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Whilst every effort is made to ensure technical accuracy of the information supplied on iceweb.com.au, Keyfleet Pty Ltd and its employees accept no liability for any loss or damage caused by error or omission from the data supplied. Users should make and rely on their own independent inquiries. By accessing the site users accept this condition.
Posted by: Jim
Russell, March 2010
FPSO
Flow Meter Fits Just Right - Space-Saving Flow Meter Gets Engineers Out
Of Tight Spots In Offshore Applications: Ideal for Measuring Wet Gas,
Condensate and Dirty or Abrasive Flows. Thanks to our sponsor McCrometer,
have a look at their comprehensive V-Cone
page.
The following Burner Management System Papers, Articles
and Links have been added to ICEweb's BMS
page thanks to our sponsor HIMA
Australia
- Integration
of Burner Automation into the Safety System - The Combustion Engineering
Centre at BASF AG commissioned HIMA to install a safety related automation
system for the burner controller in its thermal exhaust cleaning plant at the
Ludwigshafen production facility. The plant operator decided to install the
combustion plant’s regulating and control equipment in one compact,
centralised system and to replace the conventional burner controller with a
safety-related automation solution.
- Designing
a Burner Management System to Comply with NFPA 85 & ANSI/ISA 84 -
Mike Scott/Bud Adler- This paper explores and contrasts the system
implementation requirements for a Burner Management
System mandated by NFPA 85 – The Boiler and Combustion System Hazards
Code 2001 Edition - and those mandated by ANSI/ISA
84.00.01-2004. Thanks to www.safetybase.net
- Combustion
Safety for Furnace Operation - Glenn
Showers - This article provides an overview of the requirements of
NFPA Standard 86 with an emphasis on the theory of combustion safety as it
applies to any type of combustion device, especially a direct-fired furnace-
from www.industrialheating.com
- Boiler
Safety Intuition - Diagnosing Boiler Problems Sometimes Takes all the Senses
- John R Puskar - This very interesting article gives some great tips on
how to identify when your BMS is not working too well - from www.combustionsafety.com
- Guidelines
help identify SIFs in Burner Management Systems - Is your BMS an SIS?
How do you ID SIFs in your BMS? - Sound like the latest text messages on
your teenager’s mobile phone? To some perhaps, but for those involved in
functional safety and safety instrumented systems (SIS) in the process
industries, these questions need no translation and demand serious
answers—many of which are to be presented a new ISA (International Society
of Automation) technical report from the Burner Management System (BMS)
Working Group under ANSI/ISA 84.00.01-2004 (IEC 61511 Mod) Functional
Safety: Safety Instrumented Systems for the Process Industry Sector. Thanks
to www.safetybase.net .
The following Safety Instrumented System Papers, Articles and Links
have been added to ICEweb's SIS
page thanks to our sponsor HIMA
Australia
- Integration
today - Integration solutions - For years people have been discussing
the subject of “integration” in automation technology. There are a variety
of solutions available for the integration of safety and control systems.
Provided the right decision is made you can take advantage of all the
opportunities and potential synergies of integration, long-term.
- Summary
of Offshore Health and Safety Performance Report 2007-08 - The Offshore
Health and Safety Performance Report 2007-08 was produced by the National
Offshore Petroleum Safety Authority (NOPSA), with the aim to "move beyond
the view of safety as compliance with codes and standards and towards an overall
improved safety culture within an organisation. The report contains statistics,
trends and observations of health and safety within the Australian offshore
petroleum industry for the financial year 2007-08. Areas of concern highlighted
include equipment design, risk awareness and management, procedures, ageing
equipment, supervision and a shortage of skilled personnel.
- SIF
Proof Testing Yields Process Sector Reliability Data - William H. Hearn,
Patrick Skweres, A. D. Arnold, and Angela E. Summers, Ph.D. - ANSI/ISA 84
requires periodic proof testing of SIFs to demonstrate the correct operation
of the loop elements along with sufficient historical documentation to
support analysis of discrepancies and validation of the SIF integrity and
reliability. The analysis of proof test records is an important element of
the quality assurance process necessary to support continued use of
installed equipment. The CCPS Process Equipment Reliability Database (PERD)
project has developed failure data taxonomies which provide a structure to
capture data to support chemical process data collection and analysis.
SIS-TECH® has been distributing a device failure rate database for more
than 10 years. This paper describes how SIS-TECH® will collect device
performance data under a quality plan during periodic SIF proof testing.
This data will be contributed to PERD for review and analysis so that SIL
Solver® failure rates can be validated against operating environment data.
- Overfill
Protective Systems - Complex Problem, Simple Solution - Angela E.
Summers, Ph.D - Overfills have resulted in significant process safety
incidents. Longford (Australia, 1998), Texas City (United States, 2005), and
Buncefield (United Kingdom, 2005) can be traced to loss of level control
leading to high level and ultimately to loss of containment. A tower at
Longford and a fractionating column at Texas City were overfilled, allowing
liquid to pass to downstream equipment that was not designed to receive it.
The Buncefield incident occurred when a terminal tank was overfilled
releasing hydrocarbons through its conservation vents. The causes of
overfill are easy to identify; however, the risk analysis is complicated by
the combination of manual and automated actions often necessary to control
level and to respond to abnormal level events. This paper provides a summary
of the Longford, Texas City, and Buncefield incidents from an overfill
perspective and highlights 5 common factors that contributed to making these
incidents possible. Fortunately, while overfill can be a complex problem,
the risk reduction strategy is surprisingly simple.
- Lessons
Learned While Auditing Automation Systems for PSM Compliance - Angela E.
Summers, Ph.D - While reliance on instrumentation has increased at an
incredible pace, resources allocated to design and manage the equipment have
declined in many companies, leading to more burden and expectations being
placed on fewer and fewer people. Quality instrumented system performance
relies on a rigorous management system that minimizes human error and
equipment failure potential. This paper focuses on safety instrumented
systems and applicable process safety management requirements. Observations
from assessments and audits are provided, illustrating poor performing
instrumented systems, inadequate operating and maintenance procedures,
recordkeeping and retention practices, and out-of-date documentation.
- Consistent
Consequence Severity Estimation -Angela Summers,
PhD, PE William Vogtmann and Steven Smolen - Most risk analysis methods rely
on a qualitative judgment of consequence severity, overstatement creates
excessive risk reduction requirements, understatement results in inadequate
risk reduction. This paper provides justification for developing
semi-quantitative look-up tables to support a LOPA team's assessment of
consequence severity.
- Safety
Management is a Virtue - Angela E. Summers, Ph.D - This paper discusses
various challenges to sustaining safe operation of process equipment. Each
challenge is introduced using a Chinese fortune cookie to remind the reader
that the barriers against progress are not new but have existed from many
years. In most cases, the solutions are also well known and generally
require deployment of robust equipment, proven techniques, and competent
resources.
- SafetyBase.com
is a site that is full of some excellent information about Boiler Management
Systems, Machine and Process Safety. You’ll be able to share ideas with
colleagues across the country, stay current with compliance requirements,
and read the latest case studies, white papers, and articles that can help
you keep your people safe and your process moving.
- An
Introduction to Inherently Safer Design - Inherently safer design (ISD)
is a philosophy for addressing safety issues in the design and
operation of chemical processes and manufacturing plants. When considering
ISD, the designer tries to manage process risk by
eliminating or significantly reducing hazards. Thanks to Centre
for Chemical Process Safety.
- Center for
Chemical Process Safety - The Global Community Committed to Process
Safety - CCPS is a not-for-profit, corporate membership organization within
AIChE that identifies and addresses process safety needs within the
chemical, pharmaceutical, and petroleum industries. CCPS brings
together manufacturers, government agencies, consultants, academia and
insurers to lead the way in improving industrial process safety.
HIPPS solutions - Safe Operation and Nonstop Availability - The main reasons for using HIPPS (high-integrity pressure protection systems) are safety, environmental and economic. Safety to ensure that you can confidently operate close to design limits. Environmental to avoid unnecessary flaring and thereby limiting air emissions. And economic to reduce costs, because it is always cheaper to use HIPPS than to install full-flaring capacity and full-schedule piping and equipment. The continuous operation of equipment is a prerequisite. Nonstop operation – this is the advantage offered by HIMA HIPPS solutions. All applicable standards up to SIL 3 and even SIL 4 are also met. Thanks to our sponsor HIMA Australia.
OPC
Communications - Stephen Mueller/
Summary
of Offshore Health and Safety Performance Report 2007-08 - The Offshore
Health and Safety Performance Report 2007-08 was produced by the National
Offshore Petroleum Safety Authority (NOPSA), with the aim to "move
beyond the view of safety as compliance with codes and standards and towards
an overall improved safety culture within an organisation. The report
contains statistics, trends and observations of health and safety within the
Australian offshore petroleum industry for the financial year 2007-08. Areas
of concern highlighted include equipment design, risk awareness and
management, procedures, ageing equipment, supervision and a shortage of
skilled personnel. Thanks to our sponsor HIMA
Australia.
Posted by: Jim
Russell, February 2010
Gas Jobs, Careers and Vacancies: Your Energy Jobs - Your Energy Jobs is a job site dedicated to finding you the best energy industry jobs, careers and vacancies in the UK. The site includes hundreds of vacancies across key UK energy industry sectors, including gas jobs, as well as oil jobs, jobs in coal, nuclear jobs, jobs in electric and renewable energy jobs.
Packaging
for experts - Safe, Flexible Drive Technology for Surimi, Sandwiches etc
- Whether it’s a pudding in a glass, with or without
outer packaging, fresh herbs in a plastic tray, or the spoon in an ice cream
tub – different products require different packaging solutions. In this
case the quality of the packaging is just as important as the productivity
and multifunctionality of the actual packaging line. Packaging lines must
also satisfy the highest requirements in terms of productivity, flexibility
and reliability. Flexible drive technology guarantees that foodstuffs are
packaged quickly, precisely and carefully.
Posted by: Jim
Russell, January 2010
****FDT
Technology Provides Valuable Information on the Desktop
ARC Advisory Group: Control In The Field Enhances Process Integrity - In the white paper, titled "The Business Value Proposition of Control in the Field," ARC describes the incorporation of a function block structure and other supporting functions in Foundation fieldbus providing a complete automation infrastructure for operational excellence. Embedded control functionality in Foundation devices is one of the key enablers for achieving high availability control and a stepping-stone towards single-loop integrity.
Flow & Measurement Articles - This super website contains an absolute "swag" of published articles on flow and measurement written by Dr. Jesse Yoder. These articles have been published in various trade journals beginning in 1995.
The following Technical Articles are from Northwire
Inc
- Cable
Fables - Confusion and Misconceptions about NFPA-79 - Confusion
abounds about the “new” NFPA (National Fire Protection Association)
regulations pertaining to UL-recognized (AWM
style) cable. Long after the practice became widespread,inspectors became
aware of the ubiquitous use of AWM (Appliance Wiring Material) style cables
in machine interconnecting sensors, actuators,
switches and other components—often as part of premolded
connector assemblies. The 2007 change to the
NFPA-79 electrical code states that AWM-style single-conductor wire or
multi-conductor cable is not permitted on machinery
unless it is part of a UL-listed assembly. In
other words, machine wiring requires UL-listed cable. Clearly, UL-listed
cable has been available for many years. So the
real question is, which UL listing is appropriate for particular
applications?
- Flame
Testing - Testing for Flame Resistance of Electrical Cables - Harold
Gjerning – Agency Compliance Technician - The National Fire Protection
Agency (NFPA) publishes flame-resistance standards through its published
National Electrical Code (NEC). Other agencies, such as UL and CSA also
publish standards and also define certain tests for determine flame
resistance (or lack thereof). Flame resistance requirements are for the most
part governed by local and national codes which define the various levels of
flame hazard, plus the severity of the fires to which cables may be exposed.
The important considerations are propagation of flame, support of further
combustion, generation and propagation of smoke. The NEC deals primarily
with fire hazards in buildings, whereas UL and CSA deal with requirements
based on use.
- Custom
Cables for Medical Applications - Medical cables have to meet
requirements that are more demanding than the non medical variety.
This article discusses these.
- Slimmer
Cables Can Take More Flexing
- Selecting
the Right Cable for Foundation fieldbus Control Networks – What you need
to know - Sandy Fulton - FF-844 is the Fieldbus Foundation cable
compliance specification. FF-844 includes the electrical requirements of ISA
50.02 and IEC 61158, but it also contains some additional requirements which
help you know your cable is the right cable for use in FOUNDATION fieldbus
control networks.|
- Cable
Innovation Makes Industrial Networking Faster, Easier & More Reliable
- Cable Innovation Makes Industrial Networking Easier, Faster and More
Reliable - As engineers and systems integrators gain experience with
FOUNDATION™ fieldbus installations, they are realizing the advantages of
multi-pair fieldbus trunk lines in plant installations. These users are
simplifying installations by merging formerly scattered control and
instrument points into common bus segments and junction boxes. The benefits
include installation cost savings, more compact cable housing in a tray or
conduit and neater assemblage in the junction boxes. Instead of running
bundles of single-pair trunk lines, cable specifiers are requesting
multi-pair fieldbus trunk cables.
- Know
Your High-Flex-Life Cable - When your application
calls for cable meant to stand the tests of
time and motion, you need to know what topurchase and what constitutes
product quality. Cable designed to survive 10
million to 20 million flexing cycles is
high-flex-life cable. It’s different from high-flex cable,
which is designed to be supple and highly flexible. High-flex-life
cable may actually feel stiffer than high-flex cable.
The two products are distinctly different and mutually
exclusive. Try bending the cable, twisting it,
pulling it, rolling it back and forth in a
track, having it bear weight, rubbing it and subjecting
it to extremes of temperature and to solvents, oils and chemicals. Now do
these things 10 million times in continuous
motion, without ceasing. You’ll learn the difference between highflex-
life and high-flex cable quickly – one cable isn’t
the same as the next.
- Why
Order Custom Cable? - Ted Beach - A project engineer can choose
off-the-shelf cable – the manufacturer's way – and then adapt it to
specific needs, or that same engineer can choose custom cabling designed for
a specific purpose – the project engineer's way. There are advantages and
disadvantages to both choices. this article reviews these.
- Cable
Goes Twist Friendly - Constant motion can turn ordinary wiring into a
big maintenance item on equipment. Read how continuous motion can destroy
ordinary cables and what Northwire is doing to produce cable that will last
millions of twist, roll, and bend cycles. Consider how typical
industrial-automation equipment works today. Most of it is in use nearly
24/7. It frequently contains robotic elements and assemblies that execute
motions repeating hundreds of times or more every minute. No question that
these applications put stringent demands on moving parts. This is true even
for the cabling that connects moving equipment to controls. This cabling can
see millions of flex cycles in the course of normal use. From Machine
Design.
- Out of
the Frying Pan and onto the Cable - Teflon® and Other Fluoropolymers -
Teflon, a product developed by DuPont and a common coating on cookware, is
one of a group of compounds known as fluoropolymers. Fluoropolymers are
fluorocarbon-based polymers with multiple strong carbon–fluorine bonds.
Teflon FEP - a different grade than the product used on cookware and other
fluoropolymers possess special electrical properties and have a high
resistance to solvents, acids and bases. These and other characteristics
make fluoropolymers ideal materials used in the manufacture of wire and
cable products.
- Current
Capacity of Copper Conductors
CAN-do Cable Solutions for Many Applications - Previously, automobiles utilized harnesses (many wires wrapped together) to directly wire individual devices, such as a brake pedal to the brake lights, creating a jumble of wires throughout the vehicle. Using as few as two wires, a CAN system connects the engine management ECU with other ECUs for controlling the transmission, airbags, antilock brakes, automatic windows and other electronic devices. Using a CAN system improves functionality, diagnostics and monitoring capabilities while providing greater reliability due to fewer needed wires and connections. Thanks to Northwire.
Cool "Techie Website" - WolframAlpha is sponsored by Stephen Wolfram who developed Mathematica - the scientific software program used in colleges all over the country. It is effectively the GOOGLE for SCIENTISTS. Simple word queries can be useful in getting answers to everything.
Emergency Stops – Make sure yours Comply - As Emergency Stops are the last line of defence in machine safety it is imperative that they operate correctly when/if required. So what are some of the things you can do to ensure the E-Stop will work when called upon? This technical paper takes a detailed look at the different types of Emergency Stop Devices and what you can do to ensure their effectiveness. Thanks to our sponsor Pilz Australia.
The following links to Electrical Equipment
in Hazardous Areas basic information plus links to a series of incidents on
video are from EPEE
Consulting
- Gases
and Vapours
- Combustible
Dust
- Flammable
/ Combustible Liquids
Thanks to Pilz
Australia ICEweb's Manufacturing
and Automation Safety Page has been updated to include the following
useful technical papers;
- Safety
Blows the Wind - Wind turbines fall under the scope of the Machinery
Directive - The revised version of the Machinery Directive 2006/42/EC comes
into force on 29.12.2009. Even wind turbine manufacturers will be required
to deal with the new Machinery Directive because, by definition, a wind
turbine is a functional machine, and as such it falls within the scope of
the Machinery Directive.
- Safety
Compendium - For the application of functional safety standards - The
primary purpose of safety technology on and in machinery is to protect
people from potential hazards. At the same time it protects the environment
and the actual machine from harm.The new safety compendium is aimed at all
those in mechanical engineering who deal with the issue of functional safety
and all its associated aspects. The compendium is intended as an orientation
guide for the application of functional safety standards. View the
compendium for free here.
- Safety
of machinery - Notes on the application of standards EN 62061 and EN ISO
13849-1- Are you a machine manufacturer or system integrator? Do you
upgrade machinery? This is what you need to consider in future in terms of
functional safety! What do you need to do to place a machine on the market
in compliance with the directives? The EU Machinery Directive stipulates
that machinery should not present a risk (risk assessment in accordance with
EN 1050 or EN ISO 14121-1). Given that there is no such thing as zero risk
in technology, the aim is to achieve an acceptable residual risk. This
technical article compares the two standards. From Siemens.
- IEC/EN
62061 "Safety of Machinery – Functional Safety of Safety-related
Electrical, Electronic and Programmable Electronic Control Systems"
- Some useful notes on this standard.
- Selecting
Protective Devices - Standard EN ISO 12100-2 notes on selecting protective
devices - If the hazards cannot be prevented or sufficiently limited by
constructive measures, protective devices must be planned and provided. The
selection of a suitable protective device must be made either in accordance
with an existing machine specific provision, e.g. a European C-standard, or
on the basis of a risk assessment of the respective machine.
- Guarding
with opto-electronic protective devices IEC TS 62046 "Safety of
machinery – Application of protective equipment to detect the presence of
persons" contains basic information for selecting, applying, connecting
and putting active opto-electronic protective devices and pressure-sensitive
Safety Mats into operation. It addresses the authors of machine-specific
C-standards, designers, test centres and anyone that is involved with the
professional installation of such protective devices. The information refers
to the recommendations of IEC TS 62046 as the international state of
technology. In principle to be observed with priority: the operating
instructions of the protective devices, regional regulations or machine-
specific standards.
- Selecting
and applying opto-electronic protective - The steps required in
accordance with the standards.
- Calculating
safety distance - Opto-electronic protective devices can only perform
their protective function if they are installed with a sufficient safety
distance from the nearest point of operation. The safety distance from the
protective device to the point of operation must big enough that the
dangerous movement will have stopped before a part of the person’s body
can reach the point of operation. This note refers to the calculation
formulas of ISO 13855/EN 999 "Safety of machinery – Positioning of
protective equipment with respect to the approach speeds of parts of the
human body" and the recommendations of IEC TS 62046.
- Calculation
safety distance, right-angle approach - Calculation formula for the
minimum safety distance for AOPD with right-angle approach (point of
operation guarding).
- Calculation
safety distance, parallel approach - Calculation formula for the minimum
safety distance for AOPD with parallel approach (danger area guarding).
- Calculation
safety distance, access guarding - Calculation formula for the minimum
safety distance of Multiple Light Beam Safety Devices for access guarding.
