Presentation Programme Abstracts - Emerson Exchange · Presentation Programme Abstracts. ... The...

106 Presentations have been selected by the Exchange Board

Presentation Programme Abstracts

Business & Projects

15 Presentations have been selected for the Business & Projects Track

Page 2 of 115Emerson Global Users Exchange EMEA 2016Presentation Programme V1 4-Dec-15

Business & Projects

MAC partnership coordinates C&I system improvements on 5 platforms to ensure profitability

The control & instrumentation system of any process plant is like a cross between a human’s central nervous system & a car dashboard. When the C&I systems are in ‘peak physical fitness’ the plant can be run well ensuring profitability. But when they are not in peak condition the operators cannot drive the plant effectively & profitability suffers.

Apache selected Emerson as a MAC partner to bring the C&I systems on 5 offshore platforms into peak condition. During the 10 year programme a combination of coordinated upgrades to BPCS & SIS, smart instrumentation & export metering has given Apache assets which can be ‘driven’ profitably

In 2003, with Brent crude oil price around $35 per barrel, Apache acquired 5 ageing assets from BP (Forties Field) which were seen as being at end of useful life and non profitable to operate.These assets were facing depleted production wells and obsolescence issues with inefficient C&I infrastructure and processes.

Apache selected Emerson as MAC partner.Over the next 10 years Apache replaced legacy third part systems with Delta V on 5 assets.Field devices upgraded to Rosemount/MMI.Last piece of the jigsaw installation of a Danpac metering system which fully integrates the oil export system with Delta V,leveraging efficiencies from shared resources.

Production from the Forties field peaked in 1979,when assets were sold to apache in 2003 production was averaging 45000 bpd.In 2015 production from the Forties field was 60000 bpd.Apache extended the lifeby 20 years and enjoy one of the lowest lifting costs in the North Sea due to improved efficiencies.

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Business & Projects Industry Oil & Gas

Michael Will Metering TA

Gary Ingram Sales Manager Fiscal Flow Products

Apache North Sea UK

Emerson UK

(End User)

ID 2199


Business & Projects

Virtual Project Delivery for today's challenging project environment

Recent economic uncertainty has accelerated the evolution of project delivery in the process industries Projects are larger and the number of stakeholders has increased - work is much more complex and customer expectations are changing.

These dynamics have the potential to drive up costs and increase project delivery risk. To address these challenges, Bechtel Corporation is moving towards a “Virtual Project Delivery” structure, which embraces standardization, modularity, supply chain partnering, cloud-based information sharing and LEAN work processes.

The presentation will outline Bechtel’s cost-effective project delivery paradigm using some recent examples to demonstrate how it positively affects schedule, cost, and risk on projects of any size.

Projects are larger and the number of stakeholders has increased - work is much more complex and customer expectations are changing

Virtual Project Delivery” structure, which embraces standardization, modularity, supply chain partnering, cloud-based information sharing and LEAN work processes

Virtual Project Delivery positively affects schedule, cost, and risk on projects of any size.

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Business & Projects Industry Engineering

Luke Rubens Chief Control Systems Engineer

Bechtel UK

(EPC Contractor)

ID 2252


Business & Projects

Close relationship between automation partner & end user assures success on mid-size projects

Valspar have become closer & closer to a single automation vendor by working together on the solution of a range of plant problems ranging from valve selection through to operator interface on mobile devices

The presentation shares experience on how to succeed in leveraging the strengths of both organisations

Realising the benefits of modern C&I / Process Automation systems from field to operator is not easy; especially for mid-seize players

Working with one vendor to solve problems from the pipe flange up to operator interface on mobile devices

Planned, Integrated approach to technology adoption drives continouous improvement in capability to operate, maintain & develop the plant

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Business & Projects Industry Chemical

Julian Annison Principle Industry Consultant

Steve Currie

Emerson UK

Valspar UK

(End User)

ID 2255


Business & Projects

Look in the mirror - You are in sales!

Whether you are promoting an idea at work, or trying to ask that special someone to spend the rest of their life with you, you are selling and don't even know it. We all have great ideas, many of which we've been sitting on for quite some time, but how do we get them approved?

This session will explore how to get your idea or proposal ahead of your peers and the approval of management to proceed. It may even get you a partner for life!

We all have programs or projects that we want to get funded. New technology that we want to try. But getting funding, especially in this environment, is a challenge. Justifying the expense above other ideas or programs is key to getting your idea launched.

This session will explore the concepts of presenting ideas to management and using real math, and personal, (and humorous) examples of how I was able to sell my, as well as customer ideas, funded.

Projects were funded, and I've been married for 20 years.

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Business & Projects Industry General

David Kraft Vice President

Emerson UAE

(Emerson)

ID 1641


Business & Projects

Developing a Business Case for Modular Project Execution

Project overruns (cost and time) are increasing and as sites become more 4D (dull, distant, dangerous and dirty) so modularization project economics become more compelling. Moving site hours to fabrication yards has been used for decades in offshore O&G, but is now becoming viable for other industries.

This paper looks at drivers for and against modularization and introduces an economic analysis framework, tools and processes to help decision making and module design optimization. It will also show how Emerson’s technology and project tools complement a modular construction approach.

Economically deciding to move a proportion of site man-hours into a module fabrication yard is complex. Engineers tend to focus on minimizing material quantities. Not a reasonable surrogate for economic efficiency on a modular project. A decision support system to effectively exploit the benefits of modularization is needed.

A developed decision support system enables analysis of project drivers (opportunities and challenges faced by projects challenged by remote location, scarcity of labor, environmentally sensitive surroundings and other challenges) to determine the optimum proportion of man-hours to aggregate into modules and construct in cost effective yards for installation on site.

The decision support system proved successful in defining optimum man-hours to move offsite and maximize realizable benefits to the project - considering additional costs for fabrication and assembly of module content, transport, install, hook-up and test modules at site. This optimum ranged from 10% - 60% of construction direct hours.

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William Meyer Module Execution Manager

Fluor UK

(EPC Contractor)

ID 1822


Business & Projects

Organisational readiness for a multi-facility MES introduction

GSK produce material for clinical supplies at nine locations around the world. To meet forecast demand GSK chose the Syncade MES platform to enable the streamlining of work processes across the company. Organisational readiness, including quality process impacts and user training is a key factor in the success of the project.

The interface between the worlds of Automation and IT are particularly significant and can impact on the success of a MES project.

This workshop describes the actions taken to prepare for a project with significant potential business impact

Introducing a MES system into a company means affecting existing procedures and processes in many parts of the business. These range from IT to quality to work procedures on the factory floor.Significant challenges exist in planning and anticipating these business needs and their impact on the project during implementation phase

GSK addressed these challenges by involving the Emersonteam early in the project implementation in order to mitigate anticipated risks using a combination of technology and human factor solutions. Key to success is strong sponsorship from both organisations and a structure providing organisational and project learning during deployment of the solution.

Adoption of this structure enabled GSK to successfully implement the project despite a major realignment of the R&D manufacturing network mid-way through project implementation

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Business & Projects Industry Life Sciences

Colin Chapman Manufacturing Control & Automation Leader

Owen Bonner

GSK Ireland

Emerson Ireland

(End User)

ID 2067


Business & Projects

Shrinking Orgs. Evergrowing Responsibilities. Ways to Cope.

Many industries have experienced a loss of expertise due to retirements and organizational “right-sizing”. The results of these trends are broadening responsibilities and less expertise to solve the challenges the business faces.

We will share ways to cope with these trends through the innovative use of freely available technologies, applications and social networks. In addition, as the importance of mobile communications continues to increase, we’ll share ways to take advantage of these tools in a smart phone or tablet environment.

Our goal is for you to take away a least one fresh idea to bring back and apply in your organization.

As expertise in organizations shrinks over time and the complexity of the operation grows, novel technologies and workflows have been created to compensate and cope with these issues.

By using collaborative, non-traditional applications and technologies such as mobile messaging, cloud-based file storage and mobile-based search answers to issues are provided much faster than what was previously possible.

Applying these innovative solutions mean: •More efficient time use—during work and afterhours •Access to wider knowledge within team •Use of pictures to reduce troubleshooting time •Support less familiar equipment without deep expertise by tapping into other’s knowledge •Data access whenever and wherever needed without need for physical proximity.

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Business & Projects Industry Chemical

Phil Webb Automation Systems Manager

Jim Cahill Chief Blogger / Social Marketing Manager

Inovyn UK

Emerson USA

(End User)

ID 2190


Business & Projects

Remote virtual approach to DCS migration project supports customer continuous improvement effort

The combination of a remote virtual project approach together with distributed DCS (DeltaV) architecture address increases in project complexity, leverages appropriate skills independent of personnel location (both in vendor & customer), enables testing without travel, allows later testing & hardware order placement.

The impact of new features can also be explored & the project database made available for early training. Global standards are also more easily adhered to

Execute Projects on Time, within Budget, and overcome Lifecycle Support Challenges. In a world facing increasing challenges coming from Late Project Changes, People and Company Culture Changes, as well as Increasing Complexity of Automation Projects.

Novartis together with Emerson identified that utilizing Emerson’s global Remote Virtual Office (RVO2) Services in combination with Emerson’s Distributed DeltaV (DDV) solution has tremendous potential helping to overcome many of todays’ challenges end-users face in projects, as well as over the lifecycle of an installed automation solution.

Cost avoidance seen in a recent SIEMENS PCS7 migration project in Switzerland using RVO2 for SFAT and recipes development. By utilizing Emerson’s Distributed DeltaV (DDV) the test team saw additional benefits by being able to incorporate existing legacy IO subsystems into the SFAT.

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Business & Projects Industry Life Sciences

Mary Peterson Principal Automation Engineer

Thomas Steiner

Novartis Switzerland

Emerson Switzerland

(End User)

ID 2070


Business & Projects

Upgrade When Your System is a “Black Box”: Way Out in 3 Weeks with I/O on-Demand

Large unit under old DCS control with operation life over 15 years was in need to upgrade. The total lack of documentation in electronic form and very poor documentation on paper made task extremely difficult. Also was made many undocumented changes. Actually, unit control system without documentation is a "black box" in operation. Additional problem, young management team of the unit with no experience in startup of DCS.

Main challenge was the need to start-up object in 3 weeks, time of downturn. During this time old control system should be replaced, new one installed including SIS. One day of missed deadlines start is threaten with huge fines.

Application of Electronic Marshalling technology made possible quick upgrade of entire DCS of the unit: installation and performed commissioning of DeltaV DCS based on CHARacterization Modules and DeltaV SIS (SLS) systems. During implementation Emerson experts implemented a number of special technological know-how of as additional benefit for a customer.

With technology I/O on Demand even newbies in automation can start up complex unit in a short time. “Turnkey” solution delivered less than in 3 weeks. Benefits of cutting-edge technology use and brilliant project execution now drives customer for the expansion of DCS with no doubts.

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Business & Projects Industry Petrochemical

Ilya Tolmachev Project Office Manager

Alexey Tekin Chief Metrologist

NPP Neftekhimia Russian Federation

NPP Neftekhimia (GazpromNeft and Sibur) Russian Federation

(End User)

ID 1621


Business & Projects

How Implementating Smart Automation Techniques can save cost ,time & Schedule for Petrofac

Petrofac is a Global EPC and Leader in Middle East Market with over a $22B backlog of active EPC Projects In today’s highly competitive market executing a project within a tight budget & schedule is a key measure of performance for I&C Division of Petrofac. Petrofac deals with clients like Aramco, ADNOC, KOC being NOC's and major upstream companies that contribute significant amount of revenue to their respective countries/economies. Petrofac is viewed as a strategic engineering contractor to these NOC's who understand their pains and necessities.

Delivering the project on time, on schedule and on budget to the NOC Companies is a key commitment and imperative by the PMT team. The I&C BU is responsible for the execution, engineering & delivery of Automation on projects. Applying modern technology for DCS, measurement etc. are ways where the I&C BU was able to improve TICC & improve schedule on some projects.

When you look at an overall Project the I&C Lead on the projects will encounter many areas of Instrumentation & control where problem & challenges emerge on a project. Control Space, I/O capacity & spare sizing on brownfield upgrades projects & tie ins.

Some of the Emerson solutions 1) Implementation of Charms/Electronic Marshaling 2) Implementation of Shelter Free Analyzers 3) Electro Hydraulic Actuators on Shutdown Valves 4) Smart Meter verification & multivariable instrument on Well head applications 5) Remote diagnostics with DVC's 6) Implementing Wireless Technolgy reduces engineering efforts & site activity

Providing state of the art solution to the client which enables them to own & operate the plant with latest technology that eliminates complexities like wiring, footprint and provides advanced diagnostics. - Reduction of engineering hours, site activity thereby improving project schedule & total installed costs

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Pradeep Virmani HOD Instrumentation

Anil Ajith EPC Business Development Leader

Petrofac UAE

Emerson UAE

(EPC Contractor)

ID 2198


Business & Projects

Managing us, managing them – putting the Strategic into the Supplier Relationship

A shift in product balance, prices, demand and operating on a 90 year old site, required a business strategy to move from Solomon 3rd to 1st Quartile performance.

Petroineos had to rethink how they worked with their core suppliers to maximize their impact on the business. Emerson was the first supplier that they chose to collaborate with more strategically, and developed a novel approach to strategy development and subsequent improvement initiatives that have been pioneered

Petroineos a joint venture between PetroChina and Ineos has operated the Grangemouth refinery in Scotland since 2011

Automation strategies are usually developed bottom-up, focusing on known production issues and well-established technologies; but modern automation technologies offer much more than any of us can realistically manage. By thinking top-down you start by developing the key business drivers and opportunities that maximizes the business impact.

A collaborative process was developed which was based around a workshop for senior site Managers and Engineers working alongside Emerson Consultants. The process reviewed what had shaped the current status and through looking at where the refinery could be, identified where strategic opportunities could best be supported by automation technologies

Through this process an Automation Projects & Services Road-Map was created that aligned with the business opportunities and 5 prioritised initiatives started. These have then been developed and championed jointly by initiative leaders from both companies and cover key areas of reliability, energy / cost management, business systems and competency.

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Neil King Reliability and Integrity Manager


Petroineos UK

Emerson UK

(End User)

ID 2122


Business & Projects

How to reduce instrumentation & control system detailed engineering cost & commissioning time (When Several Package Units need to be Integrated)

Tips to reduce Instrumentation and Control System Detailed Engineering cost and commissioning time in projects where several package units need to be integrated.

Main challenge in the development of Detailed Engineering for Instrumentations and Control Systems is the integration of the controls of different package units. Typically package unit vendors only look at the controls inside of their battery limit and don’t take care or sometimes overlook important details of the integration of their package units with other package units and with the rest of the client plant. Also quite often they don’t take enough care of the client specifications.

This leads to a lot of misunderstandings and endless hours for clarifications during the detailed engineering phase. And typically not all aspects are considered during the detailed engineering phase, so they only appear during commissioning, when different package units and the rest of the plant need to work together

- Typical few signals to integrate several package units that are overlooked during the engineering phase and cause big troubles during commissioning. - Unnecessary engineering hours during Detailed Engineering for clarifications around control systems integration. - Commissioning delay when unforeseen hardwired signals needed be exchanged between package units appear

- A “Best Practices” document was generated (with the experience gained during 15 years working in this type of projects). - Functional Design Specification for Control System Software was developed integrating the Control and Interlocks narratives of the different package unit vendors and the client.

- Many engineering hours during Detailed Engineering phase of the project for Control and Instrumentation disciplines saved. - Commissioning and start-up time shortened.

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Business & Projects Industry General

Julián Sáez Mateo Control & Instrumentation Engineer

Positive Engineering Spain

(EPC Contractor)

ID 1540


Business & Projects

Application of CHARMS for the Redeployment of a Mothballed Methanol Plant

The reconstruction and commissioning of a mothballed methanol process unit at a new site comes with many challenges including the development of completely new instrumentation systems in a very short time window. Equipment from the mothballed process plant had to be combined with several pieces of new equipment to form a functional unit. The control logic from the original process unit needed to be adapted and integrated with the requirements for the new equipment to allow the unit to function as a whole. This together with the accelerated time schedule therefore required a high degree of flexibility in the systems that needed to be deployed. It was also a requirement that the main systems (DCS, SIS and F&G) be ordered as early as possible in the project cycle before the completion of the detailed engineering.

The application of CHARMS to this project enabled the maximum flexibility to be achieved.

The need to order the main instrument systems early in the project cycle before the completion of the detailed engineering could not be achieved with a conventional system topology – including the tight integration of the DCS, SIS and F&G systems.

The CHARM electronic marshalling systems were deployed at strategic locations throughout the facility to minimize the installation complexity and to maximize flexibility in cases of additions and changes.

The many changes that needed to be implemented after the detailed engineering were completed efficiently at the plant site due to the nature of the CHARM electronic marshalling. During plant commissioning several last minute changes were implemented in a very timely fashion reducing the overall commissioning time for the plant.

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Joffre Bourgeois Senior Engineering Manager Process / E&I

Bernd Dahmen Senior Sales Engineer

PROMAN Gesellschaft für Projektmanagement Germany

Emerson Germany

(EPC Contractor)

ID 2135


Business & Projects

Lean Concept for Gas Well Hook Up Great Enabler for Small Gas Field Exploitation. A struggle to survive!

Gas extraction on small Dutch fields is only profitable, when investment and operational cost become substantially lower. A project team has investigated and designed a standard unmanned lean gas well hook-up, without any substitute to safety.

A skid mounted hook-up already proved to be a cost effective solution to hook-up and provides the base for design. Looking at the potential scope of many, every euro saved with a leaner design can be multiplied. The concept covers steel work, piping, field instruments, control and safety systems and also extensive standardization of how to install these skids on site once built in shop.

The entire concept is engineered and built with standard functionality and allows local operational tuning. The CAPEX savings go up to 65%. Hence the viability to exploit this concept at smaller gas fields.

NAM, the Dutch supplier for natural gas, faces a make or buy decision. Gas extraction on smaller fields is only profitable if skids can be built at a quarter of previous cost and savings should be made on commissioning and start up. If not, there is no business case.

Ultimate standardization leads to a lean, integrated, safe to operate skid concept. Skids are constructed and fully tested in shop. On site a skid is easily added by adjusting settings and allocating a skid to a location. This concept enables extreme savings that allows exploitation of smaller gas fields.

Once well and piping at site are ready, site specific commissioning and startup of skids to deliver gas is just one week. Thanks to the high degree of standardization only site specific parameters have to be tested. The skids are placed at unmanned locations and remotely operated reducing operational costs.

