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 Benefits of an O2-based fuel controller for biomass plants
February 15, 2016

Benefits of an O2-based fuel controller for biomass plants

By Andrew Gentile and Sheldon Schultz
An O2 controller was installed in a boiler in 2010. Process data was collected in 1 minute increments on 8 June 2010. Steam flow, drum pressure percent O2, feed rate, and control mode (auto or manual) were collected. The data elements are represented as a percentage of their respective averages. This was done to compare the data on relative terms.

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Sequenced changeover yields system upgrade without production downtime
February 15, 2016

Sequenced changeover yields system upgrade without production downtime

By Marc Hunter
Recently, with the help of a consulting engineering firm and system integrator, a major Midwest steel producer successfully upgraded the main blast furnace and stove control system with no interruption in overall blast furnace or stove control system operations.

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Scalable control system is at the heart of water-treatment process skid
December 24, 2015

Scalable control system is at the heart of water-treatment process skid

Control Design
By Gregory Möller, University of Idaho-Washington State University
The University of Idaho’s research water-treatment-process trailer includes PLC, HMI, power-distribution components, motor starters, stepper drives and local I/O.

California Olive Ranch Chooses Stainless Steel for Harsh Production
December 24, 2015

California Olive Ranch Chooses Stainless Steel for Harsh Production

Pumps & Systems
A combination of caustic cleaning fluid, high temperature and high head was causing the plant's original cast-iron pumps to fail.

Industrial wireless for mobile video monitoring, leak alarm
December 18, 2015

Industrial wireless for mobile video monitoring, leak alarm

Control Engineering
Industrial wireless takes on high-bandwidth mobile video monitoring at the Samref refinery complex in Yanbu, Saudi Arabia, and mission-critical safety leak detection at an unnamedLNG facility.

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DCS enter new territory, do more and better
December 18, 2015

DCS enter new territory, do more and better

Control
By Jim Montague
Hi-tech accessories, software and networking are allowing distributed control systems (DCS) to expand their job descriptions and take on non-traditional tasks. Here are some examples.

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Inverter drive cuts the cost of automation
December 18, 2015

Inverter drive cuts the cost of automation

Process and Control Today
Bottle and pouch fillers with electronic adjustment for filling volume offer important benefits over machines with manual adjustment but, until now, higher cost has limited their adoption. In the latest IMSB machines, however, an Eaton inverter drive replaces the costly servo-controlled filling system, making these novel machines much more affordable.

Drive And Motor Solution Cuts Extruder Energy Usage By 9%
December 18, 2015

Drive And Motor Solution Cuts Extruder Energy Usage By 9%

Process and Control Today
Emerson was able to help Stål & Plast, a Danish extrusion specialist, improve its production processes by replacing three worn-out DC electric motors with energy-friendly Dyneo PM motors and a Unidrive M variable speed drive at the company's extruder plant.

Re-Assembly Impacting Machine Performance
November 21, 2015

Re-Assembly Impacting Machine Performance

Maintenance Online
By Jyoti K. Sinha
Measures adopted when a primary air fan in a coal-fired power plant exhibited, after maintenance, high vibration which led to failure of the motor bearing and eventual stoppage of power production. The measurement of the vibration, the solution of the problem and the message for the maintenance team are discussed.

A Flow Measurement System Finds Alternative Applications
November 17, 2015

A Flow Measurement System Finds Alternative Applications

Flow Control
The original plan was to develop a flow measurement and control system with leak detection and energy-use calculations for liquid-cooled supercomputers at the Lawrence Livermore National Laboratory.

Universal Robots Helps Betacom Light Up New Zealand
October 01, 2015

Universal Robots Helps Betacom Light Up New Zealand

Industrial Automation Asia
Betacom Limited designs, manufactures and assembles a range of lighting products which are sold throughout New Zealand and Australia. It uses a UR10 robot to pick up and assemble circuit boards.

Vision guides high-speed robotic packaging
October 01, 2015

Vision guides high-speed robotic packaging

Control Design
Multiple vision sensors and a high-speed robot provide robust and easily configurable part handling on packaging system at Global Controls in Saint Charles, Illinois.

DC Facility Employs High-Capacity Pump Station for Nitrogen Removal
September 30, 2015

DC Facility Employs High-Capacity Pump Station for Nitrogen Removal

Pumps & Systems
The Blue Plains Advanced Wastewater Treatment Plant (AWTP) in Washington D.C. built an Enhanced Nitrogen Removal Facility (ENRF) that uses submersible wastewater pumps. Optimization of the selected submersible propeller pumps saved the facility up to $200,000 per year.

