1 Overview Op Benefits

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Operational Benefits Operational Benefits Seminar Seminar

Agenda Agenda Agenda Big Picture Overview

Operational Benefits – Key Considerations

PlantWeb Solutions for Improving Operations

Wrap-up and Conclusion



Agenda Agenda Agenda 1:00 Big Picture Overview

2:00 Break

2:15 Operational Benefits – Key Considerations

2:45 PlantWeb Solutions for Improving Operations

(Part 1)

3:45 Break

4:00 PlantWeb Solutions for Improving Operations

(Part 2)

4:45 Wrap-up and Conclusion

Big Picture Overview Big Picture Overview



Agenda Agenda Agenda

Emerson Introduction PlantWeb Review

The Digital Plant

Emerson: Company Profile Emerson: Company Profile Emerson: Company Profile Diversified global manufacturingand technology company servingindustrial, commercial, andconsumer markets around theworld

St. Louis, MO Headquarters Publicly traded (NYSE: EMR)

Headquarters in St. Louis, MO (USA)

Recognized for outstanding management process and

record of consistent long-term performance Manufacturing and/or sales presence in more than 150

countries

Founded in 1890 – in business for 115 years



$0

$5

$10

$15

71 73 75 77 79 81 83 85 87 89 91 93 95 97 99 01 03 05

48 consecutive years ofincreased dividends per share,a compound annual growthrate of 11%

Earnings per share haveincreased at a compound annualgrowth rate of 10%

Emerson Growth and Performance Emerson Growth and Performance 19711971- - 2005 2005

Sales$B

FY05Sales

$17.3B

2005 Emerson Summary 2005 Emerson Summary 2005 Emerson Summary

ProcessManagement

IndustrialAutomation

Appliance& Tools

Network Power

ClimateTechnologies

Europe

Asia UnitedStates

ROW

Locations

US & Canada 125Europe 75

Asia 40

ROW 35

Total 275

Consumer

Industrial

Electronics

2005 Sales by Segment

2005 Sales by Geography

24%24%

19%19%

19%19%

21%21%

17%17%

53%53%

22%22%

14%14%

11%11%

2005 HighlightsSales $17.3BOP* $2.6BOP Margin* 15.0%EPS $3.40Mkt. Cap. $29BEmployees 114k

* Reconciliation to GAAP measure at the end of the presentation;Market Cap as of 9/30/05



Emerson Brands Emerson Brands Emerson Brands

$17.3 Billion in revenues with over 60 divisions

26%

31%

0%

10%

20%

30%

40%

1995 2005

$354

$469

$0

$100

$200

$300

$400

$500

1995 2005

Emerson Growth Through

Technology Leadership

Emerson Growth Through Emerson Growth Through

Technology Leadership Technology Leadership

Engineering & Development Investment ($M)Engineering & Development Investment ($M) New Products as a Percent of SalesNew Products as a Percent of Sales

~



• Systems & Solutions

• DeltaV

• OVATION

• INDUSTRY Solution Centers

• Asset Optimization

• AMS SUITE Software

• PlantWeb Services

• Control Valves & Regulators

• FISHER

• Precision Measurement

• BROOKS Flow

• DANIEL Fiscal Metering

• MICRO MOTION Mass Flow

• MOBREY Level, Density, & Viscosity

• ROSEMOUNT Pressure,Temperature, Flow & Level

• ROSEMOUNT ANALYTICAL Gas &Liquid Analysis

• SAAB ROSEMOUNT Radar Level

Emerson Process Management Emerson Process Management Emerson Process Management

21%21%

17%17%

24%24%

Appliance& Tools

NetworkPower

ProcessManagementProcessManagement

19%19%

19%

Climate Technologies

IndustrialAutomation

• Rosemount

• SaabRosemount

• Micro Motion

• Brooks

• RosemountAnalytical

• Daniel

• Fisher

• Bettis

• El-O-Matic

• Shafer

Measurement Valves &Regulators

• DeltaV

• Ovation

• IndustryCenters• Chemical• Oil & Gas• Refining• Power & Water• Life Sciences• Metals & Mining• Pulp & Paper• Food & Beverage

Systems &Solutions

AssetOptimization

• AMS Suite

• Services andTechnologies• Rotating

Equipment• Electrical

Systems• ProcessEquipment

• Instruments& Valves

Emerson ConfidentialRevised Mar 2006, Slide 12



Emerson Process Management Emerson Process Management Emerson Process Management

Total 2005 Sales $4.2BTotal 2005 Sales $4.2BTotal 2005 Sales $4.2B

2005 Business Mix by World Area 2005 Business Mix by World Area 2005 Business Mix by World Area



2005 Business Mix by Industry 2005 Business Mix by Industry 2005 Business Mix by Industry

Agenda Agenda Agenda Emerson Introduction

PlantWeb Review

The Digital Plant



What is PlantWeb? What is PlantWeb?

