Optimising quality control lab testing.

New QC lab scheduling capability synchronises lab testing with real-time production conditions to improve efficiency and flexibility.

DeltaV™ Real-Time Scheduling (RTS) software has been enhanced by Emerson so that extends integrated, real-time manufacturing scheduling capabilities to quality control (QC) labs. The new capability automates complex scheduling rules and logic to optimise lab operations and keep QC activities continuously synchronised with changing production conditions, helping life sciences manufacturers improve throughput, reduce delays and accelerate decision-making.

QC labs face numerous challenges that limit efficiency and scalability. Labs receive many samples from multiple points throughout the manufacturing processes across a plant and must conduct a wide range of tests on those samples. As labs navigate equipment availability, multi-sample test capabilities, technician capacity, incoming samples and shifting priorities, scheduling quickly becomes too complex for the whiteboards, spreadsheets and lab information management systems commonly used today.

“Well-run QC labs are a keystone of ensuring quality and meeting delivery commitments. By driving efficiency, QC teams ensure samples are tested with results returned promptly, enabling manufacturing to proceed without delays and quality teams to promptly determine product disposition so therapies can reach patients on time,” said Kristel Biehler, vice president of life sciences for Emerson’s process systems and solutions business. “QC scheduling in DeltaV RTS software is a simple and effective tool providing automated, real-time scheduling to integrate the lab with the shop floor to make the most effective use of resources and eliminate bottlenecks.”

The enhancement provides fit-for-purpose QC lab scheduling directly into Emerson’s proven DeltaV RTS software, harmonising schedules with manufacturing operations. Users can ensure that testing is executed correctly at the right time on the right equipment, including both production-dependent and final product testing. Integration with real-time lab information management systems automates lab schedule alignment, ensuring accurate updates to changing priorities and sample availability. The software empowers teams to implement and automate complex rules to optimise the lab, such as analytical test run sample batching and other advanced scheduling strategies.

This expanded DeltaV RTS functionality enables the scheduling rules to be configured in a flexible manner, which empowers lab schedulers to quickly adapt to the dynamic needs of the testing lab, even when supporting new product introductions. Ultimately, this functionality can reduce the manual QC lab scheduling effort and improve on-time delivery of test results to enable faster, more reliable release of batches.

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Automation for Caspian Sea compression project.

Integrated control and safety systems provide process control, safety shutdown, fire and gas detection, and power management.

BP has awarded Emerson a multi-million-dollar contract to deliver automation technologies for the Shah Deniz Compression project off the coast of Azerbaijan (AZ).

“Emerson has served as the main automation contractor for the Shah Deniz development for over a decade, demonstrating how our proven, end-to-end execution model delivers well beyond the initial build,” said Ram Krishnan, chief operating officer of Emerson. “We are pleased to continue our collaboration with BP, deploying advanced systems to enable remote operations and significantly expand the production profile of Shah Deniz.”

Photo: BP

Emerson previously served as the main automation contractor for the Azeri Central East and Shah Deniz Stage 2 developments. Under the new contract, Emerson will provide integrated control and safety systems to enhance production, safety and reliability on the new offshore compression platform.

The $2.9 billion Shah Deniz Compression project, which includes an electrically powered, normally unattended offshore production platform, represents the next stage in developing the Shah Deniz field in the Caspian Sea. Designed to access low-pressure gas reserves and maximise overall recovery, the platform will be equipped with four 11MW compressors and serve as the central compression hub for gas from the Shah Deniz Alpha and Bravo platforms. The facility will operate remotely from BP's onshore Sangachal terminal, located 55 km south of Baku.

Emerson’s integrated solution includes its DeltaV™ Distributed Control System and DeltaV Safety Instrumented System, which provide process control, safety shutdown, fire and gas detection, and power management. Together, these systems deliver real-time visibility and control of critical operations remotely, helping to reduce operating costs, while improving efficiency, safety and platform availability.

Unlike approaches focused solely on upfront capital costs, Emerson optimises across the full project lifecycle, improving schedule predictability, reducing cost and complexity, and accommodating change when it matters most. Cloud engineering services and digital twin technology bring virtual testing, system integration and operator training together in one connected workflow.

The project is expected to enable approximately 50 billion cubic meters of additional gas and around 25 million barrels of condensate production and export. Construction is scheduled to be completed in 2029, with first gas compression expected from the Shah Deniz Alpha platform in 2029 and from the Shah Deniz Bravo platform in 2030.

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Intelligent, unified automation architecture for data centres.

Monitoring and control layer integrates data centre critical infrastructure, coordinating across the thermal, mechanical and electrical subsystems for real-time response to power and cooling load changes.

As artificial intelligence (Ai) accelerates data centre demand and compresses project timelines, infrastructure complexity is at an all-time high. Emerson’s DeltaV™ Automation Platform for Data Centers meets this challenge with an automation portfolio designed for AI-scale data centres – where speed, reliability and operational excellence are non-negotiable. This delivers a unified automation system for the monitoring and control of data centre critical infrastructure, bringing together the thermal, mechanical and electrical sub-systems under a highly scalable, flexible architecture.

In the Ai era, faster time to market directly impacts revenue, customer commitments and competitive advantage. These compressed project timelines put tremendous pressure on supply chains, engineering and design teams, electricians, engineers and other project personnel who must rapidly complete the project while simultaneously meeting the reliability, flexibility and dynamic operational needs of modern data centres.

To bring gigawatt-scale facilities online faster while maximising operational reliability, the DeltaV Automation Platform for Data Centers replaces point solutions and complex mappings with an integrated automation architecture from the inception of project design. Rather than separate, manual coordination of sub-systems, the DeltaV platform unifies them under a single unified control solution, reducing engineering effort, simplifying integration and creating consistency across commissioning, operations and maintenance.

