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.
Public Service Electric and Gas implemented the SAP PM (Plant Maintenance) system in 2000 to enhance the efficiency of its transmission and distribution equipment maintenance. While this application did improve maintenance systems, it did not provide the proactive, predictive approach to T&D maintenance that the company wanted.
A special project was begun in 2001 to design and implement a computerized maintenance management system (CMMS) that would allow PSE&G to monitor equipment status and handle maintenance procedures using a condition-based approach rather than a calendar-based system. The PI System from OSIsoft in San Leandro, Calif., is the foundation on which PSE&Gs engineering and IT staffs created their CMMS solution. The system proposal called for a full ROI by 2005, but the system was launched in early 2002 and began delivering cost savings in its first year. It also is extending the life of aging equipment through more efficient monitoring of performance.
Until a few years ago, QNIs cobalt/nickel refinery in Yabulu, Australia, used manual process-recording methods. Process engineers found it difficult to determine the influence of variables on product quality and to generate timely reports for management. Management was frustrated by the challenges of accounting for monthly reconciled recovery, determining where losses occurred and tracking quality by batch.
To gain control over its operations and processes, QNI needed to track key performance indicators (KPIs) and overall equipment effectiveness (OEE). Though QNI already had a functioning ABB distributed control system, it couldnt store process data for more than three weeks not really long enough to track production records and monitor KPIs. Faced with ISO 9001 compliance and the need to implement Six Sigma in its manufacture of high-grade nickel and cobalt products, QNI chose OSIsofts solution to combine production data from its six business units with their total of eight separate control rooms.
The Roche Group maintains three types of manufacturing facilities: chemical, biotech and galenical. To sustain growth in an increasingly competitive global business environment, the company sought a technically superior information platform that would enable operational improvements in efficiency, performance, quality and compliance with Good Manufacturing Practices (GMP).
Roche considered the PI System to be the best foundation to gain visibility into operational performance and enable faster response time and analysis for more cost-effective actions. As a successful global initiative, PI allows management to make more effective business decisions based on reliable and current information. Local plant management can optimize process operations to respond to real-world product demand. Operators, engineers, chemists and managers can now plan better, improve production and increase efficiency.
IEEE 802.11 wireless technology is being deployed rapidly in many industrial plants as the security and bandwidth of these products have improved. The need to gather data from and provide data to equipment and employees moving around a facility is one of the primary applications for these wireless devices. Configuring wireless networks requires careful planning to insure that the network will function as required without causing problems with adjacent installations. This white paper provides a starting point for your wireless design.
In our professional lives were constantly reminded that it is better to be proactive rather than reactive. Taking a more proactive approach implies that were prepared and have a sense of what is happening within our environment. Why not extend this proactive approach to fieldbus network management?
Download this white paper to learn how to extend preventive maintenance methodology to your plant fieldbus network.
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.
A wastewater treatment organization in Massachusetts has been implementing OSIsofts PI System (PI) as the core of an enterprise-wide solution. With the help of the real-time data collected and distributed by PI, the Massachusetts Water Resource Authority (MWRA) is able to achieve real-time notification of events to the employees who need to know; real-time pricing of power in order to determine the most cost-effective approach to on-site power usage; deliver accurate and timely compliance reporting to local and federal agencies; and, perhaps best of all, play a key role in improving the quality of the environment in Boston Harbor and Massachusetts Bay.
This interactive and educational PDF, written by the editorial staff of Control, includes conference highlights from the ABB Automation and Power World 2009. Download now for videos and articles covering topics such as how to weather the economic storm, laying the groundwork for sustainable energy management, and green instrumentation practices.
In the last few years, the cost of energy has increased many fold. This has made the measurement and management of energy a key area of activity in the industry. As the demand of energy increases world wide, the pressure on resources increases and this leads to the increase in costs. It is a simple issue of demand and supply.
This paper comments on possible ways to manage energy in a processing plant. More specifically it concentrates on better energy measurements and how to increase efficiency through benchmarking and information management. The paper offers practical ways to reduce operational costs with small capital expenditure and thus a fast ROI.
If you are an industrial automation control engineer or technician embarking upon the design and installation of an industrial network, you will quickly confront a bewildering array of standards written by a host of international, regional, national and trade organizations.
This white paper will give you some historical perspective on what has caused such a proliferation of standards. It presents an overview of the primary standards organizations you should be familiar with and how they relate to one another (if at all). It looks at the key standards these organizations write, the current status of those standards, and what the future may hold. This white paper will also guide you as you ferret out the particular sections in the standards that apply to your Ethernet network and where you can turn for help as you plan, install and maintain it.
This white paper will describe how and why an AC variablefrequency drive must simultaneously control output frequency and voltage to efficiently control the speed of a threephase induction motor. Highly educational and practical.
