Emerson Exchange 365

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Digital Transformation Key to Vaccine Development and Rollout

Jim Cahill

The first doses of a Covid-19 vaccine were administered on Dec 14, 2020, about a year after the disease was first detected. Tested, FDA-approved for emergency use, rapidly manufactured and safely delivered at sub-freezing temperatures, this was, by any measure, the fastest pathway to vaccination in human history. One of the latest examples of development from scratch was the mumps vaccine in the 1960s. It took four…
- 14 Jul 2021
Addressing Common Misconceptions in Safety System Configuration

Jim Cahill

Traditional safety systems have a centralized architecture, meaning that a large processor unit runs hundreds of safety instrumented functions (SIF). Modern safety systems have a distributed architecture where multiple smaller processor units execute dozens of SIFs. Distributed safety systems offer many cost and maintenance benefits, but some users worry they’re harder to configure than a centralized safety system. I…
- 1 Jul 2021
Digital Tools and Frameworks for Digital Transformation

Jim Cahill

Manufacturers and producers are undertaking digital transformation initiatives across many areas of their businesses—energy & environmental sustainability, production management, people & culture, business insights & analytics, reliability & maintenance, safety & risk management, supply chain management, systems interoperability & governance, and IT security & operations. Their business objectives drive their strategies…
- 1 Jul 2021
PID Algorithm ISA Technical Reference

Jim Cahill

Earlier this week, I shared a podcast with James Beall , who as a long-time Control Performance Consultant shared some of his thoughts on common control performance issues and ways to address them. James is quite generous in sharing his expertise at professional and industry events such as ISA and AIChE. Today, I’ll recap one of his AIChE Spring21+17 th GCPS presentations he co-presented with CMiD Solutions’ Mark Darby…
- 30 Jun 2021
Podcast: Process Control Consulting Stories with James Beall

Jim Cahill

When the plant is not running the way it should, with excessive variability, alarm conditions or sub-optimized performance, plant engineers often connect with the Emerson Production Performance consultants . I had the opportunity to sit down and record a podcast with Emerson’s James Beall who is a member of the team. You may remember James from an earlier podcast, 5 Questions for Principal Process Control Consultant…
- 28 Jun 2021
Improving Logical Changeover Production Readiness in the Life Sciences

Jim Cahill

Pharmaceutical and biopharmaceutical manufacturers have long felt the pressures of moving products from discovery to delivery as fast as they can—even given the highly regulated industry in which they operate. Technology has continued to advance and provide ways to assist these companies with production readiness. Improper set up and qualification of automation and information management production applications cause…
- 24 Jun 2021
Improving Polymer Reactor Control Performance

Jim Cahill

The chemical engineering professional organization, AIChE held their 2021 AIChE Spring Meeting & 17th Global Congress on Process Safety as a virtual conference in April. Emerson’s James Beall presented Novel Techniques to Improve Polymer Reactor Tuning based on a project he worked on. Reactor control is complex with many interactions between control loops. The way to tackle this challenge is to start by identifying…
- 13 May 2021
Emerson Technologies Supporting Fast COVID-19 Vaccine Development and Rollout

Jim Cahill

In a Pharmaceutical Processing World article, Emerson’s Ben Arriola and Zach Blum discuss technologies advancing vaccine development. It’s safe to say that there has never been a pharmaceutical effort so huge, fast, and successful as developing multiple vaccines for COVID-19. It is truly global in that countries all over the world are developing their own formulations. Making this possible and practical has depended…
- 30 Apr 2021
Operator Control Moves—Too Many or Too Few?

Jim Cahill

The Center for Operator Performance (COP) combines industry companies, suppliers, and academia: …to raise the performance level of our operators and improve Health, Safety, and Environmental effectiveness is accomplished through: Openly sharing knowledge and ideas, Including vendors in research decisions, Teaming with leading human factors researchers and universities, and Collaborating with a focus on HS&E…
- 13 Apr 2021
Control System Strategy is Key to Meeting Long-Term Operational Goals

Jim Cahill

Organizations have come to expect that their control systems will operate for many years and often anticipate using the same systems for decades. New improvements in cloud computing coupled with rapid advancement of control system technology has many people wondering if these control system trends will change. Sean Sims , vice president for Emerson’s DeltaV platform, recently spoke with Control Engineering Europe to…
- 26 Mar 2021
INVISTA Improves Uptime with State Based Control

Jim Cahill

Operators are the heart of any process. Experience, skill, and attentiveness give the best operators an intuitive feel for processes that helps ensure uptime, safety, repeatability, and quality—even in the most infrequent process situations. But with a major shortage of skilled personnel, plants find themselves needing to maintain exceptional performance and safety while simultaneously helping new operators gain experience…
- 18 Mar 2021
Optimizing Hydrocyclone Separation Processes

Jim Cahill

Diagram of a hydrocyclone: 1. the liquid-solid mixture enters, 2. heavy solids leave, 3. cleaned liquid leaves. Photo credit: “hydrocyclone” by VanBuren is licensed under CC BY 3.0 In the mining industry, hydrocyclones are mineral processing equipment used in slurry pulps to separate coarse and fine particles according to their size and density. From Wikipedia : The mixture [slurry pulp] is injected into the hydrocyclone…
- 15 Mar 2021
Exploring the Future of the Control System