“Data centre performance is no longer defined by individual components alone, but by how effectively critical systems work together,” said Nathan Pettus, president of Emerson’s process systems and solutions business. “The DeltaV Automation Platform for Data Centers gives operators the unified visibility and coordinated control they need to commission projects predictably, operate reliably at scale and meet aggressive timelines. It’s the foundation that turns speed into sustainable competitive advantage.”

The DeltaV Automation Platform for Data Centers delivers:

• Precision Control: Real-time monitoring and management of highly variable loads and cooling optimisation – providing equipment-level and facility-wide control that dynamically adjusts to changing thermal loads.
• Industrial-Grade Reliability at Scale: Integrated control and operational visibility in the DeltaV Automation Platform helps data centre teams detect abnormal conditions earlier, respond faster and maintain consistent, reliable operations 24/7.
• Project Expertise: Repeatable, standardised designs and decades of mega-project expertise helps engineering teams reduce execution risk, compress timelines and deliver projects that perform reliably from day one.
• Lifecycle Partner for Continuous Improvement: Beyond project delivery, Emerson provides repeatable operating models and continuous intelligence that help data centres scale across their expansions and optimise lifecycle operations across multiple facilities and geographies.

The DeltaV Automation Platform for Data Centers provides a comprehensive automation portfolio including its industry-leading DeltaV Distributed Control System (DCS) and DeltaV Programmable Logic Controllers (PLCs) that connect to the DCS for system-wide process control. Both the DeltaV DCS and DeltaV PLCs incorporate context-specific AI solutions to accelerate engineering workflows, provide advanced process control and enable data centres to integrate AI optimisation models. The DeltaV DCS and PLCs natively work together to deliver continuous intelligence – enabling faster builds, lower costs, predictable performance, and eventually, autonomous operations.

“AI data centres are pushing at the very limits of scale, speed and complexity, exposing the limitations of piecemeal automation architectures,” concludes Pettus. “The DeltaV Automation Platform for Data Centers is built on intelligent, unified automation architectures instead of isolated systems to provide the flexibility not only to quickly reach first token, but also help data centres stay competitive, secure and relevant across the lifecycle of operation.”

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Eliminating nuisance and non-actionable alarms means better operator effectiveness.

Software reduces control system alarm volumes by more than 95% achieving EEMUA 191 recommended alarm performance levels.

Rompetrol Rafinare has reduced distributed control system (DCS) alarm volumes by more than 95% using DeltaV™ AgileOps operations management software at its Petromidia refinery in Navodari, (RO). The project improved control system alarm performance, increased operator effectiveness and brought refinery alarm rates within the Engineering Equipment and Materials Users Association (EEMUA) 191 guideline recommendations at Romania’s largest refinery.

“Modern control systems provide enormous amounts of operational information, but operators need the right context and visibility to act effectively,” explained Guido Wink, vice president of Emerson’s control systems and software business in Europe. “DeltaV AgileOps helps organisations continuously monitor and improve alarm system performance so operators can focus on the events that matter most to safe, efficient operation.”

With an annual processing capacity of approximately five million tonnes of fuel products, the Petromidia facility operates a broad range of conversion units and maintains a Nelson Complexity Index of 9.32, creating significant volumes of process data and alarms. Over time, control system alarms had evolved beyond recommended best practices, exposing operators to high alarm volumes, particularly during plant disturbances. Chattering alarms also contributed unnecessary noise, making it more difficult for operators to identify and respond to critical process events. Operators routinely experienced alarm flooding, while some alarms remained permanently active under normal operating conditions.

To address these challenges, Rominserv, Rompetrol’s engineering and maintenance services provider, collaborated with Emerson to improve alarm quality and reduce nuisance alarms across the refinery. The team implemented Emerson’s DeltaV AgileOps software to provide continuous visibility into alarm performance, including average and peak alarm rates, recurring alarm sequences and time spent outside recommended operating thresholds.

DeltaV AgileOps software captures alarm and event data directly from the DeltaV Distributed Control System which operates the plant, enabling engineering teams to identify high-frequency alarms, stale alarms and nuisance ‘bad actor’ alarms responsible for disproportionate alarm activity. Using performance dashboards and historical trending tools, refinery personnel evaluated alarm behaviour during steady-state operation, start-up conditions and process disturbances, while validating proposed changes to alarm limits, priorities and suppression strategies against actual plant data.

As a result of the project, the refinery reduced alarm generation from more than two million alarms per month during normal operation to fewer than 50,000 alarms per month. According to EEMUA 191 guidelines, operators should receive no more than one alarm every ten minutes during steady-state operation.

“Alarm management plays a critical role in maintaining safe, efficient refinery operations,” said Nilca George, process engineering director, Rompetrol Rafinare. “The continuous alarm performance monitoring and analytics provided by DeltaV AgileOps has significantly reduced operator alarm burden while improving overall operational awareness. The resulting system is more stable and better aligned with actual plant conditions, enabling operators to focus on meaningful alarms and respond more effectively to process disturbances.”

The implementation also improved long-term visibility into control system performance through automated alarm and event reporting. Existing historical alarm and event retention was extended – from approximately four to five days to nearly two months – enabling more effective analysis of recurring issues and supporting better-informed maintenance and optimisation decisions.

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Visibility of operator graphics across the enterprise.

Accelerating edge ecosystem for real-time enterprise operations intelligence.

Emerson continues to define the industrial edge with the release of DeltaV™ Live Enterprise View, a new application that securely extends real-time control system visualization beyond the control room. The new software joins Emerson’s rapidly expanding edge application ecosystem and empowers engineering, maintenance, reliability and leadership teams with browser-based, read-only access to live plant displays – as operators see them – without requiring display conversion, additional engineering or changes to the control system.

