AN ADVERTISING SUPPLEMENT TO
Operate Your
Plant to Its
Full Potential
• Boost Safety
and Compliance
While Testing
New Limits
• Head Off Downtime
and Shorten
Turnarounds
• Set New Standards
in Productivity
and Efficiency
PLUS:
Rosemount President
Tom Moser on the
Ever Expanding
Role of Process
Instrumentation
SPONSORED BY
January 2013
Meeting safety and environmental
regulations is a growing burden. I need
to stay compliant but also profitable.
You CAN Do THAT
Run a safer and more compliant operation with Rosemount® instrumentation.
Rosemount measurement instrumentation allows you to protect your workers and the environment
while running at your full potential, too. Rosemount solutions are designed to perform in extreme
environments and are easy to install, safeguarding your staff by significantly reducing time in the field
for configuration and recalibration. And they feature advanced diagnostics to help you quickly identify
and address trouble spots before they cause a safety incident or regulatory fines. Plus, automated
solutions such as wireless transmitters can increase your process insight in remote locations, while
keeping your team out of harm’s way. To discover all the ways Emerson can help you stay safety
compliant with measurement instrumentation, see case studies at Rosemount.com/fullpotential
View video with
our take on safety
The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2012 Emerson Electric Co.
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Contents
Beyond the Process Variable � � � � � � � � � � � 4
The global process industries must deal with a
broad array of conflicting pressures, pushing
production assets to new limits even as they face
an aging workforce and stricter environmental
and safety regulations. Tom Moser believes that
instrumentation is a big part of the solution to
industry’s dilemmas.
Head off Downtime and Shorten
Turnarounds � � � � � � � � � � � � � � � � � � � � � � � � 14
Avoiding upsets that can impact production – as
well as keeping planned shutdowns as short and
infrequent as possible – are top priorities for
process manufacturers. Instrumentation can help
prevent, diagnose and cure a broad range of asset
utilization ills.
Boost Safety and Compliance
While Testing New Limits � � � � � � � � � � � � � � 8
Even as companies strive for optimal performance
of their operating assets, safety and regulatory
compliance necessarily come first. But many plants
simply weren’t designed or built to meet today’s
stringent requirements. Enabled by wireless networks, instrumentation is taking on new roles.
Set New Standards in Productivity
and Efficiency � � � � � � � � � � � � � � � � � � � � � � � 21
Process instrumentation can help prevent the
equipment failure, safety incident or compliance
lapse that can shut down operations in a hurry. But
it can also help address the thousand other dayto-day inefficiencies that sap the productivity of
people and processes—and chip away at profits.
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Beyond the
Process Variable
Rosemount President
Tom Moser on the New
Frontiers of Process
Instrumentation
T
he global process industries have never
been under more pressure. Plants are
expected to meet new standards of safety
and environmental compliance even as they are
pushed to explore new operating limits. Asset
utilization is connected so directly to corporate profits that planned turnarounds are ever
shorter and further apart, and a single unscheduled shutdown can negate a whole year’s worth
January 2013 • SPECIAL ADVERTISING SUPPLEMENT
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of optimization effort. People and processes
must operate more efficiently and productively,
even as industry must bring a new generation of
less experienced workers online. In the face of
all this, how will the process industries continue
to manage?
Tom Moser believes that instrumentation is a
big part of the answer. Moser, president of the
Rosemount Measurement business unit of Emer4
3/18/13 4:48 PM
son Process Management, offers as evidence the
ongoing evolution of instrumentation capabilities
as well as the application revolution enabled by
wireless technology. Control’s Keith Larson caught
up with Moser at the 2012 Emerson Global Users
Exchange in Anaheim, Calif., to hear his views on
how instrumentation is helping users boost plant
performance across a range of important metrics.
Read on for the highlights of their talk, or visit
ControlGlobal.com/Moser to watch the full video
version of their conversation.
Q
Today’s process instrumentation is capable
of doing far more than just reporting
back a process variable signal. What are some
of the new instrumentation capabilities that
Rosemount is bringing to bear on behalf of its
process industry users?
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A
At Emerson, we’ve been measuring pressure, temperature, level and flow for quite a
long time. And as the industry has moved from a
traditional 4-20mA signal into smart instrumentation, it started to bring in more information from
those devices and we have begun to do many more
things with that information, such as provide
instrumentation diagnostics.
We’re looking at ways to take our existing
measurements and apply them in more kinds of
applications as well as looking at additional measurement technologies. A few examples enabled
by wireless in just the past several years include
the monitoring of pressure relief valves, safety
showers and steam traps. These new applications
are allowing instrumentation to help address key
business drivers that really have been there all
long: plant safety and energy efficiency. Wireless
instrumentation can make it more economically
feasible for facilities to come into compliance with
new regulatory requirements, too.
tional information they posses. Is the time at hand
to finally put those diagnostics to work?
