• Blog

    • 34 posts
    • Updated over 2 years ago
Activity
    • 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...
    • 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...
    • 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...
    • 6 Jul 2015

    Real-time Measurements Improve Energy Efficiency

    The latest Innovations in Process Control publication by the Emerson team in Europe has an article on where additional measurements can help identify opportunities to reduce energy consumption and improve operations. For readers who have English as a second language, this publication is also available in German , Italian , Spanish and French . Emerson’s Irfan Khan shares where some of these energy optimization...
    • 9 Jun 2015

    Optimizing Energy Consumption with Real-Time Feedback

    As energy prices slowly creep higher from earlier lows, the need for managing energy usage remains constant for most process manufacturers and producers. The U.S. Department of Energy’s Energy-Intensive Process Portfolio list processes in the refining, petrochemicals, chemicals, plastics metals, pulp & paper as large energy consumers. In an earlier post, Identifying Components then Optimizing Industrial Energy Consumption...
    • 16 Apr 2015

    Identifying Components then Optimizing Industrial Energy Consumption

    When optimizing operating costs at a production facility, the bias is toward that which can be measured. For example, the cost of chemicals additives for a process is something easily measured based upon the amount consumed. For components such as the energy to produce steam, the costs may not be so clear. Emerson’s Barbara Hamilton shared a couple of stories with me about how cost optimizations changed once unknown...
    • 12 Jan 2015

    Managing and Improving Energy Usage

    Last week, we highlighted how energy savings could be achieved through better combustion . Today, let’s look at a way to manage energy consumption throughout a plant or production facility. Barbara Hamilton Consultant / Program Manager for Energy Solutions In this 3:39 video, Energy Advisor from Emerson, Real-Time Energy Monitoring , Emerson’s Barbara Hamilton describes ways to uncover, realize, and document energy...
    • 6 Jan 2015

    Managing Efficient Combustion

    While the cost of energy has dropped recently, the need for efficient combustion remains important due to its impact on emissions, plant equipment fouling, and the reliability of the process. Bob Sabin Consulting Engineer Emerson’s Bob Sabin is featured in a series of new videos posted on the Rosemount Measurement YouTube channel. The videos include: Energy Management Concepts for Industrial Sites (3:34...
    • 9 Sep 2014

    Solving Boiler Drum Level Swings

    Effectively controlling the drum level in an industrial boiler helps to maximize overall energy efficiency. When the drum level varies it can not only impact boiler efficiency, but overall reliability due to unplanned shutdowns. Mark Coughran Process Control Consultant Emerson’s Mark Coughran shared a story with me about a major North American university that was having difficulty with one of the boilers that supplies...
    • 2 Jul 2014

    Sustainable Energy Efficiency User Guide

    For many process manufacturers, energy is one of the largest components in overall operating costs. Improving efficiency can provide ongoing savings. Emerson’s Bob Sabin shared a new user guide with me, Sustainable Energy Efficiency, which is available for download. For European manufacturers and producers, the EU Energy Efficiency Directive 2011/172 (referred to as the EED) […] Read the full text.
    • 10 Mar 2014

    Finding Areas for Energy Efficiency Improvements

    Managing the consumption of energy in a large, industrial plant can be a daunting challenge. There are systems for steam, air, fuels, and water and often these don’t have the measurements needed to see the trends in consumption and waste. The team responsible...
    • 4 Mar 2014

    Meeting the European Union Energy Efficiency Directive

    March 7 is fast approaching if you want to get the 200 Euro discount to the April 1-3 Emerson Exchange conference in Stuttgart, Germany. One of the presentations you’ll want to catch is on the implications of the EU Energy Efficiency Directive. Emerson...
    • 15 Jan 2014

    Managing Energy Consumption

    Process manufacturer’s operating budgets typically require 25-30% be spent on utilities—energy for steam, air, fuel, and water. For energy intensive industries such as steel manufacturing and refining, these costs can be in the tens to a hundred million...
    • 12 Dec 2013

    Energy from Municipal Waste Project Update

    In an earlier post, Plasma Gasification-Municipal Waste as a Power Source, we highlighted this process as an effective way to create energy from waste. I received news from Emerson’s Barbara Hamilton that the Industrial Energy consulting and global project...
    • 14 Nov 2013

    Industrial Energy Team Peels Reliability like an Onion-Part II

    Emerson’s Jennifer Sandstrom explores reliable combustion air flow in today’s post. Last time, we started to talk about how Emerson’s Industrial Energy group deconstructs a problem to create a reliable solution. Again, remembering the very definition...
    • 17 Oct 2013

    Optimizing Steam Usage in Oil and Gas Processing Complexes

    Utility management is a large part of the oil and gas industry and boiler management and steam balancing is often an overlooked factor for upstream and downstream processing. Steam optimization helps to reduce boiler loads, streamlines process efficiency...
    • 8 Aug 2013

    Industrial Energy Team Peels Reliability like Onion!

    Having reliable process manufacturing operations begins with reliable components and reliable control strategies to handle changing conditions. Emerson’s Jennifer Sandstrom, a senior industrial energy consultant, highlights the role of consultants in...