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Early Detection of MV Cable Problems Improves Overall System Reliability

(Asset Optimization Track, Session 280)
45 Minute Workshop
Presented by: Cliff Kirby, Emerson Process Management

Medium voltage cable construction has evolved from expensive paper insulated lead cable to more economical plastic insulation materials. This development brought new savings and new insulation life hazards. Traditional maintenance and testing methods are no longer adequate. This presentation discusses the change in testing and evaluation processes to meet these new cable technologies.

Electrical Systems Testing at Utility Generation Plants

(Maintenance & Reliability Track, Session 271)
45 Minute Workshop
Presented by: Derek Hoffpauir, Entergy and Gregory Smith, Emerson Process Management

This presentation will discuss testing electrical systems at utility generation plants. It will discuss the criteria Entergy’s Nelson plant went through in assessing their system, the process for determining the right contracting partner, and the system that was implemented.

Electromechanical Relay Replacement in Industrial Applications

(Asset Optimization Track, Session 286)
45 Minute Workshop
Presented by: Jim Olkowski, SEL and Lee Bigham, Emerson Process Management

A general overview with real-world examples where aging electro-mechanical relays were upgraded to modern, microprocessor based relays providing new and innovative application solutions for electrical asset management and system diagnostics in industrial and power plant installations.

How an Agricultural Chemicals Company Effectively Implemented an Arc Flash Program for Ten Phosphate Mines through Outsourcing

(Maintenance & Reliability Track, Session 278)
45 Minute Workshop
Presented by: Fred Toepfer, Emerson Process Management

Electrical facility owners and operators are aware of the personal safety and economic risks associated with arc flash hazards. However many do not have the in house resources and expertise required to implement an effective solution. This presentation discusses how an agricultural chemical company successfully implemented an arc flash safety program at ten phosphate mines in central Florida.

New Requirements in the National Electrical Safety Code (NESC) Means Changes for the Utility Industry

(Project Management & Engineering Tools Track, Session 255)
45 Minute Workshop
Presented by: Fred Toepfer, Emerson Process Management

Effective January 1, 2009 new regulations regarding arc flash hazards will hit the utility industry. These changes will require all electric utilities to perform an assessment of their system’s arc flash potential. This presentation provides the information you’ll need to comply with the latest NESC requirements for electrical safety.

Predictive Cable Testing Improves Facility Reliability at a Leading Chemical Manufacturer

(Maintenance & Reliability Track, Session 279)
45 Minute Workshop
Presented by: Cliff Kirby, Emerson Process Management

The chemical industry relies on uninterrupted power to maintain their process and system safety. At one leading chemical manufacturer’s facility, the maintenance practices were altered to utilize non-destructive testing processes to evaluate their MV power cable system. The goal was to expand techniques that improved facility uptime reliability. This presentation discusses the reliability successes at several of the manufacturer’s plants.

Save Time and Money During a Planned Shutdown with These Planning Tips and Shutdown Steps

(Project Management & Engineering Tools Track, Session 273)
45 Minute Workshop
Presented by: Rod Olinger, Emerson Process Management

All electrical equipment requires maintenance of one type or another. In many industries, seasonal plant shutdowns are a routine event. Whatever the reason for your shutdown, don't let poor planning determine your outcome.  In this workshop you will learn how to effectively plan your next shutdown with these cost saving planning tips.

SEL Relay Upgrade and Integration

(Asset Optimization Track, Session 281)
45 Minute Workshop
Presented by: Thor Lunde, Emerson Process Management

This abstract describes one project utilizing SEL (Schweitzer Engineering Laboratories) equipment to upgrade existing protection, replace malfunctioning control equipment and provide integration capabilities for local and remote monitoring and control.

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Coffeyville Resources – Better Than Before: Rebuilding, Innovating, and Improving a Post-Disaster Site

(Valve Applications Track, Session 447)
Presented by: Shane Scoles, Coffeyville Resources, Randy Rubenthaler,Experitec and John Berna, Emerson Process Management

When a Kansas refinery suffered a massive flood forcing a shutdown, a complete site assessment revealed massive numbers of valves, transmitters, and flow meters needing attention. Emerson supplied the technicians, tools, new equipment, and parts to achieve the desired startup date.

