5 Questions for Modernization Solutions Consultant Joel Galmor

Emerson’s Joel Galmor joins our continuing podcast series on 5 Questions for an Emerson Expert. Joel is a member of our Modernization Solutions Consulting team. The team creates wiring and control solutions, develops engineering tools, and provides subject matter expertise to minimize cost and risk in control system and safety instrumented system modernization projects.

Send me an email or LinkedIn message if there is an Emerson expert you’d like me to interview as well as the questions you’d like me to ask them.

Joel Galmor-5 Questions for an Emerson Expert


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Disruptive Innovations in Automation

Technology advances have disrupted many markets including photography, music, video and communications to name just a few. These disruptive innovations have improved usability and reduced costs for those taking advantage of the technology advancements.

In our world of industrial instrumentation and automation, Emerson’s Roel Van Doren notes:

Emerson's Roel Van Doren…the introduction of microprocessors and digital communications led to distributed control systems, digital plant architectures and the introduction of intelligence into field devices. These technological advances enabled users to gain far greater insight into their plants – not just more process variables, but also important information with respect to equipment health and performance. This additional data facilitates a step change in business performance through more flexible operations, increased safety and reduced cost.

His quote, from the newest edition of innovations in process control, leads into an exploration of disruptive technologies that are continuing to improve operations for manufacturers across the globe.

These technologies are not created in a vacuum, but as a direct response to challenges manufacturers face. In the article, Business challenges create disruptive technologies, Bob Karschnia describes how additional online monitoring via wireless instrumentation was required for challenges such as loss of experienced operators to retirement, energy optimization and equipment health.

Here is a brief synopsis of some of the other articles in this edition. Continue Reading

Generating IIoT Return on Investment

Justifying instrumentation- and automation-related projects in process manufacturing operations typically involves quantifying expected returns in reliability, efficiency or reductions in risks associated with safety and emissions. As Industrial Internet of Things (IIoT) technologies have emerged, the need for project justification remains as strong as ever.

Emerson's Travis Hesketh

In a Smart Machines & Factories article, Securing a return on investment from IIoT, Emerson’s Travis Hesketh describes ways that IIoT deliver quantifiable operational performance improvements and financial returns.

Smart Machines & Factories: Securing a return on investment from IIoTTravis opens noting that although operational losses for global process manufacturers exceed $1 trillion USD each year, that:

…many companies have become stuck in decades-old work practices that fail to take advantage of the advanced digital technologies now available.

He highlights the performance of process manufacturers in the top quartile versus average performers. They:

…incur one-third as many safety incidents as their average industry peers. They spend half as much on maintenance, one-third of the industry average on energy costs, and 20% less on production-related expenses. They also achieve 15 days more production availability per year and produce 30% less CO2 emissions.

IIoT-based applications help improve operational performance by allowing companies: Continue Reading

Continuous Floating Roof Tank Condition Monitoring

Floating roofs are used on storage tanks to minimize vapor space between the top of the tank and the level of the liquid, typically a petroleum-based product, inside the tank. Per the External floating roof tank Wikipedia entry:

The roof rises and falls with the liquid level in the tank. As opposed to a fixed roof tank there is no vapor space (ullage) in the floating roof tank (except for very low liquid level situations). In principle, this eliminates breathing losses and greatly reduces the evaporative loss of the stored liquid. There is a rim seal system between the tank shell and roof to reduce rim evaporation.

Emerson’s Ulf Johannesson

In this 3:40 YouTube video, How to Increase Safety with Continuous Surveillance of Floating Roof Movements, Emerson’s Ulf Johannesson explains how wired or wireless radar level measurement technologies are used to monitor the location of the roof in relationship to the level of the liquid. By continuously monitoring the roof location at different points on the roof, issues such as a stuck or tilted roof condition can be discovered early and corrected before an abnormal situation occurs and worsens.

Ulf opens highlighting some of the common issues that can occur with floating roof tanks. These include wind-induced roof tilt, imbalance causes by rain or snow, rim seal friction, pontoon or deck leaks, tank wall abnormalities, roof access ladder binding and block roof drains. Continue Reading

Enabling Right-the-First-Time Manufacturing

Emerson's Michalle Adkins

Quality and compliance are indispensable in pharmaceutical and biopharmaceutical manufacturing processes. In a Pharmaceutical Manufacturing magazine article, Crazy About Quality and Compliance?, Emerson’s Michalle Adkins shares how organizational engagement, technologies and work practices must come together for safe, efficient and profitable manufacturing.

Pharmaceutical magazine: Crazy About Quality and Compliance?Michalle opens sharing her experiences in pharmaceutical production management and the difficulties in avoiding problems:

…during the planning, manufacturing, testing, reviewing, releasing and storage of a batch…

It starts with a clear vision of right-the-first-time manufacturing and understanding the critical attributes. Delivering high-quality products happens:

…by putting compliance-ready processes in place from research through commercial manufacturing, within the supply chain process, as well as on the shop floor and in the labs.

Many technologies can help play a role as compliance enablers, such as: Continue Reading