PCS Nitrogen improves profitability and safety by transitioning legacy control system to Emerson's PlantWeb

Stepwise migration solutions enable fast and cost effective modernization to new technology.

AUSTIN, TEXAS (September 27, 2004) — Emerson Process Management announced today that PCS Nitrogen Fertilizer, LP has successfully completed the transition of their legacy Foxboro I/A system controlling a portion of their Geismar, Louisiana, plant to Emerson's PlantWeb digital plant architecture with the DeltaV™ digital automation system.

The Geismar facility was originally constructed in 1967 as part of AlliedSignal. Until recently, the entire plant was operating under the control of the legacy control system, which was installed in the late 1980s. During the past several years, reliability and service associated with the legacy control system started affecting process availability in the phosphoric acid area of the plant. Regulatory compliance and improving automation system reliability and service were becoming key driving factors for implementing a change.

Management at the Geismar plant was eager to adopt a digital plant architecture, which had inherent connectivity to a variety of digital bus technologies being used in the plant. In addition, the automation system was to interface with the legacy control system for facilitating plantwide controls.

Emerson's migration solution for PCS Nitrogen's Geismar plant includes an OPC server connecting the DeltaV system to the Foxboro I/A system. Other migration solutions include conversion services for point databases, graphic displays and control strategies to reduce migration costs.

"Emerson's OPC-based migration solution enabled us to switch over live from our legacy system to the DeltaV system, enabling us to comply with environmental regulations while maintaining our production," said Kirk Hadeed, senior engineer of instrumentation and controls at PCS Nitrogen.

"The AMS™ Suite asset management software included in the PlantWeb digital plant architecture enabled us to maintain and operate our FOUNDATION fieldbus field devices at their peak efficiency, thereby improving plant reliability and safety," said Hadeed.

"Manufacturers across the world are challenged today to extract the most value out of their existing assets," said Tom Snead, president of the process systems and solutions division of Emerson Process Management. "We are allowing manufacturers to gain more value out of their existing assets by making the transition process from older automation systems easier. Users can transition components of their legacy systems at a pace that suits them to take advantage of new capabilities embedded in Emerson technologies."

About Emerson's Migration Solutions

According to Larry O'Brien, ARC research director for process industries, "Lifecycle costs, which include costs to upgrade and migrate automation systems, have become more important than initial purchase prices. We believe that Emerson has developed an effective migration strategy for its own legacy systems. Emerson is also one of the few suppliers that has placed considerable focus on a strategy for migration from competitive systems."

Within the past year Emerson has released a wide range of migration solutions (www.EasyDeltaV.com/EasyConnect). These solutions have been specifically designed to upgrade a wide range of legacy systems, including those from ABB, Bailey, Honeywell, GSE Systems, Invensys/Foxboro, Siemens, Yokogawa, General Electric, Allen-Bradley, and Modicon, to the DeltaV system.

Migration solutions provide flexibility and deliver efficiency

Emerson's migration products for field connections, operator interface, and control, combined with its simulation, training, and conversion services, reduce installation costs and minimize downtime during an automation system upgrade.

Using FlexConnect, Emerson can reduce rewiring costs as much as 50 percent and process downtime by 75 percent. Emerson's migration services include database conversion and graphics conversion, or complete redesign of displays. Simulation tools expedite checkout and reduce the learning curve for operator training.

Local services provide support for fastrack migration projects

Emerson's Migration group, working in conjunction with local Emerson local business partner John H. Carter, Inc. (www.johnhcarter.com), assisted PCS Nitrogen's moving to newer automation technologies by providing services such as database, control strategy, and graphic display conversions, complete with an offline configuration checkout prior to actual connection of the new digital plant architecture.

"With our migration solutions and in-house domain expertise for a wide range of legacy systems, Emerson makes the modernization process from outdated automation systems to new digital technology a much easier and faster process," said Laurie Ben, director of the migration group at Emerson. "The quicker we can get our customer up and running on the DeltaV system and PlantWeb architecture, the faster they can start realizing the impact of these technologies on their bottom line."

About PCS Nitrogen Fertilizer, LP

Potash Corporation of Saskatchewan, Inc. (PotashCorp) acquired PCS Nitrogen Fertilizer, LP in 1997. PotashCorp is the world's largest integrated producer of nitrogen, phosphate and potash with approximately 5200 employees in five countries, and customers on six continents. It is publicly traded on the Toronto and New York stock exchanges (NYSE: POT). For more information, visit www.potashcorp.com.

Products produced at PCS Nitrogen's Geismar plant include ammonia, urea, nitric acid, UAN solution, phosphoric acid, sulfuric acid, superphosphoric acid, and Poly-N. These products are predominately used as a fertilizer for agricultural purposes, as well as for raw materials in other manufacturing processes including ingredients in foods, pharmaceuticals, clothing, lumber, and animal feed supplements.

About Emerson Process Management

Emerson Process Management (www.emersonprocess.com), an Emerson business, is a leader in helping businesses automate their production, processing and distribution in the chemical, oil and gas, refining, pulp and paper, power, food and beverage, pharmaceutical and other industries. The company combines superior products and technology with industry-specific engineering, consulting, project management and maintenance services. Its brands include PlantWeb®, Fisher®, Micro Motion®, Rosemount®, Daniel®, DeltaV™, Ovation®, and AMS™ Suite.

About Emerson

St. Louis-based Emerson (www.gotoemerson.com) is a global leader in bringing technology and engineering together to provide innovative solutions to customers in process control; electronics and telecommunications; industrial automation; heating, ventilating and air conditioning; and appliance and tools. Sales in fiscal 2003 were $14 billion.

PlantWeb, Fisher, Micro Motion, Rosemount, Daniel, DeltaV, and Ovation are marks of Emerson Process Management. Other marks are property of their respective owners.