by Gary Mintchell | Oct 16, 2015 | Asset Performance Management, Automation, News, Operations Management, Process Control, Security, Technology, Wireless
This is another long post—and it is a summary—running through many of the new products introduced to the press and analysts durning Emerson Exchange 2015. If any of these whet your appetite, visit the Emerson Process Website for more information.
Another place to catch up on happenings at the conference is Jim Cahill’s Emerson Process Experts blog. He also has been introducing readers to highlighted sessions.
Machinery protection
CSI 6500 ATG protection system, a stand-alone machinery protection solution that allows users to cost-effectively introduce prediction monitoring of critical assets from the same system. Predictive intelligence is a key component to increasing availability and improving the reliability of plant assets.
These multi-functional cards can be easily reconfigured for a wide range of measurements, including the impacting or peak-to-peak data used in Emerson’s unique PeakVue technology. In addition to monitoring the start-up and coastdown of critical turbo machinery for safe operation, users will be able to utilize PeakVue technology to identify the earliest indications of developing faults in gearboxes and bearings.
With the CSI 6500 ATG, it is no longer necessary to return to the control room or open cabinets in the field to view or analyze data. The CSI 6500 ATG can be networked over wired or wireless Ethernet to deliver asset health information to authorized users through a PC or phone application.
To facilitate easy system integration with third party systems, CSI 6500 ATG is the first protection system to include a secure embedded OPC UA server.
Gas ultrasonic flow meter
A new Daniel gas ultrasonic flow meter platform elevates its well-proven British Gas design by providing two meters and transmitters in a single body to help natural gas operators and pipelines improve reliability and efficiency. Designed to maximize capital budgets by permitting two completely independent measurements with the installation of just a single flowmeter, the new 3415 (four-path + one-path) and 3416 (four-path + two-path) gas ultrasonic flow meters combine a four-path fiscal meter with an additional check meter, while the new 3417 (four-path + four-path) meter provides two fiscal meters for full redundancy and equal accuracy within one meter body. This two-in-one redundant design delivers continuous on-line verification of custody transfer measurement integrity, device health and process conditions, and improves fiscal metering confidence while ensuring regulatory compliance.
Both Daniel 3415 and 3416 gas ultrasonic meters measure flow using four horizontal chordal paths in addition to a reflective path dedicated to verification of the primary measurement, enabling improved metering insight, more informed decision making and simplified flow meter verification. For enhanced immunity to pipe wall contamination, the 3416 meter is equipped with an additional vertical reflective path to detect liquid or very thin layers of contamination at the bottom of the meter that otherwise remain completely hidden in a direct-path meter design. This allows reliable monitoring of process changes before they affect measurement, thus reducing calibration frequency and enabling maintenance to be condition-based instead of calendar-based.
Electric actuator control
DCMlink Software, a unified electric actuator control, monitoring and diagnostics platform, will allow, for the first time, Emerson customers to diagnose, configure, and monitor all electric actuators from a central location independent of protocol, actuator or host system. The software extends the useful life of field assets by providing actuator data gathering, condition monitoring, events log and prioritization of actuator alarms in a unified and consistent user interface. Actuator configuration includes custom characterization, as well as the ability to import and export historical configuration profiles.
Whether it is viewing value torque profile, live trending data or actionable alarms straight from the actuator, plant operators will be able to access detailed monitoring and diagnostics data, allowing them to take action before a fault occurs. DCMlink offers advanced control and diagnostics, including torque profile curves, initiating partial stroke test or emergency shut down and alarms in NE-107 format. Current communications support included Modbus, TCP-IP, and Bluetooth.
DeltaV v13
Version 13 (v13) of the DeltaV distributed control system (DCS) new features focus on integration, advanced alarm management, and security with an overarching design that improves ease of use and minimizes the need for specialized expertise.
DeltaV v13 delivers technologies to bring sources together for easy operator access and use. These technologies include an Ethernet I/O card (EIOC) for integrating Ethernet-based subsystems and devices, including a direct interface with smart motor control centers and substations. It improves the factory acceptance testing (FAT) experience by providing enhanced safety instrumented system simulation capabilities and easy-to-use virtualization environment.