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Maarten Kuipers Lead Instrumentation Engineer

Tebodin Netherlands Netherlands

(EPC Contractor)

ID 2026


Business & Projects

Technip-Emerson Work Process Integration to size down Project cost and risk.

Control Valves discipline leads this partnership Technip KPI initiative •Knowhow and clear understanding of our respective Internal Organization, •Alignment and Agreement of what the key Engineering phases shall focus on: Smart sizing and selection; specification review process; deviations & alternatives •Importance and high criticality of Our Project Management: in Organization, processes, standards and Management of Changes •Awareness of Perfect Execution will be tightly linked to: Potential Emerson support during Technip estimation and Bid process; Different project phases, gates, processes; Mutual expectations and related actions; Delivery integrity and lead time; Document control; Inspection and Test Plan •Future product development and direction of International standards •Material Supply Chain: Supplier selection process, QA/QC system •Optimizing documentation package (set of various document to provide and Technip review/approval cycle)

•Clear definition and understanding of our respective project execution constraints. (gates) •Mutual acceptance and commitment to embed in internal work process the most critical Emerson and Technip constraints (gates)

•Issue common and shared pursuit procedure to be officially cascade down to Project Team this work process integration procedure.

•Mutualize our sales approach •Develop Sales Key Differentiator’s, •Secure project Perfect Execution, •Proven Cost Saving (sourcing, technology, engineering hours,…)

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Salvatore Sauza Commodity Family Manager

Jean-Luc MOTHES Global Key Account Director Technip

Technip Italy

Emerson France

(EPC Contractor)

ID 2021


Business & Projects

Control System Applications & Migrations

12 Presentations have been selected for the Control System Applications & Migrations Track



What are the benefits of a migration plan?

The time has come to change the legacy BPCS and SIS that already provide more than 25 years of service and production. Difficulties to migrate a global plant are to justify the amount of investment to produce the same as it is.

ADISSEO approach was to identify potential gains; One of the main objectives for a company is to work on operational excellence that could be explained by the way to increase efficiency at multiple level of the plant. ADISSEO and Emerson have worked for a global approach with CHARMs technology and also how we could provide potential gain by using technology and software suite?

First challenge was to migrate the old systems with the new feature provided by the DeltaV solution, work closely for startup succeeds and increase efficiency with the contribution of technology.

All Legacy Provox and Triconex system were obsolete on site. ADISSEO needs to migrate with 10 years commitment. Challenging were to provide switching old system to new one using existing technical room with no place to add new cabinet, using existing field wiring and removing old IS barrier.

ADISSEO chose to migration all the plant & execute the project with Emerson team in France using CHARMs technology for DCS and SIS including all Charms functionalities as integrated relay for DeltaV, integrated SIL3 relay for DeltaV SIS and Intrinsically Safe barrier for DeltaV and DeltaV SIS.

CHARMs technology solution for DCS and SIS, integrated software suite from Emerson brought a new approach to reduce cabinet footprint more than 50%, give flexibility and integrated barrier for project execution, and provide solution as AlarmHelp, DeltaV insight, … to increase efficiency for a long term partnership.

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Control System Applications & Migrations Industry Chemical

Patrick Roussel IEA manager

POUZET Christian SYSTEM EXPERT

ADISSEO France

ADISSEO France

(End User)

ID 2062



Four different multi products batch system four different software logics and one common standardized solution.

We have four multi products Emerson DeltaV batch system. These systems have different solutions of software logics but in the end we will standardized this system with Emerson configurastion tool set PCSD.

The actual problems: The technology is not so flexible one phase handle everything inside in the unit. Hard to move the operators for one plant to another because of different handling systems. The phases not containing report parameters, so we can’t create electronic batch records on the future

Rewriting the whole software logics using with Emerson PCSD. But it must ensure that existing capacity is not exceeded controllers with new software. So before the installation of the real system we have to check the controller capacity in Emerson RVO system

Standardized user interface of the four batch systems

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Control System Applications & Migrations Industry Life Sciences

István Veszteg Process Automation Engineer

Tibor Nagy Lead Engineer

Chinoin Hungary

Chinoin Ltd. group Sanofi Hungary

(End User)

ID 2088



Extremely Hot Cutover in a 3 Day Outage

In 2012 Cofely Energy Services took over responsibility for operating and maintaining a CHP plant in Barry,UK. The plant is critical to the operation of the main production site, providing Steam, Energy and Utilities full time.

Cofely engaged Emerson as their partner in solving a number of site based challenges. Primarily driven by obsolescence a project was created to migrate a number of disparate control and safety system platforms, including both the Emerson RS3 control system and a number of non-Emerson systems (HIMA Safety and Burner Management, Silvertech Fire and Gas plus some bespoke 3rd party PLC based applications); to a single integrated control platform.

The additional level of complexity to add into this project was the fact that the production plant had only a 3-day steam outage window in which the 2000 I/O control and safety system cutover could be performed.

A rationalisation of the safety functions and identification of some additional measurements required to enhance process safety; adoption of some advanced boiler control techniques to maximise energy efficiency; enhanced steam output stability and new BMS software to allow for clean and efficient operation at low loads.

Using the Ovation Control System as the basis for the solution. A series of collaborative consultant led engagements were used to identify the most efficient and risk averse cut over strategy; whilst also taking the opportunity to identify a series of process automation enhancements which could be implemented.

This presentation will explain how the project was defined and how the successful implementation was completed during the 3-day outage window; and the performance improvements gained as a result.

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Control System Applications & Migrations Industry Power

Stuart Wilcox Business Manager - Speciliast Services

James Fraser sales and marketing director

Cofely Energy Services UK

Emerson UK

(End User)

ID 2136



Virtualization of real production control system – lifecycle management benefits

Some say world is changing more and more rapidly each decade. Use of IT solutions and infrastructure in industrial systems is changing and evolving even faster. How to keep pace with workstation obsolescence? How to address software compatibility and support? Is there any solution available on the market that would be protecting initial investment without jeopardizing flexibility and expandability of the control system?

Well established solution, being widely used in IT environment, is virtualization. There were always some fears and uncertainties if the same what is good for IT would be equally good for control system real production environment. In over decade of use virtualization has proven its reliability and stability e.g. in banking systems. Cluster servers provides more computation power, redundancy and data safety than any system build of regular workstations and servers. It is high time for process control industry to go for virtualization.

Develop solution for workstation hardware obsolescence and Windows operating system compatibility issue to serve for long term support of lifecycle of the control system and the plant. Reduce cost of Ovation DCS maintenance and improve expandability flexibility.

Implementation of virtual environment Ovation DCS based on high reliability server cluster. Upgrade of Ovation DCS to the newest release.

Implementation of virtualization in real production environment provides midterm and long term savings in maintenance cost, improves I&C team efficiency, extends system lifecycle and secures higher availability and accessibility. Improves security through faster and easier backup and restore functions.

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Control System Applications & Migrations Industry Power

Rob Petie Senior Technical Specialist E, I&C

Christian Lopez Marketing Manager Europe (PWS)

Engie Netherlands

Emerson Spain

(End User)

ID 2114



Migration DCS system from a different perspective – Operators back in charge

After an unplanned shutdown difficulties during start up caused a significant production loss. Analysis showed that operators lacked experience in dealing with abnormal situations, were hindered by alarm floods & could not see sequence status. A new DCS was installed with: 1. Redesigned sequences allowing operator intervention. 2. Improved alarm management by suppression and reducing alarms, adjusting logics to events and tuning limits set. 3. Human Centered Design, intuitive graphics help operators focus on process deviations. 4. An Operator Training Simulator to train operators on abnormal situations.

The project was completed in 14 months due to close co-operation between Huntsman, Tebodin & Emerson. Using the new system the plant started up and went into production as planned. The project benefitted from DeltaV’s characteristic flexible I/O with electronic marshalling and Emerson’s ability to expand their team utilizing its centralized back offices flexible workforce.

In case of unforeseen shutdown events operators lacked experience to respond in time and were limited in their options to intervene. The DCS in place gave them insufficient insight in the progression of the sequences. They were flooded with an unmanageable amount of alarms.

1.Redesigned sequences allow operator intervention. 2.Improved alarm management by suppression and reducing alarms, adjusting logics to events and tuning limits set. 3.Human Centered Design, intuitive graphical displays help operators focus on process deviations. 4.Operators trained to deal with abnormal situations using the Operator Training Simulator

The migration to DeltaV has enabled a smooth startup with the plant running on spec quickly. As the operators now have better operational control and information on the sequences. Operators were trained to start up the plant and react on anomalies using the new control system.

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Jasper Rutten Process Engineering Team Leader

Huntsman Netherlands

(End User)

ID 2022



Remote Monitoring of LNG Facilities

Emerson is the Main Automation Contractor for Santos' GLNG project. Technologies and expertise provided by Emerson help Santos gather and integrate real-time data from wells and compressor stations in Queensland, Australia. Remote data and video from the field is transmitted 500 km to an Operations Center in Brisbane.

This workshop presents the architecture of monitoring and control systems provided by Emerson with a focus on video subsystems provided by IVC. Topics will include technologies implemented along with methodologies used to integrate remote data at the Brisbane Operations Center (BOC).

Santos was challenged with finding an efficient way to operate its plants, monitor and control gas fields, and integrate real-time data from wells and facilities located in Queensland, Australia – from a remote control center in Brisbane (a distance of approximately 600 km).

DeltaV, in concert with IVC video systems, provides visual verification via live and recorded video from remote sites to local operators and the Brisbane operations center. Santos engineers and planners can use real-time video and information from the fields to anticipate issues, improve decisions and maximize key performance indicators.

1) Comprehensive remote monitoring at BOC allows for reduced personnel requirements at each hub. 2) Confluence of data from well heads and hubs, coupled with video, improve situation awareness for operators and management -- resulting in well-informed, timely decisions. 3) Technologies combine to drive down operational costs and maximize productivity

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Control System Applications & Migrations Industry Oil & Gas

Dipak Sagar Emerson Sales Manager at IVC

Industrial Video & Control USA

(Supplier)

ID 2124



Full potential control system virtualization unleashed in life sciences manufacturing resulting in high availability, flexibility and reduced TcO

The Janssen sites from Leiden (Netherlands) and Geel (Belgium), both part of Johnson & Johnson, are faced with some barriers that need to be resolved to enable their global induced Lab-to-Patient Vision, to reduce their total cost of ownership and to increase the availability of their manufacturing control systems.

The control system landscape within a Janssen site typically consists of a variety of separate automation pockets, each having its own lifecycle, own set of rules and governance, own upgrade path, training path and support contracts. As some of those control systems became obsolete, optimizing the migration paths poses another challenge. Janssen has therefore standardized globally on DeltaV System Architecture, Infrastructure and Content (Module Libraries), in which the deployment of a virtualized DeltaV site infrastructure plays a key role.

This session describes how this standardization is being implemented globally and also depicts how Emerson is acting to support such a global approach.

Reduction of Total-Cost-of-Ownership for the control system landscape and its availability increased. Moreover standardizing the automation layer enables an optimized integration into the IT layer which enables the use of standard IT services and interfaces to support enabling services such as patch management, anti-virus, active directory, backup & restore, etc.

Global Standardization of: -The DeltaV Site Infrastructure based on a redundant virtualized server & network architecture -The secure gateway to standard IT systems (MES/PI) & services -The DeltaV module libraries managed by a Global Governance / Technical Authority

Expected reduced cost-of-ownership and improved scalability due to standardization. Expected High availability / less downtime of the redundant virtualized system set-up. Blueprint for virtual architecture including all required template documents that can be used to be deployed in other production sites within the J&J network.

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David Cools Sr. Manager Execution Systems

Johan Holierhoek Sr. Engineer Execution Systems

Janssen (Johnson & Johnson) Belgium

Janssen (Johnson & Johnson) Netherlands

(End User)

ID 2092



Using multi-variate batch models for process monitoring and optimization.

Traditionally, the “golden batch” approach has been used to improve consistency. However, in addition to other issues, this approach doesn’t really provide the engineer with information on which variables influence variability on the end results of the batch.

Multivariate statistics allow the engineers to build mathematical batch models that provide detailed insight on the process, identify which variables (and their interactions) do really influence process variability, and indicate how should they be acted upon to reduce it and improve the final output. Moreover, the generated model can be used to continuously monitor the process as it runs, enabling on-line prediction of the end of batch conditions in advance, and warning the operators when any of the influential variables or interactions start to deviate before they become potentially a cause for a process upset or an out of spec batch.

Engineers optimizing complex batch processes are often faced with limited information on which variables really drive their processes. Also, running batches monitoring strategies don’t usually take interactions between variables into account, even though sometimes they may have an even higher influence than the variables themselves.

Multivariate statistics batch modeling allows engineers to build batch models that provide detailed understanding on the influential variables and interactions driving the process variability. Then through Emerson’s Batch Analytics tool they can take a step further and deploy models into DeltaV to allow online monitoring and improve plant operations.

- Multivariate models provide very detailed process knowledge, allowing engineers to focus on the really influential variables. - Batch processes can be continuously monitored vs the model, generating continuous predictions of the end of batch conditions and proactively warning operators of deviations before they impact the process.

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Manuel Martín Process Improvement Specialist

Francesc Luque Sales Engineer

Lubrizol Spain

Emerson Spain

(End User)

ID 2109



Qatargas’ $1B Jetty Boil Off Gas Recovery Project: Automating the World’s Largest Gas Recovery Project

This presentation discusses the engineering and automation behind Qatargas' largest environmental investment, which will reduce greenhouse gas emissions by 1.6 million tonnes annually. Now at full capacity, the Jetty Boil Off Gas Recovery facility recovers the gas flared during liquefied natural gas (LNG) loading at six LNG berths in Ras Laffan Port in Qatar. The recovered gas is compressed and then sent to Qatargas’ LNG production facilities for use as fuel or as LNG.

It will focus on the implementation of the DeltaV system, marshalling, power distribution, and third-party interfaces; the development of dynamic simulation models for operator training; and ongoing process optimization.

Due to boil off gas phenomenon, almost 600,000 tonnes of LNG are wasted or an equivalent loss of 0.6 million tonnes of flared gas per year. This translates to 1.6million tonnes of CO2 per year in the atmosphere.

Qatargas worked with Emerson as the MICC (Main Instrumentation and Control contractor) to provide distributed control systems to monitor operations, and automation solutions including control valves, measurement instruments, and flowmeters. along with automation engineering, startup, training, commissioning support. and other services.

The project is expected to recover more than 600,000 tonnes of liquefied natural gas per year – equivalent to the energy supply for more than 300,000 homes.

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Michael Koo Project Manager

Hamid Mukhtar Account Manager -QP

QatarGas Qatar

Emerson Qatar

(End User)

ID 2060



Flexible assembly of manufacturing recipes using Syncade in a biotech multi-purpose GMP facility for the production of drug substance

For production of clinical trial material individual recipes have to be generated describing the respective production process for each new product. In order to be able to build such recipes in short time reusable recipe building blocks (BBs) have been defined.

We start with a description of our process for analyzing and specifying the required BBs. Next, we detail the testing and implementation of these BBs. Finally, we will highlight our concepts for validation and change management and describe the recipe assembly process.

The main challenge is to maintain a high degree of flexibility that is comparable to our current paper-based process. In addition, we aim to enable the easy integration of improvements and quality requirements into our BBs, in order to meet future compliance challenges.

In order to maintain flexibility, we created a library of reusable building blocks for rapid recipe deployment.

Benefits are the advantages of an electronic system, e.g. four-eye principle that improve compliance and help us meet our high standard of quality requirements.

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Christoph Nagel Process Assistent Fermentation

Albert Landman MES Consultant

Roche Diagnostics Germany

Emerson Germany

(End User)

ID 2167



“Electronic Marshalling with CHARMs - Broad I/O Coverage Increases Conformance with Project Requirements and Reduces Installation Costs”

Software configurable IO is becoming more widespread, with various solutions available from multiple process control vendors. Past workshops have documented how this technology can shorten project schedules, eliminate project tasks, simplify late changes, and reduce footprint and required spares; resulting in lower project execution costs.

This workshop will perform a different analysis and focus on how Electronic Marshaling with CHARMs can better conform to project requirements: • How support for a greater number of IO types and wiring solutions results in increased flexibility and cost reductions • Illustrate how to quantify these financial benefits

How can users justify the purchase price of Electronic Marshaling with CHARMs versus traditional IO?

Electronic Marshaling with CHARMs’ increased IO and wiring coverage allows enhanced conformance to project requirements and provides quantifiable benefits over other software configurable IO offerings.

Project analysis will be provided to document Electronic Marshaling with CHARMs’ financial impact • Superior conformance to project needs via greater coverage of IO types and wiring applications • Greater IO and wiring coverage facilitates standardized cabinets • The IO Cloud lowers both CAPEX and OPEX costs.

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Chuck Campbell Projects and Technology - Automation

Mike Alsup Business Development

Shell USA

Emerson USA

(End User)

ID 2211



Introducing DeltaV SIS™ with Electronic Marshalling on Solvay Tavaux

During this project, the objectives are: - Renovate old systems that have become obselete (Provox and Foxboro) - Tight schedule requiring the ability to anticipate the work - Standardization and practicality of driving a single supervison - Introduction of a new technology on the part SIS - Reduces installed cost of system. - Simplified safety lifecycle management. - Flexibility with Plug and Play I/O - Easy for the diagnostic and maintenance.

Challenges has resolve were: - Facilitate engineering and on-site assembly - Lack of space in the technical area - Installation of a lot of IS signals - Compliance with good practices (engagement of the Solvay group) and standards. - Have the flexibility to add or easily change a signal

EM with DeltaV SIS allowed to reveal these challenges: - not use cross-wiring. (Reduces installed cost of system) -Engineering optimized by setting up a simple and direct signal -I/O unit for adding or easily remove signals -Ability to take into account the SI and avoiding adding intermediate barriers.

EM with SIS CHARM, and conventional CHARM allowed us to optimize the implementation on-site and connecting a part of the signals before to the shutdown of unit. This solution can optimized process reliability and plant avaibility The tests are facilitated by Plug and Play I/O.The diagnosis is simple.

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Nicolas Hayme Technical IT Manager

Solvay Tavaux France

(End User)

ID 2130



Final Control Valve Applications

6 Presentations have been selected for the Final Control Valve Applications Track



Multiport Flow Selector Manifold for Well Testing

Regular monitoring and testing of constituent flows are crucial parts of the production process specifically in oil and gas industry.