Go Big or Go Home: Managing an Expanding Turnaround at ConocoPhillips

(Project Management & Engineering Tools Track, Session 495)
Presented by: Wade Martin, ConocoPhillips, Eric Barton, PCE Pacific, and Jim Boyles, Emerson Process Management

A mid-sized ConocoPhillips turnaround tripled in size with additional complexities needing higher level of service. Despite the additional work, the turnaround was completed within the original time frame and there have been no unplanned outages since the start-up.

Tight Timeline Turnarounds: Mobilizing Manpower for BP Toledo Turnaround Success

(Maintenance & Reliability Track, Session 518)
Presented by: Dan Dybowski, BP Toledo, Joe Mullner, AE Ehrke, and Scott Grunwald, Emerson Process Management

BP Toledo was able to flawlessly execute the largest turnaround in their 88 year history by working with Emerson’s Six Step Turnaround Process. With proper planning and constant communication, on and off the job site, on-time completion with accurate documentation was achieved, even when additional work was revealed.

Extreme Makeover, Emerson Edition: Refreshing BP Gas Plant Documentation During the Sunray Turnaround

(Project Management & Engineering Tools Track, Session 440)
Presented by: Erick Fletcher, BP Sunray and Tate Williams, Emerson Process Management, Steve Jaksich, Emerson Process Manager

When the BP Sunray Gas Processing Plant planned their 2007 turnarounds, they called on Emerson to provide loop checkout and asset documentation of the field instrumentation, control valves, and process control. An Emerson crew accessed the process areas and documented the loops, including calibration and reconfiguration to make sure plant drawings accurately reflected the process.

Beyond Project Management: Building Systematic Success with QC3 at Suncor Energy

(Project Management & Engineering Tools Track, Session 465)
Presented by: Rebecca Jones, Suncor and Wade Enns, Emerson Process Management

When Suncor’s Firebag operations planned a new construction project, they brought in Emerson’s Technical Services to implement large scale data management project based on QC3 commissioning process. Tech Services manages the process of migrating the completed exhibits from QC3 to the Suncor Livelink internal process documentation system.

Utilizing the Synergies of Emerson: Increasing Capacity with Single Service Solution

(Maintenance & Reliability Track, Session 510)
Presented by: Roger Barnett and Richard Kirtley, Emerson Process Management

A West Virginia producer of polymers and high-performance plastics had production sold out 24 hours a day, 7 days a week. They needed maximum uptime and an increased capacity to handle the workload. Emerson Process Management provided a single point solution with proactive maintenance programs to achieve no unplanned outages for the past five years.

Parts, People, Process; The Winning Formula for Emerson Turnarounds and Certified Services

(Emerson Product/Service Updates Track, Session 503)
Presented by: Chris Forland, Scott Grunwald, and Miranda Pilrose, Emerson Process Management

Customers chose Emerson’s Instrument & Valve Services for the quality of the services provided. While there are other suppliers who offer similar-sounding services, no other offering ensures the device will be operating to factory tolerances, using factory parts and processes. IVS services ensure the instrument or valve maintains certifications and delivers the best return on investment.

Liquid Pipeline Control Optimization Maximizes Throughput

(Process Optimization Track, Session 121)
Presented by: Otero Fernando, Emerson Process Management

Pipelines was to increase its throughput capacity in one of its major lines that transports heavy and light crude oil. Higher throughputs had not been previously achieved on a reliable basis due to the occurrence of line instabilities. Control optimization solved these problems.

Trimming the Losses: Rohm and Haas Control Valve Reliability Improvement Journey

(Maintenance & Reliability Track, Session 461)
Presented by: Antonio Alves, Rohm & Hass, Jeff Wilson, Puffer Sweiven, and Shannon McClennen, Emerson Process Management

Frequent equipment breakdowns prompted Rohm & Haas to complete a control valve reliability study from April 2004 through March 2006. Findings indicated that 799 hours of production losses were occurring due to control valves. Emerson installed 2 Asset Managers at their site to help them improve control valve reliability through various proactive maintenance methods that significantly cut lost production.

Unraveling History Using ExxonMobil's Diagonostic Savvy

(Maintenance & Reliability Track, Session 457)
Presented by: Dan Upton, ExxonMobil, Pete Priest, Scallon Controls, and Jon Kresser, Emerson Process Management

Periodic critical control valve issues led ExxonMobil Chemical to call on Emerson to renew valve assemblies and add Performance Diagnostics to their control process to help determine the root cause of unexpected shutdowns. During startup, on-line monitoring from smart positioners paid off immediately when valve performance tracking helped prevent problems from occurring.

