Chemical Processing-August 2008

mAking it work early in the project, before the initial migration began. The advantages of modernizing to a digital plant architecture and switching to predictive maintenance techniques were explained to plant operators, maintenance staff and supervisors. During training, staff easily adapted to using the new tools and found PlantWeb to be user friendly. The new interfaces provide more plant data on each screen than were available through the prior DCS, allowing staff, who have learned how to assess this increased information, to improve the quality and speed of their decision-making about maintenance and operations (Figure 1). They’ve also gained mobility — a wireless network enables them to perform asset maintenance in the field, using their laptops to access operational and diagnostic data through remote DeltaV desktop and AMS Suite applications. more and better information relAteD resourCes oN ChemICAlproCessINg.Com: • Plants Get Help in Boosting Reliability, www.ChemicalPro cessing.com/articles/2007/033.html • AMS Benefits Chemical Plant from Start to Finish, www. ChemicalProcessing.com/articles/2005/430.html • Automation Vision Comes to Life, www.ChemicalProcess ing.com/articles/2004/319.html tions, anticipate product changes to avoid second-rate quality, and produce less scrap. The plant also has reduced variability through advanced control tools. Neural network software provides more effective quality prediction for the reactors, enabling increased rates for certain products. Operators can rapidly determine the melt flow index of a product and adjust production accordingly through data collected by their “neuron web” of intelligent devices. In the past, they would have to wait for lab test results before making changes in production. After the switch to digital, staff members were able to quickly detect and diagnose a faulty seal on a pump, correcting a problem that in the past would have caused a plant shutdown. Plant stoppages have been reduced from once per year to once every two years through predictive maintenance. The decisionmaking power of maintenance staff has grown by switching to these new tools, plus other personnel — especially process engineers — now are more involved in maintenance diagnoses. Further progress Figure 1. Operators now see more plant data on each screen, speeding and improving their decision-making. Management anticipates continued and growing benefits for high-impact and crystal polystyrene operations from the scalable automation technology platform. The ImpressIve results Proactive maintenance techniques available through plant is installing wireless field devices to extend the this smart digital platform have increased plant reli- modernization. Training continues to further develop the analytic skills of staff so they can make the most of ability by 2% to 3% and have reduced maintenance costs by 10% to 12%. Production is more predictable the predictive intelligence data provided. Managers also are considering bringing the bi-oriented polystyrene and better controlled now because operators can manufacturing operations into the fold. And Petrobras confidently increase rates for certain products. The plant’s availability is 99% and annual production has Zarate personnel and their peers at other Petrobras risen by 3% to 5% — to 66,000 tons of high impact manufacturing plants across Argentina have established an integration forum to share experiences and discuss and crystal polystyrene — since the modernization. the advantages of choosing a smart digital network. Maintenance staff now can predict incorrect functioning in valves, transmitters and other assets, and address problems before they cause production to ADolFo suIFFet is maintenance manager at Petrobras be scaled back or shut down. Staff use their experiZarate, Zarate, Argentina. roBerto gorBArAN is supervience and AMS Suite software to analyze the new, sor, electrical and instrumentation, for Petrobras Zarate. mArIo more reliable plant information collected to optimize BlANCo is a key account manager for Emerson Process Manproduction without the help of consultants. Predicagement Argentina, Buenos Aires. Reach them by e-mail at: adolfo. tive intelligence from plant assets allows staff to better suiffet@petrobras.com, roberto.gorbaran@petrobras.com and utilize raw materials, more quickly correct flow devia- mario.blanco@emerson.com. 40 August 2008 chemicAlprocessing.com http://ChemicalProcessing.com http://www.ChemicalProcessing.com/articles/2007/033.html http://www.ChemicalProcessing.com/articles/2007/033.html http://www.ChemicalProcessing.com/articles/2005/430.html http://www.ChemicalProcessing.com/articles/2005/430.html http://www.chemicalprocessing.com/articles/2004/319.html http://www.chemicalprocessing.com/articles/2004/319.html http://chemicalprocessing.com

Table of Contents Feed for the Digital Edition of Chemical Processing-August 2008

Chemical Processing- August 2008 Contents From the Editor ChemicalProcessing.com Field Notes In Process Energy Saver Compliance Advisor Protect your Plant What’s on Tap for Water? Keep Operations Safe Polystyrene Plant Gains Extra Output and More Process Puzzler Plant InSites Equipment & Services Adlits Product Spotlight/Classifieds Ad Index End Point

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