A process automation architecture that uses the power of field

intelligence to improve plant process and financial

performance

Architecture shift to PlantWeb Architecture shift to PlantWeb

Valves Motors

PC’s

PLC’s

Business

Systems

DCS

Analytical

Products & Systems

LIMS



PlantWeb uses the predictive power of field intelligence toimprove plant performance

SMARTDIGITAL CONTROL

SMARTFINAL CONTROL

SMARTMEASUREMENT

SMARTASSET OPTIMIZATION

SMARTREMOTE AUTOMATION

SMARTMACHINERY HEALTH

SMARTSAFETY

SMARTFINAL CONTROL

Emerson is unpluggingPlantWeb to extend the benefitsto assets previously out ofreach

SMARTMEASUREMENT

SMARTREMOTE AUTOMATION


SMARTMEASUREMENT

SMARTMEASUREMENT



SMARTMOBILE WORKER

SMARTSAFETY



Agenda Agenda Agenda

Emerson Introduction PlantWeb Review

The Digital Plant

The World Has Gone DIGITAL! The World Has Gone DIGITAL! The World Has Gone DIGITAL!



Law Of Accelerating Returns Law Of Accelerating Returns Law Of Accelerating Returns

Analysis showsthat Technological

change isexponential

Analysis showsthat Technological

change isexponential

Disposable printers?Disposable printers?

Storage is ‘free’: $65Storage is ‘free’: $65

My old PCMy old PC



1940 1960 1980 2000 2020

Value

CentralizedDCS

HardwiredPanel Boards

F u t u r e p h o t o c o u r t e s y B r a d A d a m ' s W a l k e r

A r c h i t e c t u r e ,

P . C . ,

D e n v e r , C o l o r a d o .

Digital Technology Has Changed The Process Control Landscape Digital Technology Has Changed The Digital Technology Has Changed The Process Control Landscape Process Control Landscape

Time

Digital PlantArchitecture

Shell Deer Park Refining CompanyDeer Park Refining Limited Partnership

“Our Vision” – Shell Deer Park “ “ Our Vision Our Vision ” ” – – Shell Deer Park Shell Deer Park

Use the newest technology to create the “Refinery ofthe Future”

Concentrate on safety and environmental concerns – System must be robust

Focus on cost – Low life cycle cost

Manpower training – Must be easy to operate andmaintain

Obsolescence resistance – must be based onindustry standard software norms



The Technology Universe The Technology Universe The Technology Universe

Parallel computingParallel computing

Moore’s LawMoore’s Law

WPFWPF

ArtificialIntelligenceArtificialIntelligence

HARTHART

Process DiagnosticsProcess Diagnostics

Predictive AlgorithmsPredictive Algorithms

Energy ScavengingEnergy Scavenging

DSP’sDSP’s

Enhanced EDDLEnhanced EDDL

UltrasonicUltrasonic

Fuel CellsFuel Cells

MP3MP3

802.11a,b,g,n,i802.11a,b,g,n,i

802.15.4802.15.4

GPSGPSUMPCsUMPCs

WinWFWinWFModel BaseProgrammingModel BaseProgramming

ScaleableGraphics

ScaleableGraphics

MotesMotes

FireFoxFireFox

MEMSMEMS

Advanced Signal ProcessingAdvanced Signal ProcessingOPC UAOPC UA

Smart ObjectsSmart Objects

GPRSGPRS

PATPAT

Security S99Security S99

Bit TorrentBit Torrent

AESAES

RSSRSS

XMLXML

UMLUML

SecuritySecurity

VistaVistaSOASOA

.NET 3.NET 3

W-bluetoothW-bluetooth

SkypeSkypeOPMLOPML

Core 2 DuoCore 2 Duo

The Role of Field Devices Has Changed The Role of Field Devices Has Changed

On-board computing powerenables step changes infunctionality

Become “informationservers” in the field basedarchitecture

An integral part of theprocess automation system

Diagnostics and loop speedincrease the value of thefield device.



