ELECTRICITY
600# STEAM
REFINERY GAS
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Use of energy in processes is one of the biggest and most controllable operating costs in most plants. An
energy conservation program is essential to maintaining competitiveness, and improvement in automation
can be effective and easily implemented solutions to achieve your goals. The first edition of Emerson
Innovations bring you closer to these solutions for maximum energy efficiency in your plant.
Making a
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difference
Emerson has become a trusted partner and its Rosemount® and Micro Motion®
measurement technologies have enabled savings of ¤1 million per year.
Marian Stancu, Chief Energy Engineer, CAROM Onesti
Mass balance is vital for complex processes within reactors and distillation columns, and achieving
that balance requires accurate and reliable flow measurement. At its petrochemical production
and distribution facility in Romania, CAROM Onesti has applied Emerson’s Vortex and Coriolis flow
measurement technologies. More accurate and reliable measurements have reduced product loss in
the MTBE plant by 150 metric tons per month creating savings of €700,000 per year, improved boiler
efficiency by 3%, saving more than €200,000 per year in fuel, and eliminated the need to rework tanker
filling operations in its distribution terminal, enabling savings of over €90,000 per year. The faster train
turnaround is also saving over 300 labour hours a year. Read more about the Rosemount 8800D
Vortex Flowmeter at EmersonProcess.com/IM602
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Emerson’s solution will help
improve our overall operational
efficiency and raise customer
confidence in the quality of
our deliveries.
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Emerson’s wireless mobile worker
solution dramatically improves
operator productivity and efficiency
by providing instant access to data
from the control system.
Wim Schauvliege, Project Engineer,
Stora Enso Langerbrugge N.V.
Deniz Eraydin, General Manager,
CYE Petrol
An upgrade to Emerson’s DeltaV™ distributed control
system and a new Wi-Fi network in the de-inking
section of the Stora Enso mill in Ghent, Belgium
has provided hotspot access to process operations
using ruggedised Apple iPad 4 tablets with DeltaV
Remote Operator Station application, helping to
improve operator efficiency. Find out how Smart
Wireless can empower your plant workers at
EmersonProcess.com/IM605
CYE Petrol has chosen Emerson’s Micro Motion
Certified Bunker Measurement Solutions to enable
accurate, transparent fuel deliveries from two new
bunker barges in Turkey. The Measuring Instrument
Directive (MID) approved solution will reduce
measurement uncertainty that can lead to disputes
or delayed vessel movements. Read more about
the Certified Marine Bunker Measurement
Solution at EmersonProcess.com/IM601
Welcome to
innovations
Energy represents less than 30% of the
operating costs in a typical industrial
facility, and it is estimated that industrial
manufacturer’s consume 50% of the
world’s energy. Many of the countries in
Latin America have to reduce energy
consumption and update their
regulations in reference to the energy
efficiency needs.
The compliance of such regulations demand reductions in
consumption and emissions, higher use of alternative fuels,
annual audits and energy management programs. Emerson
provides a great range of solutions and engineering services
for enterprises to achieve these demanding objectives.
Our experts with over 40 years of experience in industrial
energy will advise on where new measurements points would
enhance the visibility of energy consumption in your plant.
These new measurement points can be implemented quickly
with intelligent wireless networks and frontline non-invasive
techniques to prevent production slowdowns.
This edition of ‘Innovations in Process Control’ contains
articles enlisting initiatives and technologies designed to
help you improve the energy efficiency of your plant.
Discover the Emerson Solutions that will allow you improve
the energy management of your plant visiting
EmersonProcess.com/industrialEnergy.
Leonardo Rodriguez
President
Emerson Process Management Latin America
Contents
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6
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10
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16
Energy management
information
A measured approach to
energy consumption
Reducing
steam losses
Improving combustion
process performance
Wireless minimises cost
of new energy measurements
Innovative
technologies
Further
information
3
Energy management
information
Monitoring and
understanding energy
consumption in an
industrial operation is
often difficult explains
Steve Offer, Industrial
Energy Business Development Manager
at Emerson. Our recently introduced
Energy Advisor energy management
information system provides a real-time
insight into process consumption and
loss, helping to improve energy efficiency
while meeting the requirements of the
latest European Union directive.
