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Process Control Portal

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Application Stories

Fuel cell generator units controlled by NI hardware and software  - 05/21/12
Machine Building, May 2012
By National Instruments
To turn ammonia into electricity, ammonia must be reformed into hydrogen and nitrogen, the hydrogen is separated from the gas stream, and the pure hydrogen stream fed to a fuel cell to produce electricity. In Diverse Energy's PowerCube, NI CompactRIO hardware controls and monitors the entire process.
 
New applications for positive displacement pumps  - 05/21/12
Asian Engineer, May 2012
By Eugene McCarthy
The process industry is finding uses for positive displacement pumps that are very different from traditional applications.
 
Controllers tackle all aspects of plant operation  - 05/21/12
Process Engineer, May 2012
La Vichimica in Italy specialises in the reprocessing of solvents from different process industries, notably pharmaceuticals. ControlCare Field-based Control System (FCS) from Endress+Hauser controls the process.
 
Control system helps to gather maintenance data  - 05/18/12
PlantServices.com, May 2012
Control system helps to gather maintenance data at Texas Municipal Power Agency. The power company installed condition monitoring modules to make better maintenance decisions.
 
Food Manufacturing: Batch Control for Multiple Kitchens  - 05/13/12
Automation World, May 2012
By Randy J. Otto, ECS Solutions
Systems integrator ECS followed the ISA 88 Batch standard when installing a control system at an unnamed food manufacturer. Rockwell’s FactoryTalk Batch software was chosen for batch management portion of the controls.
 

 
Better control through predictive behaviour  - 04/26/12
European Chemical Engineer, April 2012
To optimise plant operations at its chemical production facility in Spain, Solvay used Honeywell's Profit Loop model-predictive controller algorithm for most of its existing control loops.
 
A Charming New Facility  - 04/21/12
Control, April 2012
By Bryan Beyer, Southern States Chemical
Southern States installed HART communications, remote terminal displays, flow elements, DeviceNet networking and a DeltaV automation system from Emerson to control an acid plant.
 
Optimizing Process Operations From Afar  - 04/21/12
Control, April 2012
By Dan Hebert
AOC Resins uses remote wireless connections to access Emerson control systems at their seven process plants across North America from its corporate headquarters.
 
Prototyping for Small and Large APC Applications  - 04/21/12
Control, April 2012
By Jim Montague
DuPont has been using ARC applications for many years, but lately some DuPont engineers have been using rapid prototyping methods to help choose, implement and gain MPC's benefits in smaller applications.
 
Cooled Fusion Works for Chemical Processor  - 04/21/12
IMPO, April 2012
One of the prime enemies of controlling a chemical reaction is excessive heat generated by the reaction itself, which can make a process unstable and corrupt the outcome. This not only causes product quality problems, but can also introduce elevated hazardous conditions.
 
ABB helps turn electronic scrap into gold for Boliden ABB helps turn electronic scrap into gold for Boliden  - 03/20/12
The e-scrap recycling process at Boliden's Rönnskär copper smelter is controlled by ABB’s 800xA Extended Automation System.
 
DCS migration offers increased availability, reduced cycle times and less waste  - 03/10/12
Control Engineering Europe, February 2012
Cost and operational efficiency benefits have been identified at Fuchs Lubricants since the addition of Siemens’ PCS 7 distributed process control system and SIMATIC Batch to the control system mix.
 
Wurzburger Hofbräu brews up a storm  - 03/10/12
Control Engineering Europe, March 2012
A Siemens Braumat brewery process control system has enabled the Hofbräu brewery in Wurzburg, Germany to modernise its fermenting and storage cellar operations.
 
Ale now Produced by Stroud Brewery in Larger Quantities  - 03/10/12
Process & Control Today, February 2012
Burkert UK installed a flow, temperature and level control system including the sensors, valves and control panel required to manage the new micro brewery installation at Stroud Brewery.
 
Balancing Steam Supply with Demand Saves Energy  - 03/10/12
Control Engineering, March 2012
By Pasi Airikka, Metso
APC platform helps Brazil’s Cenibra pulp mill reduce vented steam by 90%. Fuel costs are down and the carbon footprint of the power boilers has been slashed.
 
ABB control system keeps ammonia levels in check  - 03/10/12
Instrumentation, March 2012
Alpheus Environmental installed ABB control and measurement equipment to regulate effluent flows into the receiving sewage treatment works at Basildon. The enhanced performance improved operations and will reduce future costs on site.
 
ABB improves production process for Podilsky Cement ABB improves production process for Podilsky Cement  - 03/04/12
ABB supplied switchgear, motor control centers, variable speed drives, instrumentation, gas analyzers, collaborative production management systems, and an 800xA automation system.
 
Industrial PC streamlines SCADA system and reduces costs  - 02/21/12
Trimax Systems, a California-based system integrator, upgraded the SCADA system at the WRCRWA facility owned by Western Municipal Water District with Phoenix Contact’s Valueline industrial PCs.
 
New Technology for Analyzing HF Alkylation Processes  - 02/17/12
New Technology for Analyzing HF Alkylation Processes
Control, February 2012
By Mark Clark, ConocoPhillips, and Steve West, Invensys
The ConocoPhillips refinery in Sweeny, Texas, uses the Invensys ACA.HF system for optimization of the alkylation process.
 
Woodlands Dairy chooses Wonderware  - 02/17/12
South Africa Instrumentation & Control, February 2012
Woodlands Dairy previously bought a second hand powder plant but the control system was outdated. They replaced it with Wonderware’s System Platform consisting of the Application Server, InTouch (HMI/SCADA), Historian and ActiveFactory trending and reporting tool.
 
Legacy system upgraded to support future manufacture  - 02/15/12
Control Engineering Europe, January 2012
A Honeywell batch control system at the Alloa glassworks in Scotland, was replaced with four Siemens S7 PLCs and WinCC SCADA.
 
Sacci uses Malvern particle size analyzer to make cement Sacci uses Malvern particle size analyzer to make cement  - 02/14/12
Particle size data is used to automatically vary the speed of the classifier used to separate the milled cement into a fine product stream and a coarser recycle.
 
Digital architecture helps tank farm meet safety requirements  - 01/29/12
Industrial Ethernet Book, February 2012
Emerson’s wireless level and pressure transmitters and a plant-wide wireless network have been used to automate tank storage level monitoring in Sweden, improving safety and reducing costs.
 
HART Communication proves valuable on a major project  - 01/29/12
Control Engineering, January 2012
The 2011 HART Plant of the Year is Shell’s Scotford Upgrader, recognized after programming and commissioning 1,500 devices from Rosemount, E+H, Fisher, Krohne, K-Tek, Magnetrol, Metso, and Ohmart Vega.
 
ABB controls world’s newest copper mine ABB controls world’s newest copper mine  - 01/24/12
ABB supplied gearless mill drives, process and electrical control systems, power quality systems, a substation and a System 800xA integrated operations center.
 
Improve process control for natural gas heat exchangers  - 01/22/12
Hydrocarbon Processing, January 2012
In this case history, a first-principle dynamic model of a natural gas/steam heat exchanger system is built using a commercially available dynamic simulator. Four scenarios for operability and safety are investigated. Registration required to read story.
 
APC application yields significant operability, economic benefits  - 01/22/12
Hydrocarbon Processing, January 2012
The Karratha Gas Plant used multivariable predictive control (MPC) on an LNG liquefaction train and got a 4,000% return on investment.
 
SIPOS fieldbus solution supports RWE scheme  - 01/11/12
Process & Control Engineering, January 2012
SIPOS managed the DCS and Profibus DP fieldbus commissioning of over 2,000 actuators at the Neurath power plant in Germany.
 
Shared Documents Aid Valve Repairs  - 01/11/12
Control, January 2012
By Jim Montague
Maintenance engineers at BP's Texas City refinery used new file-sharing and procedural tools to complete a huge valve turnaround project in just under nine weeks.
 
Hooking Up the Plant and the Enterprise  - 01/11/12
Control, January 2012
By Dan Hebert
At a major oil refinery, Yokogawa's Manufacturing Data Exchange (MDX) software replaced a proprietary interface to integrate a plant's process control system with an aging, in-house ERP system.
 
Cube Technologies assists with boiler control  - 12/27/11
South Africa Instrumentation & Control, December 2011
Cube replaced an aging Bailey Network90 system, which controls the boilers in the Australian Country Choice meat processing plant, with a Siemens PCS7 distributed control system.
 
Metso controls renewable diesel plant Metso controls renewable diesel plant  - 12/19/11
Metso supplied two DNA automation systems with HART for the Neste Oil renewable diesel plant in Rotterdam, the Netherlands.
 
Overcoming obsolescence issues with minimal disruption  - 12/18/11
Control Engineering Europe, December 2011
TOTAL E&P UK has succeeded in safely upgrading a number of vital systems on two of its Alywyn Area fields platforms. A number of obsolescence issues led the company to call on Rockwell Automation to supply engineers, components and support
 
Wireless conductivity transmitters help prevent chemical discharge  - 12/18/11
Control Engineering Europe, December 2011
Korsnäs Gävle is using Emerson’s Smart Wireless conductivity and temperature transmitters to collect critical leak-detection monitoring data at its board and paper production unit at Gävlebukten, Sweden.
 
Nyrstar converts DCS to Rockwell Automation PlantPAx  - 12/18/11
Process & Control Engineering, December 2011
Rockwell Automation will replace a DCS with the PlantPAx process automation system at Nyrstar Hobart’s zinc smelting operation in Tasmania.
 
Simplicity = Freedom  - 12/18/11
Control, December 2011
By Jim Montague
Southern States Chemical used Emerson's CHARacterization Modules (CHARMs) for Delta V electronic marshalling to simplify and streamline a new sulfuric acid plant in Wilmington, N.C.
 
Blending Controls Sweetens Soda Pop  - 12/18/11
Control, December 2011
By Jim Montague
Schweppes Australia upgraded the control systems in the syrup room. The project included migrating process control functions that had been performed by a legacy DCS to a new control system based on the PlantPAx process control solution from Rockwell Automation.
 
Finding the unexpected benefits of wireless  - 12/07/11
InTech, December 2011
By Andrew Nolan
HollyFrontier’s El Dorado refinery in southeast Kansas discovered several uses for its industrial wireless mesh network on top of its original application.
 
Utilizing asset data for predictive asset management  - 12/07/11
InTech, December 2011
By Alexandre Augusto da Silva, et al
Asset management is enabling Braskem, a Brazilian petrochemical company and a leading producer of thermoplastic resins, to move toward predictive maintenance and away from costly preventive and reactive maintenance.
 
450 Routers enable remote monitoring at Thames Water sites  - 12/01/11
eWON Ethernet routers allow Thames Water to remotely monitor and control critical assets located at its water pumping stations and sewage treatment works across the UK.
 
Lessons learned, success in simulation  - 11/24/11
Control Engineering, November 2011
By Donald M. Brooks
A firsthand review of a successful operator training simulator program, with some thoughts for avoiding bumps if you try the same approach.
 
Lonmin system platform upgrade  - 11/18/11
South Africa Instrumentation & Control, November 2011
Lonmin’s Marikana complex is one of the largest platinum mining and processing operations in the world. It uses uses five ArchestrA Galaxy Repository servers, 43 ArchestrA Object Servers, 42 view stations, 14 Wonderware Historian servers and 68 PLCs.
 
Acoustic process analytics  - 11/18/11
South Africa Instrumentation & Control, November 2011
Europe’s largest production facility for ammonia and nitrogen fertiliser in Sluiskil, The Netherlands, tried to measure nitric acid, but it ate the flowmeters. An ultrasonic meter saved the day.
 
Plant-wide control optimisation  - 11/14/11
International Process Engineer, November 2011
By Eugene McCarthy
For many process companies plant-wide control optimisation is one of the cornerstones of efficient production - as these case studies demonstrate.
 
Vibration Analysis Pinpoints Valve Noise Source  - 11/05/11
Valve Magazine, October 2011
By Daniel Eilers, Emerson
For many years, very loud harmonic noises (over 113 dBA) were generated somewhere in the ISOMAX process unit near the hydrogen compressors and hydrogen quench control valves. The highest piping vibration levels were found next to the quench valves, with the highest overall reading being taken on the valve stems.
 
Emerson controls boilers at Tata Steel in UK Emerson controls boilers at Tata Steel in UK  - 10/25/11
The boiler controls enable Tata to increase energy efficiency and maximize use of waste fuels, reducing emissions as well as reliance on purchased fuels.
 
Rotork supplies valves for storage tank expansion project Rotork supplies valves for storage tank expansion project  - 10/23/11
Rotork supplied electric actuators for valves, digital control systems, valve gearboxes, valve adaptation, workshop motorisation, on-site retrofitting and commissioning.
 
Simulation Aids Pulp and Paper Production  - 10/21/11
Simulation Aids Pulp and Paper Production
Control, October 2011
By Matt Taylor
Iggesund Paperboard uses National Instruments' data-logging and supervisory control software to simulate and control pulp and paper production and predictively control pH levels.
 
DCS Migrations: Risk vs Return  - 10/21/11
Industrial Automation Asia, September 2011
By Mike Vernak, Rockwell Automation and John Bryant, Arkema
Arkema, an industrial chemical producer in Alabama, recently used a phased DCS legacy migration program to migrate their Square-D CRISP platform to an updated control system that is multidisciplined, information-enabled and scalable for future upgrades.
 
Consider model-based inferential properties for reformers  - 10/21/11
Hydrocarbon Processing, October 2011
By Beautyman, A. C., AspenTech, et al
Eni, A European refiner opts to apply embedded multivariable predictive controllers as part of an advanced process control system. Registration required to read article.
 
Instrument Accuracy Saves Money  - 10/18/11
Automation World, October 2011
At Cartiere del Garda’s paper mill in Italy, a Micro Motion 7845 straight tube, liquid density meter makes real-time measurement of kaolin and other additives in the paper-coating process, resulting in direct savings for the company.
 
Automation upgrade at Sebokeng wastewater plant  - 10/17/11
South Africa Instrumentation & Control, October 2011
The plant installed a new DCS, PLCs, Profibus network, Wonderware SCADA system, and Endress+Hauser flow meters, analyzers and level transmitters.
 
Retrofitting a refinery  - 10/17/11
Valve World, October 2011
The BP Refinery in Rotterdam installed over 1,000 explosion-proof actuators, Here’s how the retrofit was accomplished.
 
Innovative projectors suit control room projects  - 10/15/11
Control Engineering Europe, October 2011
Global Control Center Design, a Norwegian systems integrator, has installed Projectiondesign FR12 Remote Light Source projectors on the Statfjord C oil platform as part of an offshore control room monitoring project.
 
Wireless Overspill Solution Protects Workers & Environment  - 10/15/11
IEN, October 2011
FH Tank Storage AB is using Emerson’s wireless level and pressure transmitters to provide overspill protection at its Kalmar storage terminal on the east coast of Sweden. The company has installed a plant-wide Smart Wireless network, DeltaV digital automation system, and AMS Suite predictive maintenance software to automate tank storage level monitoring.
 
K-Tork retrofits valve actuators in Las Vegas K-Tork retrofits valve actuators in Las Vegas  - 10/10/11
K-Tork Internationalcompleted a $1.9M retrofit contract for the supply and installation of valve actuators at the Las Vegas Water & Pollution Control facility.
 
B. Braun installs Werum MES n Switzerland  - 10/10/11
Process and Control Today, October 2011
B. Braun installed Werum’s PAS-X system at its production facility in Sempach, Switzerland. PAS-X will optimize the manufacturing of liquids, and operate in explosion-proof areas.
 
Utility optimization  - 10/06/11
InTech, October 2011
By David Twohig, Eli Lilly
Eli Lilly used various automation technologies to reduce costs and improve the performance of a large compressed air system.
 
Striving for Perfection Through Workflow-Instruction Technology  - 09/29/11
Automation World, September 2011
By James Koelsch
Managers at Chivas Brothers and elsewhere are using Rockwell’s FactoryTalk ProductionCentre software to capture and disseminate the expertise of their star operators.
 
More Water Savings Through Automation  - 09/24/11
Control, September 2011
By Mike Crabtree, Forshock
PLCs from AutomationDirect control pumps and video surveillance cameras at Mission Springs Water District in California.
 
Going Green With Fuel Use Optimization  - 09/24/11
Control, September 2011
By Luther Kemp, Minnesota Power
The M.L. Hibbard Renewable Energy Center power plant in Duluth, Minnesota has a multi-fuel, traveling-grate boiler that burns both wood waste and coal. Model Predictive Control from Emerson controls the boiler.
 
Flowmeters Phone Home  - 09/24/11
Control, September 2011
By Dennis Brown, Dart Oil and Gas
Thanks to the web environment created by Open Automation Software products data can be pulled by a smart phone such as the iPhone, manipulated, and then pushed from the iPhone though the OPC Server to the test meters in the field.
 
Alaskan Hatchery Nets Automated Alarm and Monitoring System Alaskan Hatchery Nets Automated Alarm and Monitoring System  - 09/22/11
Automation.com, September 2011
By Benjamin Smith, Hidden Falls Hatchery
PLCs from AutomationDirect provide a fully functional automation and alarm system to monitor the processes vital to keeping fish alive and healthy at this hatchery in Alaska.
 
Deacom ERP runs Independent Beverage Company  - 09/19/11
ERP provides recipe management, purchasing, production scheduling, inventory and lot control, order entry, warehouse management, accounting, and reporting.
 
ABB control systems allow Tata Steel to use lower cost oxygen  - 09/08/11
Process & Control Today, August 2011
ABB control systems are helping Tata Steel cut the cost of iron production at its Scunthorpe plant by allowing it to use medium pressure oxygen in its blast furnaces.
 
Application of HOLLiAS MACS System in GuiZhou Qianbei Power  - 09/05/11
By Hollysys
Hollysys installed a HOLLiAS-MACS DCS with Profibus DP to control Units 3 and 4 of the GuiZhou Qianbei 300MW Power Plant.
 
