"Migration could be the biggest single issue facing automation end-users today," stresses a report from the ARC Advisory Group. ARC estimates that installed automation systems worth about $65 billion are reaching the end of their useful lives. Distributed control systems (DCSs) more than 20 years old will need replacement within the next ten years. In this Chemical Processing Special Report: Migration we cover:
- Updating process control systems – understanding the challenges and missteps to avoid
- Case Study: FMC Corporation – we look at the production processes, operational challenges and automated solutions this diversified global chemical company chose when migrating their DCS
- Case Study: PRALCA – control systems migration for a petrochemicals facility
- The business case for control systems migration - strategies for protecting investments, improving business results and reducing risks
The U.S. Occupational Safety and Health Administration’s Process Safety Management (PSM) Standard [29 CFR 1910.119(j)] require plant management to identify and address hazards. Further challenging plant management, the mechanical integrity (MI) element of the PSM has been difficult for many facilities to implement. In fact, PSM audits by OSHA have consistently demonstrated that MI accounts for a large number of citations at most facilities. In this Chemical Processing Special Report, we take a look at how to effectively implement strategies to comply with PSM standards including:
- Common piping, hoses and valves hazards – what PHA (Process Handling Analysis) teams should look for to improve the quality of the hazard evaluation
- MI element of PSM – an in-depth look at the stated MI requirements, the perceived interpretation of these requirements and further considerations for identifying your plant’s compliance strategy
- MI implications – the impact MI has on plant’s written procedures, training, inspection & testing, and how equipment deficiencies and quality assurance programs are managed
Combustible dust fires happen in plants everyday. This white paper helps manufacturers learn more about combustible dust hazards and ways to handle combustible dust in your manufacturing plant in order to comply with OSHA's NEP. Learn more about choosing the right cleaning tools for your facility.07/25/2012
The purpose of installing a flowmeter system is to accurately measure flow in a reliable manner. Issues related to physical properties, process parameters, electronic features and interconnections are often given much consideration. Relatively little emphasis, however, is given as to how well the flowmeter will perform its intended purpose. Adding to the confusion are the differences in how performance is expressed and the incomplete nature of the available information. Nevertheless, the quality of flow measurement should be a concern. This Chemical Processing eHandbook takes a look at technologies and solutions affecting flow including: * Coriolis meters - steps you can take optimize performance when faced with entrained gas * Magmeters -- why you should consider using them * How to achieve effective flow control with centrifugal pumps07/17/2012
By understanding the key functions and architecture of a process-oriented, formula based ERP application, you will have a better foundation for choosing a solution that best suits your company and type of manufacturing.
This practical guide and checklist ties the unique operations of chemical manufacturers to specific ERP functionality and architecture. Topics include:
- Formula Specifications
- Variability and Quality
- Product Accountability and Costing
- IT Maintenance
Don't settle for a "one size fits all" ERP solution. With the "right fit" ERP solution, you will be able to streamline operations, reduce costs and scale production, while complying with federal regulations -- all with minimum customization.
Heat transfer and other process fluids -- from mineral oils to synthetic and organic-based formulas -- are the lifeblood of many critical operations within chemical and the process industries. Their condition reveals critical details about the health of the entire process itself, and that of the components of the system and their interoperation. Register for access to two special E-Books, which come in an interactive PDF format with links to additional web resources.04/23/2012
For the latest strategies on how to set an effective reliability program, download this Special Report: Cost-Justify Your Reliability Initiatives. In this report youll find: Predictive tools and technologies for enhanced equipment reliability The four things a plant manager can do that maximize reliability Critical equipment for an effective maintenance program04/16/2012
Dependable pH determination in chlor-alkali brine is notoriously difficult. Process conditions and high impedance signals from pH sensors mean maintaining measurement accuracy has been a headache for instrumentation engineers - until now.03/26/2012
Market activity shows that manufacturing in North America and Western Europe won't die soon, but some manufacturers will. The future belongs to the agile, and this white paper is your survival guide. Learn how to implement change, achieve real sustainability and boost profitability for the long run.03/26/2012
When steam traps leak or fail, energy is lost and there could also be steam equipment failure or damage and potential safety hazards. A major food manufacturer improved their steam trap program and enhanced their ongoing leak repair campaign with remote steam trap monitoring using Smart Wireless Solutions from Emerson.03/13/2012
The past two years have been a real wakeup call for the industrial automation industry. For the first time ever it has been the target of sophisticated cyber attacks like Stuxnet, Night Dragon and Duqu.