Robot anchors new keg line
August 24, 2015

Robot anchors new keg line

Packaging World
Asahi Premium Beverages (APB) of Melbourne, Australia, installed an Innopal RK 6 robot, which handles both palletizing and depalletizing of kegs. It’s capable of handling kegs from 10 to 58 L.

Robots rise to packaging challenges
August 24, 2015

Robots rise to packaging challenges

Packaging World
How robots are being used to package bottles, cans, pasta, organic foods and snack foods in thjese five case studies.

India's largest car-maker makes the connection
August 24, 2015

India's largest car-maker makes the connection

Drives & Controls
India’s biggest car-maker, Maruti Suzuki, is turning increasingly to the CC-Link open network to help it cut its automation costs, to share data, and to make its operations more efficient.

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Industrial network management software improves productivity
August 24, 2015

Industrial network management software improves productivity

South African Instrumentation and Control
By Heather MacKenzie, Belden
The Qatar Aluminum (Qatalum) smelter located near Mesajeed Industrial City in Qatar has a network with more than 1000 nodes including many industrially hardened Ethernet switches and a network management system (NMS).

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DC to AC conversion avoids costly plant overhaul at UK carpet maker
August 18, 2015

DC to AC conversion avoids costly plant overhaul at UK carpet maker

Process & Control Today
Converting spinning frames from inefficient direct current (DC) control to alternating control (AC) has helped increase production capacity of spun yarn at Brintons Carpets, while eliminating motor spare parts, lowering maintenance costs and saving energy.

Steel maker improves roller table reliability with AC drives
August 18, 2015

Steel maker improves roller table reliability with AC drives

Process & Control Today
Celsa Manufacturing’s existing roller table drives were obsolete. The roller table has 80 rollers to transport finished steel billets, and each drive controls four banks of 20 roller motors. As a trial, they installed an ABB ACS550,to replace one drive, and will replace the other three.

Water treatment plant solution solves DEP requirements and more
August 12, 2015

Water treatment plant solution solves DEP requirements and more

InTech
By Jim Barish
At Quality Life Services in Butler, Pa, a programmable logic controller–based control system was installed to connect the site’s existing wells to a new water treatment system and storage tower.

The Anatomy of a Cyber Security Assessment
August 10, 2015

The Anatomy of a Cyber Security Assessment

Design News
By Rob Speigel
Over the last five years, the DuPont Co. has regularly monitored all aspects of the security of its Sabine River Works plant on the Gulf Coast of Texas. The plant produces ethylene copolymers used in plastic packaging. The monitoring process began with a full security assessment. The assessment focused heavily – though not exclusively – on cyber threats.

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Ammonia plant simulation shortens ramp up, improves training
July 18, 2015

Ammonia plant simulation shortens ramp up, improves training

Control
By Dylan Charles and Todd Jaco
Austin Powder's U.S. Nitrogen uses Mynah's Mimic simulation software to speed up implementation and training, and improve process optimization.

Clever application story
July 18, 2015

Clever application story

Process and Control Today
In Altavilla Vicentina, Italy, a Clever Sleever Machine places and shrink-wraps bottles at a rate of 18,000 pieces per hour. That’s five pieces per second. A CompactLogix communicates to the Point I/O through ProSoft Technology’s radios.

Industrial WLAN enables mobile monitoring
July 18, 2015

Industrial WLAN enables mobile monitoring

Control Engineering Europe
CP Kelco in Lille Skensved, Denmark, a producer of pectin, is striving toward a production environment in which each operator moves around freely with an iPad, monitoring and managing machines quickly and efficiently – without the need for a stationary computer and IP addresses instead of stationary operator stations and push buttons.

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How to link machine controls to IT systems
June 24, 2015

How to link machine controls to IT systems

Control Design
Connecting machines to IT systems provides a number of benefits for machine builders and their customers. Here are several examples.

How OPC aids integration
June 24, 2015

How OPC aids integration

Control Design
The Owens Design 300 mm wafer platform is designed for semiconductor metrology equipment applications and is linked to IT systems via OPC.

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Modular design shrinks big machine problems
June 24, 2015

Modular design shrinks big machine problems

Control Design
By Hank Hogan
Modular machines can save wiring and installation costs, as compared to a completely custom design. They also add flexibility and allow a greater variety of product to be produced in a smaller footprint compared to a one-of-a-kind approach. Here are several examples.

