Ensuring your PAC-based control system is an integrated, robust and flexible information producer helps improve business performance, lower costs and uncover unique opportunities for competitiveness.
All companies seek ways to make their businesses grow for the long-term. Ask any manufacturer today what he/she needs in an increasingly challenging economy. It's likely to include cutting costs, improving yield, increasing functionality and becoming more competitive in the global marketplace.
Manufacturing convergence helps companies meet these business drivers - globalization, innovation, productivity and sustainability - by more closely aligning manufacturing technologies and production system operations with the rest of the enterprise. This convergence is enabled throughout the manufacturing environment with the technologies of convergence - control, power, information and communication.
Alarm management affects the bottom line. A well-functioning alarm system can help a process run closer to its ideal operating point - leading to higher yields, reduced production costs, increased throughput and higher quality, all of which add up to higher profits. Poor alarm management, on the other hand, is one of the leading causes of unplanned downtime and has been a major contributor to some of the worst industrial accidents on record. Changing the practices and procedures used in the plant has become easier and more important with the release of a new ISA standard on alarm management. The ISA-18.2 standard, which provides a blueprint for creating a safer and more productive plant, is expected to be adopted by OSHA and insurance agencies as "good engineering practice." Download this white paper to see an overview of the new standard, examples of how to follow it and more.
Today's process plant is a complicated place. Multiple raw materials combine with multiple energy streams to produce primary and secondary products. Process variability comes from the raw materials, operating practices, weather, process upsets, maintenance issues and hundreds of other sources. Finding the root cause of a process upset is critically important to permanently solving process upsets. Trying to tune all the affected control loops is simply chasing after symptoms, rather than getting to the heart of the issue. Download this paper to learn how to pinpoint the root cause of problems in process plants.
Vibration is a characteristic of virtually all industrial machines. When vibration increases beyond normal levels, it may indicate only normal wear, it may signal the need for further assessment of the underlying causes, or for immediate maintenance action. But how can the plant maintenance professional tell the difference between acceptable, normal vibration and the kind of vibration that requires immediate attention to service or replace troubled equipment? Download this white paper and learn how to tell this difference.
Today's control system engineers face competing design demands: increase embedded system performance and functionality, without sacrificing quality or breaking the budget. It is difficult to meet these challenges using traditional design and verification approaches.
Without simulation it is impossible to verify a control design until late in the development process when hardware prototypes become available. This is not an insurmountable problem for simpler designs with predictable system behavior, because there are fewer sources of error in simpler control algorithms--and those errors can often be resolved by tuning the controller on the hardware prototype.
Today's multidomain designs combine mechanical, electrical, hydraulic, control, and embedded software components. For these systems, it is no longer practical to delay verification until late in the development process. As system complexity grows, the potential for errors and suboptimal designs increase. These problems are easiest to address when they are identified early in the development process. When design problems are discovered late, they are often expensive to correct and require time-consuming hardware fixes. In some cases the hardware simply cannot be changed late in the development process, resulting in a product that fails to meet its original specifications.
Traditional verification methods are also inadequate for testing all corner cases in a design. For some control applications, it is impractical or unsafe to test the full operating envelope of the system on hardware.
Arkadiy Turevskiy, Technical Marketing Manager, The MathWorks
Applying virtualization technology to open industrial control systems reduces lifecycle costs and improves manageability. Virtualization helps reduce hardware and operating system (OS) changes, improve computer platform resource utilization and makes the system easier to maintain. Read this white paper to learn more.
Carbon-dioxide capture and storage (CCS) offers the potential for major reductions in carbon dioxide emissions of fossil fuel-based power generation in the fairly short term, and oxyfuel combustion is one of the identified CCS technology options. Foster Wheeler (FW) is working on reduction of carbon dioxide with its integrated Flexi-Burn dual-oxidant PC and CFB technology.
The proven high efficiency circulating fluidized-bed (CFB) technology offers a solution for carbon dioxide reduction both in re-powering and in greenfield power plants. CFB technology has the advantages of a more uniform furnace heat flux, excellent fuel flexibility and offers the opportunity to further reduce carbon dioxide emissions by co-firing coal with bio-fuels.
Development and design of an integrated Flexi-Burn dual-oxidant CFB boiler and balance of plant system was conducted in both air mode and oxyfuel mode. Through proper configuration and design, the same boiler can be switched from air mode to oxyfuel mode. The dual-oxidant CFB system incorporates features to maximize plant efficiency and power output when operating in the oxy-firing mode through firing more fuel in the same boiler.
Existing boiler design tools are being modified to incorporate the features of oxy-combustion, so that various design options can be evaluated. The 460 MWe supercritical CFB power plant (currently under construction by FW) has been used as the basis for an integrated Flexi-Burn dual-oxidant CFB study.
Foster Wheeler USA and Foster Wheeler Energia Oy, Finland
In today's world, automation is used prominently in every major industry. While different industries often use different specialized devices, control systems and applications, they all share a common rapidly growing challenge - how to share data amongst all these components and the rest of the enterprise. OPC is the solution - it solves the problem of communication between devices, controllers and applications. It is a standardized approach to data connectivity that does not get caught up in the usual custom-drive based connectivity problems.