A
One of the early functions of smart instrument diagnostics was to quickly determine
if there was a problem with the loop. Is the
measurement itself okay? If the instrument can
tell you that the measurement itself is good, the
maintenance technician can start to move downstream, to more quickly find out the root cause of
a problem. For HART-based transmitters already
installed with straight analog 4-20mA wiring, our
Smart Wireless THUM Adaptor provides an easy,
cost effective way to extract that HART diagnostic
data and send it over a wireless network.
But today, looking at applying instruments
in new applications, it’s really about taking the
core measurement itself and allowing that to be a
diagnostic for a piece of equipment. If a pressure
relief valve goes off, you want to be able to find
it quickly and determine what caused the release
“Any time an employee is in the plant,
on the wellhead, on the platform,
there’s the potential for a safety incident.
Wireless is taking away some of the reasons
for those trips into the plant.”
in the first place. I think that diagnostics will
continue to be increasingly important, along with
applications like our AMS Suite and its online
monitoring to bring them forward.
Instrumentation also is being used for statistical process monitoring: measuring not just the
static variable, but understanding the dynamics
of the process itself. If you know you have a good
pressure or temperature measurement that’s well
coupled to the process, the noise level of the measurement can tell you a lot. Customers are starting
to find some very unique ways to apply that capability. But the foundation is still the fundamentally reliable measurement for which Rosemount
products are renowned. Bring that together with
fast I/O and signal processing capabilities and you
can begin to capture more transients in the signal
and gain a better understanding of what’s happening in the process.
Q
Over the past several years, human centered
design has been a central strategic initiative
across the entire Emerson Process Management
organization. Can you speak to how HCD is
manifesting itself in the Rosemount offering?
A
Human centered design begins with making our products easier to use, so we really
started with our AMS Suite software—making
sure that templates are consistent and intuitive
across all of our products. Now we’re starting
to move that into our hardware, which means
more consistency in our local displays to make
configuration and startup easier to do. If a
Q
Smart instruments are in widespread use
today, yet many have been installed without
the ability to continuously communicate the addiJanuary 2013 • SPECIAL ADVERTISING SUPPLEMENT
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Control’s Keith Larson talked with Tom Moser, president of Emerson Process Management’s
Rosemount Measurement business, at the 2012 Emerson Global Users Exchange in Anaheim,
Calif. Visit ControlGlobal.com/Moser or click the QR code to watch the full conversation on how
instrumentation is helping users boost plant performance across a range of important metrics.
customer understands one product, they should
be able to apply that knowledge to using other
products of ours. We want to make the time
spent on our products as efficient and productive as possible.
All of our multivariable measurement technologies also are examples of HCD at work. We’re
putting multiple variable measurements together
into a single package, and now we’re even adding the differential pressure flow element. The end
result is time saved in engineering, procurement
and installation effort.
surements in different ways to fundamentally
improve the safe operation of their plants. In the
case of safety shower monitoring, as soon as that
safety shower is pulled, there’s a message to the
control room and an emergency response team is
sent out. Mustering, or people tracking, is another
example—you can easily and automatically know
if someone has reported in during an emergency
situation.
Q
Obviously, a lot more than technical functionality goes into the typical process instrumentation purchase decision. Can you speak to the new
differentiators in the instrument market today?
Q
Instrumentation has an obvious role in safety
instrumented systems (SIS), but new applications such as safety shower and pressure relief
valve monitoring address entirely new aspects of
safety that traditionally have not been instrumented. Can you tell me more about instrumentation’s
role in safety?
A
While the criteria are evolving all the time, I
think our customers still rely on the quality
and reliability that comes with the Emerson and
Rosemount brands. In addition, more customers
around world are looking for more help in properly applying those technologies. There are lots of
ways to measure level and lots of ways to measure
flow. As new instrument engineers are coming online, and lots of expertise is retiring, there’s a need
for help in applying products in the best way possible. We help our customers understand the best
technology for their application and how to make
the most of it. That’s a differentiator for us.
Further, we can bring the full solutions capability of Emerson Process Management to bear
on behalf of our customers. HCD is making our
products easier to use. And wireless is really opening up the whole solution space including the ability to solve entirely new problems.
A
Traditional safety systems identify upsets and
take the plant to a safe condition as quickly
as possible. But safety in a broader sense means
safety of the local environment as well as safety of
workers. As we start to evolve our wireless technologies, we see customers focus on how they can
reduce the number of people walking around the
facility. Any time an employee is in the plant, on
the wellhead, on the platform, there’s the potential
for a safety incident. Wireless with online monitoring is taking away some of the reasons for these
trips to the plant, to help improve overall safety.
Customers are looking at ways to apply mea7
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Boost Safety
and Compliance
While Testing
New Limits
Enabled By Wireless, Instrumentation
Takes on New Safety Roles
E
ven as companies strive for optimal performance of
their operating assets, safety and regulatory compliance
necessarily come first. But many plants simply weren’t
designed or built to meet today’s stringent requirements, and
finding ways to keep legacy equipment up to code presents a
constant challenge.
