Upgrading Boiler Burner Management and Combustion Control Systems

Authors: Bob Sabin, Peter Kline

The Emerson Industrial Energy consulting team assisted a Northeastern U.S. specialty chemical manufacturer with modernizing the controls on two 1960’s vintage Combustion Engineering “D” Type process steam boilers. These units are critical to site operation as they supply steam to a common header that feeds processes throughout the production facility.

For each boiler, the existing controls consisted of hardwired relays for Burner Management System (BMS) functions and standalone single loop controllers for Combustion Control System (CCS) purposes.

Over years of operation, boiler field wiring had fallen into disarray and the hardwired BMS panels had always been very difficult to troubleshoot. The CCS loop controllers had provided good service for many years, but they were limited in functionality and had reached the end of their useful life. All these created challenges for plant personnel in maintaining reliable and optimal utility plant operation. This drove the development of a boiler controls improvement project.

The Industrial Energy consultants and project team helped the client start the modernization effort by engaging in a holistic approach to control modernization. This process began with a site survey that examined the condition of the boilers and reviewed the instrumentation and field devices that were in place. The team conducted a review of the overall boiler processes and their devices for compliance with the latest NFPA codes and recommended practices. In addition, the team interviewed plant personnel to understand their project objectives, issues that needed to be resolved, and ideas for achieving optimal utility area performance. Continue Reading

Sensors and Analytics for Reliable and Efficient Electrical Generation

The reliable and resilient flow of electrical energy to our homes and businesses is the goal of every power producer. What are some ways that advancing technology is helping these producers achieve these goals?

In a Power magazine article, New Monitoring and Analytics Tools Improve Plant Performance, Emerson’s Brian Joe and Juan Panama describe how Industrial Internet of Things (IIoT) technologies help electrical generating plants increase reliability and overall efficiency. Continue Reading

Answers to Coriolis Meter Drive Gain Diagnostic Questions

In an earlier post, How Coriolis Meter Drive Gain Indication Works, Emerson’s Marc Buttler addressed questions on how the Micro Motion Coriolis meter drive gain diagnostic is calculated.

We received two additional questions, so I thought it warrants a second post to bring more visibility to Marc’s responses to the questions.

  1. What is the max value of drive gain that you can believe the meter reading with confidence?

Marc responded: Continue Reading

BioPhorum Best Practices on Knowledge Management

The BioPhorum organization was formed in 2004 with the mission, “…to create environments where the global biopharmaceutical industry can collaborate and accelerate its rate of progress, for the benefit of all.”

Emerson’s Michalle Adkins alerted me to the release of a new BioPhorum Knowledge Management white paper, A Test Case in CMC Business Processes from Late-Stage Development to Commercial Manufacturing.

Here is its description: Continue Reading

Improving CAR-T Therapeutical Production

With the world’s attention focused on the Coronavirus, I wanted to focus on some of the amazing therapies being developed in the Life Sciences industry. I caught up with Emerson’s Alan Johnston who shared a presentation he gave at the Simposio AFI last year.

He discussed gene therapy, cell therapy and CAR-T which combines both. These have the goal to treat disease by changing the blueprint to our body at a microscopic level. This is done by using minute pieces of ourselves to repair problems that may cause disease. This approach is designed to fix problems at their source and potentially provide a permanent cure rather than a lifetime of treatment. Continue Reading