Cargill Saves Money, Improves Plant Reliability with AMS Suite: Intelligent Device Manager

Cargill Saves Money, Improves Plant Reliability with AMS Suite: Intelligent Device Manager
Cargill Saves Money, Improves Plant
Reliability With AMS Suite:
Intelligent Device Manager
• 20% reduction on scrubber load by preventing
nitrogen loss.
• Documented savings of hundreds of thousands of
dollars since 2001 through decreased process variability
and improved reliability.
• Savings through cost avoidance are even greater.
Vitamin E Production Unit
Cargill Health and Food Technologies, Eddyville, Iowa
Built in 1996, the Cargill Vitamin E plant has nearly 1500 HART®
smart field devices connected to its distributed control system.
In addition, about 350 FIELDVUE® digital valve controllers, or smart
positioners, are installed on control valves throughout the facility.
During the early years, schedule-based preventive maintenance was
supported by reactive maintenance. Nothing was done to seek out
potential problems, and when a piece of production equipment failed,
it was repaired as quickly as possible to prevent further downtime.
However, preventive maintenance costs were excessive, and too
many unexpected stoppages were reducing productivity and
costing money.
Emerson’s AMSTM Suite: Intelligent Device Manager software
was installed in 2001 to monitor the performance of the field
instrumentation and control valves and to gather diagnostic data
generated by those smart devices. The plant’s Asset Manager now
relies on this information to predict maintenance needs and reduce
or eliminate maintenance on plant assets not requiring attention.
He also closely monitors the health and status of 30 Critical Control
Points identified as essential to the safety and quality of the
Vitamin E product.
For more information:
“Our work practices have
certainly changed. We have been
able to shift our focus to prevent
from correct, and the documented
savings are significant. We intend
to keep exploiting the predictive
maintenance environment and
avoiding unexpected stoppages.
The more we can plan and
schedule our work, the more
efficient we will be, and that
is our ultimate goal.”
Wade Howarth,
Automation Manager
Cargill Vitamin E Plant
By continuously checking on these critical points for baseline and
calibration certification using NIST-traceable procedures, the plant
has been able to change a quality control procedure from fully
analytical to a process instrumentation-based system. “The
reduction of in-process testing saved us enormous amounts
in analytical testing time and dollars,” according to Wade Howarth,
Automation Manager in the Vitamin E Plant.
The predictive maintenance strategy now in place helps identify
evolving problems before they can adversely impact quality or
productivity. For example, a travel deviation alert on a control valve
prompted maintenance technicians to check out the valve, where
they found a plastic air supply line had melted and collapsed because
it was located too close to a steam line. The situation was corrected
before operators knew anything was wrong. In another case,
technicians discovered a valve had “failed open”, allowing the loss
of nitrogen in a scrubber system. Fixing the valve eliminated loss of
the gas and reduced loading on the scrubber by about 20 percent.
Many potentially serious problems are simply avoided because the
Asset Manager systematically checks every instrument on the network
every day, looking for warning signs that indicate an impending failure.
When he catches a transmitter before it gets too far out of calibration
or expires, he is helping to maintain the reliability of the production
system. Unexpected plant shutdowns are avoided along with the
substantial costs associated with lost production.
Cargill Vitamin E Facility in Eddyville, Iowa
As Wade Howarth has said, “The predictive maintenance program at
our Vitamin E plant has yielded hundreds of thousands of dollars in
documented savings since 2001 through decreased process variability
and improved reliability. Estimated savings through cost avoidance
are even greater. Plant shutdowns have probably been prevented by
daily monitoring of the field devices and control valves, and then
doing the maintenance based on the criticality of those devices.”
Emerson Process Management
Asset Optimization Division
12001 Technology Drive
Eden Prairie, MN 55344 USA
T 1(952) 828-3022
F 1(952) 828-3033
AMS Suite: Intelligent Device
Manager powers PlantWeb
through predictive and proactive
maintenance of intelligent
field devices to improve
availability and performance.
©2004, Emerson Process Management.
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 or guarantees, express or implied,
regarding the products or services described herein or their use or applicability. All sales are governed by our
terms and conditions, which are available on request. We reserve the right to modify or improve the designs
or specifications of our products at any time without notice.
All rights reserved. AMSTM Suite, PlantWeb®, ValveLink, and FIELDVUE are marks of one of the Emerson Process
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