The costs of compliance are not trivial. Many industries face
increasing regulation that puts 30 to 50 percent of their profits
at stake, according to a recent McKinsey report. Furthermore,
the U.S. Dept. of the Interior estimated that new safety regulations introduced in 2010 added $1.4 million in annual operating
costs to each of the oil and gas industry’s deep water drills with
floating rigs.
Compounding these operational demands, people every day
still must travel to remote areas or go into harm’s way to take
manual process measurements deemed too expensive or impractical to automate even a few years ago. They need instrumentation that runs reliably and accurately at high and low temperatures and under other extreme conditions. Further, added
measurement points in increasingly remote or hard-to-reach
areas dictate minimal maintenance or calibration requirements
that repeatedly endanger plant personnel. Managers, engineers and operators also need better predictive diagnostics and
improved visibility into their plant’s true capabilities if they’re
to safely squeeze more productivity and efficiency out of their
processes. And they’re turning to a new generation of high-performance instrumentation technologies to make that possible.
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Wireless pressure transmitters monitor tank levels and help protect against spills at FH Tank Storage in Sweden.
Minimize Risky Worker Procedures
Perhaps nowhere else is the instrumentation
payoff greater than where it can prevent the need
for a worker to risk injury in pursuit of a process
measurement. Instrumentation that is both easy
and cost-effective to install—and then performs
reliably and accurately in even the harshest conditions—will help ensure that workers seldom have
to visit these oftentimes hazardous or, hard-toreach areas again. Overall safety increases as do
process control and predictability, owing to the
improved vigilance and consistency of a dedicated,
high-performance instrument as compared to
manual measurement.
At the AOC resin manufacturing facility in
Perris, Calif., Rosemount wireless temperature
sensors eliminated clipboard rounds that were an
inefficient use of operator time, subjected personnel to a safety risk, and lengthened time to market.
The new Smart Wireless network ensures proper
mixing of AOC’s intermediate resin products with
micro-additives at target temperatures to achieve
customer-specific formulations and quality—all
from the safety of the control room.
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“By replacing manual sampling with on-line measurements, we were able to decrease cycle time up to
10 percent,” said Tou Moua, AOC product engineer.
“We also improved operator safety, and freed up
their time to focus on other key areas of the plant.”
And at chemical intermediates manufacturer
Croda, Inc. in Mill Hall, Pa., Rosemount wireless
temperature sensors tackled an application that
previously had been both unsafe and impractical
for traditional wired approaches: the early detection of exothermic reactions in railcars. With continuous temperature monitoring that goes wherever the railcars do, if the temperature starts to
rise, operators are alerted and can take preventive
action well before a hazardous situation escalates.
“The Emerson Smart Wireless solution not
only saves us time and money, since plant personnel no longer have to monitor those railcars daily,
it has also greatly enhanced the overall safety of
the plant and our personnel,” says Danny Fetters,
Croda I&E designer. “No matter where a railcar
is positioned on-site, the quality of the transmissions is unaffected, and the signals integrate
seamlessly into our control system.”
10
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them. By installing a wireless network instead of
a traditional wired network, they were able to
save about 60 percent in installation costs, and
know immediately when and where there is a
safety issue.
In another non-traditional instrumentation
application, the Rosemount 708 Wireless Acoustic Transmitter can be configured to detect the
discharge of a pressure relief valve (PRV) and
automatically alert operations. And while a PRV
is technically a piece of safety equipment itself,
acting to prevent a high pressure excursion from
Wireless instruments typically can be installed
for a small fraction of the price and effort of a
wired instrument. But perhaps the ultimate in
installation ease—and safety—is the new Rosemount 0085 Pipe Clamp Sensor which together
with a Rosemount 648 Wireless Transmitter provides a simple, fast solution for adding temperature measurements, exactly where you need them,
without interrupting the process. The sensor’s
spring-loaded silver or nickel tip is designed to ensure contact against the pipe surface and provide
measurement accuracy and fast response time.
The ease with which reliable new measurement
points can be added is only one factor in the wireless safety equation. By installing Emerson Smart
Wireless THUM Adaptors on existing instruments—especially those critical, hard-to-reach devices—plants can easily access and finally begin to
leverage the advanced diagnostics and multivariable
capabilities of the many HART-capable devices that
currently communicate only their 4-20mA process
variable signal. Liberating stranded diagnostics and
secondary process variables provides added insight
into the status of these instruments themselves, as
well as feeding critical asset health information to
operations, maintenance and reliability systems—
contributing to safer, more reliable and more efficient operations.
“We improved operator
safety and freed up their
time to focus on other
key areas of the plant.”
