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Increase Resource Efficiency with Universal, Integrated Metric

Posted Yesterday, under Process Optimization
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If you’re in the energy business—upstream, midstream, downstream, and electrical power generation & distribution, IHS Markit has a great CERAWeek On-Demand Video site of presentations and interviews from the conference.

One example is the presentation, Decarbonization vs. Profit: Eliminating the Rivalry Through Exergy, given by Emerson’s Ana Gonzalez Hernandez. Ana received her PhD from Cambridge University and is a Resource Efficiency & Commercialization Manager, based in the U.K.

Ana sees big potential for manufacturers along a decarbonization path to use a resource efficiency benchmark for continuous improvement. The challenge is to overcome current perceptions which consider energy efficiency, measured in terms of energy intensity, or material efficiency in terms of yield rates or materials intensity, separately instead of holistically. The interactions between energy and materials is much more complicated as they flow through the production process.

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Remote Proof Testing Safety Level Switches

Posted 2 days ago, under Level, Safety
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One of the necessities in managing safety instrumented systems throughout the IEC 61511 safety lifecycle is to perform periodic proof tests on the components in a safety instrumented function to verify proper function.

A short 2:44 YouTube video, How to Remotely Proof-Test the Rosemount 2140:SIS shows how this proof testing can be performed remotely for safety level switches to save time & costs and reduce risk. Continue Reading ▶

Applying Embedded Model Predictive Control

Posted 6 days ago, under Process Optimization
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The history of model predictive control (MPC) dates back to the early 1970s invented at Shell Oil and was known as Dynamic Matrix Control. MPC was designed at that time to solve largescale control challenges. As technology advanced, this technology could be more widely applied on smaller-scale challenges.

MPC Control on a Lime Kiln ProcessAt this past 2019 AIChE Spring Meeting, Emerson’s James Beall presented Unique Applications for Embedded Model Predictive Control Technology. In his presentation, he shared several examples of smaller applications ideally suited for MPC-based control strategies.

James opened by defining what MPC is. It uses the past to predict the future by using modeled relationships among the process inputs and outputs. It is multi-variable in the numbers of inputs and outputs. These variables can be dependent on and independent of one another as he showed in this Lime Kiln process example.

As explained on the MPC Wikipedia page:

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Improved Machine Control with IIoT

Posted 1 week ago, under Fluid and Motion Control
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In several Industrial Internet of Things (IIoT)-related posts here on the blog, we discussed a number of ways these technologies can help improve performance in safety, reliability, efficiency & emissions, and production for process manufacturers. But what about hybrid and discrete manufacturers?

In a Control Engineering article, IIoT-ready technologies improve machine controls, Emerson’s Steven Fales describes how diagnostics and prognostics embedded in IIoT devices enables improved business performance.

Control Engineering: IIoT-ready technologies improve machine controlsSteven opens contrasting the typical approach for an operator to troubleshoot on a bottling line by accessing a programmable logic controller (PLC). In an IIoT-enabled bottling line:

…the operator pulls out a smartphone, connects to the machine’s pneumatic valve system, and pulls up a web page showing diagnostic data on the equipment’s pneumatic system performance. It’s apparent a solenoid coil has burned out in a directional control valve that controls one of the machine’s actuators. Within minutes, a maintenance technician plugs in a new control valve and the bottling line is running again with little lost productivity or major control system intervention.

The promise of IIoT technologies is:

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Specification Requirements for Corrosion Monitoring Systems

Posted 2 weeks ago, under Wireless
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Process manufacturing involves moving fluids through pipes and vessels. A major concern in many industries is the corrosion and erosion that may occur inside the pipe walls. Corrosion monitoring systems are designed to track this degradation process.

In a Flow Control article, How to Specify a Corrosion Monitoring System, Emerson’s Jake Davies provides insights in requirements to consider in the selection process.

Jake opens the article noting the financial impact of erosion and corrosion globally in the process industries—excluding costs associated with safety & environmental incidents:

According to a National Association of Corrosion Engineers International study, “The global cost of corrosion is estimated to be US$2.5 trillion, which was equivalent to 3.4 percent of the global GDP in 2013. By using available corrosion control practices, it is estimated that savings of between 15 and 35 percent of the cost of corrosion could be realized; i.e., between US$375 and $875 billion annually on a global basis.

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