In addition, an unprecedented number of security vulnerabilities have been exposed in industrial control products and regulatory agencies are demanding compliance to complex and confusing regulations. Cyber security has quickly become a serious issue for professionals in the process and critical infrastructure industries.
If you are a process control engineer, an IT professional in a company with an automation division, or a business manager responsible for safety or security, you may be wondering how your organization can get moving on more robust cyber security practices.
In order to provide you with guidance in this area, Tofino Security and exida Consulting LLC have condensed material from numerous industry standards and best practice documents. They also combined experience in assessing the security of dozens of industrial control systems.
The result is an easy-to-follow 7-step process.02/28/2012
Avoid Instrument Failure: Ensure Proper Filtration and Delivery of Samples to On Line Process Analyzers
Precise process control strategies have accelerated the use of on-line chemical composition analyzers in plant applications. Contaminants in plant samples are the most frequent cause of problems with on-line analyzers. Trace contaminants can rapidly build up and cause instrument failure.01/20/2012
In chemicals processing, significant hazards exist -- such as those from fire, explosions or toxic release. The processes themselves, the chemicals being processed and the procedures followed, or lack thereof, can all contribute to the risk exposure of these hazards. What can processors do to mitigate these risks? For chemicals processors, it's crucial to implement processes and solutions to detect and prevent these hazards from occurring in the first place.
Chemical Processing has taken an in-depth look at plant safety -- how to identify the hazards and implement processes and procedures to ensure a safer working environment. This comprehensive Chemical Processing Special Report titled: Improve Plant Safety is now available to download for free.12/14/2011
Rock stars get parties, limousines, fame, and dates with supermodels. What do Demand Planners get? Hopefully they may get fewer forecast errors. Learn how you can minimize production schedule changes, eliminate expedited transfers and shipments, reduce stock-outs, and more. Be a star at your company!09/06/2011
Specific case studies on the benefits of rotary impingement and CIP optimization vs. the standard tank cleaning processes. Benefits include: increased revenue and production with drastic reductions of operating costs pertaining to tank cleaning.06/17/2011
Implementation of rapid loss on drying and ash analyzers significantly reduces testing times associated with traditional methods, allowing companies to bring products to market faster, increasing production. These features will aide biomass material manufacturers in maximizing control of the market.05/06/2011
Automation systems today have become warehouses of knowledge and information. Beyond system configuration, years of effort is inevitably invested in them. This paper will discuss a few factors contributing to the automation knowledge crisis, present industry examples, and provide an optimal solution02/15/2011
Chemical Processing Special Report: Beyond Condition Monitoring: Prevent Failures through Condition Management
For years chemicals makers have tracked the health of key equipment yet they still grapple with unplanned outages that can significantly impact financial performance through lost production and extra repair costs. In this Special Report, we'll explore underlying condition monitoring challenges and introduce the concept of condition management -- an enhanced approach that helps companies reap the full benefit from their condition monitoring investments; we'll also discuss how CMMS tools can help to provide a clear understanding of maintenance operations performance as well as provide some guidance on what you can expect from a CMMS vendor. Lastly, listen to the lively discussion between Chemical Processing's Senior Digital Editor,Traci Purdum, and Edgewater Fullscope's Senior Vice President, Russell Smith, as they converse on how ERP can help manage the supply chain.12/16/2010
A complete alarm philosophy document (APD) covers all elements, including design principles, KPIs and escalation policies. Creating an APD to outline these elements is the first step in a successful alarm management project. This paper provides an overview for the essential parts of a complete APD.10/13/2010
In this white paper, we review the new possibilities offered by measurement systems based on polarographic technology. Unlike other systems, polarographic sensors are built directly into the process gas stream, eliminating the need for cumbersome gas sampling and conditioning systems. Further, polarographic sensors require very little maintenance.10/12/2010