Communicating Diagnostic Data in a Legacy Environment  - 08/31/11
Control Engineering, August 2011
By Steven Moore
A pulp and paper mill in North America recently solved a nagging problem with a misbehaving magnetic flowmeter by using a wireless device to report diagnostic information that was not coming through the wired I/O.
 
Emerson controls tank storage terminal in Sweden  - 08/29/11
FH Tank Storage AB is using Emerson’s Rosemount wireless level and pressure transmitters to provide overspill protection at its Kalmar storage terminal on the east coast of Sweden.
 
Invensys installs simulation Software at DOE  - 08/22/11
The U.S. Department of Energy (DOE) has deployed an operator training simulator for an integrated gasification combined cycle (IGCC) power plant.
 
Distributed control system with benefits  - 08/18/11
PlantServices, August 2011
Rand Whitney Containerboard's mill in Montville, Connecticut, replaced and upgraded the DCS on a mini-mill it built in 1995 with ABB's System 800xA.
 
Radar Technology for Level Measurement  - 08/18/11
Control, August 2011
Precise knowledge of the grain level in UCML's storage silos is essential to production. Radar measurement is the key.
 
Remote Emergency Shutdown Device for Oil Production Platform  - 08/18/11
Control, August 2011
ENI Petroleum installed a solution from Moore Industries consisting of a NET Concentrator Systems. The system uses an IEC 61131-compliant software configuration program, which sets up the data concentrators to collect contact switch input signals, timers and communicate with each other.
 
Chilean challenges met by AUMA actuators  - 08/13/11
Valve World, August 2011
Actuators capable of performing at high altitudes have been supplied by AUMA to the Collahuasi copper mine in a mountainous region of northern Chile. Sixty modular electric actuators automate valves control materials that travel through pipelines starting 4,300m above sea level.
 
Dutch Food Manufacturer Employs GE Software for Quality  - 08/07/11
Process and Control Today, July 2011
Bolletje, a Dutch baked goods manufacturer, had variation in the quality of its dough from batch to batch due to inconsistent process execution. Bolletje chose the Proficy Software platform, because it provided an integrated platform for Batch execution, MES automation and visualization.
 
Chemical plant replaces outdated PLCs with automation system  - 08/07/11
Control Engineering Europe, August 2011
AkzoNobel Functional Chemicals is modernising its production facility in Herkenbosch, The Netherlands, using Emerson Process Management's DeltaV digital automation system.
 
Large actuator control helps to safely regulate oil flow  - 08/07/11
Control Engineering Europe, August 2011
Surgutneftegas is using Actuator Control Systems from ASCO Numatics to control large actuators at its Kirishi refinery near St Petersburg in Russia.
 
ABB controls cement production plant ABB controls cement production plant  - 08/04/11
ABB delivered a complete power and automation solution for a new cement facility built by Drake Cement in Arizona.
 
Matrox Graphics Optimizes Italian Control Room Matrox Graphics Optimizes Italian Control Room  - 08/03/11
A2A Reti Elettriche selected Matrox Extio Series KVM extenders to remotely drive 19 dual- and quad-monitor workstations in their control room facility.
 
Wastewater Treatment Plant Pares Energy Consumption  - 07/25/11
Sustainable Plant, June 2011
In 2010, the WRA IN Des Moines, Iowa, embarked on a project to improve its energy efficiency by integrating its SCADA and enterprise asset management (EAM) applications.
 
Efficiency drives major investments in automation and control technology  - 07/23/11
Oil & Gas Engineer, July 2011
Operating companies continue to invest heavily in automation and control technologies, both for new plants and revamps, in the drive for better efficiency.
 
Improving Batch Operations with Load Cells  - 07/23/11
Control, July 2011
By Kirsten Strahlendorf, et al
When every batch is worth a fortune and accuracy is paramount, load cells may be the answer. Here’s how Sanofi Pasteur used load cells to make vaccines.
 
Bags, Batch Software and Biotech  - 07/23/11
Control, July 2011
By Jim Montague
How Shire Biopharmaceuticals accellerated construction plans for their newest facility by using Honeywell Process Solution's Experion Batch Manager system, C300 controllers, and some OneWirelesss networking.
 
Instrumentation challenges of walnut processing  - 07/23/11
Control Engineering, July 2011
By Ben Orchard, Opto 22
Walnut meat kernels have to be dried to optimum moisture content quickly and efficiently. How do you measure that?
 
Industrial gas producer upgrades control  - 07/23/11
Control Engineering, July 2011
By Rich Chmielewski, Siemens Industry
Airgas Madison plant runs were sold out, downtime is very costly, so upgrading its DCS to a Siemens system helped maximize production and maintain operational data.
 
Density meter reduces costs and improves quality at paper mill  - 07/23/11
Control Engineering Europe, July 2010
Cartiere del Garda is using a Micro Motion density meter from Emerson Process Management to measure the concentration of kaolin and other additives in the coating process at its paper mill in Italy.
 
Hyperion provides Operator Training Simulator to Refinery  - 07/23/11
Process & Control Today, July 2011
Hyperion provided an OTS for the new Crude Distillation Unit (CDU) for Motor Oil Hellas (MOH), located at Corinth Refineries in Greece.
 
Vegetable oil producer saves energy with new pump technology  - 07/23/11
What’s New in Process Technology, July 2011
Feed Energy, based in Sioux City, Iowa, uses air-operated double-diaphragm (AODD) pumps for high-transfer, high-circulation processes because they are portable and require minimal maintenance.
 
Refinery Benefits from Smart Devices  - 07/23/11
Automation World, July 2011
Beginning in 2002, engineers at the MOL Danube Refinery near Budapest, Hungary made the strategic decision to install HART-enabled devices throughout their operation. The results have been award-winning, and extremely profitable.
 
Emerson density meter reduces waste at Italian paper mill Emerson density meter reduces waste at Italian paper mill  - 06/30/11
The Micro Motion 7845 Density and Concentration Meter provides highly accurate density measurements under entrained gas conditions.
 
Cloud Computing Finds Its Target with Mid-Size Manufacturers  - 06/28/11
Automation World, June 2011
By James R. Koelsch
Small and mid-size manufacturers are finding "software as a service" to be more than just the latest rage in Internet computing. It can be a practical way to stretch your IT dollars and enable global operations.
 
New Process Technology Increases Production Capacity  - 06/27/11
IMPO, June 2011
GEA Liquid Processing in Skanderborg, Denmark, delivered a batch mixing system to Urtekram International A/S. The mixing system has contributed both to an increase of production capacity and continued maintenance of product quality.
 
Modular Automation Allows for Food Manufacturing Flexibility  - 06/27/11
Control, June 2011
By Bob Sperber
Denmark-based dairy Arla Foods standardized on SAP enterprise software and MES software from Wonderware with installs at 35 plants. Estimated benefits of the SAP-Wonderware integration initiative include reduced work hours; process and scheduling improvements; compliance to food safety; reduced stoppages/downtime; and improved quality.
 
Cardinal Ethanol - Plant Sustainability With a Plant-Wide Optimization Control System  - 06/27/11
Control, June 2011
By Jeremey Herlyn, Cardinal Ethanol
Rockwell Automation suggested that Cardinal Ethanol consider implementing a plant-wide model predictive control (MPC) optimization technology. The solution improved plant stability and reduced variability on all key process variables, especially the batch fermentation operations.
 
Serious Sustainability  - 06/27/11
Control, June 2011
By Jim Montague
There's a lot more to truly going green than efficiency. Here's how some experienced end users and their applications are mastering process sustainability.
 
Honeywell Drives Communication Efficiency in Hindustan Petroleum  - 06/27/11
Process & Control Today, June 2011
Hindustan Petroleum (HPCL) implemented Honeywell Process Solutions’ Mobile Stations in their $200 million Fluid Catalytic Cracking Unit (FCCU) project at their Mumbai refinery.
 
Protecting the WGEP Pipeline  - 06/27/11
Process & Control Today, June 2011
Hima-Sella completed delivery of safety solutions at all 20 valve stations along the length of SABIC UK Petrochemicals’ 250km Wilton-Grangemouth Ethylene Pipeline (WGEP); one of a number of pipelines used to link ethylene production plants in the UK.
 
Emerson supplies 1000 valves to Dutch gas field Emerson supplies 1000 valves to Dutch gas field  - 06/14/11
Emerson supplied more than 1000 Fisher control valves, FIELDVUE digital valve controllers, and AMS ValveLink SNAP-ON software to the Nederlandse Aardolie Maatschappij Groningen gas field in The Netherlands.
 
Wessex Water undertakes control system upgrade  - 06/12/11
Control Engineering Europe, May 2011
Siemens provided PLCs, HMIs, SCADA and other equipment to replace a 20-year old control system at Wessex Water in the UK. The site’s SCADA system was completely replaced with a system that now contains nearly 30,000 tags, over 4,500 alarms and over 300 mimics
 
Western refining cuts wiring costs, improves performance  - 06/12/11
Control Engineering, June 2011
By Reginald Joseph, Western Refining
The Gallup refinery uses a legacy Honeywell TDC 3000 DCS. Management sought to extend monitoring capabilities to remote tank farm areas. After a site survey, a wireless system is being integrated with existing power and network infrastructure.
 
Omron delivers savings at hatcheries  - 06/12/11
South Africa Instrumentation & Control, June 2011
Chick Master’s heat recovery control systems uses the Omron CJ1-M series programmable controllers with extensive use made of the PID control options.
 
Don’t Get Caught Short  - 06/12/11
Process Heating, June 2011
By Tim Hanes, AutomationDirect
In many applications, single-loop temperature controllers are sufficient to provide control of heating and cooling. But in some applications, such as this meltdown machine, closely coordinated control among many temperature control loops is needed. In those cases and others, PLC-based temperature control can be the best solution.
 
SCADA standardization  - 06/12/11
InTech, June 2011
By Graham Nasby and Matthew Phillips
The City of Guelph’s Water Services department in Canada embarked on a multi-year program to modernize and enhance its Supervisory Control and Data Acquisition (SCADA) system using a standards-based approach.
 
Emerson radar level sensors save money at Absolute Energy Emerson radar level sensors save money at Absolute Energy  - 06/09/11
Replacing the plant’s existing level transmitters, the new equipment has helped avoid shutdowns that can cost as much as $20,000 an hour in lost production and potential equipment damage costing over $200,000.
 
Honeywell supplies Mobile Stations to Hindustan refinery  - 06/02/11
Hindustan Petroleum implemented Honeywell’s Mobile Stations in their $200 million Fluid Catalytic Cracking Unit (FCCU) project at their Mumbai refinery.
 
ABB controls gold mine in Chile  - 05/30/11
ABB completed the commissioning of three gearless mill drive (GMD) systems for the Esperanza project of Antofagasta Minerals in Chile.
 
Logic PD brings the power of IT to the manufacturing floor  - 05/25/11
Automation.com, May 2011
By Jay Mellen, Savigent Software
Logic PD implemented a system to fully automate Logic tracking and control of its box-build processes. The new system empowers Logic PD to scale faster, bring products to market more rapidly, increase customer visibility, and improve overall manufacturing efficiencies.
 
SCADA expands and optimises bio-diesel production process  - 05/14/11
Control Engineering Europe, May 2011
Fox Petroli, an Italian bio-diesel producer, optimised and expanded the production process at its Vasta plant by investing in Progea Movicon SCADA.
 
Apprion develops Wireless Application Site Plan for BASF FINA  - 05/08/11
Apprion conducted an on-site survey, which included RF spectrum analysis, various grid simulation output with signal power levels and a technical evaluation of the site’s infrastructure.
 
INITEC Energía adopts AVEVA Diagrams software  - 05/04/11
INITEC Energía uses the software to develop and manage HVAC diagrams and P&ID systems.
 
Pharmaceutical manufacturer saves 40% in CIP costs  - 04/24/11
Control Engineering Europe, March 2011
Converting a manual clean-in-place (CIP) process to automatic across 80 reaction vessels, using pressure transmitters, condition sensors and flow meters, enabled a UK-based pharmaceutical manufacturer to achieve savings of £120,000 per annum.
 
CNPC Jilin Petrochemical Reduces Energy Costs by 5 Percent  - 04/24/11
Process & Control Today, April 2011
Invensys provided its ROMeo process optimisation software and consulting services, enabling CNPC to respond in real time to changes in feedstock variation, process conditions and utilities prices to achieve sustainable energy savings.
 
Veolia adopts Prosoft radios for its solar sludge drying process  - 04/24/11
Process & Control Today, April 2011
Veolia’s solar sludge drying process uses an automated turner. The operation is automated, and the robots are radio-controlled, which provides a more robust solution than the traditional wired approach.
 
Movicon SCADA Optimises Production Process for Bio-diesel Production  - 04/24/11
Process & Control Today, April 2011
Fox Petroli, the Italian leader in the bio-diesel, has optimised and expanded the production process at its Vasta Plant by investing in Progea Movicon SCADA.
 
Wonderware MES 4.0 helps Alfa Laval increase productivity  - 04/24/11
Process & Control Today, April 2011
Alfa Laval upgraded to MES 4.0 from Invensys Wonderware. The new solution helps reduce unplanned downtime by identifying and analysing the causes of outages and enables in a standardised way the comparison of production data in the continuous improvement process supported by the OEE number.
 
Distillery retains tradition, but upgrades control system  - 04/17/11
Control Engineering, April 2011
By Ken Keiser, Siemens Industry
The distillery began a migration strategy that upgraded to a Siemens Simatic PCS 7 DCS, while retaining the existing controllers, I/O, and field wiring.
 
Invensys installs optimization software at China National Petroleum Invensys installs optimization software at China National Petroleum  - 03/31/11
ROMeo optimization software enables CNPC to respond in real time to changes in feedstock variation, process conditions and utilities prices for sustainable energy savings.
 
Emerson upgrades turbine controls at Mexico power plant  - 03/26/11
Process and Control Today, February 2011
Emerson Process Management is replacing outdated gas and steam turbine controls, as well as balance of plant (BOP) controls, at the Felipe Carrillo Puerto power plant in Valladolid, Mexico. When the retrofit is complete in April, the Ovation system will manage more than 6,000 I/O points.
 
Genzyme monitors 50,000 SCADA points with Anybus  - 03/26/11
Process and Control Today, March 2011
Genzyme uses thirty HMS Anybus Communicator gateways to enable consistent SCADA management across all the devices in use at its polyclonal antibody production site in Lyon, UK.
 
Plascon Mobeni batch implementation  - 03/26/11
South Africa Instrumentation & Control, March 2011
Plascon’s Mobeni paint plant in South Africa upgraded its 2005 Wonderware InBatch system to ISA-88 batch standards and an InBatch Server and Development Client, Information Server, Historian, System Platform and an InTouch View Client.
 
Mini-mill Operator Gets a Handle on Data  - 03/26/11
Automation World, March 2011
Gerdau Ameristeel in Tampa, Fla., is a mini-mill steel producer and steel recycler. It relies on KepServerEX and OPC to manage the myriad programmable logic controllers (PLCs) distributed throughout its 11 mills.
 
Remote Wind Energy SCADA Control System  - 03/24/11
Control, March 2011
By Harm Toren
In a room that looks a little like NASA's Mission Control, our generation dispatchers and systems analysts oversee every turbine at every wind farm (and soon solar and biomass projects) throughout the country around the clock.
 
Cataloging loop drawings, tags in a spreadsheet  - 03/24/11
Control Engineering, March 2011
By Leland (Lee) Borgelt, Frontier El Dorado Refining Company
How a refinery used Excel to document its automation infrastructure during a DCS upgrade. Some simple tools can keep it all in order.
 
Networked plant sets standard  - 03/24/11
Process & Control Engineering, March 2011
By Hartley Henderson
The MidCoast Wwater treatment plant in New South Wales is controlled using a redundant ControlLogix PLC and a Citect SCADA system for the operator interface, data recording (trends/historical data) and reporting.
 
Ohio WWTP uses Flo-Corp radar level transmitter for influent water flow Ohio WWTP uses Flo-Corp radar level transmitter for influent water flow  - 03/10/11
The accuracy of the radar level system at the WWTP is extremely important and the data collected has helped addressed an ongoing problem with I & I (infiltration and inflow).
 
Leveraging Workflow Automation in the Batch Environment Leveraging Workflow Automation in the Batch Environment  - 03/03/11
Automation.com, March 2011
By Jay Mellen, Savigent Software
HallStar, a specialty chemical company near Chicago, uses Catalyst xM and PDC software to automate batch execution, electronic batch record management, and collect key manufacturing intelligence related to plant asset management.
 
Pipe Pressure Relief  - 02/28/11
Flow Control, January 2011
By Brad Clarke, District of Central Saanich
When fluids travel such long distances, there is always the potential for pressure buildups from even the slightest changes in velocity. This is exactly what was happening in Central Saanich due to aging infrastructure and surges from pumps stopping and power failures.
 
The fix is in at MGM Grand Macau The fix is in at MGM Grand Macau  - 02/14/11
Automation.com, February 2011
The MGM Grand Hotel and Casino Macau is a $1.6 billion property about three years old located on prime water front land in Macau. Their power bills were $1.6 million per month. The CFO called in John Leslie and his team to make some changes that saved $3.1 million in energy bills in the first 11 months.
 
Flow-Cal controls West African Gas Pipeline Flow-Cal controls West African Gas Pipeline  - 02/10/11
With the FLOWCAL Enterprise system, WAPCo is able to identify and correct key anomalies from both a volumetric and gas quality perspective.
 
Belden installs WLAN Process Control solution for Shell Belden installs WLAN Process Control solution for Shell  - 02/08/11
Belden designed and delivered a wireless Profinet infrastructure, which acts as an interface to the process control systems at Shell's Ethylene Cracker Complex in Singapore.
 
Powerful PAC Upgrades Wastewater Treatment Centrifuge  - 02/07/11
Control Engineering, January 2011
By Jeremy Poarch
PAC and HMI from Automation Direct help Moccasin Bend wastewater treatment plant improve operations, increase redundancy, and save time and money.
 
Technologies cooperate to control critical mixing operation  - 02/07/11
Control Engineering, January 2011
By Adrienne Lutovsky and Danetta Bramhall, ProSoft Technology
Mixing ablative coating for space shuttle rocket boosters requires very high levels of precision and repeatability. NASA uses PLCs, PACs, and Modbus communications.
 
