Life sciences manufacturers face increasing pressure to ensure regulatory compliance, real-time release, and validated process control as they scale production. When measurement confidence is low, teams add manual checks, increase calibration frequency, and accept downtime that delays the next batch.
Posts by or with Jim Cahill
Quantifying Risk to Sharpen Capital and Operating Decisions
Project engineers and engineering, procurement, and construction (EPC) contractors live with constant tension between overspending capital and underspending opportunity. Equipment-level reliability models help, but they often miss what happens when storage, logistics, recycle flows, weather, and demand interact across the full system.
Turning Fuel Gas Conditioning into a Path to Better Plant Performance
Combined-cycle power plants pair gas turbines with a steam turbine to achieve roughly 60% overall efficiency, placing them among the most efficient large-scale generation technologies available today. Those gains depend entirely on precise fuel gas conditioning.
Mastering Tank Pressure: Practical Ways to Reduce Risk, Product Loss, and Emissions
Storage tanks may look static, but pressure inside them is constantly changing. Filling, emptying, solar heating, rain cooling, vapor generation, inert gas supply, and connected recovery systems can all affect the pressure in the vapor space above the liquid. If those pressure changes are not managed, a tank can exceed its maximum allowable working pressure or fall below its maximum allowable working vacuum.
Optimizing Power Plant Efficiency with Pressure Relief and Blowdown Valves
In high-pressure, high-temperature service, small deviations in valve performance translate into measurable efficiency losses and safety risk. Code-compliant selection, proven design features, and factory-verified testing help operators avoid unplanned outages, extend maintenance intervals, and protect critical assets.
RF and Wireless Technology Trends Shaping 2026: A Test Engineer’s View
Explore the wireless and radio frequency trends for the interconnected web, with artificial intelligence (AI), sixth-generation wireless (6G), non-terrestrial networks (NTN), defense priorities, and semiconductor supply chains.
Rethinking Reliability in Gold Mining: Why Run-to-Fail No Longer Pays in Critical Valve Service
Control valves sit at the center of slurry density, cyanide dosing, and recycled water duties, where small controllability problems compound directly into lost ounces. Treating those valves as commodity components rather than performance assets has become an increasingly expensive habit.
Corrosion in the Chemical Industry: From Inspection to Continuous Insight
Inline corrosion is driven by aggressive chemistry, temperature, pressure, flow effects, and phase changes that can rapidly shift operating conditions. The financial impact goes well beyond replacement cost, with unplanned downtime, environmental consequences, and safety risks often representing the largest exposure.
Understanding Valve Operations in Heat Recovery Steam Generators
HRSG valve applications span an unusually wide range of operating conditions. During startup, a feedwater valve may see the full discharge pressure of the boiler feed pump against an empty, atmospheric-pressure drum, creating severe cavitation potential.
Dead Time Compensation: What Every Control Engineer Should Know Before Turning It On
Dead time is the single most limiting factor in any control loop. It is the total elapsed time from the start of a change until it completes a trip around the entire loop and returns to the point of origin.
Integrated Heat Exchanger Design and Rating—Closing the Gaps Between Process, Thermal, and Mechanical Engineering
Heat exchangers are among the most common and most consequential pieces of equipment in process plants. They influence plant energy efficiency, emissions, capital investment, and operating costs, and they are often implicated in throughput limitations or even unplanned shutdowns.
Smarter Control Valves, Better Operating Decisions: A Conversation with Clint Schneider
Control valves sit at the point where process decisions become physical actions. Better data from the valve, delivered to the right person in the right place, shortens the path from detection to response.
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