The new DeltaV Alarm Mosaic has an intuitive alarm display that enables operators to more quickly identify, analyze, and respond correctly to the root cause of an abnormal process condition. The new release also provides trend display optimizations for better visibility of process changes.
SCADA
OpenEnterprise v3.2 release adds a native interface to the AMS Device Manager asset management software, enabling users to remotely manage and maintain HART and WirelessHART devices in wide-area SCADA networks.
OpenEnterprise v3.2 together with AMS Device Manager allows asset owners to extend the reach of their predictive maintenance capability out to their remote assets, providing a powerful and proactive method of diagnosing potential device problems remotely. This results in reduced trips to the field and helps to avoid unplanned process shutdowns, improving safety, reliability, and profitability.
The native interface of OpenEnterprise v3.2 to AMS Device Manager enables the collection of wired and wireless HART digital device data over low bandwidth wide-area SCADA networks from Emerson ROC, FloBoss, and ControlWave RTUs without adding the additional complexity and expense of external HART multiplexers. Support for AMS Device Manager SNAP-ON applications, OpenEnterprise SCADA server redundancy, multiple deployment options, and data collection for up to 10,000 HART devices ensures flexibility and scalability for a wide range of remote oil and gas applications.
Machinery health in PowerGen
Emerson now offers its power generation and water/wastewater industry customers native machinery health monitoring and protection capability within the Ovation distributed control system.
Ovation Machinery Health Monitor leverages the Ovation platform through a high-performance I/O module dedicated to machinery health functions. Simply install by inserting the module into a spare I/O slot.
With the Ovation Machinery Health Monitor, operators receive alerts from a single set of common plant HMIs and no longer need to manually check machinery functions through a separate system.
The Ovation Machinery Health Monitor also reduces the risk of cyber attack by eliminating links to standalone systems and isolating process information – all of which can help facilities meet NERC CIP and other security regulations.
Silica sensing
Costly damage to turbine blades caused by silica deposition can occur due to a poorly monitored steam purity program. The new Rosemount 2056 Silica Analyzer provides continuous accurate measurements of silica in process streams with a range of 0.5 ppb to 5000 ppb. The 2056’s usability features make it one of the easiest -to-use and high performing analyzers.
Harsh duty pressure sensing
Rosemount 3051S Thermal Range Expander with new UltraTherm 805 oil fill fluid enables pressure measurements by direct-mounting a diaphragm seal system to processes that reach up to 410°C (770°F) without requiring the challenging impulse piping or heat tracing used in traditional connection technology. In applications where ambient temperatures drop below ideal operating conditions, system response time becomes slow, resulting in delayed process pressure readings. Traditionally, this problem is solved by using heat tracing which is costly, maintenance intensive, and difficult to install. By using the new thermal range expander dual fill fluid seal, the Rosemount 3051S can reliably measure pressure at extremely high process and low ambient temperatures.
The Rosemount 3051S Electronic Remote Sensors (ERS) System now has safety certification. The ERS System calculates differential pressure through a digital architecture — and is now suitable for SIL 2 and 3 applications.
Rosemount 3051S High Static Differential Pressure Transmitter provides reliable flow measurement in high pressure applications with capabilities up to 15,000 psi (1034 bar). The transmitter’s SuperModule platform and coplanar design reduce potential leak points by 50 percent compared to traditional designs, ensuring the highest differential pressure measurement accuracy, field reliability and safety.
Corrosion monitoring
The Roxar Corrosion Monitoring system, consisting of wireless-based probes, will provide refineries with flexible, responsive, integrated and highly accurate corrosion monitoring.
Combined with the Emerson’s non-intrusive Field Signature Method (FSM) technology, a non-intrusive system for monitoring internal corrosion at the pipewall, refinery operators will be able to access more comprehensive corrosion information and corrosion rates, leading to improved operator insight and control over assets.
The system will also help identify and track opportunity/high TAN crudes and their corrosive elements. Such crudes are less expensive but more corrosive than others with the new system enabling the maximum amount of such crudes to be blended into the mix without increasing corrosion risk.
Wireless pressure gauge
Emerson Process Management has introduced the industry’s first WirelessHART pressure gauge. The Rosemount Wireless Pressure Gauge enables remote collection of field data.