- US
specifications for safety distance calculation - The U.S. Code of
Federal Regulations, Volume 29, Part 1910, Subpart 0 defines the calculation
of the minimum safety distance of a protective device. OSHA 1910.217
requires that with the installation of a Safety Light Curtain a minimum
distance, which corresponds with the prescribed distance of a hard guard, is
observed in every case (see OSHA 1910.217, table 0-10). If the safety
distance calculation results in a greater value, this must be used.
- Guarding
with hard guards - A note on guarding with hard guards (fence heights,
fixing instructions, safety distances, etc.)
- Fixed
hard guards - Fixed hard guards can always be used when the access to
the danger area is not required during the normal operation. These include
protective fences, barriers, fixed covers, etc. Fixed hard guards are also
frequently used in combination with opto-electronic protective devices as
supplementary protective devices. EN ISO 12100-2 requires that fixed hard
guards must be firmly held in their place with constructive measures.
- Movable
hard guards - If the access to the danger area is required during the
normal operation or for maintenance work, active opto-electronic protective
devices, such as Safety Light Curtains or moveable hard guards such as
protective doors or flaps, must be used. This kinds of movable protective
devices must be position monitored via safety switches or safety guard
interlocking, and electrically connected with the control unit (for further
requirements see EN ISO 12100-2).
- Machine Safety in the EU and USA
Thanks to Samson
Controls Australia ICEweb's Control
Valve page has been updated to include the following useful information;
The
Plant Maintenance Resource Center has some very useful links on Control
Valves including;
- Control
Valve Actuator Operating Modes - Details on fail safe conditions, fail
closed and fail open.
- Control
Valve Concepts - Control Valves Do What They Are Told!
- Control
Valve Flow Characteristics - Trim design will affect how the valve
capacity changes as the valve moves through its complete travel. Because of
the variation in trim design, many valves are not linear in nature. THE
RELATIONSHIP BETWEEN VALVE CAPACITY AND VALVE TRAVEL IS KNOWN AS THE FLOW
CHARACTERISTIC OF THE VALVE. Valve trims are specially designed, or
characterized, in order to meet the large variety of control application
needs. This is necessary because most control loops have some inherent
nonlinearities, which you can compensate for when selecting control valve
trim.
- Control
Valve Packing - Packing is a sealing system which normally consists of a
deformable material such as TFE, graphite, asbestos, Kalrez, etc. Usually
the material is in the form of solid or split rings contained in a packing
box. Packing material is compressed to provide an effective pressure seal
between the fluid in the valve body and the outside atmosphere.
- Control
Valve Seat Leakage Classifications - There are actually six different
seat leakage classifications as defined by ANSI/FCI 70-2-1976. But for the
most part you will be concerned with just two of them: CLASS IV and CLASS
VI. CLASS IV is also known as METAL TO METAL. It is the kind of leakage rate
you can expect from a valve with a metal plug and metal seat. CLASS VI is
known as a SOFT SEAT classification. SOFT SEAT VALVES are those where either
the plug or seat or both are made from some kind of composition material
such as Teflon.
- Control
Valve Terminology - A comprehensive terminology list.
- Control
Valve Tips & Tricks - An excellent list of useful tips and tricks
for the control valve user.
- Control
Valves - Flow Recovery Coefficient
- Control
Valves - Pressure Recovery Factor
- Improving
Valve Life and Operating Efficiency The Easy Way - John C.
Robertson - Eight often-overlooked valve maintenance basics.
- Use
of Ultrasonic Analysis in the Testing of Isolating Valves - Offshore
installations use a series of isolation valves to divert the flows from the
various pumps. One of the main reasons a pump test can "fail", is
if the isolating valves are passing. This article describes testing the
isolating valves using ultrasonic analysis. Overhaul of an isolating valve
costs significantly less than undertaking an unnecessary pump major
overhaul.
- Valve
Positioners - Some general but useful information on valve positioners.
- Positioner
and Actuator Operating Modes - The terms "direct" and
"reverse" are frequently used when discussing control valves,
positioners, and controllers. While the definitions of direct and reverse
seem pretty straightforward, they cause quite a bit of confusion -
especially when split-ranging is done.
- Your
Best Bet in Control Valves - Hans Bauman - Control valves may be the
most important, but sometimes the most neglected, part of a control loop.
The reason is usually the instrument engineer’s unfamiliarity with the
facets, terminologies, and areas of engineering disciplines, such as fluid
mechanics, metallurgy, noise control, and piping and vessel design that can
be involved depending on the severity of service conditions - From ISA and
InTech.
- Determine
the Characteristic Curve of an Installed Control Valve - Jeff Sines -
The performance of a control valve is defined by its inherent and installed
characteristic curves. The inherent characteristic curve is a plot of the
percent of valve opening vs. the percent of maximum flow coefficient (CV).
The inherent characteristic curve is determined by measuring the flow rate
at various positions of valve travel with a fixed differential pressure
across the valve (typically 1 psid) and calculating the CV at each position
using a form of the generalized Control Valve CV equation - From Engineered
Software.
Fire and Gas Detection Mapping - Computer aided design to increase safety and reduce cost - Kevin Keefe - Using highly developed assessment methods together with custom software the flame detection assessment, gas detection assessment and heat detection assessment packages are able to review and assess arrangements from initial designs through construction and onto existing installation. The assessments are used to optimise and validate designs and maybe used in formal safety studies - from Micropack. ( Go to page 20)
Fire Protection adds Value to Offshore Project Planning - Larry Watrous - The importance of fire protection in the design and construction of offshore structures can be a critical factor in the success of today’s offshore oil and gas projects. Integrating this component into the planning of a production facility is taking on increasing importance. This article addresses the changing needs and expectations, scope of equipment and services, and regulation in the fire protection discipline, as well as the capabilities and roles of the fire protection professional. The article further emphasizes the timing necessary for implementing a formal fire protection program in the design and construction of new offshore structures or the revamping of existing facilities, and the need for the expertise of a trained fire protection engineer to be involved with the development of all phases of these projects - from Mustang Engineering.
Design Engineering Key to Adequate Fire Protection - Larry Watrous - This article has useful tips on the skills required of a Fire Protection Engineer - from Mustang Engineering.
Posted by: Jim Russell, December 2009
This is a pretty "neat" concept - Tuning the Forgotten Loop - We can tune PID controllers, but what about tuning the operator? - Steve Rubin - The purpose of tuning loops is to reduce errors and thus provide more efficient operation that returns quickly to steady-state efficiency after upsets, errors or changes in load. State-of-the-art manufacturers in process and discrete industries have invested in advanced control software, manufacturing execution software and modeling software to “tune” everything from control loops to supply chains, thus driving higher quality and productivity. The “forgotten loop” has been the operator, who is typically trained to “average” parameters to run adequately under most steady-state conditions. “Advanced tuning” of the operator could yield even better outputs, with higher quality, fewer errors and a wider response to fluctuating operating conditions. This paper explores the issue of improving operator actions, and a method for doing so.
Operators on alert - Operator response, alarm standards, protection layers keys to safe plants - David Hatch and Todd Stauffer - As plants run closer to their performance limits with fewer operators and support staff, alarm management is becoming paramount to maintaining plant safety. The key to maximizing the safety protection the operator provides is creating an environment where they are able to detect, diagnose, and respond to alarms properly and on time. One way to do this is adopt the requirements and recommendations of the standard on alarm management (ANSI\ISA-18.2 standard, Management of Alarm Systems for the Process Industries) and take a coordinated approach to alarm management and safety instrumented system (SIS) design. The ANSI\ISA-18.2 standard offers guidance on how alarm management can help a plant operate more safely. The standard can also bring together the disciplines of alarm management and safety-system design, which must work more closely to prevent future accidents. Thanks to InTech and ISA.
HIMA
Australia are running the following courses;
- TÜV Functional Safety Program
Perth
29 June- 2 July 2010
- Analysis & Design of SIS Course
- The objective of this course is to provide engineers with the functional
safety knowledge required to analyse and design safety instrumented systems for
the process industry in compliance with the analysis and realisation phases of
the AS 61511 safety lifecycle.
Melbourne
2 February 2010, Darwin
23 February, Perth
20 April , Adelaide
27 April, Brisbane
8 June .
- Operation & Maintenance of SIS Course
- The objective of this course is to provide operations and maintenance
personnel with the functional safety knowledge required to operate and maintain
any safety instrumented system such that the designated functional safety is
maintained throughout the operation and maintenance phase of the AS 61511 safety
lifecycle.
Melbourne
3 February 2010, Darwin
24 February, Perth
21 April, Adelaide
28 April, Brisbane
9 June .
- Electronic Machine Guarding - This training course is designed for
electrical workers who design, modify, service and commission machines with
electrical safeguards. From concept to commissioning, and well into the
operational phase of a device, participants will have the skills and knowledge
to comprehend and solve most machine safety problems.
Melbourne
16-17 February 2010, Melbourne
16-17 March, Adelaide
4-5 May
- HIQuad Maintenance Course
Perth
9-10 March 2010
- HIMatrix Engineering Project Development
Perth
30 March – 1 April 2010
- HIQuad Advanced System Training
Perth
13-16 April 2010
Shutoff Valves - This paper from Mokveld highlights the HIPS applications.
Instrumented
Protection Systems – HIPPS, High Integrity Pressure Protection Systems
- High Integrity Pressure Protection Systems (HIPPS) are used to reduce the
risk that a system can exceed its design pressure to a tolerable level.
Conventional design standards applied in the oil and gas industry stipulate
that final protection of piping and pressure vessels against
over-pressurisation shall be provided by means of mechanical relief devices.
Sometimes the use of these devices, like relief valves, is undesirable or
impossible. Instrumented protection systems provide a technically sound and
economically more attractive solution to this problem in situations where:
- Extremely high-pressures, or flow rates are processed.
- Environmental constraints or restrictions limit the use of conventional
relief systems.
- The economic viability of a development needs improvement.
- The risk profile of the plant must be further reduced.
High Integrity Protection Systems (HIPS) for Flare Load Mitigation - Angela E. Summers, Ph.D., P.E., President, SIS-TECH Solutions, LLC - The American Petroleum Institute (API) and American Society of Mechanical Engineers (ASME) provide criteria for the protection of vessels and pipelines from excess pressure. In conventional design, a Pressure Relief Valve (PRV) is used as the primary means of protection, and a flare is used to safely combust the gases relieved during an overpressure event. Although conventional, the use of a PRV is sometimes an unattractive proposition, particularly where the pressure relief involves a large flare load. API 521 and Code Case 2211 of ASME Section VIII, Division 1 and 2 allow the use of an SIS in lieu of a PRV as long as the SIS meets or exceeds the protection that would have been provided by the PRV. As an SIS, the design must follow the safety lifecycle provided in the United States standard ANSI/ISA 84.01-1996 or the international standard IEC 61511. The required risk reduction results in the need for high SIS safety availability; therefore, these systems are often called High Integrity Protection Systems (HIPS)
Posted by: Jim Russell, November 2009
Applications in the Oil and Gas Industry - This application bulletin illustrates the practical concepts and special features in both the upstream and downstream sectors of the oil and gas industries - Thanks to our valued sponsor Weidmuller Australia.
U Tube Videos - There are a useful
series of videos on U Tube giving examples of how to connect using
Weidmuller terminals:
Screw
Type Terminal Blocks W-Series
Tension
Type Terminal Blocks Z-Series
IDC
Type Terminal Blocks I-Series
Push-In
Type Terminal Blocks P-Series
Electrical Cabinet Construction - Lots of examples and technical information along with some innovative solutions are detailed - Thanks to our valued sponsor Weidmuller Australia.
Keep Your RF at Home - Jud Strock - Your product design is underway, and you expect to have a prototype completed in two months. That will be soon enough to start thinking about EMC, and a good enclosure will solve all of your EMC problems. Right? Absolutely not. The enclosure is an integral part of your product, and the time to choose an enclosure is at the very beginning of the design cycle - thanks to Evaluation Engineering.
Typical Instrument Enclosure Specification - This document highlights the typical items that need to be considered when specifying an enclosure. From INTERTEC Instrumentation.
Addressable Gas Detection Systems - Analogue Gas detection systems serve many applications and are installed across the whole spectrum of industry. These systems have provided solutions to monitoring problems for many years gathering information on changing levels of gas for trending and logging applications or as part of safety warning/shutdown systems for Toxic and Flammable gas applications. From Extronics.
Wireless Considerations in Hazardous Areas
Resilient
Wireless Ethernet on an FPSO - The need to provide Ethernet connectivity
to locations round production plant or other facilities is becoming more
common place due to the fact that most modern control and instrumentation
equipment is now supplied with an Ethernet interface as the primary means of
communicating with the device. In many cases it is simply a matter of
running an Ethernet cable from the switch to the device as this more often
than not provides power as well using the 802.3af POE standard. From
Extronics.
Making
Safe Waves in Hazardous Areas White Paper - As wireless devices such as
mobile phones and laptop computers become more reliable and cost effective,
there is growing interest amongst the process industry as to the benefits to
be found from enabling such devices to be used in hazardous areas. However,
unlike most industries this is not a simple task. Installing wireless
networks in hazardous areas requires careful, expert planning and execution.
From Extronics.
Wireless Technologies take Personnel Safety in the Process Industries to a New Level - In modern times the Process Industries have implemented many strategies to improve the operational safety of plants to protect personnel and the surrounding environment, to the extent that accidents are thankfully few and far between. From Extronics.
The Following are available from Proctor
Machine Guarding - A short registration process is required to access them
but it is worth it.
Risk
Assessment Calculator (XLS) - A free Risk
Assessment Calculator that is based on the requirements of BS EN 1050, the
standard for machinery risk assessments. Designed to be easy to use, the
Risk Assessment Calculator incorporates checklists and look-up tables to
enable risk assessments to be carried out on almost any static machinery. A
Hazard Rating Number (HRN) and Risk Level are calculated automatically for
each identified hazard, thereby indicating at-a-glance where users should
consider taking action. The Risk Assessment Calculator is based on a
Microsoft Excel spreadsheet, though very little knowledge of this software
package is required in order to use the tool. All of the calculations are
handled automatically, leaving the user to enter the data and decide on the
values to use for 'Likelihood of Occurrence', 'Frequency of Exposure',
'Degree of Possible Harm' and the 'Number of Persons at Risk' using the
guides provided.
Free
Guide to Machinery Guarding Standards - A free guide to machinery
guarding standards. Available as a PDF document that can be printed by the
recipient, this guide is the second edition of the hugely popular 'On Your
Guard', updated to reflect changes in standards and with additional
references to conveyor guarding.
Workshop
Safety Free Guide - A free guide to workshop safety that will benefit
anyone responsible for the safety of machinery and work equipment. The
guide covers the folllowing topics: costs and benefits; regulations and
legislation; general requirements for machine guards; specific machine
types; other measures relating to machinery safety; standard; official
information and guidance; useful resources; and sources of further
information.
Machine
Accident Investigation Kit - a free Machine Accident Investigation Kit
that will help small and medium-sized manufacturing companies perform
investigations so that they meet their statutory obligations and prevent
similar accidents from occurring in the future.
Safety
Distance Calculator (XLS) - a free Safety Distance Calculator for
establishing the required safety distances and heights of machine guards in
accordance with BS EN 294, Safety of machinery - Safety distances to prevent
danger zones being reached by the upper limbs.
Guide
to the new Machinery Directive -On 29 December 2009 the existing
Machinery Directive will be replaced by a new Directive 2006/42/EC, which
has important implications for companies building or importing machinery for
use in the European Economic Area. Procter Machine Guarding is offering a
free 'Guide to the New Machinery Directive' to help companies prepare for
the new regime. Although the main thrust of the new Directive is
simplification and clarification - especially with regard to relationships
with other Directives - there are other changes that will have a significant
impact. In this third amendment of the Machinery Directive, alterations have
been made in respect of the scope, partly-completed machinery, fixed guards,
conformity assessment procedures, enforcement and other areas.
FREE
White Paper: new Machinery Directive and Fixings for Fixed Guards - The
new Machinery Directive 2006/42/EC and the latest edition of the guarding
standard BS EN 953 include a requirement for fixings for fixed guards to
remain attached when the guards are removed. This white paper explains
the requirement and provides information to help designers select fasteners
for particular guarding applications. Useful design tips will also
help to minimise the costs associated with installing captive
fasteners.
What is Conformity assessment? - Conformity Assessment is defined as "activity that provides demonstration that specified requirements relating to a product, process, system, person or body are fulfilled."
What is CASS? - Accredited Certification for Safety Systems - to IEC 61508 and Related Standards - CASS is a scheme for assessing the compliance of safety related systems with the requirements of IEC 61508 and associated standards. It provides a systematic approach to be used by certification bodies and others when assessing compliance at all stages from the specification of safety requirements through the design, development and manufacture of system components to integration, commissioning, operation and maintenance. At each stage CASS takes the conformity assessor through the logical steps of defining the scope of the assessment, the target of evaluation, the requirements to be met and the process of demonstrating and recording conformity.
Legacy Systems - Basic Principles for Safety - Engineered systems are relied upon for safety in a wide range of work environments. There is however, a general lack of awareness of the exact role played by such systems, and whether adequate safety is, in fact, being achieved. This is particularly true of systems that have been in place for many years. This document describes how to assess the capability of so called Legacy Systems, focussing on how electrical, electronic, or programmable devices achieve adequate safety in conjunction with other technologies such as mechanical systems and operational expectations.
Toolbox
Talks - This excellent page from the 61508
Association gives you the essential toolbox tips in just a few sheets
that will help your team to all be “singing from the same hymn sheet”
which covers:
• Directors
• Senior
Management
• Purchaser
• Project
Manager
• Project
Engineer
• Inspection
and QA
• Operations
• Maintenance
• Service
Engineer
• What
is Functional Safety Management
• Proven in use / Prior use claims
• Functional
Safety Management cross-reference
between IEC61508 and IEC61511
Improving PID Controller Performance - Proportional integral derivative (PID) control is the most commonly used control algorithm in the industry today. PID controller popularity can be attributed to the controller’s effectiveness in a wide range of operation conditions, its functional simplicity, and the ease with which engineers can implement it using current computer technology. This paper covers some of the PID drawbacks and how to resolve them while improving performance in current implementations through changes in the algorithm - from National Instruments.
The following calibration links are from
Dickson
Are
All Metrology Labs Alike? - Short answer – NO!!! In fact, to those of
us in the industry who truly know what it takes to recalibrate instruments
to objectively defined standards, a better question might be— Are you
using the equivalent of a meat thermometer to validate conditions in your
processing plant or laboratories?
“Before”
Calibrations Count More than Many Think - As most know,
temperature and humidity dataloggers and chart recorders need to be
recalibrated periodically to ensure this accuracy, and competent quality
managers need to establish schedules for recalibrations that reflect due
diligence to monitor that temperatures and humidity are kept within
acceptable and pre-defined tolerances. But "recalibration" can
mean different things, and what could be termed "recalibration on the
cheap" does NOT demonstrate the accuracy of your recorded data
(instruments).
Monitoring
Revisited - While
most pharmaceutical quality managers realize the importance of temperature
and humidity tracking to guarantee both quality and compliance, the way in
which many go about it is adding hidden costs. Technology for
temperature/humidity tracking continues to evolve, and there are numerous
time-saving features in recent temperature/humidity data loggers that can
make a difference. On one hand, some quality managers are doing too much to
track temperature /humidity data, while on the other hand some are doing too
little. For many, it’s timely to revisit temperature and humidity
monitoring. Here are some key points to consider.
Monitoring
Temperature and Humidity - Monitoring temperature and/or humidity
conditions is an essential ingredient of a wide range of quality assurance
applications. There are many common methodological errors, however, in ways
that this task is approached that either compromise quality standards or add
unnecessary time and expense to the monitoring task. Insufficient
calibration of temperature and humidity monitoring instruments is high on
the list of problematic areas. Mismatching technology to the monitoring task
at hand is another problematic area. This article revisits technology trends
in monitoring instrumentation, provide tips on calibration and discuss
common methodological errors that quality managers should avoid.
Calibrate
- How Often? - This article details the various calibration steps.
