Activity
    • 2 Apr 2020

    Upgrading Boiler Burner Management and Combustion Control Systems

    Bob Sabin Peter Kline Authors: Bob Sabin , Peter Kline The Emerson Industrial Energy consulting team assisted a Northeastern U.S. specialty chemical manufacturer with modernizing the controls on two 1960’s vintage Combustion Engineering “D” Type process steam boilers. These units are critical to site operation as they supply steam to a common header that feeds processes throughout the production facility. For...
    • 30 Oct 2019

    Optimizing Energy Consumption and Overall Reliability

    Sam Thiara I heard a great story from Emerson’s Sam Thiara of a polymer producer in the Middle East region that was looking to improve energy efficiency across the facility’s steam system. They wanted to reduce energy costs and their carbon footprint, while also improving the stability and reliability of the process. The plant staff worked with Emerson industrial energy consultants to benchmark existing operations...
    • 15 Mar 2019

    What Lies Ahead for the Energy Industries?

    It’s been quite a whirlwind of week here at CERAWeek 2019. There were far more choices on what sessions to attend than ever before. For those with the fortitude to make it all the way to Friday, it’s one of my favorite days. It opens with a panel of the IHS Markit senior analysts sharing their perspectives from the week. I’ll try to capture a few of the key points I hear. Atul Arya moderated the panel and panelists...
    • 14 Mar 2019

    India Energy Security–Choices in Affordability and Sustainability

    India is currently seeing a great transition in energy supply and consumption. This has brought up many questions in the industry: What affordable fuel mix is optimal, and should the market or government policy decide? To decrease pollution in Indian cities, how will the fuel mix choices need to change, especially in the power and transport sectors, where fossil fuels now dominate? How can national champions leverage...
    • 20 Feb 2019

    Improving Energy Efficiency with IIoT

    Think about an “Internet of Things” (IoT) device that you may use in your home life. It’s typically an ordinary device, such a thermostat, and made into an IoT device with communications and a visual interface to remotely view date & control actions from the device. For instance, my Emerson Sensi thermostats communicate through my home network and Internet to a Sensi app on my smart phone where I can monitor & control...
    • 14 Jan 2019

    Shifting Toward Real-Time Predictive Manufacturing

    Last week we shared a post about the COP24 conference and the need for more sustainable manufacturing . Emerson’s Chris Hamlin also attended this conference held in Poland in early December. In an Energetyka 24 video interview , Chris explained how we are now undergoing a huge, transformative shift where data and information are available almost anywhere you want it, in whatever quantity you need, at almost zero cost...
    • 7 Jan 2019

    Podcast: How to Approach Energy Management Projects

    Emerson’s Sam Thiara joined me virtually from the UK for our continuing FIRSTHAND: Operational Certainty Consulting in a Pod podcast series. Sam, whom you may recall from earlier energy management-related posts , is a member of the Operational Certainty Consulting Group speaking with manufacturers about their energy management challenges. In this 10-minute podcast , we discuss the process of planning and executing...
    • 15 Nov 2018

    5 Questions for Operational Certainty Consultant Sam Thiara

    Emerson’s Sam Thiara joins our continuing podcast series, 5 questions for an Emerson Expert. Sam works with manufacturers across the process industries to improve operational performance and achieve top quartile performance. We’ll have an in-depth podcast in the coming weeks with Sam’s perspectives on how the Operational Certainty consultants on how they work with process manufacturers to achieve and sustain improved...
    • 10 Oct 2018

    5 Questions for Resource Efficiency Consultant Ana Gonzalez Hernandez

    Emerson’s Ana Gonzalez Hernandez joins our continuing podcast series, 5 questions for an Emerson Expert . Ana received her PhD from the University of Cambridge and is a resource efficiency consultant within the Operational Certainty consulting team . We’ll have an in-depth podcast in the coming weeks on how the Operational Certainty consultants are applying Ana’s research to work with manufacturers on data-driven...
    • 4 Oct 2018

    Optimized Combustion Control without Fuel-Air Curves

    At the 2018 Emerson Exchange conference, Emerson’s Bob Sabin and Scott Pettigrew presented, Combustion Control Optimized with Patented Control Configuration. Bob opened describing the Emerson Industrial Energy Consulting group and how they work with manufacturers and producers in many industries about combustion control and optimization. Fuel air curves have been used for decades to control combustion. They are inherently...
    • 16 Nov 2016

    Optimizing Energy Usage in Multi-Fuel Boilers

    Steam is a critical part of many process manufacturing processes and the energy to produce it can be a significant source of operational costs. I recently caught up with process automation hall-of-fame member Greg McMillan and Emerson’s Scott Pettigrew at the Emerson Exchange conference here in Austin. Greg and Stan Weiner had recently interviewed Scott in a ControlGlobal.com article, Boilers as fast as can be . ...
    • 16 Nov 2016

    Optimizing Energy Usage in Multi-Fuel Boilers

    Steam is a critical part of many process manufacturing processes and the energy to produce it can be a significant source of operational costs. I recently caught up with process automation hall-of-fame member Greg McMillan and Emerson’s Scott Pettigrew at the Emerson Exchange conference here in Austin. Greg and Stan Weiner had recently interviewed Scott in a ControlGlobal.com article, Boilers as fast as can be . ...
    • 16 Nov 2016

