The document discusses modernizing legacy automation systems to regain competitive advantages through increased productivity, communication between process and business systems, and maximizing plant availability. It highlights how Emerson can help customers modernize through their global project experience, digital technologies, and expertise to deliver more performance for a more profitable plant while minimizing downtime and risks during modernization.

1. Automation System Modernization
Regain your competitive edge.

2. With today’s increasing global competition and rapid
technological advances, many plants around the world
have legacy automation systems that aren't able to keep
up with today's production demands.
Better plant performance begins with better automation.
And, with today's digital technologies you can expect
increased productivity and better communications
between your process information and your business
CONTENTS systems.
2 Regaining your competitive edge
Correcting Missed Opportunities 10 Minimize your downtime during
Maximize Availability
through modernization. modernization with Emerson
technology and expertise.
4 Why modernize with Emerson
How Emerson delivers more
performance for a more
12 Get more from your automation
Maximizing ROI
profitable plant. investment with Emerson’s world-
class training and simulation tools.
6 Build a business case Solid PlanOPEX
Starting Out with a
based on
and CAPEX for the life of your plant.
14 Sustained Improvement
and Support
A flexible portfolio of industry
8 Global Standards and
Best Practices
leading support in your city and
around the world.
Manage your modernization with
global project experience.
2

3. A legacy of lost opportunities.
When should you consider system modernization?
Yesterday’s systems may have been a good investment, but today’s “Emerson is widely
technology and expertise provide opportunities and benefits that just
weren’t available when these systems were designed. You should consider recognized as today's
a modernization when: leader with respect to
Production & energy costs keep rising
Inventories of raw materials and finished product pile up process instruments
Product quality is inconsistent and customer complaints increase and automation
Start up and product grade changes cost more than they should
Plant trip and alarm systems are unreliable and/or inadequate
systems. We expect to
Production is inflexible and start-up time is lengthy benefit greatly from
Recurring emission problems are constraining throughput
their experience in
Business systems lack meaningful plant floor production data
Customers are demanding more but your plant cannot deliver: applying these
more specialized products and packaging
technologies to the
tighter quality specifications or delivery times
better service processing of bitumen,
Obsolete system support costs continue to increase. integrating the
What are you missing? engineering phase of
You may want to consider how your system (and your current automation the project, and
supplier) would respond to:
Plant expansion (including bus-based or wireless I/O) for improved
bringing state-of-the-
plant diagnostics and increased plant uptime art efficiency to the
Reducing variability to establish a foundation for advanced controls
operation of our
and process optimization for better throughput and yields
Providing field service alerts to operators and/or maintenance, upgrader.”
improving response times to specific needs
Integrating DCS information with your business systems for more Robert Pearce
informed and timely business decision-making President
Integrating predictive maintenance practices to focus your North West Upgrading Inc.
maintenance resources, saving time and money.
See how Emerson’s digital technologies and expertise enable the safest
and most scalable path to on-going capital expense and operational
expense savings.
For more information:
EmersonProcess.com/
Solutions
3

4. Why modernize with Emerson?
Take advantage of Modernize for
Emerson’s experience measurable results
Highlights of customer measurable
with thousands of process results in thousands of PlantWeb
installations worldwide include:
automation projects 30% increase in capacity without
worldwide. additional personnel
10% increase in throughput
Automation leaders 20% reduction in raw material
The keystone to Emerson’s usage
automation technology leadership 15% reduction in rework
is the proven PlantWeb® digital 50% reduction in maintenance
plant architecture, an open costs with remote diagnostics
standards-based digital solution New high-margin products never
that networks intelligent field before possible
Control room space requirement
Reduce your risk
devices, digital systems, and
With PlantWeb, you can achieve an
software, controlling processes and reduced as much as 85%
effective program for managing
managing equipment and other Automation investment payback
safety, health, and environmental
assets. Embedded, advanced in less than 4 months.
risks and costs—one that goes
control means a more efficient,
beyond abnormal situation
consistent, available and optimized Leaders in service management to abnormal situation
operation. Emerson’s global network of prevention.
engineers and consultants has the
Emerson’s commitment to open real-world industry and process AMS™ Suite: Intelligent Device
standards, highlighted by our automation knowledge to help you Manager gives you key online access
donation of the HART protocol in the design, plan and implement your to your instrument and valve
1980’s, continues today with our automation concept with: process information, diagnostic
work on FOUNDATION fieldbus and Modernization and migration status information, and automatic
wireless standards. consulting documentation of all field device
Fieldbus consulting maintenance information. And
Process safety management DeltaV™ SIS, at the heart of
Human factors optimization Emerson’s smart SIS, works with
Production information AMS to continuously diagnose your
management intelligent field services and safety
Advanced automation & functions. This helps ensure your
optimization process shuts down only when
Plant system security. it should.
4