Get
Before Data - Before data (a.k.a. "as received data")
documents the accuracy of your data logger or chart recorder before it is
calibrated. When your instrument is re-calibrated it is returned to original
specifications. You cannot retroactively obtain "before" data.
1-Point,
3-Point, or Custom Point? - Choosing between 1-Point, 3-Point and Custom
Point Calibrations is very straightforward when you know how calibration
REALLY works...
Calibration
Glossary - A useful glossary explaining calibration terms.
Maritime Security: Meeting Threats to the Offshore Oil and Gas Industry - This paper covers challenges faced by the oil & gas industry in securing its vital offshore production assets. It discusses key requirements for an effective platform security strategy, and describes the latest technology enabling an integrated security management system - from Honeywell.
The following papers are available thanks to Apex
Optimisation, see more on ICEweb's Control
Systems Page.
Experience
with “Grey Box” Modelling and Optimisation of Refinery Processes - An
Rigden, Henrik Terndrup and Marco Smaling. This paper discusses experience with
an alternative approach to process modelling and realtime optimisation at the
Chevron refinery at Pembroke, UK and focuses primarily on the optimisation of
the Heat Exchange Network of the crude unit as an example of the modelling and
real time optimisation of non-linear systems using a “grey box” modelling
approach. Thanks to Apex Optimisation.
Timely
Advanced Control Upgrades: Recapture and Multiply Benefits
- Andrew Taylor - This
paper discusses the establishment of Advanced Process Control (APC) in
refining, petrochemical and oil &
gas production facilities and the various mechanisms which dictate the
lifecycle of an APC application. The
benefits of appropriate APC upgrades are examined with the key elements of a variety of case studies highlighted. The case
studies cited include an APC technology upgrade and various
APC revamps following process context changes (e.g. clean fuels refinery
upgrades). The key elements in an APC
lifecycle management program are proposed. from ProSys Engineering.
Modern
Advanced Control Pays Back Rapidly - From Hydrocarbon Processing
Optimize
Surge Vessel Control - From Hydrocarbon Processing
Refinery
Fuel System Control and Optimisation - Pavlos Ioakimidis, Henrik Terndrup,
Andrew Trenchard - This paper discusses an application of Honeywell’s Robust
Multivariable Predictive Control Technology (RMPCT) to the control and
optimisation of a refinery fuel system. A plant-wide fuel system application was
commissioned in August 2003 and has delivered significant financial and
operational benefits.
LPG
Fractionation Unit Advanced Control Revamp - Woodside Energy Ltd and ProSys
Engineering Pty Ltd - WEL are mature users of advanced process control
technology with a decade of experience in use of Multivariable Predictive
Control (MPC) technology. This technology uses a dynamic process model coupled
with an embedded optimiser to control multiple input – multiple output
systems. Use of MPC has delivered substantial economic benefits to WEL’s
bottom line and set the company apart from most of their Oil & Gas peers.
Seven MPC applications were commissioned on the Fractionation Unit in early 1997
with an immediate improvement in process stability and profitability. With
gradual change in the process conditions due to throughput increases, the
performance of the MPC had deteriorated. In addition, with the prospect of LPG
production losses being suffered due to Fractionation Unit capacity constraints,
a review of the MPC design with a capacity maximisation focus in mind was
appropriate.
Real
Time Optimisation of Ultra Low Sulphur Diesel Production -Francisco Arista,
Andres Porcel, Pedro Villar, Henrik Terndrup,Marco Smaling - This paper
discusses the experience with real time optimisation of the production of Ultra
Low Sulphur Diesel at CEPSA’s Huelva La Rabida refinery and describes how
these functionalities are integrated as well as some novel techniques used for
the modelling and optimisation of this relatively complex system.
Condensate
Stabiliser MPC Revamp - Most MPC technologies use dynamic process models
coupled with embedded optimisers to control multiple input – multiple output
systems. Dynamic process model accuracy is the proverbial Achilles’ heel of
any MPC application, as model mismatch is the main cause for MPC application
performance degradation. The challenge, however, is often to determine the
causes of the model mismatch. The Stabiliser MPC applications at the Karratha
Gas Plant suffered similar performance degradation problems and the performance
of the applications has gradually degraded over the last few years to the point
where the service factor of the applications had dropped significantly. This was
particularly evident during the summer months when the applications were not
maximising feed rates. ProSys Engineering Pty Ltd now Apex Optimisation assisted
with review and revamp the MPC applications on the Stabiliser trains, this paper
discusses this.
Moomba
Gas Plant Throughput Maximisation - This paper discusses process control
improvement at the Santos Moomba site. One of the initial objectives was to
maximise plant throughput capacity and this was pursued via three primary
mechanisms:
(1) Minimising DP across the CO2 removal trains;
(2) Minimising the LRP inlet pressure in order to facilitate a plant inlet
pressure reduction. This provides immediate production improvement from all
field compressors and provides an improved basis for reconfiguration of the
reciprocating compressors to deliver more flow at constant power (and reduced
field to plant inlet DP).
(3) Using the SWQ pipeline surge capacity to dynamically reduce feed gas supply
to Moomba without reducing the production rate at Ballera. This helps eliminate
spikes of high Moomba inlet pressure which would otherwise result in field
compressor high discharge pressure trips.
Advanced
Process Control Boosts Plant Performance - Andrew Taylor, Daniel Duff y and
Randall Yeates - This article describes an initiative undertaken by Santos and
Apex Optimisation to improve the profitability and operability of the Port
Bonython liquid hydrocarbons processing plant in South Australia through
multivariable predictive control (MPC).
Precipitation
Tanks – Multivariable Predictive Control Magic - This paper discusses a
project to minimise the potential for overflow incidents at an Aluminium
refinery.
Honeywell Analytics Gas Book - This updated handbook is intended to offer a simple guide to anyone considering the use of gas detection equipment. It provides an explanation of both the principles involved and the instrumentation needed for satisfactory protection of personnel, plant and environment. The aim has been to answer as many as possible of the most commonly asked questions about the selection and use of industrial gas detection equipment.
Gas Hazards & Areas - This technical article covers Flammable Gas Hazards, Flammable Limit, Flammable Gas Properties, Flammable Gases Data , Toxic Gas Hazards, Hygiene Monitoring, Toxic Exposure Limits, Toxic Gases Data, Asphyxiant (Oxygen Deficiency) Hazard, Oxygen Enrichment, and Typical Areas that Require Gas Detection.
Principles of Gas Detection - This technical article covers Combustible Gas Sensors, Catalytic Sensor, Sensor Output, Speed of Response , Calibration, Semiconductor Sensor, Thermal Conductivity, Infrared Gas Detector, Open Path Flammable Infrared Gas Detector, Electrochemical Sensor, Chemcassette® Sensor and Comparison of Gas Detection Techniques.
Gas Detection Systems - This technical article covers Cables and Junction Boxes, Location of Sensors, Typical Sensor Mounting Options, Typical System Configurations, Installation Methods.
Certification & Classification - Covers European and Rest of World Hazardous Area Standards and Approvals, ATEX, Equipment Markings, Area Classification, Apparatus Design, Apparatus Classification, Ingress Protection of Enclosures and Safety Integrity Levels (SIL).
www.jobrapido.com.au - Jobrapido enables you to search through over 150,000 jobs posted on job boards, recruitment agencies and company websites. Looking for a job? See ICEweb's employment pages.
Posted by: Jim Russell, October 2009
Metal
Lathes - Can they be made Safe? -
Frank Schrever
-
How can these risks be minimised? A simple interlocked
chuck guard connected via a Category 4 control system in accordance with
AS4024.1 that prevents the machine from starting while open, will remove or
significantly reduce most lathe safety risks.
Advice For Maintaining Hydraulic Accumulators - Brendan Casey - Gas-charged accumulators are ubiquitous on modern hydraulic systems. They carry out numerous functions, which include energy storage and reserve, leakage and thermal compensation, shock absorption, and energy recovery. While accumulators present a number of advantages in hydraulic system operation and can provide many years of trouble-free service, they are a maintenance item. From machinerylubrication.com
Industrial
Ethernet Handbook for Engineers - Engineers working to understand the
nuances of Ethernet topologies, interconnection schemes, and application
guidelines will find HARTING’s Industrial Ethernet Handbook a valuable
engineering reference source. The detailed, 168-page handbook covers the
technical details of Ethernet, comparing it to other fieldbus systems, and
explaining its Open System Interconnection (ISO/OSI) Reference Model. Its
Annex details pertinent standards and application guidelines, such as EN,
IEEE, IEC, UL, and HD/VDE. This Annex also contains an extensive
bibliography on fieldbus and Ethernet technology, along with Internet links
to other resources.
The HARTING Handbook explains:
• Open System Interconnection (ISO/OSI) Reference Model
• Comparison of Ethernet to other fieldbus systems
• Power over Ethernet (PoE) connectivity
• 26-page glossary of terms/acronyms
Save Money with Best Practices and an Energy Inspection Checklist - With the economic downturn, many facility managers are facing very tight operation and maintenance budgets. Luckily, many facilities are sitting on multiple energy conservation opportunities that can save thousands of dollars per year with relatively little capital investment. From Fluke.
Engineering Careers for 2009 - Growing technology in the world means that careers in engineering have a bright future. Some ups and downs can slow down the growth but the trend of development will continue and engineers will have new career opportunities every day. Thanks to IDC Technologies.
Job Interviews Made Easy - Great tips for job interviews, just take the time to read this and it might make the "difference". Thanks to IDC Technologies.
Expertune has a fantastic Library
of Articles and White papers covering:
- Control
Loop Monitoring
- Basic
PID Tutorials
- Recorded Webinars
- PID
Loop Optimization
- Video
Presentations
The 7 Habits of Highly Successful Controls Engineers - George Buckbee - Highly successful control engineers didn’t become that way by accident. The most successful engineers develop habits that improve results and recognition of those results. This paper addresses specific habits that you can develop or enhance to be more successful. From ExperTune, Inc.
Wireless Networking in Plant -Dick Caro - The advantages of a mesh network are redundancy, increased total distance, and removal of the line-of-sight restriction. The reduced cost of Ethernet-based networks is driving this fast, low-level, and low-cost technology to the field and shop floor. Another Ethernet side effect is the application of wireless technology in the Wi-Fi group of wireless protocols. Wi-Fi is essentially wireless Ethernet. Any higher-level application layer and user layer can communicate via Wi-Fi at data rates up to 600 Mbps, without knowledge of the fact that it is on a radio link. From the ISA and InTech.
A Technical Glossary of Pressure Regulator Terms has been added to our comprehensive Pressure Regulator Page. Thanks to ICEweb sponsor Emerson Process Management.
Baldor has released a software estimating tool that enables users to evaluate the energy efficiency of electric motors and variable speed drives. Known as BE$T, the Baldor Energy Savings Tool can be downloaded free of charge from the company’s website. The software analyses the efficiency and annual electricity usage of users’ existing motors, and calculates the cost savings that can be achieved by replacing them with equivalent higher efficiency models. Built-in motor performance and pricing information enables the software to suggest optimum replacements and to estimate the investment payback period.
Fieldbus Diagnostics latest Advancements Optimise Plant Asset Management - Stephen Mitschke - Since May 2006, the Fieldbus Foundation has been collaborating with NAMUR an international process industry end-user association based in Germany, on fieldbus performance enhancements such as device diagnostics, which both parties identified as requiring further clarification and guidance for the user community. A key objective of this collaborative effort is to unify the integration of fieldbus self-monitoring data to ensure the availability of valuable device diagnostic information to process plant personnel. Advancements in field diagnostics support a structured approach to asset management, which simplifies operators’ tasks and increases their confidence in utilizing equipment diagnostics and asset software.
The following additional technical information on the V-Cone flowmeter can be found on ICEweb's new look V-Cone page - thanks to our sponsor McCrometer .
Wet
Gas Metering with V-Cone - Dr. Richard Steven and Dr. RJW Peters -
With the industrial requirement to meter wet gas flows increasing worldwide
McCrometer has tested the performance of the single phase V-Cone meter (a
Differential Pressure (DP) type meter) in wet gas flows in both the NEL and
CEESI wet gas loops. These tests have shown how the V-Cone meter responds to
different amounts of liquid entrained in a gas flow and have enabled correction
factors to be developed.
API
22.2 Revised from API 5.7 -A Summary by Dr R.J.W. (Bob) Peters - McCrometer
V-Cone Meters Tested in Accordance with API 5.7 "Testing Protocol for
Differential Pressure Flow Measurement Devices" and Subsequently Further
Tested to meet the Additional Requirements of API 22 "Testing
Protocol" Section 2 – "Differential Pressure Flow Measurement
Devices" (a Revision of API 5.7 ).
Custody
Transfer Measurement with the V-Cone Flowmeter - Stephen A. Ifft - This
paper discusses the approval of the McCrometer V-Cone flowmeter for custody
transfer measurement in Canada.
V-Cone®,
An Alternative to Orifice Meter in Wet Gas Applications - Stephen A. Ifft -
This paper will discuss the use of the V-Cone differential pressure flowmeter to
measure the flow of wet gas. Wet gas flow measurement is gaining considerable
attention due to its importance in the oil and gas industry. Separator and
well-head flow lines are two examples where wet gas can occur in a production
system. Orifice plates have long been used for these applications. While orifice
plates offer good measurement in clean gas applications, an alternative is
needed that will provide better performance in the harsh environment of wet gas
flow.
Partially
Closed Valve Effects on the V-Cone Flowmeter - Stephen A. Ifft - Research
conducted indicates that the V-Cone flowmeter is less susceptible to upstream
flow disturbances than traditional flowmeters. This testing has placed
various flow disturbances upstream of the V-Cone including single elbows, double
elbows out-of-plane, valves, and swirl generators. In an effort to further
quantify the effects of partially closed valves on the V-Cone, McCrometer has
completed the first in a series of valve installation effects tests.
Permanent
Pressure Loss Comparison Among Various Flowmeter Technologies - Stephen A.
Ifft - This paper explores the issue of permanent pressure loss through various
types of flow metering technologies. Of particular interest is the V-Cone. The
V-Cone flowmeter is a differential pressure device produced by McCrometer,
Hemet, California, USA. By design, the V-Cone measures differential pressure
created by a cone positioned in the center of the pipe. The open area through
which the fluid passes is stretched over the edge of the cone. This annular
space appears to constrict flow dramatically compared to other metering
technologies. This paper compares the permanent pressure loss among meters in a
typical application.
Don’t
Let Valves Come Between You and Accurate Flow Measurement - Jim Panek -
Getting valves and flow meters to work together is sometimes a challenging task
within industrial water and wastewater applications. Valves tend to create the
kind of irregular media flow patterns in pipelines that make it a real challenge
to achieve accurate flow measurement of liquids, gas or steam. That’s why many
types of popular liquid flow meters require straight pipe runs. Unfortunately,
the nature of the process or the kind of space required for long straight runs
of pipe is often an impossible luxury in many of today’s plants.
Flow
Meter Research for APS Beam-Lines - Jeff T. Collins & Brian Batzka -
Many critical APS beam-line components, such as the photon shutters and fixed
masks, utilise porous media for heat transfer enhancement and consequently rely
on steady operation at design flow rates to ensure that the proper levels of
heat transfer enhancement are maintained. it is therefore necessary to ensure
that the flow metering system, which the component is interlocked on, has a high
degree of reliability.
Flowmeter
Smoothes City's Troubled Waters - An application note for the water
industry.
V-Cone
Coke Oven Gas Case Study - Flow monitoring of coke-oven gas is difficult due
to solids build up on interior surfaces. Heavy accumulation often renders
venturis, orifice and segmental orifice plates incapable of accurate flow
measurement. In addition, the pressure-sensing ports of venturi or orifice plate
flowmeters become plugged, making the readings of these primary differential
pressure devices difficult, if not impossible.
Wellhead
Metering Using V-Cone® Technology - This paper describes the McCrometer
V-cone D.P. meter as currently used by the Oil and Gas industry in the role of
wellhead injection and allocation metering in on-shore, topside and sub-sea
production applications.
The
Economic and Technical Justification for changing from a Nozzle Flow Meter to a
V-Cone Flow Meter on the outlet of a Steam Recovery Boiler in a Paper Plant
- A very large integrated Paper Plant desired to improve productivity of paper
production utilizing the existing equipment. The technical paper describes the
reasons why the Paper Plant considered the replacement of a flow meter on the
steam outlet of a Recovery Boiler.
Use
of V-Cone Fuel Flow Meter to Measure Coke Oven Gas & Natural Gas Flow in a
Combined Heat and Power Plant - Ann McIver and Dr. R.J.W. Peters - This
paper describes key aspects of the Citizens Thermal Energy district energy
system in Indianapolis. It will present the requirements imposed, through the
continuous emissions monitoring rules established by the Environmental
Protection Agency (EPA), as delineated in 40 CFR 75. The reason for the choice
of the V-Cone, which is not a fuel flow metering technology specifically
addressed in the regulations, will be presented and the tests required by the
EPA to enable the V-Cone to be accepted. The results of the flow tests in an
independent laboratory before and after a period in service will be given.
Signal
Noise Ratio Comparison for V-Cone and Orifice Plate Flowmeters - Stephen A.
Ifft - This paper discusses and compares the relative signal noise between the
V-Cone differential pressure flowmeter and a typical orifice plate differential
pressure flowmeter.
The
Power of Speed - One Company’s Journey towards Operational Excellence
-
CT76 Modular Substrate and Component System - This bulletin from ICEweb sponsor Circor describes why this is "State of the Art" for modular systems.
Rethink Sample System Automation - NeSSI provides new tools to tackle the challenges and improve performance - By Robert N. Dubois, consulting analytical specialist - Thanks to chemicalprocessing.com
Streamline Your Sampling System - Selecting the right stream selection assembly can improve performance - John Wawrowski, Doug Nordstrom and Joel Feldman - Thanks to chemicalprocessing.com
NeSSI™ Generation II Specification - A Conceptual and Functional Specification Describing the Use of Miniature, Modular Electrical Components for adaptation to the ANSI/ISA SP76 Substrate in Electrically Hazardous Environments - This functional and conceptual specification is based on the use of the miniaturized, modular analytical systems designed to the ANSI/ISA SP76.00.02-2002 standard substrate. This 2nd generation specification deals chiefly with integrating electrical components such as sensors and actuators (collectively referred to as transducers) onto the substrate in a manner suitable for use in electrically hazardous areas commonly found in petrochemical, refining and chemical facilities - Thanks to CPAC
Center
for Process Analytical Chemistry - CPAC,
established at the University of Washington in 1984, is a consortium of
Industrial, National Laboratory and Government Agency Sponsors addressing
multidisciplinary challenges in Process Analytical Technology (PAT) and
Process Control through fundamental and directed academic research. The
present CPAC program can be summarized by two main components;
(1) new measurement approaches including the miniaturization of traditional
instrumentation and the development of new sensors and non-traditional
instruments.
(2) mechanisms for interaction, collaboration, and communication of Center
activities, research programs, and information related to process analytical
technology (PAT) among
sponsors, other universities and academic departments, government agencies,
and the general measurement and control community. CPAC has an
established track record in fostering academic/industrial/national
laboratory interactions, which aim at bridging the gap between basic
research and full-scale process/product development.
Posted by: Jim Russell, September 2009
Relief Valve Orifice Sizes - This article details general relief valve information along with orifice sizes. Thanks to controlandinstrumentation.com.
Valve Configuration Goes Next Generation - Today’s Online Tools Ease the Valve Selection Process - Matt Migliore - The process of fluid handling systems design, like many engineering tasks, has changed drastically with the emergence of Internet-based business over the past 10-15 years. And perhaps nowhere is this evolutionary trend more evident today than in the area of valve specification, as the era of massive binders full of product data sheets makes way for a new generation of online tools aimed at streamlining the valve selection process - Thanks to our sponsor ASCO.
Gas to flare system ESV & ESD valves - This application note from Metso Automation describes the requirements.