The ability to take fast, decisive action in today’s volatile markets is a critical enabler of operational excellence. However, layered solutions without native integration introduce latency and ongoing engineering overhead, constraining enterprise productivity. DeltaV Live Enterprise View addresses this challenge by leveraging Emerson’s innovative edge capabilities to deliver DeltaV Live displays via secure, read-only browser access available to users from any location within the network with a viable internet connection.

 

“DeltaV Live Enterprise View is an ideal fit for organizations leveraging the DeltaV Edge Environment as a secure OT-to-IT data platform,” said Seán Saul, vice president of product for Emerson’s process systems and solutions business. “As one of several high-value applications available in a rapidly expanding DeltaV Edge Marketplace, DeltaV Live Enterprise View builds on Emerson’s enterprise operations platform and boundless automation vision by delivering operator-grade, real-time control system visualization to relevant operations personnel through a standard web browser – strengthening collaboration to improve operational performance.”  

Most enterprise visualization solutions require duplication, transformation or redesign of graphics. In contrast, DeltaV Live Enterprise View automatically renders graphics as they are configured in DeltaV Live, delivering instant, visible, role-based value. Enterprise users see what operators see, customised to their own needs, lowering friction and speeding adoption.

DeltaV Live Enterprise View’s secure, read-only visibility of operations is delivered via unidirectional data flow through the DeltaV Edge Environment. The DeltaV Edge Environment provides secure access to fully contextualized DeltaV data while maintaining proper system boundaries.

DeltaV Live Enterprise View joins an existing marketplace of powerful applications available at the edge including DeltaV Edge Explorer, DeltaV Agent.Connect and a wide variety of curated open-source applications such as Grafana, Jupyter Notebook and Node-RED. The applications empower users to drive enterprise-wide optimisation via advanced analytics, AI assistance, customizable dashboards, trending, alarm analysis, workflow automation and batch investigation.

As Emerson expands upon its vision for the enterprise operations platform – the first flexible, software-defined OT-ready digital platform built on scalable control, industrial AI and zero trust cybersecurity – more applications like DeltaV Live Enterprise View will continue to enable seamless scaling from edge to enterprise.

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Automation in advanced carbon capture project.

Louisiana project will convert forestry waste into reliable, carbon-negative electricity.

Strategic Biofuels’ have chosen Emerson to automate the $2-billion landmark Louisiana Green Fuels (LGF) power facility in Caldwell Parish. The project consists of a wood-fired power plant fully integrated with commercial-scale carbon capture and sequestration (CCS), delivering carbon-neutral electricity to Louisiana’s grid.

At full operation, LGF will convert 1.3 million tons of forestry residuals each year – material that would otherwise be left to decompose or be burned – into renewable baseload power, while capturing and permanently storing 1.1 million metric tons of CO₂ annually in secure geologic formations nearly a mile underground. The project will generate 100 megawatts of clean, dispatchable electricity, positioning Louisiana as a leader in carbon-neutral energy production.

“This project represents a significant milestone in Caldwell Parish and for energy independence to support Louisiana’s future,” said Paul Schubert, Ph.D., Strategic Biofuels CEO. “Emerson is the industry leader in process automation and their extensive experience and expertise in biomass power plants and carbon capture makes them the right partner for our project. We know they will be crucial to this project being completed on schedule.”

To optimise the plant’s integrated operations, Emerson will deploy its DeltaV™ Automation Platform, along with a full suite of advanced automation, measurement and reliability technologies. Emerson’s portfolio – including Rosemount™ smart sensing, control valves, isolation valves, pressure protection devices, Micro Motion™ and Flexim™ flow and gas analysis solutions, and AspenTech® data management software – will provide the high-fidelity visibility and dynamic optimisation tools required for a first-of-its-kind carbon-neutral power system.

“Strategic Biofuels is charting a new course for clean, resilient energy by turning waste biomass into reliable power while permanently removing carbon from the atmosphere,” said Mike Train, Emerson's chief sustainability officer. “Emerson is proud to support this breakthrough project with the automation technologies and CCS expertise needed to ensure safe, efficient and continuous operation of next-generation clean energy facilities.”

With its end-to-end automation capabilities and decades of experience supporting energy transition infrastructure, Emerson will help LGF maximise efficiency, reduce operational risk, and deliver on its mission of creating a replicable, commercially deployable pathway to carbon-neutral energy.

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Tool automates batch record creation.

Streamlining Life Sciences recipe creation for faster time to market.

The just announced DeltaV™ MES Recipe Importer Tool is a no-code paper-on-glass application designed to eliminate traditional barriers to digitalisation. By automating recipe creation, the software empowers pharmaceutical manufacturers to accelerate deployment and bring lifesaving treatments to market faster – even with limited information technology (IT) resources and no manufacturing execution system (MES) coding expertise.

“Many batch records that an operator must follow contain hundreds of steps, and building recipes has traditionally been tedious and extremely time-consuming,” said Nathan Pettus, president of Emerson’s process systems and solutions business*. “Our new DeltaV Recipe Importer Tool empowers teams to accomplish months of work in just a few days, accelerating validation and production while reducing costs and improving agility.”

Traditionally, converting paper batch records into digital MES recipes is a complex, time-consuming process requiring multiple workshops, configurations, reviews, tests and coding expertise. These steps often take months and demand close collaboration between IT and operational technology teams (e.g., manufacturing, quality, process, etc.). The DeltaV MES Recipe Importer Tool eliminates these bottlenecks, significantly reducing recipe creation timelines.

With a no-code approach, process developers can streamline batch record digitisation by first translating paper batch records into a preformatted Microsoft Word™ template that includes clear, step-by-step instructions. This template is then uploaded into the DeltaV MES Recipe Importer Tool for conversion into a digital batch record. Once converted, developers review and validate all content, including process instructions, step numbers and required signatures. Finally, they can use the built-in simulation tool to test workflow execution before moving into production, ensuring accuracy and compliance.