    Optimizing Energy Usage in Multi-Fuel Boilers

    Steam is a critical part of many process manufacturing processes and the energy to produce it can be a significant source of operational costs. I recently caught up with process automation hall-of-fame member Greg McMillan and Emerson’s Scott Pettigrew at the Emerson Exchange conference here in Austin. Greg and Stan Weiner had recently interviewed Scott in a ControlGlobal.com article, Boilers as fast as can be . ...
    • 9 Sep 2016

    Reducing Demand Charges in Energy Bills

    The cost of electrical power has grown more complex over time. It used to be that your kilowatt-hours (kwh) consumed were tallied to arrive at the cost. As the metering has grown more sophisticated, variable rates have emerged based on peak energy usage, time of day, usage thresholds and more. I connected with Emerson’s Bill Thackston to learn about a meeting he recently attended on energy management information systems...
    • 9 Sep 2016

    Reducing Demand Charges in Energy Bills

    The cost of electrical power has grown more complex over time. It used to be that your kilowatt-hours (kwh) consumed were tallied to arrive at the cost. As the metering has grown more sophisticated, variable rates have emerged based on peak energy usage, time of day, usage thresholds and more. I connected with Emerson’s Bill Thackston to learn about a meeting he recently attended on energy management information systems...
    • 9 Sep 2016

    Reducing Demand Charges in Energy Bills

    The cost of electrical power has grown more complex over time. It used to be that your kilowatt-hours (kwh) consumed were tallied to arrive at the cost. As the metering has grown more sophisticated, variable rates have emerged based on peak energy usage, time of day, usage thresholds and more. I connected with Emerson’s Bill Thackston to learn about a meeting he recently attended on energy management information systems...
    • 30 Aug 2016

    Energy Management-Plan Do Check Act

    Plan. Do. Check. Act. From Wikipedia : PDCA ( plan–do–check–act or plan–do–check–adjust ) is an iterative four-step management method used in business for the control and continual improvement of processes and products. It is also known as the Deming circle/cycle/wheel , Shewhart cycle , control circle/cycle , or plan–do–study–act ( PDSA ). The ISO 50001:2011 global energy management standard , modeled after...
    • 30 Aug 2016

    Energy Management-Plan Do Check Act

    Plan. Do. Check. Act. From Wikipedia : PDCA ( plan–do–check–act or plan–do–check–adjust ) is an iterative four-step management method used in business for the control and continual improvement of processes and products. It is also known as the Deming circle/cycle/wheel , Shewhart cycle , control circle/cycle , or plan–do–study–act ( PDSA ). The ISO 50001:2011 global energy management standard , modeled after...
    • 30 Aug 2016

    Energy Management-Plan Do Check Act

    Plan. Do. Check. Act. From Wikipedia : PDCA ( plan–do–check–act or plan–do–check–adjust ) is an iterative four-step management method used in business for the control and continual improvement of processes and products. It is also known as the Deming circle/cycle/wheel , Shewhart cycle , control circle/cycle , or plan–do–study–act ( PDSA ). The ISO 50001:2011 global energy management standard , modeled after...
    • 12 Aug 2016

    Optimizing Sugar Mill Boiler Performance

    Steam boilers are used in sugar mills to generate electricity and for heat in various stages of production, such as crystallization process . This process converts the sugar syrup into sugar crystals. Optimizing the performance of the boilers improves energy efficiency and reliability for this required heat and electricity. I caught up with Emerson’s Scott Pettigrew when he was in town last week and he shared the...
    • 12 Aug 2016

    Optimizing Sugar Mill Boiler Performance

    Steam boilers are used in sugar mills to generate electricity and for heat in various stages of production, such as crystallization process . This process converts the sugar syrup into sugar crystals. Optimizing the performance of the boilers improves energy efficiency and reliability for this required heat and electricity. I caught up with Emerson’s Scott Pettigrew when he was in town last week and he shared the...
    • 12 Aug 2016

    Optimizing Sugar Mill Boiler Performance

    Steam boilers are used in sugar mills to generate electricity and for heat in various stages of production, such as crystallization process . This process converts the sugar syrup into sugar crystals. Optimizing the performance of the boilers improves energy efficiency and reliability for this required heat and electricity. I caught up with Emerson’s Scott Pettigrew when he was in town last week and he shared the...
    • 13 Oct 2015

    Improving Boiler Operations with Better Measurements

    Emerson’s Bob Sabin , Tim Badger and Scott Pettigrew teamed up on the presentation, Fix Tough Measurement Problems to Improve Boiler Operation. Their abstract: While boilers are crucial to plant/mill business results, many times their performance is lacking. Poor combustion causes higher fuel costs and increased emissions. Lack of reliability and response hurts site production throughput and quality. A root cause...
    • 23 Jul 2015

    Reducing Plant Energy Consumption

    In an earlier post, Identifying Components then Optimizing Industrial Energy Consumption , we discussed how energy optimization initiatives were affected by what could be measured. Emerson’s Jonas Berge added a great comment to that post, which I will share here to bring it greater visibility. Running fans at excess speed, failed steam traps, fouling, inefficient combustion, pipe leaks, poor insulation on steam and...
    • 21 Jul 2015

    Avoiding the Impact of Steam Trap Failures

    According to the U.S. Energy Information Administration , industrial manufacturers are larger energy consumers than the transportation, residential and commercial sectors. The industrial sector accounts for around 30 trillion BTUs of energy consumed annually. Energy-intensive processes are found in many industries including chemicals, refining, mining & metals, pulp & paper to name several. Optimizing steam usage...