Achieving
Redundant Intrinsically-Safe Fieldbus
Economic Case for Using FOUNDATION Technology - Modern DCS systems are major distributed networks with multiple data paths, which, in the interests of security and the highest plant availability, are almost always duplicated and made redundant. This article describes how FOUNDATION fieldbus systems can now incorporate redundancy and fault-tolerance right down to the H1 field layer. The major impact is on project ROI and plant revenues, and only FOUNDATION technology can offer this level of security and benefit to the plant operator - From the Fieldbus Report
Challenges of Temperature Sensing - Measuring each of the "big four" process variables has its specific peculiarities, but temperature seems particularly controversial. In fact, this apparently simple task often gets complicated. This tutorial explains why- from Control Engineering Magazine and Moore Industries-Pacific, Inc.
Emphasis on Safety - Rob Stockham, Moore Industries-Europe General Manager and safety expert, looks at the latest method being employed by the UK nuclear industry to access control systems in safety-related and safety-critical applications in power stations.
Ethernet Based Instrumentation - While extending Ethernet to a PLC or DCS I/O block is very common, the idea of using it to connect to individual process or discrete sensing devices is relatively rare. But is that assessment changing? In this article, Control Engineering magazine's Peter Welander discusses the role of Ethernet based instrumentation in device-level networks.- from Control Engineering and Moore Industries-Pacific, Inc.
Networked Safety- Mainstream or Marketing? Discussing the advantages and potential caveats of networked safety systems, and specifically the Fieldbus Foundation’s FF-SIF safety protocol, this article offers expert testimony and answers key questions about the technologies. Moore Industries’ Director of Technology, Charles Larson, contributes to the debate noting the considerable benefits of networked safety - from Automation World
Signal Isolators, Converters and Interfaces: The "Ins" and "Outs"- Parts 1 and 2 , This primer details how to select and use the correct signal isolator in the correct way to optimize your process. Learn about selecting isolators that share, split, boost, protect, step down, linearize and even digitize process signals- from Moore Industries-Pacific, Inc.
Fieldbus Installation - Short-Circuiting Fieldbus Installation Problems - Tim Wilson and Jeff Marsh - Like other process industry operations, bio-fuel production plants seek state-of-the-art automation technology in order to reduce raw material costs, increase yields, comply with regulatory standards and maximize revenues. However, plant managers must ensure control systems provide reliable operation and a low cost of ownership over the life of installed assets. Although modern, fieldbus-based process control systems offer many operational benefits, ethanol producers need effective measures to protect the fieldbus physical layer against short circuits, improper termination and other problems that can adversely affect system performance and reliability. They also need solutions enabling a quick ramp-up from installation to operation of the control system in order to improve their time to market - from Moore Industries-Pacific, Inc. and Control Global.
Relays Show Staying Power: As Their Control Capabilities Increase, Relays Encroach on PLCs - Jim McConahay contributes to this article outlining advantages of relays and programmable relays over PLCs. Relays have many electrical and safety advantages over PLCs, and programmable relays can outshine PLCs in real-time control and monitoring. From and Control Design.
Posted by: Jim Russell, August 2009
Breathe Easy - Darrell Leetham -For many organisations today, one aspect of the manufacturing process that needs to be monitored and controlled, for both efficiency and environmental benefit, is gaseous emissions - Plants are constantly looking for means to increase production and decrease costs. Increases in production are generally associated with an increase in fuel consumed and, in turn, a subsequent increase in emissions generated. In addition, regulatory entities are increasingly implementing standards and setting requirements for monitoring and reporting data on plant emissions. In order to improve efficiency throughout a manufacturing process and at the same time meet the needs of sustainable development goals, industry is finding an increased need for robust, reliable and accurate gas analysis methods. To meet the needs of this demand, different technologies for gaseous emissions sampling and analysis have been developed over the years. One particular technique is to extract a gas sample and dilute that sample prior to analysis. This article explains some advantages of the dilution extractive method. From Thermo Fisher Scientific and processonline.com.au.
What
a Mesh! Part 1 - The Ins and Outs Of Mesh Networking - Joel
K. Young - The first part of this two-part article discusses the basics:
what do you need to know about wireless mesh networking and what criteria
you should use when assessing a mesh networking technology.
What
a Mesh! Part 2—Networking Architectures and Protocols - Joel
K. Young - In
the second part of this two-part article we tackle network architectures and
compare and contrast point-to-multipoint, ZigBee PRO (ZigBee 2007), 6LoWPAN,
Wireless HART, and Digi Mesh networking protocols, laying out their key
characteristics, benefits, and limitations.
Both parts thanks to sensorsmag.com
and Digi International.
50 years: Online Gas Chromatograph - Stephen M Bostic & Dr Jerry M Clemons - The most prolific and flexible online analytical measurement device for analysing discrete hydrocarbons in the hydrocarbon processing industry (HPI) is the process gas chromatograph (GC). It is estimated that there are more than 30,000 process gas chromatographs installed worldwide- This article takes a look at the past, present and a glimpse of the future of the online process gas chromatograph. Thanks to ABB and PACE.
Making a Smart Wireless Decision - Wireless networks have become an essential part of communication in the last century. From the internet to mobile phones, this invisible technology is now one of the world's favourite buzz words. While consumers and commercial users tend to take immediate advantage of wireless technologies as they become available, industrial users have historically been a bit more cautious. This caution is generally due to concerns related to critical infrastructure security and reliability. However, if the right wireless solution is chosen, early adoptors of industrial wireless technology can have the best of both worlds – security and reliability while leveraging the efficiency and benefits of wireless technology - from Honeywell Process Solutions and PACE.
Test Lamp for Multispectrum Flame Detectors - This is a useful tool. Hazardous Area Certified Test Lamp a range of Multispectrum Optical Flame Detectors covering both IR3 and UV/IR detection range. The LT15 is a handheld flashing test lamp for functional test of optical flame detectors. The emission spectrum of the lamp covers both UV and IR detection range. The emission is modulated to simulate the typical flickering of flames. This allows testing of most UV, IR and UV/IR flame detectors as well as Simtronics range of MultiSpectrum Optical Flame Detectors (IR3 & UV/2IR) It is ATEX approved Ex d IICT6-T5 and suitable for operation in hazardous areas, (area 1 and 2) in accordance with the EN 60079-0 and EN 60079-1 (2004) standards. From ICEweb sponsor ProDetec.
Pressure Gauge Selection - When selecting a pressure gauge consideration should be given to a number of parameters which have an effect on gauge accuracy, safety, and utility - from McDaniel Controls.
Emergency Shutdown Valve Study - Industry Operating Experiences and Views; The Way Forward- John Peters - An older study but still very relevant. From the UK HSE.
Assessment of Valve Failures in the Offshore Oil & Gas Sector - John Peters - This comprehensive report describes the findings of an assessment study of data-set information regarding valve problems in the UK Offshore Oil & Gas Industry. It was undertaken by the National Engineering Laboratory, on behalf of the Offshore Division of Health & Safety Executive, as part of a wider initiative to reduce hydrocarbon releases. From the UK HSE.
Technology Status Report on Natural Gas Leak Detection in Pipelines - The reliable and timely detection of failure of any part of the pipeline is critical to ensure the reliability of the natural gas infrastructure. This report reviews the current status of the technology for leak detection from the natural gas pipelines. The first part briefly reviews various leak detection methods used in the natural gas pipelines. The second part reviews the optical methods used for natural gas leak detection, and the final part reviews the potential sensors that can be used with optical methods.
Analyse This - Todd Reeves - Many production problems can be averted with better information regarding the condition of pumping equipment. Route-based vibration monitoring systems contribute useful data, but they do not provide frequent enough coverage of critical motor-pump trains and other machines. However, a technology now exists to continuously monitor such equipment and identify process-induced machine anomalies before harm is done. From Emerson Process Management.
Optimising Process Equipment Performance - Todd Reeves - Advances in transmitters and related systems can maximise rotating equipment and pump reliability at minimum cost. These advances involve integration of online equipment monitoring with process control systems. From Emerson Process Management.
The Case for Condition Monitoring - What exactly is condition monitoring? How does it differ from other maintenance philosophies? And in what way does it impact the discipline of control engineering in the typical plant? Steve Sabin provides some answers. Thanks to Control Engineering Asia.
Accelerometer Selection Considerations - Jim Lally - This paper reviews sensor selection considerations involving two general types of piezoelectric sensors. High impedance, charge mode (PE) type and Integral Electronic Piezo Electric (referred to as IEPE) with a characteristic low impedance output. In addition to sensor electrical and physical characteristics, several factors play a role in the selection of an accelerometer for a specific application. These factors include environmental, operational, channel count and system compatibility considerations. From Davidson.
Condition Monitoring in the 21st Century - Sandy Dunn - This paper outlines some of the key business opportunities and issues which are driving change in the industry, summarise some of the resulting trends and then draws some conclusions regarding the implications of these trends for Condition Monitoring equipment manufacturers and suppliers, Condition Monitoring contractors, and organisations employing Condition Monitoring techniques.The focus of this paper is on Vibration Monitoring technologies, but many of the issues, opportunities, trends and implications are similar across the other areas of Condition Monitoring technology. Thanks to plant-maintenance.com.
The Plant Maintenance Resource Center has some very useful links on Control Valves.
Improving Valve Life and Operating Efficiency The Easy Way - John C. Robertson - Valves are, unquestionably, the most important part of any piping and pumping system because they direct the flow of fluids and regulate temperatures. Properly used and maintained, they can improve process efficiency and lower costs. It is wise to apply the basics of proper valve maintenance in ways that improve their life cycle and operating efficiency. Here are eight often-overlooked valve maintenance basics that can help you do just that. From maintenanceresources.com.
Rethink your Control Valve Maintenance - Neal Rinehart - Learn how new diagnostic tools can help make predictive maintenance a reality - Far too little has been done over the years to sustain the performance of control valves once they go into operation, despite widespread agreement on the impact that valves have on process efficiency. Rather than considering control valves as assets to be preserved, too many plants treat them as liabilities — frequently replacing critical valves during shutdown for no reason other than length of service. As a result, millions of dollars have been wasted and perfectly good control valves often have been discarded - from our valued sponsor Emerson Process Management
How to achieve optimal Control Valve Performance - Shawn Anderson and Neal Rinehart. - Leaders in the process industries realise that good process control performance is an essential element in achieving world-class reliability as well as optimizing overall process efficiency. Since control valves are the only devices in the process loop that actually “move” to adjust the process, their performance is critical. The best way to achieve excellent performance is to initially select the most appropriate final control valve for the application and then to maintain its performance over time - from our valued sponsor Emerson Process Management
Protection or Degradation - Separate the ‘quiet’ cables such as analog I/O lines, digital I/O lines, or LAN connections - Motors starting, stopping, switches on and off, controls blinking in and out … it is a cacophony of electrical clatter. In today’s industrial environments, electronic devices, signal and power wiring, and other electrical plant/process equipment often interact to create “noise” or electromagnetic interference (EMI) problems, which can degrade critical measurement and control signals. Proper grounding and shielding techniques can help reduce or eliminate these problems and maintain signal integrity. From InTech.
Introduction & background to IEC 61508 - Ron Bell - Over the past 25 years there have been a number of initiatives worldwide to develop guidelines and standards to enable the safe exploitation of programmable electronic systems used for safety applications. In the context of industrial applications (to distinguish from aerospace and military applications) a major initiative has been focussed on IEC 61508 and this standard is emerging as a key international standard in many industrial sectors. This paper looks at the background to the development of IEC 61508, considers some of the key features and indicates some of the issues that are being considered in the current revision of the standard. Thanks to the Safety Users group.
A new application guide entitled Liquid Analysis for Metals Extraction and Processing is available from our sponsor Emerson Process Management. The guide outlines liquid analytical solutions for leaching and ore extraction, concentration and separation, finished product purification and waste disposal as well as approaches to network management for metals processing plants. The new guide literally walks the user through the major extraction and processing methodologies and techniques such as cyanide extraction, flotation, phase difference, steel treatment and much more.
Heated Tubing: Prefabricated or Field Trace & Insulate? - Peter R. Baen and Rory R. Johnson - Heated instrument tubing is common throughout industry and is most often used for winterization. It is also common for tubing to be maintained at high temperatures for viscous processes or to keep gas samples above dew point and prevent condensation. In many cases the tubing is field routed, electrical heat tracing is then installed, followed by the insulation and weather barrier. Alternatively, pre-insulated and heat traced "tube bundles" are designed to expedite installation, minimize total installed cost, and ensure predictable and reliable operation. This paper addresses the advantages and limitations of both approaches.
Condition Monitoring Software made Easy - Researchers at the Fraunhofer Institute for Experimental Software Engineering IESE in Kaiserslautern, Germany, have developed a condition monitoring system for Lösi GmbH, which can adapt to various facilities without the need for manual programming. From ISA.
Subsea Flow Measurement - Marcus Davis - Flow measurement in subsea production systems, modules and templates is a challenge for flow meters. The complexity of subsea production systems ranges from simple satellite wells with one line to complex multiple well sites with a network of lines. Several pipe lines join together below the surface and will eventually extend to a fixed platform, Floating Production Storage and Offloading Vessel (FPSO), or perhaps a pipeline running to a land-based operation. Flow measurement is required in all phases of these operations, especially at well heads and where lines merge - Thanks to our sponsor McCrometer.
Forms of Corrosion - This article from cheresources covers Uniform Attack, Galvanic, Crevice, Pitting, Intergranular, Selective Leaching, Erosion, and Stress Corrosion.
Focus on Liquid Flow Measurement - Controlling the flow rate of liquids is a key control mechanism for any chemical plant. There are many different types of devices available to measure flow. This article from cheresources covers some of the basics.
Smart Instruments in Safety Instrumented Systems - Tom Nobes - The U.K.'s largest nuclear site operator implements IEC61508 and finds the quality of instrument firmware to be variable, but improving. From ISA.
Vessel overflow protection systems seem so simple, so straightforward—that is until one of them fails to work properly and your plant is the six o’clock news - The underlying concept required of an automated overfill protection system seems so simple: If the level of a vessel reaches a pre-determined maximum, then stop the flow of liquid filling the vessel. Satisfying such a simple requirement occurs in toilets, clothes washers, and dishwashers every day, so what is the big deal? The big deal is the liquid in toilets, washers, and dishwashers is water, not a highly flammable, possibly toxic, fuel or chemical. In addition, remember if the overfill protection system fails and there is even a minor incident, government investigators are going to want to see evidence you applied the principles of IEC 61511. Thanks to InTech.
Safety Instrumented Systems: The "Logic" of Single Loop Logic Solvers - What can the "new generation" of safety-certified Single Loop Logic Solvers do for you?
Cyber Security And The Pipeline Control System - Eric J. Byres - Sound strategy, regardless of whether it is for military, physical or cyber security, relies on the concept of “defense in depth.” Effective security is created by layering multiple security solutions so that if one is bypassed another will provide the defense. This means not overrelying on any single technology such as a firewall. Firewalls aren’t bad technology. In fact, they are a fantastic tool in the security toolbox. But, industry has misused them by believing they will solve all security - from Tofino Security.
Posted by: Jim Russell, June 2009
Next Generation Safety Controller Maximizes Availability for Demanding Process Applications - The nemesis of all continuous processes is unplanned stoppage resulting from controls malfunction, equipment failure, or operator error. System availability can be improved significantly through the use of redundant control architectures – especially those that allow hot-swapping or on-the-fly program changes. Modern process safety solutions provide comprehensive diagnostics that help users to recognize safety-critical situations and act quickly and accordingly to avoid unnecessary system shutdowns. This paper from ARC highlights why companies should invest in process safety.
Need to update your knowledge? Thanks to our valued sponsor Abhisam Software ICEweb's Education Page has been extensively updated.
FISCO Intrinsically Safe Fieldbus Systems - This application note is a practical guide to the selection, installation and maintenance of equipment complying with the Fieldbus Intrinsically Safe Concept (FISCO). The document begins with a discussion of the origins of FISCO and an introduction to the main elements that should be considered when assembling FISCO systems. Later sections then develop each subject in more detail, with the intention of providing clear guidance to new and experienced Fieldbus users. From MTL.
Seize
Control of Safety and Productivity -
The following have been
added to ICEweb's Hydraulic
page
Wellhead Control and Hydraulic Power - An overview design requirements
NORSKE standard.
What
Happened to NAS 1638? - Mike Day - If you obtain the latest issue of NAS
1638 you will find the following statements: “Inactive for new designs
after May 30, 2001, see AS4059C” and “6.1.3 This standard should not be
used with Automatic Particle Counting.” This is a result of recent changes
to the ISO contamination standards for automatic particle counter (APC)
calibration3, which necessitated the review of NAS 1638 and
resulted in its withdrawal for newly designed systems - From oilanalysis.com
Wellhead
Hydraulic Control Panel Water Based Fluids - Oceanic HW fluids are water
based hydraulic media specifically form-ulated for use in modern subsea
production control systems. Their low viscosity promotes optimum system
response, while a sophisticated additive package provides a high degree of
protection against wear, cor-rosion and microbiological degradation. The
Oceanic HW fluids have been developed in close consultation with component
manufacturers, and are now in worldwide use, helping to achieve maximum
production system safety and reliability.
Wellhead
Hydraulic Control Panel Specification - Although not a full
specification this is a useful design guide.
HIMA Australia are running the following courses; Analysis
& Design of SIS Training Course - The objective of this course is to
provide engineers with the knowledge required to analyse and design safety
instrumented systems (SIS) in accordance with the analysis and realisation
phases of the AS61511 safety life-cycle.
Perth
- Tuesday 2nd June
Sydney
– Tuesday 8th September
Darwin
– Tuesday 22nd September
Gladstone
– Tuesday 6th October
Melbourne
– Wednesday 4th November
Brisbane
– Tuesday 10th November
Posted by: Jim Russell, May 2009
ICEweb's Control page has added a whole heap of information on OPC.
Sensor Frequently Asked Questions - From dataTaker - This link provides an excellent range of questions relating to sensors covering Wiring & Installation issues, Enclosures & Ambient conditions, Temperature Measurement including Thermocouples, RTD's and Thermistors, Resistance Devices, Current and 4-20mA Loops, Load Cells, Bridges and Strain Gauges and finally Vibrating Wire Strain Gauges.
DataTaker have a range of online training
options including;
- DataTaker Online Training Workshop - The complete set of presentation
slides developed for the 3 day dataTaker Training Workshop. Designed to be
used on your own, at your own pace. The presentation focuses on
understanding the fundamentals of data acquisition and data logging.
Including detailed programming examples, covering basic to advanced users of
data loggers. Used in conjunction with the self paced worked example
exercises within a hands on environment.
- Online
Video Tutorials
- Online
Workshop Exercises
- Need
to program a DataTaker? - The datataker WIKI is a really great site
specific to datataker programming
Posted by: Jim Russell, April 2009 ****
Thanks to our sponsor HINCO the Datalogger
page has been updated with new links as follows;
- Australian
Datataker helps save Chinese Rice Crops - In the surrounds of the city
of Guangzhou (Canton), a spell of cold weather poetically named the cold
winds, threaten to slash the yields from the second rice crop of the season
by 50%. These conditions frequently occur within the months of September and
October. Rice breeders at the Guangdong Academy of Agricultural Science aim
to develop new varieties that can withstand and thrive in the cold dew
winds. Apart from records of average daily temperature, they lack precise
information on the severity of the adverse conditions that new varieties
have to endure to survive. The lack of data severely hampers the development
of the new rice varieties.
- The
National Gymnasium Building Structure Monitoring System In China - The
newly-constructed national gymnasium in Beijing, China played a key role
during the Olympic Games in 2008. Its iconic status will remain afterwards
in the country’s landscape as a multifunctional gymnasium that is capable
of hosting not only sporting events but also other large-scale functions
such as commemorations, exhibitions and literary functions. It then has
become critical that the building structure is able to maintain its rigidity
and integrity during the entire designated life-span of the Gymnasium. Hence
a permanent structure-monitoringscheme is required to be in place.
- Data
loggers monitor Capital Airport A380 Hangar - The biggest technical
difficulty involves the entire lifting of the three layers of spherical
jointing ball steel net frame. The total area of the steel net frame is 41
thousand square meters, or equal to 6 football fields, gross weight is over
10 thousand tons, using an advanced constructing method of ground group
engagement the complete lift to reach the designated position – is a world
first! Clearly it is necessary to monitor the force during lifting process.