WLAN process control solution for petrochemical plant  - 02/07/11
Control Engineering Europe, January 2011
A new Ethylene Cracker Complex has recently been completed by Shell Eastern Petroleum in Singapore. Belden Wireless technology has been deployed at the site to gain mobile access to the process control system.
 
Process solution for Petrovis LLC  - 02/07/11
Control Engineering Europe, February 2011
Petrovis LLC, the largest petroleum provider in Mongolia, is using Honeywell technology to improve the efficiency and safety of a newly constructed fuel depot near the capital, Ulaanbaatar.
 
Hudson and Knight upgrade at edible oils refinery  - 02/07/11
South Africa Instrumentation & Control, February 2011
Software solutions include the Wonderware System Platform, InTouch HMI/Scada, Wonderware Information Server and the Wonderware Historian.
 
Talvivaara mining company relies on Metso  - 02/07/11
South Africa Instrumentation & Control, February 2011
Equipment includes hundreds of Endress+Hauser flow, pressure, surface analysis and temperature measurements, dozens of intelligent Neles control valves, actuators and positioners, and a metsoDNA automation system.
 
Invensys controls ExxonMobil lubricants plant  - 01/27/11
InFusion ECS will manage the operating facility, controlling major processes and integrating the existing SAP enterprise resource planning, batch process and final packaging and shipping systems.
 
Honeywell controls Petrovis fuel depot in Mongolia  - 01/26/11
Honeywell supplied a PKS control system, OneWireless, Digital Video Manager and Enraf Tank Gauging System to improve the efficiency and safety of a fuel depot near Ulaanbaatar.
 
ABB System 800xA controls Potash Company in Jordan ABB System 800xA controls Potash Company in Jordan  - 01/24/11
ABB provided an electrical, control and instrumentation package to help boost capacity at Aqaba and make the storage and loading process faster and more efficient.
 
Xcel Energy Riverside Repowering Project  - 01/22/11
Energy-Tech, January 2011
Xcel Energy’s Riverside Plant was converted from being a coal-fired facility to a combined-cycle facility firing natural gas. Fuel switching to natural gas from coal resulted in significant benefits regarding plant emissions. Emissions of sulfur dioxide (SO2) decreased 99 percent, NOX decreased 96 percent, and mercury was eliminated entirely.
 
Brewery Implements High Operating Distance Sensors  - 01/22/11
IMPO, January 2011
The König brewery in Duisburg, Germany, uses Turck sensors to measure the position of pipe elbow adapters which distribute and feed liquids such as brewing water and wort. This is because of frequent loosening and fixing of the screw connection. The seal suffers damage so that the distance between sensor and pipe elbow varies.
 
Automatic Tank Gauging Relieves Anxiety  - 01/22/11
IMPO, January 2011
There’s nothing inherently wrong with the traditional systems that are used to monitor and record AST product levels. But when you’re talking about storage vessels that can be upwards of 50 feet tall and contain up to 500,000 gallons of product, they are just not as accurate at recording product levels.
 
GE controls six Rolls-Royce turbines in the United Arab Emirates  - 01/20/11
Six Mark VIe control panels were supplied for the Rolls-Royce turbines and process compressors, along with redundant network and communications interfaces to third party equipment and the plant DCS.
 
Fisher Control-Disk valves improve control at INEOS Chlor Fisher Control-Disk valves improve control at INEOS Chlor  - 01/18/11
Enhanced butterfly valves help INEOS Chlor plant in Runcorn, United Kingdom, avoid six unplanned shutdowns and save an estimated $600,000 USD.
 
D&R Packaging builds Filling Station with Avery Weight Indicator D&R Packaging builds Filling Station with Avery Weight Indicator  - 01/16/11
D&R Packaging designed and built a two-head liquid filling station in three weeks, using a PLC and an Avery Weigh-Tronix E1070 indicator.
 
Discrete Event Simulation Offers Real Value  - 01/16/11
Chemical Processing, January 2011
By Bernard McGarvey, et al, Eli Lilly
Pharmaceutical plants gain design, troubleshooting and other insights from models. Eli Lilly and Company has been using DES to model many of its manufacturing facilities for quite a few years.
 
WirelessHART Successfully Handles Control  - 01/16/11
Chemical Processing, January 2011
By Frank Seibert, UT, and Terry Blevins, Emerson
Comparable control performance versus wired, as measured by IAE, was achieved for both pressure control and steam flow control using WirelessHART measurements with the PID modified for wireless communication.
 
Keeping air filters clean is the key to energy efficiency  - 01/16/11
Plant Services, January 2011
Centro Energia Teverola’s cogeneration power plant in Teverola, Italy, installed an AMS Performance Monitor system to analyze two gas turbines, two heat recovery steam generators (HRSGs) and one steam turbine. AMS found that filters needed to be changed, and paid for itself.
 
Process models, advanced control support super steel mill  - 01/09/11
Control Engineering, December 2010
Extensive system integration and custom advanced control software supports steel mill. The mill automation system supports a continuous process requiring precision control of motor speeds and integration of auxiliary equipment.
 
Integrated process control system supports ‘agile’ manufacturing needs  - 01/09/11
Control Engineering Europe, January 2011
Siemens Industry Automation has been working with UK-based chemical and pharmaceutical intermediates manufacturer, Phoenix Chemicals, to provide process control solutions that have helped deliver three key benefits - enhanced production flexibility, improved product consistency and a reduction in costs.
 
Hyperion Delivers Operator Training Simulator for a Fluid Catalytic Cracker Unit  - 01/09/11
Process & Control Today, December 2010
Hyperion delivered a Fluid Catalytic Cracker Unit (FCCU) Operator Training Simulator (OTS) system to Preem Petroleum’s Lysekil refinery in Sweden. The OTS will be used for operator training, control system check out, and ongoing engineering and operational analyses.
 
Original thinker redefines bioreactor control  - 01/09/11
Process & Control Today, December 2010
I4Innovation in Thetford, UK, married four Mitsubishi Electric Alpha PLCs with the GT15 HMI to constantly monitor and adjust pumps, propellers, inlet and outlet valves and multiple sensors to manage the growth of cell cultures in bioreactors.
 
Bio-ethanol: motors process wheat and beet syrup  - 12/20/10
International Power Engineer, December 2010
WEG motors help BioWanze in Belgium process wheat and beet syrup to produce bio-ethanol. With this innovative system, BioWanze intends eventually to provide half the amount of the bio-fuel consumed in Belgium.
 
Invensys controls Inner Mongolia Power Plant  - 12/15/10
Advanced process control (APC) project helped save energy, reduce emissions, and double the ramp up rate for electric power plant units #1 and #2 in Baotou, Inner Mongolia.
 
Cutler MAX APC controls World's Largest Ammonia Plant  - 12/13/10
SAFCO's Jubail Saudi Arabia Urea plant, the largest in the world, has been running the MAX APC controller since April 2010.
 
More Water Savings through Automation  - 12/12/10
Control, December 2010
By Mike Crabtree
PLCs from AutmationDirect control the water distribution system for Mission Springs Water District in California. The PLCs also control video surveillance systems to monitor intrusion and security events.
 
Wireless helps Plains Exploration & Production (PXP)  - 12/12/10
Control Engineering, November 2010
PXP transformed its steam injection metering and data acquisition systems into a highly sophisticated, automated process comprised of a large network of WirelessHART transmitters and industrial broadband radios.
 
The Role of Simulator Technology in Operator Training Programs  - 12/12/10
Control Engineering, November 2010
By Al Roe and John Mason, Agrium
Agrium, operator of several ammonia plants in North America, has been using operator simulators for training since 1983. They find that simulators are a best practice for training control room panel operators on abnormal situations and other “real world” plant scenarios.
 
Automation and valves for Russian mill project  - 12/12/10
Control Engineering Europe, November 2010
Metso installed metsoDNA control systems, HIMA safety systems, and 1400 control and automated on/off valves and 5500 manual valves at the Syktyvkar pulp mill in Russia.
 
Wireless HART technology helps boost production and cuts  - 12/12/10
Control Engineering Europe, November 2010
Smart Wireless technology, based on the WirelessHART (IEC 62591) standard, is enabling Tecpetrol to boost production, while reducing maintenance and operations costs at natural gas compression and delivery facilities in Argentina.
 
Motion Controller Perfects Yorkshire Pudding Recipe  - 12/12/10
Process and Control Today, December 2010
Western Mechanical Handling developed a new technology for depositing Yorkshire pudding batter into baking moulds. Using peristaltic pumps and a Mitsubishi Q170M motion controller running on a Q series PLC, the batter delivery is now accurate to +/- 0.1g.
 
Emerson Wireless technology helps boost production in Argentina Emerson Wireless technology helps boost production in Argentina  - 11/22/10
Data from Rosemount wireless transmitters helps Tecpetrol increase production by $4 million while reducing maintenance costs by 62% and supervisory control costs by 35%.
 
Goodyear Gives Variability a One-Two Punch  - 11/21/10
Control, November 2010
By Jim Montague
As part of a DeltaV migration project at its Beaumont plant, Goodyear implemented Emerson's SmartProcess distillation optimizer, which uses embedded DeltaV APC, and has on-line key performance indicator (KPI) calculations.
 
Monitoring a Water Plant In Real-time  - 11/21/10
Automation World, November 2010
By Rob Spiegel
The Sheboygan Regional Wastewater Treatment Facility, in Sheboygan, WI, replaced their bi-metallic overload relays with Motor Insight overload and monitoring relays from Eaton. They detected conditions that might have resulted in motor or pump failure and energy waste
 
Wastewater treatment optimisation provides savings  - 11/15/10
European Process Engineer, November 2010
By Dr Michael Haeck, Hach Lange
In combination with Hach Lange sensors, nutrient removal and sludge treatment processes can now be optimised in order to achieve savings in aeration energy and chemical consumption, even on small waste water treatment facilities.
 
Emerson automates Varandey oil export terminal in Russia Emerson automates Varandey oil export terminal in Russia  - 11/10/10
Emerson supplied DeltaV control systems, AMS software, Rosemount instrumentation and Fisher control valves, communicating via HART, Modbus and FOUNDATION fieldbus protocols.
 
Portraits of Simulation Success  - 10/19/10
Control, October 2010
By Jim Montague
Three end users employ several types of simulators from Invensys to improve design, training and operations in power, mining and other applications.
 
Need an Automation Plant in a Hurry?  - 10/19/10
Control, October 2010
By Charlie Henderson, Fluor
Fluor uses Coriolis flowmeters to help fast-track construction of the world's largest solar-grade polysilicon plant in China to meet the needs of photovoltaic cell manufacturers.
 
Hazardous Area Flow Meter Takes On Pharmaceutical Batching  - 10/19/10
Process & Control Today, September 2010
Macfarlan Smith’s pharmaceutical manufacturing site in Edinburgh uses an ABLE hazardous area portable flow meter as a volumetric totaliser of solvent into a batch of product. Accurate measurement is required for product quality, batch consistency and prevention of increased energy consumption due to overfilling.
 
Rotork supplies SIL2 valve actuators for Bolivian gas plant  - 10/19/10
Process & Control Today, September 2010
Rotork Fluid Systems supplied thirty-one SIL2 spring-return failsafe quarter-turn scotch yoke pneumatic actuator packages with mechanical partial stroke test facilities to the La Vertiente gas plant in Villamontes in Bolivia.
 
Keeping Tyseley on Track  - 10/19/10
Process & Control Today, October 2010
The Tyseley plant in the UK incinerates 350,000 tonnes of Birmingham’s non-recyclable rubbish each year. To maximise boiler efficiency, Tyseley produces high purity deionised water on site and adds chemicals to scavenge oxygen and adjust the pH to prevent corrosion.
 
Emerson's Wireless saved Atlas Pipeline $725,000 in installation costs  - 10/13/10
The wireless network includes 99 Rosemount wireless temperature, pressure, level, and discrete-input transmitters that communicate with three Smart Wireless Gateways.
 
Refinery in Kuwait converts 1,750 steam traps Refinery in Kuwait converts 1,750 steam traps  - 09/29/10
Shauiba Refinery in Kuwait converted 1,750 mechanical traps to GEM Venturi Orifice design. The hot condensate header pressure dropped from highs of 175 psig to just 90 psig.
 
Emerson’s Wireless network boosts production at Northstar Bluescope Steel Emerson’s Wireless network boosts production at Northstar Bluescope Steel  - 09/28/10
Replacing traditional wired network with wireless for control and monitoring has improved operations and worker safety in harsh environment.
 
ABB controls iron ore pellet plant in Bahrain  - 09/22/10
ABB supplied a System 800xA process control system, field instrumentation, motor control centers, motors and variable speed drives to Gulf Industrial Investment, Bahrain.
 
Cogent Android Phones Gain Access to Live Process Data Cogent Android Phones Gain Access to Live Process Data  - 09/14/10
Java-based solution puts real-time data from industrial processes into a mobile phone or other Android-based device, using the OPC DataHub from Cogent Real-Time Systems.
 
Emerson automates separations research facility  - 09/12/10
The pilot plant uses DeltaV S-series controllers with Electronic Marshalling, HART I/O, Smart Wireless communications, sensors and transmitters, digital control valves, and Coriolis meters.
 
Wiri Oil turns to Honeywell  - 09/12/10
South Africa Instrumentation & Control, September 2010
Wiri upgraded to Honeywell’s Experion R300 HMI with the help of the Legacy Input/Output Module (LIOM), an integrated solution for taking advantage of Experion while ensuring the best utilisation of existing LCS I/Os. It used its existing LCS 620 I/O, keeping the hardware in place.
 
To Hell and Back  - 09/10/10
Control, September 2010
By Jon DiPietro
The control room at Goulburn Valley Water in Australia was completely incinerated, destroying the electrical switchgear, plant HMI, laboratory, instrumentation and chemical dosing systems. They rebuilt it in five days.
 
How to Integrate Safety  - 09/10/10
Control Engineering, August 2010
By Jeanine Katzel
Incorporating safety into a machine or a process at the design stage is more cost-effective than doing so later. Here’s a look at how several integrators and manufacturers approach upfront safety integration and the resulting benefits.
 
Mersen overhauls process control with Burkert  - 09/10/10
Control Engineering Europe, August 2010
Mersen chose Burkert to provide process control for its new Moulding Station and Effluent Treatment plant at its production facility at Eurocentral in Scotland. The Burkert system handles level and flow monitoring, fluid control and process actuation.
 
Detection system improves factory safety  - 09/10/10
HazardEx, August 2010
ATEX's ACOM detection system monitors process air for the presence of volatile pyrolysis components, indicating the potential presence of thermal decomposition or smoulder spot development. An Allen-Bradley L32E CompactLogix PAC connects to a CO analyser and a PanelView Plus 600 HMI.
 
Audit Helps Kaiser Aluminum Save Energy, Improve Productivity  - 08/26/10
Reliable Plant, August 2010
DOE’s Industrial Technologies Program (ITP) helps industrial plants operate more efficiently and profitably by identifying ways to reduce energy use in key industrial process systems.
 
Wireless – Overcoming challenges of PID control & analyzer applications  - 08/23/10
InTech, August 2010
By Greg McMillan
An enhanced PID controller simplifies tuning and improves loop stability and reliability for loops dominated by discontinuous measurement updates.
 
AspenTech’s APC Reduces Energy Costs for Czech Refinery  - 08/23/10
Process and Control Today, August 2010
Unipetrol deployed 18 DMCplus controllers from AspenTech, all of which remain online more than 95 per cent of the time. In addition to achieving better control of the process, Unipetrol is using the AspenTech APC solutions on a daily basis to compare actual data from its plant to targets created using a model.
 
Benxi Steel migrates to Ovation control system in less than six days  - 08/23/10
Process and Control Today, August 2010
Installing the new Ovation system was accomplished in five days and 14 hours within a scheduled maintenance outage. The quick turnaround was critical: to avoid equipment damage, a high temperature needed to be maintained in the furnace – even when it was not producing steel.
 
Burkert Provides Process Control System For Mersen Eurocentral Facility  - 08/23/10
Process and Control Today, August 2010
Burkert provided a process control system, including level and flow monitoring, fluid control and process actuation, for a new Moulding Station and Effluent Treatment plant, installed at Mersen’s new production facility at Eurocentral in Scotland.
 
ABB flowmeters save money at Virginia Commonwealth University ABB flowmeters save money at Virginia Commonwealth University  - 08/17/10
ABB flowmeters cut steam losses and recovered more than $1.25 million a year in lost revenues.
 
NextEra Energy adds Triple-Redundant controls to Nuclear Turbine Generator  - 08/17/10
GE Energy supplied a Mark VIe Triple Modular Redundant (TMR) turbine control system to NextEra Energy's Seabrook Station.
 
Selecting Suppliers for Global Ambitions  - 08/13/10
Control Engineering, July 2010
By Rich Chmielewski, Siemens
Orbitek uses a Siemens Simatic S7 315 controller, drives, flow meters and pressure transmitters to control its biodiesel plant.
 
APC Improves Energy Efficiency  - 08/13/10
Control Engineering, July 2010
By Don Morrison, Honeywell Process Solutions
Fertilizer producer improves process in key areas through advanced process control, and integrates more operator knowledge into control strategy.
 
Wi-Fi network improves operator efficiency for Novartis in France  - 08/13/10
Control Engineering Europe, July 2010
The combination of a digital automation system with a fully integrated Wi-Fi network and mobile operator stations provides process and plant information to operators and maintenance staff throughout the facility.
 
Turnkey automation project at sugar mill  - 08/13/10
HazardEx, July 2010
WEG drives, inverters and control systems automated the Jaguaruana ethanol plant in the state of Ceará. Brazil.
 
Benxi Steel migrates to new control system in less than six days  - 08/02/10
Emerson Process Management completed a WDPF-to-Ovation control system migration project at the Benxi Steel Company’s No. 5 Blast Furnace in China.
 
ABB controls silicon production line at plant in Norway ABB controls silicon production line at plant in Norway  - 07/27/10
The System 800xA solution includes operator workplaces, five AC 800M controllers, and approximately 3000 I/O, and uses Foundation Fieldbus to communicate with the various types of process equipment.
 
