“It seemed like a good idea at the time.” That phrase is often the first response for something failing or otherwise going wrong. The same concept applies in many operational situations for process plants. It may relate to an outright failure, but may be more subtle, resulting in a bottleneck or maintenance headache. Ultimately it reflects an equipment selection or other design decision that proved to be less than ideal.

In some cases, the problem may be completely unnoticed within the plant, with operations going on sub-optimally and nobody recognizing where a change could have a significant positive impact. Spotting those types of issues and mitigating them is what we call performance management, and it is the topic of my article in Processing, Extending Maintenance Services Into Performance Management.

This is the third and final installment in my series on Lifecycle Services. The first article describes maintenance as a service, and how it can be applied to complex equipment. The second describes how reliability uses advanced diagnostic tools to predict problems, rather than simply responding. Now we move into performance management.

Performance extends the concepts of maintenance and reliability to deliver additional operational benefits. For example, imagine this common situation: a strategic flowmeter measures output from a reactor for a continuous process. It is a typical application present in some form in most process manufacturing plants.

In this situation, during a plant walkdown, maintenance and reliability teams could conclude, correctly, that everything is operating as it should, and no action is needed. The evaluation may stop there, but performance management looks at the situation more closely.

But if one of Emerson’s staff examines the flowmeter, a deeper analysis is possible:

• Is it sized and ranged correctly? (The reliability team should have verified this already.)
• Is it installed correctly, in accordance with the relevant P&ID, and in the right position with suitable piping? (Again, it should be reviewed during reliability walkdown.)
• Are there valves or fittings nearby that could interfere with accuracy?
• Is it placed in the optimum location to make this measurement?
• Does it use the best measuring technology for the application?
• Are there aspects of the process (e.g., gas entrainment) able to corrupt its accuracy?
• Is it communicating effectively with the automation host system?
• Are there other useful ancillary functions (e.g., temperature) that it could provide?
• Does the control room display for the flowmeter reflect its function and performance well?
• Does it support the process as completely as possible, providing data useful for optimization?

These questions often cross into the realm of process engineering, reevaluating process decisions that seemed like a good idea at the time.

Although many of these questions were, or should have been, answered during the initial plant design, inevitable changes through the years make it important to revisit these and related issues periodically.

The article goes into more detail as to why and how processes change, and why they may need reevaluation, including ongoing technological advances. The most important point is that such questions should be asked, and often a new set of eyes may notice an issue that has long passed for normal. Emerson has the expertise, technology, and processes to enable manufacturers to operate safely, improve asset reliability, and optimize processes, while helping optimize plant performance and achieve business goals.

A proactive strategy is more important than ever, applying automation, continuous monitoring, performance services, remote assistance and remote access services. These services work with in-house staff to provide timely, data-driven decision making related to maintenance and repair, while ensuring safety and reliability remains intact.

Visit the Emerson Lifecycle Services pages at Emerson.com. You can also connect and interact with other engineers in the Chemical Processing and Refining Groups at the Emerson Exchange 365 community.