PHARMACEUTICAL Cargill Saves Money, Improves Plant Reliability With AMS Suite: Intelligent Device Manager ™ RESULTS • 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. APPLICATION Vitamin E Production Unit CUSTOMER Cargill Health and Food Technologies, Eddyville, Iowa CHALLENGE 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. SOLUTION 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: www.assetweb.com “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 POWER GENERATION PHARMACEUTICAL 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 www.assetweb.com 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 Management group of companies. The Emerson logo is a trademark and service mark of Emerson Electric Company. All other marks are the property of their respective owners.
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