The Wireless Pressure Gauge eliminates mechanical gauge common weak points by removing the components that inhibit the device from reporting/displaying pressure and providing up to a 10-year life, which reduces maintenance cost and time. The large 4.5-inch gauge face provides easy field visibility.
by Gary Mintchell | Oct 15, 2015 | Automation, News, Operations Management, Technology, Wireless
This is a long post, but it brings together several of the more important announcements from this week’s conference. I’ve seen bits of this coming as Emerson has moved its message to incorporate asset management over the past couple of years and is now taking the message to an even higher level in the customer organization. I find it interesting that it takes a holistic look at its product portfolio and then bundles it in such a way as to serve a higher purpose at the customer’s business.
Steve Sonnenberg, Emerson EVP and Emerson Process Management president, said during the opening keynote to Emerson Global Users Exchange 2015, “Managers are looking for dramatic improvements. This is not a time to be satisfied to be as good as everyone else. All are talking top quartile performance. What do you do when all the usual approaches no longer work? Top companies are finding all new approaches. “
The phrase of the day was “Top Quartile Companies.”
Then the concept of improvements in project management and execution was introduced. Jim Nyquist, president of Emerson Systems and Solutions business, added, “Projects are in crisis. 65% of industry’s projects over $1 billion are failing. 33% of projects of $500 million. It seems the larger the project the larger the overrun.”
Global market means more competition leading to increases in the scale of projects.
What’s needed to rein in this runaway stage coach? Nyquist declared that design, engineering, and project management need a reset. Budgets need a resent and predictability and reliability must be improved. Top quartile projects are completed at half the cost and half the schedule of 4th quartile companies. “Industry is at inflection point,” he predicted.
Project Certainty
Then he announced the launch of Project Certainty, an innovative technology- and engineering-based approach for improved capital efficiency and more reliable project schedules.
Emerson’s Project Certainty begins with early engagement during engineering and design studies to define project goals and high impact strategies to meet those goals. Despite traditionally accounting for approximately 4 percent of a project investment, automation is revealing unique and repeatable ways to eliminate cost, reduce complexity and accommodate late-stage project changes, beyond the automation discipline.
For example, Project Certainty relies on the right design engineering strategy to eliminate centralized control system room requirements by 70 to 80 percent, and can eliminate piping in some applications up to 50 to 60 percent. Additionally, tens of millions of dollars in capital spare parts can be eliminated through project-wide equipment reliability analysis.
“Project Certainty also tackles complexity by decoupling the dependencies suppliers have on each other, eliminating bottlenecks and allowing concurrent work streams,” said Nyquist. “Likewise, we are addressing the complexity of data and documentation with innovative technologies that provide features like a single source of project data as well as automated documentation.”
Addressing one of the greatest project vulnerabilities, Project Certainty significantly improves project schedule performance. Technologies like Electronic Marshalling with CHARMs, and pervasive wireless field instrumentation are helping project teams accommodate inevitable last-minute design changes without impacting schedule.
“The path to Top Quartile project performance is right in front of us,” said Nyquist. “The technologies and proven methodologies are here. It will take collaboration and commitment to eliminate outdated project approaches and drive change into the industry.”
Data Link
Part of this new environment is Project Data Link, a project engineering environment that helps reduce complexity and accommodate changes in capital projects. As projects become more complex with multiple contractors and stakeholders, Project Data Link helps keep projects off the critical path by efficiently and consistently translating project information, including tag databases and instrument indices, from multiple sources into project deliverables. It mitigates project risk by normalizing specifications into a single data source with traceability and an integrated change-management system.
Project Data Link gives multiple suppliers, engineering firms, and other stakeholders access to project information including specifications related to field devices and the distributed control system (including control logic and configuration). In addition, data provided in various formats are normalized so that all information is available in a single, consolidated standard view.
The integrity of project information is especially important during late project changes. The data link is always up to date, so when a change is initiated Project Data Link automatically reconciles it against what is in the system, identifies what needs to be changed, automatically sends updates to the DeltaV distributed control system and provides an audit trail of what has changed. This saves time and eliminates errors during the critical late stages of the project.
“Moving forward to improve project certainty, Emerson continues to find methods to reduce the risk of project errors, accommodate change and improve engineering efficiency,” said Randall Fong, project technical manager. “We are confident that Project Data Link will help our customers move towards on-budget and on-time projects.”