4
For many process industries, energy is one of the
largest components of cost of goods produced.
However, understanding energy consumption and
loss is often difficult. The complexity of processes,
variability in operations and a lack of energy
measurement points often present challenges.
Furthermore, most manufacturers analyse energy use
retrospectively, which prohibits them from taking
action on abnormal use as it occurs.
The introduction of the European Union Energy
Efficiency Directive (EED) in July 2014 covers a
complete spectrum of activities and operations.
Managers need to understand the impact of this new
legislation and how current best practices can be put
to use to develop a sustainable plan that will lead to
long term energy efficient operation.
The ISO 50001:2011 standard for Energy
Management Systems provides a framework of
requirements that make it easier for organisations
to integrate energy management into their overall
efforts to improve quality and environmental
performance. A key requirement of ISO 50001 is the
need to complete regular energy audits which must
lead to energy saving programmes. Companies are
also encouraged to implement energy management
systems (EMIS) and adopt best practices.
Emerson’s Energy Advisor makes it possible to
effectively manage energy by providing an insight
into operational consumption and loss. With Energy
Advisor, all energy measurement data from around
the production site is aggregated in real-time in a
central database. The system compares current
energy use to desired targets either set by operations,
from models of past good performance, or from
first principle models. When performance is
abnormal, operating teams are notified with an
alert so that corrective action can be taken and
the organisation can move closer to its energy
management objectives.
Energy Advisor meets the requirements of the
ISO 50001 energy standard to monitor, target
and report. Energy Advisor integrates seamlessly
with current site DCS, SCADA and/or enterprise
systems, allowing the implementation of an EMIS
solution in a straightforward and cost-effective
manner. Emerson can also provide the means to
obtain needed energy measurements by specifying
and delivering best-in-class wired or wireless
instrumentation. With wireless technology the cost
of measurement implementation can be reduced by
two thirds, allowing any missing flow, pressure
and/or temperature instruments to be brought
back to the monitoring system cost-effectively.
Reduce energy consumption and increase energy visibility with
Energy Advisor
Emerson’s Energy Advisor provides a better insight
into energy consumption and loss, turning energy
data into actionable information that enables
site-wide energy performance targets to be achieved.
This can identify potential savings that could reduce
energy usage by 5-15%.
To find out how Energy Advisor can provide an
insight into your plant energy consumption go to
EmersonProcess.com/IM607
5
A measured approach
to energy
consumption
Within a typical
process plant, there are
hundreds of problems
that prevent optimal
energy use. Irfan Khan,
Business Development
Manager – Energy Management at
Emerson, explains how real-time,
accurate measurement allows even
small inefficiencies to be detected,
revealing the next level of improvements
that will transform your energy profile.
Wherever energy is used in a process plant there is
the potential for waste. Every leak and loss is money
down the drain. You cannot manage what you do not
measure, so measurement instrumentation provides
the key to finding hidden efficiency opportunities –
but where do you start? Here to help you are five key
measurement priorities:
Utility fluids – metering flow and managing use
Water, gas and steam are all crucial to your
operations and it is estimated that 5 to 15% of a site’s
energy is wasted or misused. Measuring of all utility
fluids will help you understand the usage patterns
throughout your plant. Combining Rosemount
flowmeters with Emerson’s Energy Advisor gives
you visibility and energy decision-making capability,
providing the opportunity to recoup that 15% of
wasted energy.
Compressed air – measuring flow and
managing use
The compressed air system in your plant is a major
energy user. More points of flow measurement allow
tighter control of leaks and better management of
the system’s health. Further savings can be made by
replacing traditional orifice plate flowmeters with
Rosemount Annubar Flowmeters.
6
Permanent pressure loss is greatly reduced, therefore
it becomes negligible in the calculation of energy
consumed by the compressor.
Boilers – improving drum level measurement
In boilers, the water level in the steam drum must be
precisely controlled to optimise steam production,
maximise boiler efficiency and maintain safe
operation. Traditionally, steam boiler water level has
been difficult to measure due to variations in density
caused by changes in temperature and pressure.
