Wireless, Enhanced Sensing Lead Emerson Product Announcements

Wireless, Enhanced Sensing Lead Emerson Product Announcements

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.

I’m Back With a Leadership Lesson

It was something that had to be tried. I went from consulting to working full time for several months on a creative project with another magazine. Because of that, I had little time to devote to this blog. As of the first of the month, I’m back to consulting–and writing. Some things work and some just don’t work out. That’s life.

I took some time mostly off the grid to lead a mission trip to an orphanage and women’s shelter in Tijuana. Then a few days for grandkids’ birthdays.

Now, it’s refreshed and ready to go.

On this blog, I like to write about topics such as manufacturing strategy & technology as well as leadership & management. I wrote this post on my other blog and thought the leadership lessons would be beneficial here, too.

From Faith Venture

The church had a leadership void in a ministry area. I accepted a lunch invitation and wound up agreeing to fill that void. The position was leader of our missions ministry. Lunch was just over a year ago.

Last week a team of eleven people returned from a week working at an orphanage and women’s shelter operated by the Tijuana Christian Mission. We have had a longstanding relationship with TCM, but the leadership void had caused a break in the relationship.

This seemed like a good time to reflect on the past year and share some leadership thoughts. None of these are ground-breaking ideas. Humans have known about doing leadership for thousands of years. We just need reminding and encouraging.

Vision

I had a vision of restarting the relationships and trips to Tijuana and Haiti. Circumstances pointed to Tijuana as the best place to start.

My “reach” vision is to start new relationships leveraging two groups with ties to our church with ministries in Africa–Kenya and Ethiopia.

Obstacles

One of the staff people strongly suggested that the first thing I do is form a committee, hold committee meetings, build a formal organization with all manner of job descriptions–just like the business she had come from.

Then when I told her that I was organizing a trip to Tijuana, I was told no. That was not in my area of responsibility.

Then I found other leadership problems–mostly apathy of senior staff.

Gathering advisers

So I started finding advisers and helpers to tackle the various obstacles so we could get moving. There were internal leadership advisers and advisers who could help me plan and prepare for the trips. Such help was invaluable.

Recruiting a team

Approvals received. Dates for the trip established. It was time to recruit. Once again getting help from other leaders was essential. Circumstances beyond my control dictated a trip with only three months to recruit, plan, fund raise and go.

But a group was recruited and we began to prepare them for the trip.

Planning to smallest detail

Here are some of the planning details. We had to plan around several unknowns, but we do that in business all the time.

  • develop budget
  • agree on projects with TCM
  • budget time and money for the projects
  • plan air travel for a group
  • make sure all had passports
  • plan each day’s activities–when we eat out, when we eat at the orphanage, when we work on projects, when we work with the kids, when we arrive, when we leave

Flexibility

There are many circumstances that cannot be planned. Vans may not be available just when we think we need them. Meals may be later (or earlier) than we planned. The scope of the project may change. We had to be flexible to go with the flow and accept schedule changes.

Reflection

We gathered each day in the morning and the evening to reflect on the trip and our objectives, as well as our personal reactions.

Writing this post is another way of reflecting on the trip–what we did, what we learned. Each team member is expected to also reflect on the trip and feedback thoughts for future trips.

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