- Data
Loggers used in Saving Greenhouse Gases and Turning Waste to Power -
This application describes how a data logger monitors the gas collected from
aerobic ponds, the amount used to power the generator and the amount burnt
by the flare.
- Open
Cut Mine Monitors Water Quality - An open cut coal mine having a high
salinity of water runoff required monitoring the quality of water in several
retaining dams.
- Onset’s
free Web Seminars and Videos offer guidance on how to use data logging
software, apply data loggers in various applications, and provide
field-proven tips and techniques to help make data logger projects
successful. You need to register to get these, titles include;
Why Your Vortex Meter Shows Zero - Liquid flow of a process fluid into a vessel was visually confirmed. However a vortex-shedding flowmeter in the feed pipe measured zero flow. The flowmeter was removed from service and was found to function properly on the flow bench in the instrument shop. Which of the following problems could cause this issue to occur? From David W Spitzer P.E and Flow Control Network.
Pioneers of Flow Measurement -Founding the Technologies of Today - Jesse Yoder, Ph.D - It is easy to forget in today’s fast-paced world the importance of the many thinkers and pioneers who have made modern-day technologies possible. This is as true in the area of flow measurement as it is in other technology segments. The following looks at some of the pioneers of flow measurement, who formulated many of the principles that underlie the sophisticated flow instruments of today - An excellent article from flowresearch.com
As Tough As They Come - Extremely Robust Control System Provides Safety Underground - A control system is normally found inside a control cabinet, where it is well protected from all types of environmental influences. But control systems can also be installed on mobile machinery, where they may be subjected to rigorous shaking. Shock and vibration must not be allowed to compromise the safe function of the control system in any way. Consequently, the Pilz programmable control systems used in mining on roadheaders, to safely monitor the spray function, need to be especially robust.
The Effect of Ambient Conditions on Flow Measurement - David W. Spitzer, P.E - The entire flow measurement system should be operated within its constraints in order to provide accurate flow measurements. This means that each component of the flow measurement system should be considered to ensure that it is operated properly. From David W Spitzer and Flow Control Network.
The following papers have been added to
ICEweb's Cables page;
- Best
Practices for Process Instrumentation Cabling - Saeed M. AL-Abeediah -
This article looks at the classes of instrumentation circuits and
wiring suitable for each class, signal noises, techniques that minimize the
impact of noise and interference on instrument signals, and conclude with a
proposed process automation grounding scheme that PAS vendors helped develop
- from ISA
- Cable
Condition Monitoring to Improve Reliability - Hilary Marazzato, Ken
Barber, Mark Jansen, and Graeme Barnewall - The electric cable industry is
definitely in the mature product stage and while there are many incremental
developments and improvements, the history and experience gathered enables
us to approach issues of cable failure and cable life maintenance with ever
improving tools. This paper discusses currently available technology, the
shortcomings, and the trends for future development - from Olex.
Wireless communication for tank farm applications - At this refinery, engineers and technicians researched wireless communication possibilities for increased efficiency and timer monitoring. They needed to determine whether reliable data transmission via radio would stand up to an environment with a high level of EMI, and if the cost of cabling a large area with remote storage tanks could be reduced or eliminated - from Phoenix Contact.
Wireless Systems Development for Distributed Machinery - Monitoring and Control - Anthony J Seman III, Michael E. Donnelly, P.E., Stephen Mastro, Ph.D. - This paper highlights the programs demonstrating the use of wireless technology for monitoring and control of shipboard machinery during the past 10 to 15 years at NAVSEA Philadelphia. This work includes the demonstration and testing of wireless systems hardware and software, and also the development of suitable architectures to fold such technologies into an overall ship machinery control and human interface that is highly functional and affordable.
Wireless Sensor Networks: Principles and Applications -Chris Townsend, Steven Arms - Recent advances have resulted in the ability to integrate sensors, radio communications, and digital electronics into a single integrated circuit (IC) package. This capability is enabling networks of very low cost sensors that are able to communicate with each other using low power wireless data routing protocols. A wireless sensor network (WSN) generally consists of a basestation (or “gateway”) that can communicate with a number of wireless sensors via a radio link. Data is collected at the wireless sensor node, compressed, and transmitted to the gateway directly or, if required, uses other wireless sensor nodes to forward data to the gateway. The transmitted data is then presented to the system by the gateway connection. The purpose of this chapter is to provide a brief technical introduction to wireless sensor networks and present a few applications in which wireless sensor networks are enabling.
ICEweb's Dynamic Process Simulators
and Training Systems page has been updated and the following papers
added;
- Enabling True Lifecycle Modeling
- Optimize Plant Performance Using Dynamic Simulation
- ME PETROTECH 2008 Simulator Based Training
- Integration of a Field Surface & Production
Network with a Reservoir Simulator Gokhan Hepguler, Santanu Barua, Wade
Bard
- Integration of Refinery Reactors into Flowsheet
Simulation Dave Bluck, Richard Yu, Lee Turpin, Robert Powell
ICEweb's comprehensive Ultrasonic Flow Metering page has been upgraded thanks to our sponsor Zedflo Australia.
Cost-Efficient On-Site Check Metering Made Easy - Brian Roughan - When a flowmeter in operation has to be verified, it usually must be uninstalled and transported to a facility for the necessary verification or check-metering. With an on-site verification device, though, this task is made much faster, easier and at a fraction of the cost. When using the right meter, the result can even be as accurate as any off-site verification.
Ultrasonic Flowmeters -By David W. Spitzer - Parts 1 to 4 - The flowmeters to be discussed use ultrasonic energy or correlation as their primary flow measurement technique. Therefore, a common class of "ultrasonic flowmeters" comprised of an open channel flowmeter (such as a flume or weir) that incorporates an ultrasonic level measurement is specifically excluded from this discussion. Ultrasonic flowmeters use sensors to generate ultrasonic waves and direct them into the flowing stream. Information from the remnants of these sound waves is used to determine the flow of fluid passing through the flowmeter. Ultrasonic flowmeters have no moving parts.
Posted by: Jim Russell, March 2009
To Repair or Replace? - Solenoid Valve Maintenance & Troubleshooting Strategy - Michael D’Amato - The small yet robust solenoid valve is a powerful electromechanical gatekeeper. It has the important task of controlling the flow of liquid, air, gases or particles for a larger system. Yet even the most reliable of valves can fatigue or become inoperable, thus shutting down or affecting a system’s performance. As with any mechanical apparatus, proactive maintenance of a solenoid valve can extend life and ensure consistent operation - from flowcontrolnetwork.com
Light my Pump is a comprehensive site covering pumps and pump systems. It includes calculations, trouble-shooting, videos of interesting experiments with fluids, tutorials and more!
The following can be found along with many
more Manufacturing and Safety Technical Articles and papers on ICEweb's Manufacturing and Automation Safety
page - thanks to our valued
sponsor Pilz
Australia
.
- Doing
Safety the “Right Way” Lifts Productivity Too
- Are safety and productivity incompatible? If safety is an afterthought,
absolutely, but safetymeasures that are worked into the very design of
manufacturing plant actually boost productivity, says Pilz managing director
Frank Schrever.
- Machinery
Safety and the need to Save Money - It can be a false economy - or
potentially dangerous - to try saving money on safety systems, yet careful
design can reap rewards. Given the state of the economy, it is
understandable that everyone has to be more careful with their budgets than
ever before. But engineers should beware of trying to save money by buying
cheaper safety-related products, as it could cost them dear in the long run.
- Monitored
at all times - Drive-integrated safety opens up new horizons - Safe
drive functions have made their mark on standards, products and applications
and may now be considered as state of the art. They are part of the
functional safety plant and machinery and, as measures that boost
productivity; they are increasingly gaining ground in the market.
- Safety
in each phase of the flight - Pilz ensures flight safety on the Sky Roller
- Speed and thrills are what’s required of the attractions on offer at
funfairs and amusement parks. On today’s modern fairground attractions,
riders are catapulted through extreme radii or carried along in hair-raising
positions; these attractions need to perform their service reliably and
virtually failure-free. Where the laws of gravity appear to be temporarily
suspended, as on the Sky Roller, a Pilz programmable safety system is there
in the background, making sure that nothing gets out of hand.
- The
True Value of Free Technical Support - Technical support enables design
and maintenance engineers to save time and money in both new projects and
existing plant.
Food and Beverages Industries go Wire Free -Khadambari Shanbagaraman - An increasing population and growing consumer demand for packaged foods has forced food and beverages industry to look at new technologies that provide flexibility, easiness of operation and constant tracking of the production process. Complete transparency is required along the production process for assuring consumers health and hygiene. This demands continuous monitoring and efficient traceability of the entire production process in the food manufacturing plant. Wireless devices provide answers to the aforementioned requirements in the Food and Beverages industry- from Frost & Sullivan.
Wireless
Devices in the Factory Automation – An Overview of Adoption Trends
ICEweb's Burner Management page has been
extensively upgraded and the following new links added thanks to our sponsor
HIMA Australia , you
can find them and more here!
- Case Study: Safety Instrumented Burner Management
System (Si-Bms) -
- Industry Update BMS
ISA04-P280 - This paper explores the current trends in the market place
and the industrial process control industry in general with respect to
Burner Management Systems and their relationship to Safety Instrumented
Systems. The concept of a Safety Instrumented Burner Management System is
introduced and explained in detail.
- Safety Instrumented Burner Management Systems
Ready or Not Here They Come! - Michael D. Scott - The concept of a
Safety Instrumented Burner Management System (SI-BMS) is to stay. If you are
unsure of this statement one should consider that six (6) different codes /
standards currently exist and / or are being revised to invoke the Safety
Lifecycle with respect to Burner Management Systems.
- Safety Instrumented Burner Management Systems –
Requirements For The Paper Industry
ICEweb's SIS page has been extensively
upgraded and the following new links added thanks to our sponsor HIMA
Australia , you can find them and more here!
- NOPSA competence findings in line with AS61511 -
The Australian National Offshore Petroleum Safety Authority recently
recommended that oil and gas facility operators implement formal staff
competency management systems to ensure that basic skills requirements for
safe plant operation are met.
- IEC 61508 Product Approvals -
Veering Off Course - Upon close examination it appears that the product
approval process of IEC 61508(1) has veered seriously off course, possibly
rendering many safety instrumented system (SIS) applications less reliable
than expected or required.
- A Process Engineering View of Safe Automation
-This step-by-step procedure applies instrumented safety systems (ISS) to
continuously reduce process risk.
- Quality Assurance in Safe Automation - A
perfect process would have no hazards, but perfection is impossible in the
real world. Nearly all process units have inherent risk associated with
their design and operation. Safe operation is maintained with a risk
reduction strategy relying on a wide variety of safety systems. This article
focuses on the most common safety systems for managing process deviations
during planned operating modes – instrumented safety systems (ISSs), such
as safety alarms, safety controls, and safety instrumented systems (SIS).
Rigorous quality assurance is necessary to achieve real-world risk
reduction, so this article follows the Plan, Do, Check, and Act process to
discuss quality assurance and its application to ISS.
- Guidelines for Safe and Reliable Instrumented
Protective Systems (IPS) - Written with
guidance from members of the CCPS’s Guidelines
for Safe and Reliable Instrumented Protective Systems subcommittee,
author and safety standards expert Dr. Angela Summers explores the decision
making processes necessary for the management of the protection systems
commonly applied throughout the process industry. Based
on the framework defined in the harmonized ANSI/ISA 84.01/IEC 61511
standards, this book provides readers with much-requested guidance in an
easy to understand discussion that addresses IPS planning, risk assessment,
design, engineering, installation, commissioning, validation, operation, and
maintenance activities.
- Statistical Signature Analysis:
Modeling Complex λD(t) from Proof Test Data and the Effects on
Computing PFDavg - Julia V. Bukowski - To compute PFDavg, we must first
have a model for λD(t), the failure rate of the equipment in the
dangerous failure mode. A dangerous failure occurs when equipment designed
for prevention or mitigation of an unsafe condition cannot properly respond
to the unsafe condition, i.e., the equipment fails on demand. For example,
consider a PRV, which, in normal operation, is closed. Should it fail in the
"stuck-shut" mode, it would be in a state of dangerous failure as
it would be unable to respond to an overpressure event if one occurred.
- Final Elements and the IEC 61508 and IEC 61511
Functional Safety Standards Book - This book reviews and explains the
application of the IEC 61508 and IEC 61511 functional safety standards as
they apply to final control elements. The overall safety lifecycle and
reliability requirements are reviewed with special focus on the challenges
encountered when dealing with complex electro-mechanical subsystems.
Throughout the book requirements for designing and implementing reliable and
effective safety instrumented functions are covered in a clear step by step
manner.
- Safety Users Group - An independent,
professional community dedicated to instrumented safety matters related to
the oil, gas, petrochemical and chemical industries. Lots of information
here!
- Recommended Guidelines for the application of IEC 61508 and IEC 61511
in the petroleum activities on the Norwegian Continental Shelf - This
very comprehensive 55 page guideline from the Norwegian Oil Industry
association is very useful.
Posted by: Jim Russell, February 2009
Advanced Online Physical Layer Diagnostics - Gunther Rogoll and Ren Kitchener -This paper covers the range of significant benefits, and the increased confidence in new technology, provided by the latest generation of advanced physical layer diagnostic equipment when applied to Foundation Fieldbus™ or Profibus PA™ fieldbus networks, to monitor the communication, cable infrastructure, fieldbus power supplies, terminators, devices and protection electronics, otherwise referred to as the physical layer. It also explains how the integration of physical layer diagnostics to every fieldbus segment can in fact reduce CAPEX & OPEX when used across the project lifecycle. Additionally, failure prevention or proactive maintenance is a key feature of any diagnostic system, also considered are the differences between basic physical layer diagnostics and advanced physical layer diagnostics.
Advanced Diagnostics Self Validates Health of Fieldbus Networks - Wil Chin and Allen Avery - Diagnostic capabilities for Fieldbus networks have evolved significantly over the years. Rudimentary tests such as instrument elevated zero outputs and simple I/O health checks gave way to superior instrument and process diagnostics with the introduction of HART, which had its limitations due to bandwidth restrictions. The advent and acceptance of Fieldbus has in-creased the use of sophisticated sensor technology and process diagnostics. Until recently, it was cost prohibitive to monitor the health of the entire Fieldbus network. However, that has changed with the introduction of more sophisticated Fieldbus hardware and advanced diagnostic systems.
Fieldbus Testing with Online Physical Layer Diagnostics - Gunther Rogoll and Ren Kitchener -Fieldbus has fully matured following its cautious introduction back in the late 1990s: Many of the major projects are now using digital fieldbus technology as the preferred platform for control and instrumentation. Most of the lessons learned from the early projects have been implemented successfully for the current projects, and there is no doubt that the companies responsible for commissioning are seeing a marked improvement in the commissioning times with a resulting reduction in CAPEX. With the recent introduction of online Advanced Physical Layer Diagnostic equipment, the transition to a fully automated network test and reporting program reduces the time and cost for construction and commissioning even further by optimizing the test process and report generation.
****
A Safe, Clean Business - Pilz Safety System Monitors an Exhaust Purification Plant - Systems for thermal exhaust purification are subject to the furnace regulations. The safety of such plants presents a particular challenge for automation technology. A multifunctional, modular safety system can not only monitor the safety functions in exhaust purification systems, but can also enable manufacturers to implement flexible burner control systems in such plants. Thanks to our valued sponsor Pilz Australia
Posted by: Jim Russell, January 2009
Accurate Flow Measurement Improves Profit - Two-wire Coriolis Flowmeter for Loop Powered Applications- Rough Economic Seas – The current economic climate means that many managers are taking a keen interest in the selection of their flow-measuring devices. Today’s decision makers understand the benefits of different flow technologies and accept that when migrating to higher performing technologies, there may be cost implications resulting from, for example, increased wiring and associated installation costs. In a new installation, these extra costs can usually be minimized through good engineering practices.
Take a look at ICEweb's new Motor Control Centre (MCC) and Intelligent Motor Control Centre page which has information on specifying, designing and other useful technical data on this subject.
Programmable Safety and Control Systems for Use in Burner Control - Adam Hallinan -There are many BMS systems running today which do not comply with current standards. They are either using non approved standard PLC’s or antiquated relay based control systems. Not only is the potential failure to danger a risk to man and machinery but even non dangerous sporadic failures can be difficult to fault find and lead to costly down time. Programmable safety and control systems (PSS) suitable for use in BMS have been available for well over 10 years now. These controllers can identify any dangerous failures before they create a hazardous situation, and also provide a level of diagnostics to minimise downtimes. By taking the I/O into the field, large distributed applications with many burners can be accommodated economically with minimum install time, and also safely. Thanks to our valued sponsor Pilz Australia
ICEweb's Manufacturing and Automation Safety page has been extensively reworked with many new links, thanks to our valued sponsor Pilz Australia .
Posted by: Jim Russell, December 2008
Temperature Regulators - The characteristic feature of self-operated temperature regulators is their compact design, including a sensor, a valve and a capillary tube. Their simple operating principle is based on fundamental mechanical, physical and thermodynamic laws. Thanks to our valued sponsor Samson Controls.
Enhanced Reliability for Final Elements - Process valves, sometimes also addressed as final elements are in many cases the most decisive factor when it comes to calculating the SIL level for a safety instrumented function (SIF). Testing procedures like partial stroke testing can provide enhanced diagnostic coverage and therefore help to get improved reliability data for the total loop. Verification of this 'diagnostic data' and proper integration of these procedures into the safety instrumented system (SIS) and basic process control system (BPCS) environment at the same time poses a challenge. New developments on actors and relevant approvals are presented as well as instrumentation with new functionality to support diagnostic coverage, different topologies for connection to SIS and BPCS are discussed. Thanks to our sponsor Samson Controls.
Why Open Path Gas Detection? - Open path detectors compliment the use of individual point detectors and offer many significant benefits including; Wider area coverage - most likely to pick up any leak, very high speed of response, no unrevealed failure modes - no possibility of blocked gas path to detector, detector location not as critical, Indicates size of hazard. This product bulletin from Honeywell Analytics gives some useful information.
Choosing the Right Gas Detection System - There are many gas detection products on the market that might appear to be the same, but a closer inspection of specification, functionality and features reveals major differences in what products can do and the potential benefits they can offer. Go to page 4 to get this article.
HIMA Australia have launched their HIMax Safety System - This Safety System sets new standards in performance, safety and availability within the process industry. In the development of flexible and intelligent safety platforms, HIMA’s special focus was on increasing the availability and profitability of process plants. Offering unique features, HIMax ideally satisfies the global process industry’s demand for increasing the profitability of safety-oriented applications. Also HIMA Australia will be displaying their HIMax system at the Australian Oil and Gas Expo in Perth, February 2009.
EDDL: Marching into Mainstream - Jonas Berge - Simple smart pressure and temperature measurement transmitters could be configured without need for graphics. However, more sophisticated (complex) devices such as valve positioners, variable speed drives, machinery health monitors, and radar level transmitters now common in process industry plants require advanced graphical setup and diagnostics. By upgrading software to the new enhancements of the international standard IEC 61804, plant personnel can make their devices, both old and new, simple and advanced, easier to use than ever before. Similarly, predictive diagnostics can be better integrated into daily work practices by displaying them to the right persons. This is achieved without making system management more difficult with respect to staying current with new devices and Windows versions. This article recommends a best practice for device integration outlined in the NAMUR NE 105 recommendation by upgrading to a single standard: IEC 61804-3.
Pressure transmitters: EDDL Equals "Easy" - Dale Perry/Jonas Berge - EDDL technology makes sophisticated pressure transmitters easier to use. within the last few years many specialised pressure transmitters have been introduced. These transmitters specialise in areas such as DP Flow, Mass Flow, Safety Certified, and Diagnostics. The value of specialised transmitters has been demonstrated to increase quality, throughput, or uptime. Any added complexity of maintaining these transmitters through their life cycle, installation, start-up, routine maintenance or emergency maintenance could be a challenge to plants.