ADMA-OPCO is one of the ADNOC group of oil and gas companies in Abu Dhabi, UAE, which has been using the Emerson BETTIS Multiport Flow Selector (MPFS) manifold for the purpose of continuously testing its offshore produced well fluids. A Multiport Flow Selector typically has eight inlet and two outlet connections. Out of eight inlets, seven are connected to the wells; the eighth port is generally used as a parking location for the selector plug when the manifold is in full production. The flow selector along with its rotating plug allows the selecting and diverting of individual flow-line out of the seven to a test outlet for testing or sampling while combining the flow of the other flow-lines into a separate group outlet carrying flows to the production header.

One problem faced during the operation of the MPFS was due to human error. One operator left the MPFS electrical enclosure open. As a result, the electronic cards and internal components got oxidized due to water ingress inside the electrical enclosure of the MPFS actuator.

Vendor will replace the damaged electrical components without shutting down the production. One possible solution to avoid such problem is to have a system interlock in the design of the MPFS that will initiate an alarm and will not allow starting the MPFS while the actuator enclosure is open.

The main advantage of using a MPFS is to improve production management and well optimization by the reliable design of the MPFS which uses reduced number of isolation valves,control points and pipings. Its compact design reduces skid weight and size. MPFS are inexpensive in initial purchase and ownership costs.

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Final Control Valve Applications Industry Oil & Gas

Batool Abu Arshid Instrument Engineer

Hisham Teggaz

ADMA-OPCO UAE

Emerson

(End User)

ID 1880



Going beyond the I/O with Advanced Process Control...

In today’s world of virtual reality it’s important to remember that practical things matter too, especially when it comes to Advanced Process Control whose principles are holistic and need to reach far beyond the controller I/O if a return on investment is to be realised.

In this presentation we’ll take a look beyond the controller I/O to a practical world where the ‘fuzzy logic’ demands of APC meet the harsh reality of control valves. The basic principles of high-performance control valve selection will be discussed, giving the audience valuable insight as to what criteria they should consider when specifying and selecting the right valve and instrumentation for an application to support APC deployment. If you’ve ever wondered... - Why all valves are not the same? - What’s important when selecting high-performance control valves?- How to make them more reliable? ...you’re likely to find some of the answers here.

Avoid limiting the potential Return on Investment benefits of APC through careful consideration of the correct hardware for the application (control valves and associated instrumentation specifically).

Use Good Practice for optimum control performance when selecting control valves.

Users will understand how to maximize their Return on Investment with APC through careful consideration and selection of control valves and associated instrumentation.

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Final Control Valve Applications Industry General

Richard Grace Fisher Instrument Business Manager, Europe

Emerson UK

(Emerson)

ID 2183



Safety and Reliability Improved with Wireless Valve Diagnostics

OXEA, a world leader in oxo chemicals, produces derivates at its Amsterdam plant in a batch related process. Greasy acids react with ethyl-alcohol.

The plant had an old, often overhauled on/off valve on top of the reactor. As raw materials got sticky, fouling built up. Valve failures caused deteriorating quality and unplanned shutdowns. The side product water is separated from end product by creating a vacuum in the reactor. Valve leakage can cause air flowing in and contact the alcohol vapors. A hazardous situation to be prevented at all times. Also major quality issues occur.

Commissioning a Fisher 12” vee-ball valve, wireless valve diagnostics and Asset Management Suite allows OXEA to schedule valve maintenance (cleaning) in time. Additionally the above flapper gate (currently controlling the bulk feed) can be removed as the on/off valve is replaced by the control valve to further optimize production and reduce maintenance costs.

An old and often overhauled on/off valve caused reliability and quality issues due to fouling building up. Valve failures created quality issues and unplanned shutdowns.

OXEA invested in a 12”vee-ball valve including diagnostics. The valve diagnostics allows OXEA to detect fouling. The diagnostics capabilities completed with the Asset Management System trigger an alarm for maintenance. Maintenance, cleaning the valve, can now be scheduled between batches.

The valve cleaning can be planned between batches, which is a much safer operation! Future valve failures and unplanned shutdowns for cleaning can be prevented. Reliability of the plant has increased. Furthermore, production can be optimized by using the valve to control the granulate bulk feed into the reactor.

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Final Control Valve Applications Industry Chemical

David van der Werf Technical Manager

OXEA Chemicals Netherlands

(End User)

ID 1983



Is Control Valve Travel Feedback linkage a pain? – Consider it Solved – End User Feedback

It has been process industries dream to get away with physical connections between Digital Valve Controller and Valve stem / Shaft. Mechanical linkages potentially start wearing away over time, causing concern for availability of control loop. Harsh climatically environment added with impacts of throttling energy created by control valve, makes linkages for positioner as weak link. Also it has been noted that linkages with sliding stem valves converts from rotary to linear. For precise diagnostics, it is required to have true actuator stem travel rather than converted motion.

Contactless linkageless with no mechanical connection solves long standing mechanical wear, tear and markings on the linkages. Solves issues with high cycle applications where breakage of linkages are constant headache. Metallic linkages thermal fatigue is common cause for high temp applications involving positioners mounted on valves.

Robust feedback Eliminates slot / pin, linkages, Resists corrosion, Infinite feedback cycle life (PSA skids), Superior closed loop control for high vibration / high temp applications, Reduced inventory / “single” platform, Actual valve stem travel, Elimination of linear crossover adjustment, Faster installation & commissioning with improved Diagnostics.

Loosening up of mechanical linkages and making grooves by pin causing loss of performance and degraded control completely eliminated. Stuck or broken linkages may sometimes causing plant trip loss of huge $$budget. Solves permanently Linkage failures caused with high vibrations high cycle applications and environmental corrosion on mechanical parts.

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Final Control Valve Applications Industry Oil & Gas

Kamel Eddine Bougazi SME (Subject Matter Expert)

riyaz Ali Director - Instruments

Ras Gas Qatar

Emerson UAE

(End User)

ID 1580



Smart use of digital positioners meets Offshore challenge to gain 20% efficiency

Martin Linge is an oil and gas field located in a water depth of 100 to 120 meters in the northern part of the Norwegian North Sea, about 150 kilometers west of Kollsnes. It’s an old discovery but for TOTAL E&P (the Operator with Statoil) it is an innovative and challenging operating philosophy.

One of the challenges is a low offshore manning operation by using an onshore operating center. Technip (EPC) and Total looked after technologies enabling diagnostic of field equipment in real time. The FIELDVUE DVC6200 had already been supplied on several On/Off valves manufacturers in Europe. Why not extend the same solution to the whole project and other projects. In the end the decision was to select and standardize the FIELDVUE technology on all Control Valves (Fisher) as well as On/Off valves (for SIS).

Reduce human exposure (17 persons compare to 78 in standard offshore operation): • In case of site incidents • During helicopter transports • Administrative work moved onshore Find a reliable solution for condition-based and predictive maintenance in 2-week campaigns every 4 weeks period.

Use a FieldVue digital valve controller analyzing continuously valve and actuator data while the valve remains in service.

Improved safety and reduced cost: • 50% reduction in offshore exposure Improved efficiency • >20% Improved production

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Final Control Valve Applications Industry Engineering

Abdelghani ET-TAÏBI Deputy Lead ICS&T / Lead Field Instrument

Technip France France

(EPC Contractor)

ID 2089



Overcoming extreme conditions on Geothermal Well head to achieve reliable flow control

Wellhead equipment has to withstand high pressures, temperatures, vibration, corrosion and other extreme load cases it is vital that the wellhead design is analyzed properly before construction begins.

At the design stage we estimated the highest probable temperature and pressure at the top of the well, then chose equipment accordingly, using standards and simple design models to assist in the design process. CV500 with HD was selected.

Geothermal wellhead equipment must withstand high temperature, high pressure, corrosive chemicals & fast flows. Scaling also requires attention. Once a well has been flowing and is subsequently shut in, a large amount of scale to builds up in stagnant crevasses.

Zorlu Energy worked with Emerson and an engineering consultant on wellhead valves. Together we chose a solution for avoiding scale buildup, erosion, and corrosion.

This helped to avoid equipment failures and maintenance difficulties caused by scale buildup, erosion, and corrosion.

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Final Control Valve Applications Industry Power

Olcay Ceylan

H. Murat Güler

Zorlu Energy, Doğal Kızıldere Geothermal Power Plant Turkey

(End User)

ID 2159



Industrial Energy Management

9 Presentations have been selected for the Industrial Energy Management Track



Steam System Optimization at a Large Gas Processing Complex – GASCO Habshan Case Study

As a part of the company’s long term commitment to sustainability and to the ISO 50001 Energy Management Standard, The Abu Dhabi Gas Industries Limited (GASCO) conducted a comprehensive Steam System Optimization Study at the Habshan-Bab Gas Processing Complex, jointly with Emerson.

Based on the detailed assessment, significant improvement opportunities were identified, achievable through instrumentation, control, optimization, and energy information system enhancements. Rigorous simulations were used to verify the potential and functionality of the solutions.

The implementation of the study recommendations is under way, and once completed GASCO expects to reduce the facility’s fuel consumption over 10% of its current level. Other benefits include higher reliability through better handling of process upsets, and improved energy awareness. The presentation describes the systematic approach taken, and the tools and methods used.

Examples are provided of the immediate and near-term opportunities uncovered, along with descriptions of the main solutions and underlying technologies

The overall design of the utilities is very complex, and difficult to monitor, operate, control, and optimize due to significant interactions between its various parts, insufficient instrumentation, and lack of energy focused information systems. Because of the high reliability requirements, the facilities are also operated conservatively, with many manual operations.

The immediate improvements included better operating practices, instrumentation repair/calibration, and base control enhancements. The solutions currently being implemented include new instrumentation, real-time closed-loop optimization (RTO/APC) for coordinated control of all boilers, turbines, and other steam system components. A comprehensive energy management information system is planned for the next phase.

While the improvement projects are under way, rigorous steady-state and dynamic simulations were used to validate the savings opportunities and verify the functionality of the solutions. Based on the simulations, the expected annual savings in fuel consumption are over 3 Million GJ, representing almost 200,000 ton reduction in CO2 contribution.

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Industrial Energy Management Industry Oil & Gas

Mohammed Al Amri

Pekka Immonen Senior Industrial Energy Consultant

Abu Dhabi Gas Industries UAE

Emerson USA

(End User)

ID 2142



Increase your combustion control and reduce your energy consumption.

Variations in the properties of natural gas feedstock results in temperature variations inside the furnace. This impacts the product quality and energy efficiency of the process. A 370XA gas analyser giving rich information (Calorific Value, Wobbe Index and compositional data) about the gas feedstock meant that AGC Glass were able to control the power and the air excess to their furnaces enabling them to maintain product quality and minimize energy use

This presentation looks at what is often considered a costly and complex instrument to utilize on your plant and how through intuitive software and functionality eliminates those perceptions. • How often is the instrument selection based on an individual’s perception or historic reference? • Has the latest product developments changed the dated perceptions?

AGC Glass, a leader in float glass production required an “easy to use” instrument to provide Calorific Value, Wobbe Index and compositional data to control the air/fuel ratio to their furnaces ensuring product quality is maintained and energy use in minimized

Traditional instruments like Wobbe Index analysers provide only the Wobbe number. Due to changes in the natural gas sources greater information on the gas being used is required. The 370XA provides the solution in a simple package allowing ease of use on site.

Low CAPEX cost with simple start up guides and intuitive software, enabling the site technicians to install and start up the product without external assistance. Greater process control with through detailed information of the fuel gas Enable remote support through MON2020 maintenance software eliminating the requirement for onsite support.

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Industrial Energy Management Industry Metals & Mining

Bruno Symoens Glas Melting & Refractories Project Leader

Siegfried Van Cauwenberge Sr Sales Engineer

AGC Glass Belgium

Emerson Belgium

(End User)

ID 1500



Master variability of fuel. The waste gasification example.

Pure syngas produced from industrial wood waste via gasification using a plasma torch is used to produce energy. Flexible and accurate controls are required to cope with the variable characteristics of the biomass fuel.

CHO-Power, part of the Europlasma Group, is using Emerson technology (Ovation, Rosemount, Fisher, wireless) to control a new waste and biomass-fed power station at Morcenx in France. The new Morcenx gasification facility generates 12 MW of power from 150 metric tons per day of industrial and wood waste, making it the most powerful plant of its type worldwide.

The station is the first of its type to use an innovative and highly efficient gasification principle, based on patented plasma torch, at a 1200°C temperature. The syngas is used to drive the turbine and generate electricity. In addition, 18MWth of hot water from the cooling system is used to heat a vegetable greenhouse and a wood drier.

The project difficulty resides in variation of fuel (hydrometric, temperature) to optimize the combustion with low CO2 emissions. The innovative gasification process demands flexible and accurate control. The waste and biomass fuel helps the plant support European energy guidelines. Cho_Power is first unit using gasification technology from industrial wood waste.

Emerson delivers Control system by using Ovation DCS, Ovation SIS and a broad range of instrumentation and valves. Emerson develops a specific engineering effort to develop gasified boiler control. Wireless technology permits to get access to specific measurement. AMS Suite enables maintenance personnel to better maintain and protect the machinery.

Ovation™ system provides to CHO_Power the levels of flexibility and control needed to cope with the varying characteristics of biomass fuels (temperature, combustion) on this innovative and challenging power plant.

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Industrial Energy Management Industry Power

Jérôme Claverie Manager I&C

CHOPOWER France

(End User)

ID 1720



Implementing combined optimisation and control solutions

A recent installation at Tata Steel’s Port Talbot Works was used to optimize gas holder fuel allocation and control the enrichment of the indigenous low energy fuel (Blast Furnace Gas) to the boilers. The application maintained the calorific value (CV) of the enriched fuel and optimized the blend by minimizing the use of natural gas and maximizing the use of the higher energy fuels (Coke Oven Gas and Basic Oxygen Steel Making Gas)

The MPC application is configured using embedded functionality in the installed DeltaV system. Emerson provided experienced consulting, project management, implementation expertise and resources to design, implement, and commission the necessary control schemes.

This paper discusses the practical and theoretical aspects of the solution and shows that these principals could be applied to other similar applications.

BOS allocation requirement resulted in many phone calls between control centers with associated operator intervention. No automated enrichment control system. Large proportion of operator’s time was manually adjusting enrichment fuels. The operator could not consistently maintain steady CV, nor optimize fuel blend. Change in CV introduced disturbance to the boilers.

Emerson’s embedded MPC software was key to achieving the operational and economic goals. The MPC maintained the enriched fuel CV whilst optimizing the enrichment fuels, minimizing NG and maximizing the use of available BOS and COG.

BOS use was optimized allocating first to the blast furnaces, then the boilers with integrated steam turbines and finally to remaining boilers The MPC application resulted in a constant enriched CV, decreasing boiler disturbances, and optimizing the fuel blend. The application freed up a large percentage of an operator’s time.

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Industrial Energy Management Industry General

George Buchanan APC Consultant

Emerson UK

(Emerson)

ID 1761



Learn how to comply with EU Energy legislation AND improve your process plant energy efficiency

Using historic reports to monitor energy utilisation & efficiency does not account for apparent large swings in energy usage. Making real-time usage available to people on plant who can influence energy performance allows them to identify opportunities to save energy & to act on those opportunities. This is the key to sustainable energy efficiency leading to savings which can be maintained over time. Recent EU legislation, i.e. Emissions Trading Scheme (ETS) & Energy Efficiency Directive (EED) force industry to focus on energy management and efficiency

This presentation reviews the legislation, provides an update on its application & proposes a real-time energy monitoring and reporting system as the vehicle to achieving both compliance & long term savings. Ways to justify the investment in both the system & required additional measurement points are discussed.

All Energy management systems (ISO50001 or otherwise) require visibility of energy usage, preferably against ideal energy targets. The traditional methodology is to run historic reports to assess energy efficiency and utilization. However, industry reports historical analysis in this way cannot easily account for apparent large swings in energy usage.

A real-time energy monitoring and reporting system, accessible by all on a plant, who can influence energy performance is possibly the ideal solution. Whilst this makes perfect sense, justifying a system and the additional metering that maybe required can be the main sticking point.

We take a look at ways energy monitoring and reporting can be justified from a return on investment view, along with energy improvement projects. Also an update on changing legislation

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Industrial Energy Management Industry General

Steve Offer Energy Efficiency Consultant

Paul Cockman Energy BDM

Emerson UK

Emerson UK

(Emerson)

ID 1680



Energy Efficiency improved through optimized mill operation

E.ON's largest coal fired power station in France, the 1,460-megawatt (MW) Emile Huchet plant is located in the Lorraine Region near the German border. Thanks to its geographical strategic location, Emile Huchet coal-fired 600 MW unit is used to respond to peak demand for the French and German power markets. Emile Huchet began commercial operation in 1981.In 2011, Emerson awarded for DCS retrofit using Ovation system (DCS, SIS, Smart process). After, the success of this critical revamping operation E.ON decided to improve Fuel consumption by oil-saving mils operation.

This presentation will describe how Emerson work closely with EON to reduce significantly fuel consumption and the benefits that resulted.

E.ON is the third largest electricity producer in France, supplying the local electricity market with four coal-fired power plants

High oil consumption = high operating costs Oil fire is needed for the shutdown and start-up of the coal burners in order to ensure an ignition and stabilization of the flame. The aim was to investigate whether any reduction or even abandonment of oil fire is possible.

The project was developed by a synergy engineering team E.ON/EMERSON and is using Ovation DCS. Emerson suggests new the logic to implement for startup and shutdowns the oil burners, and manage numbers of the burners in a function of load set point. The combustion is tune to succeed this improvement.

Emile Huchet is a 35 year-old peaking plant (50 start-up/year) and faced lots of improvements issues. The modification brought the below results: - Fuel consumption reduction - Firing improvement - Optimized combustion efficiency - Burners ease of operation - Reduce unpredictable stop

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Industrial Energy Management Industry Power

Jean-Marc Hettinger Manager I&C - EH6

EON Power France SAS France

(End User)

ID 1760



EQUATE Petrochemicals monitors Steam Trap in the Polypropylene plant using Rosemount Acoustic Transmitters

EQUATE has so many steam traps in their facilities, and like all mechanical devices, steam traps eventually fail. Failures in an open position allows costly steam losses to add up quickly. Failure in a closed position not only reduces steam system efficiency but also allows acidic condensate to attack steam system components.

EQUATE understood the need for effective steam trap monitoring and accordingly contacted Emerson to conduct a pilot project as this will eventually ensure no loses in energy and in a tough business scenario, profit margins do not shrink further.

Steam traps are known to fail and in most cases are not detected until a lot of steam is wasted and a good amount fuel been utilized, which means monetary loses. EQUATE has no means of monitoring steam traps and have Environmental KPIs to meet:steam trap monitoring is one top.

