Even as companies strive for optimal performance of their operating assets, safety and regulatory compliance necessarily come first. But many plants simply weren't designed or built to meet today's stringent requirements, and finding ways to keep legacy equipment up to code presents a constant challenge.
The costs of compliance are not trivial. Many industries face increasing regulation that puts 30 to 50 percent of their profits at stake, according to a recent McKinsey report. Furthermore, the U.S. Dept. of the Interior estimated that new safety regulations introduced in 2010 added $1.4 million in annual operating costs to each of the oil and gas industry's deep water drills with floating rigs.
Compounding these operational demands, people every day still must travel to remote areas or go into harm's way to take manual process measurements deemed too expensive or impractical to automate even a few years ago. They need instrumentation that runs reliably and accurately at high and low temperatures and under other extreme conditions. Further, added measurement points in increasingly remote or hard-to-reach areas dictate minimal maintenance or calibration requirements that repeatedly endanger plant personnel. Managers, engineers and operators also need better predictive diagnostics and improved visibility into their plant's true capabilities if they're to safely squeeze more productivity and efficiency out of their processes. And they're turning to a new generation of high-performance instrumentation technologies to make that possible.
Minimize Risky Worker Procedures
Perhaps nowhere else is the instrumentation payoff greater than where it can prevent the need for a worker to risk injury in pursuit of a process measurement. Instrumentation that is both easy and cost-effective to install—and then performs reliably and accurately in even the harshest conditions—will help ensure that workers seldom have to visit these oftentimes hazardous or, hard-to-reach areas again. Overall safety increases as do process control and predictability, owing to the improved vigilance and consistency of a dedicated, high-performance instrument as compared to manual measurement.
At the AOC resin manufacturing facility in Perris, Calif., Rosemount wireless temperature sensors eliminated clipboard rounds that were an inefficient use of operator time, subjected personnel to a safety risk, and lengthened time to market. The new Smart Wireless network ensures proper mixing of AOC's intermediate resin products with micro-additives at target temperatures to achieve customer-specific formulations and quality—all from the safety of the control room.
"By replacing manual sampling with on-line measurements, we were able to decrease cycle time up to 10 percent," said Tou Moua, AOC product engineer. "We also improved operator safety, and freed up their time to focus on other key areas of the plant."
And at chemical intermediates manufacturer Croda, Inc. in Mill Hall, Pa., Rosemount wireless temperature sensors tackled an application that previously had been both unsafe and impractical for traditional wired approaches: the early detection of exothermic reactions in railcars. With continuous temperature monitoring that goes wherever the railcars do, if the temperature starts to rise, operators are alerted and can take preventive action well before a hazardous situation escalates.
"The Emerson Smart Wireless solution not only saves us time and money, since plant personnel no longer have to monitor those railcars daily, it has also greatly enhanced the overall safety of the plant and our personnel," says Danny Fetters, Croda I&E designer. "No matter where a railcar is positioned on-site, the quality of the transmissions is unaffected, and the signals integrate seamlessly into our control system."
Wireless instruments typically can be installed for a small fraction of the price and effort of a wired instrument. But perhaps the ultimate in installation ease—and safety—is the new Rosemount 0085 Pipe Clamp Sensor which together with a Rosemount 648 Wireless Transmitter provides a simple, fast solution for adding temperature measurements, exactly where you need them, without interrupting the process. The sensor's spring-loaded silver or nickel tip is designed to ensure contact against the pipe surface and provide measurement accuracy and fast response time.
The ease with which reliable new measurement points can be added is only one factor in the wireless safety equation. By installing Emerson Smart Wireless THUM Adaptors on existing instruments—especially those critical, hard-to-reach devices—plants can easily access and finally begin to leverage the advanced diagnostics and multivariable capabilities of the many HART-capable devices that currently communicate only their 4-20mA process variable signal. Liberating stranded diagnostics and secondary process variables provides added insight into the status of these instruments themselves, as well as feeding critical asset health information to operations, maintenance and reliability systems—contributing to safer, more reliable and more efficient operations.
Instrument Your Safety Infrastructure