Smart carsmonitor tire

pressure

Smart carsmonitor tire

pressure

Tire icon indicateslow pressureTire icon indicateslow pressure

Car advises driver of abnormal situation madepossible via disruptive technologies

Car advises driver of abnormal situation madepossible via disruptive technologies

Smart Car Messages Seat belt Cargo door open Passenger door openWiper fluid low Turn signal on Right rear tire pressure low Change engine oil Fuel low

Smart Car Messages Seat belt Cargo door open Passenger door openWiper fluid low Turn signal on Right rear tire pressure low Change engine oil Fuel low

Messages I do not get ☺ Check engine Big red oil light

Messages I do not get ☺ Check engine Big red oil light



Three requirements:Sensing technologyPresentation to user at the right timeAdvanced Technology must be easy to use

Three requirements:Sensing technologyPresentation to user at the right timeAdvanced Technology must be easy to use

Early warning

Oil Pressure AlarmOil Pressure Alarm

time

C a r P e r f o r m a n c e

Sequence Of Events Sequence Of Events Sequence Of Events

Change Oil LightChange Oil Light

MajorPerformance

Impact

MajorPerformance

Impact

Safety incidentSafety incident



Technology Delivers Performance Technology Delivers Performance Technology Delivers Performance

Seat belt Cargo door open Passenger door openWiper fluid low Turn signal on Check Tire Pressure Change engine oil Fuel low etc…

We Help Our CustomersDeploy Smart Digital Plants

We Help Our CustomersDeploy Smart Digital Plants




MANAGEMENT

SMARTMEASUREMENT

SMARTMEASUREMENT

SMARTANALYTICAL

SMARTANALYTICAL

SMARTSAFETYSMARTSAFETY

Smart Plant Architecture Smart Plant Architecture Smart Plant Architecture


SMARTFINAL CONTROL

SMARTFINAL CONTROL


SAFETY

Today’s Smart Field Devices Predict Abnormal

Situations

Today Today ’ ’ s Smart Field Devices Predict Abnormal s Smart Field Devices Predict Abnormal

Situations Situations On-board computing power

enables step changes infunctionality

Often have more than one processvariable for a single pipe intrusion

Full with diagnostics

– health of device is known

– health of the application ismonitored

– health of the process is monitored

“At 12:45 tomorrow, this valve will fail”“At 12:45 tomorrow, this valve will fail”



Early warning

Device failureDevice failure

time

P l a n t P e r f o r m a n c e

Intelligent Devices Report Health Intelligent Devices Report Health Intelligent Devices Report Health

Device alertDevice alert

Process ImpactProcess Impact

Safety IncidentSafety Incident


MANAGEMENT

SMARTMEASUREMENT

SMARTMEASUREMENT

SMARTANALYTICAL

SMARTANALYTICAL


Smart Plant Architecture Smart Plant Architecture Smart Plant Architecture SMART

ASSET OPTIMIZATION

SMARTFINAL CONTROL

SMARTFINAL CONTROL


SAFETY



Smart Predictive Alerts Temperature Transmitter Example Smart Predictive Alerts Smart Predictive Alerts Temperature Transmitter Example Temperature Transmitter Example

Sensor failureSensor failure

Smart Predictive Alerts Mass Flow Example

Smart Predictive Alerts Smart Predictive Alerts Mass Flow Example Mass Flow Example

Process problemProcess problem



Smart Predictive Alerts Valve Example Smart Predictive Alerts Smart Predictive Alerts Valve Example Valve Example

Valve is performing sub-optimallyValve is performing sub-optimally

Smart Predictive Alerts Valve Example

Smart Predictive Alerts Smart Predictive Alerts Valve Example Valve Example

Valve needs maintenanceValve needs maintenance



Smart Predictive Alerts Pump Protection Example Smart Predictive Alerts Smart Predictive Alerts Pump Protection Example Pump Protection Example

Pump needs maintenancePump needs maintenance

In most 10 year old plants, there are

NO EARLY WARNING SYSTEMS

In most 10 year old plants, there are

NO EARLY WARNING SYSTEMS



What Is Really Happening? What Is Really Happening? What Is Really Happening?





A Real Case Of Not Seeing What Is

Happening

A Real Case Of Not Seeing What Is A Real Case Of Not Seeing What Is

Happening Happening

The explosion was caused by flammable hydrocarbon liquid continuously being pumpedinto a process vessel that, due to a valve malfunction, had its outlet closed.

The explosion was caused by f lammable hydrocarbon liquid continuously being pumpedinto a process vessel that, due to a valve malfunction, had its outlet closed.

A control valve being shut when the control system indicated it was open.A control valve being shut when the control system indicated it was open.




MANAGEMENT

SMARTMEASUREMENT

SMARTMEASUREMENT

SMARTANALYTICAL

SMARTANALYTICAL


Should All These Alarms Go To The Operator? Should All These Alarms Go To The Operator? Should All These Alarms Go To The Operator?


SMARTFINAL CONTROL

SMARTFINAL CONTROL


SAFETY

??