The DeltaV MES Recipe Importer Tool is part of Emerson’s Digital Batch Record (DBR) solution, which uses a streamlined approach to digitalising batch execution from recipe creation through manufacturing review. Built on the DeltaV MES platform, DBR eliminates error-prone paper processes while enabling audit-ready traceability, electronic signatures and simplified compliance – all within a validated environment.

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*The DeltaV MES Recipe Importer Tool and Emerson’s DBR solution will be on display at Emerson Exchange 2026, to be held May 19-21 in Dubai (UAE).

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Enhanced control system released.

Acelerates the path to an OT-ready enterprise operations platform to seamlessly integrate and optimise industrial operations.

The DeltaV™ Automation Platform has been enhanced through the release of version 16 of its Distributed Control System (DCS) and integrated Safety Instrumented System. DeltaV version 16.LTS delivers software-defined capabilities that reduce automation costs, enhance operational intelligence, improve data visibility across the enterprise and strengthen cybersecurity. This long-term support (LTS) release consolidates new field-proven capabilities in a single release.

“The speed of technological innovation and rise of industrial AI coupled with growing compute demands at the control layer have created an inflection point requiring a new way for companies to unify operational data and scale automation across the enterprise,” said Nathan Pettus, president of Emerson’s process systems and solutions business. “DeltaV version 16.LTS is the next step in delivering the software-defined enterprise operations platform that will meet those needs, unlocking unlimited flexibility and future-proofing technology choices for years to come.”

With enhanced modularity and flexibility, DeltaV version 16.LTS enables efficient deployment and expansion of automation systems. This includes access to the DeltaV IQ Controller, a fault-tolerant, modular, software-defined controller deployed in a server-based environment and able to handle the most demanding process control applications. In addition, Emerson’s flexible subscription model, DeltaV Flex System, provides companies with full DeltaV DCS capability that allows companies to pay for utilisation over time and scale up or down quickly as market factors dictate.

DeltaV version 16.LTS also integrates intelligence via more seamless data and I/O connectivity enabled by next-generation field networks, providing increased intelligence to optimise and maintain assets and processes. Native support for PROFINET over Ethernet-APL on the DeltaV PK Controller enables high-speed connectivity to field devices in demanding environments across process and hybrid manufacturing operations.

DeltaV Continuous Historian Elite software builds on the power of Emerson’s AspenTech product portfolio to deliver an enhanced data foundation for enterprise-wide optimisation. Creating seamless connectivity between the DCS and enterprise data management solutions, Continuous Historian Elite allows contextualised data to flow freely across the enterprise to power analytics and AI.

Enhancements to DeltaV Live continue to provide an expanded, cohesive view of operations by streaming data through the DeltaV Edge Environment to support enterprise-level decision-making and situational awareness. The new DeltaV Live Enterprise View allows secure, read-only access to displays outside of the control room, making it possible to serve control room data to enterprise-level consumers for trending and continuous improvement of operations. Enhancements also include web application integration that empowers users to bring third-party software applications – such as optimisation tools – natively into the DeltaV control interface.

DeltaV version 16.LTS will also maintain its International Society of Automation (ISA) System Security Assurance (SSA) Level 1 (L1) certification. ISA SSA L1 certification provides third-party assurance of secure-by-design practices that meet ISA/IEC-62443-3-3 and 4-1 requirements.

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More from the mobile app.

Update empowers operators and technicians with more visibility, awareness and customisation options regardless of location.

The mobile app for Emerson's DeltaV™ SaaS supervisory control and data acquisition (SCADA) software has been redesigned. The new app is to empower operators and technicians to do more in the field from their mobile devices, helping teams in critical industries like oil and gas, specialty chemical and others achieve more efficient, optimised operations.

“Today, many operators and technicians are using mobile devices as their primary interface to their SCADA systems,” said Dawn Marruchella, vice president of Emerson’s Guardian software and solutions business. “We’ve redesigned the DeltaV SaaS SCADA mobile app from the ground up with this in mind —delivering a more seamless, intuitive way for users to access all the key information they need, in the format they desire, from anywhere across their plant, facility, or enterprise.” 

Operators and field technicians increasingly rely on mobile applications for SCADA solutions to help them monitor and manage production on the go, manually input data, change settings and issue commands and simplify the work of recording chart estimates from anywhere across a plant or facility. However, today’s most efficient and effective teams need more robust mobile applications and a user-friendly interface to allow them to do more from anywhere. The redesigned mobile app for DeltaV SaaS SCADA is designed to give operators and technicians the control and clarity they need to be effective in the field, without the need to drag a laptop along with them.

The rebuilt DeltaV SaaS SCADA mobile app provides an entirely redesigned user interface (UI) for more intuitive viewing of critical operations information. Via the new UI, users can create and customise their own reports, allowing them to compare multiple sensors and locations to have better visibility into how operations are working in the field. The new UI also delivers alarms via push notifications, helping ensure operators and technicians are made aware of problems as quickly as possible.

Users also gain access to new route planning features. They can create and manage routes/runs on the fly directly from the mobile app, making it easier to customise runs to their specific schedules and daily plans. An operator or technician can view the stops on the route at any time to quickly see which are in alarm and can seamlessly pass location information directly to the mobile device’s mapping app to be guided to locations.

 DeltaV SaaS SCADA’s mobile app also features new widgets to simplify operation, making it easy for users to quickly see total alarms for selected locations and comparison of volumes produced.

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Shorter technology transfer helps life sciences and patients.

Emerson collaborated with Roche, one of the world’s largest biotechnology companies, to deliver a digital library of modalities for faster deployment and utilisation of DeltaV™ Process Knowledge Management (PKM) software, minimising the time it takes to develop a process specification through its lifecycle to full commercial scale.

The DeltaV PKM Modality Library provides a set of software building blocks to help organisations quickly establish a modular approach to characterising process definitions. By further standardising process specification elements and relationships, life sciences innovators can more rapidly deliver lifesaving and life-improving treatments to patients in need.