Emerson will be using Rosemount 708 Wireless Acoustic Transmitter. Every Steam trap, in operation, generates a noise level. The Rosemount 708 Wireless Acoustic Transmitter detects the presence of the acoustic noise along with sensor temperature. Then converts the acoustic and temperature measurements into output data and alerts

Up to 40% savings in steam leaks which means you save significantly on input costs.Operator time freed up for higher value activities.Improved availability of various plant operations by reducing unplanned equipment failure.Wireless systems provide reliable real-time data,eliminating unnecessary field visits to give higher ease of operability and increased personnel safety

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Industrial Energy Management Industry Oil & Gas

Christy Thomas Instrument Engineer

Eman Wagdy Account Manager

EQUATE Petrochemicals Kuwait

Emerson Kuwait

(End User)

ID 1800



Reduce Your Energy Consumption with Help of Measurement Systems at Refinery Columns

Since up to 60% of the refinery costs can be spent to cover electricity bill, many refineries currently struggle to reduce their energy consumption. And task to save energy spending is one of the most important in the current economic environment. Production can have thousands of processes, and efficiency improve is individual way for each plant. But in order to achieve significant results not always need a major upgrade of the enterprise

Good example of one of the five major refineries in Russia - going through modernization of level measurement systems for deep conversion complex (DCC) columns set the objective to reduce energy use by the plant units.

In order to control product parameters columns are equipped with heating systems designed to heat measurement systems impulse piping due to seasonal subzero temperatures. Need a new method of measurement that eliminates heating costs, saving 250 thousands of rub/year.

Proposed solution based on Electronic Remote Sensors system to measure product parameters in the columns eliminated the need for the impulse piping and, as follows, in their heating. Optimally designed control and measurement systems allow KINEF to provide reliable continuous level measurements that does not depend on the ambient temperature.

Solution helps to improve energy efficiency of DCC units and reduce instrumentation power consumption on vacuum columns in 10 times due to upgrade of measurement systems for product level control at refinery units. Since no need for impulse piping and heating cable allowed to save over 60000 USD as well.

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Industrial Energy Management Industry Refining

Alexander Shapov Head of Operating Facility #3

Andrey Fedorov Pressure product manager CIS

Kirishinefteorgsintez Russian Federation

Emerson Russian Federation

(End User)

ID 1843



Energy efficiency improvement through Advanced Process Control in the Gas Oil Hydrotreater unit of MOL Plc. Hungary

The environmental legislative requirements in greenhouse gas emission and the change of the business climate also force refiners to look for efficiency improvement opportunities. Due to that the energy use accounts about half of the refining cost it is inevitable that the energy field is the most important source of cost efficiency improvement ideas.

MOL decided that on one of its most critical and newest technology, the Gas Oil Hydrotreater Unit-3 (GHT-3), with the utilization of an Advanced Process Control (APC) application, energy efficiency improvement can be made through the reduction of the quality giveaways and through the advanced control of reactor parameters in the summer and winter operation modes.

This paper describes the techniques of the developed solution and the justified results of it

Frequent variations of feed stock parameters affected the operation of the Dewaxing- and Desulphurization reactors, having variations in the product qualities (information on Cloud point and Sulphur content has 2.5 hours delay).Prediction of qualities by inferential values enables the early compensation of quality modifications,resulting a stabilised final product quality.

Feasibility study was carried out to verify the suitable predictions of quality parameters and on furnace dynamics. This determined the correlations among the key process parameters and qualities. It verified that the prediction is inside the expected deviation range. Based on that, the inferential calculations and APC project were implemented.

Process operation was improved by tuning the control system. APC of the Dewaxing reactor was implemented on the winter operational period and APC on the Desulphurization reactor was implemented after catalyst replacement. The reliability of product qualities was greatly improved and the specific energy usage has been decreased significantly.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Industrial Energy Management Industry Refining

Ferenc Tandari Senior Automation Expert

Gyorgy Jablonkai Unit manager

MOL Hungary

MOL Hungary

(End User)

ID 2156



Instrumentation Applications

16 Presentations have been selected for the Instrumentation Applications Track



Finding the best level measurement solution can be easy – if you know where to look and what to look for. AAK will show how high sensitivity radars i

This workshop will show how AarhusKarlshamn (AAK) used high sensitive and easy-to-use radars in various applications where no other tested technology worked at a vegetable oil plant. We will show how this decreased installation and maintenance cost and increased performance and safety. We will also discuss how knowledge transfer with the vendor helped to find the best solutions.

AAK used different methods to measure level in their vessels, but often faced problems. Final product depend on the exact recipe being followed, accuracy and reliability are key. AAK found process radars to be a perfect fit, as well as easy to install and maintain.

The radar technology has the reliability and accuracy needed to control the levels in the batch reactors and storage vessels. In addition, the capabilities of advanced diagnostics to predict possible maintenance, has reduced maintenance costs as well as downtime. Working closely together with the vendor ensured the optimal solution.

Valuable information about instruments and process are visible in the asset management / legacy system. Actions can be taken before the measurement migh fail, additionally problem areas can be identified earlier and additional parameters can be monitored. This resulted in increased uptime and throughput, reduced operating cost and higher safety.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Instrumentation Applications Industry Food & Beverage

Fredrik Brorsson Instrument Engineer

Ingemar Serneby Senior Application Specialist

AarhusKarlshamn Sweden

Emerson Sweden

(End User)

ID 1820



Wireless Tank Gauging

Ak-tas is a supplier of bulk and packaged chemicals of the largest and pioneering producers in the world and stores various chemicals in two different locations in Turkey.

In Kocaeli Terminal, 38 Rosemount Pro Gauges are in operation more than 15 years. Beside all these satisfaction and experience, Aktas decided to go with Rosemount Tank Gauging system in “new” Adana terminal as well.

In new tank farm, there was no gauging system, communication cable infrastructures and overfill prevention system.

For the automatic tank gauging side, wireless tank gauging was the perfect match and overfill prevention side solution is 2120 fork level switches and Delta-V ESD according to the API 2350 recommendations.

Increasing safety - Completing government regulations at tank farm. - Protecting environment. Reduce installation costs - Less Excavation work, minimum installation time and no installation of new communication cables. - Minimum engineering and commissioning time.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Instrumentation Applications Industry Chemical

Cenk Turkay Managing Partner

Ak-tas Dıs Ticaret Turkey

(End User)

ID 1960



Can multiphase flow accurately be measured with current flow measurement technologies?

Can current flow technology correctly measure multiphase flow?Can it be used to adequately predict the gas content in a gas/liquid mixture?

By using a combination of volume flow and mass flow, the density can be calculated and the gas void fraction can be determined. Measuring multiphase flow correctly will help in determining the exact quantity in custody transfer in oil and gas applications, but it will also help to determine the correct mass-flow of high viscosity chemicals with entrained air or in food and beverage applications. Not every mass flow meter will perform similar in a multiphase mixture.

This session will explain why Micro Motion Coriolis mass flow meters are the best choice to accurately measure mixtures of gas and liquid.

The Atlas Copco air compressors are using a mixture of oil and air to function properly. The challenge is to determine the maximum of air allowed in the oil/air mixture before decreased cooling efficiency starts to affect the performance of the compressor.

By measuring a volume flow and a mass flow, the density can be calculated and the gas void fraction can be determined. Being able to determine the GVF means that a reliable 2-phase flow measurement becomes possible.

The Atlas Copco R&D team was capable to find the tipping point where the mixture oil/air wasn’t capable of cooling the compressor anymore By using the Micro Motion Coriolis meter, the team could accurately define this tipping point and determine when the compressor was working out of specifications.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Instrumentation Applications Industry General

Johan Dom Technology Developer

Kristof Heyndrickx Sales and Marketing Manager

Atlas Copco Belgium

Emerson Belgium

(OEM)

ID 1681



Perstorp Speciality Chemicals AB and COWI solves challenging level application with Emerson instrumentation

Perstorp has chosen Emerson as their main provider of process instrumentation for project Valerox thanks to the great solution support and reliable products. Together with COWI, Perstorp has solved two very challenging applications.

The first application is a special separator tank with differential pressure and radar measurement. Application two is an interface measurement with difficult media properties that required a very sensitive guided wave radar from Emerson to work.

Getting level and interface measurement in separators where no single technology could work. Guided wave radar could not be used due to the large amount of obstacles that would have required very expensive rework of the separator.

A radar together with a differential pressure transmitter solved the application challenge were the differential pressure transmitter measures interface and level up to the demister and the radar measures accurately at the top part of the separator.

Perstorp can now optimize the separator usage in the top thanks to the high accuracy radar while the differential pressure unit measures interface and level in the lower part. The operators can now monitor the interface level and Perstorp has increased the batch volume and decreased the batch time.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter


Mathias Reman Instrument Engineer

Ludvig Bengtsson Marketing Engineer

COWI Sweden

Emerson Sweden

(End User)

ID 2090



Increased revenue due to implementation of 3rd party certified bunker measurement solution

CYE was already a reliable and trustworthy supplier in the port of Istanbul, but with implementing the CBMS, they are also able to prove this to the market and attract more ship owners to come and bunker with CYE. The result is a growth in number of customers and a growth in revenue as customers are willing to pay more for a delivery that is accurate and the guarantee that they get what they pay for. Not only CYE benefits from this, but also the port of Istanbul will be seen as a reliable port where customers can get a trustworthy, high quality bunker before entering the Black Sea.

In the world of bunkering, there are many uncertainties and challenges in the fuel supply chain. Partly this is caused by the difficult process conditions of bunkering, but also the politics and the parties involved in the loading/ unloading and fuelling of vessels make it a complex operation.

CYE implemented Emersons CBMS (Certified Bunker Measurement Solution) without any involvement or mandate from the government or customers and this is unique for the current marine industry.

CYE increased their business with more than 30% within 6 months after installation and they gained more customers and increased their reliability image in the market

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Instrumentation Applications Industry Oil & Gas

Deniz Eraydin Director/ Owner

Kaan Cuce Sales Leader, Micro Motion and Rosemount Flow

CYE Turkey

Emerson Turkey

(End User)

ID 1401



2-in-1 Smart Ultrasonic Metering Family Improves Accuracy in Fiscal Metering and Sales Allocation

The financial risk for large volume fiscal and sales allocation metering can be quite high. Thus smart ultrasonic solutions with a proven reduction of these uncertainties are of key value to any party involved in gas trading. A new innovative approach through a series of ultrasonic 2-in-1 meters with smart path layouts (4+1, 4+2, 4+4 and 8-path), addressing various measurement concerns in a systematic manner.

DNV GL has performed a technology qualification of these solutions to verify whether the technology can meet the industry requirements set for fiscal and sales allocation applications of various size. This assessment is based on comparison with best industry practice and a classification model which reflects the metering risk in an operational uncertainty for various annual throughputs. The assessment also reflects typical real world field issues that do occur in fiscal and sales allocation applications.

Current qualification schemes as OIML and ISO do not fully address the typical field issues like fouling or dust. Therefore due to lack of verification options the metering risks can be very high. On the other hand OPEX and CAPEX can be high in relation to the metering risk.

DNV GL provides a scheme reflecting practical metering qualification approach. The ultrasonic flow meter family is a cost effective solution as it combines direct and reflective path arrangements in a smart way addressing typical field issues with early warnings. In this way operational uncertainty and maintenance can be reduced.

The tests performed take into account the industrial need that a meter performs Fit for Purpose. Measurement uncertainties are reduced. Maintenance costs lowered. Custody and fiscal correct transfer ensured.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter


Henk Riezebos Sr. Principal Consultant

Jacob Freeke Director Marketing Ultrasonic

DNV GL Netherlands

Emerson Netherlands

(End User)

ID 2149



Evaluation of small size Coriolis mass flow meters by WIB Users group.

As the use of small Coriolis mass flow meters expanded from pilot plants and research environment to world scale plants, they directly influence product quality and plant availability. WIB (Dutch Users Group) evaluated the performance by testing the latest generation mini-Coriolis meters and an earlier model. The project team agreed to test new Micro Motion models CMFS010 and CMFS015 and the CMF010 meter as it has become the industry standard for low flow dosing in the chemical/petro-chemical industry.

This session explains the testing methods used, the influences of viscosity, air, product temperatures and ambient temperatures and also depicts the test results and recommendations. Tests showed that meters still have a very good performance at 5% of their maximum range.

Amongst the Members of the WIB users group are big oil and gas companies, chemical producers and Namur members.

Small Coriolis meters must perform at the low end of the meter capacity as the optimum in the chemical industry is most of the time a tube size big enough to overcome plugging because of product properties still being able to measure very low flow rates.

Based on these testing results the new generation Micro Motion Coriolis meters will be the preferred solution for low flow applications for a lot of users.

Accuracy under reference conditions were within suppliers specifications. Results under influenced conditions were outstanding, minor shift at low flow, still very repeatable. The CMFS015 with maximum flow range of 300 kg/hr , still has an excellent performance at 3 kg/hr under influenced conditions.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter


Kees Kaijser Sr engineering manager

Bert Roos Business Development Manager Flow Density Viscosity

DOW Netherlands

Emerson Netherlands

(End User)

ID 2134



Fast Measurement of Calorific Values and Density of Natural Gas for Turbine Control

Natural gas shows strong variations in its composition depending on the location of the gas field. While natural gas from Russia or Europe typically contains CO2 in the range of a few percent, in Asia it shows CO2 concentrations up to 20%. These large variations are challenging when using natural gas from several resources in gas turbines. Changes in composition lead to changes in calorific values, which result in changes in combustion properties. This can lead to a reduction of the combustion efficiency and might even cause damage of the burning chamber. Finally, gas composition can also influences the pollutant emissions like NOx.

To guarantee optimum turbine performance a fast real time gas analysis including properties like heating value, Wobbe index, gas density has become necessary. Gas chromatographs are commonly used for natural gas analysis, but their response time of several minutes is too long.

The long response time was reduced with acceptable accuracy allowing better control of the gas turbine.

Non-disperse infrared photometry allows the detection of most fuel gas components within seconds. Heating value measurements can be provided by common measurements of CH4 and C2+. For the calculation of density and Wobbe index, a CO2 channel can also be integrated.

The power company gets better energy efficiency, lower emissions and protects its investment in the expensive gas turbine.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter


Marko Bartusch Projektingenieur

Andreas Jung Product Manager

EEE Anlagenbau Germany

Emerson Germany

(EPC Contractor)

ID 1845



Using Multiphase Meters for Accurate Measurements and Improved Oil & Gas Recovery in a High Sulphur Environment

One of the biggest challenges for multiphase meters is operating in high sulphur (H2S) fields where high, fluctuating H2S concentrations make it difficult to measure oil, water and gas flow rates in the well stream. Such information is vital to detect production threats (water) and optimize well performance. With TCO struggling to source this information, this presentation illustrates how the Roxar multiphase meter met these measurement challenges in Kazakhstan’s Tengiz field – a field that produced up to 18% hydrogen sulfide (H2S) in 2014 and which had limited water treatment facilities.

The presentation looks at lessons learned due to the collaboration between operator and vendor that was key to the project’s success. The measurement principle behind the meter proved to be highly robust against H2S concentrations delivering accurate oil, water and gas measurements. The result for TCO was project certainty, effective well testing and continued production from the field.

The Tengiz field has limited water treatment capacity. Therefore, accurate water and flow rates measurement is essential to pre-empt production threats. Yet, 18% of production is H2S making it difficult to measure flow rates accurately. The field also experienced reducing pressures, increasing volume flow – another flow measurement challenge.

TCO deployed three Roxar third generation multiphase meters that generate accurate Gas Oil Ratios (GORs), water cuts and other flow measurements. This is due to the meter’s robust material, a new measurement principle, that includes electrical impedance measurements and a single high- energy gamma, and strong service support.

The meters helped TCO identify water cut and GOR changes, tackle problem wells, and ensure continued production - in TCO’s words “world-class multiphase flow measurement”. Emerson also directly addressed ambient temperature fluctuation and mixed density measurement challenges, giving TCO complete confidence in the meter’s mechanical integrity and measurements.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter


Kelda Dinsdale Strategic Business Development

John Clarke Petroleum Engineer

Emerson Norway

Chevron Kazakhstan

(Emerson)

ID 2170



Reliable Analysis of Blast Gases Helps Iron and Steel Works to Meet the Requirements for Environmental Protection

The largest metallurgy plant in Russia has 10 blast furnaces each of them has four hot stoves (cowpers). In connection with environmental protection directive there is necessary to measure composition of the incoming gases that go to the air at each Cowper.

Iron and Steel Works had to implement solution to control gaseous emissions from stoves of one blast furnace. Incoming gases formed by combustion mixture of natural, blast furnace and coke oven gases. This mixture has a large number of different mechanical impurities and has corrosive properties because of high sulfur content.

Built analysis solution based on reliable sample system to be able to cope with aggressive gas. High humidity of the sample gas complicates analysis as well. Besides that stoves work in variable modes in which the pressure of analyzed gas changing from vacuum to excess that makes analysis very difficult.

Solution included implementation of four systems for each cowper based on gas analyzer. Each system simultaneously measures four components for CO, CO2 and O2 determination with reliable probe sampling system mounted in a "turnkey" weatherproof heated cabinet. Optimally designed analytical systems ensure plant with reliable sustainable/online analysis of exhaust gases.

Four systems were successfully commissioned in 2014, and despite severe conditions of use, operates normally. Solution allowed customer to control emissions and to save fuel, along with meeting the compliance for Environmental Protection and performing of additional control of technological regime.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Instrumentation Applications Industry Metals & Mining

Alexander Moev Analytical Sales Director, CIS

Nafisa Ishmatova Automation Project Manager


Magnitogorsk Iron and Steel Works Russian Federation

(End User)

ID 1627



Solvay improves Quality and Throughput of PVC Rotary Dryers with Emerson’s Wireless Temperature Monitoring

Solvay's PVC plant in Jemeppe-sur-Sambre, Belgium was facing regular problems of temperature stability on rotary dryers. They could only measure the outlet temperature of the dryers because they could not find a reliable temperature solution for rotating equipment. Drying is a critical part of the PVC production process, with the goal being to reach specific quality metrics such as moisture content. Since it is a continuous process, the temperature must be high enough to drive off moisture at the proper rate as determined by the flow, or throughput. If the temperature is too high, however, the polymer can begin to degrade and discolor.