Motor OverheatingMotor Overheating

time

D e v i c e P e r f o r m a n c e

Alarms To Operator? Example shown: NO

Alarms To Operator? Alarms To Operator? Example shown: NO Example shown: NO

Impellor ImbalanceImpellor Imbalance

Process ImpactProcess Impact

Time For Action > 6 months

Early alarm to MAINTENANCE onlyas there is a long time before process

impact.

Early alarm to MAINTENANCE onlyas there is a long time before process

impact.



time


Alarms To Operator? Example shown: NO (long time before failure) Alarms To Operator? Alarms To Operator? Example shown: NO (long time before failure) Example shown: NO (long time before failure)

Valve frozen open inutilities plant

Valve frozen open inutilities plant

Process impactProcess impact

Time For Action > 1 year

Early alarm to MAINTENANCE only asthere is long time before process impact

Early alarm to MAINTENANCE only asthere is long time before process impact

time


Failure of a Critical Valve Column

Impacts The Process Immediately

Failure of a Failure of a Critical Critical Valve Column Valve Column

Impacts The Process Immediately Impacts The Process Immediately

Valve frozen open indistillation column

Valve frozen open indistillation column

Process impactProcess impact

Time For Action < 30 minutes

Early alarm to MAINTENANCE andOPERATOR as action is required

immediately to prevent process problems

Early alarm to MAINTENANCE andOPERATOR as action is required

immediately to prevent process problems



Plants Must Have An Alarm Message Map Plants Must Have An Alarm Message Map Plants Must Have An Alarm Message Map

Cost ofIgnoring

Alarm

Time To Avoid Process/Safety Impact

Alarm Destination Map Alarm Destination Map Alarm Destination Map

High PriorityHigh Priority Medium PriorityMedium Priority

Low PriorityLow PriorityMedium PriorityMedium Priority

• Operator• Operator

• Maintenance• Optimization Personnel• Safety Personnel

• Maintenance• Optimization Personnel• Safety Personnel

• Maintenance• Optimization Personnel• History Collection

• Maintenance• Optimization Personnel• History Collection

• Operator• Maintenance• Safety Personnel

• Operator• Maintenance• Safety Personnel

The Importance Of Alarm Handling The Importance Of Alarm Handling The Importance Of Alarm Handling

In the last 11 minutes before explosion, the operatorshad to recognize, acknowledge and act on 276 alarms

In the last 11 minutes before explosion, the operatorshad to recognize, acknowledge and act on 276 alarms

Milford Haven was 25x therecommended maximum

Milford Haven was 25x therecommended maximum




MANAGEMENT

SMARTMEASUREMENT

SMARTMEASUREMENT

SMARTANALYTICAL

SMARTANALYTICAL


Alarm Messaging Map Alarm Messaging Map Alarm Messaging Map


SMARTFINAL CONTROL

SMARTFINAL CONTROL


SAFETY

Predictive AbnormalSituation Alarms

Predictive AbnormalSituation Alarms

Degraded SafetyAlarms


Asset HealthAsset Health


MANAGEMENT

SMARTMEASUREMENT

SMARTMEASUREMENT

SMARTANALYTICAL

SMARTANALYTICAL


All Critical Alarms – To Operator (Regardless of whether a device or controller created them)

All Critical Alarms All Critical Alarms – – To Operator To Operator (Regardless of whether a device or controller created them) (Regardless of whether a device or controller created them)


SMARTFINAL CONTROL

SMARTFINAL CONTROL


SAFETY

OPERATORINTERFACE

OPERATORINTERFACE



FT-101

Operator InterfaceOperator Interface

Alert The Operator Before Process ImpactAlert The Operator Before Process Impact


MANAGEMENT

SMARTMEASUREMENT

SMARTMEASUREMENT

SMARTANALYTICAL

SMARTANALYTICAL


All Asset Alarms To Maintenance All Asset Alarms To Maintenance All Asset Alarms To Maintenance SMART

ASSET OPTIMIZATION

SMARTFINAL CONTROL

SMARTFINAL CONTROL


SAFETY

ASSET INTERFACEASSET INTERFACE



Maintenance /Reliability Dashboard

Maintenance /Reliability Dashboard


MANAGEMENT

SMARTMEASUREMENT

SMARTMEASUREMENT

SMARTANALYTICAL

SMARTANALYTICAL


All Safety Alarms To Safety Personnel All Safety Alarms To Safety Personnel All Safety Alarms To Safety Personnel SMART

ASSET OPTIMIZATION

SMARTFINAL CONTROL

SMARTFINAL CONTROL


SAFETY





Safety Personnel Are Roaming Safety Personnel Are Roaming Safety Personnel Are Roaming

Cell phone, pager, email… Detailed Summary

In A Smart Plant, Does The Number Of Alarms

To the Operator Increase?

