REFINING

Emerson Technologies and Services DeliverSignificant Savings to Refinery Before andDuring Major Turnaround

RESULTS

•Over $1 million in documented annual savingsthrough work of onsite asset manager

•Evaluation, diagnosis, and prioritization of valvecondition prior to turnaround enabled on-timecompletion of required maintenance

•No valve issues encountered during or after startup

APPLICATIONNumerous control valves were repaired and post repair diagnosticsperformed. Critical and problematic control valves in a refinery’sHydrocracker Unit (HCU) were upgraded in the largest maintenanceturnaround effort in more than 12 years.

CUSTOMERA fully integrated refinery and petrochemical plant in the US.

CHALLENGEThe control valves in the HCU at this refinery are critical to its overallperformance. The failure of any one of these valves, many of whichare subjected to high temperatures and high frequency vibration,could force a shutdown of the entire unit, with a subsequent loss ofproductivity across the entire refinery. Various control valve issueswere evident and needed to be addressed during an upcomingmajor turnaround. In addition to previously identified repairs,refinery engineers requested a thorough evaluation, of all 270control valves in the unit — all within a 30-day turnaround.

“Emerson brought in additionalresources from all over thecountry to meet our needs ina restricted time frame. Wegreatly appreciated theirwork.”Manager of Process Control Engineering

For more information:www.assetweb.com

POWER GENERATION

©2010, Emerson Process Management.

The contents of this publication are presented for informational purposes only, and while every effort has beenmade to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied,regarding the products or services described herein or their use or applicability. All sales are governed by ourterms and conditions, which are available on request. We reserve the right to modify or improve the designsor specifications of our products at any time without notice.

All rights reserved. AMS, ValveLink, Fisher, FIELDVUE and SNAP-ON are marks of one of the Emerson ProcessManagement group of companies. The Emerson logo is a trademark and service mark of Emerson ElectricCompany. All other marks are the property of their respective owners.

REFINING

SOLUTION

Prior to the turnaround, the plant’s control valve Asset Managerevaluated PlantWeb® alerts and indicators using AMS™ Suite:Intelligent Device Manager. During the turnaround, techniciansfrom Emerson and the local business partner made extensive useof AMS Device Manager predictive maintenance software withAMS Valve-Link™ SNAP-ON™ application to monitor the conditionand track the performance of the Fisher® FIELDVUE™ digital valvecontrollers (DVCs) mounted on critical and general service valvesin the HCU.

AMS Device Manager and the ValveLink SNAP-ON were used togather detailed information on the condition of all 270 valvesduring the turnaround. By stroking the valves and comparing theresults with benchmark studies done during installation of theDVCs, planners were able to learn which valves were most inneed of overhaul, allowing the refinery to prioritize the repairwork. Some valves were found to be in good condition withoutneeding repair, saving time and the expense of unnecessarilypulling the valves for evaluation.

In one instance, prior to the turnaround, the Emerson team alertedrefinery operators of a valve travel sensor failure, enabling them toavoid an unplanned shutdown and saving the facility an estimated$625,000 in repairs and lost productivity. The technicians actuallydeveloped a repair strategy to return the device to like-new condition— while maintaining operations in the HCU. Control of the valve’sposition was maintained within 0.5 percent of the setpoint afterrepair without recalibration. This valve has continued to operatewithout causing further alerts or process upsets.

During the turnaround itself, teams from Emerson’s Instrument &Valve Services worked with the local business partner to completethe successful valve overhaul and the re-instrumentation, calibration,and tuning of new and existing DVCs followed by an on-time startup.

The refinery’s resident control valve Asset Manager has been a majorforce in monitoring the day-to-day diagnostics generated by the valveDVCs and working proactively to eliminate systemic failures. Savingsof more than $1 million annually have been documented due to theefforts of this asset manager. Additional “soft” savings — also welldocumented — have exceeded $2 million

Emerson Process ManagementAsset Optimization Division12001 Technology DriveEden Prairie, MN 55344 USAT (952) 828-3633F (952) 828-3006www.assetweb.com

AMS Suite: Intelligent DeviceManager powers PlantWebthrough predictive and proactivemaintenance of intelligent fielddevices to improve availabilityand performance