Solvay was struggling to operate the rotary dryers properly. Without the right temperature measurements, they had a significant number of discarded batches

Solvay selected Emerson's Smart Wireless solution, which is based on the IEC62591 (WirelessHART®) standard, to provide on-line temperature monitoring of the polyvinyl-chloride at multiple points throughout the dryer. The solution eliminated the need to install a new cable infrastructure and any slip/ring collector traditionally required for rotary equipment.

On-line wireless monitoring has enabled operators to prevent excessive temperatures in the rotary dryers, leading to a 50% reduction in off-spec production, Solvay improved quality with better powder drying, and have realized a 1-2% increase in production

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter


Luc Body Head of Automation

Christophe Corbier Account Manager

INOVYN (ex Solvay) Belgium

Emerson Belgium

(End User)

ID 1624



World’s first Innovative solution created Reliability and Cost Saving at one of the largest P&P Mill in the world.

This story is about a unique person who dare and think outside the box. He will risk his own career and his credibility by trying to find a solution to the problem. This problem has always existed and still exist in all other P&P Mills (and other industries as well

The problem was (and it still is for every Digester in the world) the complete solution around the Digester doesn’t work properly. It’s the heart of the Pulp Mill. The wood chips are cooked in huge pressurized vessels called Digester. The white liquor is added to the pulp in the impregnation zone of the digester where it is heated and circulated, cooking the pulp.

Reliable flow measurement is critical in accurately controlling the alkali to wood ratio which directly affects digester performance.

Challenges for the applications: large temperature variations, vacuum, progressive coating. Measuring problems: lining failure, electrode short circuit, clogging impulse tubes, burned meters.

Billerudkorsnäs solved this flow measurement challenge by choosing a different flow metering technology to measure white liquor flow in this application “Never used before in the world in white liquor applications” ‘

The flow availability has increased to 100% The result is more consistent pulp quality at lower cost per ton of pulp. Further, the mill is able to save on maintenance cost for cleaning the failed flow meter and reduce the personnel’s exposure related to maintenance and manual operation.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Instrumentation Applications Industry Pulp & Paper

Peter Hallenberg Project Engineer

Michael Jägbeck Country Manager, Measure & Analyze

Korsnäs bruk Sweden

Emerson Sweden

(End User)

ID 1821



Improved Reliability of Geothermal Power Production Measurement

Geothermal fields are characterized by water coming from wellheads at temperatures up to 175°C. Hot water is driven to separators to meet optimal process conditions in order to maximize production of electricity that is functional to wellhead flowrate. Changes in process conditions might require adapting the flash process conditions or even drilling new wellheads in time to satisfy the energy production with the natural variation of geothermal fields. Ability to predict the geothermal field behavior is essential in increasing the power production and energy efficiency of the plant.

This presentation will show how to effectively correlate the energy production and plant efficiency with a proper measurement of brine flowrate. The technology comparison to drive a proper choice in terms of measurement principle and materials both for greenfields and brownfields implementation. Proper design of flowmetering allows increasing reliability, reducing at the same time downtime and repair that heavily affect total energy production.

Maren needed to implement a reliable system to predict geothermal field variations and optimal configuration of plant variables in order to increase/improve their plant productivity.

Implementing a specially developed system for Brine Measurement and correlate flow variables with geothermal field dynamics.To achieve critical measurements Rosemount Magmeters has been installed and meters have been operating without issue since their installation resulting in elimination of frequent flowmeter maintenance,improved accuracy resulting in greater productivity&reliability in this difficult application.

In 2014, Maren increased power production by 200 MWh, and reduced the unplanned shutdowns to ZERO. The energy efficiency of the production plan increased near to 0,5%.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Instrumentation Applications Industry Power

Mehmet Şişman General Manager

Sedat Cankaya Area Sales Leader

Maren Enerji Turkey

Emerson Turkey

(End User)

ID 2139



Extending Life of Field with a Little Bit of Data

Produced hydrocarbons at surface are warm. Notable drops in flowing temperatures indicate a halt in production.

If a well is liquid loaded, there is a clear signature in the pressure build-up curve. Using this curve, hydrostatic pressures can be extrapolated, and using completion data, it is possible to calculate the volume of the liquid. Pressure and temperature data are used to optimise production by cycling and foaming.

Cycling the wells based on length of time it takes for a SIWHP to stabilise (i.e. all liquids forced from the wellbore back into the formation). And Foaming based on the volumes calculated. Alarms alert control room when flowing temperatures drop.

This prevents the wells from fully liquid loading. Another alarm tells when the shut-in pressures are achieved, minimising downtime. On platforms where remote foaming facilities are available, treatments can be performed once the well comes offline.

As reservoir pressures decline, well productivity reduces. Condensed & formation fluids build-up within the wellbore. The resultant hydrostatic pressure chokes the well & prevents flow. Without the facility to see the flowing pressure and temperature, it becomes difficult to determine when the wells stop producing.

wireless pressure & temperature monitoring

Production declines have been arrested, uptimes have been maximised

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter


Mark Browne Senior Production Engineer

Perenco UK UK

(End User)

ID 1903



How to avoid a furnace tubes coking and improve reliability of VGO high pressure flow measurement with catalyst and coke particles.

PKN ORLEN is a modern, complex refinery and petrochemical complex in Poland. Our aim is to continuously improve all possible areas of operational efficiency, safety and reliability. To obtain these results we use all available and cost effective techniques.

One of the areas we have taken to improve is an impulse lines plugging of typical DP flow measurement. It is not so easy if you cannot replace a differential pressure flowmeter to other technology like Coriolis or Vortex due to a process requirements. So, we were looking for the cost effective solution to avoid problematic DP impulse lines plugging for the liquids with a high temperature, high pressure and heavy particles content like coke and catalyst. Because of well adopted wireless communication at our plants we decided to deploy Rosemount DP transmitters with advanced diagnostic feature to detect a plugging with wirelessTHUM adapters.

We have increased significantly the reliability of a flow measurement used for APC purposes where accuracy and reliability of a signal is crucial. Impulse lines plugging have caused in the past big problem with a coking of a furnace pipes and resulting high fuel gas consumption.

We have started the tests in 2013 at Hydrocracker unit and having very good results now we implement that technology at VGO Hydrotreater. Obsolete DP transmitters has been replaced with those ones having an advanced diagnostics which analyze a pressure noise to detect abnormal situations.

Detection of plugging increasing safety and reliability of a hydrocarbons flow measurement with a heavy particles content. Less coking inside the furnace pipe coils resulting less fuel consumption and shorter time needed to clean the pipe coils. Significant time and maintenance cost reduction is another benefit for PKN ORLEN.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Instrumentation Applications Industry Refining

Dariusz Zygadliński Automation Supervisor

Piotr Burgs KAM Refining Poland & Baltics

PKN ORLEN Poland

Emerson Poland

(End User)

ID 2230



Improve inventory control and operational efficiency of your Calcium Carbonate storage silos

Storage silos have uneven surface making difficult to show true representation of the real volume by using single point measurement. In order to achieve control of the capital tied up in the silo, Solvay needed to find a way to reliably and accurately measure the volume. Additional concern was caused by the calcium carbonate frequently sticking on the silo walls meaning stock levels of up to 40% sat in the silo without even knowing. With no instrumentation, an operator had to climb on the top of the roof to take manual measurements, created concerns for the employees’ safety.

Due to the wide 14m diameter of the silo, Solvay were thinking of installing 8 radars to get sufficient amount of readings to calculate the estimated volume. We offered our brand new Rosemount 3D solids scanner with our visualization software in order to comply with all of their requests.

Improve inventory control and operational efficiency by knowing the real volume of material: production tracking and accurate forecasting of usage. Get a better understanding of material availability by detecting build-up and schedule predictive maintenance. Increase safety by preventing regular top of vessel inventory checks.

Install a multi scanner solution to get true volume and use our 3D visualization software for mapping build-up. This involved installing 4 scanners on the silo working together to compile information and deliver one entire volume measurement.

Better control of Calcium Carbonate stock to always deliver on time customer’s orders (no more out of stock). Increase of safety by scheduling maintenance.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter


Olivier Prieur B.E / AMRA Technician

Nicolas ODRU Business Development Manager

Solvay Carbonate France

Emerson France

(End User)

ID 1901



Maintenance & Reliability

19 Presentations have been selected for the Maintenance & Reliability Track



Essential Asset Monitoring Saves Money within the Lifecycle of a Plant

For its new sulfa plant a chemical manufacturer in the Netherlands set some preconditions • Technical availability of 98% • Turn Around interval of 6 years • Minimal corrective maintenance • Focus on predictive maintenance • Optimal spare parts management The project team looked at the total lifecycle of the plant while justifying the solution for reliability: • About 1% of unplanned production losses are related to failures detectable with Condition Monitoring • Engineering partners assumed that with early detection by condition monitoring the amount of unplanned production losses can be reduced to 0,5% • 0,5% unplanned production losses = about 300k€/year It is for DSM key to apply condition based maintenance with an applicable interval timing per equipment criticality.

Implementation of an online system gives better insights that improves plant reliability as an iterative process.

This greenfield project needed to result in a maintenance -free factory. The business case for predictive maintenance was built by looking at the total cost of ownership and production time for the lifespan of the plant instead of the shorter return on investment only.

Not only critical assets (such as turbo machinery) but also essentials assets (like fans and ancillary pumps) will be monitored online. Assets that have a quick failure mode and need more than an monthly measurement during rounds such as pumps, separators/dryers, fans, conveyors and cooling towers.

By means of a solid business case the end user benefits. By continuously monitoring critical and essential assets total reliability incrementally increases from startup and will be higher than in any other factory. As maintenance will not be surprised by asset failure uptime increases and less stops are needed.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Maintenance & Reliability Industry Chemical

Kris Deckers Technical Director

Allied Reliability Group Belgium

(Supplier)

ID 1984



Online Condition Monitoring Solution helps Arabian Cement Company to protect its critical rotating asset and prevent 70,000-ton production loss. Wow!

Arabian Cement Company (ACC) has a production capacity of 5 million tons/yr, producing high quality cement for local and international market. In cement production, rotating assets like crushers & mills are at great risk. Worn rotating parts lead to internal faults like mechanical imbalance, loose components, and rubbing parts. Our 185 Ton/Hr cement mill is driven by a 6 MW gearbox that showed a sudden increase in vibration level. Inspection showed fracture in one of the CARB bearing cages of intermediate shaft. There was no spare bearing and the lead time for a replacement was more than a month.

Emerson’s Online Condition Monitoring system helped ACC run a critical asset for 17 days continuously with 24/7 monitoring. It prevented $6M in production loss & moved from reactive to predictive maintenance.

CM Gearbox Inspection showed fracture in one of the CARB bearing cages. There was no spare bearing and lead time for replacement was more than a month. Our challenge was running the mill in a bearing failed condition until we received the spare and preventing a month of production loss.

Emerson proposed & installed Online Condition Monitoring system to continue operation within acceptable parameters. It gave us 24/7 visibility to the health of gearbox and allowing 17 days safe production. When system detected a condition that was outside the set parameters, Emerson advised us to stop Mill for inspection.

Online Solution helped us run system for 17 days continually with 24/7 monitoring. It prevented 70,000 ton production loss of cement/$6M sales if we had been shut down for full month. Emerson helped us move from reactive to predictive maintenance, improve spare parts management, outage planning and plant availability.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Maintenance & Reliability Industry Metals & Mining

Ahmed Orban Mechanical Manager

Asad Malik Business Development Manager

Arabian Cement Company Egypt

Emerson UAE

(End User)

ID 2100



Refinery Turnaround (TAR) preparation time halved by integrating all data needed into one place accessible by all

Turnaround (TAR) and maintenance disciplines in petrochemicals have struggled to take the next step to combine BIG DATA and make data Smart. Data is available in several systems and every sequence of the TAR the process of scoping, planning supplying starts from scratch each time. Working together as one team (owners and contractors) in one data source would be ideal.

In preparation for the 2017 TAR a single IT environmental has been created allowing everyone has access to the data enabling them to work in an efficient and effective way, so we can better compete globally. The paper mountain is no longer needed as everyone using tablets or PDA with Wi-Fi can access cloud data such as real time progress, status reports and findings.

The next TAR can use the history data and in this ideal world, the time needed to complete preparation could be downsized by 50%.

The plant’s IT landscape took a lot of time to update, requiring manual interfaces and storing data on share points and drivers. Inflexibility of ERP system led to adding an own-developed database to control TAR data and process. Scope process lacked rigid control regarding scope freeze and scope revisions.

Evaluation of current ERP functionalities triggers implementation of new IT systems linking with all master data, allowing all people to collaborate by using new technology and eliminate paperwork and control scope. Reporting, steering of the progress of planning and execution work is under control and track and traceable.

Ability to do the job with less people in a uniform and more controllable way. Self-developed systems and manual maintenance of excel sheets ended. Participants working in one system cuts amount of interfaces and (overhead) resources in upcoming TAR. Re-use of data will provide major benefits for future turnarounds.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Maintenance & Reliability Industry Oil & Gas

Henk van der Meer Team Leader Events

BP Raffinaderij Rotterdam Netherlands

(End User)

ID 1501



The POWER of Pro-active maintenance

Utilizing the POWER of the AMS Device Manager, you will learn from case examples how to efficiently and effectively use this tool for diagnostic and troubleshooting purposes. We will demonstrate how a small staff can tackle a large installed base, and stay ahead of potential downtime causing failures by being Pro-active using configured alerts and valve scans.

Users will walk away with a specific action plan on how to make this a reality in your facility.

AMS integrated with DeltaV can be a great solution, but improper installation can cause random alerts. Getting buy-in from an older work force, and trying to add additional work to a small staff seems overwhelming. Learn how these can be overcome for success.

Building templates for field devices is the initial key for consistency in alerts. Proper wiring techniques will help you avoid phantom alerts. Showing the staff how Pro-Active maintenance can make their jobs easier, will begin to win over even the toughest bird. Demonstrate how Valve signatures adds icing on the...

While bridging gaps between instrumentation, automation, maintenance, and operations we have begun utilizing intelligent information which has enabled operators to diagnose and resolve instrumentation issues. This has reduced reactive maintenance by over 50%, and saved over $100,000 in avoided downtime, manpower, and rework. This translates into POWER!

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Maintenance & Reliability Industry Pulp & Paper

Doug De Bruin Sr. Projects Director

Clearwater Paper USA

(End User)

ID 2094



Connecting AMS Device Manager to Siemens process and safety system on 4 O&G platforms

Conocophillips Norway have just started to produce oil from their new production platform Eldfisk S. The control and safety system (SAS) is Siemens S7.

AMS Device Manager with Valvelink was chosen for valve diagnostic with remote communication from Onshore Remote Support centre. A new generation of AMS D M interface to Siemens SAS allows installations on separate serves and network. Also three brownfield platforms on Eldfisk is included in the same interface, giving access to more than 2000 field devices on close to 50 SAS process nodes.

Establish online communication with especially valves so predictive maintance can be introduced.

Developed online communication through Siemens SAS to field devices, without need for HART muxes or other hardware. AMS Device Manager V 13 are also installed, to secure different access levels to process and safety field devices.

Conocophillips can now start to monitor field devices online and also better plan for condition based maintenance on valves.

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Kristian Frafjord Haarr Facility Engineer, Instrument

Rolf Jenssen Product Manager

ConocoPhillips Norway

Emerson Norway

(End User)

ID 2219



Egyptian LNG achieves safe & reliable operation with wireless vib monitoring by avoiding fans catastrophic failures which were jeopardizing safety.

Egyptian LNG plant is installed in dry region and acceptable cooling water quality is not available. We consider Ethylene and Methane 72 fans as the most critical fans. Their impact on production is huge since there is no spare cooling capacity in summer.

Fans present a real challenge when it comes to vibration measurements. Only solution to assess fan’s bearings condition is to enter fan’s flow path and attach vibration sensors to bearings; however, doing so involves two severe risks. The more serious is the operation of fan while technician is exposed to moving parts or air currents that could force him into moving parts. The other is sensor could become dislodged and damages fan during testing. These fans recorded more than 30 catastrophic failures since 2005 caused by unmonitored sudden bearing failure. Due to absence of condition monitoring, catastrophic failures have impacted huge financial losses and human safety hazards.

Fan vibration monitoring at reasonable time intervals, which eliminates the problem of data acquisition. Improved safety conditions and avoids catastrophic failures.Technicians are no more exposed to moving parts with wireless Vibration Transmitters installation.

Due to Permanently installed sensors, there is no risk of dislodged and loose sensors during testing.

ELNG installed vibration transmitters and sensors on the fans upper and lower bearings to collect vibration readings. Vibration data is readily available to Operator/Reliability Engineer for further analysis for early fault detection which was not possible earlier. Wireless gateways are connected to AMS Machinery Manager software Server through plant LAN.

Avoiding fans catastrophic failures which were significantly jeopardizing safety and LNG production. Maintenance converted from time-based, which costs expensive overhauls, into condition based, which shall save more than $350,000 from maintenance budget along the 4 years. Saved installation time and cost since it does not require any cabling.

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Sherif Saeed Machinery Engineer


Egyptian LNG Egypt

Emerson UAE

(End User)

ID 2105



Taking Advantage of Turnarounds - From “Fix It” To “Improve It”

Traditionally turnarounds have been focused on returning unit equipment to performance close to original design effectiveness with minimum off line time.

But turnarounds also provide the opportunity to increase the unit’s ongoing mechanical availability and reduce operating costs through improved operations analysis and control - without increasing the turnaround duration.

Operational improvements were resolved in many plants of refineries, from Crude units to Hydrotreaters. Some of these problems were monitoring of fouling in Heat Exchangers, Improved operation of Fired-heaters, improved performance of separators, cooling tower health monitoring and performance monitoring.

This can be done by installing systems for early detection of potential equipment faults, more detailed analysis of equipment performance, and better control. These additions also commonly improve the safety environment by reducing the time the staff has to spend in the more hazardous sections of the plant.

Case studies from several refineries will be presented. Paybacks range from months to less than a year.

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Maintenance & Reliability Industry General

Marcelo Carugo Director, Global Refining Industry

Jose Alfredo Chavez Ortega Gerente de Refinacion

Emerson USA

Pemex Mexico

(Emerson)

ID 2194



An Economic Study in Enterprise Asset Management

Complex process plant operations often make it difficult to make timely and informed decisions about plant management and maintenance strategies. Emerson services are designed to ensure maximum potential benefit is achieved from automation and monitoring solutions.

This workshop shows where Emerson has implemented solutions to overcome key challenges in reliability, process, energy and Health, Safety, Security, and Environment (HSSE). Examples include heat exchanger, cooling tower, steam trap, relief valve and pump monitoring. Annual savings range from $450,000 up to $3.6 million.