In A Smart Plant, Does The Number Of Alarms In A Smart Plant, Does The Number Of Alarms

To the Operator Increase? To the Operator Increase? No

– Best practices areestablished in the designof the alarm system

• EEMUA

• Alarm Map

– Early warning alarmsproperly acted on shoulddecrease the incomingalarms as processalarms may be avoided



Poor Health Delivers Unsatisfactory Results At 60 mph !!! Poor Health Delivers Unsatisfactory Results At Poor Health Delivers Unsatisfactory Results At 60 mph !!! 60 mph !!!

Mercury FilledTransmitters & Switches

DisconnectedDamper Drive

Leaking ValveBody

Expect Poor Performance In Plants With Poor

Asset Health

Expect Poor Performance In Plants With Poor Expect Poor Performance In Plants With Poor

Asset Health Asset Health

Poor Equipment Results in PoorPerformance and Unsafe Plants

Poor Equipment Results in PoorPerformance and Unsafe Plants



Expect Poor Performance In Plants With Poor Expect Poor Performance In Plants With Poor Asset Health Asset Health

Enterprise Integration: Validated Data (Inventory, Loss,

etc) Is transmitted to SAP Asset alerts are transmitted to

SAP for scheduling

Enterprise Integration: Validated Data (Inventory, Loss,

etc) Is transmitted to SAP Asset alerts are transmitted to

SAP for scheduling

Integrating Transactions is Easy Reversing them (on bad data) is

very difficult

Integrating Transactions is Easy Reversing them (on bad data) is

very difficult

Control Valves, Instrumentation, Critical Assets

Regulatory Control and SIS

Advanced ProcessControl

Optimization

Data Validation Occurs in the Field

And Is Propagated To All Applications

Data Validation Occurs in the Field Data Validation Occurs in the Field

And Is Propagated To All Applications And Is Propagated To All Applications

PV is MarkedBAD

PV is MarkedBAD

and propagatedand propagated



Shell Deer Park Revamp Shell Deer Park Revamp Shell Deer Park Revamp

Control Room Control Room Control Room

BEFOREBEFORE AFTERAFTER




Cabinet Cabinet Cabinet



Field Junction Field Junction Field Junction





Panel Being Cut Over …hotPanel Being Cut Over …hot

Control Valve Diagnostics Control Valve Diagnostics Control Valve Diagnostics

ValveLink diagnostics prior tocutover found a hidden problem.

This valve has notbeen in automatic for years!

ValveLink diagnostics prior tocutover found a hidden problem.

This valve has notbeen in automatic for years!

Roger Erfurdt, Deer Park ControlSystems manager, has statedthat getting this loop to run in

automatic has paid for the entireinvestment in diagnostics.

Roger Erfurdt, Deer Park ControlSystems manager, has statedthat getting this loop to run in

automatic has paid for the entireinvestment in diagnostics.



Control Valve Signature - ValveLink Control Valve Signature Control Valve Signature - - ValveLink ValveLink


travel travel A c t u a t o r P r e s s u r e

Results Delivered Results Delivered Results Delivered Operational Excellence

– Safety: No OSHA’s

– Environmental: No Incidents

– State of the art operating interfaces

Financial

– 1% maintenance cost reduction achieved(3%+ is believed possible)

– Overall 1-3% utilization improvement

– Improved unit reliability

– Greatly improved maintenance effectiveness – Huge project savings by reutilizing previous engineering



BARRIERS To Operational Excellence BARRIERS BARRIERS To Operational Excellence To Operational Excellence

Overly aggressive focus onCAPEX

The technology change is theeasiest

In plant visionaries arenecessary and hard to find

Management support iscritical

The human resistance tochange is greater than youthink

Satellite Service Providers Know Tire

Pressure…

Satellite Service Providers Know Tire Satellite Service Providers Know Tire

Pressure Pressure ……

What use is there for theold-fashioned tire gauge?

What use is there for theold-fashioned tire gauge?



“Change Or Be Changed” “ “ Change Or Be Changed Change Or Be Changed ” ” There are two kinds of organizations in today's world:

– those that are changing

– those that are going out of business

Similarly, there are also two kinds of people

– Those who are changing

– Those who are setting themselves up to be victims of change

Jim Clemmerhttp://www.clemmer.net

Cannot Be Done Without TechnologyCannot Be Done With Technology Alone

Cannot Be Done Without TechnologyCannot Be Done With Technology Alone

1 Overview Op Benefits

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