Migration solutions enable fast, effective transition to modern automation with FOUNDATION fieldbus technology and DeltaV™ systems
AUSTIN, TEXAS (September 27, 2004) — Emerson Process Management announced today that The Lubrizol Corporation's Deer Park, Texas, facility has modernized by successfully completing the transition of one of their older ABB MOD 300 manufacturing process control systems to Emerson's PlantWeb® digital plant architecture with the DeltaV™ digital automation system, and using FOUNDATION fieldbus technology. "Lubrizol Deer Park's migration solution involving Emerson is part of the corporation's overall Operations Management System initiative," said Bob Wojewodka, process improvement team leader for Lubrizol. "This includes a broad alliance agreement between Lubrizol and Emerson Process Management to further optimize Lubrizol plants around the globe with PlantWeb services and technologies.
The goal is to make further strides in reducing process and product variation, provide customers with more consistent, higher quality products and to further drive costs out of the Lubrizol manufacturing processes." Until recently, the plant's manufacturing process control was based upon various disparate legacy control systems, many of which were installed in the early 1990s. During the past several years, incompatibility between the disparate legacy systems and increasingly higher engineering, procurement and maintenance costs associated with these systems were resulting in higher manufacturing costs.
Reducing life cycle costs associated with the automation equipment, and improving worker productivity and safety while concurrently improving production quality, were key driving factors for implementing a change. Management at the Deer Park plant realized the need to adopt a digital plant architecture that had inherent connectivity to a variety of digital bus technologies such as FOUNDATION fieldbus. In addition, the new digital automation system interfaces with the legacy control systems and business systems such as SAP for facilitating plantwide controls.
"Emerson's stepwise migration solutions have provided us the opportunity to gain immediate benefits from built-in support for state-of-the-art digital technologies like FOUNDATION fieldbus," said Bruce Johnson, manager of instrumentation and controls at Lubrizol's Deer Park plant." Lubrizol has demonstrated an extraordinary vision in leveraging digital plant technology to achieve operational excellence," said Tom Snead, president of the process systems and solutions division of Emerson Process Management. "We are honored to be a part of Lubrizol's vision. With PlantWeb services and technologies, Lubrizol will make the transition process from older, disparate automation systems to the DeltaV system easier and affordable.
Lubrizol will be able to transition selective components of their legacy systems to take advantage of Emerson technologies like advanced control, digital buses, embedded tuning, and predictive technologies capable of delivering quantified performance benefits."
Emerson's Migration group, working in conjunction with local Emerson partners Puffer Sweiven, Inc. ( www.puffer.com ) near Lubrizol's Houston, Texas, plants and A.E.
Ehrke & Co. ( www.ehrke.com ) near Lubrizol's corporate offices in Wickliffe, Ohio, assisted Lubrizol in moving to newer automation technologies by providing services such as database, control strategy, and graphic display conversions, complete with an offline configuration checkout prior to actual connection of the new digital plant architecture." Having migrated several older automation systems to the PlantWeb architecture, often without loss of production, we have developed domain expertise and business methodologies to transition to the new digital technology a much easier and faster process," said Laurie Ben, director of the migration group at Emerson.
"Our alliance with Lubrizol provides us with a framework to fast-track the migration of older automation systems to the DeltaV system and PlantWeb architecture for achieving higher returns."
About Emerson's Migration Solutions
Emerson's stepwise migration solutions enable fast and cost effective modernizations to new technology. According to Larry O'Brien, ARC research director for process industries, "Lifecycle costs, which include costs to upgrade and migrate automation systems, have become more important than initial purchase prices. We believe that Emerson has developed an effective migration strategy for its own legacy systems. Emerson is also one of the few suppliers that has placed considerable focus on a strategy for migration from competitive systems." Within the past year Emerson has released a wide range of migration solutions, including the DeltaV Connect for ABB systems.
These solutions have been specifically designed to upgrade a wide range of legacy systems, including those from ABB, Bailey, Honeywell, GSE Systems, Invensys/Foxboro, Siemens, Yokogawa, General Electric, Allen-Bradley, and Modicon, to the DeltaV automation system. Migration solutions provide flexibility and deliver efficiency Emerson's migration products for field connections, operator interface, and control, combined with its simulation, training, and conversion services, reduce installation costs and minimize downtime during an automation system upgrade.Using Emerson's FlexConnect and 848T 8-input temperature transmitter with FOUNDATION fieldbus, Emerson can reduce rewiring costs as much as 50 percent and process downtime by 75 percent.
Emerson's migration services include database conversion and graphics conversion or complete redesign or displays. Simulation tools expedite checkout and reduce learning curve for operator training.
About Lubrizol
The Lubrizol Corporation (NYSE: LZ) is a global provider of specialty chemicals and materials for a wide variety of markets and end-use applications, such as lubricant additives for engine oils, other transportation-related fluids and industrial lubricants, as well as fuel additives for gasoline and diesel fuel. In addition, Lubrizol makes ingredients and additives for personal care products and pharmaceuticals; specialty materials, including polymer additives and plastics technology; performance coatings in the form of specialty resins and additives; and additives for the food and beverage industry.
Lubrizol's industry-leading positions in additives, ingredients and compounds enhance the quality, performance and value of customers' products, while reducing their environmental impact.Headquartered in Wickliffe, Ohio, The Lubrizol Corporation owns and operates manufacturing facilities in 22 countries, as well as sales and technical offices around the world. Founded in 1928, Lubrizol has more than 7,800 employees worldwide. In June 2004, Lubrizol acquired Noveon International, Inc.
With Noveon, Lubrizol generated pro forma revenues of $3.2 billion in 2003.
For more information, visit www.lubrizol.com or www.noveoninc.com .
About Emerson Process Management
Emerson Process Management ( www.emersonprocess.com ), an Emerson business, is a leader in helping businesses automate their production, processing and distribution in the chemical, oil and gas, refining, pulp and paper, power, food and beverage, pharmaceutical and other industries. The company combines superior products and technology with industry-specific engineering, consulting, project management and maintenance services. Its brands include PlantWeb®, Fisher®, Micro Motion®, Rosemount®, Daniel®, DeltaV™, Ovation®, and AMS™ Suite.
About Emerson
St. Louis-based Emerson ( www.gotoemerson.com ) is a global leader in bringing technology and engineering together to provide innovative solutions to customers in process control; electronics and telecommunications; industrial automation; heating, ventilating and air conditioning; and appliance and tools. Sales in fiscal 2003 were $14 billion.
