TREND REPORT / SPRING 2015

YOUR MISSIONIS TOO IMPORTANT TO FAILThe power industry is facing “perfect storm” conditions that make consistent, reliable energy delivery more difficult. Increased cycling can stress equipment to the point of breakdown and the unpredictable nature of renewables creates spikes in demand for energy from traditional sources. The aging, dwindling workforce is causing a growing knowledge gap and puts added stress on your staff. Shifting environmental regulations are creating uncertainty in regard to costs and hiring, but the transition to natural gas – and adjusting your operations to accommodate that transition – is plainly on the horizon.1

Emerson & Micro Motion Puts You Into the Power PositionHeightened operational readiness, enabled by making proactive adjustments to your power plant that builds agility, can allow you to quickly respond to changing demand. When you partner with Emerson, you can:

Have greater control of process emissions for better environmental compliance Improve plant reliability with better insight into equipment health Manage cycling better to boost operational agility Access the technology and expertise to enhance staff effectiveness

And you can do it regardless of operating profile. We’ve developed this Trend Report so you learn more about how we can help you navigate the changing power industry and establish heightened operational readiness.

Natural

gas-fired

generation

is projected

to grow 3.1 percent a year through 20383

1. http://www2.epa.gov/carbon-pollution-standards/regulatory-actions2.http://www.ey.com/Publication/vwLUAssets/Business_Pulse:_power_and_utilities/$FILE/Business_Pulse_Power_and_Utilities.pdf3.Make Your Plant Ready for Cycling Operations, Power, 2011

What’s more, over the coming decades the power generation industry will face a daunting challenge: meeting rising global energy needs. The U.S. International Energy Agency (IEA) forecasts that China’s demand will rise 60% by 2035, while India is set to more than double.2

G

CASE STUDYSUMMARY > Many coal plants use Flue Gas Desulfurization (FGD) (specifically, a Wet Limestone Slurry process) for Sulfur Dioxide emission reduction. Recently coal plants in Poland and Texas installed Micro Motion Fork Density Meters in their FGD systems to improve performance in meeting environmental compliance.

CHALLENGE > Nuclear densitometers were previously installed on the Lime Slurry process line for the purposes of measuring the density of the slurry. Lime slurry density directly correlates to the effectiveness of the desulfurization process, and accurate measurement of the slurry density allows operators to have more direct control over the process, and is a key measurement to help mitigate lime scaling and maximize limestone utilization.

The nuclear densitometers were installed in a slip stream which was prone to plugging due to the small pipe diameter, and the meters themselves can also experience buildup of the lime slurry on the sides of the meter vessel, leading to inaccurate readings. The meters also did not provide sufficient accuracy to meet the operational needs of the facility, and were routinely recalibrated in an attempt to improve their density measurement accuracy. Furthermore, the nuclear densitometers (a radiation source) were subject to Atomic Energy Commission regulations which required properly trained personnel to exclusively handle all maintenance activities. This was cost prohibitive and ineffective.

SOLUTION > Micro Motion Fork Density Meters (FDMs) were installed in the primary lime slurry process pipe which reduces the likelihood of pipe plugging issues, and can be mounted into a pipe recess which reduces the meter’s exposure to high velocity abrasive slurry. The FDM also provides improved accuracy and more reliable operation than the incumbent nuclear densitometers.

CLICK HERE to find out more about Micro Motion FDM capabilities.

GET PROACTIVETaking pressure off your staff is as important as taking the stress off your equipment. Installing predictive diagnostic solutions opens a window into system performance that keeps personnel out of “fire fighting” mode and improves workplace safety.

Measurement Confidence & Better DecisionsBy combining Emerson asset management software (AMS Suite, including Emerson’s Ovation expert control technology) with Micro Motion Smart Meter Verification (SMV), you’ll optimize flow and density instrumentation performance, reliability and plant uptime. You’ll be able to respond quickly to the temperate loads that current market conditions require, plan downtime and have the measurement confidence you need to make better process and resource decisions.