“Today’s life sciences innovators love PKM’s ability to shorten technology transfer but are continually searching for ways to improve alignment between process development and manufacturing recipe development,” said Nathan Pettus, president of Emerson’s process systems and solutions business. “The DeltaV PKM Modality Library enables a fully digital path to technology transfer, making the entire process faster, easier and more repeatable and reliable.”

Today it can take months to establish an organisation’s standards and then create the associated validatable building blocks using the PKM collaboration environment. Users must align on an ontology, equipment classes and capabilities, use of materials and formulations, quality testing plans, etc., before they can begin creating process specification recipes. All of this must also be aligned with the submission and licensing process and within the global supply chain.

Technology transfer is a major obstacle in delivering new medical breakthroughs to patients globally. This specialised library can allow companies to overcome this hurdle by streamlining and accelerating the move from research to commercial launch.

PKM software is designed to dramatically improve and shorten the technology transfer process. It replaces manual methods with a structured repository to define the process specification and a collaborative digital platform to manage changes as that specification evolves during the process development lifecycle.

The DeltaV PKM Modality Library provides a prebuilt, proven, customisable set of specification elements where the framework for the elements is already established for a given modality. This includes examples of underlying process steps, activities, key process parameters and critical quality attributes.

Prebuilt software frameworks cut months off development and organisational alignment efforts and establish digital foundations for faster future innovation. The modality library then facilitates seamless integration into execution systems to digitally transfer specification information into working recipes.

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AI Empowerment for manufacturers.

Expanded AI Portfolio paves the way for more optimised autonomous operations.

Manufacturers across every industry are being empowered by Emerson to drive toward optimised autonomous operations with the most advanced industrial artificial intelligence (AI) and data solutions for online, mission-critical applications. Emerson’s comprehensive AI portfolio – supported by its recent acquisition of the Aspen Technology business and built on decades of domain expertise – will help organisations implement AI solutions that deliver consistent, sustainable value.

AI tools have reached an inflection point as open AI frameworks and foundational models trained on vast amounts of data have become more robust and accessible. However, while today’s companies see industrial AI as an essential tool to help automate workflows, eliminate complexity and increase agility, the unsecure and unreliable nature of public generative AI (GenAI) technologies is not suitable for high-availability, mission-critical industrial manufacturing.

Emerson tackles this challenge with an AI portfolio featuring local models with embedded knowledge and guidance grounded in first principles. These physics- and engineering-based models eliminate the potential for tools to generate the impossible, unrealistic and unsafe results that plague AI technologies that are not fit-for-purpose. Leveraging local, customisable, industry-specific models provides more interpretable, trustworthy results and eliminates the need to expose sensitive data to public cloud architectures.

“Generic large language models are necessary for AI, but they are insufficient for a live, mission-critical industrial plant that cannot afford unreliable or unsafe results,” said Ram Krishnan, chief operating officer at Emerson. “Emerson’s solutions leverage industrial AI, built on decades of industry expertise and first principles constraints, to deliver correct, actionable guidance users can count on to make better operational and business decisions that will safely and rapidly drive competitive advantage.”

Emerson’s AI tools provide users with powerful automated engineering workflows. Emerson’s AspenTech Optiplant® AI Equipment Layout leverages GenAI to quickly and easily provide multiple viable design options for greenfield and brownfield plants. Users provide their requirements to AI that rapidly presents multiple options to fulfil them, enabling engineers to more efficiently select layouts that are not only suitable for performance but also meet additional non-functional requirements such as buffer zones, safety and proximity, and more.

DeltaV™ Revamp uses AI to accelerate a low-risk transition of legacy control and safety system configuration to a modern DeltaV system, informed by data gathered from thousands of modernisation projects across every industry. The AI tools in Emerson’s DeltaV Revamp analyse information learned from each control system update to further improve the core database for increased speed, accuracy and agility with each modernisation.

AspenTech Strategic Planning for Sustainability Pathways™ leverages GenAI technology to navigate complex options and pathways to help companies more easily develop long-term strategies for decarbonisation.

In addition, Aspen Virtual Advisor (AVA), an AI-driven advisor built into Emerson technologies, provides expert operational guidance to users across a wide range of experience levels as they navigate sophisticated tools used for design, planning, scheduling and automation of operations. Today, AVA leverages deep knowledge of Aspen PIMS™ planning software and Aspen DMC3™ adaptive process control software, allowing users to ask natural language questions to identify process bottlenecks or find ways to achieve specific goals.

Other virtual advisors, like those built into Emerson’s Ovation™ 4.0 Automation Platform and Guardian™ Digital Platform, provide the tools users need to visually translate and simplify complex issues to easily understand what is happening in their control system.

“Emerson is the only company with the wide range of domain expertise, deep stores of first principles models, vast array of fit-for-purpose technology solutions, and history of industry-shaping innovation necessary to deliver industrial AI tools that modern manufacturers can trust in a mission-critical environment,” Krishnan said. “With Emerson’s expertise, data and Boundless Automation vision, we are perfectly positioned to advance AI solutions that actually deliver on their promises.”

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See also: Effortless integration of AI and automation technologies. (20/5/2025)

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Getting lifesaving therapies to patients faster!

Emerson is empowering manufacturers with seamless data mobility across a new suite of life sciences software in the DeltaV™ Automation Platform. Providing key automation solutions from the earliest stages of recipe development through commercial manufacturing, Emerson’s suite of life sciences software makes it easier for organisations to select and connect critical tools necessary to bring quality treatments to patients faster, safer and more sustainably.

