Emerson Exchange 365

 It’s often said that there's no substitute for experience. And if Emerson Process Management's 135 years of expertise (dating back to the original Fisher Controls) is any indication, the company clearly continues to deliver on its time-tested adage of turning “technical milestones into customer cornerstones.”

"We say that good technology fulfills a spec, but great technology delivers business value and empowers people," said Peter Zornio, Emerson chief strategic officer as he kicked off the annual “technology tornado” overview for media and analysts of all the new solutions on parade at Emerson Global Users Exchange this week in Denver.

"Eight years ago, we embraced the concept of going beyond technical capacity to embrace greater ease of use and simplicity,” Zornio said. “This led to our Human-Centered Design program that's embedded in our development organizations, and continues today to eliminate unnecessary work, remove complexity and embed specialized knowledge within our offering, so new users can easily get value from our solutions."

Measure & Analyze: Pervasive Sensing

"Last year, we talked about our Pervasive Sensing strategy: the use of innovative sensors and strategic data interpretation to enable action by users,” said Bob Karshnia, Emerson vice president, wireless. “This week we're launching Pervasive Sensing applications that allow users to see and respond to issues more quickly. We've also web-enabled Pervasive Sensing, so our solutions can scale up and down to any application, and further improve ease of use with simple dashboards that provide even faster views."

For example, he reported that Marathon Petroleum recently had pressure relief valves (PRVs) going off regularly, but it was hard to tell where these releases and leaks were happening; it could take two days to two weeks to find the source. Marathon implemented non-intrusive, wireless acoustic transmitters to find PRV releases in real time. "Pervasive Sensing immediately found 20 bad actors that were resolved within one hour, detected at least 200 incidents, and this has allowed Marathon to optimize its process and run to the edge of its capabilities—but not over," explained Karshnia. "Payback was achieved in five months, and this project resulted in a 270% return on investment via increased throughput."

Other key measurement and analysis solutions introduced this year include:

• The Rosemount Wireless Pressure Gauge features field-proven piezoresistive sensor technology, is reported to be the industry’s first WirelessHART pressure gauge, and has up to 150x overpressure capabilities and dual-process isolation. It provides reliable visual readings to operators in the field, pressure data and device status indication remotely to operations, and has increased field protection. It will be available in Spring 2016.
• The Rosemount 2056 Silica Analyzer is a colorimetric analyzer that continuously measures silica in up to six process streams, and is designed for ease-of-use from installation and start-up through maintenance. It provides insight into silica deposition on turbine blades to aid cleaning, and includes easy analyzer operation and maintenance.
• Three platform extensions to Rosemount 3015S flagship pressure transmitter family are all available now. First, the Rosemount 3051S Thermal Range Expander features an intermediate diaphragm that allows for two fill fluids and UltraTherm 805 fill fluid for high-temperature applications up to 410°C (770°F). Second, the Rosemount 3051S Electronic Remote Sensor (ERS) system features digitally-calculated differential pressure that's now available with safety certification and is suitable for SIL 2/3 applications. Third, the Rosemount 3051S High-Static DP transmitter features all-welded, hermetic stainless-steel, Coplanar SuperModule design, and can withstand pressures of up to 15,000 psi (1,034 bar).

Measure & Analyze: Flow

"We're hearing from customers that they're concerned about reliability, robustness and calibration certainty, and so we've redesigned our Rosemount 8750W magnetic flowmeter platform from the bottom up," said Bret Shanahan, marketing VP for flow measurement at Emerson. "Also, increasing use of natural gas means more users are buying and selling it, and so they need custody transfer solutions with better redundancy of measurement, such as our new Daniel 3410 Series ultrasonic flowmeters. Finally, our Roxar Corrosion Monitoring System enables our refinery users to blend more opportunity crudes, and do it more safely and consistently."

