This new offering is enabled by the Plantweb™ digital ecosystem and includes use of wireless sensing, location awareness, predictive diagnostics and data analytics combined with Emerson’s turnaround expertise and proven seven-step turnaround process.
This new approach will provide scope assurance, schedule assurance and improved labour effectiveness while minimising emergent and discovery work. The result is reduced labour and materials costs of up to 10% and shortened schedules of up to 6%.
“About 25% of turnaround projects run over-budget, and more than 50% fail to meet targeted schedules – mainly due to discovery and emergent work during turnaround execution,” said Johan Claassen, vice president, Global Lifecycle Services, Emerson Automation Solutions. “We can now provide customers scope assurance across all their asset classes to avoid last-minute surprises during turnaround execution.”
Market research indicates that 60% of the turnaround cost comes from fixed process assets such as distillation columns, heat exchangers, piping, and structural supports. Emerson is expanding its capability to provide predictive diagnostics, data analytics, and scope planning expertise to these critical assets. Emerson’s comprehensive strategy is to leverage the investment in automation and analytics used to operate the plant to transform the planning and execution of turnarounds by combining this with deep industry expertise, proven work practices and a broad portfolio of lifecycle services offerings.
On an average turnaround, these benefits could save US$3.1 million in labour and materials and shorten the schedule by at least two days. According to Emerson, these savings multiplied across an estimated 8000 turnarounds performed annually could save customers as much as US$25 billion per year in opportunity costs across all process industries worldwide.
Other elements of the new framework include:
- Scheduling early engagement with Emerson’s Operational Certainty Consulting and turnaround experts to perform a discovery workshop.
- Emerson performs walkdowns using a digital mobile app to digitise the installed base and provide a visual inspection of the asset with report and recommendations.
- Applying turnaround expertise to optimise budgets and scheduling based on existing resources and production requirements.
- Leveraging Emerson’s Location Awareness, a new personnel location system within the Plantweb digital ecosystem, to manage safety by reducing labour congestion and inefficiencies of not only employees, but also contractors and temporary workers onsite during turnarounds.
The new Mobile Service and Command Centre acts as a central point where all turnaround asset data is monitored and analysed through Emerson’s experts. It also serves as an inventory warehouse stocked with parts. For unplanned needs, it provides a direct factory link to expedite parts for shipping through the Emerson QuickShip programme.
“By providing a consistent, effective, decision-driven solution grounded on a solid digital technology foundation, we can revolutionise turnarounds for the global process industries,” said Claassen, “This empowers customers to reduce cost and schedule, ensure worker safety, and create a path to peer-leading performance, recouping billions of dollars in lost profits in the process.”
Delivering results through enhanced insight
Effective digital transformation is about results, and Plantweb can help you get them. A scalable portfolio of technologies, software and services, Plantweb enables measurable performance improvement in the areas of production, reliability, safety and energy management by empowering personnel with new insights and actionable information. From small, targeted applications to enterprise-wide solutions, Plantweb drives true performance gains and accelerates your journey to Top Quartile performance.
Enabling Meaningful Actions
Information is power – but only if you know what to do with it. Plantweb turns data into actionable information to drive decisions that lead to measurable operation improvement.
What’s Inside Plantweb
Data：Harvest the data that matters with Pervasive SensingTM strategies that leverage existing measurement technologies and newly developed sensors for enhanced visibility.
Connectivity：Ensure data in your existing systems is seamlessly and securely connected to operational applications or to the appropriate expert – whether on premise or offsite.
Services：Supplement your workforce with third-party services that help deliver improved outcomes through new monitoring solutions, analytics capabilities and commercial models.
Analytics：Make sense of your data using scalable analytics to generate actionable information that can be delivered to the right person at the right time for improved decision making.
Enabling Technologies
Plantweb™ Optics：
Prioritize and deliver relevant asset health information to the right people at the right time.
Connected Services：
Securely access analytics and industry expertise for improved asset health.
Secure First Mile™ Connectivity：
Facilitate the secure transfer of plant data to appropriate applications, services or mobile users.
Pervasive Sensing™ Strategies：
Easily and cost-effectively harvest relevant data through innovative sensor technologies that improve operational visibility.
Plantweb™ Insight：
Strategically interpret data for improved decision making related to specific asset classes or devices.
Plantweb™ Advisor
Transform vast amounts of data into actionable information for improved site-wide decision making.
Fisher Digital Valve Controllers
Gain easy access to information critical to process operation, as well as process control
AMS Device Manager
Avoid unnecessary maintenance costs with a universal window into the health of intelligent field devices.
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