Automation System ModernizationRegain your competitive edge.

2

With today’s increasing global competition and rapidtechnological advances, many plants around the worldhave legacy automation systems that aren't able to keepup with today's production demands.

Better plant performance begins with better automation.And, with today's digital technologies you can expectincreased productivity and better communicationsbetween your process information and your businesssystems.

2 Correcting Missed OpportunitiesRegaining your competitive edgethrough modernization.

4 Why modernize with Emerson How Emerson delivers moreperformance for a moreprofitable plant.

6 Starting Out with a Solid Plan Build a business case based on OPEXand CAPEX for the life of your plant.

8 Global Standards and Best PracticesManage your modernization withglobal project experience.

10 Maximize AvailabilityMinimize your downtime duringmodernization with Emersontechnology and expertise.

12 Maximizing ROI Get more from your automationinvestment with Emerson’s world-class training and simulation tools.

14 Sustained Improvementand SupportA flexible portfolio of industryleading support in your city andaround the world.

CONTENTS

“Emerson is widely

recognized as today's

leader with respect to

process instruments

and automation

systems. We expect to

benefit greatly from

their experience in

applying these

technologies to the

processing of bitumen,

integrating the

engineering phase of

the project, and

bringing state-of-the-

art efficiency to the

operation of our

upgrader.”

Robert PearcePresident

North West Upgrading Inc.

3

When should you consider system modernization?Yesterday’s systems may have been a good investment, but today’stechnology and expertise provide opportunities and benefits that justweren’t available when these systems were designed. You should considera modernization when:� Production & energy costs keep rising� Inventories of raw materials and finished product pile up� Product quality is inconsistent and customer complaints increase� Start up and product grade changes cost more than they should� Plant trip and alarm systems are unreliable and/or inadequate� Production is inflexible and start-up time is lengthy� Recurring emission problems are constraining throughput� Business systems lack meaningful plant floor production data � Customers are demanding more but your plant cannot deliver:

� more specialized products and packaging� tighter quality specifications or delivery times� better service

� Obsolete system support costs continue to increase.

What are you missing?You may want to consider how your system (and your current automationsupplier) would respond to:� Plant expansion (including bus-based or wireless I/O) for improved

plant diagnostics and increased plant uptime � Reducing variability to establish a foundation for advanced controls

and process optimization for better throughput and yields� Providing field service alerts to operators and/or maintenance,

improving response times to specific needs� Integrating DCS information with your business systems for more

informed and timely business decision-making � Integrating predictive maintenance practices to focus your

maintenance resources, saving time and money.

See how Emerson’s digital technologies and expertise enable the safestand most scalable path to on-going capital expense and operationalexpense savings.

A legacy of lost opportunities.

For more information:� EmersonProcess.com/

Solutions

Take advantage ofEmerson’s experiencewith thousands of processautomation projectsworldwide.

Automation leaders The keystone to Emerson’sautomation technology leadershipis the proven PlantWeb® digitalplant architecture, an openstandards-based digital solutionthat networks intelligent fielddevices, digital systems, andsoftware, controlling processes andmanaging equipment and otherassets. Embedded, advancedcontrol means a more efficient,consistent, available and optimizedoperation.

Emerson’s commitment to openstandards, highlighted by ourdonation of the HART protocol in the1980’s, continues today with ourwork on FOUNDATION fieldbus andwireless standards.

Modernize formeasurable resultsHighlights of customer measurableresults in thousands of PlantWebinstallations worldwide include:� 30% increase in capacity without

additional personnel� 10% increase in throughput� 20% reduction in raw material

usage� 15% reduction in rework� 50% reduction in maintenance

costs with remote diagnostics� New high-margin products never

before possible� Control room space requirement

reduced as much as 85% � Automation investment payback

in less than 4 months.

Leaders in service Emerson’s global network ofengineers and consultants has thereal-world industry and processautomation knowledge to help youdesign, plan and implement yourautomation concept with:� Modernization and migration

consulting� Fieldbus consulting� Process safety management� Human factors optimization� Production information

management� Advanced automation &

optimization� Plant system security.