5. Better performance.
Operating on the
leading edge “We looked for a
Process manufacturers lose
millions of dollars each year due
company that had the
to process variability and poor right technology and
control performance, often
also a strong support
unaware that a problem exists.
The powerful new DeltaV InSight network that would
monitors control performance;
be available to us. We
identifies and diagnoses problem
loops; recommends tuning and selected the
maintenance improvements; and PlantWeb digital
continuously adapts to changing
process conditions. plant architecture
Manufacturers have real issues from Emerson Process
everyday that effective wireless Management. We
solutions can help solve.
Emerson’s Wireless SmartPack™
also selected Emerson
helps you create a secure network as our main
right out of the box, giving you
automation
convenient access to information
you simply don’t have today. contractor because of
its proven project
Often, fewer than 10 modules
management
cause 40% or more of alarm
activations. So by addressing just experience and
a few alarms, you can significantly
intimate knowledge
improve operator alarm loading.
DeltaV Analyze makes it easy to of the technology we
find the most frequently occuring had selected.”
alarms.
Evelio Hernandez,
Process Control
Systems Manager
Emerson Process Management was again voted the best
supplier of process management technologies in CONTROL
Magazine’s 2007 Readers’ Choice Awards. This is the
14th consecutive year that Emerson has captured For more information:
EmersonProcess.com/
the user-voted recognition.
PlantWeb
EmersonProcess.com/
ARC and Control Magazine also placed Emerson as SmartWireless
#1 on their Top 50 Automation Companies List. EasyDeltaV.com
5

6. How do I get started?
Emerson experts and Based on your business objectives, This plan may cover:
a site assessment , tailored to your Migration to a new automation
technology help you needs, defines performance system
evaluate where you are criteria: Process modifications
Key process measurements Additional instrumentation
and plan where you’re Process constraints and Improved regulatory and/or
limitations advanced control strategies
going.
Process disturbances Safety, environmental and
Equipment or operational equipment protection
The challenge
limitations. Information integration
Selecting the right technology,
Asset management.
the right partner, the right
implementation plan and the
Planning for your
right budget minimizes risk.
specific needs An Emerson modernization plan
The site assessment feeds a will consider a variety of migration
Emerson offers unparalleled
process automation feasibility types and specific needs, and
capabilities to help you set the
study used to develop the process informs you of viable and profitable
stage for a more profitable plant.
automation modernization plan. options for your system:
Full system upgrade -
Building the business
This study includes a cost/benefit controllers, I/O and consoles
case for modernization
analysis based on both CAPEX and Controller upgrade using I/O bus
Emerson works with you and your
OPEX over the lifetime of the interface
team to help you define and justify
system. This defines the business Upgrades that work with your
a migration path based on your
case and helps you answer the existing controllers and I/0
business and production
question: “Will improving my Console upgrade
perspectives. This often begins
process automation improve my Advanced control
with a review that includes all
key performance indicators?”. implementation
appropriate plant and corporate
Historian consolidation.
groups to establish business goals
that could include:
Your plant:
Increased availability
Reduced manufacturing costs
Increased throughput
Reduced plant emissions
An asset to perform
Improved quality
Improved ability to introduce
new products
Improved response to customer
demands
Increased safety.
6

7. With a solid business plan.
Front-end engineering The FEED package would typically
and design provide a Project Execution Plan
2007 Frost & Sullivan
Once a process automation with the following elements:
Safety and Environment Plan Company of the Year
modernization plan has been
developed, Emerson’s world-class Quality Plan Award
team of automation experts Master Project Schedule for Industrial
continue to work with your key Staffing Plan Automation and
stakeholders to develop a Front- Project Controls Plan Process Control
end engineering and design Project Communication Plan
(FEED) plan. Hot Cutover Plan “The global footprint
Turnaround Plan
An Emerson FEED study is the Installation Management Plan. of the company and its
foundation for a controllable and
profitable project making certain
outstanding
Emerson total value
that your design meets your orga- Emerson’s FEED capabilities are engineering capability
nization's overall needs by: part of a total value proposition coupled with a sound
Ensuring that the design meets to create smart plant solutions
with proven benefits:
business process
your project’s time, budget,
ROI and operating cost criteria Lower capital expenditure to empowers Emerson to
Setting scope boundaries by reduce automation costs 20% -
deliver the same
quantifying and justifying the 30%
investment required for a given Faster time to profitability benefits at all
benefit Increased profitability
customer locations.”
Preventing unnecessary Superior system manageability.
changes through better change Kishnan M. Bhat
management Industry Manager
Identifying and providing for Frost & Sullivan
project risks
Achieving faster
implementation of technology.
ance
For more information:
EmersonProcess.com/
Solutions/ProjectServices
7