Tou Moua, AOC
escalating to catastrophic failure, a PRV release
often implies an environmental emission (and potential fine) as well as an accompanying root-cause
condition that merits further investigation.
Automate Monitoring, Ensure Compliance
In its broadest sense, plant safety includes not
just plant personnel but people and the environment outside the plant’s perimeter as well. Also
critically important is compliance with current
safety and environmental regulations, along with
the ability to prove being in compliance to regulatory authorities.
Demonstrating compliance often hinges on
accurate record-keeping, a constant challenge in
even the most organized plants. But Rosemount
instrumentation is designed to help with these
tasks, too. Date stamps and audit trails built into
each product show when measurements have
been taken and other compliance-related tasks
performed. Further, this information is collected
and stored in an online database for easy access if an audit is requested. Experienced Emerson personnel can even help evaluate whether
older instrumentation is running safely and in
compliance: they’ll do a top-to-bottom installation audit, identify high risk areas, make sure
instruments are installed correctly, and make any
Instrument Your Safety Infrastructure
A key non-traditional arena where wireless instrumentation is proving its worth is in the monitoring
of safety infrastructure, including safety showers
and pressure relief valves.
At Lion Oil’s El Dorado, Ark., facility, for instance,
remote safety showers are equipped with Rosemount
702 Wireless Discrete Transmitters and TopWorx
GO Switches and Brackets to alert operators when
a safety shower has been activated. This provides
an immediate alert to emergency personnel and a
digital record that the event occurred. “The discrete
switches on the showers would easily have cost
$10,000 each to wire,” said Wilson Borosvskis, Lion
Oil instrumentation and control engineer.
At a paper mill in Idaho, eyewash stations are
wirelessly instrumented, in part because drivers
unloading chemicals don’t have a direct communication channel with operators. Although
they use lots of radios at the plant, none of the
contractors and only some of the employees have
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adjustments needed to ensure devices are performing to specification.
For an existing plant challenged to keep up with
an ever-changing regulatory landscape, wireless
instrumentation is proving itself an especially costeffective solution. This includes safety measures as
well as the monitoring and prevention of environmental impacts.
Tank farms are a common beneficiary, as wireless savings rapidly compound in these often
sprawling environments. At FH Tank Storage in
Kalmar, Sweden, Rosemount 3051S Wireless Differential Pressure Sensors automate level measurement in 14 of the petrochemical terminal’s smaller
solvent and chemical tanks, while 15 Rosemount
5402 non-contacting radar devices with Smart
Wireless THUM Adapters are on the larger tanks,
many with floating roofs. “Not only has the new
system improved the monitoring of tank levels,
it has provided a fully approved overspill protection solution,” says Lars Ferm, site manager. “The
Smart Wireless network was relatively simple to
install and both the network and the transmitters
have been extremely reliable,” Ferm says. And
at another refinery site in the U.S., wireless level
switches are on trial to provide an added independent protection layer (IPL) to the tank farm’s
primary instrumentation.
Safety Only the Start
These are only a few examples of companies that
started down the wireless path with a specific regulatory compliance need in mind. Indeed, for many a
process industry facility around the world, improved
safety or compliance with an environmental regulation helped clear the initial justification hurdle for
implementing its first wireless instrument network.
But once that first network is in place, they’re discovering that new measurement points are easy and
relatively inexpensive to add. This is opening their
eyes to incremental applications that can advance
other plant performance metrics such as production
throughput, energy efficiency and asset utilization
rates. Confident that their operations are now safe
and compliant, they’re pushing facilities to operate
closer to their full potential.
Smart Wireless Marks One Billion Operating Hours
was destroyed, Emerson’s wireless network was still
operating after the waters receded, including a fire
damaged wireless transmitter.
Since its release five years ago, Emerson estimates
put the total installed savings resulting from Smart
Wireless field devices at more than $350 million and
reductions in commissioning and installation time at
16 man-years.
“We knew wireless technology offered substantial savings and it is gratifying to see its rapid and
widespread adoption,” says Bob Karschnia, Emerson
Process Management vice president, wireless.
Improved plant safety is both a key driver and
deliverable for many of these Smart Wireless installations. “General conditions, and the environments
we work in, have become more extreme, making it
more dangerous to send employees into the field
to take measurements,” Karschnia says. “Reliable,
high-performance instrumentation, enabled by
wireless, reduces safety risk every time a worker
doesn’t have to go into the field to check on an
instrument or piece of equipment.”
In refineries, oil fields, offshore platforms, chemical plants and other industrial facilities around
the world, Emerson Smart Wireless technology is
helping to improve worker and plant safety, optimize operations, and reduce emissions and other
environmental impacts.
At the 2012 Emerson Global Users Exchange
the company marked one billion hours of operation
across more than 10,000 systems, noting that more
customers than ever have confidence in and have
adopted wireless technologies for not only hard-toreach, extreme applications, but also for critical, dayto-day process control and monitoring requirements.