Reduce your riskWith PlantWeb, you can achieve aneffective program for managingsafety, health, and environmentalrisks and costs—one that goesbeyond abnormal situationmanagement to abnormal situationprevention.

AMS™ Suite: Intelligent DeviceManager gives you key online accessto your instrument and valveprocess information, diagnosticstatus information, and automaticdocumentation of all field devicemaintenance information. AndDeltaV™ SIS, at the heart ofEmerson’s smart SIS, works withAMS to continuously diagnose yourintelligent field services and safetyfunctions. This helps ensure yourprocess shuts down only when it should.

Why modernize with Emerson?

4

“We looked for a

company that had the

right technology and

also a strong support

network that would

be available to us. We

selected the

PlantWeb digital

plant architecture

from Emerson Process

Management. We

also selected Emerson

as our main

automation

contractor because of

its proven project

management

experience and

intimate knowledge

of the technology we

had selected.”

Evelio Hernandez, Process Control

Systems Manager

5

Better performance.

Operating on the leading edgeProcess manufacturers losemillions of dollars each year dueto process variability and poorcontrol performance, oftenunaware that a problem exists.The powerful new DeltaV InSightmonitors control performance;identifies and diagnoses problemloops; recommends tuning andmaintenance improvements; andcontinuously adapts to changingprocess conditions.

Often, fewer than 10 modulescause 40% or more of alarmactivations. So by addressing justa few alarms, you can significantlyimprove operator alarm loading.DeltaV Analyze makes it easy tofind the most frequently occuringalarms.

Manufacturers have real issueseveryday that effective wirelesssolutions can help solve.Emerson’s Wireless SmartPack™

helps you create a secure networkright out of the box, giving youconvenient access to informationyou simply don’t have today.

For more information:� EmersonProcess.com/

PlantWeb� EmersonProcess.com/

SmartWireless� EasyDeltaV.com

Emerson Process Management was again voted the bestsupplier of process management technologies in CONTROL

Magazine’s 2007 Readers’ Choice Awards. This is the14th consecutive year that Emerson has captured

the user-voted recognition.

ARC and Control Magazine also placed Emerson as #1 on their Top 50 Automation Companies List.

How do I get started?

6

Emerson experts andtechnology help youevaluate where you areand plan where you’regoing.

The challengeSelecting the right technology,the right partner, the rightimplementation plan and theright budget minimizes risk.Emerson offers unparalleledcapabilities to help you set thestage for a more profitable plant.

Building the businesscase for modernizationEmerson works with you and yourteam to help you define and justifya migration path based on yourbusiness and productionperspectives. This often beginswith a review that includes allappropriate plant and corporategroups to establish business goalsthat could include:� Increased availability� Reduced manufacturing costs� Increased throughput� Reduced plant emissions� Improved quality� Improved ability to introduce

new products� Improved response to customer

demands� Increased safety.

Based on your business objectives,a site assessment , tailored to yourneeds, defines performancecriteria:� Key process measurements� Process constraints and

limitations� Process disturbances� Equipment or operational

limitations.

Planning for yourspecific needsThe site assessment feeds aprocess automation feasibilitystudy used to develop the processautomation modernization plan.

This study includes a cost/benefitanalysis based on both CAPEX andOPEX over the lifetime of thesystem. This defines the businesscase and helps you answer thequestion: “Will improving myprocess automation improve mykey performance indicators ?”.

This plan may cover:� Migration to a new automation

system� Process modifications� Additional instrumentation� Improved regulatory and/or

advanced control strategies� Safety, environmental and

equipment protection� Information integration� Asset management.

An Emerson modernization planwill consider a variety of migrationtypes and specific needs, andinforms you of viable and profitableoptions for your system: � Full system upgrade -

controllers, I/O and consoles � Controller upgrade using I/O bus

interface� Upgrades that work with your

existing controllers and I/0� Console upgrade� Advanced control implementation� Historian consolidation.

Your plant: An asset to perform

With a solid business plan.

