Dow Corning reports 55 percent cost savings using Emerson Valve Diagnostic Services |

Dow Corning reports 55 percent cost savings using Emerson Valve Diagnostic Services

Over 800 control valves will be monitored under three year agreement.

AUSTIN, TEXAS (December 16, 2002) - Dow Corning has signed a three year agreement with Emerson Process Management for valve monitoring services at their plant in Barry, South Wales. As Dow Corning's largest manufacturing plant for silicon-based products globally, production continuity is crucial for the company and its customers. Valve monitoring services are one element of Emerson's Asset Optimization offering through which the company delivers improved availability and performance of production assets: mechanical equipment, electrical systems, process equipment, instruments and valves.

Emerson's service personnel will be leveraging the company's advanced diagnostics tools including AMS ValveLink(R) SNAP-ON application and Flowscanner(TM) software. Two trials have proved to Dow Corning that this diagnostics approach leads to increased efficiency and savings in maintenance costs. In the first trial, on a relatively new section of plant, the Emerson Flowscanner software showed that of the 26 control valves that would normally have been removed for overhaul, 22 required a minor adjustment or no work at all. It was only necessary to remove four valves from the line for repair. In this trial, the control valve diagnostic checks saved 73 percent of the cost over the traditional methods of valve maintenance. In the second year, an older section of plant was inspected. Two thirds of the valves were found to be okay, and only 10 out of 31 valves were removed for overhaul. This represented a 55 percent cost saving. Statistical analysis has shown, with 95 percent certainty, that there has been no change in valve failure rates following the adoption of this strategy.

Lee Hookem, Reliability Engineer at Dow Corning, conducted the trial
evaluation and commented, "We wanted to introduce predictive maintenance, rather than dismantling and repairing all control valves on a scheduled basis. Cost savings arise by reducing the number of lines that need breaking and control valves lifted off the plant for overhaul. In addition, the FlowScanner surveys identified I/P converter and valve positioner faults that could be fixed in situ. These minor faults may not have been picked up under our traditional maintenance regime. The contract for use of ValveLink software, and maintenance using Emerson personnel, will extend these savings across all control valves on the site."

Peter Ball, UK Valve Sales director for Emerson commented: "The AMS
ValveLink monitoring and diagnostic service is a powerful tool for
identifying wear in valves, or poor performance in a control loop. Savings result from knowing which valves and loops need attention, and which ones are running fine and should be left alone. We take pride in the combined performance of our technology and our experienced team of site consultants and analysis staff as they deliver on key performance indicators that will produce significant savings for Dow Corning."

Valve diagnostics are one of the services offered by Emerson's Asset
Optimization division. Asset Optimization combines world-class services with innovative technologies to significantly improve process plant reliability. The results include improved process availability and performance of production assets. AMS and ValveLink SNAP-ON are key elements of the PlantWeb(R) digital plant architecture that automates the flow of information on asset reliability and performance to the people who run the business.

About Emerson Process Management
Emerson Process Management (, 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(R); Fisher(R); Micro Motion(R); Rosemount(R); DeltaV(TM); AMS; MDC; and CSI.

About Emerson
St. Louis-based Emerson ( 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 2002 were $13.8 billion.
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