OPC made easy - EDDL can save numerous man-hours of OPC server configuration and speed up project completion - Jonas Berge - OPC is an o p e n standard me t h o d for transferring data between software applications, used for example to obtain data from devices. Once an OPC server is configured, external software in HMI clients and other users can easily access the wealth of detailed diagnostics and information in hundreds or thousands of intelligent devices around the plant. Configuring OPC clients is easy: just point and click on data in the OPC server. To enable this, the OPC server must first be configured. Electronic device description language (EDDL) makes this easy.
Temperature Transmitters Warming Up to EDDL - Jonas Berge - Enhancements to the EDDL IEC 61804-3 standards have improved advanced setup and diagnosis of high-end temperature transmitters. Temperature transmitters communicate digitally using protocols such as HART, Foundation fieldbus, and WirelessHART. Supporting this mix of transmitters can be a challenge. However, modern temperature transmitters diagnose themselves, the sensor wiring, and the temperature element. This allows for more effective maintenance schemes that help keep the loop and plant running with minimum downtime.
Building on the Foundation - Jonas Berge - Steady improvements and enhancements over the last decade together with an increasing knowledge base in the process industries have made it far easier to realize the promised benefits of Foundation fieldbus plant network technology.
Wireless Widens the View - Jonas Berge - A wider window into the plant is now possible as previously "difficult to access" field data becomes easier to collect and transmit with the latest wireless technology. The practical and economical barriers to collecting more information from the plant floor and surrounding areas have been dramatically lowered by the emergence of reliable wireless field communications systems. The technology of transmitting information from stand-alone instruments can be put to use today, even in plants with legacy control systems. Information that was previously difficult or impossible to access in the past is now easily collected and transmitted from wireless devices to the plant control system.
Wireless Technology & Best Practices to Reduce Project Costs - Mark Menezes - Benefits of wireless seem obvious – “no wires”. Despite this, fewer than 1% of installed measurements in process plants and mills are wireless. Fortunately, real and perceived obstacles to wireless deployment are being overcome with improved technology, most recently the “self organising network”. Other obstacles are not based on technology, but on the lack of security, standards, and consensus on appropriate applications, so are best addressed with a discussion around “best practices”. Users can now consider adding measurements previously impossible to cost-justify, improving safety, reliability, efficiency and environmental compliance.
Asset Management Leverages Smart Wireless Devices - Laura Briggs/Joseph Citrano III - Smart Wireless Devices generate diagnostics that extend the value of asset management systems.
pH made Easy, Reliable - Jonas Berge - Water and wastewater treatment plants, as well as other industries, use several types of liquid analyzers to monitor quality in terms of many different properties. The pH meter is one of the most important. Analyzers communicate digitally using protocols such as HART®, Foundation® fieldbus, and WirelessHART. Maintaining this mix of analyzers can be a challenge. This is a result of analyzer probes being in direct contact with the process and subject to various different problems depending on the process conditions. However, modern pH analyzers diagnose themselves, the glass, and reference electrodes in the sensor, as well as the temperature sensor. This allows for more effective maintenance schemes that help keep the loop and plant running with minimum downtime. Recent enhancements to the EDDL (Electronic Device Description Language) IEC 61804-3 standards have helped improve calibration and advanced diagnosis of high-end pH analysers.
Posted by: Jim Russell, November 2008
Optimizing Production Rates and Reducing Life-Cycle Cost for High-Pressure Fields - S. Patni - A key enabling technology for developing high pressure fields is a high integrity pressure protection system (HIPPS). The HIPPS isolates the lower pressure rated flowlines and riser from an overpressure. Thus HIPPS would allow a high-pressure field to tie-in to existing lower pressure rated infrastructure, a capability that will facilitate the development of high-pressure fields. Thanks to otcnet.org
Subsea HIPPS offers high-pressure field development option - Sandeep Patni and Janardhan Davalath - A major challenge in developing a deepwater project is recovering reserves at a reasonable capex investment for flowline and riser installation. A high-integrity pressure protection system (HIPPS) is a step toward improving recoverability. HIPPS provides a pressure break between subsea systems that are rated to full shut-in pressure and the flowline and riser, rated to a lower pressure. Thanks to offshore-mag.com
What is HIPPS? - This useful paper from Mokveld describes the technology well.
Considerations in designing HIPPS - Willem-Jan Nuis / Rens Wolters - Due to environmental constraints and cost saving, HIPPS has gained popularity over the last years as the last line of defence, replacing pressure safety valves (PSV), blow down and flare systems. Although HIPPS is applied for more than a quarter of a century, design and implementation of HIPPS is still not as obvious as one might expect. The main reason for this is the way the IEC 61508 and the more recently introduced IEC 61511 standards are written. The oil and gas industry for years has been accustomed to work with prescriptive standards. Thanks to the safety users group.
Polytron – challenging tests, passed with flying colours - The Polytron 2 Offshore and Polytron 2 IR transmitters were type-tested for use on sea-going vessels, industrial sites and installations surveyed by classification societies. This article gives the details of these tests. Thanks to our sponsor Draeger Australia
ICEweb's Terminals page has been extensively upgraded thanks to sponsor Weidmuller Australia , so if you use terminals this the first page to get the best technical details.
We have also added additional technical references to our Enclosures page, again thanks to Weidmuller Australia .
Posted by: Jim Russell, October 2008
Radio Theory De-Mystified - Brian Cunningham - With increasing demands placed on plant managers to reduce operating costs, wireless is presenting attractive alternatives to buried cable and conduit runs. The issue at stake in choosing this alternative is reliability, and trust must be established before users will confidently invest in this technology. This paper discusses the different types of radio that are currently in use with a focus on spread spectrum in process control applications. An explanation of how a radio works is followed by a discussion of fixed frequency, direct sequence spread spectrum, frequency hopping spread spectrum and orthogonal frequency division multiplexing technology. Emerging radio standards are reviewed and there is a section on how to interpret specifications and how they differentiate one radio's performance from another. Classes of criticality for wireless applications will be studied. Range determinations, interference mitigation and multipath are addressed, along with issues surrounding the multitude of frequencies in use and the advantages and disadvantages of each - from the Wireless Industrial Networking Alliance.
Convert Word 2007 Documents to Word 2003 - Microsoft has provided a compatibility kit to convert Office 2007 files to be compatible with earlier versions. See more tools like this on ICEweb's tools page.
Equipment, don't fail me now - Calculating failure probabilities works better with systematic approach - Peter Morgan - One step in this approach is calculating the target probability of failure on demand (PFD) for the system. Because calculating PFDs for repairable systems commonly seems complicated, the approach does not curry favor with the average control and instrumentation specialist; some manufacturers defer the design analysis to others or they do not do it at all. But there is benefit in the approach for designing general protective systems in addition to meeting the mandatory requirements for a SIS. From the ISA and InTech
Posted by: Jim Russell, September 2008
Industrial network integrity- New-era industrial network communications require fresh skills and tools -Ian Verhappen and Eric Byres - If the reliability of the process rides under a veil of question and uncertainty, there is big trouble. With industrial communications networks playing a critical role in today’s control systems, it is vitally important these networks have the highest level of reliability possible - from the ISA and InTech.
Network, Organize Thyself - Industrial environments could benefit from reliability of self-organizing wireless networks - Gabe Sierra, Dan Carlson, Bob Karschnia, and Brandon Robinson - When process personnel hear the term wireless instruments, they immediately think, great, no wires. But how do you know if you are receiving good data on time, every time? To go a step further, what are the limitations of self-organizing wireless network reliability, and where should you apply it in a dynamic industrial environment? Can wireless field devices ever be reliable enough for today's complicated industrial environments - from ISA and InTech.
Process Safety what are the Odds? - Enhancing a safety system's ability to perform on demand requires improved diagnostic coverage, maintenance, and regular testing. From controleng.com
Let it flow - Measuring the flow of liquids in industrial plants is critical - In some operations, the ability to conduct accurate flow measurements is so important it can make the difference between making a profit and taking a loss. In other cases, inaccurate flow measurements or failure to take measurements can cause serious or disastrous results. Includes a flowmeter selection guide. Thanks to ISA and InTech.
Fuzzy Logic Clarifies Operations - Statistical tool can give real-time predictive process fault analysis - Richard J. Fickelscherer, Douglas H. Lenz, and Daniel L. Chester - A fuzzy logic based real-time diagnostic method called the Method of Minimal Evidence (MOME) uses first principle or statistical models, correlations, and experiential heuristics to define relationships between particular measured sensor data and assumed unmeasured process variables that describe normal process operation. From the ISA and InTech. See more on ICEweb's Fuzzy Logic page.
Alarms and Trips: The Ups and Downs - While limit alarm trips are best known as a sure way to activate a warning light, siren or bell when a process problem occurs, they are also called upon to do much more. In fact, today’s highly flexible and versatile alarm trips can be found working in a wide range of applications, under an impressive list of pseudonyms. From our valued sponsor Moore Industries-Pacific, Inc.
Comparing oil-in-water measurement Varying government regulations and measurement methods call for standardization - Colin C. Tyrie, and Dan D. Caudle - There are several instrumental methods for measuring oil in produced water. None of them measure all the organic compounds in the water. Comparing what the commercially available methods actually measure will illustrate the problem of interpreting oil in water (OIW) analysis. From www.worldoil.com
Lightning and surge protection in emissions monitoring - Donald Long - At any given moment, there are over 1,800 thunderstorms occurring - The 1,000-ft stacks at electrical power generating plants are huge lightning rods reaching up into the sky. The very same stacks, selective catalytic reaction (SCR) beds, ammonia injectors, and precipitators, only now carrying expensive nitrogen oxide/sulfur dioxide (NOx/SO2) emissions monitoring equipment and associated power and instrumentation cabling, take on nature's fury in the form of potentially 200,000-ampere bolts of lightning. How can one effectively deal with this phenomenon? How does lightning get into the continuous emissions monitoring system (CEMS)? Is this the only form of surge? Is proper grounding the answer? Thanks to ISA and InTech.
Don't be Alarmed - Avoid unplanned downtime from alarm overload, use top techniques to improve alarm management - Gary Goble and Todd Stauffer - Alarm management is one of the most undervalued and underused assets of process automation. With process automation systems losing $20 billion to unplanned downtime, and with 40% of it attributed to preventable human error, alarm management has never been more important. An important factor lending itself to human errors is the cacophony of alarms, which preclude the operator's ability to respond quickly and correctly. Thanks to InTech and ISA.
Ethernet on the Floor - There is a proper time and place for industrial communications deployment - Mark Fondl - There is no doubt about it: Ethernet continues to grow from year to year throughout the automation industry. But the real issue is why aren't users adopting it at a more rapid pace? From the InTech and ISA.
The Golden Rules of Risk Assessment - Frank Schrever - At its worst, the risk assessment is a bureaucratic time-waster that does nothing to make workplaces safer. On the other hand, following five golden rules mean risk assessments can be both functional and lifesaving. From Pilz and Manufacturers Monthly.
ICEwebs Valveweb page has been completely reworked to help you get to your required information quickly and efficiently. Thanks to our sponsors tyco flow control pacific
The following additional papers have been
added to ICEweb's comprehensive Pressure
Relief Valve Page thanks to our sponsors tyco
flow control pacific
- Reducing Pressure Relief Valve Discharge Noise to Acceptable Levels
- From Crosby
- Selection and Sizing of Pressure relief Valves - Randall W.
Whitesides - This is an excellent document - The function of a pressure
relief valve is to protect pressure vessels, piping systems, and other
equipment from pressures exceeding their design pressure by more that a
fixed predetermined amount. The permissible amount of overpressure is
covered by various codes and is a function of the type of equipment and the
conditions causing the overpressure. It is not the purpose of a pressure
relief valve to control or regulate the pressure in the vessel or system
that the valve protects, and it does not take the place of a control or
regulating valve. Proper sizing, selection, manufacture, assembly, test,
installation, and maintenance of a pressure relief valve are critical to
obtaining maximum protection.
- Minimisation Pressure Relief Valve Seat Leakage through optimisation of
Design Parameters
- Pressure Relief "Grace Under Pressure" - Harry J Toups -
This presentation is an excellent overview of Pressure Relief terminology,
systems, design, code requirements, location of relief systems,
choosing relief types, backpressure, Pros and Cons of various types of
relief valves and rupture discs, relief event scenarios, sizing of reliefs,
typical calcs, chatter, worst case event scenario, Installation, Inspection
and Maintenance and typical errors. From the Safety and Chemical Engineering
Education Program.
- Pressure Relief Design
- This resource from cheresources.com has a real "vault" of
excellent technical articles including:
- Relief Valve Set Pressures
- Relief Valves: "What Can Go Wrong" Scenarios
- Wireless Pressure Relief Valve Monitoring System Provides Significant
Operational Benefits - Clifford Lewis - Recently,
technology has been introduced that enables continuous monitoring of
pressure relief valves using non-invasive sensors that communicate through a
wireless radio link to a central data collection point.
Bursting Disk Sizing - When sizing of bursting disc safety devices in undertaken, it is important to consider not only the pressure relief devices but the whole of the pressure relief system so as not to reduce the relieving capacity below that required or adversely affect the proper operation of the pressure relieving devices. From Fike.
Introduction To EtherNet/IP - An in-depth discussion of the CIP protocol, explains OSI layers and illustrates key concepts. EtherNet/IP (Ethernet Industrial Protocol) is traditional Ethernet combined with an industrial application layer protocol targeted to industrial automation. This application layer protocol is the Control and Information Protocol (CIP™). Thanks to Acromag and Automation World.
ICEweb's Solenoid page has loads of new
super technical links thanks to our sponsor ASCO iincluding;
- Considering
Valve Specification & Installation, Flow Control - Best Practices
& Technology to Ensure Long-Term Performance - Matt
Migliore - When specifying valves for a given
application, it is important to first determine
the intended function. A lack of functional
understanding is often where valve performance
issues begin. The user, rather than fully
considering the application in which the valve
will operate finds later on that the valve isn’t
all that well suited to meet the needs of the
job it is being asked to do. Thus
it is worthwhile answering a few simple questions
when considering a valve purchase.
- Solenoid
Valve Technology,Technical Characteristics Function, Terminology and
Construction types -A very useful overview of solenoid operation,
construction, terminology and operating parameters
- Understanding
Solenoid Valves - Solenoid valves are highly engineered products that
can be used in many diverse and unique system applications. A brief overview
of the components and functional varieties of solenoid valves - from achrnews.com
- Solenoid
Valves Trouble Shooting Guide & FAQ - A useful
troubleshooting guide from solenoidvalvesuk.
- Solenoid
Valve Common Symbols - From Connexion Developments
Ltd
- Solenoid
Valve Seal Basic Guide - Selecting the correct
sealing material for your solenoid valve requires an understanding of
available sealing materials. Seals are usually the most limiting factor of a
solenoid valve. The seal selection should take the following items into
consideration;
- Chemical properties of the media
- Temperature of the media
- Pressure to be used
From solenoidvalvesuk
- How
to Specify Solenoid Valves for a Particular Safety Integrity Level
- S.A. Nagy - Selection must be done with care and understanding of safety
and reliability standards to avoid the risks associated with an operational
failure of a critical plant system - thanks to chem.info
A new section on Sight Glasses has been added
to ICEweb's
Level Page - It includes the following technical information;
- Mechanically Prestessed
Gas/Steel Sight Windows Resist Pressure and Impact Failure - An article from
Chemical equipment and L.J.
Star Inc.
- On-line engineering tutorial on sight glass technology as it applies to
chemical processing and pharmaceutical processing. This free webinar
begins with an overview of the essential aspects of glass, noting the
various formulations used in chemical, food and pharmaceutical process
observation equipment. Concentrating on sight glass selection, installation,
and proper maintenance, the webinar explains how to safely and effectively
use sight glasses in process applications ranging from standard lines to
exceptionally demanding applications with high temperature, high pressure,
and sanitary requirements.
- Are
You Gambling with Your Sightglass? - Selection Strategies for When
Failure Is Not an Option - Andrew Obertanec -Sightglasses
are sometimes called “the weakest link” in a processing system because
of the fragility of the glass. Actually, that’s not necessarily true. A
sightglass need not be a weak link in a processing system because glass,
when uniquely designed, is not necessarily fragile. Thanks to
flowcontrolnetwork.com.
-Technical
Information and Guidelines for the Specification, Installation and
Maintenance of Sight Glasses in Chemical and Pharmaceutical Processing
Plants - This illustrated "Chemical and Pharmaceutical Sight Glass
Application Handbook" spans the full scope of the subject from
descriptions of common glass formulations to design factors, to a
step-by-step checklist for installation and maintenance. From L.J. Star Inc
- You will have to register to get a copy.
- Critical
Standards for Specifying Sight Glasses - Sight glasses are highly
engineered products. Although brands look alike, differences in their specs
have tremendous importance for worker safety, sanitary processes, and
maintenance costs. From L.J.
Star Inc.
ICEweb's Shutdown, ESD and Blowdown Valve page has been completely reworked and many more technical papers have been added.
Good for Maintenance - Even Better with Monitoring! - Ulrich Gensicke - FDT-based device and asset management software saves more than time and costs. To be competitive, high productivity and reliability are important factors. Use of an online diagnostic and monitoring system guarantees that all the functions of intelligent field devices can be exploited to the maximum - From our valued sponsor Metso Automation.
FDT/DTM - the most powerful way to release intelligence built in smart field devices - Visualization of these diagnostics requires a graphical user interface which meets customer expectations for openness and the capability to be integrated in any system. The technology supporting these very basic requirements is FDT (Field Device Tool). FDT is developed and marketed by the FDT group, which is a group of leading automation suppliers to both the process and factory automation industries. Go to page 7 to get this article - From our valued sponsor Metso Automation.
Check out ICEwebs new Variable Speed Drives and Cables Pages. We are looking for more technical papers on these and other Electrical subjects.
The Following Technical Papers have been
added to ICEweb's Electrical
Motors page
A
Comparison of the Characteristics of AC and DC Motors - As AC
motors continue to be used in applications traditionally served by DC
motors, some comparisons of the characteristics of AC and DC motors seem
appropriate. The aspects of AC and DC motors which will be reviewed include
typical construction, torque production, equivalent circuits, ratings (power
and torque density), speed ranges, load ranges, etc. This comparison will
also highlight some of the relative advantages and disadvantages of each
type of motor in variable speed applications. In addition, looking at
variable speed AC motors with a “DC motor mentality” can offer a more
“user-friendly” understanding of these AC machines. This point of view
can also suggest ways to optimize AC motors for variable speed
applications.
What Is Regeneration? - When the rotor of an induction motor
turns slower than the speed set by the applied frequency, the motor is
transforming electrical energy into mechanical energy at the motor shaft.
This process is referred to as ‘motoring’. When the rotor turns faster
than the synchronous speed set by a drive output, the motor is transforming
mechanical energy from the motor shaft into electrical energy. It may be a
ramp to stop, a reduction in commanded speed or an overhauling load that
causes the shaft speed to be greater than the synchronous speed. In any case
this, condition isreferred to as ‘regeneration”.
Drive and Motor Basics - An adjustable speed drive is a device
that controls speed, and direction of an AC or DC motor. Some high
performance drives are able to run in torque regulation mode.
Motor Load Characteristics - Motor loads are classified into
two main groups depending on how their torque requirement varies with
operating speed. The following paragraphs deal with the various load types
found in industry.
Power Distribution Systems - The type of transformer and the
connection configuration feeding a drive plays an important role in its
performance and safety. The following is a brief description of some of the
more common configurations and a discussion of their virtues and
shortcomings.
Dealing with Power Factor Correction Capacitor switching and AC drives
- There are two significant concerns regarding the existence of power factor
correction capacitors being located on the input of an AC Drive. One concern
is the additional current loading that may exist in the capacitor. The other
concern occurs when capacitor switching is used to adjust any variations in
the power factor of the motor load.
Timely Advanced Control Upgrades: Recapture and Multiply Benefits - Andrew Taylor - This paper discusses the establishment of Advanced Process Control (APC) in refining, petrochemical and oil & gas production facilities and the various mechanisms which dictate the lifecycle of an APC application. The benefits of appropriate APC upgrades are examined with the key elements of a variety of case studies highlighted. The case studies cited include an APC technology upgrade and various APC revamps following process context changes (e.g. clean fuels refinery upgrades). The key elements in an APC lifecycle management program are proposed. from ProSys Engineering. See this and more Advanced Process Control papers on ICEweb's Control page.
