Smarter instruments add up to better maintenance for Mitsubishi Chemicals

PublishTime：2022-03-22

Control system health management is a game best played all-in. Control loop problems do not just occur in the sensors or the transmitters or the connections to the host-it's best to take an approach that will help anticipate, identify and diagnose trouble wherever it might occur.
Mitsubishi Chemical's Kashima plant processes naphtha into ethylene, propylene, cracked oil and downstream products. The plant's innovative use of HART communications, Rosemount 3051 transmitters with internal diagnostics, and Emerson Process Management's AMS Suite asset management software led to its selection in 2009 as HART Plant of the Year. The plant continues to find new ways to save thousands of man-hours while paring unplanned downtime.
“Our most common maintenance issues are control valves and transmitters. Our sticky resin causes valves to stick and transmitter signals to become non-linear,” said Atsushi Kondo, instrumentation and maintenance group, Mitsubishi Chemical, presenting the session “Mitsubishi Chemical Uses Diagnostics and Smart Maintenance to Reduce Costs and Improve Uptime” with Takayuki Aoyama, instrumentation and maintenance group manager, Mitsubishi Chemical and Bill Zhou, Asia Pacific product manager, Rosemount, at this week's Emerson Global Users Exchange 2015 in Denver.
When issues with valves or signals occurred, the plant used to call the maintenance engineers, who would then check the DCS, loop and devices; analyze the gathered information; then find and then fix the abnormal value or status. This procedure is labor-intensive and time-consuming, often resulting in a shutdown. Instead, AMS can perform the same preliminaries as the maintenance engineers, saving labor and reducing lost production.
“AMS monitors all of the devices,” Kondo said. “By the time the maintenance engineers arrive, they already know all the information.” He walked attendees through examples of three common plant issues and described how the company applied automation to overcome them.

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Language：	English Chinese Chinese and English Japanese
Date of Creation：	October 23 2015
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