Find out the Best Reliability Program at the Emerson Exchange Conference

One of the things we highlighted in the lead up to last year’s Emerson Exchange conference in the Dallas/Fort Worth, Texas area, was the Reliability Program of the Year. The program spotlights process manufacturers and producers’ effective reliability programs. Emerson Process Management and the University of Tennessee Reliability & Maintainability Center will recognize leaders who best demonstrated effective use of reliability-based technologies.

Reliability-Program-of-YearThis recognition program will take place again at next week’s Emerson Exchange Conference in Orlando. In the Emerson Exchange Personal Scheduler Application, the sessions are described:

TF-2595 – Reliability Programs – Technologies that Work

Each customer will present their Company’s Reliability Program to demonstrate their effective use of reliability based technologies, effective work processes, return on investment, integrated maintenance best practices, and leadership in implementing a “best in class” Reliability program. The customer presentations will be the culmination of competing in an extension reliability program competition against their peers and having successfully been selected to present their best in class programs during these technology forums. A winner will be announced and recognized by Emerson at the conclusion of the Technology Forum.

The four customer finalists that are competing for the 2014 Reliability Program of the Year are: Continue Reading

Could Technology Help Prevent Costly Environmental Incidents?

Emerson's Juan Carlos Bravo

Juan Carlos Bravo
Mining & Power Industry Manager

Author: Juan Carlos Bravo

Recently, a major mining company spilled around 40,000 cubic meters of copper sulfate acid solution into the Bacanuchi and Sonora rivers, in the Mexican state of Sonora.

This spill led authorities to shut down wells in the affected areas, leading to water shortages for an estimated 22,000 inhabitants and prompting the distribution of water in trucks and plastic bottles. As schools across the country returned this week from the summer vacations, Sonora authorities kept 89 schools in nine municipalities closed until inspections can be completed and the quality of water guaranteed.

Source: Jaime Morán posted this image on Twitter on Aug. 11, 2014. (Photo: @tiocanuto/Twitter)

Also the Mexican environmental authority, Profepa, pressed charges against mining company for alleged violations of environmental laws, including possible negligence in the handling of dangerous substances. Profepa said the company could face fines up to 43 million pesos ($3.3 million), including 3 million pesos for violating waste-management regulations, in addition to any environmental cleanup costs and damages. Continue Reading

Measuring Level, Volume, and Mass of Bulk Solids

Some exciting news on measuring bulk solids level, mass, and volume came out today. In a release, Emerson introduces 3D solids scanners for highly accurate continuous level and volume measurement of bulk solids, it notes:

Rosemount-5708-Series-3D-Solids-ScannersRosemount 5708 Series 3D Solids Scanners provide highly accurate measurements of stored contents for improved process and inventory control. Unlike laser-based technologies that can take several hours to take measurements and require the process to be shut down, Rosemount 3D Solids Scanners provide continuous volume measurements that are representative of the material’s surface.

They can measure practically any kind of material including difficult-to-measure fly ash and materials with a low dielectric that would challenge other technologies. The self-cleaning design requires low maintenance even when used in the dustiest environments.

I wanted to share some YouTube videos developed by Emerson’s team managing the Rosemount brand. The first, Rosemount 5708 Series 3D Solids Scanner : taking the guesswork out of measuring solids (3:04) shows how these devices measure the level and volume of bulk solids using dust-penetrating, low-frequency acoustic waves. Continue Reading

Solving a Pipe-Rattling Control Valve

As we close in on the Emerson Exchange conference October 6-10 in Orlando, I wanted to share a problem solving story. This story is typical of what you’ll find throughout the weeklong conference.

Jeff Wilson Control Valve Reliability Specialist

Jeff Wilson
Control Valve Reliability Specialist

Jeff Wilson, with Emerson’s local business partner, Puffer-Sweiven, was asked to investigate a control valve that was shaking the pipe due to the actuator being too small. This valve control cooling water flow in a chemical manufacturing facility.

To understand what was going on, Jeff used ValveLink SNAP-ON in the AMS Device Manager software. When he first stroked the valve, anytime it was within 10% or less open, the piping would begin to shake violently as the process was overcoming the actuator force.

Cooling-Water-Valve-as-found

He worked with members of the valve team at Puffer-Sweiven to come up with a solution to add an extra Fisher 2052 spring-and-diaphragm rotary actuator spring to overcome the process pressure. This provided the extra torque required for this application. Continue Reading

Innovative Uses and Proven Results with HART Digital Communications Protocol

You may have seen the recent news of the HART Communications Foundation and the Fieldbus Foundation merging to form the FieldComm Group. Ted Masters, President and CEO of the FieldComm Group noted:

…the creation of FieldComm Group is an unprecedented opportunity to build upon existing technologies and develop a single future vision toward harmonization of standards for the process automation industry worldwide.

We’ve highlighted in numerous digital bus-related posts how these digital communications protocols are being used to improve control performance, perform predictive maintenance activities, and provide richer information to optimize and operate plants more reliably.

For new members to the process automation community, the HART protocol:

…(Highway Addressable Remote Transducer Protocol) is an early implementation of Fieldbus, a digital industrial automation protocol. Its most notable advantage is that it can communicate over legacy 4-20 mA analog instrumentation wiring, sharing the pair of wires used by the older system. According to Emerson,[1] due to the huge installed base of 4-20 mA systems throughout the world, the HART Protocol is one of the most popular industrial protocols today.

I mention this because I saw a post this morning in the Wireless track of the Emerson Exchange 365 community by Emerson’s Deanna Johnson. In the discussion thread, Looking for nominees for the 13th Annual HART Plant of the Year Award, Deanna highlights the opportunity to be recognized for innovative use and results achieved with the HART protocol:

Deanna Johnson Wireless Marketing Manager Global Solutions

Deanna Johnson
Wireless Marketing Manager, Global Solutions

Is your plant or mill using HART Communication in an innovative way? Or do know someone at a plant who has?

The HART Communication Foundation wants to recognize innovative people who use HART Technology, for the 13th Annual HART Plant of the Year Award. Continue Reading