Emerson believes the best way to solve a problem is to prevent the problem altogether. Across a variety of industries, Emerson’s PlantWeb® digital plant architecture is giving operators the power of predictive intelligence, enabling them to save costs and address potential concerns proactively rather than incur expensive and timely repair costs when equipment fails or malfunctions.
With Emerson’s Smart Wireless technology, process manufacturers can use PlantWeb technology in places they were never able to before. Additionally, with the cost of adding one wireless sensor being one-tenth that of a traditional hard-wired solution, wireless networks are now enabling facilities to “cut the cords” and cost-effectively implement process control techniques that improve efficiency of their business operations.
BP, one of the world’s largest energy companies, has championed the innovative use of Emerson’s Smart Wireless technology for business improvement in its refineries worldwide. Emerson’s wireless technology enables BP’s refineries to accumulate and analyze more data than before – all while saving time and money.
Collaborating with Emerson Process Management, BP initially introduced wireless technology at its refinery in Cherry Point, Wash. BP Cherry Point processes more than 225,000 barrels of oil a day and is the largest supplier of calcined coke to the aluminum industry. The 15-transmitter installation at the Cherry Point facility that was set up by Emerson in 2006 is believed to be the world’s first industrial wireless mesh network.
With Emerson’s engineering help, BP Cherry Point has since expanded to a 35-transmitter Smart Wireless network that monitors bearing and calciner coke temperatures to help warn of possible fan and conveyor failure. Inoperable fans can cost up to $100,000 to repair and require a shutdown for up to 10 days, resulting in significant production loss. The wireless network helps operators track and prevent such occurrences from happening.
Following the successful implementation of its Cherry Point wireless network, BP looked to modernize its facility in Naperville, Ill., using Emerson’s Smart Wireless. BP Naperville R&D is a world-class technology center that helps develop processing technology for BP refineries worldwide.
BP Naperville’s 45-transmitter wireless network enables operators to track what is happening in the facility 24 hours a day by recording data constantly. The wireless network in this facility uses Rosemount® wireless transmitters to monitor suction, discharge pressures, levels, flow, and temperatures throughout the facility. The wireless network can reach places where wired devices either could not reach or would be too costly to install. These wireless networks enhance productivity by collecting data into one central point, abolishing the need for operators to travel to multiple areas of the refinery and record values.
With the support of BP and dozens of other customers around the world, Emerson is leading the way in establishing the industry standard for implementing interoperable wireless technology to enhance plant reliability, safety, and environmental compliance.
Related Information:
Emerson Announces Expanded Use of its Wireless Technology by BP to Improve Process Equipment Monitoring and Availability (September 30, 2008 press release)