Automation System Modernization.pdf

Automation System Modernization

Regain your competitive edge.

With today’s increasing global competition and rapid

technological advances, many plants around the world

have legacy automation systems that aren't able to keep

up with today's production demands.

C ONTENTS

Better plant performance begins with better automation.

And, with today's digital technologies you can expect

increased productivity and better communications

between your process information and your business

systems.

2 Correcting Missed Opportunities

Regaining your competitive edge

through modernization.

10 Maximize Availability

Minimize your downtime during

modernization with Emerson

technology and expertise.

4 Why modernize with Emerson

How Emerson delivers more

performance for a more

profitable plant.

12 Maximizing ROI

Get more from your automation

investment with Emerson’s world-

class training and simulation tools.

6 Starting Out with a Solid Plan

Build a business case based on OPEX

and CAPEX for the life of your plant.

14 Sustained Improvement

and Support

A flexible portfolio of industry

leading support in your city and

around the world.

8 Global Standards and

Best Practices

Manage your modernization with

global project experience.

A legacy of lost opportunities.

When should you consider system modernization?

Yesterday’s systems may have been a good investment, but today’s

technology and expertise provide opportunities and benefits that just

weren’t available when these systems were designed. You should consider

a modernization when:

“Emerson is widely

recognized as today's

leader with respect to

process instruments

and automation

systems. We expect to

benefit greatly from

their experience in

applying these

technologies to the

processing of bitumen,

integrating the

engineering phase of

the project, and

bringing state-of-the-

art efficiency to the

operation of our

upgrader.”

Inventories of raw materials and finished product pile up

Product quality is inconsistent and customer complaints increase

Start up and product grade changes cost more than they should

Plant trip and alarm systems are unreliable and/or inadequate

Production is inflexible and start-up time is lengthy

Recurring emission problems are constraining throughput

Business systems lack meaningful plant floor production data

Customers are demanding more but your plant cannot deliver:

more specialized products and packaging

tighter quality specifications or delivery times

better service

Obsolete system support costs continue to increase.

What are you missing?

You may want to consider how your system (and your current automation

supplier) would respond to:

Reducing variability to establish a foundation for advanced controls

and process optimization for better throughput and yields

Providing field service alerts to operators and/or maintenance,

improving response times to specific needs

Integrating DCS information with your business systems for more

informed and timely business decision-making

Robert Pearce

President

North West Upgrading Inc.

Integrating predictive maintenance practices to focus your

maintenance resources, saving time and money.

See how Emerson’s digital technologies and expertise enable the safest

and most scalable path to on-going capital expense and operational

expense savings.

For more information:

EmersonProcess.com/

Solutions

Production & energy costs keep rising

Plant expansion (including bus-based or wireless I/O) for improved

plant diagnostics and increased plant uptime

Why modernize with Emerson?

Ta ke ad va ntage of

Emerson’s experience

with thousands of process

automation projects

worldwide .

Modernize for

measurable results

Highlights of customer measurable

results in thousands of PlantWeb

installations worldwide include:

10% increase in throughput

Automation leaders

The keystone to Emerson’s

automation technology leadership

is the proven PlantWeb ® digital

plant architecture, an open

standards-based digital solution

that networks intelligent field

devices, digital systems, and

software, controlling processes and

managing equipment and other

assets. Embedded, advanced

control means a more efficient,

consistent, available and optimized

operation.

20% reduction in raw material

usage

15% reduction in rework

50% reduction in maintenance

costs with remote diagnostics

New high-margin products never

before possible

Reduce your risk

With PlantWeb, you can achieve an

effective program for managing

safety, health, and environmental

risks and costs—one that goes

beyond abnormal situation

management to abnormal situation

prevention .

Control room space requirement

reduced as much as 85%

Automation investment payback

in less than 4 months.

Leaders in service

Emerson’s global network of

engineers and consultants has the

real-world industry and process

automation knowledge to help you

design, plan and implement your

automation concept with:

Emerson’s commitment to open

standards, highlighted by our

donation of the HART protocol in the

1980’s, continues today with our

work on F OUNDATION fieldbus and

wireless standards.

Modernization and migration

consulting

AMS ™ Suite: Intelligent Device

Manager gives you key online access

to your instrument and valve

process information, diagnostic

status information, and automatic

documentation of all field device

maintenance information. And

DeltaV ™ SIS, at the heart of

Emerson’s smart SIS, works with

AMS to continuously diagnose your

intelligent field services and safety

functions. This helps ensure your

process shuts down only when

it should.

Fieldbus consulting

Process safety management

Human factors optimization

Production information

management

Advanced automation &

optimization

Plant system security.

30% increase in capacity without

additional personnel

Better performance.

Operating on the

leading edge

Process manufacturers lose

millions of dollars each year due

to process variability and poor

control performance, often

unaware that a problem exists.

The powerful new DeltaV InSight

monitors control performance;

identifies and diagnoses problem

loops; recommends tuning and

maintenance improvements; and

continuously adapts to changing

process conditions.

“We looked for a

company that had the

right technology and

also a strong support

network that would

be available to us. We

selected the

PlantWeb digital

plant architecture

from Emerson Process

Management. We

also selected Emerson

as our main

automation

contractor because of

its proven project

management

experience and

intimate knowledge

of the technology we

had selected.”

Manufacturers have real issues

everyday that effective wireless

solutions can help solve.

Emerson’s Wireless SmartPack ™

helps you create a secure network

right out of the box, giving you

convenient access to information

you simply don’t have today.

Often, fewer than 10 modules

cause 40% or more of alarm

activations. So by addressing just

a few alarms, you can significantly

improve operator alarm loading.

DeltaV Analyze makes it easy to

find the most frequently occuring

alarms.

Evelio Hernandez,

Process Control

Systems Manager

Emerson Process Management was again voted the best

supplier of process management technologies in CONTROL

Magazine’s 2007 Readers’ Choice Awards. This is the

14th consecutive year that Emerson has captured

the user-voted recognition.

For more information:

EmersonProcess.com/

PlantWeb

EmersonProcess.com/

SmartWireless

EasyDeltaV.com

ARC and Control Magazine also placed Emerson as

#1 on their Top 50 Automation Companies List.

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