segment of the Chemical Industry. This presentation will provide insight into the process by which Emerson Process Management Fisher qualifies suppliers for high alloy castings and how control valve users, in collaboration with Emerson, can leverage perbance history and process knowledge to make inbed material selections. Proper material selection allows users to maximize product reliability and availability thereby limiting unplanned downtime and increasing product throughput. Control valve challenges within the chemical industry are often attributed to poor material selection. These challenges include, but are not limited to, perbance, throughput, availability, safety, and reliability. Improper material selection introduces unnecessary risk in to the process control equation and has the ability to create additional issues downstream. The bology outlined in this presentation provides control valve users with the tools needed to make material selections with confidence. The ability to match the correct material selection with a given application allows users to maximize uptime without over specification thereby saving time and money. Stringent supplier qualification requirements in combination with Emerson's material and application expertise and the user's process knowledge and historical valve perbance allow users to make inbed material selections. The bology outlined in this presentation accelerates the material selection process and establishes a process for the future. Control Valves Reliability, Severe Service, Safety Chemicals (Industrial, Specialty) Engineer Workshop Jonathan Vance Emerson Meredith Bell Emerson - - - - - - - - Control Valves -
5. Business Management & Career Development Approved 3 Superpowers to Boost Your Career Career growth has little to do with how smart you are or how hard you work. Despite the long hours, we stay in our role,? wondering when we will get promoted or when our efforts will be recognized. Often we believe that others are holding us back, preventing us from getting that promotion or recognition and causing us stress. The truth is that, beyond a perbance threshold, success has more to do with ourselves holding us back. The? good news about this is that we can control ourselves. In this workshop, I will share three key concepts and techniques that I have learned that have helped me move from a worker to a leader - compleby changing my career trajectory and limitations as a result. Engineers are often hired for their knowledge or technical skills. But over the course of a career, they need to develop professionally - developing new skills and changing others' perception in order to gain visibility and to be given the opportunities to expand professionally. Since beginning to employ these strategies, my career has taken off. I made significant contributions outside of my role. Over the next few years I was granted an $85,000? scholarship from my company to pay for an Executive MBA, at age 30 I was named a Leader Under 40 by Control Engineering magazine, and I was promoted 3 times in 4 years up to a Global Director role at age 33. First, change your relationship with fear. By changing our relationship with fear we change the decisions that we make. Second, change your story. This changes the perception of your ambitions and contributions. Third, learn to breathe. The ability to take a breath and then act in a considered way helps you deal with the challenges of change and it also builds others' confidence in you. Personal Improvement Business, Management, Leadership All / Cross-Industry Consultant, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Sales / Marketing, Project Manager / Lead, Plant or General Manager, Other, Operator, Engineer, Director Workshop Aaron Crews Emerson Process Management - - - - - - Career Development - - - - -
5. Business Management & Career Development Approved Best Practices for Preparing and Delivering a Successful PowerPoint Presentation This course will provide bable strategies to deliver a well-polished and organized PowerPoint presentation.? Learn about common PowerPoint pitfalls that can be a distrb to your presentation.? Conversely, see what makes a successful PowerPoint presentation including overall flow and content organization, slide layout and structure, graphics and visuals, and overall presentation tips. Nothing can cause an important meeting to go wrong like a poorly executed PowerPoint.? A presentation that is unorganized, messy, and confusing is not only distracting, but it can cause great ideas and proposals to get rejected.? Even worse, consistently delivering poor? presentations can be a barrier for career growth and advancement. A polished PowerPoint presentation ensures your key messages and ideas are communicated to management with clarity and vision.? More importantly, it is a direct reflection on you that can leave a lasting impression with your management. Just like a standard five paragraph thesis, a well-executed PowerPoint presentation has hierarchy, structure, key messages, and clarity.? To achieve these goals, this session will go over best practices for? slide titles, graphics and images, text, and overall slide layout. Personal Improvement Leadership, Motivational, Management All / Cross-Industry Consultant, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Sales / Marketing, Project Manager / Lead, President / Principal, Plant or General Manager, Other, Operator, Engineer, Director Short Course Michael Olivier Emerson Ben Louwagie Emerson - - - - Career Development - - - - -