2007 Frost & SullivanCompany of the Year

Award for Industrial

Automation andProcess Control

“The global footprint

of the company and its

outstanding

engineering capability

coupled with a sound

business process

empowers Emerson to

deliver the same

benefits at all

customer locations.”

Kishnan M. BhatIndustry Manager

Frost & Sullivan

7

For more information:� EmersonProcess.com/

Solutions/ProjectServices

ance

Front-end engineeringand designOnce a process automationmodernization plan has beendeveloped, Emerson’s world-classteam of automation expertscontinue to work with your keystakeholders to develop a Front-end engineering and design(FEED) plan.

An Emerson FEED study is thefoundation for a controllable andprofitable project making certainthat your design meets your orga-nization's overall needs by:

� Ensuring that the design meetsyour project’s time, budget,ROI and operating cost criteria

� Setting scope boundaries byquantifying and justifying theinvestment required for a givenbenefit

� Preventing unnecessarychanges through better changemanagement

� Identifying and providing forproject risks

� Achieving fasterimplementation of technology.

The FEED package would typicallyprovide a Project Execution Planwith the following elements:� Safety and Environment Plan� Quality Plan� Master Project Schedule� Staffing Plan� Project Controls Plan� Project Communication Plan� Hot Cutover Plan� Turnaround Plan� Installation Management Plan.

Emerson total valueEmerson’s FEED capabilities arepart of a total value propositionto create smart plant solutionswith proven benefits:� Lower capital expenditure to

reduce automation costs 20% -30%

� Faster time to profitability� Increased profitability� Superior system manageability.

Precise control over yourproject at a time ofmajor change is criticalto maintaining plantoperations and businessobjectives.

Detailed processes andglobal standardsEmerson integrates globalstandards and best practices inproject management processes.Project deliverables includedocumentation, support tools,and technical standards that helpreduce errors and omissions inbudgeting, scheduling, training,and maintenance.

Emerson's project managementwork process is built upon therecommended best practices ofauthorities such as ConstructionIndustry Institute (CII), ProjectManagement Institute (PMI), andIndependent Project Analysis (IPA)methodologies.

Global standards in this contextrefer to standard, modular, pre-tested pieces of automation likecontrol modules, equipmentmodules, phases, etc.

These standards:� Incorporate accumulated

knowledge and best practices � Help facilitate communication

between team members� Shorten the learning curve for

new project team members� Include a customer feedback

mechanism for continuousimprovement.

Our project managers have thetraining and experience to deliverconsistent results: � Highly effective planning and

design� Excellent change management� Strong performance to

budgets; both time and cost� Optimized product and

technology benefits� Highly efficient

implementation � Risk containment� Smooth startups and

commissioning� Faster ramp up to full

production.

Expert implementation Emerson’s engineering teamshave strong advanced technology,integration and optimizationexpertise targeted atmodernization.

Conversion Services and utilitiesConversion services for graphics,database, and otherconfigurations are available tohelp minimize switching costs andreclaim the value of your legacysystem investments for use withthe DeltaV system.

Focused conversion serviceengineers are dedicatedresources, familiar with commonerrors and best practicesregarding conversions. Theirexpertise covers all aspects of theautomation project includingoperator interface, batcharchitecture, continuous control,devices and I/O, and integrationwith external systems.

Emerson has extensiveinvestments in conversion utilitiesthat make conversion servicesefficient and accurate withoutextensive or unnecessary rework.

How do I manage risk?

8

Scalable automation services

With a wealth of experience.

Platform expertiseEmerson has invested in legacysystem domain experts for avariety of platforms, includingnon-Emerson systems. Theseexperts understand how toaddress system-specific intricaciesfor successful migrations.

Connectivity servicesEmerson has the services and toolsto connect your new automationsystem to existing advancedapplications and productionsystems. One example is an auto-tag conversion tool that helpsmigrate existing layeredapplications over to newertechnologies.

Vertical integrationEmerson’s family ofinstrumentation delivers valid,actionable field information to theDeltaV system’s suite of operationsmanagement, advanced control,and asset managementapplications. Valid plantinformation in advance of a plantevent or upset is the essence ofabnormal situation prevention(ASP). Rather than attempting tomanage operational incidents, ASPis focused on preventing the lossesassociated with facility upsetsaltogether.