8. How do I manage risk?
Precise control over your Global standards in this context Expert implementation
refer to standard, modular, pre- Emerson’s engineering teams
project at a time of tested pieces of automation like have strong advanced technology,
major change is critical control modules, equipment integration and optimization
modules, phases, etc. expertise targeted at
to maintaining plant modernization.
These standards:
operations and business
Incorporate accumulated Conversion Services and utilities
objectives. knowledge and best practices Conversion services for graphics,
Help facilitate communication database, and other
Detailed processes and between team members configurations are available to
global standards Shorten the learning curve for help minimize switching costs and
Emerson integrates global new project team members reclaim the value of your legacy
standards and best practices in Include a customer feedback system investments for use with
project management processes. mechanism for continuous the DeltaV system.
Project deliverables include improvement.
documentation, support tools, Focused conversion service
and technical standards that help Our project managers have the engineers are dedicated
reduce errors and omissions in training and experience to deliver resources, familiar with common
budgeting, scheduling, training, consistent results: errors and best practices
and maintenance. Highly effective planning and regarding conversions. Their
design expertise covers all aspects of the
Emerson's project management Excellent change management automation project including
work process is built upon the Strong performance to operator interface, batch
recommended best practices of budgets; both time and cost architecture, continuous control,
authorities such as Construction Optimized product and devices and I/O, and integration
Industry Institute (CII), Project technology benefits with external systems.
Management Institute (PMI), and Highly efficient
Independent Project Analysis (IPA) implementation Emerson has extensive
methodologies. Risk containment investments in conversion utilities
Smooth startups and that make conversion services
commissioning efficient and accurate without
Faster ramp up to full extensive or unnecessary rework.
production.
Scalable automation services
8

9. With a wealth of experience.
Platform expertise Optimization services
Emerson has invested in legacy Asset optimization services help
system domain experts for a with asset prioritization, critical
“Emerson's goal is to
variety of platforms, including asset reliability improvements, and design a reliable,
non-Emerson systems. These maintenance work process
experts understand how to development. We provide
advanced instrument
address system-specific intricacies assistance to maximize asset value and control system to
for successful migrations. extraction, performance
assure safe, stable, and
improvement and optimization,
Connectivity services technology deployment long-term quality
Emerson has the services and tools improvement, integration of
operations while
to connect your new automation maintenance and performance
system to existing advanced information-driving key maximizing the
applications and production performance indices in the right profitability of the
systems. One example is an auto- direction.
tag conversion tool that helps company. Emerson has
migrate existing layered Variability management proven technologies
applications over to newer Process variability eats away at
technologies. product quality and plant and a proven track
availability and wastes raw record in China.
Vertical integration materials and energy.
Emerson’s family of
Emerson’s local
instrumentation delivers valid, Variability management consulting resources and the
actionable field information to the services provide a comprehensive
DeltaV system’s suite of operations holistic approach to minimizing
support of its global
management, advanced control, process variability for optimal resources help to
and asset management control performance.
mitigate and minimize
applications. Valid plant
information in advance of a plant Client engagements are performed risks for owners.”
event or upset is the essence of by senior professionals who have Hongye Hu
abnormal situation prevention an in-depth understanding of MICC Manager
(ASP). Rather than attempting to process dynamics, control Fujian Refinery
manage operational incidents, ASP equipment, and control strategies. August, 2007
is focused on preventing the losses They use systematic and scientific
associated with facility upsets methods of control design, loop
altogether. tuning, and process
troubleshooting.
For more information:
EmersonProcess.com/
Solutions/Consulting/
VariabillityManagement
9