Many automation engineers are coming face to face with real fieldbus applications for the first time. Fieldbus is a technology with many benefits, but its installation requires considerations over and above normal 420mA projects. In this article, we will discuss some of those issues and show you how to deal with them.
In the last few years, the cost of energy has increased many fold. This has made the measurement and management of energy a key area of activity in the industry. In the modern competitive world, tangible costs must be reduced and efficiency optimized to be competitive. It is amazing how we can achieve both goals of lower costs through better efficiency and lower emissions through better energy management. This paper comments on possible ways to manage energy in a processing plant, concentrating on better energy measurement and increasing efficiency through benchmarking and information management.
Siliken Renewable Energy Optimizes Solar Panel Production by Standardizing on NI Hardware and Software
The Challenge: Optimizing the production and installation of solar panels from Silicon purification to end-of-line manufacturing verification to final installation and monitoring.
The Solution: Using NI hardware and software to optimize the solar panel production process, from purifying silicon ore to manufacturing and testing the final product, to ensure that we consistently produce high-quality solar panels.
The Kodak Park, located in Rochester, N.Y., is over 100 years old. The site has 1300 acres, two utility power plants, two company-owned water and waste water treatment plants, 150 buildings and 11,000 employees. The Kodak Park utility power plants have enormous generation output and demand requirements including 2,000,000 pounds per hour steam load and a 125 MW electric load.
The site also has 600 electric distribution meters, 600 additional non-electric distribution meters and many generation site meters. The utilities systems were operated and monitored by a group of disparate building automation systems and distributed control systems.
With such a vast energy and management system, Kodak shares many of the same concerns as regional utility companies conservation, optimization of resources and consolidation of data from various legacy systems. Any new technology solution added to this mix had to be compatible with our well-defined information architecture requirements.
Formed in 2001 as the result of a government initiative to create competitive subsidiaries in the power generation industry, Korea Hydro & Nuclear Power Company (KHNP) needed to monitor different variables at its multiple nuclear power facilities. KHNP also wanted to actively manage the changing business conditions in Korea. There was increasing public and government concern about safety and the environmental impact of nuclear power. Residents in the towns surrounding the plants were demanding greater transparency of operations and systems. Additional requirements were to enhance the efficiency of information between facilities and integrate plant data with the companys SAP Enterprise Resource Planning system. To solve information access and transparency problems, KNHP chose the PI System from OSIsoft.
Editor in chief Walt Boyes reports and interprets Controls latest readership survey. This time we asked our readers about their understanding and usage practices concerning safety instrumented systems. Safety is one of the most important issues facing the process industries, especially as retirement takes much of the institutional knowledge and experience from plants worldwide.
As industrial Ethernet networks grow in number and importance, keeping the right traffic on and off the network becomes essential
The use of Ethernet for industrial automation has grown dramatically. One of the main benefits of moving from legacy fieldbus to Ethernet is the ability to connect the front office to the manufacturing system. This is possible because Ethernet is not a proprietary communication protocol. The non-proprietary nature of Ethernet allows engineers to mix and match equipment from different vendors and get competitive bids. This combination of better office-factory communication and open standards helped industrial Ethernet gain recent widespread acceptance.
But with these benefits come potential problems. As networks and the services they provide evolve and servers or user machines are replaced and upgraded, the likelihood of passing unwanted, often obsolete protocols within the network increases.
Potentially more challenging is the existence of unknown protocols that may degrade the performance of the network. Unknown protocols are often caused by well-intended but uninformed employees who attach unauthorized devices, such as wireless access points, to the network. They can also be caused by traffic such as streaming audio from employees listening to Internet radio stations while working.
Business leaders in todays manufacturing industries are facing a key issue, lack of visibility into plant business performance in real-time. Thus, real-time information for plant costs, production value, and contribution margin are generally not available to key decision-makers within the operation. Energy management is a key area where the lack of real-time information has a significant impact. Most companies still do not have a clear understanding of the relationship between energy consumption and the impact on real-time costs. This lack of critical information makes it difficult to make informed decisions as energy-related pricing and costs change frequently, affecting manufacturing business performance. Energy prices comprise a large percentage of variable costs in most operations. The dynamic nature of their impact on the business further confounds the situation owing to factors such as:
- New green energy sources
- Complex and fast changing energy market rates and metering dynamics
- Multiple fuel-burning choices
- New and changing environmental requirements
During these difficult economic times, this problem is magnified and presents a significant challenge to improving efficiencies and managing environmental responsibilities. Todays business world requires better business information of the manufacturing environment, propagated to all relevant people within the organization to enable and empower better decision-making to improve business performance. Invensys Process Systems (IPS) Real-Time Energy Measurement and Real-Time Energy Empowerment are an effective solution to this problem.