A technology first adopted for use in harsh,
remote environments where wired instrumentation
was not feasible, Smart Wireless technology has
proven its reliability and performance in traditionally
wired applications. Just last year, a Japanese oil refinery and adjacent tank farm were badly damaged
by the 9.0 magnitude earthquake and tsunami, with
raging fires followed by hours of immersion in sea
water. While much of the cabled instrumentation
January 2013 • SPECIAL ADVERTISING SUPPLEMENT
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The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2012 Emerson Electric Co.
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Head off
Downtime
and Shorten
Turnarounds
A Potent Mix of
Prevention, Diagnosis
and Cure for Your Asset
Utilization Ills
D
owntime is without a doubt the least
productive time in the lifecycle of an
asset. When you’re down, you’re not
making product. And when you’re not making product, you’re not making money. It’s no
wonder that for production managers worldwide, unplanned downtime is enemy number
one—followed by scheduled downtime, which
they’d like to see as short as possible (and
would eliminate if they could). Next to eliminate would be process variability, which typically contributes to sub-optimal operation and
off-spec production.
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Despite the best of intentions and much handwringing, the process industries continue to
struggle with poor availability, boosting total
production costs by as much as 10% annually. Indeed, ARC Advisory Group estimates the average
cost for plant downtime at $12,500 per hour; at
some plants, of course, it’s much higher. Research
also indicates that those scheduled maintenance
turnarounds may be longer than they need to be; a
full 50% of all maintenance work may be unnecessary and 10% is actually harmful, according to
the Gartner Group.
To begin to move the needle on asset utilization
in a positive direction, plants need a combination
of better process reliability, visibility, control and
understanding. Across all of these dimensions,
measurement instrumentation plays an outsized
role. First, the correct choice of properly applied
instrumentation can be a direct contributor to
January 2013 • SPECIAL ADVERTISING SUPPLEMENT
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overall process efficiency and reliability. Second,
instrumentation can help identify and diagnose
a growing number of process conditions that,
if left unaddressed, could escalate to a production outage. Third, wireless technology allows
the cost-effective addition of new measurement
points that can help fine-tune performance, as
well as liberate stranded diagnostic information
needed for a more complete picture of equipment
health. Finally, the integration and presentation of
diagnostic information in ways that can be quickly
and intuitively understood—and acted upon—can
help speed turnaround time, in no small part by
helping to determine what maintenance activities
need not be done at all.
First Things First
At Perry’s Ice Cream in Akron, N.Y., the plant’s
sanitary washdown procedures caused persistent
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These advanced diagnostics alert operators or
other personnel to potential issues before they
become disruptive. Dashboards and local displays deliver information in clear, concise language, conveying immediate understanding of the
nature of any operational issue for quick resolution. And because the user-friendly interface is
used consistently across a wide breadth of Emerson products, personnel can be more productive
without having to learn a different interface for
each type of instrument.
In the U.K., at the SSE Slough Heat and Power
facility, Rosemount Analytical wireless conductivity transmitters are preventing process downtime by detecting changes in boiler condensate
conductivity that could be caused by cooling-
“Maintenance can be
scheduled before the problem
leads to an unplanned
shutdown or damage.”
Emma Wilcockson, SSE
water leaks in the turbine’s condenser. If left
undetected, the contaminated feedwater causes
hydrogen embrittlement of the furnace tubes
resulting in tube failure.
The 80MW combined heat and power (CHP)
plant had previously relied on manual sampling
and laboratory analysis of turbine condensate. However, this method caused delays in detecting leaks and, as a result, the boilers sometimes
had to be shut down while repairs were made.
“Emerson Smart Wireless conductivity transmitters allow us to continuously monitor the condensate extract lines,” says Emma Wilcockson,
electrical, control and instrumentation technician
at SSE. “If we detect a change in conductivity,
maintenance can be scheduled before the problem leads to an unplanned shutdown or damage
to the plant.”
Rosemount’s workhorse pressure and temperature transmitters also pack an increasingly
powerful set of process diagnostic capabilities.
For example, the Rosemount 848T Foundation
Fieldbus Temperature Transmitter now features a
new Measurement Validation Diagnostic, designed
to detect temperature measurement and process
failures of its Coriolis and magmeter flow instrumentation. Water repeatedly entered the flowmeter
housings, causing the electronics to eventually fail.
Since switching four years ago to Emerson’s Rosemount Magmeters and Micro Motion Coriolis
meters which are designed to withstand extreme
operating conditions such as repeated washdowns,
“I never have to worry about reliability,” says
Dave Foley, senior plant engineering technician.
Once your process instrumentation is no longer
adding to downtime problems, you can start to enlist its detection and diagnostic capabilities to spot
process conditions that may be early indicators
of trouble. Indeed, Rosemount instrumentation
comes equipped with a broad range of advanced
diagnostic capabilities designed to help monitor the integrity of the instruments themselves as
well as the health of equipment assets and related
infrastructure.