Information needed to pinpoint issues isn’t always available, making it challenging to prioritize and budget plant improvement projects. Plants need to pinpoint issues, identify solutions, and develop a project plan. Outside expertise from a supplier with hardware and software solutions, and domain expertise, is often needed to perform this analysis.

Emerson uses a five-step structured process to help personnel identify process improvement priorities. This includes a preliminary assessment and site walk-through to evaluate the current situation; defining solutions with OPEX priorities in mind; presenting the solutions, obtaining company approval; implementing the solutions and training personnel; and verifying performance afterward.

Examples in workshop show how consolidating budgets and using a plant-wide Pervasive Sensing wireless infrastructure helps plants increase productivity and reduce cost by implementing a comprehensive range of solutions. Solutions were previously too costly and time consuming to automate, but Emerson’s project management expertise and Pervasive Sensing made them profitable.

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Melissa Stiegler Global Product Management

Emerson USA

(Emerson)

ID 2235



Wow! Emirates Steel reduces Downtime and Saves more than $I.9M with Emerson’s Machinery Health Management technologies.

Established in 1998, Emirates Steel grew from a simple re-roller of imported steel billets to a complex integrated manufacturing plant, using modern solutions to tackle traditional industrial problems. The CSI 2130 Machinery Health Analyzer gives condition monitoring team the ability to collect and analyze data rapidly, and AMS Suite Machinery Health Manager software used advanced PeakVue® technology to reveal vital information of a plant needs to stay at peak performance.

Condition monitoring team’s enhanced diagnostics reveal hidden problems and avoided costly emergency shutdown in the past few years. Emerson vibration diagnostics and analysis system has been used for several years as basis for predictive maintenance to protect critical rotating machinery in Emirates Steel.

The company’s investment in vibration monitoring tools has paid off in a big way.

Emergency shutdown of Rolling Mill lasting more than few minutes can be very costl y.At Emirates Steel, one day stoppage of Rolling Mill results in loss of 2,400tons,worth $1.3M/day.Cost is often much greater if heavy equipment is involved. If faulty bearing goes undetected,it can seize, causing damage to heavy pinion gears/driveshafts.

Emerson vibration diagnostics/analysis system has been used for several years as basis for predictive maintenance to protect critical rotating machinery.AMS Machinery Manager and PeakVue technology enabled the detection of roller bearing and gearbox anomalies. The company’s investment in vibration monitoring using portable Analyzer CSI2130 has paid off in big way.

Emirates Steel condition monitoring team detects Electrical and Mechanical faults in the rolling bearing and prevented unexpected breakdowns through early identification of defective motor bearings and Gearbox pinion. It saved more than USD1.9M in lost production by avoiding pinion failure and further damage to plant on Rolling Mill#1.

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Maintenance & Reliability Industry Metals & Mining

Yahia Zedan Head of Condition Monitoring


Emirates Steel UAE

Emerson UAE

(End User)

ID 2152



Introducing predictive technologies through smart instrument management

Problems with aging instrumentation and breakdown maintenance strategy are contributes to device failure, unplanned shutdowns & long turnarounds. The mixture of Emerson & other smart field devices are managed by different systems. As part of a new work philosophy to close the gap between E&I Maintenance, Reliability, Operations & Control Automation the existing AMS Device Manager system (part of a 2,500 point DeltaV & SIS) was extended to cover all HART field devices. The consistent approach to device management has enabled a transition to predictive maintenance rather than reactive.

This session gives background information of this change management program and what actions were performed to drive this mind shift which is helping the company to reach its vision to reach Operation Excellence (Knowledge) and improve the business KPI’s. The focus is to bring cultural change along with removing technology challenges.

Demand for increased plant reliability, availability and compliancy needs regarding safety, environment and product quality. •Too many technical challenges and reluctance from end users (maintenance) •Lack of awareness and planning •Management requires project justification (technical and financial) •Uncertainty on project owner , roles and responsibilities •Unavailability of work procedures

A DCS modernization program was initiated in which the AMS project plays a key role. Incorporates all HART devices: Emerson & others •Gap analysis (people, procedure and skills) •Conduct pilot projects, hands-on workshops •Present business case •Identify project owner/roles •Reporting work process, creating check lists and propose planning forward

•Proven results from Hexion US sites show ease in compliancy and improved plant reliability •Management agreed to devote man hours to fully implement AMS for predictive technologies •TAR2016 identified as window of opportunity •Agreed to purchase many more smart instruments and plans to extend it to rotating equipment monitoring

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Ankit Agarwal Mechanical (Reliability) Engineer

Hexion Netherlands

(End User)

ID 1986



Reduce your maintenance cost at Refinery crude units up to 20% using critical assets monitoring solution

Unplanned shutdowns of crude unit can cause great economic losses. In current economic situation petroleum refiners have to deal with tighter targets.

Lukoil headquarters set that overhaul life at their refinery should be increased to three years and maintenance spending should be reduced. Retirement and replacement of qualified workers and operators makes this task even more challenging.

LUKOIL Perm refinery is one of the largest in central Russia. It produced over 12 mln tons of refined products per year.

Perm refinery needed automatic equipment monitoring and decision support system. Potential issue is absence of qualified specialist who can analyze current condition and estimate residual life of mechanical equipment. LUKOIL refinery reported that many of potential slowdowns were prevented by only timely measures of operators and maintenance personnel.

Offered Emerson`s automatic diagnostics based on vibration monitoring and protection system connected to plant DCS for reliable machinery health monitor. Combination of unique PeakVue technology allows detection of faults on early stage with trending and automatic analysis of vibration amplitudes at characteristic frequencies provided by DeltaV control system.

New automatic diagnostics system helps LUKOIL refinery to avoid unplanned slowdowns. It allows identifying different types of defects before they cause real problems for the process. Estimated reduction of maintenance cost of mechanical equipment about 20%.

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Maintenance & Reliability Industry Refining

Sergey Lipatnikov Chief Metrologist Deputy

Aleksey Zarembo General Manager

LUKOIL Perm refinery Russian Federation

LBP ASU Engineering Russian Federation

(End User)

ID 1628



The uncertain matter of integrating Metrology into Asset Management

Metrology, measurement uncertainty, metering equipment, diagnostics and re-calibration are often considered as a unique field of expertise. However, this does not necessarily mean all metrological maintenance should be performed by metering experts.

An alternative approach is sketched, where most metering expertise is applied in the early days of a measuring system’s lifetime, followed by scheduled supervision by Maintenance departments, under their regular Asset Management System(s). In order to have metrological maintenance, including re-calibration, performed by Maintenance Engineers, they must be provided with clear instructions and need to know when to call on experts. This requires all key aspects to be dealt with upfront and translated into clear working instructions. Relevant aspects include not only metering expertise, but also financial data on the criticality of individual measuring systems’ accuracy / uncertainty.

This results in a type of maintenance which is risk-based, financially justifiable and integrated into an organisation.

By integrating Metrology – the Art of Measurement – into an existing Asset Management system, measuring equipment and its maintenance can be supervised from a single system. Moreover, the extent of effort (re-calibration, diagnostics check, …) can now be tailored to the importance of each measurement.

Accuracy (measurement uncertainty) represents a chance. When multiplied by throughput, this represents a risk. Knowing the risk, the desired type and frequency of metrological maintenance can be determined. The last step is to define comprehensive instructions to Maintenance in the Asset Management System. A pragmatic approach to a complex field.

By doing the expert activities upfront, the maintenance efforts can be tuned to an acceptable risk. The actual maintenance can then be run from the same system as other similar activities, and unless exceptional phenomena occur, be performed by regular maintenance staff. Overall, on longer term, cost savings are achieved.

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Wim Volmer Senior Product Manager Oil & Gas

NMi Certin Netherlands

(End User)

ID 1823



Reducing plant risk through proactive maintenance practices

In this paper impact of change in maintenance philosophy on plant risk will be analyzed through two aspects; technical and organizational.

Technical aspect details integration of Emerson solution with Customer processes. Maintenance philosophy change is driven primarily through Customer focus on executing key activities that minimize control system risks. Emerson solution helps Customer to timely obtain needed information as well as monitor impact of key activities with regards to control system risks. In addition, Emerson solution is used to automate monitoring activities what introduces additional risk measures and saves time for automation team that can now focus on more value added activities to reduce plant risks.

Organizational aspect observes how automation team value is maximized in daily routine. Using Emerson solution Customer is able to quantify amount of activities performed by automation team as well as value produced from these activities.

Customer faced challenges from changes in Control System update process (proprietary to open) to Operations IT getting more complex. Continuing to add tasks and complexity to existing staff increases plant risk. Emerson Solution helps Customer to effectively address these risks in the face of daily challenges.

Guardian Support is integrated with Customer processes to keep control system up-to-date with DeltaV hotfixes, Microsoft patches etc., as well as to quantify level of risk associated with control system. System Health Monitoring is used to automate monitoring activities and measure risk that would otherwise not be monitored.

Following metrics will be detailed in the paper: •Increase in plant availability today vs. 10 years ago (before Guardian Support. Decrease in number of incidents. •Increase in number of activities (patches, monitoring checks etc.) •Reduced system risks after automating monitoring activities •Reduced system risks when performing frequent small updates

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Andy Smith Engineer – Control Engineering, Process Engineering & Automation Group

John Ellis Business Developement Manager

SABIC UK

Emerson UK

(End User)

ID 2165



Saudi Aramco’s Best Practices for Using Advanced Diagnostics to Improve Reliability at the Ras Tanura Refinery

One of the biggest challenges of any vibration monitoring program is identifying the real source of unacceptable vibration levels. Spectral analysis may not be enough to capture certain kind of problems, therefore, additional information it is required to tune the analysis. Best practices at our refinery require that we collect time waveform data from all the rotating equipment. This allows us to verify any additional change in the vibration signature that could be hidden in the spectrum. Special approaches are applied to time waveform analysis in order to discard the influence of other signals that might interfere with the final diagnostic.

We implemented advanced diagnostics into our vibration monitoring program using time waveform, PeakVue (Autocorrelation Factor) and Synchronous time averaging technologies that have significantly improved our ability to detect issues and make maintenance recommendations.

Certain problems such as a high frequency faults cannot be analyzed by just looking only one part of the vibration signal. Now that we are using time waveform information, we can see the conditions deteriorate at early stage of failure and catch the issue before it causes an upset.

We implemented advanced diagnostics into our vibration monitoring program using time waveform, PeakVue (Autocorrelation Factor) and Synchronous time averaging, technologies that are available from CSI 2130 and AMS Suite: Machinery Health Management Software. With this practice enhancement, we have significantly improved our ability to detect issues and make maintenance recommendations.

We have seen cost savings, improved reliability, and improved safety. Our program has proven itself in decreasing, in fact eliminating, sudden failures and allowing us to take proactive approach to maintenance.

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Juan Ustiola Vibration Monitoring Leader


Saudi Aramco Saudi Arabia

Emerson UAE

(End User)

ID 2101



Pilot installation of Roxar wireless corrosion transmitter on O&G platform

Due to changes in process parameters for an existing oil and gas field there was a need to follow-up any resulting change in corrosivity for the oil export pipeline.

A Roxar ER-probe connected to an offline logger was already installed in topside piping connected to the oil export pipeline, and there was a need to perform more frequent readings than every third Month to follow-up the process changes. As there already was installed wireless gateways and AMS Device Manager, plus established data transfer to PI Data Historian and the control system, it was easy to introduce a new type of wireless measurement. The pilot transmitter will be purchased for permanent installation.

The ER-probe and the offline logger was installed in a remote location, and offshore personnel had to perform weekly manual readings from the offline logger and uploading the data to Roxar MultiTrend.

To reduce the man-hours required for performing this task, and to ensure immediate response to increased corrosivity, a wireless logger was installed, using existing probe. Use of the wireless logger made the readings available for corrosion engineers at any time, and there was no lag in evaluating the results.

Measurements are now received every 5 minutes, compared to every 3 rd Month with manual offline logging. There are no lag in the measurements. Installations cost been low as existing probes are used and no need to wiring. This is the company's first installation of a wireless corrosion transmitter.

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Line Lilleby Bjering Senior Engineer, Materials & Corrosion Technology

Rolf Jenssen Product Manager

Statoil Norway

Emerson Norway

(End User)

ID 2215



Control valve remote monitoring and diagnostics for offshore and remote location O&G installations

The presentation describes briefly the Statoil operations in Norway and the typical challenges related to offshore and remote location installations and well as the business drivers. As part of an initiative to improve operating performance Statoil recognized the possibilities with their installed base of AMS and Fieldvue technologies. It was identified that these technologies were not being utilized to a maximum extend and a project was launched to include these technologies in their Integrated Operations.

This was achieved by installing Meridium APM within the central onshore operations senter and connecting this to 3 different sites as part of a pilot trail project.

The presentation will further describe the solution architecture build on AMS and Fieldvue, as well as the implementation process including workshops and cooperation with subject matter experts. A success charter was developed describing the expectations and actions needed to secure results.

Statoil identified control valves to be amongst the most critical equipment impacting operational availability and cost. A single control valve failure can stop production and remote specialist expertise is often required to troubleshoot and repair. In the study it was also identified that technologies in place were not utilized.

The solution includes AMS and Fieldvue technologies in place on the various installations. These were integrated with the Meridium APM AMS analytics software installed in an onshore iOps center. Onshore based experts are now able to monitor the remote installation and make recommendations to the operations and maintenance staff.

The results for Statoil can be measured in less offshore work, avoided critical failures, increased availability and increased maintenance effectiveness.

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Ragnvald Soldal Leading Advisor Maintenance Automation

Sander van der Meer Site Team Leader

Statoil Norway

Emerson Norway

(End User)

ID 2020



Flow Calibration On Site: How to maximize your turnaround.

Turnarounds are more and more time limited. But production and quality departments' requests remain for calibration and certification. TEREOS and NESTLE, in North of France, worked with Emerson to find a solution. Job was done on their plant, thanks to a Flow Calibration Mobile Bench.

Both companies saved money and time, eliminate risks, get flexibility in turnaround management and deliver expected certificates on time to their production and quality departments

Many Flowmeters have to be calibrated during a 1 week turnaround. Send them to suppliers factories benches was very risky in time and flowmeters could have been damaged during transportation. Manage and coordinate several suppliers was also time consuming.

Emerson proposed to calibrate flowmeters, whatever brands, on TEREOS and NESTLE plants with a Flow Calibration Mobile Bench, without risks, as Flowmeters remain on customers sites. Large flow range and high accuracy authorize to target a large scope of work. Coriolis, Magmeters and Vortex could be calibrated.

More flexibility on calibration management during turnaround. Modular concept for mobile bench make it easy to install. Very good stability performance associated to Emerson Field Services Expert get results by delivering on time expected certificates to production and quality managers.

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Christophe Tripenne Maintenance Manager

Jerome DESMOULIERES Services Sales Manager

Tereos France

Emerson France

(End User)

ID 1982



Maintaining Custody Transfer Metering System; Availability & Reliability

TPAO has been operating sole underground gas storage facility located in Silivri-Istanbul since 2007. Custody Transfer metering of gas at facility is essential in determining precise quantity of gas transferred. Custody Transfer measurement applies both for injection and withdrawal processes. Injection(gas transferred from national transmission network to underground reservoirs) is generally carried out when there is less demand for natural gas in warmer months, whereas withdrawal (gas transferred from underground reservoirs to national transmission network) is required when greater demand arises due to colder winter climate.

Our annual maintenance contract with Emerson ensures the availability and reliability of the metering system based on the ISO 5167 Accuracy recommendations. This involves periodic calibrations of field transmitters and analysers, orifice plate inspection and re-certification/replacement, and flow computer calculation checks. This ensures that we fully control the financial risk on the metering and we report accurate metering results for gas quantity transferred to our customers.

Since CustodyTransfer MeteringSystems are considered as CashRegisters,seemingly small measurement error can have significant impact on operation’s bottom line.If left unchecked,preventable uncertainty in CustodyTransfer/FiscalFlow measurement can amplify over time,resulting in millions of dollars of financial exposure.This creates necessity to have certified metering experts to inspect and maintain whole metering system.

Emerson lifecycle services create detailed and comprehensive maintenance plan to have continuously optimized performance of metering system.Scheduled maintenance on metering system is essential to provide confidence on accurate measurement of reported gas volumes&properties (composition of Methane,Ethane,other hydrocarbon compounds,Sulphur,Nitrogen, CO2,hydrocarbon&water dew point)and to meet supply requirements for national gas transmission network.

Accurate&sustainable measurement of gas quantities increases our confidence(operator);our customers’ confidence(owner of gas)that exact transferred gas volume is reported correctly which satisfies supply requirements for national transmission network.The maintenance services increases our revenue not only keeping uncertainty of metering system minimum level but also extending life time of metering system components.

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Maintenance & Reliability Industry Storage & Terminals

Serhat Günaydın Senior Chemical Engineer at Planning & Customer Department

Tunahan Avcı Sales Engineer

TPAO Turkey

Emerson Turkey

(End User)

ID 2140



Condition Monitoring Services and CSI 2140 Help ZADCO Identify Gas Turbine Faults and Move From Preventive to Predictive Maintenance

Zakum Development Company (ZADCO) was challenged to quickly identify developing faults of their equipment, so they worked with Emerson on a Condition Monitoring Program covering 95 rotary and 280 non-rotary equipment.

This presentation will discuss how ZADCO was able to improve their plant's reliability with a focus on one of their regenerative gas turbines, which was tripping frequently. Using the CSI 2140, ZADCO was able to identify the underlying root cause of the turbine's trips, get recommendations to prevent these trips, and ultimately reduce equipment downtime.

ZADCO identified a fault condition in one of regenerative gas turbines. The vibrations were trending higher when the turbine was loading beyond 300-600KW & at 7800 RPM.To avoid downtime of equipment,ZADCO needed a solution to identify&address faults early not only in this turbinebut in nearly 400 machines across the facility

Using the CSI 2140,ZADCO was able to conduct a vibration analysis &find out that the vibration source was a result of a surge condition in the turbine's generator.This allowed them to perform corrective actions, including compressor waterwash to clean dirt and process deposits;by loading the machine with theminimum possible increment

Emerson's ConditonMonitoring Services helped ZADCO to move from preventive maintenance to predictive maintenance & improve the plant's reliability.The rotary equipment downtime is reduced by 10%.The Predictive Maintenance to Corrective Maintenance (PM/CM)Ratio improved from 55/45 to 65/35.