5. Business Management & Career Development Approved E+R=O Success Mantra for Professionals The book “The Success Principles” by Jack Canfield focusses on the Success Mantra “Event(E) + Response(R) = Outcome(O)”. The Speaker decided to specialize in Functional Safety and within a short span of 4 years, rose through the ranks from being a SIS Programmer to Functional Safety Discipline Technical Authority & ISA84 Voting Member for his company by directly applying the principles covered in this book. The essence of this mantra is that we are faced with Events in our life that we mostly cannot control. The Outcome to these Events can be directly controlled by our Response. If we don’t like the Outcome, we should change our Response until we get the Outcome we want. The speaker will go over several examples of how strategies captured in this book can be used in our day to day life. We are faced with Events (E) that happens in our lives. Most people tend to blame the Event (E) if they don’t get the results they want. Instead of seeing how to improve the situation by taking a positive b, they tend to complain to the wrong people and end up with the same Outcome (O). Being stuck with a team member who does not perb is one example. By using this Success Mantra “E + R = O”, each individual can achieve the results they want; to go from where they are to where they want to be. This presentation is a tribute to the book “The Success Principles” by Jack Canfield that has made a huge positive impact in the Speaker Personal and Professional Life. The ultimate goal is to take 100% responsibility for your Life. Instead of complaining about the Event, it would be more effective if people would continue changing their Response till they get the Outcome they want. In this instance, b communication and talking directly with your team member and setting b expectations is a solution instead of complaining to others that your team member is not doing his part. Personal Improvement Leadership, Motivational, Management All / Cross-Industry Consultant, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Sales / Marketing, Project Manager / Lead, President / Principal, Plant or General Manager, Operator, Engineer, Director Workshop Nagappan Muthiah Wood Group - - - - - - Personal Productivity - - - - -
5. Business Management & Career Development Approved What's In It For Me To Change? The human brain is lazy and risk averse by nature. If you’re frustrated by a seeming inability of others to buy into your ideas or causes, your approach could be wrong. Are you thinking about it from your point of view or your audience’s point of view? You must wake up the brain by moving past the noise and creating a reason for change.? That reason answers the question in the mind of your audience: “What’s in it for me to change / buy into your idea?” Learn why people behave the way they do and become an effective change agent. We’re frustrated with our ability to drive change. The problem is we often ignore why people change in the first place: either risk aversion or personal gain. Once we place ourselves in the shoes of the audience, we begin to drive results. Once you understand people change for personal gain, it’s easier to drive results. People don’t change because they have to. People change because they want to. Utilizing basic neuroscience will accelerate your career because you’ll be seen as someone who sets a vision that others WANT to embrace. People change when this is answered:? “What’s in it for me? Why should I change or buy into your idea?” Facts and data support the reason, but don’t provide the impetus. Understanding and utilizing? the psychology behind change will create buy-in and accelerate your career . Personal Improvement Leadership, Motivational, Management All / Cross-Industry Consultant, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Sales / Marketing, Project Manager / Lead, President / Principal, Plant or General Manager, Operator, Engineer, Director Workshop Mitch Jones Robert E. Mason & Associates - - - - - - Career Development - - - - -
5. Business Management & Career Development Approved Conducting Virtual Presentations – How to Engage, Influence, and Persuade Technology allows us to conduct meetings and presentations bly.? We save money and travel time by sitting at our desk delivering inbation. Others sit at their desks to watch, listen, and absorb what we share.? Or do they?? Presentations that do not maintain attention waste company resources.? ?The key to realizing good return is to maintain audience engagement.? Regardless of the software used, simple tools and techniques can ensure that your audience is not tempted to read email, browse other sites, or become distracted from what you have to say.? Mastering the elements of good design and execution can transb drab disengaging Online presentations into dynamic interesting mind-changing events that leave audiences asking for more instead of wondering when it will be over. Have you ever attended a boring Online presentation?? Worse, have you ever given one?? ?How much time and money was wasted?? Virtual presentations are different than face-to-face sessions.? Yet too few have learned those differences or use the Online tools effectively.? Disengaging sessions waste resources because the audience finds other things to do during the PowerPoint and narration. By learning and using a few simple tools and design principles, audiences have paid more attention, increased retention, and given feedback that an improved Online experience flew by quickly instead of dragging on for too long.? Presenters are rewarded with higher levels of interest and recognition of maintaining the best of professional standards. Using a few easy tips and techniques common to most Online meeting software, virtual presenters can turn boring to interesting, disengaged to motivated, and money wasting into true savings.? Whether it is training, sales, project status, or general updates, practicing good online design and execution will make the presenter appear more professional through increased confidence and competence. Personal Improvement Business, Training, Leadership All / Cross-Industry Consultant, Vice President, Supervisor / Manager / Dept. Head, Sales / Marketing, Project Manager / Lead, Engineer Workshop Bruce Smith Emerson - - - - - - Personal Productivity - - - - -