Jim Cahill

Control systems have been a stable foundation for operational excellence and reliable, repeatable performance in manufacturing for decades. However, just as needs have changed across those decades, so too have control systems themselves, evolving to meet the ever-changing requirements of the modern plant and enterprise. In a recent article in Control Engineering magazine , Sean Sims , Emerson’s vice president for the…
- 8 Mar 2021
Safety Instrumented System Useful Life

Jim Cahill

Safety instrumented systems (SISs) are used to reduce risks and bring to process to a safe state in the event of an upset or abnormal condition. Assessing this risk over the lifecycle of the operations is part of the IEC 61511 global safety standard. In a LinkedIn article, The risks and the opportunities of running an obsolete Safety Instrumented Systems (SIS) , Emerson’s Mohamed Salman shares his expertise on evaluating…
- 1 Mar 2021
Digital Transformation Helps Moderna Safely Deliver COVID-19 Vaccine in Record Time

Jim Cahill

A common theme across the Emerson Exchange Virtual Series has been the way software and digital technologies have helped us all deal with an unexpected and unprecedented pandemic. Wherever there is adversity, there are also innovators who step up to the challenge of delivering solutions to critical problems. In the February keynote address, Speed to Market, Jim Nyquist , chairman of Emerson’s systems and software business…
- 12 Feb 2021
How Does PID Loop Dynamic Reset Limit Work?

Jim Cahill

In the DeltaV discussion forum in the Emerson Exchange 365 community , there is a post, Question about Dynamic reset limit and “Use PV for bkcal” options . What caught my eye was a response by Emerson’s James Beall describing dynamic reset limiting and specifically how it is performed in the DeltaV distributed control system controller. Part of the question asked was: Also, how exactly does the dynamic reset limit work…
- 27 Aug 2020
Unpredictable Mother Nature Drives New Sugar Production Process

Jim Cahill

American Crystal Sugar produces a lot of sugar in its six factories. The first step in the process is to wash sugar beets, and this creates a great deal of waste mud that has to be properly disposed. Shifting weather conditions – rainier than average seasons – increased the amount of water in the process, which drove the company to increase use of aged polymer that aids in the flocculation process and helps prevent buildup…
- 17 Jun 2020
Unpredictable Mother Nature Drives New Sugar Production Process

Jim Cahill

American Crystal Sugar produces a lot of sugar in its six factories. The first step in the process is to wash sugar beets, and this creates a great deal of waste mud that has to be properly disposed. Shifting weather conditions – rainier than average seasons – increased the amount of water in the process, which drove the company to increase use of aged polymer that aids in the flocculation process and helps prevent buildup…
- 17 Jun 2020
Mobile Information Accessibility Benefits

Jim Cahill

Mariana Dionisio One of the critical elements in Digital Transformation initiatives is mobile access to information. Mobility enables improvements, collaboration and issue resolution to improve overall operational performance. In a Control Engineering article, Seven benefits to using mobile software in your organization , Emerson’s Mariana Dionisio describes how this mobility helps organizations drive business performance…
- 8 May 2020
Cybersecurity Considerations for Automation Architectures

Jim Cahill

Sergio Diaz Alexandre Peixoto Automation architectures extend beyond the instrumentation and control systems to safety instrumented systems, asset management systems, manufacturing execution systems, and more. All these systems and devices must be considered in managing strong cyber defenses. In an Industrial Safety and Security Source article, Considerations in Choosing a Defendable Safety System Architecture …
- 30 Apr 2020
Driving a Mobile Human Machine Interface Strategy

Jim Cahill

Danny Strinden Mariana Dionisio In a recent post, Key Criteria for Mobile HMIs , I shared a recap of an article of things to consider in mobile device displays of control system human machine interfaces (HMIs). Having a strategy for deploying this technology is also key. Changing and streamlining work practices is at the heart of digital transformation initiatives. In a Control Engineering article, A mobile HMI…
- 16 Apr 2020
Key Criteria for Mobile HMIs

Jim Cahill

Mariana Dionisio Camilo Fadul Cindy Scott Smart phones and tablets have been a revolution for connecting us to other people and information more quickly, efficiently, and effectively than was possible prior to their arrival. For manufacturers and producers, one example is the control system human machine interfaces (HMIs) that have arrived in this mobile environment. In a Control Engineering article, Five essential…
- 9 Apr 2020
Upgrading Boiler Burner Management and Combustion Control Systems

Jim Cahill

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…
- 2 Apr 2020
Upgrading Boiler Burner Management and Combustion Control Systems

Jim Cahill

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…
- 2 Apr 2020
ISASecure Family of Certifications Builds Foundation for Automation Cybersecurity

Jim Cahill

Alexandre Peixoto Andre Ristaino Authors: Emerson’s Alexandre Peixoto , International Society of Automation (ISA)’s Andre Ristaino Selecting, engineering, implementing, and operating a control system is a significant, long-term investment. Applying a defense-in-depth strategy to protect the process from cybersecurity risks is another significant, long-term investment that can be made more complicated if the inherent…
- 11 Feb 2020

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