If an out-of-control situation is detected, you can quickly make changes to bring the process back into control. It’s a dance that requires monitoring and action.
To help you with process-control footwork, Chemical Processing has put together an eHandbook. It includes insight on:
- Perform A Proper Pre-Startup Safety Review -- Protect personnel and processes by conducting a thorough review before operating new or updated units.
- Online Monitoring Optimizes Polymerization Processes -- Plant enhances product quality and reduces cycle times.
- Promptly Address Control Valve Issues -- Testing process helps screen for issues quickly without the need to pull equipment
In batch processing, there are several things to consider. It’s not unusual for a facility to average more than 1,000 alarms per month. But alarm-remediation projects can reduce total alarms by over 70%. When it comes to blenders, choice can affect end results. As for quality control, what you must understand is you need to focus first on your ingredients, not the product.
To help you improve your batch processing, Chemical Processing has put together an eHandbook. It includes insight on:
- Rethink Batch-Manufacturing Alarm Systems -- You can avoid common failings and improve performance.
- First, Select The Right Blender -- Understand the pros and cons of three key kinds of devices.
- Quell Quality Control Quagmires -- Understand the limits of possible improvements and when enough is enough.
Many companies have old DCS platforms. In computing terms, they’re ancient. Considering all that is connected and controlled by the DCS — thousands of field instruments, valves, operator interfaces and other devices working together to make the process run efficiently and reliably, having an ancient platform is flirting with disaster.
The risks are many:
- System failures
- Part availability issues
- Difficulty integrating new apps and systems
- Reduced support availability
- Operation inefficiency
While the headache of migration is sometimes too much to bear, fortunately, the DCS you install today may never have to be completely replaced because its modularity will allow it to be improved incrementally.
This white paper will detail the steps to make proper migration choices and manage the process to get more out of your DCS system.12/19/2018
The importance of selecting the right process automation technology can far outweigh the cost of an automation investment itself. Selecting the right technology and the right supplier can help your company respond quickly to changing market conditions, ensure long term maintainability, and minimize the Total Cost of Ownership (TCO) over the life of your plant.
The convergence of process automation technologies such as PLC, DCS and SCADA systems have created a situation where it is more challenging than ever for process manufacturers to select the best technology for their application.
Download this white paper and learn:
- DCS vs. PLC vs. Hybrid - 5 Factors to consider
- Who to Include in the Decision Process
- Vendor Selection Criteria- 6 Key Considerations
Enhanced control valve technology helps all kinds of manufacturers continually improve process efficiency and product quality, while safeguarding people, plant assets and the environment. The right solution can support a comprehensive system to track every step of the manufacturing process.09/25/2017
Are you challenged by level measurement issues? Are you looking for more information on control and performance?
This Chemical Processing eHandbook takes a look at how chemicals manufacturers are finding level measurement solutions. Download this Chemical Processing eHandbook and gain access to these articles:
- Neglect Level Control at Your Peril: This first article in a four-part series examines reset mode tuning issues.
- Be Levelheaded About Surge-Tank Control: Vessels used to smooth out flow pose special tuning issues.
- Understand Ultrasonic Sensor Performance: Frequency, beam patterns and a target’s reflection characteristics all play a role.
- Get Data Where and When You Need It: Advances in level sensor technology help to improve inventory management.
Have you ever received a call in the middle of the night because of a plant operational crisis that took longer to correct than you would like? What you may not know is that modeling technology, which solves these kinds of complex process issues, can be accessed by your team through an easy to use Microsoft Excel® interface. Download this white paper today and discover how your company can build a model-based culture to improve plant operations and performance.04/06/2016
The chemical processing industry has a unique set of requirements that makes shopping for Enterprise Resource Planning (ERP) systems, and business systems in general, a challenging experience. Although the more advanced business systems continue to add features applicable to functions throughout the enterprise, including operations management, supply chain, finance, and so on, only a few vendors offer systems that meet the particular needs of chemical processors.
