BP Chemicals Commissions Emerson Process Management's PlantWeb to Automate New $100-million Plant

Business Wire, May 8, 2001

Business Editors & High-Tech Writers

LIMA, Ohio--(BUSINESS WIRE)--May 8, 2001

Project Makes Broad Application of "Control in the Field" Using

FOUNDATION(tm) fieldbus

BP Chemicals Inc. has commissioned Emerson Process Management's PlantWeb(R) field-based automation architecture for a new $100 million chemical plant in Lima, Ohio.

The new plant produces 1,4-butanediol (BDO), a chemical compound used in specialized fibers, plastics and adhesives.

PlantWeb architecture is the innovative automation solution of Fisher-Rosemount, now doing business as Emerson Process Management, the process business of Emerson (NYSE:EMR). The architecture brings to the project what is believed to be the most extensive use to date of distributed automation control using FOUNDATION(tm) fieldbus standards. Developed by the Fieldbus Foundation, a consortium of more than 100 companies from around the globe, the standards provide for interoperability of instrumentation in process systems.

The PlantWeb installation at Lima distributes process-control logic to the plant's field devices rather than centralizing control in traditional computer control systems. The resulting benefits include cost savings from design flexibility due to the open, standards-based technology and broad functionality of field devices, as well as greater system reliability without the need for costly redundant components.

"In designing this new plant we wanted to avoid older analog communications or proprietary digital buses and instruments," said John Rezabek, controls specialist at BP Chemicals' Lima Complex. "These would reduce our design flexibility, inflate life-cycle costs, and complicate upgrades."

In the project's extensive use of FOUNDATION fieldbus, control algorithms -- the mathematical logic on which the automation system is based -- operate in 83 of the system's 85 Fisher FIELDVUE(R) digital valve controllers. Another 71 fieldbus segments serve 350 Rosemount, Rosemount Analytical, Micro Motion, and Fisher instruments and valves.

Rezabek noted that the new field-based architecture leverages the full extent of FOUNDATION fieldbus' capabilities, which are built into the PlantWeb architecture, rather than being patched into an existing control system.

"Our desire to extensively distribute logic control throughout the system required us to re-evaluate the entire concept of process control reliability," said Rezabek. "Achieving high reliability with these distributed technologies is different from achieving it with a traditional process control system. Our rigorous analysis demonstrated that redundancy no longer is the cornerstone of these systems. PlantWeb and FOUNDATION fieldbus give us a new path to achieve high reliability with less complexity."

Operation of PlantWeb architecture's DeltaV(tm) automation system was configured graphically by simple drag-and-drop methods that are widely familiar to Windows users.

"PlantWeb is providing superior visibility," Rezabek said. "Operators can see valve movements on their displays, which is very helpful when balancing flows or determining if a valve is poorly tuned or sluggish."

Installation costs in the project were minimized through pre-engineering of logic functions, avoiding the need to write extensive computer codes, and advance calibration of valves and instruments.

Emerson Process Management (www.emersonprocess.com), an Emerson business, is a leading supplier of process management solutions that help automate, control and manage complex plant processes used in the chemical, oil and gas, pulp and paper, 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 tailored solutions reduce capital project costs, integrate information for decision-making, manage plant processes, and maintain reliable equipment for highest plant performance and availability. Emerson Process Management includes the following branded products: Fisher Controls, Micro Motion, PlantWeb, Rosemount, and Westinghouse Process Control.

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 2000 were $15.5 billion.

PlantWeb, DeltaV, and FIELDVUE are marks of one of the Emerson Process Management divisions. FOUNDATION is a mark of the Fieldbus Foundation.