Agrochemical Operation Reduces pH Maintenance Hours By 50% Agrochemical Operation Reduces pH Maintenance Hours By 50%  - 07/21/10
Agrochemical producer saved $450,000 per year by switching to Endress+Hauser’s pH analyzers. Specifically, maintenance labor was reduced by 50% and consumable usage was cut by 60%.
 
Batch to the Future  - 07/18/10
Control, July 2010
By Jim Montague
Pigment dispersions manufacturer plasticolors uses predictive-adaptive material transfer control to continuously tighten the accuracy of its filling batches on the fly.
 
Safety And The Environment -- "Zero" Really Adds Up  - 07/18/10
Chemical Processing, July 2010
By Kim Hoyt, Huntsman
Project Zero went live in May 2009 and now is deployed at more than 70% of the plant with complete coverage expected this summer. It's already markedly improved the number of defects captured and reduced redundant efforts.
 
Coriolis Mass Flowmeters Used To Measure Bulk Condensate In Gas Field  - 07/18/10
Pipeline & Gas Journal, July 2010
By Mark Davis, Jerry E. Stevens and Michael Keilty
Shell understood the technical limitations of positive displacement technology and proposed a new approach for bulk condensate measurement using Coriolis flowmeters from Endress+Hauser for the Pinedale Anticline natural gas field in Wyoming.
 
Cloud Computing with SAP: One User’s Experience  - 07/12/10
Automation World, July 2010
By Wes Iversen
Quick implementation and predictable costs were among benefits of using SAP’s new Software-as-a-Service ERP product for a start-up plant in China.
 
Bio-ethanol plant installs high efficiency motors on cooling towers  - 07/10/10
Control Engineering Europe, June 2010
WEG supplied high efficiency motors for the BioWanze project—a plant that began producing bioethanol from wheat and sugar beet last year, and produces half the annual bioethanol volume for Belgium.
 
Technology with Added Value  - 07/10/10
Control Engineering Europe, June 2010
By Jane Goh, Changi Water Reclamation Plant
The Changi Water Reclamation Plant in Singapore is one of the biggest Profibus installations in the world, with 7,000 Profibus DP and 2,500 Profibus PA instruments. They rely on FDT technology for device integration.
 
Commissioning like a pro  - 07/10/10
Control Engineering Europe, June 2010
By Mike Babb
Foundation fieldbus Instrumentation from Endress+Hauser was configured with DTMs to monitor gas burners at the ADA Carbon Solutions plant in Coushatta, Louisiana.
 
Cutting the cost of power  - 06/16/10
South Africa Instrumentation & Control, June 2010
Depending on the temperature of the boiler and turbine, start up times can vary from one hour to several. OSI’s startANALYSIS provides RWE with the guidance to reduce variation in start up times and ensure the correct sequencing of activities.
 
Upgrade at Pilsner brewery  - 06/12/10
Control Engineering Europe, June 2010
Czech beer Pilsner Urquell updated its existing SIEMENS S5 to an S7 system with wireless and Profinet communications, and eliminated 14 PLCs in the process.
 
Reliable Pumping Of Abrasive Slurry  - 06/12/10
Process & Control Engineering, May 2010
The Verderflex VF40 pumps abrasive mining slurry, a medium with 60% solid content, at at the Xstrata Alloys Rhovan mine in South Africa. Whilst centrifugal pumps struggle to perform well with such slurries Verderflex pumps these dense fluids, continuously and problem-free.
 
Load cells ensure high accuracy in Weigh Blending Systems  - 06/12/10
Process & Control Today, June 2010
TSM Control Systems in Ireland is using HBM’s single point load cells to ensure high accuracy in its Weigh Blending Systems. The blending systems measure a recipe of different plastic granules by weight and then blend the resulting mix so that it can be used in different types of plastic processing.
 
Rotork in storage project to secure Baltic gas supplies  - 06/12/10
Process & Control Today, June 2010
Actuators operate ball valves controlling the receiving of gas and its injection into the storage wells. Additional IQM modulating actuators are installed on ball valves in the site’s metering plant. All actuators are connected to PLCs and controlled by a centralised SCADA system.
 
Emerson improves productivity at Cambrex Profarmaco Emerson improves productivity at Cambrex Profarmaco  - 06/02/10
Cambrex Profarmaco of Milan, Italy, successfully implemented Emerson's DeltaV digital automation system, AMS Suite, Rosemount instruments and meters, and Micro Motion F-Series Coriolis mass flowmeters.
 
Smart Wireless improves furnace operations at Ternium Siderar  - 05/27/10
Emerson's Smart Wireless network is helping deliver improved furnace operation and safety at Ternium Siderar’s steelmaking facility in San Nicolás Argentina.
 
Krško takes control  - 05/23/10
Nuclear Engineering International, May 2010
By Mark Zilavy and Damir Mandic
In 2007, a project was launched at Slovenia’s Krško NPP to upgrade the digital electro hydraulic (DEH) turbine control system, which was becoming obsolete. A new Westinghouse system has improved functionality and reliability, although its installation was complex.
 
Syngenta monitors heat exchangers with Smart Wireless  - 05/20/10
Using wireless devices based on WirelessHART, Syngenta expects $25-$50K in annual raw materials savings through cost-effective monitoring of heat exchangers.
 
Refined Integration  - 05/19/10
Industrial Automation Asia, May 2010
By Antonio Carvalho and Johan Hansson, AB
The integration of an electrical control system into the process control system increases productivity and availability by permitting a single strategy in the areas of engineering, maintenance and operations.
 
WirelessHART Keeps Equipment Connected to the DCS  - 05/19/10
Control Design, May 2010
By Scott Broadley, Broadley-James
When a skid is portable and routinely moved within the plant, even a few pluggable connections to the DCS can become a maintenance issue. WirelessHART field devices solves this since the connection to the DCS is independent of its physical location.
 
Integrated Control And Safety For Scottish & Southern Energy.  - 05/15/10
Process and Control Today, April 2010
Scottish & Southern Energy installed a Siemens PCS7 platform to monitor and control a key gas storage facility, which has also seen the seamless integration of a safety system.
 
Quarry upgraded whilst fully operational  - 05/15/10
South Africa Instrumentation & Control, May 2010
Laezonia Quarry in South Africa installed new electrical and instrumentation cable racking, cables, local isolator panels, safety instrumentation, pull ropes etc, without impacting on production and with both plants in operation.
 
WirelessHART Network monitors Mining Operation’s Movable Leach Fields WirelessHART Network monitors Mining Operation’s Movable Leach Fields  - 05/13/10
The system uses 44 Endress+Hauser Promag 53P flowmeters and Cerabar WirelessHART pressure transmitters to monitor flow and pressure in leach fields that are regularly relocated, and use movable, temporary piping.
 
Wireless helps Dubai Aluminum manage compressed air Wireless helps Dubai Aluminum manage compressed air  - 05/12/10
Rosemount wireless transmitters provide reliable data to existing SCADA system despite strong magnetic field, allow operators to reduce energy use by 13 percent.
 
Cementing the Process  - 05/12/10
Control Engineering Asia, April 2010
By Bob Gill
A Siemens PCS 7 control system specifically targeted at meeting at the needs of cement producers proved to be a judicious choice at this Indonesian plant.
 
Wireless Applications Put to the Test  - 05/12/10
Control Engineering Europe, May 2010
By Jeff Becker, Honeywell Process Solutions
Three industrial plants share their experiences with industrial wireless. In all three cases — alcohol storage tanks, oil and gas pipelines, and a hot furnace in a steel factory — wireless helped them solve perplexing problems that probably would not have been solved otherwise.
 
Wireless technology helps Lion Oil check product inventory  - 05/06/10
Emerson's Smart Wireless technology is helping Lion Oil cost-effectively check product inventory, prevent overfill and remediation costs, and monitor UPS power for the radio tower.
 
Intangible benefits of upgrading control technology  - 05/02/10
InTech, April 2010
By Pamela K. Quillin, P.E.
A silica plant in the U.S., built decades ago, was still running on 1960s vintage technology by the late 1990s. Installation of a DCS enabled automation throughout the process.
 
PROFIBUS solution manages a helium-cooling system PROFIBUS solution manages a helium-cooling system  - 04/21/10
By Softing
Softing Profibus equipment controls DESY, Germany’s largest helium cooling system. Profibus protocol software provided the foundation for achieving redundancy, with Profibus guaranteeing an instantaneous and bump-less switchover of all connected I/O devices.
 
Cutting costs with energy auditing  - 04/16/10
Reliable Plant, April 2010
24-7 Power, an electrical consulting and engineering service company, uses a three-step approach to help a company lower its energy bills. With the right tools and knowledge, your company can follow the same process using your own personnel.
 
Krško takes control  - 04/14/10
Nuclear Engineering International, April 2010
By Mark Zilavy and Damir Mandic
In 2007, a project was launched at Slovenia’s Krško NPP to upgrade the digital electro hydraulic (DEH) turbine control system, which was becoming obsolete. A new Westinghouse system has improved functionality and reliability, although its installation was complex.
 
Brewery in a Box?  - 04/14/10
Control, April 2010
By Walt Boyes
The Saint Louis Brewery upgraded its home-brewed control system to a Simatic Braumat PCS7 control system designed especially for brewing applications.
 
Diversity linked on a common platform  - 04/08/10
Control Engineering, April 2010
By Christine Eckert, FDT Group
Device integration at the world’s largest wastewater treatment plant, the Changi Water Reclamation Plant in Singapore, links multiple manufacturers on common fieldbus and management networks.
 
Tankvision - tank gauging re-imagined  - 04/08/10
South Africa Instrumentation & Control, April 2010
By Hennie Blignaut, Endress+Hauser South Africa
The Tanzanian & Italian Petroleum Company installed a wireless Modbus Tankvision system to measure product in 20 large storage tanks using level, pressure and temperature gauges.
 
Opto 22 controls water in Leadville
By Opto 22
The Bureau of Reclamation installed Opto 22 SNAP PACs and I/O to replace older Opto 22 Mistic controllers in a water treatment system to cleans up water from mines near Leadville, Colorado.
 
Opto 22 Controls New Belgium Brewing Wirelessly
By Opto 22
SNAP PAC systems handle 10,000 digital and analog I/O, use a wireless Ethernet system, and control seven brewing processes at New Belgium Brewing, makers of Fat Tire beer.
 
Opto 22 upgrades furnace control system
By Opto 22
Older Opto 22 controllers on a furnace control system at Advanced Energy were upgraded by Malisko Engineering to SNAP I/O and controllers.
 
Rexroth Brings Servo Precision to Web Converting Machine
By Rexroth
A Rexroth SYNAX 200 control system, servo drives and SERCOS control Summit Machine’s web converter, a 20-axis converting machine that takes material compounds and precisely forms them against a substrate to create the final product.
 
Rexroth controls servo-driven lumber sticker stacker  - 04/01/10
By Rexroth
MoCo Engineering and Fabricating uses Rexroth regenerative drive system in its all electric servo-driven lumber stacking machine. Energy consumption dropped from 100-180 kW for a previous hydraulic machine to 58 kW for the servo-driven machine.
 
MCI Electrotechnics employs explosion-proof enclosures MCI Electrotechnics employs explosion-proof enclosures  - 03/29/10
MCI Electrotechnics uses explosion-proof enclosures from Cooper Crouse-Hinds to protect a variety of electrical equipment destined for offshore and onshore oil, gas and petrochemical applications.
 
Modular actuation solutions for major refineries  - 03/26/10
Oil & Gas Engineer, March 2010
By Michael Herbstritt, Auma
Auma products have been selected for a number of Shell projects on the North Coast of Borneo, where extracted gas is liquefied for transportation. The devices replaced existing actuators that have not met the rigorous performance standards demanded by offshore applications.
 
GE controls HelioVolt solar panel manufacturing process  - 03/24/10
HelioVolt implemented Proficy Software in its new thin film solar PV module manufacturing plant in Austin, Texas.
 
Emerson monitors biomass gasification at Polish power plant  - 03/22/10
Temperature data is being transmitted over a WirelessHART network to operators to ensure that the ceramic walls of the chamber are not damaged by stress fractures through overheating.
 
Emerson controls cut fuel costs for INEOS Chlor  - 03/17/10
Using PlantWeb control and predictive maintenance technologies, INEOS Chlor has been able to reduce venting of hydrogen gas and instead use it as a fuel to heat onsite boilers for power generation.
 
Simple, Strong and Easy-to-Use  - 03/13/10
Control, March 2010
By Jim Montague
BHP Billiton Worsley Alumina in Australia upgraded a TDC2000 DCS to a Honeywell Experion DCS, operator stations, software and other equipment. The new controls had to make room for close to 4,000 process signals and more than 300 drives that were migrated from the old plant equipment to new systems, and do it without hindering operations.
 
Improving HMI Functions at Pilot Plant  - 03/13/10
Control Engineering, March 2010
By Roberto Zerbi, Invensys
Pfizer migrates to an updated HMI platform to overcome obsolescence issues and 'future-proof’ operations. Innovative software licensing helps.
 
Integrated process control that works  - 03/13/10
Process & Control Engineering, March 2010
By Sean Cahill, Siemens
Cadbury upgraded a dental care production process in Australia with a Siemens SIMATIC PCS. The original process was a manual system, where various pieces of process equipment each with its own control system had been added.
 
Schneider Electric provides interface for Nicholl Food Packaging  - 03/13/10
Process and Control Today, March 2010
Nicholl Food Packaging in the UK had problems with failure of HMIs, some apparently caused by machine vibration. They installed Magelis HMIs with touch screens and interfaced them to the plant’s old PLCs.
 
Focus on Critical Assets Pays Off  - 03/10/10
Chemical Processing, February 2010
By Joel Holmes, Monsanto
Since an Emerson AMS asset optimization program was initiated more than two years ago at the Monsanto herbicides plant in Muscatine, Iowa, it's prevented several potentially expensive process interruptions, saving the company tens of thousands of dollars.
 
Steam turbine vibrations  - 03/10/10
Energy Tech, March 2010
By Patrick J. Smith
The causes of rotating machinery vibration problems are not always obvious. The effects of pipe strain and lubrication issues for example, can be difficult to identify. This article describes an example of one of these cases.
 
Emerson wireless helps improve operator efficiency for Novartis Emerson wireless helps improve operator efficiency for Novartis  - 03/09/10
Emerson’s DeltaV with a Wi-Fi network and mobile operator stations are providing process and plant information to operators at the Novartis biotech production centre in France.
 
Opting for Wireless Technology  - 02/26/10
Power Engineering, February 2010
When Entergy Nuclear adopted Motorola wireless technology at its River Bend Nuclear Station, the company successfully modernized one of its plants and maximized performance—and saved $4 million in the process.
 
The Advanced Digital Fieldbus Option for Nuclear Plants  - 02/26/10
Power, February 2010
By Jack Y. Zhao, U.S. Nuclear Regulatory Commission
Digital fieldbus technologies, including Foundation fieldbus and Profibus, are increasingly being used with success in the nuclear and fossil fuel power industries. This article compares a conventional control system with a Foundation fieldbus – based digital control system used in a typical circulating water system in a nuclear power plant.
 
Farmers profit by controlling biogas  - 02/19/10
Process and Control Today, February 2010
CC-Link fieldbus control is helping farmers extract valuable biogas from slurry to fuel cogeneration plants. The controller is a MELSEC FX3U PLC which communicates with the system’s various automation components via a CC-Link master module and standard serial ports.
 
Distillery selects PC system for hazardous areas  - 02/19/10
HazardEX, February 2010
An ATEX-certified PC system from R.Stahl is now in use at Aberdeenshire based Ardmore Distillery. The fully automated control system allows the operators to control all aspects of the distilling process from one central location right next to the spirit safes in the heart of the still-house.
 
Schweppes control in the can  - 02/19/10
Process & Control Engineering, February 2010
By Sarah Falson
Schweppes Australia upgraded its syrup room DCS control system at its Huntingwood facility to a control system based on PlantPAx and FactoryTalkView SE software from Rockwell Automation.
 
Wireless boosts operational efficiency at brewery  - 02/19/10
Process and Control Today, January 2010
Plzeòský Prazdroj, the leading brewery in central Europe, upgraded from an existing Siemens S5 control system on its kegging line to the Siemens S7 system, incorporating ProfiNet wireless communication.
 
The Worlds Largest Foundation Fieldbus Project  - 02/19/10
Control, February 2010
By B. R. Mehta, et al
The Jamnagar Export Refinery Project greenfield refinery in India, with 20,000+ Foundation fieldbus tags, is one of the world's largest FF sites. Equipment was supplied by Invensys and MTL.
 
Smart Compressors Drive Efficiencies  - 02/16/10
Control Engineering, February 2010
By Renee Robbins
New Siemens HMI and control systems allow Quincy Compressor to enable networked compressors, desktop data portals, and other innovations.
 
STW cuts costs with pump management  - 02/16/10
Control Engineering Europe, January 2010
Severn Trent Water (STW) in the UK claimed savings of up to £2,400 (€2,700) a week when it overhauled its pump maintenance with control software from ABB.
 
ABB upgrades Expert Optimizer systems in Brazil ABB upgrades Expert Optimizer systems in Brazil  - 02/14/10
Upgrade improves reliability and efficiency of alternative fuel use for Votorantim’s Itau and Salto plants in Brazil. Expert Optimizer was first installed at the plants in 1995.
 
Wireless network automates data collection at Petrobras  - 02/10/10
Emerson’s WirelessHART network delivers real-time compressor data while saving $200,000 installed cost and overcoming difficult conditions for wired approach
 
AMS software helps Centro Energia Teverola increase efficiency AMS software helps Centro Energia Teverola increase efficiency  - 02/09/10
Centro Energia Teverola optimized their maintenance strategy for inlet filters on gas turbines, contributing to an overall efficiency improvement of more than 1%.
 
Emerson automates ethanol plant in Sweden Emerson automates ethanol plant in Sweden  - 01/27/10
A pilot ethanol processing plant built by Chematur Engineering uses Emerson's DeltaV control system with WirelessHART, Wi-Fi, FOUNDATION fieldbus, AMS, and Rosemount wireless pressure and temperature transmitters.
 