10. How do I minimize operational impact?
Emerson’s solutions and In one example, three key Each piece of instrumentation has
PlantWeb technologies were used a special cutover procedure,
experience give you in the process to help perform a based on years of experience in
choices for implementing hot cutover from pneumatic implementing cutovers. AMS
control to FOUNDATION™ fieldbus. Device Manager is used by the
your modernization. The FIELDVUE® DVC6000f, with team to help coordinate these
its unique pressure control programs, reducing project
Options for functionality, allows a fieldbus risk by:
modernization connection to the DeltaV system Verifying device:
Whether you’re migrating to a new while also sending a pressure configurations match
automation system during a signal to the existing actuator or specifications
turnaround (cold cutover) or while pneumatic positioner. Once connection and ranging
the process is up and running (hot pressures are balanced within the construction materials
cutover), Emerson project system, control is transferred to Ensuring that devices function
personnel work with your the digital valve controller. as a system, whether checking
operations team to carefully plan interlocks, stroking valves, or
and safely implement your During this phase, AMS Suite: verifying alarm points on
modernization plan while saving Intelligent Device Manager, field devices
valuable production time. helps reduce the risk in finalizing Minimizing device configuration
the hot cutover by enabling local and implementation times.
communication with the valve to
monitor exactly what is
happening during the process of
mounting, adjusting, stroking,
and calibrating the valve.
Flexible automation solutions
10

11. Any way you need to.
Flexible solutions Switchover savings
A number of other Emerson As you replace and upgrade your “Emerson’s
solutions help to save time and legacy controllers and I/O with
prevent disruption while giving DeltaV components, get fast experience really
you flexibility during a system switchover while retaining your made a difference in
upgrade. These technologies termination panel and wiring
allow DeltaV Operator Stations to investments. the planning and
be added to a variety of legacy implementation of the
systems with the process online Our solutions use existing legacy
and used side-by-side with field wiring terminations for the hot cutover to our
existing consoles while the DeltaV system without lifting or new control system.
process continues to run. removing wires. These solutions
can:
Their digital
You can also add DeltaV Save your existing wiring technology was also
controllers at any time and these investment
critical as they worked
can co-exist with your legacy Speed startup by not disturbing
system while allowing you to take field connections with us to install and
advantage of technologies such Reduce process downtime by
commission 1100 new
as predictive field device 75% or more compared
intelligence, embedded advance to rewiring. instruments. This
control, and integrated asset project was under
management. Reduce risk with
DeltaV Simulate budget with no OSHA
With these flexible solutions, With DeltaV Simulate, you can or environment
FOUNDATION fieldbus and other develop and fully test control
digital busses such as HART, strategies in an offline laptop or incidents. You cannot
Profibus DP, DeviceNet and AS-i desktop PC environment. You can get much better than
bus can be easily integrated with verify all your DeltaV
your existing legacy equipment. configurations before you that!”
migrate control. With add-on Bob Sherven
software such as MiMic® I/O Project Manager
simulation, you can also checkout Shell Deer Park Refinery
I/O before connecting live.
For more information:
FIELDVUE.com
EasyDeltaV.com
EmersonProcess.com/AMS/
index.htm
EmersonProcess.com/
Solutions/Migration
11

12. How do I maximize return on investment?
Emerson’s training Get more from your operations, engineering and
solutions deliver skilled automation investment management. Our diverse
To remain competitive, learning methods range from
operators and companies need a highly skilled general classroom offerings to in-
operational excellence workforce, equipped with the plant customized training.
anywhere in the world. knowledge, skills, and ability to Recent eLearning courses to
take action and be proactive. consider are DeltaV Operator
Emerson’s Educational Services Interface for Continuous Control
Start with the basics team has been training industry and Fisher Valve Fundamentals.
PlantWeb University facilitates professionals around the world for These new on-line courses allow
your understanding and over 65 years with: you the opportunity to learn about
evaluation of new ways to
44 fully manned and equipped these products at just the right
improve project, process, and
training centers time for you.
plant performance. PlantWeb
University provides practical, real- 120 full-time and 45 part-time New equipment and technologies
world information about how to professional staff mean you need to recalibrate your
improve process and business Over 20,000 students trained operations and maintenance
performance to over 20,000 annually. program; we can show you how.
industry users around the world. Hundreds of courses and training Training to consider during a
solutions are available for every modernization can include:
level of your organization from
front-line technicians, to Simulation-based operator
training
Control engineer training
Process operations training
Digital bus training
Safety Instrumented Systems
training
Smart wireless training
Advanced control and
optimization training.
12