Smart Commissioning
Here is yet another part of the portfolio of improving products–Smart Commissioning, a technology-enabled process that reduces automation commissioning time and effort. Smart Commissioning helps automation projects meet strict and shifting deadlines by reducing trips to the field, eliminating tasks, and accommodating late project changes. Smart Automation Commissioning builds on advances made possible by the combination of the DeltaV distributed control system (DCS) Electronic Marshalling with CHARMs and AMS Device Manager Software to remove automation from the critical path of projects.
With the release of version 13 software for the DeltaV DCS and AMS Suite, Smart Commissioning brings ease to automation project implementation. From the initial device connections to final system testing, users save money as they shave weeks off the project schedule by reducing time spent on automation commissioning activities.
Upon arrival at a project site, pre-tagged smart devices can be connected immediately to any channel in a nearby junction box — no need to wait for wiring designs to be complete. Smart Commissioning also eliminates potential errors by automatically finding and identifying all smart devices, then binding them to the configuration. To further accelerate implementation, the device configuration is pushed to all devices based on pre-configured templates. Testing is easily and safely done from the control room by using digital communication, requiring no personnel in the field for confirmation.
“With Smart Commissioning, members of the project team can more easily meet tight project timelines and are not hampered by late design changes,” said Mark Howard, vice president of project execution for Emerson Process Management. “Developed based on industry experience, this solution is another step from Emerson toward attaining project certainty for users.”
Projects in Action
Sasol, an international energy and chemical company, has selected Emerson Process Management to help automate its $8.9 billion petrochemical complex in Lake Charles, La., designed to take advantage of abundant, low cost natural gas. The automation project is one of the largest in history awarded to Emerson.
When completed sometime in 2018, the massive petrochemical complex will more than triple Sasol’s chemical production capacity in the United States. The complex includes an ethane cracker that will produce 1.5 million tons of ethylene annually, as well as six chemical manufacturing plants designed to convert the ethylene into a diverse range of chemicals. Ethylene is a key ingredient in the production of plastics, detergents, anti-freeze, and other petrochemical products.
Emerson Process Management implemented a detailed engineering and project execution plan designed to mitigate project risks, lower costs and reduce time to completion, all part of the company’s strategic Project Certainty initiative.
“For a project of this scale, managing budget and schedule risk is paramount,” said Jim Nyquist, group vice president of Emerson. “This is a great example of our Project Certainty initiative. Early engineering and design work is being used to identify opportunities for automation technology to reduce complexity, create project cost savings, and reduce schedule and cost risks. As the project moves into the execution phase, Emerson is well-positioned to implement the design, accommodate late changes and reduce on-site work – all of which speed execution without compromising quality, safety or reliability.”
by Gary Mintchell | Oct 14, 2015 | Automation, News, Operations Management, Technology
Is it possible to remove automation from the critical path of a large process industry project? Not only that, but use automation to shorten the other paths of the project?
That is the goal of the latest thinking from Emerson Process Management–especially the Systems and Solutions business.
I have been at the 2015 edition of the Emerson Global Users Exchange in Denver this week. I have many details to share. I’ll get those on the plane going home this afternoon.
Before I talk about “Project Certainty”, a few thoughts on the conference.
Everyone knows how the oil & gas industry has been hit by falling oil prices (thank you shale and Saudi Arabia). The impact was first apparent in conference in our part of the industry when travel was cut and attendance at the ARC Advisory Group conference dropped. Same here. While this is still a large conference, the impact of travel budget cuts was obvious.
There were lots of sessions and around 2,500 people around, but in a more normal year there probably would have been maybe a thousand more.
But Emerson still unveiled lots of new products and initiatives.
The photo captures Emerson EVP and Emerson Process President Steve Sonnenberg and Emerson Process Systems and Solutions business President Jim Nyquist introducing Project Certainty.
What Emerson has done has been to look at all the technologies introduced and deployed over the past ten years or so and apply to the bigger picture. They have put forth an answer to how can wireless products, electronic marshaling, the CHARMS configurable I/O, and many more help companies shorten the project path if project planners use the ideas from the beginning of planning and design of a project.
The example is SASOL who is building what is in effect eight plants in Louisiana using these ideas and already showing returns.