Guided wave radar transmitters with Dynamic Vapour
Compensation overcome this issue to provide highly
accurate level measurements, which enable improved
boiler efficiency and lower energy consumption.
Heat exchangers – predicting and
detecting fouling
Heat exchangers, which can foul over time, directly
affect production capacity, maintenance costs and
energy use. Emerson’s Heat Exchanger Monitoring
Solution provides temperature and pressure
measurements that are trended and analysed to
alert operators to potential fouling. This provides
operators with calculated heat transfer, exchanger
heat transfer coefficient, fouling factors and the cost
of degradation; to help keep heat exchangers running
at optimal performance.
Steam system – monitoring steam traps
When a steam trap fails it is either open or closed.
An open steam trap will leak steam, wasting valuable
energy. A closed steam trap will allow condensed
water to build up, causing reliability issues and
‘water hammer’ events. The Rosemount 708
Wireless Acoustic Transmitter monitors steam traps
continuously and identifies failed traps immediately.
To obtain your free Engineer Insight Report:
‘Top 5 Measurements in Energy Management’
go to EmersonProcess.com/IM608
Improved measurement and monitoring
enables better energy management
throughout the plant.
7
Reducing
steam losses
Failed steam traps can
cause inefficient heat
transfer and pose a
serious risk to personnel
and equipment.
However, knowing
when they have failed is a challenge,
explains Ralf Kueper, Wireless Business
Development Manager at Emerson.
Continuous monitoring of older and
critical steam traps at LEVACO has
identified malfunctioning units, helping
to reduce leakage and save energy.
8
In recent years, rising fuel costs and increasingly
rigorous environmental standards have encouraged
process companies to find ways to conserve energy.
Steam traps, which remove condensation from steam
lines, are easy targets for potential savings. There are
hundreds of them in most plants and they can have
an immediate impact on profitability when they fail.
Studies have shown that the life expectancy of most
steam traps is in the range of four to eight years,
with failure rates of 12-25%, depending on their
construction and duty. The average inspection period
is just once a year, so in the meantime a process could
be unknowingly leaking money.
LEVACO (at the time operating as Tanatex Chemicals
GmbH) partnered with Emerson to implement the
ISO 50001 energy management standards at its
Leverkusen chemical plant in Germany. LEVACO
project managers developed a plan to fit about
100 of the facility’s older, more critical steam traps
with Emerson’s Rosemount 708 wireless acoustic
transmitters linked to a WirelessHART® network.
Wireless sensing technology enables
continuous steam trap monitoring.
Emerson has combined its expertise in wireless and
instrumentation to create a solution for the steam
trap issue. The Rosemount 708 is a simple wireless
transmitter based on proven technology that allows
real-time visibility of critical steam traps. It uses
acoustic ‘listening’ technology, combined with
temperature measurement, to identify turbulent
flow generated by failed steam traps or leaks. The
Rosemount 708 works on any manufacturer’s steam
trap and any trap type. With a 10-year battery life, it
rarely needs attention, so maintenance resources can
be directed towards more important matters.
Traditionally, adding a measurement device has
required supporting power and data cabling which
can be difficult and costly to install at some locations.
The existing WirelessHART network at the LEVACO
plant enabled new wireless devices to quickly join
the network, without the cost and inconvenience of
installing new cabling infrastructure.
LEVACO estimates that the monitoring system will
save them at least €40,000 a year, with a projected
return on investment of two years or less. Plans are in
place to expand the Leverkusen plant’s WirelessHART
network to handle additional measurement
capabilities and LEVACO is looking to install similar
systems at its other facilities in Europe.
Emerson’s wireless sensing technology has enabled
LEVACO to monitor its steam traps continuously
for 365 days a year, minimising energy loss and
freeing up maintenance resources. The system is
performing flawlessly and LEVACO are very pleased
with the results.
Read more about Wireless Acoustic Transmitters
at EmersonProcess.com/IM609
The physical installation process at the Leverkusen
plant was completed in a matter of hours without any
downtime or pipe cutting necessary and the system
was fully operational within two days. SteamLogic™
software allows operators to quickly and easily
identify which steam traps are normal, cold
(stuck closed) or blown-thru (stuck open), and
whether the monitors are functioning properly. This
can help make sure that the right repairs are made at
the right time, reducing maintenance costs.