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Slahadin Ali K. Ashair Manager Rotating Machinery, ZADCO

Jawad Sherwani Regional Sales Engineer

ZADCO UAE

Emerson UAE

(End User)

ID 2300



Operate Safely, Securely & Legally

19 Presentations have been selected for the Operate Safely, Securely & Legally Track



Infected - Handling of malware incidents in the industrial environment

The presentation describes the best practices in case of a malware infection on an automation system. The content would be: 1.) What do the standards say to the issue of malware removal (short overview) 2.) What are necessary and immediate actions after detection? 3.) General considerations for malware removal? IT vs. Automation Technology? Important boundary conditions? 4.) Which antivirus software can be used? 5.) Lessons learned after an incident? Review with the affected plant!

In depending on the presentation duration I could additionally go into the Automation Security approach of DeltaV, the concrete implementations in BASF Ludwigshafen and our experiences so far.

The removal of detected malware on automation systems.

Usage of best practices and Automation Security concept of DeltaV

Retention of availability of systems in the process automation and prevention of risks for security, safety, health and environment

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Operate Safely, Securely & Legally Industry Chemical

Martin Elsner Engineering Manager

BASF Germany

(End User)

ID 2166



How to develop a proof test concept for SIS instruments?

This presentation will give you an idea how to develop a test concept for a instruments used in Safety Instrumented Systems.

For end users often it's a challenge to develop test procedures for SIS instruments. A lot of things needs to be considered and there can be a big impact on plant operations at example if a plant shut down is needed to do a SIS proof test.

With help of some enhanced PFD formulas to calculate random failures and a checklist to cover systematic failures the end user is able to demonstrate, that the needed SIL portion of a SIS instrument will be reached.

With the presented methodology you can develop the best proof test strategy to fulfill your business requirements by doing several partial tests at different times.

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Udo Menck European SIS Implementation Leader

Dr.-Ing. Thomas Gabriel SIS SME

Dow Chemical Germany

Bayer Technology Services Germany

(End User)

ID 2189



In controller class based simulation made easy.

During the execution of several projects, we were looking for an easy way to do code debugging and graphics checkout. Simulation is ideal to achieve this but building a simulation model can be very labor intensive and often requires additional skills and/or software packages.

Wouldn’t it be nice to have simulation model that ran fully within DeltaV, in a controller or a standalone simulation node? Then DeltaV engineers/technician could do the full development cycle, even for minor modifications.

In this session we will demonstrate how a dynamic engineering simulation can be generated using the standard DeltaV tool set. The resulting simulation can modified and operated just as any DeltaV module, but due to the naming convention used it can be hardly mixed with real control modules. A set of integrated faceplates is used to interact with the simulation from the workstation, which makes it even suitable for operator training.

During the execution of several migration and expansion projects, we were looking for a simulation system which could be easily generated by and configured by DeltaV skilled engineers. Ideally the whole setup should be usable on DeltaV simulate running on a laptop.

We created an excel macro, using bulk edit files, to generate a medium fidelity simulation model based, on well-designed DeltaV control classes. The generated model has the basic tie-backing and can be configured and tweaked from the DelatV explorer or the DeltaV workstation.

By using the simulation generator junior and senior DeltaV engineers were capable of creating their own dynamic models which later on were merged and reused into the overall project model. The concurrent development and reusability of these simulation saved us valuable time during project execution.

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Koen Verstringe Engineering associate

Lieven Cortvriendt Project engineer

Eastman Chemicals Belgium

Colibri Services Belgium

(End User)

ID 2085



Improved start-up/shutdown operation by advanced sequencing

EDF Energy wanted to reduce the shutdown time of its gas fired units at West Burton. They wanted to identify areas for potential improvement to give maximum benefit to plant, efficiency and operating costs.

The Ovation High Fidelity Simulator was used to investigate and confirm improved operating conditions to allow the successfull implementation of the modifications whilst minimising the risk to the existing operating units.

The shutdown time of the combined cycle operating units. Training of the operations and engineering teams to be fully aware of the changes implemented.

The unit shutdown was reduced from 35 minutes to 15 minutes. The Ovation High Fidelity Simulator allowed process parameter and functional modifications to be implemented, tested, optimised and rolled to the live plant DCS.

The improved shutdown process: - saves gas / fuel - time - operating costs and improves plant flexibility, availability and reliability. This modification alone saves the power station around £700 per unit, per shutdown.

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Operate Safely, Securely & Legally Industry Power

David Snell DCS Technician

EDF Energy West Burton B Power Station UK

(End User)

ID 2187



Human Factors – A Complete Approach for Safe & Efficient Operation

A process plant is a complex machine designed, operated, maintained & updated in widely varying conditions by changing teams of people (operations, maintenance & engineering) throughout its lifetime

Human Factors addresses the links between these People, the Plant & the way the Plant is managed (its Management System)

This presentation provides an outline of the elements of Human Factors by considering the big picture including comparison with other industries such as aviation & medicine.

Many safety & efficiency issues are due to people behaving in a way that is not appropriate for the conditions

Holistic, big picture, multi-disciplinary, collaborative approach

Safe & efficient operation

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Operate Safely, Securely & Legally Industry General


Travis Hesketh VP Marketing

Emerson UK

Emerson UK

(Emerson)

ID 2260



A path to Operational Excellence: Multi-Purpose Dynamic Simulation with 3D Immersive Technology

Dynamic Simulation has evolved over recent years. This has enabled simulation technology and Multi-Purpose Dynamic Simulator (MPDS) to be applied widely. The next generation of simulation uses 3D immersive technology integrated into the core MPDS of the process.

This enables the view of the external operator to be simulated with that of the control room operator, creating a unique platform to support integrated operations.

This presentation outlines how the MPDS of a process can be used for different activities, integrated with 3D immersive technology to achieve operational excellence.

The MPDS will assist with process design and support engineering case studies. It will then evolve to assist in the development of operational procedures, before testing the DeltaV System. Resulting in a faster commissioning, reducing the overall schedule. The system can then be used for training, assessment and maintenance support.

The MPDS is developed then integrated with a replica of the DeltaV System.Providing a realistic representation of the process in a simulated environment.The 3D technology,based upon actual design data of the facility is then connected into the DeltaV System. All components are integrated using OPC,providing a robust and versatile MPDS.

Benefits are quantified into two areas, those related to operations and engineering. They include identifying operating constraints at the conceptual design phase, commissioning tool. Providing competency & abnormal situation management tool. Will also provide familiarisation with the plant via 3D technology and integrated operations with the production asset,supporting operational excellence.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter


Ronnie Bains Business Manager, Dynamic Simluation & Process Optimization, Europe

Emerson UK

(Emerson)

ID 1180



Flare stack monitor

At Marathon Petroleum’s refinery in Canton, Ohio, pressure relief valves (PRVs) were causing problems. Faulty PRVs were releasing too much product to flare stacks for burning, but operators could not easily identify which of 560 PRVs were releasing product. PRVs are notorious for not seating completely in a dirty environment, creating a slow leak that is difficult to detect, or “chattering.” It could take weeks or even months to pinpoint a problem. Marathon installed wireless acoustic sensors on 69 critical PRVs, quickly identified failed PRVs, and now can find problems as soon as they occur.

The monitoring system paid for itself in five months. This session describes the problem, solution and results.

Faulty PRVs were releasing too much isobutene and propane to flare stacks, costing the refinery millions of dollars a year in lost product. Manual rounds took too long to identify problems, were expensive, and exposed workers to hazards. Installing standard wired transmitters on all the PRVs would be prohibitively expensive.

In one month, Rosemount 708 Acoustic transmitters were installed on 69 PRVs to monitor releases, and 15 flow transmitters were also installed. The transmitters use acoustics to detect lifts, leaks, releases and blockage.

Marathon recognizes and corrects PRV problems quickly(1hr). The system allows the refinery to use trend data to run the process closer to limits, increasing throughput without compromising safety. Payback was achieved in five months with total annual savings estimated at $3 million. Marathon is installing sensors on 80 more PRVs.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter


Melissa Stiegler Global Product Management

Emerson USA

(Emerson)

ID 2237



Appropriately Comparing Failure Rates Used for Functional Safety Analysis: FMEDA Prediction vs OREDA Estimation

Failure rates predicted by Failure Modes Effects and Diagnostic Analysis (FMEDA) are compared to failure rates estimated from the Offshore Reliability Data (OREDA) project for several control and safety input devices. Because the two methods of data analysis are fundamentally different in nature, it may be surprising that, when appropriately compared, the results from the two methods are generally quite similar. The nature of the published data for FMEDA and OREDA is explored.

Guidelines are provided as to how the data from the two methods should be compared and as to when comparison is not appropriate. The relative merits of each method are discussed.

Failure rates predicted by Failure Modes Effects and Diagnostic Analysis (FMEDA) are compared to failure rates estimated from the Offshore Reliability Data (OREDA) project for several control and safety input devices.

Because the two methods of data analysis are fundamentally different in nature, it may be surprising that, when appropriately compared, the results from the two methods are generally quite similar. The nature of the published data for FMEDA and OREDA is explored.

Guidelines are provided as to how the data from the two methods should be compared and as to when comparison is not appropriate.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter


William Goble Principal Partner

exida USA

(Supplier)

ID 2213



Are you ready to crash your plant?

Many business and process owners unknowingly keep their plant at the ‘exciting’ edge of possible failure. Absence of awareness and insufficient knowledge about the need for proper security measures, play a big role in this.

The presenters from Hudson Cybertec will use several practical examples to illustrate how this exciting edge can be achieved and maintained. Some of the topics that will be addressed are absence of staff security, missing policies and procedures, and lacking to implement the right technology. The presenters will discuss which essentials measures in cyber security prevent you from keeping your plant in its current ‘ready to crash’ state. The presenters will then elaborate on how to avoid the common pitfalls of cyber security.

You will learn how and why the security of your plant can be improved significantly by taking the right measures in the areas of people, organization and technique.

Incorrectly (or not at all) managing cyber security in the Operational Technology domain of companies, keeps plants at the edge of possible failure.

Implementing cybersecurity management in a way that fits the special needs of the Operational Technology domain improves cyber security in a significant way.

Improving the cyber security of the industrial control systems, by managing the security and adopting the ISA99/IEC 62443 Industrial Control Systems security standard.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter


Arjan Meijer Technical Lead

Marcel Jutte Managing Director

Hudson Cybertec Netherlands

Hudson Cybertec/ISA Netherlands

(Supplier)

ID 2065



Why the dynamic Operator Training Simulator proves to be an Indispensable Tool

Huntsman faces a challenge to keep a qualified operator workforce: -Aging experienced operators -Increased mobility of younger operators -An imperfect fit in knowledge and skills for process operations.

Huntsman modernized its Distributed Control System from Provox to DeltaV with a completely new philosophy on control strategy bringing the operator back in the center of operations. As part of the project an Operator Training Simulator (OTS), a high accuracy, dynamic process simulator, has been developed.

OTS has been used to train and prepare the operators for the new interface & process. Change always brings some human resistance which OTS helped overcome and run a safe and efficient startup. Furthermore OTS is used to bring operator skills and knowledge on a higher level. OTS plays a vital role in the certification of CCR operators Huntsman Corporation is an American multinational manufacturer and marketer of chemical products for consumers and industrial customers.

Experienced operators are aging and retiring. -The younger workforce shows increased mobility. -In order to run the operation safe, error free and optimal Huntsman searched for ways to optimize the skill set of their operators.

Before migrating the DCS during the last turnaround, an Operator Training Simulator was installed with an exact lifelike model of the DCS. Operators were, and will be, trained on abnormal situations and startups.

The Operator Training Simulator made operators familiar with the new DCS System before startup. This supported a smooth and safe startup. Huntsman is able to train all new and existing operators. In addition, the OTS can also be used to optimize the process for a safe and error free operation.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter


Jasper Rutten Process Engineering Team Leader

Huntsman Netherlands

(End User)

ID 2132



Dynamic Simulation Modules contribute both to Human Training and Plant Availability in Life Science Manufacturing

Emerson Process Management’s European Dynamic simulation team has developed and delivered a multipurpose training and development system to Janssen Geel, Belgium. This offline, virtualized system has three core use cases.

1st case being the training of operating personnel who will be able to run recipes on a simulated plant and get realistic feedback.

Secondly, the system will be used for the engineering, development and testing of J&J’s global library of DeltaV modules in a simulated plant, remotely accessible.

The 3rd case is to maximize the frontloading for migration and upgrade projects. Migration projects will be loaded into the development system and connected to the simulation enabling upfront testing and user training before going live on the production control system. This set-up provides J&J with the capability to perform migrations more smoothly resulting in a minimum required plant shutdown.

Currently the simulation models were custom build and incorporated into the control code. This made it unpractical for them to be used in a modular global library context. Moreover, after testing it was necessary to cut out the simulation related parts in case of a migration project.

The simulation set-up is fit-for-use in a global library context, based on the S88 standard. The Equipment Modules and their counterpart simulation modules are separated to easily transfer them from the development system to the production system. New modules can be easily build using a standardized library of simulation objects.

J&J has obtained a development, testing and training capability compatible with its global library of DeltaV modules, expandable to incorporate more simulated plants and remotely accessible for other sites worldwide.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Operate Safely, Securely & Legally Industry Life Sciences

Sien Billen Project Engineer Computerized Processes

Pal Kozma OTS Consultant

Janssen Belgium

Emerson Italy

(End User)

ID 2061



Kuwait Oil Company is replacing their existing wellhead monitoring system with Emerson's solution

Oil fields are getting old, and KOC is facing challenges to maintain and show increase in production. The idea is to have a unified SCADA system that could interface and with any 3rd party RTU & SCADA system that is implemented previously and in the future. Also to have a reliable & production technology that can be increased by developing new fields and increasing production from existing fields.

This initiative also needs for SMART field implementation using wireless sensors on all the well head platforms that reduces downtime during the work over and maintenance

KOC S&EK Asset had an issue in monitoring remote wells and its artificial lift equipment ESP performance To monitor the well production on real time basis. The current existing vMonitor SCADA system had issues in providing accurate and continuous real-time data.

A solution of ControlWave Micro With Wireless Interface card to hook up wireless field instruments. CW Micro RTU hooked to OE SCADA system which provides real time interface the users who wants to monitor production and operate the entire system.Other BU details:1.two Wireless Pressure&one Temperature Transmitter.2. One HC&H2S gas detector.

The system installed provides accuracy, repeatability and reliability Improved Well Integrity Optimized Production & monitoring Efficient optimization resource utility Access to Scarce Resources by analyzing the data available over a period of time. Proven Communication Standards Minimize Exposure to Health and Safety Risks

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Operate Safely, Securely & Legally Industry Oil & Gas

Ali Faras Sr. Engineer

Yasir Al-Ghamdi Business Development Manager

Kuwait Oil Company Kuwait

Emerson Kuwait

(End User)

ID 1623



Wireless HydroCarbon Leak Detection-OMV Turkey

In today’s rapidly changing business environment, safety is one of the fundamental challenge that should always be taken into account by companies particularly in oil & gas industry considering potential harm of product over environment and people. Furthermore, regulations regarding Health, Safety and Environment specifically for oil and gas industry has been getting tighter day by day.

Considering all these challenges; Petrol Ofisi (PO), subsidiary of OMV Turkey, operates 35 % of total oil retail market, commits to sustain and improve its own HSE achievements by implementing various policies. Oil spill is one of the remarkable threat among all safety challenges which companies never want to be deal with its results in case of any incident.

Consequently, Petrol Ofisi press ahead with efforts to avoid any incidents as well as mitigate near miss cases related with oil spills due to leakage on tank farms, pipelines throughout the entire process.

Difficulty of monitoring possible leakage during loading/unloading process up to 8000 mt. long at 6-8’’ pipelines, was the crucial challenge in order to prevent an oil spill incident. Furthermore, due to installation obstacles in terms of both mechanical and wiring capital cost of the project was incredible high.

As a result of comprehensive site survey, most probable leakage points determined in order to implement Emerson's solution. Considering all obstacles regarding installation of the system such as cable trays, long start-up times etc. Emerson wireless solutions were assigned to overcome these challenges via 702 wireless discrete transmitter.

Hydrocarbon Leak detection solution, Petrol Ofisi has achieved reliable and accurate safe operation conditions by reducing capital costs down to 70 % compare with conventional wired solutions. Moreover, start-up times and complicated proof tests reduced down to one-single day per terminal.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Operate Safely, Securely & Legally Industry Storage & Terminals

Abdullah Yaltırık Electrical Engineer Department Manager

OMV Turkey Turkey

(End User)

ID 2066



Distillery improves plant safety and removes operator rounds with wireless level

The level of the waste water basin was in need of monitoring. Too high basin levels pose a risk of breaching side wall structures, and an overspill would result in environmental pollution of a close-by stream.

We will describe the solution and simple procedure operators used to remove the need for frequent operator rounds to the basin by installing wireless radar.

Frequent operator rounds take up valuable time that could have been spent on other tasks. Also, the complete lack of available wiring infrastructure made it difficult to find a reliable yet inexpensive solution to accomplish remote access to live values of the basin level.

Wireless guided wave radar runs on a battery lasting for almost a decade, and requires none to a minimal amount of maintenance.

After completion of a quick and easy commissioning, the site started to benefit from immediate time savings and significant reduction of safety risks.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Operate Safely, Securely & Legally Industry Food & Beverage

Pär Björklund

Jonas Åkesson Account Manager, Measure & Analyze

Pernod Ricard Sweden

Emerson Sweden

(End User)

ID 2229



Verification & 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 method for testing safety valve operation without disturbing the process and providing diagnostics information about the final control element as well meeting IEC61511 requirements.

The typical failure includes being stuck in last position and not operating when needed. This could result in a dangerous condition leading to an explosive situation not environment, society, commercial friendly. To ensure the needed reliability of this safety shut down valves, they need frequent testing during normal plant operation.

Digital Valve Controllers allows partial stroke test of mechanical valve without disturbing the plant. This meets “Verification” requirements per IEC61508, demonstration of activity of safety life cycle by analysis and/or tests. Also partial stroke test meets “Validation” criterion per IEC61508, activity to demonstrate safety instrumented system meets safety requirements.

Microprocessor based Digital Valve Controller not only provides 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 by peeping into health of mechanical valve - just an X-ray.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter


Kamel Eddine Bougazi SME (Subject Matter Expert)

Riyaz Ali Director - Instruments

Ras Gas Qatar

Emerson UAE

(End User)

ID 1584



New Alarm Strategy Built with Out of the Box DeltaV Software Delivers 60% Alarm Reduction.