13. With world-class training.
DeltaV OTS Training Transfer knowledge
A key concern when modernizing a and best practices
plant automation system is that Actual key process events that
your operators are skilled in occur on one shift can be “ The courses are very
making the most of this new recreated with different operators helpful and provide
technology. and crews. Simulations can be
designed to capture the loads of knowledge. I
With the new DeltaV Operator experiences and actions of senior actually enjoy the
Training Solution (OTS) program, operators so that new operators
our Educational Services team can can learn them.
courses and look
help ensure that your personnel
Real experience forward for new
are primed to capitalize on these
without risk topics.”
technologies and unlock the true
Operators will learn DeltaV
potential of your operation.
operating concepts while
Benefits include:
experiencing a breadth of process “ Very good technical
Operators are trained before scenarios. This new training offers
overview of the
actual commissioning takes the benefits of exposing operators
place to a training environment identical process digital
Faster, smoother start-ups to what they will experience in the
world.”
More confident and experienced actual control room. Benefits to
operators simulation-based operator
Reduced incident reporting training are: “ Definitely worth the
Product quality improved faster
Real experience with no risk time spent. A lot of
A better understanding of
Actual plant configuration
possible failure scenarios good practical tips
graphics and database
OSHA compliance (Article 29
Realistic dynamic process and suggestions.”
CFR PAR 1910.119).
simulation and scenarios
On-site, 24/7 learning
Custom curriculum and “ I think everyone
courseware
Professional instruction and
who is involved in the
support field or engineering
Affordable tiered solutions.
should review the
courses....”
For more information:
DeltaV OTS Architecture EmersonProcess.com/
education
Plantweb.Emerson
Process.com/University
13

14. How do I sustain these improvements?
Emerson’s SureService Comprehensive The SureService program consists
portfolio of support of service modules, each designed
portfolio contains all the to address specific support
services requirements. These modules can
right elements to tailor a We recognize that automation
be combined to customize a
system support needs vary from
program to fit your support program for your plant
one customer to another, and that
that is tailored to fit just right,
specific support needs. our customers make investments
meeting your support needs while
over the system life cycle for three
providing value and peace of mind.
To this end, Emerson has important reasons:
developed: Availability Services to keep your
A global service organization system running Guardian
Service quality processes Application Services to apply the Support
Our global Service Management best PlantWeb technologies The core element of our
System Sustainability Services to protect SureService support program will
Our comprehensive portfolio of your investment in capital and help you improve staff
automation system lifecycle intellectual property. productivity while reducing
support products. operations and maintenance costs.
Emerson’s portfolio of services can
We meet the expectations of our be combined in various ways to
customers worldwide by address your unique needs in each
consistently delivering competent, of these three areas through a
efficient and reliable services of combination of factory and field
the highest possible customer resources and local service
service. This global consistency of agreements.
service and support from
certified professionals—both The base element for Emerson
centrally-located and local to system service agreements is
you—is what separates Emerson Guardian Support, a prognostic
from all others. To you, this service designed to optimize the
difference means prompt, availability, sustainability and
professional response, no performance of your DeltaV
matter where on the globe digital automation system.
you operate.
14

15. SureService SM
Availability Services Application services can help
These are the basic, ensure the effective application of
PlantWeb technology with a focus
“...we’ve seen
essential day-to-day
system maintenance services on prevention of system issues upwards of 90%
designed to help you achieve the and overall improvement of plant
reduction in
desired level of certainty for operation.
system uptime, taking your variability on the
process, system design, and in- Sustainability operation of the kiln,
house resources into account (see Services
table). which will
Sustaining your
automation system such that it immediately give us a
Application Services can be routinely supported and positive payback.”
These services help you serviced is essential to maximizing
achieve expected results the return on your system
from the application of Jim Norcross
investment. Sustainability services
technology and related work Canadian Forest Products
can include identifying, assessing,
processes, while keeping up with planning, and implementing
evolving business conditions. technology updates and upgrades
to minimize system down time,
prevent system offsets, and
minimize total cost of ownership.
SureService Portfolio Availability Application Sustainability
Guardian Support
Project-to-Operations Transition Support
Express Module Replacement
Spares Access Programs
Emergency On-Site Services
Scheduled On-Site Services
Critical Data Backup Application
Security Assessment Service
System Upgrade Service
Application Enrichment
Alarm Management Services
Control Performance Improvement
DeltaV Evergreen Program
Integration Testing Services
System Life Planning For more information:
Training SureService.com
Premiere Service
15

16. If you found this brochure valuable, we also © 2007 EmersonProcess Management, LLLP. All rights reserved.
recommend the following brochure:
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Rosemount, AMS, Ovation, SmartProcess, and the Emerson Process Management design are marks
Emerson Automation
Contracting brochure owned by one of the Emerson Process Management legal entities. All other marks are the property of
for your project planning, design their respective owners.
and implementation needs.
The contents of this publication are presented for informational purposes only, and while every
Visit: effort has been made to ensure their accuracy, they are not to be construed as warranties or
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