Cellulosics Conversion Gets a Boost  - 01/27/10
Chemical Processing, January 2010
By Rich Chmielewski, Siemens Industry
Biofine Renewables installed a Siemens Simatic PCS 7 process control system with redundant dual-screen operator stations communicating over industrial ethernet, a Profibus fieldbus network, and 20 Siemens Micromaster variable frequency drives (1 hp to 5 hp) controlling agitators and pumps.
 
Making Migrations Successful  - 01/20/10
Control Engineering, January 2010
By Rich Chmielewski, Siemens
Control system features and functionality are critical, but how big a part does service play? Cymetech migrated from a Provox system to a Siemens PCS7 system and learned that value.
 
Controlling Diesel Hydrotreaters  - 01/20/10
Control Engineering, January 2010
By James R. Ford and Robert K. Poag, Maverick
How Maverick used APC on a Foxboro DCS to solve a chronic and burdensome operating problem on an ultra-low sulfur Diesel hydrotreater.
 
Automated manufacturing system quadruples production Automated manufacturing system quadruples production
After a fire destroyed the manufacturing process, Research Products had two options: either rebuild using equipment comparable to what had previously been used, or investigate ways to automate the manufacturing process.
 
LG Chem saves using advanced Process Control Solution  - 01/10/10
Process & Control Today, January 2010
LG Chem chemical company in Korea deployed aspenONE Advanced Process Control, resulting in $4 million of annual operational savings, while also helping the chemical company achieve its operational excellence goals.
 
BP validates storage tank protection systems via wireless BP validates storage tank protection systems via wireless  - 01/06/10
Emerson wireless temperature transmitters measure floating roof temperatures at BP Exploration’s Dalmeny onshore terminal.
 
Two birds with one stone  - 12/24/09
Nuclear Engineering International, December 2009
By Pascal Gain and Jody Ryan
Combining nuclear reactor simulators for engineering and operations applications could save money. This is what EDF did for the Flamanville 3 EPR engineering and training simulator, and what CGNPC did for the Ling Ao 2 CPR-1000 verification & validation (V&V) simulator.
 
Petrochemical Efficiency  - 12/18/09
Control Engineering, December 2009
A process control system from Honeywell delivered six weeks ahead of schedule drives efficiency for SABIC’s Ibn Zahr facility; designed production levels were reached in less than one week.
 
Ventura Foods: Flexible Batch Control  - 12/18/09
Control Engineering, December 2009
Three food processing facilities lacked capacity to handle projected business growth; a batch control solution provided the needed flexibility. System integrator ISE installed Batch Optimizer, a recipe-based batching control system.
 
Wireless Control of Critical Applications Is Just a Leap Away  - 12/15/09
Industrial Networking, December 2009
By Mike Bacidore
To reach the unreachable: examples of successful wireless field control may pave the way for future wireless control of critical applications.
 
Brewing Up in Vietnam  - 12/06/09
Control Engineering Asia, November 2009
By Bob Gill
The Hue Brewery in Hue, Viet Nam, is controlled by a Siemens PCS 7 running Simatic Batch and Route Control. S7-400 Series PLCs are connected to ET 200 remote I/O stations, with engineering and operating HMI stations.
 
Instruments Tame Troublesome Slurry  - 11/21/09
Chemical Processing, November 2009
By Kerry Haight, Lubrizol, and Joe LaPoint, FCX Performance
Lubrizol Advanced Materials’ Louisville, Ky., plant produces chlorinated polyvinyl chloride (CPVC) resin. The amount of CPVC determines the quantity of additive required, so it’s necessary to know the CPVC slurry’s flow rate and its % solids. It’s tough, however, to obtain accurate measurements with two-phase flow. Two different sensors solved the problem.
 
Flow Line Options sensors monitor Smart Fuels Biodiesel Refinery  - 11/18/09
The refinery is expected to be operational by 2010 and will produce ASTM certified biodiesel fuel from recycled, used vegetable oil and fats.
 
Wireless technology monitors temperatures at AOC resins  - 11/16/09
Eight Rosemount wireless temperature transmitters continuously check batch temperatures, sending that real-time data to a Smart Wireless Gateway integrated with the plant’s DeltaV digital automation system.
 
TRUNKGUARD Optimizes Fieldbus Installation at Ethanol Plant
By Tim Wilson, Abengo Bioenergy, and Jeff Marsh, FeedForward
Abengoa used a Yokogawa CENTUM CS3000 DCS, Foundation fieldbus for analog I/O, Profibus for motor control, and MooreHawk TRUNKGUARD device couplers to connect the FF and Profibus segments. The system had 72 fieldbus segments and 650 nodes.
 
Wireless network boosts production at Samarco's Germano mine  - 11/11/09
WirelessHART data fed directly into Emerson's DeltaV control system protects pumps and prevents process stoppages while realizing 35% savings in installed costs compared to wired network
 
Tarago reservoir automation improves Melbourne water supply  - 11/11/09
What’s New in Process Technology, November 2009
The water treatment control system can monitor and control more than 50 drives and 80 valves simultaneously. SEMF’s Melbourne-based automation group was responsible for designing and commissioning the PLC and HMI software programs (including various interfaces for SCADA and third-party plant and equipment).
 
Emerson wireless transmitters monitor gas plants in Argentina Emerson wireless transmitters monitor gas plants in Argentina  - 11/05/09
Rosemount wireless transmitters at three sites measure venting, deliver gas data for AGA3 calculations to balance plants, and provide data for fiscal accounting of sold gas.
 
Wireless helps cement plant comply with air quality regulations Wireless helps cement plant comply with air quality regulations  - 10/26/09
Emerson’s wireless network of field instrumentation monitors the process used to reduce NOx emissions inside a rotating cement kiln at CalPortland Company.
 
SAP = Maintenance Success For Centocor  - 10/22/09
Maintenance Technology, October 2009
By Rick Carter
In what some in the maintenance world might consider a minor miracle, a SAP-PM implementation for Johnson & Johnson’s Centocor paid for itself through savings in both material and time. No cries of "Why me?" or "No! No! No!" SAP-related savings actually paid for the $3.2-million investment in less than two years. Miracles do happen.
 
Remote Machinery Diagnostic Services at Nexen Petroleum  - 10/22/09
Maintenance On-Line, October 2009
Remote diagnostic services are relied upon more and more as a viable alternative to on-site service. The benefits are obvious. When a skilled analyst can access data remotely as needed to accurately diagnose a problem, the inherent delays and expenses related to travel are eliminated. With precious time saved, problems can be resolved before collateral damage occurs, and at lower cost.
 
Steel plant sees shakes  - 10/22/09
Plant Services, October 2009
In Worthington Steel’s Porter, IN, plant, rollers on the pickling line were going through two sets of bearings per year, at a cost of approximately $75,000 per bearing set. Using ProSmart’s advanced diagnostic tools to continuously monitor machine health, Worthington Steel found the problem.
 
Ultrasonic: A new method for condition monitoring  - 10/22/09
Reliable Plant, October 2009
By R. P. Naik, Raipur, National Thermal Power Corporation
A new technique called ultrasonic condition monitoring is now available which can detect even incipient faults in bearings as well as adequacy of lubricant. At the National Thermal Power Corporation’s Sipat plant in India, we are relying on only vibration measurement as a basic technique for condition monitoring of bearings.
 
Moving On Up  - 10/22/09
Control Engineering Asia, October 2009
By Bob Gill
Increasingly frequent breakdowns and difficulties in sourcing spare parts for its ageing control system finally made this Thai cement producer decide to migrate to Siemens and its PCS 7 Cemat process control system, PLCs, Profibus DP, and remote I/O stations.
 
ABB automation controls Stora Enso paper mill ABB automation controls Stora Enso paper mill  - 10/20/09
ABB automation, power distribution, variable speed drive systems and electrification equipment is being used on the PM12 paper line at Stora Enso’s Kvarnsveden paper mill in Sweden.
 
Vishay web control used in coating pilot plant  - 10/20/09
Vishay provided a web tension measurement system to Western Michigan University (WMU) for use in its Coating Pilot Plant. The system precisely measures the sheet web tension between the coater backing rolls and the chill-roll S-wrap.
 
The Water Works  - 10/19/09
Control, October 2009
By Tom Pagakis, Carlsbad Municipal Water
The SCADA system employed by Varlsbad, CA, monitors current status and provides remote control abilities for all of Carlsbad's water and reclaimed water. The key components for these systems are SNAP controllers from Opto 22.
 
What's Green and Safe and Makes Lots of Pulp?  - 10/19/09
Control, October 2009
By Juan Jorge Caceres, et al, Celulosa Arauco
Celulosa Arauco’s pulp mill in Nueva Aldea, Chile, is capable of producing 856,000 air-dried tons of kraft cellulose per year. Control is by Emerson's PlantWeb, DeltaV, Foundation fieldbus, Profibus, DeviceNet, and digital valve controllers.
 
ABB CPM software improves production at Pratt Industries paper mill  - 10/14/09
CPM provides Pratt Industries with better production and quality data visibility, centrally managed multi-mill planning and optimization, real-time integration with their box plants and paper mills and a modern IT system architecture.
 
Emerson completes WDPF-to-Ovation Control System Migration at water plant Emerson completes WDPF-to-Ovation Control System Migration at water plant  - 10/14/09
For this migration project, at Edward C. Little Water Recycling Facility Emerson supplied a total of 17 Ovation controllers and 19 workstations.
 
Emerson completes control system upgrade at Detroit Water and Sewerage Emerson completes control system upgrade at Detroit Water and Sewerage  - 10/12/09
Emerson installed an Ovation control and SCADA solution that monitors and controls the entire water distribution system and wastewater collection system.
 
ABB's 800xA controls food waste to fuel conversion process  - 10/10/09
Control Engineering Europe, October 2009
St1 Biofuels Oy in Finland is a bioethanol producer making biofuel from food waste. The plants use Ethanolix processing units devised by St1 to create a dilute biofuel using a process controlled by ABB's Extended Automation System 800xA.
 
Bulmers overhauls pumping capability at Cider Mill  - 10/10/09
Control Engineering Europe, October 2009
Bulmers, a UK cider company, has improved the efficiency of its cider making process, installing a NOV Mono Helios progressing cavity pump at its Hereford Cider Mill. The pump replaced an existing model that was failing to deliver at very low temperatures and proving slow in warm conditions.
 
Sierra Instruments flow meters control aquarium at Monterey Bay Research Sierra Instruments flow meters control aquarium at Monterey Bay Research  - 09/28/09
Sierra mass flow controllers help conduct experiments to discover how rapidly increasing atmospheric CO2 levels are affecting the enormous variety of marine animals in our seas.
 
Vital Ingredients  - 09/20/09
Control Engineering Asia, September 2009
Unilever Vietnam’s factory in Ho Chi Minh City makes shampoo. It uses the ISA S88 batch standard, Siemens PCS7 control system, and Simatic S7-400 PLCs linked via Profibus DP to eight ET 200 remote I/O modules.
 
How Many More Months Will It Run?  - 09/20/09
Chemical Processing, September 2009
By Seán Ottewell
INEOS Chlor, Runcorn, UK, the largest chlor-alkali producer in Europe, uses Emerson’s PlantWeb digital plant architecture, HART communications, and AMS Suite for startup on a large chlorine compressor. Before plant startup, 40 inputs into the compressor must be calibrated and tested.
 
Novel Approach Enhances Control System Upgrade  - 09/20/09
Chemical Processing, September 2009
By Ryan M. Iannucci, Eli Lilly
Eli Lilly’s plant in Indianapolis upgraded an obsolete Measurex DCS to an Emerson DeltaV. Measures to mock-up wiring and limit project scope as well as operational improvements provided significant benefits.
 
ARC Informatique´s PcVue software controls wind farms in Spain ARC Informatique´s PcVue software controls wind farms in Spain  - 09/17/09
PcVue SCADA software centralized information from 10 Iberdrola Ingenier wind farms. Up to 2.5 million data items are monitored by 13 PcVue file servers and multiple FrontVue client stations, which communicate via OPC over a 1,000 Mbps redundant TCP/IP Ethernet network.
 
Emerson automates Bunge rapeseed oil processing plant Emerson automates Bunge rapeseed oil processing plant  - 09/17/09
Emerson's DeltaV, PlantWeb, AMS software, valves and instruments helped increase production by 10%, cut maintenance costs by 50% and reduce utilities and raw materials at a rapeseed oil processing plant in Kruszwica, Poland.
 
After the Explosion...  - 09/13/09
Control Engineering, September 2009
By Jim McConahay, Moore Industries
Imperial Valley Resource Recovery suffered a major electrical explosion that destroyed the connection to the grid and adjacent control room electronics. It was all replaced with Ethernet-based Modbus RTU communications and controls from Moore Industries
 
Alstom: Ethernet for Plant Control System  - 09/13/09
Control Engineering, September 2009
By Stéphane Potier and Emma Cameron, Alstom Power
Alstom, a provider of energy management, power generation, and rail transport systems, uses Alspa ControPlant as its distributed control system (DCS). The incorporation of Modbus and Ethernet Powerlink into the DCS makes the network a central part of the control system.
 
Florida Rock cuts production costs using particle size analysis Florida Rock cuts production costs using particle size analysis  - 09/01/09
Florida Rock Industries uses a model predictive control package from Pavilion Technologies and a particle size analyzer from Malvern Instruments.
 
CC-Link network supports SCADA system at pharmaceutical plant in Brazil  - 08/25/09
A CC-Link open fieldbus network and Mitsubishi Electric controls now serve as the SCADA system for the Mantecorp pharmaceutical facility in Rio de Janeiro, Brazil.
 
Centrifugal compressor thermodynamic performance monitoring and analysis  - 08/24/09
Energy Tech, August 2009
By Patrick J. Smith
Condition-based monitoring involves regularly assessing the machine condition and taking action only if a potential problem is identified. This article describes how condition monitoring was used on a 2,000 HP, 3-stage integral gear type centrifugal compressor.
 
Plant studies support use of wireless in capital projects  - 08/24/09
European Chemical Engineer, August 2009
Emerson Process Management has unveiled quantified results and other findings of two independent real-world greenfield projects that recommend wireless infrastructure be a key component of all new projects.
 
Under Watchful Eyes  - 08/20/09
Automation World, August 2009
By Wes Iversen
Dutch-based Shell is pursuing an aggressive, multimillion-dollar initiative to keep computer worms, viruses and cyber intruders out of its process control systems.
 
ABB System 800xA helps turn food waste into fuel ABB System 800xA helps turn food waste into fuel  - 08/19/09
Small bioethanol plants in Finland are using local food waste to make a low-carbon gasoline and help reduce greenhouse gas emissions from cars and trucks.
 
Vintner Saves with Distributed Architecture  - 08/16/09
Control, August 2009
By Jeremy Pollard
All of the automated equipment at the Bronco winery is controlled by Rockwell Automation PLCs, with Factory PMI and Factory SQL software from Inductive Automation.
 
Rolls with speed  - 08/16/09
Process & Control Engineering, July 2009
By Sarah Falson
Fischer Brot’s new high-tech bakery factory in Australia is controlled by VIPA Speed7 PLCs, with programming via Step7 by Siemens; and visualisation and recording of data using WinCC.
 
Rockview Farms Controls Dairy Processing with In-line Near Infrared Analyzer  - 08/16/09
Process and Control Today, August 2009
Rockview Farms of Downey, California, chose ESE's Q5i Near Infrared (NIR) In-line Analyzer for improving quality control during the fluid milk standardization process.
 
Max-Trak Mass Flow Meters Help Brewer Keep Its Head  - 08/16/09
Process and Control Today, July 2009
Sierra’s Max Trak 180 mass flow meter allows accurate measurement and control of air and gas. It is being used by Orval to precisely measure the injection of nitrogen into its beer to create the perfect head
 
Infrared furnace camera watches hydro reformers at Bayernoil refinery  - 08/16/09
Process and Control Today, July 2009
Reformer reactors need a constant supply of heat of up to 510 ºC, which is provided by furnaces and carried by heat piping systems. An Infrared camera for industrial high temperature applications in hazardous areas has been developed by FLIR to keep these installations up and running efficiently.
 
Coca-Cola SABCO: a refreshing look at business  - 08/16/09
South Africa Instrumentation & Control, August 2009
Coca-Cola looked to an MES system from Wonderware to manage complexity, improve efficiency and reduce costs at its Bloemfontein, SA, facility. Apart from the usual extensive MES functionality, the system handles batch tracking, line performance, operations management and overall equipment effectiveness (OEE) functionality.
 
Emerson upgrades Bailey Infi90 control to DeltaV at Groupement Berkine Emerson upgrades Bailey Infi90 control to DeltaV at Groupement Berkine  - 08/13/09
Groupement Berkine upgraded an aging Bailey control system with DeltaV Connect and operator stations, but retained the Bailey I/O and controllers.
 
ABB analyzers improve gasoline blending at Bahrain Petroleum ABB analyzers improve gasoline blending at Bahrain Petroleum  - 08/13/09
An ABB FTIR analyzer was installed in November 2008 at the 250,000 barrel a day oil refinery of Bahrain Petroleum Company (BAPCO) in the Middle East.
 
Emerson control system improves French thermal power plant Emerson control system improves French thermal power plant  - 08/11/09
Improvements after installing PlantWeb, Ovation expert control system, Scenario simulation, AMS software and Smart Wireless technology include a 50 percent improvement in the plant’s ability to ramp up and down on demand
 
Saudi Aramco optimizes plant operations with OPC Saudi Aramco optimizes plant operations with OPC  - 07/27/09
By Integration Objects
Integration Objects used OPC to integrate a point to point connection infrastructure based on VMS and Unix platforms that connected all the Distributed Control Systems and other automation islands with Aramco’s PIMS (Plant Information Management System).
 