9
Improving combustion
process performance
Combustion processes
can deliver lower
energy consumption
and increased
profitability for
industrial sites if they
are set up and run properly. Bob Sabin,
Industrial Energy Consulting Engineer
at Emerson describes how the latest
automation and process control
technologies can help achieve better
business results.
10
Combustion processes are an often overlooked
but important piece of the industrial production
operation. Almost every industrial site has a boiler,
fired heater, incinerator or furnace and these units
are large users of energy. To minimise energy
consumption and help operators achieve their
business goals, these processes need to be reliable,
stable, efficient, and well-coordinated. However,
achieving optimal operation can be difficult due to a
number of obstacles.
Load variation presents a particular challenge. In the
industrial environment there isn’t the luxury of
running processes steady-state. Boilers for example
typically ramp up and down in load, depending on
steam requirements from the plant. Another issue
is fuel variation. Natural gas, which is considered
to be our most consistent fuel, varies in energy
content per volume by up to 10%. In addition
many sites use waste fuels or off gases such as
refinery gas or coke oven gas as low cost energy
streams for their combustion operations.
To minimise energy consumption,
combustion processes need to be reliable,
stable, efficient and well-coordinated.
Effective use of these ‘opportunity’ or ‘indigenous’
fuels reduces operating costs. However, variations
in supply and energy content per volume over
time makes it difficult to achieve safe, reliable,
and responsive operation. Managing demand
swings and the use of fuels with varying energy
intensity requires special control techniques
to maintain and optimise performance.
To address these and other issues it is important
to take a holistic approach to the optimisation
challenge. Firstly understand, and possibly resolve,
process mechanical constraints that limit achieving
the desired unit performance. Next, ensure that field
devices are in place to measure and control the unit.
Air flow is something to particularly focus on, because
it is typically difficult to repeatedly measure and
control. Once this is established it is then possible
to apply special control configuration strategies,
such as those found in Emerson’s SmartProcess®
Boiler solution, which is designed to minimise fuel
cost while delivering high reliability and response.
Emerson’s SmartProcess Boiler and SmartProcess
Energy solutions maximise low cost and alternate fuel
use and improves thermal efficiency to lower overall
fuel costs while maintaining unit responsiveness.
Equipment failure can also have a big impact on
the overall efficiency of combustion processes,
with unexpected downtime severely disrupting
operations. The key is to identify potential
failures before they take place. By monitoring the
condition of pumps, fans and critical equipment
that surrounds the combustion process, potential
problems can be identified before machinery fails
and extensive damage occurs. Equipment can
be shut down in an orderly manner and issues
addressed before there is a large impact on
production. Pre-engineered monitoring and analysis
solutions can be applied cost-effectively utilising
existing wired and new wireless instruments.
Find out how to better run your boiler processes at EmersonProcess.com/IM610
The Emerson SmartProcess Boiler solution is
unique in that it provides combustion control
without the inherent inefficiency of fuel to air
curves. Emerson helps combustion process owners
achieve lower fuel costs and better stability
by implementing a fully maths based control
strategy that determines fuel and air requirements
through stoichiometric calculations. This allows
real-time response to changes in fuel properties
and availability while managing all constraints.
11
Wireless devices provide cost effective
real-time measures and historical trends of
actual plant performance.
Wireless minimises
cost of new energy
measurements
A key challenge for any
energy management
programme is obtaining
the greatest number of
quality measurements at
the lowest life cycle cost.
Mark Menezes, Business Development
Manager at Emerson describes how
wireless helps to achieve that goal.
“If you cannot measure it, you cannot improve it”
is familiar advice to the industrial Energy Manager,
who is increasingly discovering that they don’t
have all the data they need to make informed
decisions to create energy efficiency improvements.
By introducing necessary measurements at the
appropriate points, new data can help identify and
quantify differences between potential and actual
performance on a unit-by-unit basis in real-time.
An additional benefit of this new data is that it can
be used to quickly identify potential problems,
particularly equipment that is degrading or is not
correctly returned to operation after a turn-around.