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abnormalities. By evaluating the variation in the
temperature measurement, Measurement Validation can detect abnormalities related to degraded
sensors, as well as electronic interference, corroded termination points, loose electrical connections and process upsets. By alerting the user to
these issues through continuous online monitoring, degraded temperature sensors can be replaced
before they fail or other preventive action can
be taken—resulting in fewer process shutdowns,
more efficient process operations and increased
plant safety.
Product managers for the Rosemount 3051 Pressure Transmitter family recently announced an array
of new capabilities designed to reduce both the total
cost of ownership and the number of maintenance
These enhancements join a roster of other
process diagnostic applications derived from the
dynamic behavior of process variables. Plugged
impulse lines, for example, will drive down the
standard deviation of a pressure measurement,
and this pattern can be used to trigger an operator alert. Other applications include detecting
furnace flame instability, wet gas flow and pump/
valve cavitation. Emerson is even working on
using differential pressure dynamics to detect
incipient distillation column flooding. Operators typically steer well clear of flooding conditions, says Roger Pihlaja, a Rosemount principal
engineer, but if you could manage to control the
column just before it floods, you could increase
production capacity.
“We can find out what’s
about to happen before
it causes an upset.”
More Measurements, Better Control
At a steel mill in Ohio, wireless measurement
points have improved control and reduced
downtime of the 80-in. hot strip finishing mill,
boosting overall productivity by 5%. “We are
building an infrastructure that opens up opportunities for more applications,” says their operations manager. “The result is better information
from difficult-to-reach areas of the mill, and this
is helping our personnel prevent unscheduled
downtime, meet customer quality requirements,
and optimize productivity.”
Recently, when the mill increased its product
mix with a heavier and wider material, it required
more run-out table cooling water to maintain the
proper grain structure throughout the strip. Unfortunately, as the new product was being rolled the
target coiling temperature could not be achieved.
Manual valves used to scale the curtain water flow
to the proper setting for each product could not
be confirmed with flowmeters, since they were
deemed too expensive and difficult to install in
this congested environment.
Four Rosemount Annubar primary elements
teamed with Rosemount 3051S Wireless Pressure Transmitters and an Emerson Smart Wireless
Gateway were quickly and easily installed, and
within 24 hours, the mill had the flow rates they
needed. The flow information obtained from the
wireless transmitters enabled them to fine-tune the
sprays. Since then, coiling temperature rejects have
been almost entirely eliminated.
Three other downtime problems were also solved
with wireless instruments. A malfunctioning grease
Paul Chandler, Valero Energy
work orders, while improving productivity and
safety. Power Advisory Diagnostics, for example, is
a new predictive diagnostic tool that allows users
to identify electrical loop issues, at the instrument
or anywhere in the loop, before they cause a loss
of measurement. Examples of these issues include
water or corrosion in the terminal block or junction boxes, wiring problems or even a failing power
supply. With simple three-step activation and guided
troubleshooting, users of all experience levels can
easily implement this diagnostic to help prevent
costly outages and minimize time spent diagnosing
and resolving the root cause of a measurement issue.
To improve accessibility to diagnostic information, the Rosemount 2160 Wireless Vibrating Fork
Liquid level Switch continuously monitors device
status and sends instrument health information
to the control room via Emerson PlantWeb alerts.
The alerts notify operators of conditions such as
internal or external damage to the fork sensor, media build-up on the forks, excessive corrosion, and
the potential effects of damage caused by overheating. Customers can then implement a preventative maintenance program to reduce the number
of field visits, maintenance costs, safety risks and
unplanned shutdowns.
January 2013 • SPECIAL ADVERTISING SUPPLEMENT
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delivery system was providing inadequate lubrication of roll bearings, causing downtime and surface
defects. A Rosemount 3051S Wireless Pressure
Transmitter now raises an alarm if grease pressure
drops or cannot be maintained, eliminating another
source of downtime. The mill was experiencing
work roll damage and subsequent downtime in the
roughing mill due to coolant flow problems. Work
practice changes, together with wireless pressure
transmitters to ensure adequate coolant flow and
pressure, resolved this downtime issue, too. And in
the back-up roll bearing system, Rosemount 648
Wireless Temperature Transmitters measure inlet
and outlet oil temperatures—flagging any temperature excursions so that brief repairs have now
replaced lengthy outages.
the process intelligence gathered by smart instruments and other field devices is helping make
plant turnaround activities as efficient as possible.
Valero Energy Corp.’s Wilmington, Calif., refinery uses AMS Suite asset management software
from Emerson to help make sense of data coming
from its many production assets, including process
and mechanical equipment, electrical systems,
valves and instruments. “We can find out what’s
about to happen before it causes an upset,” says
Paul Chandler, senior instrument engineer.
