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.05/01/2009
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.04/29/2009
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.04/28/2009
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.
Watch this video
New Information and Resources on Real-Time Energy Management Solutions Now Available From IPS
Learn how real-time energy management can reduce energy costs and consumption.04/28/2009
In 2000, Innovenes Sarralbe, France plant updated its antiquated legacy system infrastructure with the OSIsoft PI System to provide real-time and historical information. Next, the company wanted to increase operational and development efficiencies. They sought to avoid multiple manual inputs and to minimize custom application development.
In 2004, the Innovene, Sarralbe site implemented OSIsofts Analysis Framework (AF) for faster application configuration to help employees analyze and optimize processes more efficiently. Innovene was impressed with the OSIsoft suite of products, and they were convinced that AF could effectively leverage the power of the new infrastructure.04/24/2009
IPLOM, a privately held company, manufactures environmentally compatible fuel products. As a small player in a competitive market, IPLOM needed to manage and optimize production in a real-time environment. IPLOM also needed to demonstrate the consistency of the products in real-time in an easily accessible Web site to its customers.
IPLOM first selected OSIsoft Sigmafine to provide mass balance yields. After one year, the company purchased the PI System and is now planning an RtWebParts implementation.04/24/2009
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.04/24/2009
Industrial Automation Flirts with Wireless
The automation industry increasingly finds wireless attractive, and for several reasons.
- Running a wired network incurs significant labor and material costs, while wireless networks cost far less.
- Wireless offers connectivity for remote areas or areas not currently served by wired networks.
- Wireless controllers and I/O can manage devices and processes even in inaccessible areas, or areas where network wiring is difficult or impossible to install.
- And wireless can offer a way to provide proof-of-concept for a new project before incurring the expense of a wired network.
For all these reasons, automation engineers are beginning to seriously consider wireless solutions (specifically WLAN, wireless Ethernet, or Wi-Fi) for all or part of their applications.
But with all these good reasons to use wireless, several concerns remain. Among them are security, network performance and reliability, availability and cost of I/O components, and the necessity of choosing between wired and wireless solutions up front.04/23/2009
With the rising cost of energy, the use of variable frequency drives (VFDs) is growing at an increasing rate. By optimizing the frequency of a three-phase alternating-current (AC) induction motors voltage supply, a VFD controls the motors speed and torque while providing energy savings. And, these energy savings can be quite substantial 20% or more making VFDs a green solution as well as a wise money-saving investment.
However, in order to be truly green, a technology must be sustainable as well as energy efficient.04/17/2009
The need: Lower life cycle costs and better information flow. The solution: New standards offer more choices for integrating safety and process control
The specialty chemical industry is facing a number of difficult challenges, including increasingly stringent safety and compliance mandates, higher energy and feedstock prices, and aging plants and equipment all intensified by global competition. Compounding these challenges is the expanding breadth of specialty chemical product categories, forcing manufacturers to dedicate major resources and continuously innovate to maintain market share and capitalize on new opportunities.
Despite the size of the industry and the increase in worldwide demand for all types of specialty chemicals, margins must be managed closely due to rising costs, more demanding customers, and the fact that all products no matter how innovative eventually go off-patent and face stiff competition. While operating a chemical plant is tough business, opportunities exist for companies to optimize their investments and improve both productivity and their financial performance.
Risks prevail wherever people store, process or handle hazardous or toxic materials. In the specialty chemical industry, these risks are compounded because the hazard has the potential to impact a numerous of people. A spill of a toxic agent or explosion could be hazardous to a population within a plant or the surrounding area. One growing area of focus in recent years is the critical value of safety in protecting people, and helping safeguard the environment and plant assets, as well as reducing lifecycle costs.
This paper explores how changes in industry standards and technology developments are expanding how safety systems are applied in specialty chemical applications. It also examines the operational and competitive advantages driving the trend toward separate yet interoperable safety and process control platforms with common development tools. These benefits include reduced life cycle costs, expanded access to process data and improved plant-wide integration.04/17/2009
An HMI partner not only provides the product, but also provides assistance or guidance in HMI application development, training and tools to help you take advantage of technology that reduces overall factory costs. The HMI vendor you select will greatly impact your overall total cost of ownership for not only the HMI, but your processes and machines as well. This white paper will help you determine the needs and wants of your own internal operations that will be used to align company operations requirements with a best fit HMI vendor that provides the right mix of product and service offering.04/08/2009
Improve profitability by learning the benefits of advanced process control technology. Advanced control and real-time optimization tools have become necessary technologies for today's process operating companies to compete and maintain profitable operations. Honeywell has continuously demonstrated the benefits of advanced process control (APC) technology in improving profitability through improved process stability, increased throughput and yield, decreased operating costs, improved product quality and increased operating flexibility. Another benefit of advanced process control is that APC forms the foundation for online optimization, which typically adds an additional 20 percent of the advanced control benefits with project paybacks, often in less than six months.04/07/2009
How Wireless Remote Monitoring Enables Low-Cost Data Logging and Control
Economically meeting requirements for monitoring of mobile assets and remote processes always presents project engineers a considerable challenge. While the initial requirements are reasonable, complexityinvariably emerges when the needs of all interested parties are assessed.
