Control and Safety System Modernisation in the Chemical Industry

Enhanced capability of a modern automation system enables increases in plant efficiency, safety, throughput and profitability

Maximise operational efficiency and production throughput

Aging distributed control and safety systems can significantly impact plant efficiency, throughput and profitability. Unreliable hardware and software affects process availability and safety. An inability to leverage smart sensor and advanced control technologies prevents process optimisation. Outdated user interfaces reduce operator efficiency, increase the potential for errors and create inconsistent control practices.

Maximise operational efficiency and production throughput

Aging distributed control and safety systems can significantly impact plant efficiency, throughput and profitability. Unreliable hardware and software affects process availability and safety. An inability to leverage smart sensor and advanced control technologies prevents process optimisation. Outdated user interfaces reduce operator efficiency, increase the potential for errors and create inconsistent control practices.
Modern control technology enables you to increase plant performance
Modern control technology enables you to increase plant performance

Modernising your plant with an Emerson DeltaV™ distributed control system (DCS) and safety instrumented system (SIS) creates the opportunity to make step-change improvements in plant efficiency, safety, throughput and profitability. The DeltaV DCS is a flexible, easy-to-use control system that simplifies operational complexity for increased plant performance. The DeltaV SIS protects your assets and improves process availability. Combining the DeltaV DCS and DeltaV SIS safety system creates a modern automation solution able to run your plant at its full potential.

FREE Modernisation Configuration Report
Looking to revamp your process control system, safety instrumented system or PLC? Find out how much configuration is required to modernise your existing system to DeltaV.
High performance interfaces enhance operator efficiency and process safety
High performance interfaces enhance operator efficiency and process safety

Modern high performance human machine interfaces (HMI) incorporating human centered design and alarm rationalisation help operators to control the plant more efficiently, identify issues quicker, make improved decisions, reduce errors and increase overall productivity. Remote access to critical control system data through DeltaV Mobile functionality enhances operator efficiency further, allowing issues to be addressed immediately and contributing to improvements in plant safety and throughput.

Enhanced control functionality helps to maximise productivity and throughput
Enhanced control functionality helps to maximise productivity and throughput

The DeltaV DCS provides access to new capabilities that unlock value in your plant. State-based control helps to increase production efficiency by transitioning from a reliance on operators to fully automated control sequences that ensure consistency and process optimisation. Advanced process control, process learning and adaptive control functionality enable optimisation of interactive processes and reduced variability under changing process conditions. This helps to reduce operator requirements, increase throughput and lower energy consumption.

A modern approach increases safety integrity while improving process availability
A modern approach increases safety integrity while improving process availability

A modern control system helps to increase safety by reducing the number of workers exposed to process, through automated situational handling and reducing the probability of incidents arising from human error. By continuously monitoring the status of safety devices and diagnosing the health of the entire safety loop, the DeltaV SIS dramatically reduces risk. Single button restarts help to remove procedure complexity and lower risk, while the implementation of a reliable modern SIS can eliminate nuisance trips, helping to increase process availability and throughput.

Enhanced control functionality helps to maximise productivity and throughput
Unlock the tools to digitally transform your operations

Smart I/O functionality available with DeltaV removes the barriers that prevent access to stranded data that can be used to optimise process control. This allows you to take advantage of the wealth of new information provided by intelligent sensors and multivariable transmitters that can be used to build better and more complex models for optimised control and greater throughput. Integrated device diagnostics, which can be embedded in control strategies, identify and resolve field instrument problems earlier, helping to avoid unforeseen shutdowns that reduce availability and throughput.




Experienced global service support for your modernisation project

Emerson has extensive control system modernisation experience, supporting over 6,000 migrations to DeltaV solutions from all types of legacy systems. Established processes and people, together with artificial intelligence and machine learning tools are available to assess the state of your automation, quantify operational benefits, then plan and execute your project. With over 5,000 project resources worldwide, your control system modernisation can be executed flawlessly, on schedule, with minimum production impact.

System Modernisation Success Stories


Chemical manufacturer modernises legacy control system
Chemical manufacturer modernises legacy control system

Remote cloud engineering and virtual FAT necessarily to keep project on track while simultaneously redesigning process sequences.

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Plastic additives manufacturer migrates to DeltaV batch solution
Plastic additives manufacturer migrates to DeltaV batch solution

DCS reverse engineering, configuration, virtual FAT and redesign the batch implementation required within tight project schedule.

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