This Chemical Processing Special Report takes a look at how chemicals manufacturers are meeting these challenges head on. Download this Chemical Processing Special Report and learn more about ERP Systems including:
- Consider Integrated Technology: An ERP system should be easy to implement, use and upgrade as business evolves. Learn more about: Vertical Integration, Horizontal Integration; Asset-vx.-Labor-Intensive; Continuous v. Discrete Manufacturing; Risk Management; Integrated Deployment
- Get the Most from Your Data: Research shows how effective ERP systems significantly impact business outcomes. Data results include: Do companies with more user-friendly and accessible enterprise resource planning (ERP) systems enjoy more positive business outcomes? Are they more profitable? Do highly effective ERP systems help create a sharper upswing of revenue growth? How much difference does effective data really make to business success?
Optimize your operation in four critical areas – production, quality, energy efficiency and safety – with pressure instrumentation. This paper reviews pressure, flow and level solutions that work across all points of the operation to minimize process variability, gain process insight, reduce maintenance and downtime, and meet regulatory demands. Learn more.06/23/2015
In the decade before Stuxnet attacked process control systems in Iran, there were just five known supervisory control and data acquisition (SCADA) vulnerabilities for all control systems in the world, according to the U.S. Department of Homeland Security's Industrial Control Systems Cyber Emergency Response Team (ICS-CERT). In 2011, the year after Stuxnet, that vulnerability count jumped to more than 215. Last year, it reached 248. No surprise then that Chemical makers are increasingly focusing on protecting their process control systems from intrusion both from the inside and outside. In this Chemical Processing Special Report: Protect Process Control Systems, we take a look at:
- How to better protect your control system - "Defense in depth" is crucial, and new and maturing technologies may help
- Cyber Security Challenges - learn about countermeasures to protect control systems
- Case Study: A vulnerability assessment reveals critical gaps in the security of a natural gas pipeline
- How to mitigate security risks in legacy process control systems - several steps can help protect against threats and extend the life of legacy equipment
Learn how to secure your process control systems - and your plant. Download your copy of this Chemical Processing Special Report: Protect Process Control Systems now.10/29/2014
The debate over the virtues of DCS vs. PLC has been ongoing since these two architectures came into existence 40 years ago. For certain industries, a distributed control system (DCS) provides substantially more value as the basis for automating the plant than a programmable logic controller (PLC)-based system. As functionality differences narrow and price points align, the debate over these virtues is getting more intense and the arguments for and against each system are getting more and more murky. This white paper discusses the “Top Ten” issues to consider when evaluating a DCS vs. building your own “DIY” distributed control system using a PLC-based architecture.07/15/2014
Patching process control system software to remove security vulnerabilities is fraught with risk. System issues can be the result of installing a patch, but a system is also vulnerable without patching. Fortunately, virtual patching can improve the process and raise the system’s security at the same time.09/21/2012
While upgrading process control systems is vital to maintaining a plant’s performance, the migration process often brings confusion and frustration for customers. See how Honeywell keeps control systems running at the best possible performance throughout the migration process and into the future.08/29/2012
With an aging installed legacy Distributed Control System (DCS), the PRALCA petrochemical plant needed advanced control strategies to improve plant efficiency. Find out how a comprehensive migration solution extended the life of plant equipment and provided a cost-effective path forward to the latest automation technology.08/29/2012
The right strategy may lead to significant improvements in plant performance07/24/2008
Ensuring the security of industrial control systems is hardly a new topic. The earliest users of modern control systems in power stations and chemical plants saw the need to protect access to vital control functions from unauthorized use. Similarly, in industries such as fine chemical or pharmaceutical where the process is the product, manufacturers have always sought to protect the secrets of their unique processes from the prying eyes of industrial spies. This white paper by ARC describes how the Siemens AG PCS7 Security Concept bundles key security measures in seveal specific areas to create a deep hierarchy of security known as defense in depth.02/25/2008
Batch process control security is becoming a critical concern for the process control domain, IT technology infrastructure and the business enterprise. This paper explores several key security concerns in batch control system architectures and methods for addressing these issues.05/11/2006
Today's control system make it easy to add alarms. The result has been a proliferation of alarms that can overwhelm an operator and actually obscure situations that really require immediate attention. This paper provides practical guidance on effective procedures that can significantly reduce nuisance alarms and improve operator effectiveness.10/11/2004
This paper reviews the basic techniques for dynamic modeling of these two key operations. It covers considerations related to heat transfer, reaction chemistry, mass balances and the control system. It also discusses equipment configurations, performance characteristics and operational constraints.09/08/2004
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