TPM and Tecate: The new translation  - 07/19/09
Maintenance World, June 2009
Total Productive Maintenance does not have a great reputation in American industry these days. At Cervecería Cuauhtemoc Moctezuma, one of the largest brewers of beer in Latin America, the concept of TPM is alive and well at CCM's brewery in Tecate,
 
Migration Boosts Batch Operations  - 07/16/09
Chemical Processing, July 2009
By John Bryant, Arkema, and Mike Vernak, Rockwell Automation
Arkema was running half of its plant on a 28-year-old legacy distributed control system (DCS) and the other half on a 15-year-old version of the same system. Akema replaced both with a PlantPAx process automation system from Rockwell Automation.
 
Petroleum Development Oman deploys AlarmAnalyst  - 07/15/09
AlarmAnalyst provides the ability to proactively manage the vast amounts of time-stamped textual data generated by their plant’s oil production facilities.
 
Emerson improves production efficiency for Pernod Ricard Nordic Emerson improves production efficiency for Pernod Ricard Nordic  - 07/15/09
Emerson was responsible for the front-end engineering and design (FEED), and installation of PlantWeb, DeltaV, HART communications, AMS software and intelligent devices.
 
Redundancy is Key to Glass Plant's Future  - 07/14/09
Control Engineering, July 2009
By Moin Shaikh, Siemens Energy & Automation
Combining a very intense and hot continuous process at Cardinal Glass Industries in Menomonie, WI, with long periods between shutdowns calls for a robust and resiliant control system.
 
Digital Networks Prove Reliable, Reduce Costs  - 07/10/09
Power, July 2009
By Ali Abdallah, PE and James H. Brown, PE, PMP
Newmont Gold Mining’s 200-MW TS Power Plant is perhaps the power industry’s best example of how a plantwide digital controls architecture can provide exceptional reliability and be significantly less costly to install.
 
Experion stabilises energy consumption  - 07/10/09
South Africa Instrumentation & Control, July 2009
Honeywell provided engineering software and services to design and implement advanced process controls on a Yara Belle Plaine nitric acid plant in Saskatchewan that was recently migrated to Experion. The system controls the amount of NOx emissions leaving the combustor while minimising the consumption of fuel gas.
 
Innovative Energy Systems produces 60 MW from landfill gas  - 06/30/09
The system uses GE Fanuc controllers, HMI/SCADA software and operator interface equipment to monitor the engines and gas scrubbing systems.
 
Non-invasive Wireless Monitoring Provides Fast Payback  - 06/20/09
Chemical Processing, June 2009
By Chris Stubbs, Genentech
Wireless Steam Trap Monitors (WSTM) were placed on 56 traps at a cost of $42,000. The WSTMs provide early indication of steam leakage or blockage, which leads to failure. Data were collected on a “blue box” server for trending analysis
 
Staying in Control
By Expertune
BP uses PlantTriage to continuously monitor and analyze the health of seven refineries’ control loops and associated valves, compares the findings against established standards and, where performance is sub-optimal, conducts further analysis to pinpoint the likely causes. BP estimate that benefits of the order of $1-5 million per year are being realized in each refinery.
 
Bruce Power Uses Digital Technology to Fix Heater Drain System
Power Engineering, May 2009
By Jeff Kerker, et al
Steam hammer has been a common problem on the HX5 drain lines in all eight units at Bruce Power in Ontario, Canada, caused by an inverted loop in the saturated drains that allowed liquid to collect and inadequate heater level control. The old piping system was removed, new piping installed, control system installed and cold commissioning, all in 28 days.
 
Reliable processes for biodiesel production
Process and Control Today, April 2009
For the process automation system of its biodiesel plant in Schwedt, Germany, VERBIO decided to use a PROFIBUS fieldbus infrastructure. VERBIO decided to use the FieldConnex product range from Pepperl+Fuchs as the fieldbus interface technology throughout the plant.
 
SCR optimization helps Constellation Energy save $200,000 in NOx credits  - 05/19/09
Emerson’s SmartProcess Selective Catalytic Reduction (SCR) optimization technology improved SCR efficiency and extended SCR regeneration cycles, resulting in a 250-ton reduction in NOx.
 
Bionic Tonic Transforms German Brewery Into Health Beverage Titan
Control Design, April 2009
By Matthias Falk, Bionade Abfüll
Bionade transformed Germany’s struggling Peter Brewery in Ostheim into a European powerhouse. Programmers, engineers, electricians and production managers purchased and blended used components including old PLCs, pasteurization equipment, material handling and unpacking equipment and a case washing system into one fieldbus-based system.
 
Enterprise Manufacturing Intelligence: A Room with a View
Automation World, April 2009
By Wes Iversen
Every morning, senior managers at Valero Energy Corp. gather in the company’s Emergency Operations Center (EOC) for a daily operations call to each of the company’s 15 refineries in the United States, Canada and Aruba. Valero executives are able to call up dashboards detailing real-time operating statistics on each of the 15 sites. In rapid succession, spending less than 60 seconds per plant, managers can get a visual snapshot of the operational status of each refinery.
 
Automated Interface Solutions uses PAC for Polypropylene  - 05/14/09
By Opto 22
A polypropylene manufacturer called on system integrator AIS to help solve control and integration problems involving Measurex, Foxboro and Rockwell hardware. AIS installed an Opto 22 SNAP PAC to replace the Measurex I/O and communicate with the PLC and Wonderware HMI software.
 
Emerson controls improve profitability at SABIC Innovative Plastics Emerson controls improve profitability at SABIC Innovative Plastics  - 05/13/09
Emerson developed an Adaptive Model Predictive Controller (AMPC) that is optimizing production and improving profitability at SABIC Innovative Plastics’ Bergen op Zoom facility in The Netherlands.
 
Technology Targets Towers
Chemical Processing, April 2009
By Seán Ottewell
A modified Rosemount 3051S, a scalable device that typically handles integrated pressure, flow and level measurements around the plant, is being used at the University of Texas Austin to provide early warning about flooding in distillation columns.
 
Wireless Proves its Worth
Chemical Processing, April 2009
By Tim Gerami, PPG Industries, and Jerry Moon, Emerson Process Management
The PPG Lake Charles, La., facility is one of the world's largest producers of chlorine, caustic soda and vinyl chloride. The cost for introducing wired instruments in many remote areas of the 765-acre site is prohibitive; wiring would run from $20/foot to many times that. Wireless devices now supply data from numerous points that never could have been justified otherwise.
 
Measuring process humidity for optimal product quality
Chemical Engineer, April 2009
Kemira Oyj's paper chemicals plant in Vaasa, Finland, produces polyacrylamides for customers in the global and domestic pulp and paper industry. They installed nine Vaisala humidity transmitters to monitor the whole drying process.
 
Control system offers reliability at multi-product chemical plant
Chemical Engineer, April 2009
Chemical manufacturer Degussa Evonik replaced an existing UNIX control system with the Siemens PCS7 OS control system. It not only solved existing process control reliability and legacy issues, but the new system also offered a compatible and flexible solution for its future needs.
 
Jumbo Savings from Automated Feeding
Food Manufacturing, April 2009
Seafood Systems operates a shrimp farm in Okemos, MI. The shrimp are fed by an automated system controlled by a WAGO 750-841 Ethernet TCP/IP Programmable Fieldbus Controller, which disperses feed at precise, predetermined intervals.
 
Air Products installs GE wireless monitoring system  - 05/05/09
The new system is helping improve operational efficiency and productivity by providing a way to reliably monitor, diagnose and maintain water equipment and processes.
 
Automated water treatment plants
South African Instrumentation & Control, April 2009
Three plants in Egypt each have approximately 1200 I/O points. The process and system control uses Beckhoff PLCs, Profibus, PCs, control panels and soft PID controllers.
 
SIPOS actuators selected for combined power application
Process and Control Today, March 2009
SIPOS 5 Flash variable speed actuators have been installed at a combined heat and power (CHP) plant in Germany. A primary reason was integration of frequency converters as a standard product feature which avoids water hammer.
 
Gas Station Makes its Own Fuel
Control Engineering, April 2009
By Peter Welander
St1 Biofuels Oy in Finland builds small, automated bioethanol plants that generates ethanol from local waste feedstock. Each plant is controlled by an ABB 800xA DCS, communicating with a central control location via a virtual private network (VPN).
 
OPC Feeds Data from PLC to DCS
The Georgia Pacific paper mill in Yalova, Turkey, uses Kepware Technologies’ LinkMaster and KEPServerEX OPC Server to transfer data from a Siemens programmable controller to an ABB distributed control system.
 
Speedy Upgrade Transforms Production
Chemical Processing, March 2009
By Ian Heathcock, Siemens
Specialty chemicals producer Degussa Evonik was finding it difficult and expensive to support a legacy control system in one of its production buildings at its Seal Sands site, Teesside, U.K. Degussa opted for the Siemens PCS7 OS control system. The PCS7 OS was swapped over and tested within a three week period during the end of 2007.
 
Critical Vessel Monitoring
By FLIR
Infrared monitoring eliminates or minimizes the installation of point contact temperature sensors. Since contact sensors can only monitor “pin point” areas, there is always a concern about non-uniform temperatures throughout a vessel and across its surface. A few IR cameras eliminate this concern by monitoring the entire vessel surface, providing instantaneous non-contact temperature measurements.
 
Purely Performance-Driven
Control Design, March 2009
By Rich Gaston, Heateflex
For 18 years, Heateflex offered Power-to-Flow technology in its Aquarius line of deionized water heating systems. The algorithm was programmed in assembly language in an embedded temperature controller, a custom-designed board running a 6809 microprocessor. Heateflax relaced the 6809 with an Omron CJ1M PLC, and gained Ethernet, DeviceNet and Profibus connectivity.
 
Kemsley mill boosts efficiency
Control Engineering Europe, March 2009
St Regis Paper is overhauling automation and production equipment at its Kemsley Mill in Kent, UK. ABB is supplying a System 800xA extended automation system, a VidEOnet System IndustrialIT Enabled video surveillance system, and a ProfileIT Air-Water Profiler to provide precise moisture profile control.
 
Big Pay-Off from Automation Investments
Control Engineering, March 2009
By Mark Albano, Honeywell Process Solutions
Polpharma selected POMS MES to increase performance by tightening up reliability of the manufacturing processes. POMS controls and tracks all aspects of production, secures predictable quality, enforces GMP, and provides all necessary historical data for regulatory compliance.
 
Analyze this
Control Engineering Europe, March 2009
AS Pontes, a coal-fired power station in Spain, installed four Servomex Fluegas analysers to monitor post-combustion levels of oxygen and carbon monoxide and thereby enable the combustion process to be continuously fine-tuned.
 
Pipeline valve actuators run on gas
Process & Control Today, March 2009
Rotork valve actuators on the Kurdistan Gas Project use pipeline gas as the power source to pressurize the hydraulic operating system, which can be configured to meet virtually any valve duty requirement. The actuators for the Kurdistan Gas Project are operating ten ANSI Class 900 Econosto ball valves in sizes up to 24 inches.
 
Cutting energy consumption
InTech, March 2009
By Joel Shaprio and Thirumalaichelvam Subramaniam
By controlling the temperature of chilled water with a PAC, users were able to save up to 30% of air conditioning energy costs in tropical countries where cooling costs typically consume 45% to 60% of building energy expenses.
 
Wireless technology enables online filter monitoring Wireless technology enables online filter monitoring  - 03/17/09
Emerson's wireless technology is enabling INEOS to monitor filters within polyethylene pellet transportation tubes. Eight Rosemount 3051S DP wireless transmitters were installed as well as a single Emerson Smart Wireless gateway.
 
DL06 PLC puts heaters to the test
By Tom Brickey & Mike Sabatine, Pyromatics Automation Systems
Pyromatics built a Life Cycle Test Station for electric heating elements. If a heater failed, the test had to be shut down and QC alerted. Pyromatics used a DirectLOGIC DL06 PLC to control eight PID loops, DirectSOFT ladder logic editor, and a C-more EA7-T10C 10-inch TFT touch-screen operator interface.
 
Water and Waste Water Plants Use Java-Based SCADA Software
By Inductive Automation
Microsoft re-invents itself every five years, and makes PC-based SCADA systems obsolete. Three water plants decided to use a Java-based FactoryPMI SCADA system instead, because it doesn’t care what platform it runs on, allows unlimited tags and clients, and has no extra site license charges.
 
Tank control at Klawer
South Africa Instrumentation & Control, February 2009
Klawer required a reliable solution for its wine tank control system. Critical parameters such as temperature set-points, pump cycle times and variable pump speeds are all addressed through Adroit SCADA screens.
 
HART-Enabled Plug-In Control System Migration
By Invensys Process Systems
Two companies--Dakota Gasification and Teck Cominco—upgraded their control systems to use HART communications. In both cases, the companies had HART instrumentation that had been installed years earlier, but were not using the HART data because their old control systems didn’t support it. IPS solved the problem.
 
Clearly Superior
InTech, February 2009
By Ellen Fussell Policastro
New plant, SCADA system mean better remote control for Canadian water treatment plant. Return on investment came in record time because real-time reporting enabled more effective regular maintenance for reduced downtime.
 
Condition of Steam Cracker monitored with wireless
HazardEx, January 2009
Emerson Process Management is helping to provide condition monitoring information at the Total Petrochemicals plant in Carling Saint Avold, France. Wireless transmitters provides temperature measurement data, enabling the company to calculate changes over time in wall thickness on a boiler that provides steam to a steam cracker, enabling personnel to anticipate when it may need replacement.
 
Paper plant ups productivity, cuts errors
Control Engineering Europe, January 2009
St. Regis Paper boosted production 17 per cent and cut errors by 63 per cent at a UK mill after implementing a new process control solution from ABB. The 800xA system includes QC and scanning measurement systems and the integration of existing motor control centres, variable speed drives and instrumentation.
 
Pavilion Technologies optimizes operations at Bongards’ Creameries  - 02/02/09
Pavilion8 model-predictive control technology helps increase capacity, reduce energy consumption, and increase yield
 
Virtual Plant Provides Real Insights
Chemical Processing, January 2009
By Gregory K. McMillan, et al
Today, many pH control systems are operating in manual or severely oscillating in automatic. Effective automatic pH control often should be possible — this belief led to a project at Monsanto’s Luling, La., plant to improve a pH control system for wastewater.
 
Emerson automates China’s Huaneng coal-fired power plant  - 01/26/09
Emerson installed an Ovation expert control system, Smart Wireless, AMS Suite predictive maintenance software, and Rosemount wireless pressure and temperature transmitters.
 
Coordinated Control and Optimization of a Complex Industrial Power Plant
Power Engineering, November 2008
By George Valadez and David “Glenn” Sandberg, Alcoa
The power plant at Alcoa’s Point Comfort aluminum smelting process has a DCS that was installed during the past 20 years. The system was expanded with an ABB multi-level approach that uses real-time optimization (RTO), connected to advanced process control (APC).
 
Upgraded control system adds to power plant’s Bottom Line
Power, January 2009
The New Harquahala Generating Project (HGP) in Maricopa County, Arizona, had an inflexible Teleperm XP (TXP) control system installed as part of the original turnkey project contract. They replaced it with a Siemens SPPA-T3000 distributed control system (DCS).
 
System 800xA helps St. Regis Paper boost productivity by 17 percent System 800xA helps St. Regis Paper boost productivity by 17 percent  - 01/11/09
St. Regis Paper achieved substantial benefits in one of its mills in the UK, including a 17 percent boost in production (without increasing machine speed) and 63 percent fewer errors.
 
Overfill protection ensures Bostik don’t come unstuck
Process & Control Today, December 2008
A multi-point alarm overfill protection system, installed on latex and bitumen based storage tanks by Hycontrol, is playing a crucial safety role at Bostik’s manufacturing plant in the UK. Hycontrol’s RF level switches and ATEX vibrating probes prevent hazardous overfilling of Bitumen.
 
Better gearboxes keep obsolete thickeners thickening
Process & Control Today, December 2008
During a recent service two thickener drives at the Scottish Water sewage treatment works in Glendevon were deemed to be obsolete and the mounts had worn out. Brevini replaced the gearboxes without having to re-engineer the mounting bracket.
 
A WAVE in a cup
Control Engineering Europe, December 2008
Premier Foods manufactures packaged meals and soups in the UK. Level probes control the level of feed hoppers that supply the packing machines to fill sachets. These machines run at speeds from 160 to 600 packages per minute. Feed hoppers vary in size and use various agitators and vibrators to flow the powders.
 
Moore DCS Application upgrade
South Africa Instrumentation & Control, December 2008
By Wonderware Southern Africa
Replacing or upgrading old control systems is usually done with sombre deliberation. In the case of the Moore DCS application upgrades at ArcelorMittal South Africa’s Pretoria plant, however, things were decidedly rosier as a result of using Wonderware technology.
 
Automation solutions key to alumina refinery expansions
European Process Engineer, December 2008
By Sean Ottewell
Summaries of how major aluminium manufacturers are using state-of-the-art automation solutions.
 
Pump technology advances on automated processing lines
European Chemical Engineer, December 2008
Selden Research manufactures cleaning and hygiene chemicals. It has two automated blending plants designed by SPX Process Equipment that bring together alcohol, water, colourings, perfumes and surfactants in preset quantities and flowrates. The system uses PID control from the PLC to adjust automatically the relevant pump via speed control inverters.
 
Control system offers reliability at multi-product chemical plant
European Chemical Engineer, December 2008
Degussa Evonik’s chemical manufacturing giant replaced its problematic UNIX -based control system with a Siemens PCS7 OS control system. The PCS7 OS was swapped over and tested within a three week period.
 
Hot iron
InTech, December 2008
By Gerardo González López, Tenova HYL, and Eduardo Noriega, Emerson
A safety instrumented system (SIS) plays a critical role in direct reduced iron plants by detecting potentially dangerous conditions, taking the plant to a safe state, informing the operator about the plant status and cause of the trip, and expediting safe plant restart.
 
Buhler's Grain Milling Automation Relies on OPC Technology
By Wolfgang Langer, Softing
Buhler standardized on Softing’s S7/S5 OPC Server to provide reliable connectivity between its WinCoS.r2 grain milling automation system and multiple S7-400 PLCs.
 