I’ll have more on this in my next post. But this reveals some solid thinking about customers and needs by the Emerson team.
by Gary Mintchell | Jun 29, 2015 | Automation, Internet of Things, Networking, News, Operations Management, Technology
The Internet of Things (IoT) is nothing if not about connectivity. Connecting edge devices to control and information platforms is nothing new to industrial systems, but technology advances attempt to make things easier and faster to deploy.
Cisco’s connectivity products and technologies have long been at the core of enterprise networks. Cisco has also partnered with automation companies such as Rockwell Automation, Emerson Process Management, and Honeywell Process Solutions.
Cisco just announced its latest extensions to the technology. The new Cisco IoT System addresses the complexity of digitization “with an infrastructure that can manage a growing mix of endpoints, platforms and the data deluge.”
Within the new Cisco IoT System framework, Cisco introduced more than 15 new IoT products across six pillars to address the complexities of digitization and help organizations deploy, accelerate and innovate with IoT. Together, the framework supports the infrastructure growth requirements that organizations are facing with IoT by helping raise operational efficiency, create new services, and improve quality and security.
Six‐Pillar Approach for Cisco IoT System
The Cisco IoT System integrates six pillars that must come together for a successful IoT solution and deployment:
- Network Connectivity: Includes purpose-‐built routing, switching, and wireless products available in ruggedized and non‐ruggedized form factors.
- Fog Computing: Extends cloud connectivity closer to the edge to produce immediate insights and efficiently analyze and manage d Cisco predicts that 40% of IoT ‐created data will be processed in the fog by 2018. Over 25 of Cisco’s network products are enabled with Cisco’s fog computing or edge data processing platform, IOx.
- Security: Connects cyber and physical security for visibility into both physical and digital assets, to increase protection and expand operational benefit Cisco’s IP surveillance portfolio and network products with TrustSec security and cloud/cyber security products allow users to monitor, detect and respond to combined IT and Operational Technology (OT) attacks. Organizations in industries such as manufacturing and energy are increasingly working to integrate proprietary process control systems with the IP network infrastructure, which requires a multi‐layer security approach to maintain logical separation of business functions.
- Data Analytics: The Cisco IoT System provides an optimized infrastructure to implement analytics and harness actionable data for both the Cisco Connected Analytics Portfolio and third party analytics
- Management and Automation: The IoT System provides enhanced security, control and support for multiple siloed functions to deliver an easy-‐to-‐use system for managing an increasing volume of endpoints and applications, that field operators need an easy-‐to-‐use management system
- Application Enablement Platform: Offers a set of APIs for industries and cities, ecosystem partners and third-‐party vendors to design, develop and deploy their own applications on the foundation of IoT System capabilities.
Over 15 new IoT products across the six pillars of the IoT System:
Network Connectivity Highlights:
IE5000: Purpose-‐built IE switch that brings connectivity to factory-‐level manufacturing and cities.
IW3702: Wireless access point for connected mass transit systems and city Wi-‐Fi. IR 809, IR 829 series: Introducing 7 new industrial routers with Wi-‐Fi and 4G/LTE connectivity, ideal for transportation or IoT application deployments.
4G/LTE module for CGR 1000 for utilities, Mobile IP Gateway (MIG-‐2450) for connected rail solutions, and 5921 Embedded Services Routers for defense extend reach of industrial networking into remote environments.
Physical and Cyber Security
360° 5MP & 720p IP cameras: These high-‐quality cameras cater to versatile environments and can host 3rd party software applications. Features include 360° view for situational awareness and audio and digital sensors.
Physical Security Analytics: Camera applications include audio detection, sensor aggregation, audio message triggers, metadata generation, local video player and video summarization.
Data Analytics
Fog Data Services: Allow operators to create policies that monitor and take actions on data flowing through the IoT environment (data-‐in-‐motion). It resides on the IOx platform so users can integrate custom policies with applications.
Management and Automation
IoT Field Network Director: This management software allows operators to monitor and customize IoT network infrastructure for industrial scale.
Fog Director: Allows central management of multiple applications running at the edge. This management platform gives administrators control of application settings and lifecycle, for easier access and visibility into large-‐scale IoT deployments.