A new section on Decentralised Control has been added to ICEweb's Control page.
An Integrated Approach to Safety: Defense in Depth - Ensuring safety requires reducing the risk of incidents, faults and failures that can disrupt normal operations. This effort goes far beyond simply installing fail-safe controllers or a safety instrumented system. In fact, to mitigate the risk of serious incidents that can cause injury to personnel, equipment and the environment, it is important to consider safety from all aspects of a plant’s operation - From Honeywell - More great SIS papers can be found on ICEweb's SIS page.
HART Monitors Extract Data from Smart Instruments - Simple Modules Expand Transmitter Usefulness - Greg Feliks - The HART digital signal often contains additional process measurements and other variables that may include instrument status, diagnostic data, alarms, calibration values and commands. In many cases, HART instruments were installed simply because they could be configured and diagnosed easily with a handheld HART communicator device. For a variety of reasons, the rest of the HART data often goes unused. One reason is because of the prohibitive cost of installing a plant-wide HART monitoring system. Another reason is the lack of familiarity with alternatives. A simple and cost effective solution for gathering HART information is to use a HART interface device only in the specific instances where it is needed most. Fortunately, HART interface devices, available from several manufacturers, make acquiring HART data a fairly simple proposition. This HART data is then made available to the control system via analog signals, discrete outputs or serial communications. From our valued sponsor Moore Industries-Pacific, Inc.
Posted by: Jim Russell, August 2008
*** The August edition of ICEnews is just packed full of great tools, links, technical papers and other fantastic information.
Cuil, - This search engine combines the biggest Web index with content-based relevance methods, results organized by ideas, and complete user privacy. Cuil (www.Cuil.com) has indexed 120 billion Web pages, three times more than any other search engine. This is a fantastic resource.
ICEweb has developed a new Uninterruptible Power System page.
Edition VI of Industrial Pressure Regulator Application Guide - This 736 page, 4-color guide serves as a reference for technical applications and pressure data on Fisher® brand industrial regulators and is designed to provide assistance in selecting the right pressure regulator for a broad range of applications anywhere in the world. The Industrial Application Guide's comprehensive Technical Section includes several new and updated sections such as Regulator Components, Principles of Direct-Operated Regulators, Principles of Pilot-Operated Regulators, Selecting and Sizing Pressure Reducing Regulators, Over Pressure Protection Methods, Principles of Relief Valves, Principles of Series Regulation and Monitor Regulators, Valve Sizing calculations, Valve Sizing, Temperature Considerations, Sulfide Stress Cracking, Conversions, Equivalents, and Physical Data. Thanks to ICEweb sponsor Emerson Process Management.
All in One Glass - Alternate approach to gage-glass maintenances leads to more accurate drum level measurements - Dale P. Evely - Southern Company, a producer of electricity, fiber optics, and wireless communications, developed an alternate approach to address gage glass maintenance issues as well as measurement uncertainties associated with water-column-type measurements - from ISA and InTech
Calculating for Calibration & Conversion-Factor Inconsistency- Accurate flow measurement often entails careful attention to detail. Errors can be introduced when calculations in different parts of the flow measurement system are performed using different standard conditions. From David W. Spitzer P.E and flowcontrolnetwork.com. For a GREAT flow resource see ICEweb's Flow page.
A very useful corrosion link added to ICEwebs corrosion page is the "Corrosionist" Corrosion Search Engine.
Compressor Surging Under Control - Turbocompressors, either centrifugal or axial, are the heart of many industrial processes. Often, these compressors are critical to the operation of the plant, yet they are seldom installed with a spare unit. Surging represents a major threat to compressors and these processes. Surge prevention is an important process control problem in these environments as surging can result in costly downtime and mechanical damage to the compressors. An effective anti-surge control system is critical for every turbocompressor. From Prabhat Yadav and Cheresources.com
Have a look ICEweb's new Hydraulics page which is just full of great technical links, formulae, calculations, technical tips and Tutorials etc.
Fieldbus Wars revisited? There has been an interesting war of words over the article Profibus PA and Foundation Fieldbus - A Cost Comparison by James Powell of Seimens Milltronics. The response by Jim Cahill of Emerson Process Management is a beauty!
Posted by: Jim Russell, June 2008
Sponsor Abisham Software have provided The world's first FREE RFID e-learning course which is a no obligation , no strings attached, absolutely free RFID course, that can be downloaded to your own PC and you can view it without any restrictions at all! Plus it's a REAL e-learning course, NOT somebody's stale Power-Point presentation! It has plenty of flash based animations, graphics and text, with a self-assessment test. The visuals help you learn key concepts QUICKLY and EASILY.
ICEweb's Fire and Gas, Fire Detection and Gas Detection pages have been upgraded with new links also being added.
How to Manage Hazardous Areas effectively by using Gas Monitors - Electrical equipment installed in hazardous areas, necessarily has to conform to the area classification for that area. However, frequently, practical problems arise, where the specified equipment may not be easily available. For example, an area classified as Zone 1 under the IEC system, theoretically can accept only Zone 1 equipment. However sometimes, especially in case of specialized equipment, Zone 1 certified equipment of that type may not be available. In such cases what could be done? This paper presents the background of such situations, possible solutions and current international practices regarding this issue - Thanks to our valued sponsor Abhisam Software.
Calculate temperature and resistance tables for Minco's RTD Elements - From MINCO
Calculate temperature and millivolt tables for Thermocouples based on NIST Monograph 175 - From MINCO
How To Select And Use The Right Temperature Sensor - Ron Desmarais - This paper answers the question "How do I determine which sensor to use in my application?” After a brief review of how RTD’s and thermocouples are constructed and used to measure temperature, it discusses what differentiates these sensors from one another. It covers the topics of temperature range, tolerance, accuracy, interchangeability and relative strengths and weaknesses for each type. After reviewing these topics you will have a better understanding as to when each type of sensor should be used and why. From Pyromation, Inc.
Have a look at ICEweb's new Orifice Plate page which is full of great technical papers / articles on Orifice Plates, associated standards and associated equipment.
Fundamentals
Of Gas Measurement - D. A. Tefankjian - In any field of endeavour
for a person to completely understand the endeavour, he or she must have a
knowledge and an understanding of the fundamentals involved. People can do
well in the performance of their work without knowing the basic principles,
but to excel and progress knowledge of the fundamentals is necessary. This
is particularly true if one’s work is technical in nature - Includes –
Units of Measurement, Behaviour of the gas molecule, property of gases, the
gas laws along with the methods and means of measuring gas
A huge swag of new technical papers have been added to ICEwebs new Pressure Regulator page.
Fundamentals of Pneumatic Controllers -Doug Butler - Controllers in one form or another have been around the process industries for a number of years. In fact, they are such a familiar sight in most industrial operations that they frequently suffer from being taken for granted. Yet, the quality of performance provided by a control system is determined by the performance of the controller and the other elements in the loop. The controller, with its various adjustments, is the one element in the control loop that allows any measure of operating flexibility. For optimum performance, it is necessary to use the controller properly. This requires a thorough understanding of some fundamental relationships - From CEESI. For more Control Technical papers go to ICEweb's Control Systems page.
Determination of Specific Gravity of Gases: Fundamentals and Instruments - Faruk Civan - Specific gravity is one of the basic properties used for characterisation and measurement of gases. Instruments used for determining specific gravity are called gravitometers. There are also methods by which specific gravity can be determined indirectly. Accurate determination of specific gravity is essential for accurate measurement of gas flow rate - from CEESI
Commonsense Engineering Safety Tips When Commissioning Plant - IDC have compiled a list of tips on working safely when commissioning a plant or with machinery from an electrical, mechanical, instrumentation and IT point of view. See more tips like this on our Tools page.
ICEweb's Australian Standards for gas detection/ Ex Equipment page has been revised to detail the latest updated standards.
Posted by: Jim Russell, May2008
Control Engineering Virtual Library - This comprehensive resource from the University of Cambridge gives links to Control Groups Around the World, Professional Societies, Control Related Journals, Control Information and other Miscellaneous information.
Advanced Diploma in Industrial Automation - The aim of this 18 month e-learning programme from IDC is to provide you with core industrial automation skills.
Pressure Sensor Technologies - Peter Welander - Pressure transducers are everywhere, but do you know what’s inside? Choosing the right technology can be critical, especially in extreme applications - From Control Engineering
HIMA Australia have announced that they will be launching their new safety system "HIMax" in mid 2008 and a change in Management - HIMA Paul Hildebrandt GmbH + Co KG are launching a safety system which will set new standards in performance, safety and availability within the process industry. In the development of flexible and intelligent safety platforms, HIMA’s special focus was on increasing the availability and profitability of process plants. Offering unique features, HIMax ideally satisfies the global process industry’s demand for increasing the profitability of safety-oriented applications.
The
May
edition of ICEnews has been issued, this
is a new web based format which hopefully you will all enjoy. As usual this
bumper issue has plenty of links to really useful information across a broad
range of Instrumentation and Control Engineering.
Posted by: Jim Russell, April 2008
Frictional Ignition of Powders - Geoff Lunn - This is a comprehensive review - Surveys of industrial incidents in powder and dust handling plant show that in a substantial percentage, friction and mechanical failure and flames and flaming material are known ignition sources.
A new section on Field Device Tool (FDT) Technology has been added to ICEweb's fieldbus page. FDT (Field Device Tool) technology standardises the communication interface between field devices and systems. The key feature is its independence from the communication protocol and the software environment of either the device or the host system. FDT allows any device to be accessed from any host through any protocol.
The following technical papers from our valued sponsor Emerson
Process Management - have been added to ICEweb's comprehensive
pH page.
- Theory
and Practice of pH Measurement- An excellent 43 page
handbook.
- Advances in pH Modeling and Control - Gregory K. McMillan (Emerson)
and Mark S. Sowell (Solutia Inc) - Many chemical and biological processes
have pH control loops. Good pH control can be important for product quality
as well as environmental compliance. The extraordinary rangeability and
sensitivity of pH as a concentration measurement poses exceptional
challenges in many aspects of pH design and implementation.
- Virtual Control of Real PH - Virtual Design reduces the hassles of PH
control.
- George Pence and Richard Baril - Improvements in sensor life and
range of applications can move liquid analysis from one of the most
“cursed” functions in the plant, to one that requires only modest
attention.
Users want Happy Union with Wireless, but Doubts Linger - Patrick Schweitzer - When it comes to wireless technology, the user community wants simplicity, robustness, education to understand this new world, and coexistence among all players to make this the wireless world of our dreams. Yet as wireless picks up momentum in the industrial marketplace, users are still confounded by the potentials and pitfalls a wireless world can bring -Thanks to ISA/InTech.
In 2008, Wireless a No-Brainer - David Savells and Brent McAdams - Advantages of wireless I/O go far beyond the cost of wiring: Economies of scale, fail safe, flexibility, reliability, diagnostics and low power consumption - Historically, regardless of the industry, hardwiring has been the only option available for users to connect remote instrumentation assets in the field.However, new technology enabling greater use of spread spectrum radios gives companies the ability to connect remote instrumentation in the field without the need for a costly, wired infrastructure - Thanks to ISA/InTech.
Strategic Implementation of Wireless Technologies - The evolution in wireless technologies has opened the door to a new class of plant automation architecture that offers adopters a significant strategic advantage. Driven by substantial and measurable cost savings in engineering, installation, and logistics, as well as dramatic improvements in the frequency and reliability of field data collection, automation experts and IT professionals are presented with an opportunity to deliver a major, positive impact to their respective company’s bottom line - from FreeWave.
Cables - Best practices for process instrumentation cabling - Connectivity glues the network together; Cabling, grounding, cable routing, and the mitigation of noise and interference - Saeed M. AL-Abeediah - The health and effectiveness of any plant’s Process Automation System (PAS) relies on many factors. Among these factors is the proper selection of PAS components, seamless integration, control schemes, control system installation, and last but not least, proper electrical installation and connectivity of field instrumentation devices. This last factor, which glues the entire PAS system together, involves cabling, grounding, cable routing, and mitigation of external influences such as noise and interference. Thanks to the ISA and InTech.
ICEweb has developed a new Uninterruptible Power System page.
Getting quality down PAT - Baha Korkmaz, Arnold Martin, and Cenk Undey - Companies that proactively approach the new technological trends and invest in automation have a better chance of success. Using the concepts behind process analytical technology (PAT) is one effective tool to achieve this success, especially when incorporating batch standards, such as ISA88. From the ISA and InTech.
Lather up with batch - Matthew Leys and Sean Cahill - Unilever knew the success of its personal care consumer goods brands rested on the quality performance of its health and beauty mixing plant and aerosols plant. Economic growth paired with sound environmental management were just part of the strategy. Yet a total process control system update would help guide them to down the road to success. Also included in this article is a second article - Return to flexible batch automation - The ISA88 standard is easy to comprehend, but gaining in-depth understanding is a long process that takes understanding process operation and software engineering. From the ISA and InTech.
Brewery Taps Higher Control - Small brewer’s system allows greater productivity, flexibility - John Mallett and Todd Stauffer - When Bell’s Brewery decided to upgrade the temperature control system on its 45 fermentation tanks in mid-2006, they were just planning on expanding their existing system of dedicated single-loop controllers for each of its tank control points. Instead, after taking a look at their options and what technology suited them best, Bell’s opted to take a quantum leap forward by implementing a state-of-the-art process automation system for temperature control of its tanks. From the ISA and InTech.
A Guide to Low Resistance Measurement - Note this is a large 3 MBits download. This handbook gives an overview of low resistance measurement techniques, explains common causes of errors and how to avoid them. We have also included useful tables of wire and cable characteristics, temperature coefficients and various formulas to ensure you make the best possible choice when selecting your measuring instrument and measurement technique - from Cropico.
ICEweb's Modbus page has been extensively upgraded with new links and excellent technical information.
Using MODBUS for Process Control and Automation - MODBUS is the most popular industrial protocol being used today, for good reasons. It is simple, inexpensive, universal and easy to use. Even though MODBUS has been around for nearly 30 years, almost all major industrial instrumentation and automation equipment vendors continue to support it in new products. This white paper discusses how MODBUS works and a few clever ways it can be used in new and legacy plants. From our sponsor Moore Industries-Pacific, Inc.
Installing Fieldbus in Real-Life Applications - Many automation engineers are coming face-to-face with real fieldbus applications for the first time. Fieldbus is a wonderful technology with many benefits, but fieldbus installation requires some additional considerations over and above normal 4-20mA projects. In this in-depth white paper, we discuss some of those issues, and show you how to deal with them. From our sponsor Moore Industries-Pacific, Inc.
Can't Happen at your Site?- Eric Byres - Unless you’ve been hiding out on a desert island for the past year, you can’t help but notice the serious impact hacking and viruses have had on corporate information technology (IT) systems. At least once a month, a new hacker exploits or Trojan e-mail threatens to do considerableharm to the workings of a business network. If hackers can do that much damage to a desktop PC, what about that programmable logic controller (PLC) or human-machine interface sitting on the plant floor? From Byres Security.
Topologies for Wireless Instrumentation - To set the stage for wireless instrumentation, do you know how to get the signal from instrument to control system? Here’s a nuts-and-bolts guide to orchestrate your options for permanently mounted instrumentation - from Control Engineering.
All in One Glass - Alternate approach to gage-glass maintenances leads to more accurate drum level measurements - Dale P. Evely - Southern Company, a producer of electricity, fiber optics, and wireless communications, developed an alternate approach to address gage glass maintenance issues as well as measurement uncertainties associated with water-column-type measurements - from ISA and InTech
PACs for Industrial Control, the Future of Control - With a number of vendors producing Programmable Automation Controllers that combine the functionality of a PC and reliability of a PLC, PACs today are increasingly being incorporated into control systems. This white paper explores the origins of the PAC, how PACs differ from PLCs and PCs, and the future direction of industrial control with PACs - From National Instruments.
***
ICEweb has another new page! This one covers DataLoggers, have a look as it has a "heap" of great papers covering the huge range of uses that this technology embraces. Thanks to our new sponsor HINCO.
Development and Analysis of a Novel Vertical Axis Wind Turbine - Paul Cooper and Oliver Kennedy - This paper describes the development of a novel vertical axis wind turbine used for teaching and research purposes. The device is designed to operate at low tip speed ratios and features blades that are symmetric about the mid-chord plane. The blades are actively pitched by means of a mechanical system so that the chord of each blade rotates by 180º for every revolution of the main rotor. One of the attractions of the device is that it is self-starting and produces relatively high torque. A multiple streamtube analysis of the device has been developed and numerical predictions for the performance of the device are presented. Commissioning and field tests of a prototype are described and some preliminary performance results are presented and discussed - From the University of Wollongong
Power plant sees green with new digital bus system - John Blaney, Jim Murray, and Gary Tingley - Chasing advantages in design and construction savings, the utility wanted to incorporate digital bus technology in as many areas as possible. Both Foundation fieldbus and PROFIBUS are used significantly throughout the balance of plant systems. Another reason behind the decision was simply the opportunity to try new technology on a new plant since the technology has been proven in many other industries, just not in the power industry - From the ISA and InTech. See this paper and more at ICEweb's Fieldbus page.
The following technical articles have been
added to ICEweb's reworked Test
and Calibration pages.
- Low
Pressure Calibrations - When
you're performing a low pressure calibration, there are some things you can do
to make the job easier and better (more accurate) .
- Temperature
Calibrations (Thermocouple Edition) -There
are a few "gotchas" in temperature calibration when we're talking
about T/Cs and RTDs. Each has its own problems, This article focuses on the calibration of T/C instrumentation.
- What is the difference between calibration and adjustment?- From the UK's National
Measurement Laboratory.
- Calibrating Non Destructive Testing Instruments
- NDT Resource Centre
- Automated calibration planning lowers costs
- Calibrating Fieldbus Transmitters.
- How often should calibrators be calibrated?
- How often should instruments be calibrated?
- Traceable and efficient calibrations in the process industry.
- The Safest Way to Calibrate - An introduction to
intrinsically safe calibrators
Posted by: Jim Russell, March 2008
More new pages! ICEweb has developed the
following pages thanks to our sponsor Prochem Pipeline Products;
- Heat
Tracing and Bundles - Heat Tracing, Bundles, Heated Hose, General
theory, Applications and more!
- Instrument
Valves, Accessories, Enclosures, Sunshades and Supports
- Pressure
Regulators - General Theory, Technical Papers, Maintenance, Applications
and more.
- Samplers
- On-Line Samplers Liquid Samplers, Gas Samplers, Solids Samplers,
Applications and more.
- Monoflanges,
Instrument Manifolds - Technical Data, Specifications, Application Data,
Installation, Operation, Maintenance and more.
Check out ICEweb's new Laser Instrumentation page, it covers General Theory, Laser Level, Laser Positioning, Laser Measuring, Laser Survey and more. Thanks to our sponsor Zedflo Australia.
How much does it cost you to change a light globe? - Do you want to dramatically reduce your lighting maintenance costs and reduce your risk hazards? Lighting maintenance is a necessity and often an expensive job in the industrial work place today. The costs involved are usually high due to the positioning of light fittings. This no longer needs to be the case. The installation of an In2 Light Hatch® will dramatically reduce the costs involved in changing light globes on industrial work sites. Thanks to our sponsor Zedflo Australia.
Chemical industry gets serious about security: Perfecting programs, educating users - Ellen Fussell Policastro - This excellent article describes how the industry is sharing its knowledge about security and helping manufacturers build their fortresses, to not only comply with new government regulations, but to enhance the overall security of control systems throughout the industry - ISA and InTech
Many new very useful links have been added to Our Ultrasonic Flow Metering page, thanks to our sponsor Zedflo Australia.
ICEweb's Control Systems Page has been extensively upgraded with new links on control systems, alarm management, process security and more!
Protecting Process Control Systems & Networks - Chris Taylor, Larry Falkenau and WBF org.