For example, if the steam extraction line between
the feed water heater and turbine developed a
slow-growing leak inside the condenser, if not
recognised by the operator, this loss of steam would
lead to decreasing efficiency and eventually a more
serious rupture causing unscheduled downtime.
12
Heat balance measurements could detect the slow
leak immediately, allowing maintenance to perform
repairs during the next scheduled shutdown. Shut-off
steam valves are manually closed after a turn-around
when cold, but during normal operation these can
develop slow leaks as they heat up. The loss of steam
wastes energy and eventually wears out the valve,
resulting in expensive maintenance. In this instance,
a clamp-on temperature sensor installed downstream
of the steam line could easily detect the problem.
New measurements needed to support energy
management programmes would typically be
connected to the control system using
HART®/4-20mA communication. Modern
transmitters allow multiple measurements to be
integrated into a single device. Unfortunately,
this provides minimal benefit when using pointto-point (4-20mA) wiring, since obtaining
each variable requires a separate pair of wires.
Wireless overcomes this problem by enabling
the communication of any number of signals,
including multiple variables, diagnostics and
configuration. Wireless also helps minimise the
cost implications of adding new instrumentation,
reducing installation costs significantly when
compared with traditional wired systems.
a pressure sensor and a temperature sensor,
plus a flow computer to calculate mass flow of
compressible fluids such as gas or steam.
These compact wireless devices can be installed
by simply prying apart existing flanges and
inserting the meter between them. A built-in flow
straightener eliminates the usual requirement
for straight pipe upstream and downstream of
the flowmeter, of particular benefit in the typical
energy management retrofit application.
Wireless devices succeed in cost-effectively
providing reliable real-time measures and
historical trends of actual performance of each
unit in a plant. This allows improvements in
energy efficiency and uptime, and also in making
better long-term decisions. By comparing actual
to potential performance, managers can better
decide where to invest capital and quantify the
return on each investment as it is made.
Read more about Smart Wireless technology at
EmersonProcess.com/IM611
The simplest use of a wireless multivariable
transmitter is a 4-input temperature transmitter.
This can connect up to four RTDs, thermocouples
or voltage inputs. More sophisticated wireless
multivariable transmitters integrate a flow sensor,
13
Innovative
technologies
Flue gas oxygen analyser
optimises combustion
efficiency
Maintaining optimum oxygen levels in flue
gases helps to boost the combustion efficiency
of large boilers and industrial furnaces.
This reduces energy consumption and minimises the
production of greenhouse gases. To achieve this Emerson has enhanced the Rosemount
Analytical 6888 In Situ Flue Gas O2 Analyser with new diagnostics that help maintain optimum
oxygen levels in flue gases and reduce maintenance. A ‘calibration recommended’ diagnostic with
gas-switching solenoids embedded within the probe electronics makes automatic calibration easier and
maintains accuracy. The embedded diagnostic removes the need for a separate solenoid box and reduces
the effort to wire and pipe between the probe and electronics, decreasing man-hour requirements.
The new analyser also includes a ‘plugged diffuser/filter’ diagnostic for applications that have fly ash or
other particulate entrained in the flue gases, which helps to ensure accuracy and reduce maintenance.
Visit EmersonProcess.com/IM613 to see how the Rosemount Analytical 6888 can reduce energy costs.
Accurate solids level measurement improves process and inventory control
To make informed decisions about process and inventory control it is
important to accurately measure the level, volume and mass of bulk
solids and powders in silos, open bins, stockpiles and warehouses.
However, uneven or sloping surfaces and dusty conditions and
materials make these very challenging applications. To overcome
these issues Emerson has introduced the Rosemount 5708 Series of
3D Solids Scanners which use acoustic measurement and 3D mapping
technologies for highly accurate continuous measurement of level,
volume and mass of bulk solids and powders. Unlike laser-based
technologies that can take several hours to take measurements and
require the process to be shut down, the 5708 provides continuous
volume measurements that are representative of the material’s
surface. They can measure practically any kind of material including
difficult-to-measure fly ash and materials with a low dielectric.
