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Emerson Global Users Exchange

Let's Do Better: How to Improve Project Performance

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Emerson’ Project Certainty

Emerson’s concept begins with an early engagement in engineering and design studies to define the project goals and effective strategies for a successful implementation. It offers unique and reproducible options for cost-saving, reducing the complexity and project modifications in late-stage — also in the area of automation, said Xavier Marchant, Vice President of Process Systems and Solutions, Emerson Process Management Europe.

For instance, Project Certainty depends on a specially developed engineering strategy for eliminating 70 to 80 percent of the required space for a central control system. Piping can be shortened in some applications by around 50 to 60 percent. In addition to this, tens of millions of dollars can be saved on capital-intensive spare parts through a project-extensive reliability analysis of the equipment.

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Furthermore, Project Certainty decouples dependencies between suppliers, eliminates bottlenecks and allows parallel work flows. Emerson overcomes the complexity of data and documentation with the help of innovative technologies, which provide for functions like project data from a particular source as well as automated documentation. With respect to one of the biggest weaknesses project management, Project Certainty significantly improves the schedule performance. Technologies like Electronic Marshalling with Charms and pervasive field instrumentation should help the project teams while integrating unavoidable last-minute-design modification — without disturbing the schedule.

The following example shows how Emerson’s automation technology has helped Sasol in more than a tripling of its chemical production in the USA.

Mega-Automation Project with Sasol

Sasol chose Emerson for the automation of its 8.9 billion dollar petrochemical complex in Lake Charles, Louisiana, USA, which used abundant, cost-effective natural gas. The automation project is one of the largest projects so far, which was contracted to Emerson. With its completion in 2018 the petrochemical complex is expected to increase Sasol’s production capacity in the USA to more than threefold. It includes an Ethane cracker with a capacity of 1.5 millions of tons of ethylene per year as well as six plants for further processing of ethylene in a wide range of chemicals.

Emerson executed a detailed engineering- and project implementation plan, in order to mitigate the project risks, reduce the costs and to speed up the completion — all a part of the strategic Project Certainty initiative. “For a huge project like this, managing the budget and schedule is of utmost importance,” said Jim Nyquist, Group Vice President of Emerson. “This is an excellent example for our Project Certainty initiatives. Early engineering and design works were used to identify the options of automation technology for reducing the complexity, for cost-saving of the project and for minimizing the risks with regard to planning and calculation. When the project entered the execution phase, Emerson was well-positioned to execute the design, to incorporate any last-minute change and minimize on-field work — all of this was done rapidly and without compromising the quality, security and reliability.”

The integrated solution by Emerson comprises Emerson’s distributed control system Delta V, the process security system Delta V SIS and the AMS-Suite software for predictive maintenance for monitoring and controlling the processes and equipment of every device. Moreover, Emerson provides measurement technology and analytical technology of Micro Motion and Rosemount as well as control valves and controller for important measurement and control functions.

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