Hexion Chemicals deploys IncuityEMI as data platform
By Stephane Lacasse and David Holmes, Hexion Specialty Chemicals
Hexion Specialty Chemicals is the world’s largest producer of thermosetting resins and formaldehyde. It uses IncuityEMI software to integrate data from OSIsoft, Wonderware historian, GE Proficy Historian, DeltaV, Foxboro equipment and a Honeywell PHD System.
 
Chemtura identifies batch optimization opportunities with Incuity  - 12/15/08
By Mark Garnett, Chemtura Canada
Chemtura makes additives, intermediate chemicals and other products. It uses Incuity EMI software to increase production by two percent simply by being able to drill down into overall equipment effectiveness (OEE) data to reduce idle time in batch systems.
 
INEOS ChlorVinyls uses Emerson PlantWeb and FOUNDATION fieldbus  - 12/08/08
INEOS ChlorVinyls improved its liquid chlorine manufacturing processes and operations by implementing PlantWeb digital plant architecture with FOUNDATION fieldbus technology.
 
Emerson wireless transmitters monitor steam cracker at Total Petrochemicals Emerson wireless transmitters monitor steam cracker at Total Petrochemicals  - 12/03/08
Eight Rosemount 648 wireless temperature transmitters were installed directly onto the exterior of a boiler drum situated fifty metres above the ground.
 
Total Insight Total Control Total Insight Total Control
Industrial Automation Asia, October 2008
By Arasu Thanigai and Andreas Hennecke, Pepperl+Fuchs
Installing an Advanced Diagnostics system for an existing fieldbus infrastructure presents a cost benefit to a process plant.
 
All in Real Time
Industrial Automation Asia, October 2008
By Paul Yap and Leong Hon Mun, Honeywell Process Solutions Southeast Asia
Advanced Process Control technologies such as Model Predictive Control (MPC) are commonplace in Olefins plants and have greatly improved the consistency of product quality and constraint protection and have typically resulted in quick payback on investment.
 
The Power Of Coordination  - 11/24/08
Industrial Automation Asia, October 2008
By Pekka Immonen, et al, ABB Power Systems
Due to the lack of control coordination, industrial power plants are typically not fully optimised. The purpose of a coordinated control and optimisation system is to improve plant stability and responsiveness to demand or supply disturbances, and to minimise overall fuel costs.
 
WDDM development expands power and hydraulic systems
World Oil, November 2008
By Mamdouh Farouk and Mohamed Gaber, Burullus Gas Co
The West Delta Deep Marine (WDDM) offshore field wanted to add seven wells, but ran into a problem with power to the control system, communications and hydraulics. Here’s the analysis they made of hydraulic supplies, electrical power supplies, communications, electrical, satellite (VSAT) link, umbilical configuration and additional qualification requirements.
 
Materials Use Reduction via Advanced Process Control
Control Engineering, November 2008
By Dilip Kannan, Honeywell Automation India
Nirma’s linear alkyl benzene (LAB) complex in India is being controlled by a Honeywell DCS, resulting in fuel savings, better quality, and annual monetary savings of more than $750,000.
 
Advanced process control helps chemical maker achieve greater productivity
Intech, November 2008
By Ladislav Jurenka, Deza, and Don Morrison, Honerywell
Deza improved performance of its phthalic anhydride (PA) plant at Valasske Mezirici in the Czech Republic by using advanced process control from Honeywell.
 
Emerson wireless network keeps bitumen pipeline hot  - 11/10/08
Wireless instruments monitor heat-tracing on pipeline which must be hot to facilitate pumping.
 
Emerson wireless monitors fuel and feedstock delivery at BP Bitumen Emerson wireless monitors fuel and feedstock delivery at BP Bitumen  - 11/06/08
Wireless instruments monitor the pipeline integrity of transfer lines from the BP refinery and report exceptional conditions to control room operators.
 
ICS Triplex installs AADvance at Bayer CropScience  - 11/06/08
The Process Safety Control System was installed at Bayer CropScience’s Norwich site in June 2008 and became fully operational in August 2008.
 
ABB emissions monitoring system helps Chilean cement plant ABB emissions monitoring system helps Chilean cement plant  - 10/27/08
Emissions monitoring solution uses FTIR analyzer technology and an 800xA system to help Chilean cement manufacturer Polpaico meet targets for reducing greenhouse gas emissions.
 
Upgrading Process Controls at a Nuclear Plant
Nuclear Power, September 2008
Process control and instrumentation systems at Progress Energy’s Harris nuclear power plant in North Carolina were supplied in the 1960s and 70s. Its ventilation control was recently upgraded to a DCS including a fault tolerant Ethernet network, redundant Experion server cabinets, two redundant (C200) controller chassis pairs and remote I/O chassis. Next is the radiation monitoring system. Is controlling the reactor a possibility?
 
Batch tracking and reporting with ISA 95
South Africa Instrumentation & Control, October 2008
SAB Maltings, Cape Town, South Africa, installed a Wonderware system to track products through the process to get a complete view of production variables applicable to each batch. The system is compatible with the ISA-95 industry standard.
 
From Plants to Power
Control Engineering Asia, September 2008
By Alexandre Bouriant and Nico Hees.
Bio Power e.K. in Bavaria, uses a Simatic PCS 7 to control its biogas power generating system. Germany has 3,500 biogas plants!
 
Emerson's wireless instruments monitor tanks at Technochem  - 10/08/08
Fourteen Rosemount wireless pressure transmitters monitor levels in tanks at Technochem Environmental Complex Pte Ltd (TEC) in Singapore.
 
Emerson controls acetylene bottle filling at SABIC Emerson controls acetylene bottle filling at SABIC  - 09/23/08
PlantWeb digital plant architecture with FOUNDATION fieldbus and mass flowmeters reduces annual cost by €300,000 and improves production efficiency by 30 per cent at SABIC Europe B.V.
 
Gateway to process automation
Control Engineering, September 2008
Valspar Corp. is the third largest paint and coatings company in North America. To handle its paint blending process, MMCI uses Emerson Process Micro Motion flowmeters, a Rockwell Automation process automation system, Ethernet communications, and a ControlLogix PAC.
 
Sweetening Ethanol, Sugar Mix
Control Engineering, September 2008
By Brandon Henning, GE Fanuc
One of Brazil's largest sugar producers GE Fanuc's Proficy Plant Applications efficiency module provides a comprehensive view of key factors including equipment downtime, quantity, and event sequences. The system also uses Proficy HMI/SCADA Cimplicity, PACSystems controllers, and Series 90-30 PLCs.
 
Emerson‘s PlantWeb improves production at SABIC Europe
South Africa Instrumentation & Control, September 2008
SABIC Europe improved the efficiency of acetylene production at its Geleen, SA, plant by 30%, thanks to control enabled by Emerson’s PlantWeb digital plant architecture, Foundation Fieldbus networked instruments, and a Micro Motion Coriolis flowmeter for direct measurement of mass flow.
 
Wonderware replaces SCADA at BHP Billiton
South Africa Instrumentation & Control, September 2008
BHP Billiton’s Hillside aluminium smelter near Richards Bay in KwaZulu-Natal replaced its existing VXL supervisory system with Wonderware’s InTouch HMI/SCADA system, Historian, and ActiveFactory.
 
Solar powered actuators provide remote pipeline valve control
Process & Control Today, August 2008
The Puesto Hernanadez-El Corcobo Norte Oil Pipeline traverses 80 km of wilderness in south-west Argentina. In this unforgiving environment,remote valve control and indication has been successfully achieved by the use of Modbus-enabled Rotork EH Range electro-hydraulic actuators, operated by solar powered battery packs.
 
Boiler Optimization and SCR Systems: Reducing NOX, Managing Tradeoffs
Power Engineering, July 2008
By Rob James and Peter Spinney, NeuCo Inc.
Artificial intelligence-based optimization software is gaining traction as a tradeoff management tool. Optimization is particularly good at understanding the cause and effect impacts of multiple actions taken across multiple systems interacting in a dynamic environment. NeuCo, for example, is working with Babcock Power to more closely tie plant-wide economic optimization with SCR controls.
 
It's all in the LANs
InTech, August 2008
By Fereshteh Fatehi and Yuqiu You
In one of our latest projects, we integrated the PLC control process and data transmission by applying the local area network (LAN) technology in PLC control. We set up the communication of the remote PLC control by establishing a LAN connecting computers and PLCs.
 
Ups and Downs of Taking the Bus—Part II
Industrial Networking, Summer 2008
By Gary Forrest, Wyeth Research
Part 2: Problems come up with the implementation of Profibus-DP instrumentation and controls, and the software configuration of each Profibus-DP device.
 
ConocoPhillips Goes Wireless
Industrial Networking, Summer 2008
The ConocoPhillip Sweeny refinery in Old Ocean, Texas, standardized on Honeywell Process Solutions’ (HPS) OneWireless platform. Sweeny presently operates four mobile Experion PKS stations and 32 transmitters. So far, the plant’s wireless network has had only two multinode interruptions in more than 14 months of operation.
 
Fisher BioServices deploys General Electric Wireless Mesh
Control Engineering, August 2008
Fisher BioServices provides customized, turn-key solutions for life sciences applications. It adopted General Electric’s RF Mesh based Kaye Labwatch system to meet stringent U.S. FDA (Food & Drug Administration) regulations.
 
Sweet trace of chocolate
Control Engineering Europe, July 2008
A Turck RFID BL ident system has been applied to confectionery production systems manufactured by Winkler und Dünnebier (WDS) at its Rengsdorf plant. All plastic moulds are equipped with RFID data carriers to allow the progress of each mould to be traced from a central station.
 
STARDOM revitalises integrated control system
South Africa Instrumentation & Control, July 2008
The compressor control upgrade project for a polymerisation plant operated by Safripol in South Africa replaces existing PLCs with a STARDOM network-based control system.
 
APC: CSense intelligence improves smelter efficiency at Lonmin
South Africa Instrumentation & Control, July 2008
Dynamic process models of individual equipment in the drying plant were extracted from historical process data. These models were then used to construct a dynamic plant simulation, from which an optimal APC control system was designed.
 
China's Yellow River project
South Africa Instrumentation & Control, July 2008
Control of the river is via a Wonderware Industrial Application Server, InTouch human machine interface (HMI) software and SuiteVoyager portal software
 
Emerson and Celulosa Arauco commission pulp mill in Chile
Process and Control Today, July 2008
Emerson helped Celulosa Arauco strengthen its pulp supply capability by digitally integrating the world’s largest “smart” pulping mill at Nueva Aldea in central Chile. PlantWeb digital architecture includes DeltaV systems and FOUNDATION fieldbus networking.
 
Reliance Chemical Facility Achieves ‘Live’ Upgrade
Process Industry Informer, June 2008
ABB’s System 800xA Extended Automation was selected by Reliance Industries Limited (RIL) for the upgrade of the control system for their production of linear alkyl benzene (LAB) plant at Patalganga from a MOD-300.
 
ABB Chosen To Give Polypropylene Plant Optimum Regulatory Control
Process Industry Informer, June 2008
ABB’s Loop Performance Manager (LPM) software is giving Petroquimica Cuyo’s, Mendoza, Argentina polymer plant improved productivity. Besides its usefulness for loop tuning activities and process insight through its model building capabilities ABB’s LPM software is helping the Mendoza facility operate at peak efficiency and meet its market demands.
 
SCADA Software Keeps Eye on Big Picture
Control, July 2008
By Jim Montague
Two end users describe how they used GE Fanuc’s Proficy HMI/SCADA—iFix 4.5 to upgrade older iFix software in water treatment plants.
 
VFDs Speed Up Wastewater Processing
Control, July 2008
By John O’Reilly and John Rowe, Schneider Electric
Combining closed-loop control with variable frequency drives for oxygen basin agitators makes for faster processing with lower energy consumption.
 
Memphis Biofuels goes online
InTech, July 2008
By John Arnold and Don Mack
Memphis Biofuels converted a former chemical processing plant into one of the nation’s largest capacity production facilities of biodiesel within 90 days. The Siemens DCS with HMI was a vital component in meeting the startup goal, because it allowed engineers to make configuration changes on the fly.
 
Vishay installs Reel Optimizing System in European paper mill  - 07/09/08
The Reel Optimizing System uses strain gage-based load cells to improve roll density by controlling the nip force throughout the entire reel spool change-over process.
 
Flowmeter stabilizes control of process slurry Flowmeter stabilizes control of process slurry  - 07/07/08
By ABB Instrumentation
Replacing a faulty magmeter with an AC magnetic flowmeter eliminated erratic flow signals and improved control of catalyst slurry flow.
 
Securing Redundant Communications between an ESD and a Honeywell DCS
By Eric Byres, Tofino
Describes how a petroleum refinery used the Tofino Industrial Security Solution and Modbus to provide secure communications between a Triconex Emergency Shutdown (ESD) system and a Honeywell Experion process control system. It also explains the use of the Tofino system in redundant networks, techniques for grouping large numbers of identical devices in “networks” and the management of nuisance alarms generated by unwanted multicast traffic.
 
Relay Races to Forefront of New Design
Control Design, June 2008
By Barry Stringer, Solvere
MikroPul, in Charlotte, N.C., manufactures dust control and product recovery equipment. For its PulsePro EC baghouse control and monitoring system, MikroPul uses Siemens’ LOGO! programmable relay.
 
How to Control a 27-km-long Machine  - 06/23/08
Machine Design, May 2008
By Nipun Mathur, National Instruments
The largest machine in the world, the Large Hadron Collider (LHC), covers parts of France and Switzerland and will cost a staggering $3.5 billion U.S. to design and build. The real difficulty is synchronizing collimators that can be 13 km away from each other with jaws that are synchronized to within 100 µsec and move with accuracies of ±10 µm.
 
Ontario nuclear plant has a chilling solution
InTech, June 2008
The problem is there is not enough differential pressure between the condenser and evaporator to allow refrigerant/oil circulation to prevent damage to the chiller, especially during starting. There was an attempt to simulate the system using popular simulation packages that are available, but this proved futile, as an integrated package that could simulate the system was difficult to find.
 
Adroit heads south to manage water system
Control Engineering Europe, June 2008
The six major pump stations at the Adroit SCADA system have PLC controlled MC panels. The telemetry RTU is connected to the PLC via a serial interface using Modbus protocol and provides the ability to monitor all the inputs as well as providing the facility for remote modifications of certain measuring and controlling parameters within the PLC.
 
Siemens retrofit boosts efficiency at Corus
Control Engineering Europe, June 2008
Nine Siemens drives, including five on heat treatment furnace roller tables, and four on a roller table and tempering furnace, were installed at Corus’ Clydebridge works in Scotland with a 30 per cent increase in throughput.
 
Emerson automates world's largest pulp mill Emerson automates world's largest pulp mill  - 06/18/08
The PlantWeb solution includes DeltaV, 3300 FOUNDATION fieldbus, Profibus DP and DeviceNet devices, MCCs, PLCs, Modbus, Fisher valves with Fisher FIELDVUE digital valve controllers, and AMS Suite.
 
Anatomy of Steam Plant
Control Engineering, June 2008
By Frank Smith
To lower the cost of steam generation and become a performance-driven enterprise, this petrochemical company optimized its processes from the bottom up with dynamic performance measurements.
 
Dairy Processor Stays Flexible
Control Engineering, June 2008
By Walter Staehle, Siemens Energy & Automation
Wireless control and a SCADA system help Dietrich’s Specialty Processing specialty plant stay efficient and effective while handling a variety of critical dairy products.
 
Giving Chocolate its Crunch
Control Engineering, June 2008
By Mike Jamieson, Rockwell Automation
Mars Austria uses an integrated control environment to monitor the exact status of all system components — such as servo drives, I/O, and HMIs—in its new control system in a chocolate plant.
 
ABB upgrades Reliance Chemical facility live ABB upgrades Reliance Chemical facility live  - 06/05/08
The project involved an on-line evolution from a 1988 control system to an 800xA DCS while maintaining the plant's existing process control philosophy.
 
Wonderware steels Nucor
South Africa Instrumentation & Control, May 2008
Nucor’s mill in Berkeley, South Carolina, updated the InTouch application already in place with Wonderware’s IndustrialSQL Server historian and Application Server.
 
System Sweetens Bottom Line for Sugar-Making Company
Chem.Info, May 2008
RRB Sugar Mills, one of India’s largest sugar producers, installed back-pressure turbo-alternators with two high-pressure boilers, a turbine generator, and a back-pressure turbine generator. InduSoft Web Studio HMI/SCADA system was initially installed only to control the boilers, it worked so well that RRB expanded it to control the entire sugar-making and wastewater processes.
 
Hot cutover boosts control system migration
Chemical Processing, May 2008
By Eric Schnipke, Ineos Nitriles
Component failures in a 1980s–1990s-era DCS at Ineos Nitriles’ Lima, Ohio, complex were jeopardizing production of acrylonitrile. Ineos upgraded to a DeltaV system from Emerson in a “hot cutover,” and added Modbus and HART.
 
Plant Safety
Chem.Info, May 2008
By Nato Flores
Building a chemical plant, with its inherent safety and environmental requirements, can be particularly formidable. Huntsman, a global manufacturer and marketer of differentiated chemicals, and Tower General Contractors, a construction firm in Los Angeles, can attest to that.
 
Upgrade delivers spare parts
Control Engineering, May 2008
By Marvin Coker, Bachelor Controls
Golden Triangle Energy Cooperative in Craig, MO, had control system hardware that had been deemed obsolete by the manufacturer, and replacement parts were becoming difficult to find. Bachelor Controls upgraded the system to Rockwell Automation’s Process Automation System, ControlLogix PAC and I/O, and RSView.
 
Breaking bread habits
Intech, May 2008
By Ellen Fussell Policastro
two European food production facilities have experienced just how much automation adds to their processes—one a bakery building better batches with software to add flexibility, and the other a mill integrating processes with automatic control, monitoring, and traceability for smoother production and less worker intervention.
 
Statoil pumps up production through information sharing and smart practices
By IBM Corporation
With oil and gas production the backbone of the Norwegian economy, Statoil–the nation’s largest producer–needed a way to offset the natural trend toward declining production levels. Statoil sought to incorporate new technologies into production processes in order to transform, streamline and improve them.
 