Read this guide to learn the ABCs of OPC and how it can solve your data connectivity issues!
Process Analytics and Intelligencesometimes called Manufacturing Intelligencehas transformed the way companies produce goods, understand their manufacturing processes, and ensure a quality product in ways we could not have foreseen ten years ago.
Real-time Analytics have replaced the legacy concept of running reports. Reports that represent a static picture of a process at a fixed point in time are great tools for compliance audits and long term warranty analysis. However, they may not accurately represent the "as-is" state of a process. Reports showing large amounts of data can be difficult to interpret. There are often limitations in how the report data can be drilleddown and viewed.
With today's large volumes of data, there's a wealth of information that can be gained about the process. But how can this data be captured, managed and retrieved in a way that presents the information in an up-to-theminute easy to understand format? Real-time Analytics provides the techniques and solutions that address this problem. Instead of users having to interpret the data, it's presented in a graphical form enabling them to easily drill down to explore the data in real-time.
This white paper discusses how Process Analytics is implemented and utilized. Ways of managing and distributing Process Analytics to the organization are presented.
Thirty years ago, specifying an enclosure involved three steps: ordering the appropriately sized gray box, installing sensitive electronic equipment and hoping the enclosure would withstand its surroundings.
Since the introduction and use of the PLC as a relay replacement device, the uses of small, self contained automation controllers have mushroomed and have changed the complexion and even the architecture of the control system itself. This white paper discusses the benefits of using PACs to solve your company solutions.
The plant operator has an extremely valuable and important responsibility: being the force and energy managing a capital enterprise easily worth hundreds of millions of dollars to produce or impact a daily revenue stream of millions, give or take. We ask him to be ever mindful of what the plant might be doing. We ask him to be capable of finding every little problem before it grows into a big one. We ask him to shoulder the burden of everything that goes wrong during his watch, all without any recognition when nothing does, and precious little (if not actual blame) when it goes wrong and he manages to manage. Within his area of responsibility and authority he must be able to view every control loop, most sensors, most pieces of equipment, and much of the supporting utilities, and then adjust as appropriate.
The failure to maintain situational awareness has been present in almost every disaster event that was not the result of spontaneous complete surprise. Start with the assumption that no one wants an accident. That no one would chose disaster over success. But accidents and disasters happen. We now know to a high degree of certainty that they happen because those in charge of ensuring that they do not happen, aren't aware that they are happening. They fail to know the situation. They are unaware of what is really going on, what is likely to happen, or what isn't happening that they think is. As explained in my book Alarm Management for Process Control, the solution is facilitated by effective operator interface design. Let's follow the path of interface design that can lead to better situation awareness.
Network systems automate many of todays factories and plants, controlling tasks such as data gathering, process control and production automation. Industrial networks downtime can cost a lot of money, so being able to troubleshoot the network quickly and effectively is fundamental to your production process
The right automation solution can meet the goals of specialty chemicals producers by addressing needs for product reliability, quality, agility and efficiency the keys to a sustainable competitive advantage. It will also enable small sites to boost performance and agility, achieve reliability targets, improve quality and drive down costs. Download this white paper to learn more.
More than 30 years ago, the Dow Chemical Co. embarked on what ultimately evolved into a global corporate initiative: to develop and broadly leverage a standardized, highly integrated process automation system, incorporating basic process control, process information and safetysystem functionality. Download this document to learn why Dow chose ABB to form a collaboration that has successfully moved their operating discipline forward.
Since 1997, the Chilean-based operations of Methanex, the worlds largest producer and marketer of methanol, have been using the PI System from OSIsoft to improve product quality. With the success of using real-time data to improve operations, the company has recently begun to implement OSIsofts PI System as a strategic initiative to more fully integrate and distribute operations information throughout the company for better competitive advantages.
Like many companies, Janssen Pharmaceutical was implementing SAP as their Enterprise Resource Planning (ERP) system. In order to integrate manufacturing data from the plant floor into SAP, Janssen simultaneously installed the OSIsoft PI System. For the first time, financial people, who had never been able to link to the production floor, were now costing in real time. People in Operations, Engineering, Quality Assurance (QA), Environmental and Security were able to obtain multiple views from one data source, resulting in better operational visibility, process improvement and collaboration. The use of the PI System has led to better decisions and ongoing improvements such as: reduced cycle times, superior batch quality and releases, thorough incident investigations, decreased process variability, real-time costing, and better alarm management and security monitoring.
Now, with the implementation of OSIsofts RtReports product, Janssen can provide QA with a tool that streamlines the validation process for faster and more accurate compliance monitoring and reporting. The reams of paper with sign-offs and manual inputs from production to QA have been replaced with a few targeted reports that include batch trends. Production is able to reduce cycle time with configurable, real-time batch performance reporting. Of significant importance to Janssens business evolution is that RtReports has become a major part of Janssens progression towards electronic batch records.
The purpose of this paper is to trace the history of the development of process control, advanced process control and related applied engineering technologies, and to discuss the reasons why the industry has encountered difficulties. This paper also presents some recommendations to improve the likelihood of successful APC project implementation, and make some predictions about the future direction of the technology.