But information gathered during the course of
normal operation can also pay off at turnaround
time. For example, through valve signature analysis enabled by the AMS Suite, Valero Wilmington
discovered that “in the past we pulled many valves
for maintenance that we didn’t need to pull,”
Chandler says. In its latest turnaround, just 12
valves were pulled instead of a past average of
107. “In fact, it was almost a million dollar savings in just three turnarounds,” Chandler says.
A faster turnaround that’s less expensive, too?
That’s enough to make any production manager
proud.
Set Turnaround Priorities
In their quest to increase asset utilization, the
process industries aren’t just striving to head off
downtime due to unanticipated problems, they’re
also lengthening the time between shutdowns
for scheduled maintenance—and aiming to turn
plants around as quickly as possible. Here, too,
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Set New
Standards in
Productivity and Efficiency
The Right Instrumentation Can Help Both Processes and People Realize Their Full Potential
T
to degradation of thermocouple and RTD wiring.
Operators had to take spot measurements with an
infrared gun once a month, and manually enter
the readings so heat exchanger efficiencies could
be calculated and cleaning schedules developed. As
a result, fouled, inefficient exchangers sometimes
ran in that manner for weeks at a time between
monthly checks.
To improve this situation, ten Rosemount 648
Wireless Temperature Transmitters were installed
on the inlet and outlet of the heat exchangers
with one-minute update rates. The installation
points were hidden behind dense piping, vessels,
and tanks, but the wireless mesh network has
remained strong with high signal reliability. Now
process engineering has live, accurate information
at one-minute intervals instead of once a month.
Richer information and 43,200 automatically
measured and recorded points per month compared to one manually measured and recorded
point, gives engineering the tools they need to
optimize thermal efficiency.
The instrumentation and control fleet team at
another large U.S. power plant sought to improve
the efficiency of heat transfer in their feedwater
heaters. Controlling the level of the condensate is
critical for efficiency and reliability of the steam
generation system. If the level is too high, the
feedwater tubes are submerged, reducing the heat
transfer efficiency. But, if the levels are too low,
the steam can blow through without effectively
heating the tubes. In addition, it was essential to
monitor levels to prevent water induction (or carryover) into the turbine.
These challenges were solved with the Rosemount 5301 Guided Wave Radar (GWR) in
combination with the Rosemount 9901 Chamber. Three GWRs in duplicate external mounting
assemblies were installed on each of the eleven
feedwater heaters. True triple redundancy was
achieved through the highly accurate and consistent GWR measurements, which are unaffected
his series of articles has so far focused on
how process instrumentation can help
manage operational risks in process plant
operations. An equipment failure, safety incident
or compliance lapse can shut down operations in
a hurry. But when you’re up and running, what
about the thousand other inefficiencies that sap
the productivity of people and processes—and
chip away at profits?
Here, too, the right high-performance instrumentation can help boost efficiency and productivity in a number of important ways. Highly accurate instrumentation that remains stable in even
the harshest environments can help reduce process
variability, and, in turn, allow the process to be
operated closer to optimal conditions. New wireless instruments can help root causes of inefficiency that formerly went undetected. Instruments that
are easier to engineer, install and use help plant
personnel become more productive in their daily
tasks. And more complete and readily accessible
information can help plant personnel make better
decisions in a more timely fashion.
Closing the Loop on Energy Costs
Across the process industries, energy is a significant component of plant operating costs—and all
indications are that prices will continue to rise in
the long term. In fact, at some petroleum refineries, energy costs already account for a full half of
all operating expenditures, according to research
from the Lawrence Berkeley National Laboratory’s Industrial Energy Analysis. Wireless instrumentation, much of it measuring previously uninstrumented variables, is helping a growing number
of companies run more efficiently by providing
greater visibility into energy consumption.
For example, at one large U.S. refinery an Emerson Smart Wireless network is gathering temperature measurements in the crude oil pre-heating
area. The heat exchangers in the area had been
plagued with poor temperature measurements due
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At Barking Power in the U.K., wireless acoustic transmitters detect leaking steam traps and pressure relief valve discharges
in hard-to-reach locations.
by density changes. By improving the stability and
accuracy of the feedwater level measurements,
the plant operated at feedwater heater levels that
increased heat transfer efficiency and reduced the
risk of equipment damage.
At Plains Exploration and Production (PXP), an
independent oil and gas producer, steam injection
is used to enhance recovery from its Hopkins lease
property near Bakersfield, Calif. Thermal energy
accounts for a large portion of the company’s operating expenses, and the steam-to-oil ratio (SOR)
is an important optimization parameter. Too little
steam and production suffers. Too much steam
doesn’t just reduce energy efficiency, it also can
damage the well liner resulting in lost production
and costly repairs.
But because there was no power or communications in the vicinity of the wells, orifice flowmeters
connected to mechanical chart recorders were
the only means of process feedback. Operators
manually recorded data from as many wells as
they could visit in a day, and sent that information
back to Bakersfield where it was used to make
operating decisions.