The traditional process of creating a new treatment from research through clinical trials to commercial manufacturing is largely manual and intensely time consuming. Life sciences companies spend substantial resources in both time and money performing the steps necessary to move information across various applications to successfully develop and manufacture new products. With a wide variety of technology solutions from different providers in the various segments of the business, data can quickly become siloed in individual applications, making it difficult to move from stage to stage, and increasing the likelihood of error.

To overcome these challenges, Emerson’s life sciences software suite is purpose-built within the comprehensive DeltaV Automation Platform, streamlining the connection of critical components across the development and commercialisation pipeline to create a more collaborative environment. For example, users can create a general recipe and risk profile in DeltaV Process and Knowledge Management (PKM™), and then, using the DeltaV Tech Transfer Hub—a sophisticated mapping tool created through Emerson’s One-Click Technology Transfer™ initiative—quickly send the pertinent recipe information to the DeltaV Manufacturing Execution System (MES) or the DeltaV Distributed Control System (DCS).

“Easier integration of critical technologies in the treatment development pipeline is key to unlocking the five value drivers of life sciences: pipeline acceleration, flexible manufacturing, operational integrity, real-time release, and sustainable operations,” said Nathan Pettus, president of Emerson’s process systems and solutions business. “Combining the suite of life sciences software solutions under the unified DeltaV Automation Platform enables life sciences organisations to embrace the Boundless Automation vision of seamless data mobility. Ultimately, with this vision, organisations can unlock flexibility and operational excellence capabilities that are crucial to delivering next-generation treatments to patients in need.”

Leveraging a common data fabric made possible by Emerson’s AspenTech Inmation™ real-time data platform, the software suite including DeltaV PKM, DeltaV DCS, DeltaV MES, and DeltaV Real Time Scheduling can be integrated more easily, reducing the need for customisation.

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* Emerson’s life sciences software suite will be on display with the entire DeltaV Automation Platform at Emerson Exchange 2025 (May 19-22 in San Antonio, TX USA)

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OT data mobility out of the box.

Combines the power of edge computing with the flexibility of a cloud platform

DeltaV™ SaaS SCADA with Edge Connect has been announced by Emerson. This is a flexible, preconfigured edge solution engineered to deliver more seamless operational technology (OT) data mobility out of the box. Designed to connect existing field devices to the cloud-hosted DeltaV SaaS Supervisory Control and Data Acquisition (SCADA) system in minutes, the DeltaV SaaS SCADA with Edge Connect edge solution eliminates much of the traditional engineering work necessary to bring critical operational data into the control system for better visibility and safer, more flexible and reliable control.

Unlocks secure communication to all field devices using their native protocols.

“DeltaV SaaS SCADA with Edge Connect advances Emerson’s Boundless Automation vision of seamless data mobility from the intelligent field, through the edge, and into the cloud,” said Nina Golder, vice president of Emerson’s Guardian software and solutions business. “Designed with open protocols and preconfigured with the most advanced edge technology stack available, the DeltaV SaaS SCADA with Edge Connect edge solution empowers users to remotely monitor and configure their field assets, bringing visibility and operations online in minutes while still providing powerful capabilities to customise their experience.”

Built on Emerson’s PACEdge™ software for edge computing, the DeltaV SaaS SCADA with Edge Connect edge solution can communicate with all field devices – remote terminal units, flow computers, valves, sensors and more – in their native protocols using an Emerson-tested third-party polling engine that eliminates the need for additional conversion or adapters. PACEdge provides an IIoT application enablement platform designed to integrate information technology and OT domains without disrupting OT assets, architectures or systems.

All software necessary to connect and run the edge solution is preinstalled on the device, and additional applications can be added via a built-in marketplace. In addition, users can also build and add their own custom containerised applications with built-in Node-RED, a low-code programming platform for event-driven applications.

Built in alignment with International Society of Automation (ISA) 62443 standards and the European Union’s Cyber Resilience Act, the DeltaV SaaS SCADA with Edge Connect edge solution provides a secure platform for industrial operations. It also provides report by exception capabilities, allowing the device to automatically switch polling frequencies for increased communication when a new value is registered from a device in the field, helping teams maintain critical visibility without increasing bandwidth and communication costs. 

Data buffering features allow the DeltaV SaaS SCADA with Edge Connect edge solution to store data during communication outages and send it when communication is restored so no data is lost. Dynamic polling resolution automatically changes polling rates when events occur, helping ensure all critical data is delivered promptly.

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• The DeltaV SaaS SCADA with Edge Connect edge solution will be on display at Emerson Exchange Americas 2025, being held May 19-22 in San Antonio (TX USA).

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Lifecycle change management.

Software capabilities drive increased collaboration across the enterprise for better business outcomes.

Version 6.LTS of Emerson's DeltaV™ Mimic dynamic simulation software has been launched. The software has been enhanced to support performance and collaboration across the enterprise, helping eliminate silos of data that limit visibility into operator performance and providing tools to create digital twin simulations that deliver continuous value far beyond project execution.

Capital project teams have long known simulation software provides fast return on investment during project execution. Investment in simulation often pays for itself well before project completion as a tool for engineering design, automation testing and operator training. However, forward-thinking teams are further increasing ROI across the lifecycle of their simulation technologies by continuously maintaining them after project execution as collaborative, change management workflow solutions.

In the new DeltaV Mimic Version 6.LTS, a new focus on enterprise connectivity, parallel long-term support (LTS) lifecycle strategy for the DeltaV Distributed Control System (DCS) and DeltaV Mimic, streamlined model tuning and support for virtual controllers and larger simulations will help companies more easily accomplish their goal of implementing these holistic simulation solutions.

“A digital twin simulation is no longer just a discrete asset to deliver project success, but rather a comprehensive tool for continuous collaboration between process and automation engineering, plant management, training management, operations and maintenance, and more,” said Dustin Beebe, vice president of performance services for Emerson’s process systems and solutions business. “DeltaV Mimic Version 6.LTS is designed to streamline that evolution, incorporating Emerson’s Boundless AutomationSM vision for seamless data mobility to break down the silos of disconnected simulation systems at the plant level and bring the data to the enterprise where it can be used by cross-functional teams for continuous improvement.”