Maximizing the Uptime with Emerson Valve Diagnostics

(Valve Applications Track, Session 175)
Presented by: Tom Brunson and Matt Estabrook, Emerson Process Management

This short course is geared to end-users of Fisher® FIELDVUE® Instrumentation. We will be discussing a detailed roadmap of steps to implement FIELDVUE instrumentation effectively into your plant including real world best practice experiences, and suggested methods for quantifying the value received. Attending this short course will help you get the most out of your FIELDVUE Instruments!

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AES Reduces Boiler Fuel Costs by $20/Hour After Implementing AMS Performance Monitor

(Asset Optimization Track, Session 420)
Presented by: Ed Juliano, AES Warrior Run and Richard Drake, Emerson Process Management

AES Warrior Run operates a 180 MW Coal Fired Cogeneration Plant. AES wanted to determine two things: 1) the optimal mix of waste coal to premium coal to feed the boilers; and 2) the consequent impact on the efficiency of the continuous circulating fluidized bed (CCFB) boiler. AMS Performance Monitor helped AES justify this project and anticipate a savings of ~$20/hour in fuel costs when using an optimal fuel mix.

Best Practices for Machinery Health Management in the Beverage Industry

(Maintenance & Reliability Track, Session 612)
Presented by: Drew Mackley and Gary Effemey, Emerson Process Management

The flagship brewery of the world's largest beer producer churns out 170 million gallons each year. So any unexpected downtime translates directly into unrecoverable losses. But bearings do wear, compressors fail, wiring degrades, and pumps do break down. This paper outlines the real world approach used to improve machine health, minimize process disruptions, and maximize profitability.

Bridging the Gap Between Operations and Maintenance with the CSI 9420 Wireless Vibration Transmitter

(Asset Optimization Track, Session 538)
Presented by: Kevin Steele and Jason Schemmel, Emerson Process Management

Using the Rosemount 1420 wireless gateway, wireless vibration data is available to both operations and maintenance personnel. Plant operators can receive machinery health data into their DeltaV control system from the CSI 9420 wireless vibration transmitter, while maintenance staff receive the same data into their AMS Suite: Machinery Health Manager software.

Cost Justification for Industrial Oil Analysis

(Maintenance & Reliability Track, Session 135)
Presented by: Ray Garvey, Emerson Process Management

The life of the machinery is in the lube. Test that fluid for critical information about the functionality of that fluid, about contamination of the system, and about wear and other machinery damage that is taking place. Findings help remove root causes of failure before damage can occur and to monitor the progressive degradation of a mechanical component, thereby predicting when it will fail.

How Monitoring Equipment Performance Reduced Fuel Consumption by 2% on a Pipeline Gas Turbine

(Asset Optimization Track, Session 425)
Presented by: Mark Kramer, Northern Natural Gas and Richard Drake, Emerson Process Management

Northern Natural Gas operates a fleet of GE Frame 3 Gas Turbines to deliver gas to key Midwestern U.S. locations. AMS Performance Monitor was used to supplement extensive on-site expertise to quantify the success of planned maintenance with regard to recovering lost efficiency. The paper will detail the findings and analysis that resulted in saving $80/hr in avoided excess fuel usage.

Identify Developing Faults and Avoid Process Interruptions Using Wireless Technology

(Asset Optimization Track, Session 485)
Presented by: Mike Medley, BP and Andrew Gonzalez

The CSI 9420 Wireless Vibration Transmitter integrates easily into your DCS and provides insight into developing faults that can go undetected using conventional walk-around techniques. This discussion describes the wireless deployment at a major refinery with a focus on vibration monitoring, and highlights an example of how the CSI 9420 helped to avoid an unscheduled process interruption.

Machinery Health Information for Control Room Operators of Turbomachinery at Xcel Energy

(Asset Optimization Track, Session 488)
Presented by: Deane Horn, Emerson Process Management

Presentation on how Xcel Energy is integrating turbine Machinery Health with process control information for operators to improve the reliability and performance of critical turbines.