PXP turned to Emerson Smart Wireless technology to provide the information they needed
to measure and optimize steam injection rate in
real-time. A mile-square Smart Wireless network
and instrumentation including Rosemount 3051S
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Wireless Pressure Transmitters and Rosemount
8800 Vortex Flowmeters with Smart Wireless
THUM Adapters for 120 wells “paid for itself in
months,” according to Michael Fischback, PXP
project facilities engineer. “This technology has
opened up new possibilities for us. We plan to
continue utilizing wireless technology to improve
our oil production, improve our cost position, and
make our people more productive.”
Pinpoint Faults—and Opportunities
Improving efficiency and productivity isn’t just
about finding and correcting faults. It’s also about
identifying new opportunities: using the advanced
diagnostic capabilities of high-performance instrumentation to gain deeper insight into asset capabilities and allowing the plant to run as closely as
possible to its actual limitations.
If it’s difficult to imagine how or where to start,
Emerson instrument consultants can lend a fresh
perspective, helping to identify what steps to take
to increase productivity. They’ll bring new ideas,
technology and best practices and can even help
train employees, making experienced personnel
even more effective and getting new employees up
to speed faster.
Wireless technology in particular, is enabling many
process plants to think outside the box of “traditional” process instrumentation applications. In fact,
22
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wireless is creating whole new categories of instrument applications, such as the wireless monitoring of
steam traps and pressure relief valves.
Barking Power Limited, for example, is using 35
Rosemount 708 Wireless Acoustic Transmitters to
identify troublesome steam traps, as well as leaking pressure relief valves at its combined cycle gas
turbine (CCGT) power station in London. Barking
Power Station, operated by Thames Power Services,
is one of the largest independently-owned generating plants in the U.K., capable of generating 1,000
MW of electricity – about 2% of the peak electricity
demand in England and Wales. To remain competitive in the deregulated UK power generation market,
the plant makes continual improvements to increase
plant availability and efficiency, which in turn help
reduce overall unit generating cost.
“The margins are so small nowadays that finding all these small leaks adds up to substantial
amounts of money over time, so we’re looking
to improve all areas of the plant” explains Tony
Turp, control system technical specialist.
The plant installed 15 additional acoustic
transmitters to monitor other problematic areas,
including pressure relief valves that don’t seat correctly. Previous manual monitoring was not only
time-consuming but also failed to indicate exactly
when a release occurred, increasing the chances
of a safety, regulatory or environmental incident,
and a potential fine. The new wireless devices enable precise monitoring and alert operators when
valves have opened for as little as a single second.
Using the wireless networks already in place, additional devices can be added at much lower cost than
if they had to be wired-in individually. This provides
Barking Power with additional opportunities where
monitoring was previously cost prohibitive. Barking
also has used Emerson Smart Wireless THUM Adaptors on existing instruments in order to connect them
into the network, liberating the stranded diagnostic
capabilities of existing wired devices.
It’s not just process efficiency that can benefit
from the right instrumentation choices. People can
be more productive, too. At Emerson Process Management, human centered design (HCD) principles
are being applied across the company’s products
and solutions, with the aim of making them easier
to engineer and procure, install and use—essentially
over the entire lifecycle of an instrument.
Device dashboards, device diagnostics and local
interfaces—all designed with a common, intuitive
“look and feel” across the breadth of Rosemount
products—ease calibration, configuration and
troubleshooting tasks. Ease of installation and
stable, reliable operation further minimize initial
and ongoing field work requirements.
Help When You Need It
In addition to bringing to market products that
ease user measurement tasks, Emerson continues
to invest in people that can help along the way. In
fact, Emerson Process Management has added
more than 4,000 service personnel to its ranks since
2005 and plans to increase its global service staff at
approximately twice the industry growth rate for
the next four years. The rapid growth is part of a
strategic expansion of project and support services
to meet the growing needs of customers. These
service professionals are trained according to global
standards to ensure they provide the same high
level of expertise anywhere in the world.
“We’re committed
to helping our customers
close their performance
gaps wherever we can.”
Steve Sonnenberg,
Emerson Process Management
“Not only do customers require large amounts
of engineering effort for design, commissioning
and startup, but once they’re up and running they
need prompt, dependable support services to stay
at peak efficiency,” says Steve Sonnenberg, president, Emerson Process Management.
Indeed, Emerson realizes that managing all the
moving pieces of a new implementation can be a
complex job. Instead of assigning an internal project
manager that may not be dedicated to one project,
the Emerson Project Management Office (PMO) is
available to help manage a full range of project logistics—from scheduling shipments to providing safety
and compliance-related documentation.
“Our project managers will ensure your project
is delivered on schedule and on budget, and that it
will work to your specifications after deployment,”
Sonnenberg said. “We’re committed to helping
our customers close their performance gaps wherever we can.”
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