This is particularly the case when the asset or process consists of a small number of monitoring points. The requirements can be regulatory or economically-driven. For example, monitoring of combined sewage overflow (CSO) by water utilities meets a regulatory requirement. Compliance with mandates from agencies such as the EPA calls for monitoring of remote locations in which only a single measurement, flow or level, is taken per site.
Monitoring of vendor-managed inventory, such as a chemical level in a tank, is an economically-driven example. Again, only a single measurement, tank level or pressure, is required. Economic goals include customer satisfaction and operation of the delivery/service fleet in the most efficient manner.
Leased generators and pumps exemplify mobile assets in which, at minimum, one or two measurements are recorded. In those cases, however, requirements could grow to dozens of measurements. Customer satisfaction and optimal management and maintenance of the asset inventory are the goals.04/06/2009
Applicable Product: V1000, A1000, E7, F7, G7, and P7
(V/f Motor Control Method)
The techniques for braking of high inertial loads to a stop traditionally involved either Dynamic Braking or DC Injection Braking technology.
This article examines a new load-braking alternative called High-Slip Braking (HSB). We identify the different aspects of HSB, look at what it does, how it works, and how it is different from other braking methods. We also provide examples of real world successes, and discuss the new technologys cost effectiveness.04/02/2009
White Paper FCI's flow meter best practices white paper provides installation recommendations to avoid common performance problems caused by variations in real-world plant operating conditions versus the laboratory conditions utilized in meter calibration. This paper includes specifications and diagrams to solve problems including lack of pipe straight-run, installation orientation and probe depth.04/01/2009
End users want a safety instrumented system that protects the plant at maximum safety (SIL3) levels, only shuts down on a real process demand and does not shut down for any other reason. History shows that disasters do happen and any plant should be willing to take risks. However, how much risk can a company allow without inviting disaster to happen? Download this white paper to learn how combining integrated safety systems with DCS systems can help you avoid costly plant shutdown disasters.04/01/2009
Most of the major manufacturing automation end users and suppliers are using or considering Ethernet as an industrial control option for field devices, drives, power management equipment and special purpose controllers. Engineers and others who design Ethernet networks for these applications must follow correct installation procedures and must select network equipment that will function in plant environments with little or no downtime. This white paper explores network configuration issues and shows how to design a reliable industrial Ethernet network for manufacturing applications.04/01/2009
Off-line analysis of historical process data is an integral part of process optimization and production tracking. OPC helps maximize return on process history investments. OPC not only provides a standardized mechanism for collection of real time process data, it also enables multi-vendor historical analysis solutions. OPC facilitates highly scalable multi-vendor distributed historian architectures. OPC Data Access (DA) and OPC Historical Data Access (HDA) are two specifications that can be combined to solve many of the process history problems.03/30/2009
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. Even the environment is under threat due to increased release of greenhouse gasses. In the modern competitive world, tangible costs must be reduced and efficiency optimized to be competitive. Even at the recently G8, targets were set at reducing the emissions released through burning of fuels. 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. More specifically we will concentrate on better energy measurement and increasing efficiency through benchmarking and information management. The author will also offer practical ways to reduce operational costs with small capital expenditure and thus a fast ROI.03/30/2009
This white paper discusses how appliance transaction modules enable the sharing of data for tracking and tracing applications.
Automated tracking and tracing all aspects of a product from its initial ingredients or components, through manufacturing and into the supply chain, is not only a requirement in industries such as food and pharmaceutical, it has also become a viable strategy for all businesses. From automotive and metals to appliances and consumer goods, companies rely on tracking and tracing to lower material, production, inventory, labor and scrap costs while improving customer satisfaction.
By being able to see, analyze, manage and store selected data in real-time, companies are able to make swift changes to optimize selected areas within their production capabilities. They are also able to document their processes from incoming raw materials, through production and onto the supply chain.03/30/2009