Machinery Health: The Next Frontier in Process Optimization

(Maintenance & Reliability Track, Session 601)
Presented by: Robert Skeirik, Emerson Process Management

Process optimization brings big benefits to the bottom line, but one unplanned outage can quickly reverse these gains. This survey course outlines predictive diagnostic technologies used to monitoring machinery health, optimizing production and increasing plant profitability. Independent studies document the ROI at over 15 to 1.

Case Studies of CSI Machinery Health Transmitter Use in a Paper Plant and Metals Processing Plant

(Asset Optimization Track, Session 492)
Presented by: Stewart Bowers, Emerson Process Management

The ability to monitor important machinery in an industrial setting is crucial to avoiding unscheduled downtime. Vibration, temperature and speed data acquired simultaneously is essential to predicting mechanical failures. More importantly, that data must be effectively communicated to both the operator and maintenance personnel responsible for the production line.

No Motor, No Process, Big Problem!

(Maintenance & Reliability Track, Session 611)
Presented by: Drew Mackley and Gary Effemey, Emerson Process Management

Motors are at the heart of every process. When the motor fails, production stops. But field tested techniques for monitoring machinery health on electric motors can be applied to detect developing faults before they turn into a shutdown. Learn how to get control over your motor health and your process.

Protecting People, the Environment and Production: The Application of a Wireless Vibration System

(Wireless Track, Session 203)
Presented by: Chuck Pedley, Flint Hills Resources and Tomas Raiche, Emerson Process Management

This paper will discuss the implementation and use of a wireless vibration system at the Flint Hill Refinery in Pine Bend MN to improve Safety, Environmental Compliance and Process Reliability. The following areas will be discussed:

• Historical background
• Plant issues
• System expectations and requirements
• Decision criteria and option evaluation
• System implementation
• Results

The Integration of Machinery Health Information with the DeltaV Control System

(Asset Optimization Track, Session 543)
Presented by: Jason Schemmel, Emerson Process Management

Plant operators need visibility to the vibration data from critical equipment such as turbines and compressors. The ability to bring online machinery health data from a CSI 4500 Machinery Health Monitor and CSI 6000 Machinery Health Monitor into the DeltaV control system is now possible using Modbus communications.

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Maximizing the Value of AMS Device Manager

(Asset Optimization Track, Session 449)
Presented by: Yang Lin, SECCO and Eddie Yong, Emerson Process Management

At SECCO China’s Acrylonitrile plant, our staff had a vision to become world class in our maintenance processes. Through a combination of Emerson technologies and the services of experts from Emerson’s global network, the vision is now realized and plans are in place to increase the value of predictive diagnostics.

Designing, Implementing, and Optimizing an Asset Management Program

(Asset Optimization Track, Session 164)
Presented by: John Hill, Emerson Process Management

This presentation will focus on the demands of designing and implementing a maintenance management program that provides asset optimization, and increases the focus on predictive technologies. All with an increased focus on optimizing alarm management within DeltaV and PlantWeb architecture. The result is better understanding of the impact of every asset on Plant operations.

How ADM Used a Structured Approach to Get the Most Out of AMS Device Manager

(Asset Optimization Track, Session 471)
Presented by: Dave Mossman, ADM and Todd Schools, Emerson Process Management

ADM Peoria site installed a $30m new compressed alcohol unit with a lot of new instrumentation. The unit is ~20 minutes away from our site office. We chose that project to utilize AMS Device Manager to help us manage and plan maintenance on ~200 transmitters and valves. Our presentation covers the steps we are taking to move our focus away from being mostly reactive (currently ~70%).

How Smurfit Executed INSTALL/IMPLEMENT on AMS Device Manager

(Asset Optimization Track, Session 533)
Presented by: Curtis Nellis, Smurfit Stone and Todd Schools, Emerson Process Management

Smurfit Stone had some new equipment recently installed with ~400 new instruments. They performed a 400 tag IMPLEMENT at this site and have INCORPORATE scheduled to complete in August. The IMPLEMENT was performed on the sites’ Evaporator Set, Digesters, and Power Plant. All of these areas are critical to mill operation as the mill moves from reactive to predictive and planned maintenance.