New enterprise capability in DeltaV Mimic Train helps eliminate data silos by bringing training data out of the plant and up to the enterprise where organisations can use it in standard learning systems. Armed with comprehensive data, companies will improve record keeping, ensuring training requirements meet the organisation’s standards. Enterprise teams will also be able to combine operational data with training history to explore how differences in training may be contributing to performance disparities.

It will also improve scalability. Options for subscription licensing via Emerson’s Guardian™ digital experience will make it easier for organisations to distribute and optimise licensing across enterprise architectures. In addition, Emerson has added support for DeltaV DCS virtual controllers while also increasing node support by a factor of nearly 10 to empower users to build larger simulations in a single instance of the software and make it far easier to scale up as operations grow.

The DeltaV Mimic flow tuner has been converted to a user-facing tool to provide users a way to tune models to their own unique process variables, such as flow and temperature. Armed with the capability to fully tune models in-house, teams will reduce the amount of time it takes to bring models into alignment with actual process performance in the plant.

All new DeltaV Mimic functionality comes as part of a transition to an LTS software strategy, more closely aligning the DeltaV DCS and Mimic software to ensure that changes made to either platform are reflected in both, helping users more easily update and maintain their DeltaV solutions as part of a broader enterprise operations platform.

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Control system has increased operational agility.

Features support for PROFINET S2 devices, more flexible operator training functions and robust change management for human machine interfaces.

Emerson's DeltaV™ Automation Platform is being expanded with the DeltaV version 15 Feature Pack 3 update for its distributed control system. New capabilities in Feature Pack 3 help users improve the availability of Ethernet-based field device networks through PROFINET system redundancy. Feature pack enhancements improve users’ ability to track changes and produce validation reports for version control both internally and for regulating authorities. In addition, new simulation enhancements continue to improve training options to upskill workforces more easily.*

“DeltaV version 15 Feature Pack 3 delivers new functionality that helps modern process manufacturers meet current and future industry challenges,” said Claudio Fayad, vice president of technology for Emerson’s process systems and solutions business. “The regular feature pack cadence between major DeltaV releases continues to help users more quickly realize the project savings and operational efficiencies that come with new features for their control system software.”

The latest DeltaV release is a continuation of the evolution toward a software-defined automation system integrating proven technologies to deliver increased flexibility for adapting to an increasingly complex operating environment. With DeltaV version 15 Feature Pack 3, users now have access to the infrastructure for the highly anticipated IQ controller, a fault-tolerant, modular, software-defined controller deployed in a server-based environment performant for even the most demanding process control applications.

DeltaV PK Controller now supports S2 system redundancy for increased resilience during controller switchovers. Additionally, PK Controller’s support for PROFINET S2 devices can accommodate process changes more easily, empowering production personnel to deliver quality improvements and production increases.

Feature Pack 3 also adds version control for DeltaV Live, providing modern change management and audit trail solutions most relevant for DeltaV installations in highly regulated manufacturing segments such as the life sciences industry. Users can check graphics in and out for customization, intuitively analyse who made changes to graphics and other human machine interface elements and identify why changes were made. Additionally, version control reports can be customized and easily exported for audit documentation.

Enhancements to the DeltaV Simulate training and development suite in Feature Pack 3 improve virtual machine controller-based simulation capabilities for easy offline development and testing, as well as for effective operator training. With new “save and restore” snapshot functionality, instructors can enhance the training experience by showing operators how different choices impact operations.

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*DeltaV version 15 Feature Pack 3 will be on display at Emerson Exchange 2025, being held May 19-22 in San Antonio, Texas USA.

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Empowering batch consistency, quality, and innovation.

Updated edge technology helps drive integration for Batch Processes.

DeltaV™ Edge Environment 2.0 is the newest version of Emerson's edge technology for delivering OT applications and contextualized control data anywhere in the enterprise. The updated DeltaV Edge Environment 2.0 now supports batch data integration to help life sciences, chemical processing and other batch processing industries leverage their critical data in analytics applications, AI and machine learning applications, IT enterprise systems and more, whether on-premises or in the cloud.

“Life sciences operations rely on data democratization to optimize and validate their production. Emerson’s Boundless Automation vision, where data silos are eliminated, will empower cross-functional teams to develop the business decisions necessary to drive competitive advantage,” said Claudio Fayad, vice president of technology for Emerson’s process systems and solutions business. “Emerson’s DeltaV Edge Environment 2.0 not only unlocks that level of data mobility but does so while preserving essential batch and process context to improve operational certainty.”

Batch processing operations frequently require data reconciliation, aggregation and validation, driving a need for seamless data mobility to bring critical data to varied technologies across the enterprise. However, integrating control system data—critical to making key business decisions—is typically too difficult, costly and risky using traditional technologies.

DeltaV Edge Environment 2.0 bridges the gap between operational technology control systems and information technology-focused applications with one-way egress of control system data via a secure, read-only replica of contextualized DeltaV distributed control system data. Armed with comprehensive control data for use in tools at the edge or in the business cloud, teams can overlay batch data with process values to identify performance deviations during batch runs. Increased visibility into batch health empowers teams to intervene earlier to prevent costly, off-specification batches.

DeltaV Edge Environment 2.0 can integrate with the control system configuration hierarchy, helping clarify how configuration changes impact batch execution. OT teams also gain the ability to correlate batch-related alarms and events with other system events to identify root causes of production issues quickly and effectively.

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Industrial internet of things (IIoT) Innovation recognised.

Company’s next-gen life sciences software helps accelerate therapy commercialisation.