Optimization servicesAsset optimization services helpwith asset prioritization, criticalasset reliability improvements, andmaintenance work processdevelopment. We provideassistance to maximize asset valueextraction, performanceimprovement and optimization,technology deploymentimprovement, integration ofmaintenance and performanceinformation-driving keyperformance indices in the rightdirection.

Variability managementProcess variability eats away atproduct quality and plantavailability and wastes rawmaterials and energy.

Variability management consultingservices provide a comprehensiveholistic approach to minimizingprocess variability for optimalcontrol performance.

Client engagements are performedby senior professionals who havean in-depth understanding ofprocess dynamics, controlequipment, and control strategies.They use systematic and scientificmethods of control design, looptuning, and processtroubleshooting.

For more information:� EmersonProcess.com/

Solutions/Consulting/VariabillityManagement

“Emerson's goal is to

design a reliable,

advanced instrument

and control system to

assure safe, stable, and

long-term quality

operations while

maximizing the

profitability of the

company. Emerson has

proven technologies

and a proven track

record in China.

Emerson’s local

resources and the

support of its global

resources help to

mitigate and minimize

risks for owners.”Hongye Hu

MICC ManagerFujian Refinery

August, 2007

9

Emerson’s solutions andexperience give youchoices for implementingyour modernization.

Options for modernizationWhether you’re migrating to a newautomation system during aturnaround (cold cutover) or whilethe process is up and running (hotcutover), Emerson projectpersonnel work with youroperations team to carefully planand safely implement yourmodernization plan while savingvaluable production time.

In one example, three keyPlantWeb technologies were usedin the process to help perform ahot cutover from pneumaticcontrol to FOUNDATION™ fieldbus.The FIELDVUE® DVC6000f, withits unique pressure controlfunctionality, allows a fieldbusconnection to the DeltaV systemwhile also sending a pressuresignal to the existing actuator orpneumatic positioner. Oncepressures are balanced within thesystem, control is transferred tothe digital valve controller.

During this phase, AMS Suite:Intelligent Device Manager,helps reduce the risk in finalizingthe hot cutover by enabling localcommunication with the valve tomonitor exactly what ishappening during the process ofmounting, adjusting, stroking,and calibrating the valve.

Each piece of instrumentation hasa special cutover procedure,based on years of experience inimplementing cutovers. AMSDevice Manager is used by theteam to help coordinate theseprograms, reducing project risk by:� Verifying device:

� configurations matchspecifications� connection and ranging� construction materials

� Ensuring that devices functionas a system, whether checkinginterlocks, stroking valves, orverifying alarm points onfield devices

� Minimizing device configurationand implementation times.

How do I minimize operational impact?

10

Flexible automation solutions

Any way you need to.

Flexible solutionsA number of other Emersonsolutions help to save time andprevent disruption while givingyou flexibility during a systemupgrade. These technologiesallow DeltaV Operator Stations tobe added to a variety of legacysystems with the process onlineand used side-by-side withexisting consoles while theprocess continues to run.

You can also add DeltaVcontrollers at any time and thesecan co-exist with your legacysystem while allowing you to takeadvantage of technologies suchas predictive field deviceintelligence, embedded advancecontrol, and integrated assetmanagement.

With these flexible solutions,FOUNDATION fieldbus and otherdigital busses such as HART,Profibus DP, DeviceNet and AS-ibus can be easily integrated withyour existing legacy equipment.

Switchover savingsAs you replace and upgrade yourlegacy controllers and I/O withDeltaV components, get fastswitchover while retaining yourtermination panel and wiringinvestments.

Our solutions use existing legacyfield wiring terminations for theDeltaV system without lifting orremoving wires. These solutionscan:� Save your existing wiring

investment� Speed startup by not disturbing

field connections� Reduce process downtime by

75% or more comparedto rewiring.