How to Define a Maintenance Strategy and Rationalize PAM Technology During DESIGN in a FEED Project

(Asset Optimization Track, Session 463)
Presented by: Augie DiGiovanni and Bill Broussard, Emerson Process Management

Maintenance efficiency is usually not the highest priority of a design requirement during a new project. But it is important and beneficial to include asset management at the front end of a project. PlantWeb Services DESIGN yields an optimized Maintenance Strategy Blueprint matrix during the FEED process. The deliverable is much higher maintenance efficiency as a part of the detailed design.

Emerson’s Structure Approach to Successfully Implementing AMS Suite

(Asset Optimization Track, Session 481)
Presented by: Bill Broussard and Todd Schools, Emerson Process Management

Are your predictive technologies delivering their full value? Learn how PlantWeb Services will INSTALL, IMPLEMENT, and INCORPORATE your predictive maintenance program and improve your facility’s bottom line. PlantWeb Services adds value at any stage of a plant’s life cycle by re-engineering maintenance work process to improve manpower efficiency, helping companies to become best cost producers.

AMS Device Manager 10.0 – New Features Bring Even Greater Benefits!

(Emerson Product/Service Updates Track, Session 429)
Presented by: Laura Briggs, Emerson Process Management

With the release of AMS Device Manager 10.0, value is provided with enhancements to Alert Monitor and wireless device provisioning, easier device commissioning and replacement for FF devices with DeltaV 10.3, and support wireless workstations. This session will cover the benefits of the new functionality available and discuss the new ways to use AMS Device Manager to gain the most from your plant.

AMS Device Manager and Beamax Calibrators – A Powerful Combination Leads to Calibration Savings

(Maintenance & Reliability Track, Session 428)
Presented by: Denny Fetters, Croda and Laura Briggs, Emerson Process Management

Croda uses AMS Device Manager and Beamex MC5 calibrators to automate device calibration for HART and FF devices. AMS Device Manager allows Croda to download calibration tests directly to the smart MC5 calibrator, perform as found as left tests in the field, and then upload the data back into AMS Device Manager for analysis and record-keeping. This automated process saves time and money.

AMS Device Manager – Roadmap Details & Release Planning Process

(Emerson Product/Service Updates Track, Session 430)
Presented by: Ron Hempel and Rustin Ekness, Emerson Process Management

What’s coming next for AMS Device Manager? Ever wonder how release content is determined? Why an AMS Device Manager release is numbered 9.5 instead of 10.0? This session will explain recent AMS Device Manager releases, the future roadmap, and will describe our release process, from concept to determining feature sets to naming.

AMS Device Manager – Enhanced Asset Alert Monitoring for Process Optimization: Best Plant Practices

(Emerson Product/Service Updates Track, Session 436)
Presented by: Matt James and Laura Briggs, Emerson Process Management

With the launch of AMS Device Manager 10.0, an enhanced version of the fully integrated Alert Monitor diagnostic tool will be rolled out. This new version allows for improved alert management utilizing alert categorization, alert acknowledgement, and alert filtering. New icons including new system tray alert indicator icons will enhance the overall usability.

At Formosa Plastics Taiwan Facility, AMS Device Manager Enables Predictive Maintenance

(Asset Optimization Track, Session 435)
Presented by: Tien-You Cheg, Formosa Plastics and KG Lin, Emerson Process Management

With 4500 on-line smart field devices sending real-time diagnostics to AMS Device Manager, our staff throughout the Formosa PetroChemical plant in Taiwan have the information needed to prove predictive maintenance works. We are saving manpower on calibration, doing a better job of valve maintenance, and detecting field device problems early so we avoid unexpected plant upsets.

Chevron Gains Better Control of Field Devices and Is More Proactive Using AMS Device Manager

(Asset Optimization Track, Session 297)
Presented by: Benoit Montjardet, Chevron Oronite and David Cliquennois, Emerson Process Management

HART enabled devices provide real-time diagnostic and multivariable data while providing backward compatibility to analog only I/O. Whether connected analog, digitally or wirelessly you need to think about how to use the diagnostic and multivariable information from your HART enabled devices. The presenter will discuss the true capabilities & ways to improve the results from installed HART devices.

Hemlock Semiconductor Utilizes HART Over Profibus Interface with AMS Device Manager

(Asset Optimization Track, Session 556)
Presented by: Gary Banks, Hemlock Semiconductor and Doug Ayers, Cornerstone Controls

Hemlock Semiconductor has utilized the HART Over PROFIBUS Interface to access HART data over a PROFIBUS network for online asset management in AMS Device Manager. They were able to implement AMS Device Manager without installing multiplexers.