Process oxygen analyzer helps achieve SIL 2 at catalyst plant
Process & Control Today, April 2008
Servomex 2200 analyzers helped Süd-Chemie, a manufacturer of catalysts, have their SIS certified by the German TÜV to a safety integrity level of 2 (SIL 2) in accordance with EN 61511. The SIS is installed on the catalyst production process loop, with the oxygen analyser used as part of the process control and safety-related inerting system.
 
Siemens tracks energy provider’s nuclear materials
Process & Control Today, April 2008
Siemens implemented a SIMATIC IT MES to track and trace all nuclear materials produced by British Energy. BE needed a new Nuclear Materials Accountancy System that would allow them to catalogue and locate nuclear material in accordance with the European Commission Safeguards Regulation No 302/2005.
 
Safety overhaul at Süd-Chemie
Control Engineering Europe, April 2008
Süd-Chemie installed a safety instrumented system (SIS) at its Bruckmühl, Germany plant. The system, certified by TÜV to safety integrity level (SIL) 2, is hoped to ensure the functional safety of the plant.
 
Ryvita plant installs MES
Control Engineering Europe, April 2008
Ryvita claims to have cut manual inputs across its production system by 90 per cent, boosting efficiency and accuracy. The food manufacturer is using a Citect AMPLA MES, installed by Silchester Control Systems, at its Poole, UK site, to act as a backbone for its factory-wide reporting system.
 
Even Better Than the Real Thing
Control Engineering Asia, April 2008
By Bob Erickson
OPC connectivity enables a legacy Honeywell DCS to take its rightful place as the cornerstone of a unified plant control structure.
 
Control performance supervision enhances revamp
Chemical Processing, April 2008
By Mikko Rönkä, Borealis Polymers Oy, and George Buckbee, ExperTune
Borealis upgraded an ethylene cracker, but issues such as control valve mechanical problems, poor controller tuning and instrument failures were undermining regulatory control. They installed PlantTriage performance supervision software from ExperTune. Within a few days, they uncovered a host of control system opportunities.
 
Hot oil, cool control
Intech, April 2008
By Ellen Fussell Policastro
Austral Pacific Energy in New Zealand installed programmable automation controllers to provide capabilities of a traditional DCS system, and manage thousands of discrete, process, and safety I/O points using a single platform.
 
Orlando Plant Pioneers HMI Migration Strategy
Control, April 2008
By Todd Stauffer, Siemens Energy & Automation
Air Products and Chemicals replaced three legacy operator consoles dating back to the early 1980s with Siemens PCS 7/90 OS HMI terminals. The plant kept the existing legacy distributed control system intact, including controller hardware, input/output (I/O) modules and field wiring.
 
Few Achieve Shop Floor to Top Floor Integration (A Rare Breed)
Managing Automation, March 2008
By Jeff Moad
Manufacturers place a high strategic priority on shop floor-to-top floor integration, and most say they have at least started down that integration path. Despite the difficulties of integrating plant floor systems with enterprise business systems, Celestica, Dairy Crest, and Portucel Viana are making significant headway. (Registration required)
 
GFC installation simplified with SmartWire
Control Engineering Europe
March 2008
The Good Food Company bypassed the need for a PLC, instead using a panel wiring system from Moeller Electric in its new refrigeration system. It was able to use one control panel, instead of the three originally planned, for the installation at the Wellingborough, UK food manufacturer’s site.
 
Citect calls for alarm management
Control Engineering Europe
February 2008
Too many alarms can make safety and productivity systems less functional and are liable to ‘overwhelm operators’. Citect UK discusses why and suggests their solution.
 
Network upgrade increases performance at distillery
Control Engineering Europe
January 2008
The Midleton distillery in Ireland is a complex plant that relies on a sophisticated industrial Ethernet control network. But when that network started to become a limiting factor in terms of speed and availability, Irish Distillers turned to GarrettCom Europe for an update.
 
Video for Process Control
Control Engineering, March 2008
By Latimer Schneider, Panasonic
The video control system at Nitta Gelatin USA, which resides on dedicated workstations, allows remote monitoring of manufacturing processes and viewing of alarm-activated live video.
 
Crush control optimizes wine production
Control Engineering, March 2008
the Clos du Bois winery in California replaced analog machine controls on its grape press system with a centralized PAC control architecture that governs the entire system, from the conveyors to the pumps.
 
Lather up with batch
Intech, March 2008
By Matthew Leys, Unilever, and Sean Cahill, Siemens
Unilever’s North Rocks site in Sydney, Australia, is responsible for the manufacture of personal health and beauty products. It upgraded its existing controls and installed an ISA88-compliant batch engine.
 
Digital power
Intech, March 2008
By John Blaney, Jim Murray, and Gary Tingley
A description of how Portland General Electric installed a system that uses both Foundation Fieldbus and Profibus in a power plant.
 
Orlando plant pioneers HMI migration strategy
Chemical Processing, February 2008
By Todd Stauffer, Siemens Energy & Automation
Air Products and Chemicals developed a company-wide replacement strategy for the multitude of Human Machine Interfaces (HMI) at its hundreds of plants. The beta project involved replacing three legacy operator consoles dating back to the early 1980s with Siemens PCS 7/90 OS HMI terminals.
 
New plant learns pump tricks
Plant Services, February 2008
An ethanol plant was using a tank and pump system to mix and transfer water and urea. The original system used an off/on switch which required the operator to shut off the pump when the mixture was transferred out of the tank. The pump would occasionally be allowed to cavitate and run dry, which resulted in seal failures. The problem was solved by adding a PumpSmart controller from ITT Goulds Pumps.
 
Six Sigma Alarm Management
Control, February 2008
By Brent J. Thomas
Six Sigma methods bring order to alarm chaos at Monsanto’s Soda Springs, Idaho, phosphorus plant.
 
Europe’s largest biopharmaceutical plant uses Honeywell DCS
Control Engineering, February 2008
By Torsten Winkler, Honeywell Process Solutions
Boehringer Ingelheim Pharma in Biberach, Germany, is Europe’s largest biopharmaceutical and cell culture plant. BI is using a Honeywell Experion platform for integration of field equipment and data, batch automation, and advanced process control (APC).
 
PROFIBUS used in Changi Wastewater Plant
By Nick Belardes, ProSoft Technology
The Changi Water Reclamation Plant in Singapore has 160 ProSoft Technology PROFIBUS DPV1 modules that handle flow meters, pressure and DP level transmitters, radar/ultrasonic transmitters, dissolved oxygen analyzers, temperature transmitters and electric actuators.
 
Ahold Coffee selects Ampla to improve OEE on its production lines
SA Instrumentation & Control, February 2008
The Ahold Coffee Company selected Ampla, Citect's MES solution, which consisted of the Planner, Downtime, Production, and Metrics modules. Overall equipment effectiveness (OEE) is a key indicator, and the company has already seen significant improvements in this KPI on selected lines since Ampla was installed.
 
FlavourCraft standardises on Beckhoff Automation
SA Instrumentation & Control, February 2008
By Andrew Ashton
The Beckhoff choice allowed FlavourCraft the flexibility to build both small and large systems with the same components and programming languages. They use Beckhoff I/O, Profibus, OPC, PACs and PLCs.
 
Persian Gulf Company Uses HART to Improve Water Conversion Process
HART Communication Foundation
The Saline Water Conversion Corporation (SWCC) used HART technology in a major re-instrumentation project as the catalyst for improving asset management. The company installed more than 2,000 HART-enabled devices in a facility in Jubail, Saudi Arabia.
 
Mass Flow Controller works in Antarctica
Process & Control Today, February 2008
Researcher David Mucciarone selected the Smart-Trak 100 digital mass flow controller from Sierra Instruments to form an integral part of a carbon analyzer. Mucciarone tests the break down of inorganic carbon in sea and ice to learn how much CO2 the sea can digest. The Smart-Trak 100 monitors the amount of CO2 in samples of sea and ice.
 
Small data loggers take trips with perishable goods
Industrial Embedded Systems, January 2008
By Dov Bruker, Fourier Systems
Author discusses the technology that goes into a low-cost, tiny data logger and its accompanying software designed to monitor and analyze goods’ temperature during transportation.
 
Advanced Technology Exceeds Expectations
Control Engineering, January 2008
By David DeBari, Advanced Elastomer Systems
Using smart field instrumentation and bus-oriented plant architecture contributed to the timely startup of a new thermoplastic elastomer (TPE) production line for Advanced Elastomer Systems.
 
Optical Fibers Need Critical Process Control
Control Engineering, January 2008
By Kelly Downey, Opto 22
Lumenyte, a fiber optics manufacturer, is using Opto 22 Snap PAC systems to control and monitor a host of equipment used in the manufacturing of its plastic optical fibers, including levels, flows, temperatures, and pressures in a process using more than 35 various sensor inputs.
 
Managing MS Windows NT4
Control Engineering, January 2008
By Bob Vieraitis, Solidcore Systems
One class of systems where any change, authorized or not, creates a high-risk proposition is legacy systems running the Microsoft Windows NT4 operating system. Changes can cause in-production outages and downtime that threatens overall plant production. Here’s how one plant solved the problem.
 
Full Transparency Without a Central Process Control System
Process and Control Today, January 2008
Instead of an expensive centralized process control system, Follmann & Co, a chemical company in the UK, used compact modular controllers and HMI control terminals from Mitsubishi Electric. Follmann uses MX Sheet software to feed the process data from the controllers directly into the existing office software.
 
Crystal clear batch
Intech, December 2007
By Richard S. Harner and Nick D. Gipson
Fiber optic probe helps control batch crystallization in pharmaceutical applications. The probe responds primarily to total surface area of solids. Although touted strictly as a control device, it reliably generates an in-situ piece of information that is otherwise unknown during crystallizer operation.
 
Robots Taking Over The Job On Offshore Oil Drilling Platforms
Science Daily, January 1, 2008
An automated platform doesn't need personnel, and therefore neither does it need fire systems, sound insulation, catering or a whole range of other installations. The SINTEF test laboratory represents the next step, in which the scientists will find out how robots can be used to remotely monitor and control platform processes.
 
Emerson Improves Production and Efficiency for Brewery in Belgium
Process & Control Today, December 2007
Rosemount Analytical pH sensors withstand high temperature cleaning cycles, reducing sensor failure alarms and improving reliability at the Duvel Moortgat brewery in Puurs, Belgium, solving a production problem and improving efficiency
 
Kinder Morgan Canada Uses Matrikon Alarm Manager for Pipeline Management
Matrikon Alarm Manager collects and stores all alarm and event data, allowing Kinder Morgan Canada to measure alarms, reduce nuisance alarms, adjust workloads, manage changes and standardize alarm practices across its pipelines.
 
Paper company converts Mod 300 to System 800xA
By ABB
Technocell in Drummondville, Quebec, converted a MOD 300 control system, originally installed in 1991, to an ABB System 800xA. The project involved 17,000 control loops.
 
Phasing in DCS migration
Intech, October 2007
By Victor Aparicio, Carlos Balanza, and Eduardo Zambrana
Bolivia’s Carrasco gas plant needed to update its distributed control system (DCS). The solution was to have all facilities under a new DCS system, optimizing control links.
 
Ethanol plant boosts output and saves energy
Chemical Processing, October 2007
By Jacob Duke, Badger State Ethanol, and Lina Rueda, Pavilion Technologies
Implementation of advanced process control for distillation and dehydration steps allowed Badger State Ethanol to achieve record production rates by finding optimal process operating conditions, and cut the amount of energy needed per gallon of ethanol produced.
 
Applications of Self-tuning Control
Control Engineering, September 2007
By Vance VanDoren, Control Engineering
Loop tuning is as much an art as it is a science. A well tuned feedback control loop can quickly and safely eliminate errors between the process variable and the setpoint, but endowing the controller with the necessary balance of aggression and patience requires a certain degree of skill and experience.
 
Model Predictive Cost Control
Control Engineering, August, 2007
By Michael Tay, Pavilion Technologies
East Kansas Agri-Energy, an ethanol producer, increased production and reduced costs through MPC control strategy.
 
Integrated electrical and automation systems
By Tom F. Nestli and Peter Tubaas, ABB
Seamless integration of electrical and automation systems are highly desirable in a process plant, At the Statoil Snøhvit liquefied natural gas (LNG) plant, the Electrical Control and Supervision System (ECSS) communicates with a wide range of equipment and ensures a stable power supply to the LNG facility.
 
Matrikon integrates supply chain at AB Nynäs Petroleum
Nynas installed Matrikon’s Resolution to aggregate data from plant sources; integrate operational, business, and real-time market information; and enable desktop access to data for every aspect of plant operations.
 
Nynas Integrates supply chain with Matrikon Resolution
Nynas was faced with serious business challenges arising from fragmented data sources within their supply chain. Separate, individualized and non-standardized planning bases meant poor visibility into the production plan across the organization, and weak links between corporate planning and refinery planning resulted in suboptimal refinery production schedules
 
Matrix Technologies upgrades process control system at steel mill with OPC
Matrix upgraded the control system at one of AK Steel’s mills. The computer had to communicate with A-B and Square D PLCs. The interface was accomplished with a MatrikonOPC Server.
 
Safe Designs Dodge Downtime
Intech, February 2007
By Ellen Fussell Policastro, Associate Editor
A Virginia chemical plant, where the entire facility is a hazardous area, installed Foundation fieldbus controls. The engineer involved explains the ins and outs of its bout with intrinsic safety and fieldbus, the costs involved, and the choice it had to make between FISCO and Entity.
 
Geisum Oil Company Offshore Platform
Geisum uses InduSoft for its offshore platform emergency shutdown system in the Gulf of Suez, Egypt. The system monitors and controls all platform instruments and setpoints, and allows maintenance people to access critical data with handheld PDAs and laptops.
 
Process plant modernisation brings significant savings
Process and Control Today, March 2007
By John Houston, Editor
Achieving energy savings of at least 50% along with less downtime and cheaper maintenance were the important benefits achieved following a process water plant modernisation and pump replacement project, completed for Robert McBride Ltd, a leading manufacturer of personal care products
 
Mid-Missouri energy boosts ethanol production
Process and Control Today, April 2007
By John Houston, Editor
Mid-Missouri Energy has achieved over $3 million in annual benefits through implementation of Pavilion’s Dryer Control Application at the company’s Malta Bend, Missouri plant. The deployment enabled Mid-Missouri Energy to improve process efficiencies and resolve bottlenecks throughout the drying process, resulting in a six percent increase in ethanol production and a return on investment (ROI) within six months.
 
Coming to terms with Hydraulic Surge in pumping systems
Process and Control Today
April 2007, By John Houston, Editor
Reciprocating pumps are an essential component in a multitude of processing and production applications ranging from wastewater treatment to pharmaceutical manufacturing. However, regardless of the application a problem that can have disastrous consequences both for pumps and processing plant is hydraulic surge or “water hammer
 
Moore's QUADLOG Safety PLC controls Fuel Burners at power plant
National Power’s Didcot power plant conversion to gas and coal-fired burners included the implementation of QUADLOG for safe and cost-effective gas firing control and burner management systems.
 
All American Seasonings' Growth: Focus on Flavor and Efficiency Through Technology
All American has recently invested in a brand new production facility with over 40,000 sq. ft. It was clearly time for an upgrade in tools and procedures which captured all pertinent operations data and supported instant decision making throughout the enterprise. After an exhaustive search and performance shootouts between candidate systems, All American selected BatchMaster Software Inc. and has begun implementation of the Food ERP system.
 
Crude gets smart
InTech, March 2007
By Pavel Kataev, et al
Neural network technology proves best choice for virtual sensing in crude refining units. Perm, Russia's, LUKOIL refinery, chose to use artificial neural networks for online, real-time inferential property estimation in what could be one of the world's largest installations (in terms of the number of neural models) on a single crude unit. The neural networks run as function blocks within the automation system's controllers.
 
Bringing Nuisance Alarms Under Control
Control Engineering, March 2007
By David Gaertner
When operators have to answer 5,000 alarms in 18 hours, it’s time to attack a huge problem. To reduce alarm floods that seemed to be occurring with increasing frequency, Arizona’s Salt River Project (SRP) implemented a very effective alarm management solution at two of its generating stations, Navajo and Santan.
 
Rugged Oil and Gas Well Logging Data Acquisition System
By: Corin Chepko, Rocky Mountain Wireline Service
Rocky Mountain Wireline Service is an oil and gas perforating and logging company. The data acquisition system we use is rack-mounted in a wireline truck and must withstand vibration and dust generated as the truck moves to different locations over rough roads. These conditions cause problems with industrial PCs. We needed a system that was reliable and easy to repair or replace in the case of failure.
 
Ease of connection improves plant efficiency for Santee Cooper
OPC technology provides ease of access to the wide variety of devices in our enterprise, eliminating costly custom or proprietary interfaces. Providing us with a flexible and scalable solution we can build on for years to come. We are confident and secure in our ability to meet the 98% uptime emissions reporting requirements. Now that these manual processes are automated, we are saving approximately 4 hours of resource allocation in a 24 hour shift rotation.
 
Project: Baton Rouge Wastewater Pump Station SCADA System
By Stan Prutz, CEO, and Mark A. Medley, project engineer, QDS Systems
This fascinating blog details the adventures involved in implementing a SCADA system at a wastewater pump station, starting in July 2005 and continuing to present day, with entries nearly every month, some weekly. You may want to go all the way back to the beginning to follow this saga.
 
Process Control Improvements at USS/Kobe
Noncontact laser Doppler velocimetry has been utilized for more than 10 years as a proven technique to measure the velocity and length of various shapes and sizes of metals products. The technique eliminates process errors caused by roll slippage incurred with contact methods.
 
Global Operations Required Significant Changes
Managing energy costs is critical to the success of any industrial gas company. The highest operating cost incurred in air separation processes is the cost of electricity. This cost can be as high as two-thirds of the total cost of production, and plants that produce liquid products can potentially use tens of thousands of Kilowatts per hour. Model Predictive Control, or MPC technology has been maximizing process performance, improving efficiencies, reducing energy usage, raw material usage, and environmental impact in process industries for over 25 years.
 
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