Further details on these new flow solutions include:

• The Rosemount 8750W magnetic flowmeter is designed for utility, water and wastewater flow measurement, and has a welded-coil housing and dual compartment transmitter housing, as well as a field replaceable terminal block. It also features Smart Meter verification, process diagnostics, and an intuitive local operator interface.
• The Daniel 3410 Series gas ultrasonic flowmeter platform elevates the proven British Gas design by providing two meters and transmitters in one body. Within the series, the 3415 (four-path plus one-path) and 3416 (four-path plus two-path) meters combine a four-path fiscal meter with an additional check meter, while the new 3417 (four-path plus four-path) meter provides two fiscal meters for full redundancy and equal accuracy in one meter body. Both Daniel 3415 and 3416 ultrasonic gas meters measure flow using four horizontal chordal paths in addition to a reflective path dedicated to verification of the primary measurement.
• The Roxar Corrosion Monitoring System for refineries has wireless-based probes with high-temperature ratings, high resolution and fast response times, as well as WirelessHART connectivity and integration with Roxar Field Signature Method (FSM). It provides accurate and continuous corrosion monitoring, and real-time identification and tracking of opportunity crudes that are often acidic in nature.

Operate & Manage: Process Control and Asset Reliability

Zornio reported that Version 13 of the company’s DeltaV process automation system began shipping a few months ago, and offers further enhancements in the areas of cyber security, alarm management, Logbooks capabilities and Ethernet I/O Card (EIOC) connectivity:

• DeltaV Alarm Mosaic features dynamic graphical presentation of alarms and control actions on a scalable timeline, alarm attribute clustering and filtering, historical views of previous alarm patterns, and zero required configuration.
• Emerson Logbooks includes shift dashboards for insight into events and changeover priorities; task management capabilities for improved visibility and planned action; integration with DeltaV to deliver information in context; and automation of entries based on system events required.
• Improved cybersecurity functions such as DeltaV Security Administration Center for simplified security management; V13 enabling of Microsoft Windows Firewall; improved network hardening on L2.5 with Smart Switch; and AMS Device Manager for enhanced user management.

In addition, Zornio reported on several new machinery health and energy monitoring solutions:

• The Ovation Machinery Health Monitor features health monitoring and machinery protection in the Ovation DCS. A high-performance I/O module dedicated to machinery health functions installs easily into a spare I/O slot and eliminates hardware, wiring and overhead associated with connecting two systems.
• The CSI 6500 ATG is a standalone machinery protection solution that allows users to cost-effectively introduce predictive monitoring of critical assets. It includes multi-functional cards that can be easily reconfigured for a wide range of measurements, including peak-to-peak data used in Emerson’s PeakVue technology.
• Energy Advisor software has site-wide tracking of water, air, gas, electricity and steam use; energy consumption targets based on historical usage and process models; and intuitive energy dashboards and vast reporting tools.

Operate & Manage: SCADA and Operations Management

Next, Stuart Miller, marketing vice president for remote automation solutions at Emerson, reviewed the most notable launches in the company’s remote automation portfolio: 

• The FB1100/FB1200 and FB2100/FB2200 next-generation flow computers are compact, field-mount gas flow computers with flexible power options, mobile SCADA wireless field connectivity, and an interactive local display.
• OpenEnterprise, Version 3.2, SCADA software is optimized for wide area, low bandwidth communications, and has a native interface to AMS Device Manager.
• Syncade Logistics software for trucks and railcars has automated truck bay queuing and parking lot management, blend ratio management to ensure accurate quality, and RFID vehicle tracking.
• SmartProcess Blend, Version 5.0, has closed-loop optimization and control of in-line blenders for DeltaV; multi-lingual blend order management system with web-based interface; and configurable control modules for up to 15 components and 25 qualities.

Final Control & Regulate

Bruce Johnson, vice president for Fisher valves at Emerson, added that the most important releases in the Final Control & Regulate space are:

• Fisher Z500 severe-service ball valves that feature a two-piece floating ball valve, integral metal seat to minimize potential leak paths, and flexibility with different valve options and large size range.
• DCMlink software is a unified, electric-actuator control, monitoring and diagnostics platform that allows users to diagnose, configure and monitor all electric actuators from a central location independent of protocol, actuator or host system. It integrates management of asset data, profiles, alarm and event logs, and has Bluetooth capability.