AUSTIN, TEXAS (March 21, 2011) – The Danube Refinery of the MOL Group, Budapest, Hungary, has been named the 2010 HART Plant of the Year by the HART® Communication Foundation. This marks the fourth year out of the last six where Emerson Process Management technologies have played a key role at plants winning the award, which recognizes sites around the globe that are using the advanced capabilities of HART communication in real-time applications to improve operations, lower costs, and increase availability.
MOL’s Danube refinery was selected for the 2010 award because of its commitment to establishing a predictive and proactive maintenance program.
“It is always more cost effective to eliminate a problem before it develops than to replace a malfunctioning asset,” said Gábor Bereznai, head of instrumentation control & electrical at the Danube Refinery. “Emerson’s technologies and the expertise of their team working alongside our people have been key to helping us drive down costly maintenance issues and create a safer environment.”
Emerson’s AMS Suite predictive maintenance software provides easy access to the diagnostic data generated by more than 30,000 HART instruments throughout the refinery, including Rosemount® measurement instruments and Fisher® FIELDVUE™ digital valve controllers. Refinery personnel are able to minimize downtime through early warning of field device issues, improving profitability by millions of dollars each year. In just one case, preventing the unnecessary removal of a functioning control valve avoided an unscheduled shutdown, saving the refinery $840,000 USD.
To better leverage this diagnostic information, the refinery launched an initiative in 2005 to establish a standard maintenance strategy for all units. By 2010, AMS Suite was continuously monitoring about 3500 HART devices transmitting data via the HART Communication Protocol. Online diagnostics drive the predictive maintenance strategy for scheduling asset repairs based on operating condition and importance to the overall operation. Emerson’s portable Field Communicators are used to configure and gather data from devices not yet online. The information from the Field Communicators is uploaded into AMS Suite and the predictive maintenance environment built by MOL.
Predictive asset management also helps maintain the stable operation of critical control valves. Inaccurate control loops – often caused by valve detuning – can be identified by using the HART-enabled FIELDVUE digital valve controllers. As a result, process control can be improved and the profit-generating capability of a unit increased.
In addition, calibration costs are reduced on instruments throughout the refinery. By using AMS Suite to supply calibration information and routes, maintenance technicians are more efficient, accuracy improves, and the refinery produces better documentation for regulatory agencies.
MOL also uses the automated work notification between their online HART devices and their SAP system. The integration connects critical asset alerts and events with the CMMS to automate maintenance work procedures, increasing maintenance and operational efficiency and reducing the possibility of unnecessary work and human error.
Stuart Harris, vice president and general manager of Emerson’s Asset Optimization business, commented, “We are pleased that MOL is being recognized for their exemplary use of predictive diagnostics through HART technology to achieve operational improvements and quantified business results. This award marks a fulfillment of their vision to create a predictive and proactive maintenance environment and showcases their dedication and commitment to building a world class refinery.”
The HART Communication Protocol is a worldwide instrumentation standard supported by the HART Communication Foundation. The HART Plant of the Year Award showcases companies and their suppliers who demonstrate innovation, excellence, and leadership in using the HART technology.
The MOL Group is a leading integrated oil and gas company in central and eastern Europe with activities including exploration and production of crude oil and natural gas, refining and marketing of petroleum products, transmission of natural gas, and petrochemical production. MOL subsidiaries include one of the leading Hungarian chemical companies, TVK; the Slovakian oil company, Slovnaft; the Austrian retail and wholesale company, Roth; and a strategic partnership with the Croatian company, INA. The Group operates a regional gasoline station network of more than 1000 sites offering six different brands in ten countries.
The HART Communication Foundation (www.hartcomm.org) is an independent, not-for-profit membership organization that provides global support for the application of HART technology. The Foundation is the technology owner, standards setting body and central authority on the HART Communication Protocol, establishing and controlling new technology developments and enhancements that support the needs of the process automation industry. Founded in 1993, Foundation membership includes more than 245 companies worldwide. The HART Protocol is the leading communication technology for smart process instruments with more than 30 million devices installed worldwide.
Emerson Process Management (www.EmersonProcess.com), an Emerson business, is a leader in helping businesses automate their production, processing, and distribution in the chemical, oil and gas, refining, pulp and paper, power, water and wastewater treatment, mining and metals, food and beverage, life sciences, and other industries. The company combines superior products and technology with industry-specific engineering, consulting, project management, and maintenance services. Its brands include PlantWeb™, Syncade™, DeltaV™, Fisher®, Micro Motion®, Rosemount®, Daniel®, Ovation™, and AMS Suite.
Emerson (NYSE: EMR), based in St. Louis, Missouri (USA), is a global leader in bringing technology and engineering together to provide innovative solutions to customers in industrial, commercial, and consumer markets through its network power, process management, industrial automation, climate technologies, and tools and storage businesses. Sales in fiscal 2010 were $21 billion. For more information, visit www.Emerson.com.
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