How to Use Diagnostics from Existing Smart Devices to Develop a Condition-Based Maintenance Program

(System Application/Product Integration Track, Session 569)
Presented by: Paul Rahilly, Sempra LNG and Amy Davidson, Emerson Process Management

Sempra’s new LNG terminal wanted to take advantage of diagnostics in smart devices to create work notifications in MAXIMO. By combining the embedded diagnostic information, AMS Suite Work Notification Service, and the MIMOSA Interop Server from Mtelligence, they created an early warning system to trigger proactive work orders when equipment problems are detected to help prevent equipment failures.

Integrating AMS Asset Portal to Improve Reliability for World-Class Efficiency and Productivity

(Asset Optimization Track, Session 446)
Presented by: Luis Naranjo, Emerson Process Management

Former Ameriven employee (now Emerson employee) shares his experience in developing a world class facility. The last step for highly competitive companies is to optimize cost and productivity. AMS Asset Portal provides tools that are fundamental for plant management and reliability specialists to achieve these goals by providing a single unified view of how assets are performing in an enterprise.

PlantWeb Alerts and Diagnostics – How AMS Device Manager Can Change Your Maintenance Approach

(Maintenance & Reliability Track, Session 422)
Presented by: Walt Sigtermans, Emerson Process Management

Isn’t that “Check Engine” light on your car useless? Wouldn't’t it be better if it displayed that your spark-plugs were dirty? Then you wouldn't’t have to guess why the light is on. In a plant, you don’t have time to diagnose the issue. You need to quickly determine what the problem is, and how to correct it. AMS Device Manager aggregates device information and provides actionable details.

Pre-Commissioning and Validation of Ff Segments Improves Startup

(Asset Optimization Track, Session 283)
Presented by: David Brown, Bechtel and Alan Dewey, Emerson Process Management

Large complex system projects are looking for methods to reduce the start-up and commissioning time of FF installations. This workshop will describe specific tools and methods that have been developed to shorten startup and commissioning time of both standard stick built projects as well as modular built systems.

Risk-Based Calibration Interval Development

(Maintenance & Reliability Track, Session 167)
Presented by: Michael Meyer, Bristol-Meyer Squibb

The presenter will discuss how to apply an Overall Risk assessment to calibration interval development. The process allows end users to leverage the advanced diagnostic capability, accuracy, and stability of instrumentation available today to extend calibration intervals. The presenter will show a detailed assessment process that will be used at the $750 million BMS biotech facility in Devens, MA.

Taking Wireless Offshore

(Wireless Track, Session 202)
Presented by: Adners RoyRoy, StatoilHydro

This workshop provides an overview of the first offshore Smart Wireless installation undertaken in Europe and the first wireless installation on the StatoilHydro “Grane” platform in the North Sea. StatoilHydro have pioneered the deployment of Smart Wireless technology in the offshore environment and now see the technology as providing clear competitive advantage for their operations.

Using Device Diagnostics to Drive Work Orders in Your EAM/CMMS System Can Save You Time and Money

(Asset Optimization Track, Session 460)
Presented by: Amy Davidson, Emerson Process Management

By utilizing device diagnostic information you can save valuable time and money when using this functionality to create work notification in your SAP/MAXIMO system. This presentation will highlight how to turn information that comes from the device to drive work notifications in today’s most popular systems and help you improve your maintenance practices and efficiency.

Using Portable Maintenance Tools to Complement Host-Based Asset Management

(Asset Optimization Track, Session 439)
Presented by: Alan Dewey, Emerson Process Management

Configuration, calibration, and troubleshooting of HART and FOUNDATION field bus devices often requires being in the field with a portable, intrinsically safe tool such as the 375 Field Communicator. Still, other maintenance operations can best be done remotely using an Asset Management System. This presentation addresses how these two methodologies can complement each other.

Self Organizing Wireless Network Setup

(Educational Services Track, Session 197)
4 Hour Course
Presented by: Paul Anderson and Mark Sagstetter, Emerson Process Management

This session is for individuals who wan to gain experience setting up the components of the Emerson Process Management self-organizing network.

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