With the significant threat that system interruptions pose to business performance and profitability, businesses are increasingly seeking to gain a competitive advantage by re-engineering their solutions, driving the need to deliver higher levels of availability.
Commonly used in process industries, high availability solutions can also benefit discrete manufacturers that have high-speed, complex operations, where the economic impact of even a short period of downtime or momentary interruptions can have huge financial, operational, and reputational costs.
This paper demonstrates the financial upside of investing in high availability technology and takes a closer look at the latest features and benefits of such solutions for continuous, efficient operations.04/20/2010
This technical white paper will discuss Yokogawa's CENTUM VP DCS (Distributed Control System) product, hereafter referred to as "CENTUM VP", and the extent of its compliance with Part 11 of Title 21 of the Code of Federal Regulations, (21 CFR Part 11), the Electronic Records / Electronic Signatures Rule.
CENTUM VP Batch Management is the optional Batch control function for CENTUM VP, which provides recipe management and process management functionality based upon the ISA-88 Batch Control System standard. This whitepaper addresses the use of CENTUM VP and the Batch Management function.
A detailed analysis of Part 11 was performed, the results of which are listed in the Detailed Part 11 Compliance section (section 5) of this document, which supports the compliance of the CENTUM VP system to Part 11.
CENTUM VP is a comprehensive software package containing configurable functions that support Part 11 compliance (audit trails, electronic signatures and electronic records). The system capitalizes on its Part 11 compliance attributes in the marketing strategy of supplying FDA regulated industries with state of the art automation capabilities.
User training and education as well as the development and utilization of policies and procedures are key components of Part 11 compliance which must be established by the user.04/15/2010
Delivering increased precision and enabling advanced regulatory control strategies for continuous process control.
Process control in the most generic sense involves continuously controlling an operation or sequence of operations that changes the state of matter; specifically, this includes changing the state of energy, chemical composition, and/or physical dimension of a substance.
As complex programs need to interface with various aspects of a comprehensive production system, Logic Developer Process Edition function blocks from GE Intelligent Platforms add precision and ease of use to reduce the learning curve for engineers, enable higher operational efficiency, and lower development costs.
This white paper helps engineers and programmers explore the power provided by Logic Developer Process Edition function blocks that allow changes in the state of matter to be controlled to generate beneficial outputs that enhance life (e.g., fuel in, electricity out), and illustrates how businesses can use these function blocks to realize advanced regulatory control strategies. It also explains the differences between Logic Developer Process Edition and GE's Proficy Machine Edition PLC Logic Developer programming software, which is optimal for leveraging an integrated development environment for discrete, motion, and multi-target control applications.04/07/2010
This document specifies requirements and gives recommendations for IT security to be fulfilled by vendors of process control and automation systems to be used in Process Control Domains (PCDs).
This covers both:
- Policy; addressing the vendor's organization, IT security processes, technological solutions and governance of IT security.
- Commissioning and maintenance
When a vendor's solution complies with this set of requirements, the solution is considered by the WIB to be PCD Security Compatible.04/07/2010
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.03/24/2010
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.03/22/2010
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.03/16/2010
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.03/16/2010
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.03/02/2010
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.02/01/2010
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.09/23/2009
If you are using PLCs in process or batch applications, and looking to lower your costs, ABB has a new white paper which will show you how today's DCS systems can significantly reduce your cost.09/10/2009
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!09/09/2009
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.08/20/2009
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.08/07/2009
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.07/15/2009
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.07/08/2009
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 process06/17/2009
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.06/03/2009
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 safety system functionality.05/27/2009