A huge swag of new technical papers have been added to ICEweb's Safety Instrumented Systems Page, thanks to our sponsor Hima Australia.
HIMA safety controllers monitor heating installation on the Queen Mary 2 - Two safety-related controllers, acting as a Boiler Management System, reliably provide operational safety to the application. - Looking for more on Burner Management Systems? ICEweb's comprehensive BMS page has it!
Lightning Protection for Wind Turbines - The Lightning Protection Project was conceived by the National Renewable Energy Laboratory (NREL) to improve the understanding of lightning caused damage to wind turbines and how to protect them. This project report is very comprehensive thanks to www.solacity.com .
A New Lightning Protection System for Wind Turbines Using Two Ring-Shaped Electrodes - Yasuda Yoh - This technical paper focuses on a method for protection of low-voltage and control circuits in a wind tower, detailing a new lightning protection system with two ring-shaped electrodes attached to the wind turbine.
Surge Protection for Fieldbus without Performance Limitations -
The Following Intrinsic
Safety Technical Manual is from Cooper Crouse-Hinds and covers;
- Determining Safe Energy Levels
- Intrinsically Safe Barriers - Grounded Zener Barrier - Isolation
Barriers- Remote I/O Products
- Selecting the Proper Product for Your Intrinsically Safe Application
- Installation, Maintenance & Troubleshooting of Intrinsically Safe
Circuits
Posted by: Jim Russell, February 2008
When did you last inspect your safety light curtains? - Companies using light curtains to safeguard machinery often do not appreciate the implications of the regulatory requirement for inspections. Thanks to Pilz. For more articles like this see ICEweb's Manufacturing and Automation Safety page.
How functional safety helps to save lives -In this article Ron Bell explains functional safety and looks ahead to the revision of the IEC 61508standard that is due for publication in 2010.This article by Jeanne Erdmann was first published in the January 2008 edition of the IEC's E-TECH. http://www.iec.ch
Overboard Dump Valves - Overboard dump valves are valves that are typically used to control the flow of seawater being dumped overboard on off-shore installations. Process conditions that would be innocuous on standard applications, become severe when applied to overboard dump valves. Often users fail to realise the criticality of the application which results valves being incorrectly specified, ultimately leading to vibration, erosion and failure. This technical article addresses this - From Weir Valves. More articles can be found on ICEweb's severe service page.
Top Tips for flowmeter selection- The huge array of flow technology options on offer can make selecting the correct flowmeter for an application a bewildering task. A broad range of factors can influence flowmeter selection, of which cost is just one. Dr Bryan Franklin, Flow Products Manager, ABB Limited recommends a list of top tips for selecting the best all round flow system for an application.
ICEweb's Australian Standards for Electrical Apparatus in Hazardous Areas- Explosive Gas Areas paper has been updated. Thanks to Inlec Engineering for the review!
Solenoid Valve Engineering Information- This excellent engineering information sheet details most of what you need to know in regards to selecting a solenoid valve. It details maximum/minimum pressures and temperatures, viscosity, response times, valve seat tightness and degrees of protection provided by electrical enclosures (IP code), thanks to our sponsor ASCO.
How to Install, Troubleshoot and Maintain Solenoid Valves- Good Installation and Maintenance Tips, thanks to our sponsor ASCO.
AS2380.9 has been superseded by Standards Australia on 31 December 2007 by AS/NZS 60079.15:2006 (Electrical apparatus for explosive gas atmospheres - Construction, test and marking of type of protection, ‘n’ electrical apparatus).
Standards Australia have updated the Electrical Equipment for Hazardous Areas Handbook HB2007 - The main objective of this updated handbook is to provide a basis for understanding the principles involved in the identification of a hazardous area, relevant statutory requirements and the selection and installation, maintenance, testing, overhaul and repair of appropriate electrical equipment. This handbook also provides a basic introduction to the relevant Australian, New Zealand, Joint (Australian/New Zealand) and International Standards dealing with hazardous areas.
Posted by: Jim Russell, January 2008
ESD Valve Fire Shelter - This is a neat idea, these cabinets will provide the valve actuators with a minimum of 30 minutes of protection against fire, so that the plant's emergency shut down systems and services can quickly isolate and minimise damage, to protect employees, assets and environment.
University chilled water plant plays it cool with ultrasonic flowmeters - An application article - From InTech and the ISA
Preventing Direct Lightening Strikes - Roy B. Carpenter, Jr - This paper looks at lightening strikes and how to prevent them - from lecglobal.com
Glossary of Process Control Terms - Looking for a Control Term? You are likely to find it here - John Gerry, P.E., ExperTune Inc.
ICEweb's Corrosion Page has been updated with new links.
A new section on Cascade Control has been
added to our Control
Systems Page and the following papers included.
- Cascade Control- Handle Processes that Challenge
Regular PID Control - Arthur Holland, Holland Technical Skills- A paper
which explains how Cascade Control can be used to cater for lags in Process
Control.
- Cascade Control - The Basics - from learn control.com
Calibrating and Testing Control Components on your Heat Process - What, When and How Should I Calibrate? - Arthur Holland, Holland Technical Skills - an excellent explanation on the basics of calibration.
Signals - A look at 4 - 20 Milliamp Signals - Arthur Holland, Holland Technical Skills - A good description of 4-20Ma technology, see more great instrumentation information on ICEweb's TECHweb page.
**Programmable safety begets new standard - Safety-integrity levels spelled out in European standards increasingly impact equipment designers in the U.S. - Dave Collins - Schneider Electric - Thanks to Machinedesign.com
Why WirelessHART™? - The Right Standard at the Right Time - This paper summarises key aspects of WirelessHART, including several of the design decisions that make it the right choice for wireless process automation.
The
following papers and presentations are from the IDC Technologies "Hazardous
Areas: Classifications and Equipment Conference 2007", these papers are
recommended reading.
Electrical
Equipment in Hazardous Areas - Field Inspections - Bill Rankin - This
paper focuses on the problems which are directly related to the inspection
process. It has been written from the perspective of the
Ex inspection team who usually have no control over the
design and installation process. It is acknowledged that the competency of the
design and installation personnel will affect the quality of the installation
that is to be inspected. The failure of Ex inspection campaigns can be
attributed to four main areas:
- Poor planning of the Ex inspection activities
- Lack of competence of the Ex inspectors
- Lack of clarity of the inspectors’ roles
- Lack of clarity of the inspection scope
Ex
Inspections—Potential Pitfalls - Alan Wallace- Inlec Engineering -
Many, if not most, Ex inspection campaigns are grossly inefficient, and
their
effectiveness is often questionable. This presentation discusses the four
main reasons why Ex inspection campaigns fail to meet the clients’
expectations. It also offers recommendations to improve the quality and
efficiency of Ex inspections.
The
Application of Intrinsic Safety to Fieldbus Systems - Chris Towle
Chairman: MTL Instruments Ltd - This excellent paper covers the technical
aspects of FISCO, FNICO, Exe and Exi combination, Maintenance and Inspection
along with Intrinsically Safe Ethernet.
Myths
and Actual Practice with Industrial Data Communications and Hazardous Areas
- Steve Mackay - IDC Technologies - This presentation covers Practical
examination of data communications systems in hazardous areas for Ethernet,
Foundation Fieldbus, Profibus or RS-485 along with Practical guidelines for
best practice in designing your next industrial data communications system
in a hazardous area.
The
Current State of the IEC Intrinsically Safe Standards - Chris Towle -
Chairman: MTL Instruments Ltd - A candid discussion on the IEC IS standards
which includes IEC Organisation, Intrinsic Safety Standards, An Analysis of
the Change from ‘nL’ to ‘ic’ and advice to the First-time Designer.
Changes
to Certification and its Impact on Manufacturers - Des McDonell CSE-Ex
Pty Ltd - This presentation covers product certification in Australia.
Trends in Process Temperature Measurement -An Evolving Technology Segment Changes Focus to Meet End-User Needs - Mike Cushing - This article also covers the basics about resistance thermometers, thermocouples and the use of temperature transmitters - from www.flowcontrolnetwork.com
Our Manufacturing
and Automation Safety page has been updated with heaps of new links thanks
to sponsor Pilz Australia
including the following:
- Mining
faces growing pressure to address plant hazards Part
One and Two - With a fatality rate double the national average and an injury
rate that is 50 per cent higher, mining is a dangerous industry. The causes of
this extraordinary injury rate are equally as remarkable: machinery and plant
accounted for 75 per cent and two in every three mining injuries were put down
to bad design, far more than the 50 per cent the manufacturing sector attributes
to design. Part 2 considers
what can be done to make mining plant safe and compliant.
- Not
all e-stops are equal before the law – how to be sure yours comply -
Because emergency stop devices or “e-stops” are everywhere, they tend to be
taken for granted but the law takes them very seriously as the last line of
defence in machine safety-Australian Standard 4024
describes an emergency stop as “a device which, regardless of the power
source, e.g. electrical pneumatic or hydraulic, requires deliberate action to
bring a machine to rest when danger is recognised”. Pilz
Safe Automation's Frank Schrever explains the basics of how the Plant
Regulations and the Australian Standard for safeguarding of machinery apply to
emergency stop devices.
- SafetyBUS p - This is the first open, safe bus system to
have been approved by BG to category 4 in accordance with EN 954-1, EN 60204, EN
62061 and by TÜV to AK 6 in accordance with DIN V 19 250, SIL 3 in accordance
with EN IEC 61508 and NFPA 79. This guarantees a wide application area for
safety applications, from which users in plant and machine engineering as well
as the automotive industry can benefit.
This concise Question and Answer Article covers Wireless Advantages, Pitfalls, Best Practices, Wireless Terms, Security, Future, Comparison with Hard Wired Systems, Frequency and Operating Range - from Geof Brazier and BSB Wireless.
Effluent Flow with Suspended Solids -Facing Rising Treatment Costs, Paper Mill Reconsiders Flowmeter Installation - This article added to our comprehensive Ultrasonic Flowmeter page describes some solutions to this issue - David W. Spitzer, P.E.- Thanks to flowcontrolnetwork,com
See
our books
page for Details of Industrial Flow Measurement, 3rd Edition - David
W. Spitzer - Designed to help practicing engineers avoid costs
associated with misapplication of flowmeters, this
Links
to the Following webinars and papers can be found on our Industrial
Ethernet page.
- Industrial Ethernet, an Introduction
- Industrial Ethernet, Ethernet Network Architecture
- Industrial Ethernet, Advanced Ethernet Architecture
- PROFINET - the all-encompassing Industrial Ethernet
- Industrial Ethernet Diagnostics - This webinar on Industrial
Ethernet Diagnostics describes how to troubleshoot and diagnose problems on
an Industrial Ethernet network. It highlights which tools from
the IT world are useful for Industrial Ethernet.
- Industrial Wireless Networking- In this Industrial Wireless Networking
webinar you'll learn all about the latest Wireless technologies in use for
Industrial Wireless applications including IEEE 802.11 (Wireless Ethernet) ,
Bluetooth, and other wireless technologies.
- MES and PROFINET - The PROFINET and MES Maintenance Operations guideline
of PI (PROFIBUS & PROFINET International) defines an open integration
path between MES and PROFINET based automation systems.
- PROFINET in the Process Industries -
As a backbone network, PROFINET is ideally suited to the task of surfacing
process data stored in control systems and field devices. Media gaps that
hinder the flow of critical data between process equipment and enterprise
systems can be bridged with PROFINET proxies, creating an all-encompassing
network architecture that brings the now ubiquitous industrial Ethernet into
the process plant.
The technical paper PROFIsafe: Networked Safety for Process and Factory Automation -ARC presents some compelling benefits for using PROFIsafe and two success stories can be found on ICEweb's Manufacturing and Automation Safety Page .
Our PROFIBUS
page has been updated to include the following papers.
- Why
use a fieldbus?- This article details the advantages of using a fieldbus
system - also available as an MP3 file
- PROFIBUS PA vs. Foundation
Fieldbus - a cost comparison, also available as an MP3 file.
- A Guide to Troubleshooting PROFIBUS PA Networks -A
systematic approach makes network set-up and trouble-shooting easy - James
Powell
- The Value Proposition of PROFIBUS in the Hybrid
Industries -This ARC Advisory Group white paper shows the benefits of
PROFIBUS in the process industries. And almost all
process
industries have a discrete need as well, hence are hybrid.
- PROFINET: An All-Encompassing Industrial Ethernet
Solution - ARC presents an overview of PROFINET and some application
stories.
- Tool Calling Interface. Device tools perform user
functions such as parameterization and diagnostics directly from the
automation-system engineering tool. Device tools are based on a Tool
Calling Interface (TCI).
FOUNDATION Fieldbus Provides Automation Infrastructure for Operational Excellence - This ARC report highlights that End users are increasingly specifying automation products and services not based upon the level of technology they provide, but on the business value proposition. FOUNDATION Fieldbus technology should be looked at from the same point of view.
Posted by: Jim Russell, December 2007
Clamp on Ultrasonic Flowmeters - Your Questions Answered - Thanks to our Sponsor Zedflo Australia
Laser Level Measurement - The ultimate solution for industrial process challenges, laser exploits the unique properties of light to produce precise, reliable, fast measurements. High update rates provide accurate measurements even when objects move quickly or material levels change rapidly - from Optech and our sponsor Zedflo Australia.
Standard Platinum Resistance Thermometers - Frequently Asked Questions - From ISOTECH
Temperature Calibration; Depths of Immersion - John P. Tavener -Of all the sources of errors and uncertainties in thermal calibration by far the largest source of error and least understood effect is that of immersion of unit under test, and the reference standard - From ISOTECH
What is the difference between calibration and adjustment? - From the UK's National Measurement Laboritory
The following links can be found on our
revamped HIPPS
page.
- High Integrity Protection Systems (HIPPS) – Making
SIL Calculations Effective - Jean-Pierre Signoret Thanks to
Touchoilandgas.com
- High Integrity Pressure Protection Systems (HIPPS) -
Angela E. Summers -
- High
Integrity Protection Systems For New And Existing Vessels - Bryan A.
Zachary and Angela E. Summers - Thanks to SIS-TECH Solutions
- Flare Header Overpressure Protective HIPS System -
This application brief describes a typical High Integrity Protective Systems
(HIPS) to minimize overpressure events in reactors and distillation columns,
and thereby reduce the frequency of relieving to the flare. From Triconex.
- Preventing overpressure: A safety system success
story - using failsafe systems to prevent overpressure - David K. Thomas
-From the ISA
- High
Integrity Pressure Protection Systems [HIPPS] for the Overpressure
Protection Of Pipeline Risers - This document is to provide guidance for
Inspectors in respect of the provision of remotely located HIPPS, including
those located subsea, for the protection of pipelines, pipeline risers and
some associated topsides process pressure systems. From the HSE (UK)
Risk assessment still vital under new Victorian regulations - The new Victorian Occupational Health and Safety Regulations are designed to simplify safety but, in the case of risk assessments, their release has caused real confusion. Thanks to our sponsor Pilz Australia
Changes to European categories of safety control will come to Australia in due course - The basis of AS 4024-1501 safety related parts of control systems defines categories of control system design which become more fault resistant as the risk increases. This is changing in Europe with the adoption of EN-ISO 13849-2006, which replaces the categories defined in EN 954-1 (which is AS 4024-1501) with Performance Levels and will be fully adopted in Europe by end of November 2009. Thanks to our sponsor Pilz Australia
Working in the Sun? The Cancer Council of NSW has released a guide for working safety in the sun - some great tips here that may even save your life.
Need for an industry standard for ESD valves from an engineering and safety point of view -Meghdut Manna - Tahakum East -Since the Piper Alpha disaster in the North Sea, design of ESD valves has been given top priority and remains to be of great concern for plant safety management.
ICEweb's Choke Valve page has been upgraded, however we are desperate for quality technical papers on this subject. Please send any to ICEweb.
Have a look at our updated
Gas Detection page, this now includes many additional links including;
- The Honeywell Analytics Gas Detector Newsletter -
This is packed full of features and articles on Gas Detection
- Honeywell Analytics Gas
Book - This handbook is intended to offer a
simple guide to anyone considering the use of
gas detection equipment. It provides an
explanation of both the principles involved and
the instrumentation needed for satisfactory
protection of personnel, plant and environment.
The aim has been to answer as many as possible
of the most commonly asked questions about
the selection and use of industrial gas
detection equipment. Thanks to our sponsor Honeywell
Analytics.
Smart technologies sustain plant reliability, help control costs - Todd Gordon - This article highlights the benefits of DVC technologies in a power plant - from Emerson Process Management.
Wireless: The Golden Age of Asset Management - Peter Zornio from Emerson Process Management discusses the advancement of standards based field wireless technology.
ICEweb's Pressure page has been updated and now includes links on Pressure Best Practices, Density Measurement , Interface Measurement ,Eliminating the Need for Methods of Additional Process Sealing , Transmitter Diagnostics Reduce Maintenance Costs, Specifying the Right Solution for Vacuum Applications along with a new section on pressure gauges.
The following links have been added to the
Flow page.
- Conditioning
Orifice Plate Technology; Taking the Standard to a New Level of Capability
- Installation
and Grounding of Magmeters in Typical and Electrolytic Process Applications
- Proper installation and grounding of magnetic flowmeters is important for
accurate, reliable measurement performance.
- Magnetic
Flowmeter Material Selection Guide -A general resource for the selection
of materials for the magnetic flowmeter.
- Permeation
of Teflon Flowtube Liners and Installation Techniques to Reduce the Rate of
Permeation - Ways to Reduce Permeation including Liner Quality, Liner
Thickness, and Temperature.
- Annubar® Flow Handbook - This excellent reference book provides
all of the information necessary to accurately measure fluid flow using the
Rosemount 485 Annubar primary element.
Boiler Drum Level Transmitter Calibration - Steam Drum Level is both a critical and difficult measurement to make. Control of the water level in the drum must be precise.
Level Measurement - Transmitters with Seals -Transmitters with remote seals allow the transmitter to be removed from direct contact with the process fluid.
Deploying Industrial Wireless Solutions - Wireless technology has not been widely adopted for in-plant applications. Concerns about reliability, security, and battery life of wireless devices have slowed adoption of wireless options even where traditional wired solutions were cost-prohibitive or operationally difficult. That's changing as improvements in wireless technology address these concerns.
Self-Organizing Networks: Wireless Topologies for In-Plant Applications -The topography of a wireless network is simply the way network components are arranged. It describes the physical layout of devices, routers, and gateways, as well as the data flow paths between them. Three of the most common wireless topologies for in-plant applications are star, mesh, and cluster-tree. By understanding the strengths and weaknesses of each, you can determine which topology is best for your specific application.
Corrosion and its Effects - This technical data sheet briefly discusses some of the reasons why corrosion occurs and the problems that can result.
Lightning and Static Effects on Industrial Electronics - This data sheet from Emerson Process Management examines the damage caused by transients from lightning and static and offers advice on minimising the harmful effects of these two phenomena.
EDDL allows interoperability for devices to constantly gather information - No matter what control system a plant is using, it is now easier for users to choose best-in-class instruments for their networks. The technology that allows this is Electronic Device Description Language (EDDL). From the ISA and InTech.
Converting Serial Networks to Ethernet Communications - New communications technologies have emerged that provide high-speed wireless Ethernet communications to field applications. From the ISA and InTech.
A technical information sheet Selection and Application of Positioners, Limit Switches, Solenoid Valves and Other Accessories has been added to ICEweb's Control Valve page which has been updated thanks to our sponsor Samson Controls. This page has a wealth of Control Valve information.
Vibration Energy Harvester-Powered Wireless Condition Monitoring - John Parker - Perpetuum Ltd - This interesting application note describes the steps necessary to design the power supply and energy storage circuit of a wireless condition monitoring sensor node.
Methods for Planning, Installation, Commissioning and Diagnosis of Fieldbus Installations - Andreas Hennecke, Sven Seintsch and Thomas Kasten - This paper describes working practice for all phases of the project: planning, commissioning, plant start-up, operation and online troubleshooting of fieldbus systems. Strategies are described that enable users to maximize the benefits of fieldbus technology. Thanks to Pepperl and Fuchs.