6. U.S. Bureau of Labor and Statistics, 2010; http://www.csg.org/policy/documents/TIA_Work_Force_Dev_Electric.pdf

Half of the

electric

utility workforce

will retire

within the next

ten years.6

About 60%–80% of all (coal) power plant failures are related to cycling operations.4

One forced outage typically costs $1 million

dollars from lost generation and maintenance costs.5

4. “ Make Your Plant Ready for Cycling Operations,” Power, 2011; http://www.powermag.com/ make-your-plant-ready-for-cycling-operations/

5. NERC Generating Availability Data System (GADS), 2007-2013

GAIN CONTROLIntegrating proven automation technologies and advanced instrumentation is the first step in establishing heightened operational readiness. Coriolis mass flow and density meters give you the degree of process control that legacy instrumentation lacks, and the process visibility you need to detect emerging problems before they result in outages.

Streamlined, Safer Work PracticesMicro Motion Coriolis meters with Smart Meter Verification (SMV) technology enable critical meter health insight. SMV is our patented, automatic on-board diagnostics tool that verifies Micro Motion Coriolis meter performance and integrity under flowing conditions. With it, you can prove flowmeter performance in-line, on your schedule, in 90 seconds.

Get More ResourcesWith workforce turnover, budgetary constraints, changing environmental regulations and inexperienced people trying to ramp up their capabilities as fast as they can, you need technologies that embed expertise into your systems.

Enhance Staff EffectivenessBy partnering with Emerson, you can offset the loss of experienced talent by contracting dedicated local service teams to work onsite and streamline planned outages or perform instrument and valve maintenance services. We can help your operations contend with the need to “do more with less,” compensate for lost tribal knowledge and get new talent performing like all stars. We can you get past these challenges by taking these actions:

Action Advantage

Automating processes to offset resource losses Multivariable diagnostic capability built directly into equipment provides actionable information for embedded expertise.

Augmenting your team Consulting and Technician Expertise Services work onsite and streamline your planned outages or perform instrument and valve maintenance services.

Educating rookies and veterans alike Training to take advantage of the embedded diagnostic technology in today’s instrumentation will improve asset effectiveness.

Utilizing the latest measurement technology No routine maintenance or calibration means less time enables better plant reliability checking on instrumentation that does not need attention.

EXAMPLE:Routine calibration of flow meter instrumentation in a power plant can be costly and in many cases performed when there is nothing wrong with the device. Typically as a default work practice, meters are removed from service and sent to the manufacturer or an external calibration lab for regular calibrations regardless of whether or not a problem exists.

Recently, a large electric utility in the South East US utilized Micro Motion ELITE™ Coriolis mass flowmeters with Smart Meter Verification (SMV) to simplify standard operating procedures and extend calibration intervals and avoid unnecessary process shutdown.

The ELITE Coriolis meters were chosen for liquid fuel feeds and for ammonia flows to the scrubbers in the Selective Catalytic Reduction (SCR) section of the plant. The need to remove the meters and send them out for calibration was dramatically reduced and as a result the work load on the instrument shop was reduced.

Find out more about the unique benefits of Micro Motion Smart Meter Verification here: www.micromotion.com/smv

Smart Meter Verifcation’s accuracy and recognition can eliminate 11 proof tests per year, saving your time and money.

Micro Motion Solutions and Services Help You

WEATHER THE STORMHeightened operational readiness influences every part of your plant. Adapting the way you work, building clear instrumentation visibility and augmenting your staff with skilled consultants can be the difference between smooth operation and failure.

With Emerson as your partner, your operators can effectively access the process parameters they need to maintain stability. You can transform maintenance to hone in on the assets that actually need attention. And, you can access expertise and use revolutionary training programs that replenish lost tribal knowledge.

Instrument & Valve Services

Improves plant reliability

Consultants and training

Enhances staff

effectiveness

AMS Suite & Smart Meter Verification

Optimizes instrument

performance

MEASUREMENT TELLS A STORY. MICRO MOTION MAKES IT POSSIBLE.Confidence in your measurement is key to your process. That’s why we believe that the integrity behind your measurement is critical.

We start with the pursuit of the ultimate real world performance — even in the most critical and complex applications. And we’re committed to making your whole experience easier with our broad range of simple and scalable solutions.

With the Emerson Micro Motion team, you get more than industry-leading performance of our Coriolis flow and density meters. You also get the dedication of our people, our process and the pursuit of delivering measurement confidence in everything we do.

* The Emerson logo is a trademark and service mark of Emerson Electric Co. The Micro Motion mark is a mark of one of the Emerson Process Management family of companies.

Get the full story at www.micromotion.com/lookcloser