Reduce risk with DeltaV Simulate With DeltaV Simulate, you candevelop and fully test controlstrategies in an offline laptop ordesktop PC environment. You canverify all your DeltaVconfigurations before youmigrate control. With add-onsoftware such as MiMic® I/Osimulation, you can also checkoutI/O before connecting live.

“Emerson’s

experience really

made a difference in

the planning and

implementation of the

hot cutover to our

new control system.

Their digital

technology was also

critical as they worked

with us to install and

commission 1100 new

instruments. This

project was under

budget with no OSHA

or environment

incidents. You cannot

get much better than

that!”Bob Sherven

Project ManagerShell Deer Park Refinery

11

For more information:� FIELDVUE.com� EasyDeltaV.com� EmersonProcess.com/AMS/

index.htm� EmersonProcess.com/

Solutions/Migration

12

Emerson’s trainingsolutions deliver skilledoperators andoperational excellenceanywhere in the world.

Start with the basicsPlantWeb University facilitatesyour understanding andevaluation of new ways toimprove project, process, andplant performance. PlantWebUniversity provides practical, real-world information about how toimprove process and businessperformance to over 20,000industry users around the world.

Get more from yourautomation investmentTo remain competitive,companies need a highly skilledworkforce, equipped with theknowledge, skills, and ability totake action and be proactive.Emerson’s Educational Servicesteam has been training industryprofessionals around the world forover 65 years with:

� 44 fully manned and equippedtraining centers

� 120 full-time and 45 part-timeprofessional staff

� Over 20,000 students trainedannually.

Hundreds of courses and trainingsolutions are available for everylevel of your organization fromfront-line technicians, to

operations, engineering andmanagement. Our diverselearning methods range fromgeneral classroom offerings to in-plant customized training.

Recent eLearning courses toconsider are DeltaV OperatorInterface for Continuous Controland Fisher Valve Fundamentals.These new on-line courses allowyou the opportunity to learn aboutthese products at just the righttime for you.

New equipment and technologiesmean you need to recalibrate youroperations and maintenanceprogram; we can show you how.Training to consider during amodern ization can include:

� Simulation-based operatortraining

� Control engineer training� Process operations training� Digital bus training� Safety Instrumented Systems

training� Smart wireless training� Advanced control and

optimization training.

How do I maximize return on investment?

“ The courses are very

helpful and provide

loads of knowledge. I

actually enjoy the

courses and look

forward for new

topics.”

“ Very good technical

overview of the

process digital

world.”

“ Definitely worth the

time spent. A lot of

good practical tips

and suggestions.”

“ I think everyone

who is involved in the

field or engineering

should review the

courses....”

13

With world-class training.

DeltaV OTS Training A key concern when modernizing aplant automation system is thatyour operators are skilled inmaking the most of this newtechnology.

With the new DeltaV OperatorTraining Solution (OTS) program,our Educational Services team canhelp ensure that your personnelare primed to capitalize on thesetechnologies and unlock the truepotential of your operation.Benefits include:

� Operators are trained beforeactual commissioning takesplace

� Faster, smoother start-ups� More confident and experienced

operators� Reduced incident reporting� Product quality improved faster� A better understanding of

possible failure scenarios� OSHA compliance (Article 29

CFR PAR 1910.119).

Transfer knowledgeand best practicesActual key process events thatoccur on one shift can berecreated with different operatorsand crews. Simulations can bedesigned to capture theexperiences and actions of senioroperators so that new operatorscan learn them.

Real experiencewithout riskOperators will learn DeltaVoperating concepts whileexperiencing a breadth of processscenarios. This new training offersthe benefits of exposing operatorsto a training environment identicalto what they will experience in theactual control room. Benefits tosimulation-based operatortraining are:

� Real experience with no risk� Actual plant configuration

graphics and database� Realistic dynamic process

simulation and scenarios� On-site, 24/7 learning� Custom curriculum and

courseware� Professional instruction and

support� Affordable tiered solutions.

DeltaV OTS ArchitectureFor more information:� EmersonProcess.com/

education� Plantweb.Emerson

Process.com/University

How do I sustain these improvements?

14

Emerson’s SureServiceportfolio contains all theright elements to tailor aprogram to fit yourspecific support needs.