5. Business Management & Career Development Approved “Analysis Paralysis: Harnessing your Emotions and Intuition” We live and breathe in an analytical world, where decisions are predicated on big data, and the need for insights is further undermined by the overabundance of inbation.? How many of us can recount personal experiences where personal judgement was clouded by the rational impulse to stifle our “gut feeling,” sometimes leading to less than desirable results?? Systems and processes exist for a reason – to invoke order to the entropy of our daily lives – but we must remain cautious that such measures do not become self-serving.? This presentation explores the research and empirical evidence of the power of emotional influence and INTUITION in inbing bs, bulating strategies, and affecting our behaviors. So how (and when) do we recognize that data is actually impeding our own propensities for sound decision making?? There exists a delicate tipping point where confidence from data can regress to a lack of proficiency and effectiveness due to data overload.? This managerial paradigm persists within all of us as we strive for the most efficient use of our time and the inbation at hand. This session attempts to provide a managerial field guide to applying Intuition in the course of our professional and personal lives, in scenarios ranging from vocational experience, task mastery, workplace engagement, and intrinsic motivation.? To become more adept in our own decision making, it takes a concerted effort in recalibrating our minds and trusting our emotions. Personal improvement and adult learning are predicated on the notion that we learn from our mistakes.? In a culture shackled by risk aversion, we are depriving ourselves of the necessary experiences to develop the foundation of our Intuition.? In the absence of those critical building blocks, we must inevitably rely more and more upon data to navigate our surroundings. Personal Improvement Leadership, Motivational, Management All / Cross-Industry Consultant, Vice President, Technician / Analyst / Specialist, Supervisor / Manager / Dept. Head, Sales / Marketing, Project Manager / Lead, President / Principal, Plant or General Manager, Other, Operator, Engineer, Director Workshop Chris Helbling Experitec, Inc. - - - - - - Managerial Skills - - - - -
5. Business Management & Career Development Approved ROI is the New TCO: Get the 411 on Why You Need to Consider Perbance Improvements ASAP When it comes to making a capital investment in automation, many companies determine value by looking at the cost to install and operate a system over the course of its lifecycle. But what’s arguably more important is the impact the solution has on the overall perbance of both their facility and workforce. Our experience with many b customers shows that a return on investment (ROI) equation will determine the best overall value. This takes into consideration the total cost of ownership (TCO), plus the operational impact and monetary savings generated by perbance improvements. While every operator recognizes the cost associated with implementing new technology can only be justified if it provides a suitable return, many do an inadequate job of assessing what that return entails. Applying TCO strictly on a basis of CAPEX and OPEX fails to capture the many benefits generated as a result of improving the perbance of an asset and/or process. Thus, TCO falls short. Improvements taken into account with our ROI calculation can include reduced unscheduled downtime, improved product quality, reduced variability, more effective maintenance, and increased operational visibility. These can result in significant financial gains throughout the life of a facility, but they are often disregarded on account of the difficulty associated with assigning monetary value. Use our ROI calculation. If you’re not leveraging perbance improvements (as well as operational improvements that result in facility personnel being able to perb their job more effectively), you may miss some big opportunities — especially when the improvements are cumulated over the lifespan of the facility. Other factors, including safety and downtime, are included in the calculation. Economic Justification DeltaV, Process Control, Operations All / Cross-Industry Director, Vice President, Supervisor / Manager / Dept. Head, Project Manager / Lead, President / Principal, Plant or General Manager, Operator, Engineer Workshop Kurt Russell Eli Lilly Matt James Emerson - - - - Business Processes and Operations - - - - -
5. Business Management & Career Development Approved Getting the most out of LinkedIn and Emerson Exchange 365 "You have been too busy to keep up with social media, but are you missing out on anything important? It can be hard to keep up with your contacts, know where to go with industry questions, or find out about the newest innovations. LinkedIn has become an important way to keep up with networking and find inbation pertinent to your industry. And Emerson Exchange 365 allows for collaboration and sharing after the Emerson Global Users Exchange for this year is over.?
Learn the key benefits and rules for social media, update your LinkedIn profiles, learn the power of Emerson Exchange 365 and get more comfortable with social media with this hands on session. You'll be ready to solve problems faster, gain experience faster by learning from peers and develop your personal brand." A great challenge we face today is finding the right answers buried in a sea of inbation. Establishing networks with trusted people helps you get better answers more quickly. With some hands on help you can get your LinkedIn profile up to date (including your picture), discover the power of Emerson Exchange 365, learn how to social network & find out how it can add to your professional power. The biggest benefits you receive from active participation in communities and social networks is faster problem solving, gaining experience faster by learning from trusted peers and developing your personal brand and influence in your areas of expertise. We will help you with the basics so you can participate and get the benefits that make sense for you. We will step through some of the more popular social media platbs, cover the do's and don'ts of participation in communities & social networks,?