In 2012 Sabic the Netherlands started a project to reduce the huge number of structural alarms. Goal of the project: enable operators to make correct decisions on relevant alarms in order to better analyze, improve plant security and availability, prevent incidents and increase process stability.

Analysis on static alarms turned out they could be divided into 4 categories: 1) Actual process disruption 2) Malfunctioning equipment generating unjust alarms 3) Unfinished projects generating unjust alarms 4) Incorrectly programmed alarms

Thousands of alarms were investigated and appropriate action was taken to prevent them from being shown to operators. The number of alarms has decreased drastically.

This session shows how Sabic used native DeltaV software to build their own comprehensive conditional alarm modules and implemented an alarm strategy for their chlorine plant and utilities that is transparent and easy to understand for the operator. Thus improving safety, availability and process insight.

Huge number of alarms for several parts of the factory, and way above industry standard, hindered operators to make correct decision, obstructed plant availability and process stability and could even cause environmental risks.

Analyzing all the alarm causes on a daily basis during several months. Reducing irrelevant alarms according to philosophy that alarm relevancy should be based on action requirements. Out of the box native DeltaV functionality was used to reduce the number of alarms to industry standard and below.

Alarm reduction of 40% up to 60% over the last 2 years. Insight and process stability have improved and operators are now capable of better controlling plant trips.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter


Jaap Lageweg Sr Engineer Process Automation

SABIC Netherlands

(End User)

ID 1942



EN certified Foam Fatale Tank Storage Fire Protection System for SAC (Saudi Arabian Chevron)

Installing a new fire protection system for 10nos crude oil storage tanks confirming to EN and Chevron standards. The system is designed to suit the constraints of existing control room. Also the complete system is state of the art technology including on/off butterfly valves.

Control Room space is judiciously utilized opting for RIO concept (CHARM) in the new Fire Protection System. Triple off-set on/off Butterfly Valves used for pressure isolation & Double off-set modulating Butterfly Valves for non-pressure applications thus reducing the overall project cost without sacrificing the safety standards of EN and Chevron.

1. DeltaV standalone CSLS with remote IO concept 2. Fisher B/F valves for non-pressure modulating application 3. Virgo B/F valves for pressure isolation application 4. Rosemount Transmitters for Pressure, Temperature and Level applications

Existing control room space utilized. Monitoring the foam quality shall dictate the life of SEF (Self Expanding Foam). Automation and maintenance activities will also prolong the life expectancy of the Foam Fatale system.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter


Ven Florence Process Engineer

Liam Hurley Account Manager

Saudi Arabian Chevron Kuwait

Emerson Kuwait

(End User)

ID 1400



Standardized solution for SIS applications

This presentation briefly describes the concept developed for high level standardization of Statoil Safety Instrumented Systems, i.e. Emergency Shutdown system (ESD), Fire and Gas detection and mitigation systems (F&G) and Process Shutdown system (PSD), whilst maintaining safety and project-specific individual needs. The solution is based on the NORSOK I-005 standard and includes standardized comprehensive function blocks with associated HMI intended for different types of field devices, and control and shutdown structures.

Statoil’s take on safety structures, and methods for specifying and documenting these through Shutdown Hierarchies (ESD/PSD), Cause & Effects (ESD/PSD), Fire Protection Data Sheets (FPDS) and System Control Diagrams (SCDs) will also be discussed in the context of the library development.

As part of a framework agreement with Statoil, Emerson has together with the customer, and in parallel with the first project, developed pre-qualified software library solution incorporating module based control and safety functionality intended for reuse. The solution assures consistency and facilitates standardization across installations.

Development of a specific software library as per standard required by Statoil where the basic concept with functionality has been defined and pre-qualified in cooperation with technical advisors in Statoil.

Re-use of such pre-qualified solution will increase efficiency while reducing the risk of ambiguity in functionality for future projects. Such concept will optimize maintenance and mandatory testing for existing installations when service personnel are familiarized with the concept.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter


Jan Even Hjelmtvedt Leading Advisor Automation - Safety Instrumented Systems

Silvia Peretti SIS Lead Engineer

Statoil Norway

Emerson Norway

(End User)

ID 2143



Cyber-Security in Process Control - How to successfully run an improvement program

Thomas continues the discussion from Düsseldorf & Stuttgart & brings us up to date wth current best practice

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Problem

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Abstract

Co-Presenter

Presenter


Thomas Wegner Lead Security Architect, Yara IT

Yara Germany

(End User)

ID 1582



Process Optimisation

10 Presentations have been selected for the Process Optimisation Track



PredictPro makes BP CATS gas plant purr

This session will assess the recent project undertaken at CATS (formerly operated by BP) and present the fiscal, operational and safety benefits realised from its implementation. We have demonstrated through this work the applicability of this technology to multiple facets of an operational onshore gas terminal. This is the first such project undertaken and completed with BP, and has developed standardised tools and modules for future projects.

Through the session we will discuss the design philosophy, implementation and performance monitoring of the system as well as a number of innovative techniques used to maximise the throughput of the terminal and present bottom line efficiency savings. We will also cover some of the key challenges encountered through the delivery of this project, and how this has been managed at both BP and Emerson, and how these might be applied to future projects.

The production efficiency of the whole fractionation process was maximised through the use of a number of discrete PredictPro controllers. Regulatory controls that were unable to operate as per LOPA credits, are now operational. Implementation method standardised and consistently applied, giving robust project delivery

Implement a number of discrete PredictPro controllers within the DeltaV system, pushing the operating envelope to its design limits to improve capacity and maximise efficiency across the plant. Develop novel methods of predicting the dynamic response of the process to minimise disturbances, and to dynamically adjust the operating targets

Production and utility efficiency has been greatly enhanced, giving bottom line fiscal savings ultimately resulting in the project being cash positive 6 months from kick off. Operating performance has notably improved, lending enhanced stability across the whole fractionation train. Novel technological solutions have been refined and standardised.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Process Optimisation Industry Oil & Gas

Jonathan Newberry Control & Automation Engineer

Andrew Riley Senior Consultant

BP UK

Emerson UK

(End User)

ID 2007



Run your Distillation Towers with Advanced Process Control of Your DCS Closer to Specification Limit while Maintaining Product Quality

Many refineries are struggling with stabilization of distillation columns work. To find the way for optimized control of various processes at several units of Moscow refinery GazpromNeft decided to gain economic benefits from advanced automation and appealed to Emerson for implementation of solving problem solution.

Solution had to achieve economic benefits from improving control and optimizing setpoint to run the process closer to specification. Optimization goals involved product yield increase and energy reduction while keeping quality and technology limits, and varied at different units. Integration of advanced process control with existing DCS was required.

Embedded Advanced Process Control technology was used to execute model-based control, constraint control and optimization, and inferential measurements to control product quality. Advanced Process Control systems was seamlessly integrated into DeltaV DCS and third party DCS and connected to PI System.

Refinery achieved economic benefits at all units from product yield increase as well as reduction of energy use, prediction and accurate control of product quality, and reduction of process and quality constrain violations. Successful implementation of Advanced Process Control proves the strategic customer direction for advancing the automation level.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Process Optimisation Industry Refining

Viacheslav Kulikov Strategic Services CIS Manager

Yury Novik Head of Process Automaton Department


GazpromNeft Russian Federation

(End User)

ID 1626



This Trend Looks Funny: First Steps in Diagnosing Poor Plant Control

It can be a long road to move from a poorly controlled plant to one giving maximum economic performance -and the first step is often the most difficult. An initial focus on regulatory control can deliver large benefits at low cost. This approach will often also identify areas needing attention and allow the potential of techniques such as advanced control to be properly assessed.

This workshop focuses on regulatory control fault analysis and root cause identification, in particular looking at the characteristic signs of particular types of poor control, illustrated with real-life examples.

Problems have ranged from single,non-interacting, control loops,through to multiple interacting loops across whole production assets. They have also included issues which cannot be immediately solved, such as poorly performing valves/instruments and external disturbances, but which can be mitigated.The same types of problems have been experienced across all process industries.

This workshop shows how a review of historical data can identify many of the symptoms of loop performance and can diagnose their cause. Once the root causes have been understood work can start on solving them. This means making the loops work together to improve the control of the unit.

This is the initial step of control improvement which has been widely applied.In every case investigated the root cause was either fully resolved or its effect reduced to an acceptable level.Some results are astonishing,such as:doubling throughput;eliminating control-induced shutdowns;reduction of energy use by one third and elimination of unexpected flaring.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Process Optimisation Industry General

Istvan Nagy Advanced Loop Services/APC Consultant

Westlake Glyn Director Dynamic Simulation & Process Optimization Operatio

Emerson Hungary

Emerson UK

(Emerson)

ID 2248



Eliminating Process Trips With Regulatory Control Improvements

Enquest identified a cause of process trips on their Thistle platform in the North sea as high variability in the natural gas pressure supplying the gas turbines.

The system was sensitive to load changes which could result in a Fuel Gas & Gas Import System trip. This typically resulted in production loss for 2-3 hours.

To address this a systematic Advanced Loop Services approach was used. Initially data analysis was performed, which confirmed that the performance could be improved. Control modifications were developed to reduce the variability. These modifications were implemented and remote support provided to further optimize the performance.

The result is that the pressure control is greatly improved & and the system is able to handle significant (up to 10MW) step changes in turbine load.

The risk of production losses has now been significantly reduced.

The techniques used are widely applicable for “difficult” processes across all process industries.

The gas turbines are supplied by an external gas pipeline, the gas pressure being reduced in two stages. When the load was increased or decreased the pressure system started to swing and on occasions caused a high or low pressure trip.

The problmes were exacerbated because of the relatively small volume of gas between the let-down stages.

A preliminary control study was performed, identifying the approach how to improve the pressure system control. An Emerson consultant went to the site to implement the findings, tune all the pressure and temperature controls and address all the controllability problems.

Gas pressure trips due to normal operational changes were eliminated. The system can now handle large operational disturbances with very little pressure deviation. In addition, whilst on site the oil export system was found to be underperforming. The same techniques were applied here to eliminate further causes of trips.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter


David Boyes System Engineer

Gergo Kertesz Process Control Consultant

Enquest UK

Emerson Hungary

(End User)

ID 2250



Learn how a plant, halved its tanks nitrogen usage, reduced nitrogen Emissions & got pay back in less than 3 months

Following an increase in production, the plant noticed a substantial increase in nitrogen consumption, used for the blanketing of the liquid storage tanks. The investigation proved that this was less related to the increase in production than to the existing tank Pad/Depad regulators. These regulators though proving to be reliable for nearly 20 years, requiring little or no maintenance OPEX were in fact continuously leaking in closed position.

Consulting them to engage in a revamping plan, Emerson experts helped to identify that another improvement axis resided in the regulators set point decrease since the lower it is, the lower is the N2 flow released in the atmosphere. However, low set point usually limits the flow capacity necessary to cope with sudden tank liquid level change.

See how the use of modern tank blanketing regulators helped to solve Janseen issues while improving the whole operation reliability, profitability and safety.

The company resolved unnecessary wastage of nitrogen, it also highlighted the need for more metering in the plant to identify where plant nitrogen was being used.

15 sets of Emerson Y690/Y696 Pad Depad regulators where fitted in the autumn of 2014 and a dedicated Tank Farm Nitrogen flow meter Installed. These regulators are able to work with very low set points still keeping a high flow capacity.

After Monitoring the installation in the spring 2015 the Tank Farm usage was reported to have reduced from 23Nm3/hr to 0.05nm3/hr – and a recorded nitrogen cost reduction of 32000Euro Month more than half the plants pre-installation usage, leading to a less than 3 months pay back

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Process Optimisation Industry Life Sciences

Mark Kennedy Maintenance Supervisor

Janssen Pharmaceuticals Ireland

(End User)

ID 2154



Who needs a MES system? Specialty chemical company JSR explains.

With an uncompromising focus on quality, JSR Micro supplies high-performance materials to the world's leading manufacturers, laboratories and research facilities.

Over the last years, JSR has been implementing the Syncade MES system resulting in one of the most extensive automated production facilities in the world. This results in a consistent product quality, full traceability, removal of paper documentation and a serious reduction of operator errors.

JSR will take you on a journey explaining which motives drove them to the purchase of the Syncade system, how the business case was created to the implementation process, key functions of the system, pitfalls and initial results.

Too much paper. Quality issues where it was difficult to prove which part of the batch process was problematic Problems is weighing and dispense induced quality issues.

Syncade Paper on Glass

Consistent product quality, full traceability, removal of paper documentation and a serious reduction of operator errors.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Process Optimisation Industry Chemical

Johan Desimpelaere Facilities manager

JSR Micro Belgium

(End User)

ID 2178



Using Batch Analytics to Improve the production of Generic Medicine

In Mallinckrodt’s Dublin Facility manufactures a contrast agent which is used in medical imaging to enhance the diagnostic capability of body scanning. DeltaV Batch Analytics was installed to support the process understanding of the operators and engineering teams. It combines established signal processing and statistical techniques to generate predictions about the final outcome of batches in production before those batches complete. The offline analytic capability allows operators to compare historical batches and identify process improvement opportunities.

Mallinckrodt was able to use Batch Analytics in their generics manufacturing facility to increase process understanding and improve control of the products running through their facility

Batch operations take place in complex, highly correlated and dynamic environments. Process holdups, access to laboratory data, feedstock variations, unsteady operation, and concurrent batches all contribute to this complexity. Modeling historical data for process understanding supported Mallinkckrodt to make process improvements to the batches running through the facility

At Mallinckrodt’s Dublin Facility, Batch Analytics was installed for increased process understanding, fault indication with potential diagnosis and quality predictions of batch performance.

Mallinckrodt used the offline modeling capability of batch analytics to increase their understanding of the process and to target areas of the manufacturing operation that could be improved. A comparison of historical batches showed process improvement opportunities which were actioned as part of their continuous improvement programme.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Process Optimisation Industry Life Sciences

Basil Healy Business Development LS EU

Mallinckrodt Ireland

(End User)

ID 2071



Dynamic simulation of a multi-stage compressor unit - comparison of measured operations with results of a simulation

Summary dynamic simulations are an excellent resource to review complex technical procedures on interactions with adjacent plant parts already in the concept phase. Various software tools and various approaches to describe technical systems are available. During the creation of the simulation model, simplification is to take in order to keep the computational cost justifiable. The art here is to omit insignificant, but properly depict all significant correlations. A comparison of results from simulations with measured operating data of dynamic operations at comparable facilities is an effective means to verify model approaches.

The author presents several simulation studies of industrial equipment where dynamic processes of which data were available, were reviewed in a simulation. This could. quality of the modelling approach reviewed, and where necessary corrected

chemical plant; interactions with parts of the system occurred on failure on the part of a plant causing shutdown of entire system. Via simulation, the rule concept has been improved so breakdowns can be avoided. Iair separation plant, power outages led to pump bumps on compressors, causing damage.

Dynamic simulation of a multi-stage compressor unit - comparison of measured operations with results of a simulation

Verification & calibration of known dynamic operations simulation models, improves quality of simulation. chemical plant improved after modification in operating errors on lines avoiding interaction with neighbouring plants. air separation plant how much additional valves to install and which speeds the existing valves to upgrade are determined in the simulation

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter

Process Optimisation Industry General

Wilfried Blotenberg Consultant

MAN Diesel & Turbo Germany

(OEM)

ID 2158



DeltaV Simulate Helps Solve Production Problems

Standalone DeltaV Simulate can be used for more than developing and testing control logic and displays.

This paper presents examples of its use as a troubleshooting, prototyping, testing and training aid – and not just for installations that have DeltaV.

In one case study, relatively simple simulations demonstrated to a sceptical management how three quite basic problems with their control set-up were costing production in excess of 50,000 bbl/day, and that the proposed solutions would allow reliable operation at the full capacity of the field.

In another case, a revised control strategy for a platform’s gas process was prototyped and demonstrated before being implemented offshore, allowing gas that was previously flared to be used in the generators, displacing expensive diesel. In these and similar cases, a valuable side-benefit has been improved ability of on-site staff to recognise and overcome common problems through realistic, hands-on training.

Upstream and offshore process and control problems are surprisingly common, with the same issues appearing again and again. On-site expertise is usually limited, particularly offshore, and Operations managers are often reluctant to permit plant trials needed to diagnose problems and logic modifications needed to solve them.

Many common process and control problems can be readily simulated, and solutions demonstrated. This builds confidence that proposals will really work, overcoming managers’ natural reluctance to permit plant testing and control modifications. Standalone DeltaV Simulate is an ideal tool for this – even if the installation has a different system!

In one case, production improved from an unstable 170,000 bbl/day to a stable 220,000 (~$5M/day benefit). Elsewhere, improved gas recovery reduced diesel usage by $20,000/day. Other benefits arise from training site and offshore staff to diagnose and correct common problems. All this for $2000 on a laptop PC!

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter


Neil Brown Director

Profimation UK

(Consultant)

ID 2102



Lessons Learned from Deployment of DeltaV Embedded Intelligent Controls at Abu Safah & Qatif Crude Oil Producing Facilities

The oil industry is facing new challenges, namely falling prices, increased pressure for environmental regulations, increased energy costs and international competition on oil products. In this environment it is important to use state of the art technologies to maximize production from existing producing facilities.

This presentation and paper describe the project deployment phases, successes and lessons learned of the DeltaV Embedded Intelligent Control applications namely Multivariable Predictive Control and Neural Networks at Saudi Aramco’s Abu Safah & Qatif Crude Oil Producing (AS&QPD) facilities.

The following identified tangible as well as intangible benefits would be realized as a direct result of implementing Predict Pro and Neural Networks at the AS&QPD site; • Optimize separation between stabilized crude oil and off gases. • Consistent quality of stabilized crude. • Consistent quality of stabilized condensate. • More stable and reliable plant operation. • Reduced steam energy and compression power usage.

Falling prices, increased pressure for environmental regulations, increased energy costs and international competition on oil products. In this environment it is important to use state of the art technologies to maximize production from existing producing facilities.

Saudi Aramco used DeltaV Embedded Intelligent Control applications namely Multivariable Predictive Control and Neural Networks. We also used APC and PID controllers control performance monitoring technologies.

Th team demonstrated that using the DeltaV APC technologies we generated additional revenue through increased crude oil recovery, steam and power savings while meeting the crude oil product specifications. Other intangible benefits included improved process stability and safety.

Problem

Solution

Results Benefits

Abstract

Co-Presenter

Presenter


Othman Taha Engineering Specialist - Advanced Process Control

Ariffen Adnan Engineering Specialist, Advanced process Control



(End User)

ID 1721



Date post:	03-Apr-2018
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