Hydrocarbon and Energy Industry Center



		*Click here for a printable version of this information. (.pdf format - 116 KB) Emerson Process Management offers system and instrument hot cutover services that consistently provide our clients with tangible operational benefits. Our solutions mitigate risk, reduce downtime, enhance performance, and improve our clients’ bottom lines.
	The Challenge

	Because most plants operate continuously, an extended shutdown of a process unit is not feasible for the replacement of the control system or instrumentation. Turnarounds often serve as opportune times for performing upgrades. When starting up an entire unit after a shutdown or turnaround, all process control loops must be tuned and placed in automatic control during startup. Startups can be time-consuming, expensive, and dangerous.

	The Solution

	Emerson Process Management personnel safely cut over plant control loops and systems, while continuing plant operation. Our processes for online cutovers (i.e., of one loop at a time) are more manageable than starting up an entire unit after a shutdown or turnaround. We accomplish hot cutovers through significant planning between our project team and our clients’ plant operations personnel. The result is safely maintained production throughout the hot cutover commissioning phase.Emerson Process Management personnel provide:
	• Feasibility Solutions — Our clients have the ability to replace non-critical instrumentation and systems while continuing to operate their plant. This results in cost benefits, due to minimized shutdown for critical loops, flexible timing, and continued product revenue streams.
	• Reduced Safety Risk — Our communication plan enables our team to communicate with clients to ensure safe coordination during the hot cutover work. Emerson Process Management personnel follow daily communication procedures to ensure that all plant personnel and project team members are aware of the work being performed.
	• Reduced Project Risk — Emerson Process Management has a standard program for each piece of instrumentation, which is based on years of experience in executing hot cutovers. Our project management program for hot cutover, front-end engineering design (FEED) studies, and main automation contractor (MAC) services ensures consistent project leadership
	.• Reduced Environment Risk — Emerson Process Management has established procedures to ensure that all equipment is properly isolated and purged prior to being cut over. Our team communication plan ensures that all activities are clearly communicated and planned before project execution.
	• PlantWeb® Expertise — Emerson Process Management leads the industry with our PlantWeb architecture and support of smart field instrumentation, from HART® to FOUNDATION™ fieldbus. We select the right hardware for the application; safely and properly install the equipment; and commission the instruments for optimal performance, without sacrificing reliability or safety. In addition, AMS™ Suite: Intelligent Device Manager builds a database of equipment and information, including configuration and calibration test definitions with remote device status checking; AMS™ Device Manager delivers proven benefits in startup and commissioning that are critical in a hot cutover. AMS Device Manager:
	- readily checks that the device configurations (i.e., as received) match the specifications
	- configures instruments quickly, and requires fewer people- verifies that the right device is connected and ranged correctly
	- verifies that each device has the appropriate construction materials for the application
	- ensures that all devices function as a system, whether checking interlocks, stroking valves, or verifying alarm points on field devices
	• Added Process Control Functionality — Our tuning solutions prepare the plant to withstand a disturbance during a cutover; our solutions provide embedded tuning functionality within the DeltaV™ System to tune the control system for optimal plant performance after the cutover. DeltaV Tune is used to enhance loop performance, which often results in higher-quality products, increased production, increased profits, and avoidance of environmental and safety issues. One great advantage of using DeltaV Tune on a control system upgrade project, is that it reduces the time needed to tune a loop, from several hours to as little as 10 to 15 minutes. DeltaV Tune is included in every DeltaV system.

	The Benefits

	Our services and solutions enable our clients to optimize processes and communication, throughout each phase of a project, to provide easier transitions to new automation platforms. Benefits include:
	• cost reductions, due to minimized shutdown/turnaround periods for critical instruments and safety systems
	• safety risk mitigation
	• established project management processes
	• unmatched automation and field instrumentation expertise
	• added process control functionality embedded within the system
	• added assurance that devices function as a system• added buffers against system disturbance during a cutover

	Technology Expertise

	Our experience encompasses all automation and information technologies, including:
	• process automation and safety systems
	• enterprise information and communications systems
	• optimization of plant processes, equipment assets, and business processes
	• fiscal measurement systems

	Before cutovers, a detailed audit of the existing instrumentation is required. Our team begins work on non-critical loops to ensure that they are operating cohesively. Beginning the cutover process with “easy” loops, such as indication-only temperatures and off-sites, enables the team to adapt to and navigate about the new control system in a low-risk environment.
	Cutovers of safety instrumented systems (SIS) loops have additional risk, because they are designed to shut down the process instead of control it. Because the sudden shutdown of a portion of a process unit can cascade disturbances throughout the unit and even the facility, many refinery SIS were originally designed to require power to actuate. Today, most continuous processing facilities adopt SIS that actuate on loss of power. This usually requires careful replacement of the actuating device (e.g., solenoid valve, relay); plant management may decide against hot cutovers of these devices. Typically, critical control and SIS loops are changed over offline during a scheduled shutdown.Emerson Process Management personnel have the expertise to handle any type of cutover situation.

	Experience

	Our process and automation experience encompasses the refining, chemical, life sciences, pulp and paper, power, and food and beverage industries.

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