Panel building advances OEM’s delivery times
June 24, 2015

Panel building advances OEM’s delivery times

Control Design
By Dave Perkon
Northwind Air Systems, manufacturer of the DuroVac brand of industrial vacuums, collaborated with engineers at Eaton over about four months to create a proprietary software application that helps expedite the design, engineering, drawings and delivery of the control cabinet.

BP - Using drones to monitor safety
June 23, 2015

BP - Using drones to monitor safety

HazardEx
Until recently, the use of unmanned aerial vehicles (UAVs) – or drones – was mainly associated with the military. These days, however, they are increasingly being used for civilian and commercial purposes. BP is now using unmanned aerial vehicles at its Prudhoe Bay operations in Alaska, to help carry out safety checks in difficult terrain and temperatures.

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Eliminate Cabling Costs Through Proprietary Wireless Networking
June 23, 2015

Eliminate Cabling Costs Through Proprietary Wireless Networking

Pumps & Systems
Public water utility employees in Lage, Germany, chose a wireless system with a stand-alone solar power system to provide an independent power supply. By selecting both a wireless I/O signal radio system and a stand-alone solar power system, employees were able to eliminate the need to lay any cable. This saved between $25 and $35 per foot for digging trenches and routing cables.

How to incorporate mobility into your maintenance practices
June 16, 2015

How to incorporate mobility into your maintenance practices

Plant Services
By Sheila Kennedy
Portable asset management information puts knowledge where it’s needed. Here‘s how Northwestern Power and Loram Maintenance of Way, use mobile technology.

Controls, safety and management systems help meet demand for renewable packaging board
June 16, 2015

Controls, safety and management systems help meet demand for renewable packaging board

Control Engineering Europe
Europe’s largest pulp, board and paper manufacturer, Stora Enso, migrating the plant from its previous control system to Honeywell’s Experion PKS (Process Knowledge System), which offers a unified architecture for process control, safety systems and automation software.

Turbo generator plant upgrades to AUMA electric actuators
June 16, 2015

Turbo generator plant upgrades to AUMA electric actuators

Process & Control Today
Eraring power station in NSW Australia has upgraded pneumatic actuators for seal air dampers at 28 coal mills with AUMA’s electric actuation technology. Over 400 AUMA actuators have been adopted in all plant areas: applications include on-off, inching/positioning and modulating duty.

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Speedy delivery of calibration data
June 16, 2015

Speedy delivery of calibration data

By Jim Montague
Calibration is a complex procedure that takes time, and time is money. Here's how some facilities are saving both and also getting better data

Deploying wireless safely and securely
June 16, 2015

Deploying wireless safely and securely

Control
By Jim Montague
Wireless is expanding into more tight places and remote process applications than ever before. Here's how it's deployed safely and securely in various applications.

Industrial Internet of Things (IIoT) benefits, examples
June 16, 2015

Industrial Internet of Things (IIoT) benefits, examples

Control Engineering
By Bob Karschnia, Emerson
Industrial Internet of Things (IIoT) technologies, applied for monitoring valves in a refinery, used wireless acoustic transmitters to improve regulatory compliance and reduce hydrocarbon losses by $3 million annually due to timely detection and repair of faulty valves.

June 13, 2015

Protecting Singapore’s Changi Airport power with automatic transfer switches

InTech
By Nam Paik
Thales Group, a French military and civilian aviation systems integrator, applied an automatic transfer switch, which is essentially a battery-less UPS system with two autonomous input AC sources, to protect Singapore’s Changi Airport’s systems.

Safety management
May 25, 2015

Safety management

Packaging World
Swiss potato chip manufacturer Zweifel Pomy-Chips installed a Pilz PSS 4000 for safety and automation on the packaging line. Safety gates are fitted with magnetic safety switches PSENmag and the coded safety switches PSENcode from Pilz.

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How sensors enable information-based decisions
May 24, 2015

How sensors enable information-based decisions

Control Design
By Gary Highley
These three applications illustrate how sensors are used to optimize production, eliminate manual intervention and incorporate quality checks.

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PC-based control helps KVAL door production machines
May 24, 2015

PC-based control helps KVAL door production machines

Control Engineering
KVAL used Beckhoff PC-based control, servo drives with one cable, and EtherCAT industrial Ethernet for communications to reduce the wired-to-running time of door assembly machinery from 2 to 4 days without testing for two people to less than 1 day with testing for one person.