Real-World Benefits of Digital Transformation

TopWorx D-Series discrete valve controllers with HART are certified for use in every world area for continuous performance monitoring

A large petroleum refinery off the coast of Wales digitally transformed their operations using Emerson’s TopWorx^TM DXP discrete valve controller with HART. While the refinery came to Emerson with solenoid valve (SOV) problems, it was attracted to the advantages the DXP provides. Emerson helped the refinery solve its SOV challenges and future-proof its site for full diagnostic capabilities. With the DXP, the refinery now receives the valuable benefits from continuous performance monitoring, standard HART features and much more.

Future-proofed access to critical data

Refineries can have areas that have yet to integrate HART infrastructure or easily accessed power sources where data can be stranded. The DXP is engineered with GO Switch technology, and its feedback can be independent of the HART signal or both HART signal and wired switch. Using the TopWorx GO Switch, plants can connect wirelessly via a Rosemount 702 wireless discrete transmitter or other wireless controller, connecting otherwise digitally stranded parts of the plant. Unlike a typical proximity switch, the Go Switch does not need power to sense its target or signal, and the Rosemount 702 has an internal power source that can last up to two years.

Reduced downtime

The refinery can now quickly determine real-time valve health even in areas where HART infrastructure is not yet in place, which can significantly improve uptime. Personnel can use Emerson’s AMS Trex device communicator to access the device’s HART internal electronic to identify the device by using the HART digital TAG option as well as perform tests on the valves and monitor parameters. This capability can save hundreds of hours of expensive downtime by accurately indicating if the valve requires maintenance or not. The digital TAG also prevents a line of switchboxes from being mixed up, which can be a major issue with standard valve assemblies.

Extended component life

The refinery’s existing direct acting SOVs easily corroded, which can cause premature failure. The refinery selected Emerson’s ASCO^TM Series 327 direct-acting solenoid valves to replace them.  Where the existing SOV breathed to the marine atmosphere allowing ingress, the Series 327 does not breathe to atmosphere, keeping the elements out and corrosion at bay.

Increased energy savings

Energy consumption is critical to a refinery’s sustainability, and every way to reduce energy consumption and carbon footprint matters. In addition to longer component life, the new Series 327 SOVs consume a lower wattage. The series range offers an Ex d direct acting valve at less than 2 watts, which can save more than 10 watts per SOV. The yearly energy savings is approximately 87.6 kilowatt-hours, or 185 pounds of carbon dioxide, per SOV. As average refineries have hundreds of SOVs, the multiplied savings is a substantial advantage over higher wattage SOVs.

For additional information, please contact Mike Howells, process marketing manager, Europe, at Emerson: Mike.Howells@Emerson.com.

To meet with an Emerson Expert atValve World, visit Hall 1, Stand C52:  https://www.emerson.com/en-gb/news/automation/vw-2022

Tel No:      01695 713600
Email:       Enquiries.asco.uk@Emerson.com 
Website:   www.emerson.com 

Published: 3rd November 2022