Learn how to take the guesswork out of measuring solids at
EmersonProcess.com/IM612
14
Enhanced DCS improves automation efficiency
and performance
Increasingly competitive markets drive demand for process control efficiency and
performance improvements. Emerson’s DeltaV distributed control system helps users
reduce capital cost and risk, improve operations performance, and provide stronger
security. Advanced alarm management enables operators to respond correctly and
quicker to abnormal process conditions. An Ethernet I/O card supports integration of
subsystems and intelligent field devices. Improved cyber security is achieved through
workstation hardening and extension of DeltaV smart switch technology above the
area control network.
Read more about DeltaV at EmersonProcess.com/IM616
Expanded cybersecurity services
for the power generation industry
To help power generators achieve a strong security posture,
comply with regulations and assure reliable operations, Emerson
has enhanced its portfolio of cybersecurity services. Designed
to help Ovation™ control system users, Emerson performs
annual assessments to inventory plant-wide cyber assets, expose
vulnerabilities and suggest remediation. In addition to routinely
scheduled services such as patch deployment, backup verification
and preventive maintenance, services can be customised to meet
unique security needs at a single location or across an entire
fleet. Incident response services include root cause analysis, as
well as support for system rebuilds and hardening.
Learn more about Ovation at EmersonProcess.com/IM617
Natural gas measurement
simplified
Gas chromatograph accuracy and
reliability are critical to reducing lost
energy and revenue, but these complex
instruments can be challenging in today’s
environment of shrinking field expertise,
reduced time lines and budgets. To
simplify natural gas measurement analysis
in custody transfer, power generation and
burner fuel/air ratio control applications,
Emerson has released the Danalyzer
370XA Gas Chromatograph. Designed
for continuous online C6+ BTU/CV
analysis, the Danalyzer 370XA provides
reliable measurement accuracy, minimal
maintenance and much greater
ease-of-use through improved diagnostics
and an intuitive local operator interface.
Oil and gas operational upsets can cause safety and
environmental hazards, and costly production losses.
Providing an instantaneous and dependable response to
critical shutdowns is essential. Supporting this need, Emerson’s
new Bettis™ EHO (electro-hydraulic operator) actuator is a
complete, proven solution for critical situations, even in remote
areas where electrical power is unreliable or not available. The
compact EHO handles valve sizes from 150mm to 1500mm
and has a reliable fail safe capability with fast close or open
stroke times, suitable for emergency shutdown applications.
Read more about the Danalyzer 370XA at
EmersonProcess.com/IM614
Find out more about the Bettis EHO Electro-Hydraulic
Operator at EmersonProcess.com/IM615
Electro-hydraulic operator for remote
valve emergency shutdowns
15
Further
information
Emerson Process Management is always looking for new and
innovative ways to connect with customers. These include local
country websites, the award winning Emerson Process Experts
blog, social media pages and twitter.
Web
www.emersonprocess.com/pt-BR
Community
The Emerson Global Users Exchange is a unique
opportunity to exchange ideas, best practices and
proven solutions with leaders in the process industry.
www.EmersonExchange.org
Emerson Exchange 365 is the global
peer-to-peer on-line Emerson Users Exchange
Community with a built-in translation facility.
EmersonExchange365.com
Enter the following group names into the
search bar in LinkedIn
Emerson Process Management
Emerson Global User Exchange
www.facebook.com/EmersonProcessBrasil
Blogs
Emerson Process Experts
Connecting with the people behind the
technologies and expertise. Website equipped with
automatic translation.
www.EmersonProcessxperts.com
www.youtube.com/user/EmersonPlantWeb
DeltaV News
DeltaV – Emerson’s distributed control system.
news.easydeltav.com
Modelling and Control
The dynamic world of process control.
Website equipped with automatic translation.
www.modelingandcontrol.com
Analytic Expert
Discussing the application of liquid and
gas analysers.
www.analyticexpert.com
twitter.com/EmersonPMBrasil
twitter.com/EmersonExchange
Contact Us
www.EmersonProcess.com/pt-Br/contacts/Pages/LatinAmerica
The next edition of Innovations in Process Control
will be dedicated to Reliability.
The contents of this publication are presented for informational purposes only and, while every effort has been made to ensure their accuracy, they are not to be construed as warranties
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Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co. ©2015 Emerson Electric Co. All other marks are the property of their respective owners.