To this end, Emerson hasdeveloped:� A global service organization� Service quality processes� Our global Service Management

System� Our comprehensive portfolio of

automation system lifecyclesupport products.

We meet the expectations of ourcustomers worldwide byconsistently delivering competent,efficient and reliable services ofthe highest possible customerservice. This global consistency ofservice and support fromcertified professionals—bothcentrally-located and local toyou—is what separates Emersonfrom all others. To you, thisdifference means prompt,professional response, nomatter where on the globeyou operate.

Comprehensiveportfolio of supportservicesWe recognize that automationsystem support needs vary fromone customer to another, and thatour customers make investmentsover the system life cycle for threeimportant reasons:� Availability Services to keep your

system running� Application Services to apply the

best PlantWeb technologies� Sustainability Services to protect

your investment in capital andintellectual property.

Emerson’s portfolio of services canbe combined in various ways toaddress your unique needs in eachof these three areas through acombination of factory and fieldresources and local serviceagreements.

The base element for Emersonsystem service agreements isGuardian Support, a prognosticservice designed to optimize theavailability, sustainability andperformance of your DeltaVdigital automation system.

The SureService program consistsof service modules, each designedto address specific supportrequirements. These modules canbe combined to customize asupport program for your plantthat is tailored to fit just right,meeting your support needs whileproviding value and peace of mind.

Guardian Support

The core element of ourSureService support program willhelp you improve staffproductivity while reducingoperations and maintenance costs.

SureServiceSM

“...we’ve seen

upwards of 90%

reduction in

variability on the

operation of the kiln,

which will

immediately give us a

positive payback.”

Jim NorcrossCanadian Forest Products

15

Availability ServicesThese are the basic,essential day-to-day

system maintenance servicesdesigned to help you achieve thedesired level of certainty forsystem uptime, taking yourprocess, system design, and in-house resources into account (seetable).

Application ServicesThese services help youachieve expected results

from the application oftechnology and related workprocesses, while keeping up withevolving business conditions.

Application services can helpensure the effective application ofPlantWeb technology with a focuson prevention of system issuesand overall improvement of plantoperation.

SustainabilityServices

Sustaining yourautomation system such that itcan be routinely supported andserviced is essential to maximizingthe return on your systeminvestment. Sustainability servicescan include identifying, assessing,planning, and implementingtechnology updates and upgradesto minimize system down time,prevent system offsets, andminimize total cost of ownership.

For more information:� SureService.com

SureService Portfolio Availability Application Sustainability

Guardian Support

Project-to-Operations Transition Support

Express Module Replacement

Spares Access Programs

Emergency On-Site Services

Scheduled On-Site Services

Critical Data Backup Application

Security Assessment Service

System Upgrade Service

Application Enrichment

Alarm Management Services

Control Performance Improvement

DeltaV Evergreen Program

Integration Testing Services

System Life Planning

Training

Premiere Service

© 2007 EmersonProcess Management, LLLP. All rights reserved.

The Emerson logo is a trademark and service mark of Emerson Electric Co. PlantWeb, DeltaV,Rosemount, AMS, Ovation, SmartProcess, and the Emerson Process Management design are marksowned by one of the Emerson Process Management legal entities. All other marks are the property oftheir respective owners.

The contents of this publication are presented for informational purposes only, and while everyeffort has been made to ensure their accuracy, they are not to be construed as warranties orguarantees, express or implied, regarding the products or services described herein or their use orapplicability. All sales are governed by our software licensing agreement and terms andconditions, which are available upon request. We reserve the right to modify or improve thedesigns or specifications of our product and services at any time without notice.

Form B-00022 / Printed in USA / 20K AQ / 10K A4 / 09-07

Emerson Process Management12301 Research Blvd.Research Park Plaza, Building IIIAustin, Texas 78759 USAT +1 512.835.2190F +1 512.832.3443

If you found this brochure valuable, we alsorecommend the following brochure:

� Emerson AutomationContracting brochurefor your project planning, designand implementation needs.

Visit:EmersonProcess.com/solutions