Partners support Cisco IoT System and IOx for fog computing
Cisco IoT System enables industry verticals such as manufacturing, oil & gas, utilities, transportation, public safety and smart cities to deploy and accelerate IoT solutions and realize business benefits with targeted solutions. Key industry leaders have already ported their software applications to run on the Cisco Fog Computing system, including GE (Predix), Itron (Riva), OSISoft (PI), smartFOA in Japan, Bitstew, Davra, SK Solutions, Toshiba and more.
Cisco also announced the addition of Covacsis, which is taking advantage of Cisco IOx to provide predictive analytics to manufacturing industries. Cisco also provides comprehensive consulting and professional services for IoT. Our leading networking expertise combined with our technology partners’ expertise helps accelerate transformation and ensures IT and operational technology alignment.
Sujeet Chand, senior vice president and CTO, Rockwell Automation, noted, “Together with Cisco, we are helping customers derive value from the Internet of Things, by simplifying connectivity of assets on the plant floor with the rest of the enterprise and with remote experts. By focusing on the key values of the Cisco approach to IoT, our mutual customers can benefit from improved decision making that can lead to streamlined business and manufacturing processes, reduced network complexities and improved security. Rockwell Automation and Cisco take a collaborative approach to bring OT and IT together to deliver performance-‐critical information to drive business outcomes across The Connected Enterprise.”
by Gary Mintchell | Mar 25, 2015 | Automation, Manufacturing IT, Operations Management, Technology
During my continuous research for topics such as Industry 4.0, digital manufacturing, smart manufacturing and the industrial Internet of things, I came across this Siemens PLM software blog.
In it, Zvi Feuer, Siemens PLM Software’s Senior Vice President, Digital Factory, Manufacturing Engineering Software, shares his perspective on “how Siemens helps companies worldwide to realize innovation in manufacturing.”
Feuer says, “I want to be able to offer our customers industry solutions which provide the means to turn any manufacturing operation into a high tech manufacturer. In order for us to sell not only the software but also usage methodologies And, in fact, to increase productivity with the customer and to help the customer deliver to his customers in a better and faster shape. This will obviously create opportunities for people, opportunities for jobs.”
Siemens executives have explained its digital manufacturing strategy to me for more than 10 years. And the vision has been remarkably consistent. The first conversations were even before the UGS acquisition that led to the Siemens PLM business.
PLM As ERP for Manufacturing
The blog refers to a white paper, PLM For Manufacturing, “If you are looking for ways to connect all domains of the design/build lifecycle, consider a manufacturing process management (MPM) solution. This provides an enterprise-scalable foundation that allows you to perform product design, while simultaneously optimizing manufacturing processes. This means that you can better manage lifecycle cost, meet launch dates and maintain product quality targets.”
That statement reflects Siemens thinking even before the acquisition. Is it possible to design not only the product but the manufacturing digitally, and then proof it all out digitally before even cutting the first steel.
“We believe that an MPM system that is part of an enterprise PLM system is the best way to move
forward. This will provide an environment that supports a flexible process plan capable of reflecting any changes to the product design or requirements. This might be called a single window for enterprise data management – a single application that supports the complete lifecyle of product data in an enterprise environment. The main idea is to provide users with one platform for all their data management needs. Teamcenter PLM software is the only comprehensive system that provides a platform in which users can conduct all their data management needs from engineering to manufacturing to execution.”
Is it sustainable?
This is a grand vision. It reads like Goldratt’s “The Goal” coming to life totally automated. But, there are inherent problems to the grand scheme. I have witnessed and otherwise seen the benefits of more and better information informing production/maintenance teams enabling better decisions and improvements. But to think that this could eventually happen without human intervention–I doubt that ever happens effectively.
The white paper also talks about complexities of manufacturing and software, then it argues that it would be better to put everything into one overarching software application. I would argue, along with my Lean friends, that this would just make for one very complex software application.
Any of us who have actually done automation know that when the application gets too complex, then it doesn’t work. It is not maintained. It is not understood. People begin developing their more simplified (and understandable) workarounds.
The vision is like most things I have witnessed over the past 40 years of applying technology. We develop something. We get benefits. We get over ambitious and build something cumbersome. People stop using it. We develop something simpler. People use it. And so on.
Digital manufacturing and Industrie 4.0? Interesting. The jury is still deliberating as to whether it is giving Germany the desired competitive edge in manufacturing.