The ‘Industrial IoT Innovation of the Year’ award has been won by Emerson for its DeltaV™ Workflow Management software at the 9th annual IoT Breakthrough Awards. The award recognises Emerson’s next generation, software-as-a-service solution to help life sciences companies more efficiently develop, scale and manufacture life-changing cell and gene therapies.

Designed specifically for companies in early-stage development with limited IT infrastructure, DeltaV Workflow Management provides a cloud-based solution that transitions drug recipe workflow data from paper-based records to digital records, providing a simple and scalable solution with no coding experience required.

“Life sciences companies have a crucial job: fighting disease by bringing new, safe medicines to market as fast as possible. To do that, they need more agile, flexible and scalable processes to quickly move products through the development pipeline to the commercial market,” said Nathan Pettus, president of process systems and solutions at Emerson. “Our new DeltaV Workflow Management software provides companies with simple recipe authoring, execution and electronic data capture, so they can focus on innovation.

“Emerson is proud of this recognition of DeltaV Workflow Management – the latest in our unmatched portfolio of technologies and software solutions that help life sciences companies scale and deliver drugs to market safely, efficiently and quickly.”

Building on its Boundless Automation^SM vision, the new Emerson software also generates searchable, exportable digital records so data can be more easily analysed and reported. In addition, this digital shift minimises the contamination risks associated with paper records in sterile clean rooms.

Emerson has been recognised every year by the IoT Breakthrough Awards for its innovation since its inception in 2018*. The programme recognises innovators, leaders and visionaries from around the globe in a range of IoT categories, including Industrial IoT, Enterprise IoT, Consumer IoT, Connected Home and more. This year’s programme attracted more than 3,850 nominations from companies all over the world.

“Emerson is a consistent presence in our IoT Breakthrough Awards line-up because it’s an industrial technology company driving innovation in production, reliability, safety, workforce and sustainability across critical sectors,” said Steve Johansson, managing director at IoT Breakthrough. “We congratulate the Emerson team for its life sciences leadership by taking home our ‘Industrial IoT Innovation of the Year’ award in the ninth annual IoT Breakthrough Awards programme.”

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* Leaders in Industrial ID (January 2028)

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Control system update expands connectivity & streamlines control execution.

Control system software for seamless data integration and improved operational performance.

The DeltaV™ Automation Platform from Emerson is further expanded with the DeltaV Version 15 Feature Pack 2 update for its distributed control system (DCS). This feature pack release empowers users to easily transition to a DeltaV DCS from more third-party control systems, expands support for data-rich Ethernet device networks, and reduces the complexity of state-based control implementations.

As plants try to capture the most elusive performance gains to meet today’s ever-increasing efficiency and sustainability goals, they are looking for technologies that modernise control without excessive engineering risk, overhead and downtime. The latest release of the DeltaV control system continues the regular cadence between major DeltaV releases to help users more quickly realise the project savings and operational efficiencies that come with new features for their control system software.

“DeltaV Version 15 Feature Pack 2 provides users with new functionality, capabilities and enhancements to further expand seamless data and I/O integration, as well as applications to more easily modernise their operations, improve connectivity and collaboration, and lock in operational excellence,” said Claudio Fayad, vice president of technology for Emerson’s process systems and solutions business.

Today’s plants need to reap the benefits of modern, digital technologies that optimise operations and improve sustainability. However, one of the most common barriers to control system modernisation is the high cost and labour requirements of transitioning I/O. DeltaV IO.Connect, which lets users replace legacy control systems with modern DeltaV software and controllers while leaving legacy I/O infrastructure in place, now supports multiple third-party control systems.

Plants can now transition to a modern DeltaV control system from the most common third-party systems right away – immediately reaping the benefits of modern control – and transition their I/O infrastructure gradually, on their own schedule, to minimise downtime and risks.

Ethernet-based, high-speed, data-rich device networks continue to gain popularity across the automation landscape and will only accelerate as Advanced Physical Layer extends the application range in process and hybrid industries. With this latest release, the DeltaV control system has increased the types of data as well as the diagnostic capabilities of the wide range of supported Ethernet-based communication protocols, including PROFINET, EtherNet/IP, OPC UA, and Modbus TCP. These enhancements advance the solid foundation of DeltaV automation to exchange increasing volume and variety of data from the next generation of field device networks.

State-based control is a key enabler as many plants drive towards autonomous and semi-autonomous operations to reduce downtime and minimise safety risk. With DeltaV Version 15 Feature Pack 2, engineering and operations teams now have more options for how state-based control sequences execute when operations dictate a change in logic. This optional behaviour enables safe and reliable operations while improving the flexibility and maintainability of state-based logic. To improve operator situational awareness, the watch area capability of DeltaV Live has also been enhanced to persist as operators navigate between displays.

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Advanced process control increases polyester production.

The world-leading producer of high-tech polymer materials, Covestro, is being helped by Emerson to enhance the operational performance and sustainability of its manufacturing facility in Barcelona (ES)*. As part of a continuous plant improvement programme aimed at reducing emissions from production and external energy sources to net zero by 2035, Covestro has optimised the esterification process used to produce polyester. By implementing Emerson’s DeltaV™ advanced process control software, Covestro has improved the efficiency of polyester production, leading to increased availability and throughput, and reduced water and energy consumption.

Pic: Covestro

Covestro produces polyester resin at its Barcelona facility to be used within plastics manufacturing, but recently faced operational challenges with its batch-based production process. The need to optimise esterification and prevent unreacted glycol from plugging a downstream condenser while minimising reflux water usage prompted Covestro to seek an improved control solution.

Due to the complexity of the process variables involved, attempts to achieve these improvements through adjustments to the existing batch process control configuration were unsuccessful. Covestro therefore turned to Emerson, and after careful analysis, its consultants recommended the implementation of DeltaV PredictPro, a multivariable, model predictive control (MPC) and optimisation software solution, which is part of Emerson’s evolving DeltaV automation platform.

Emerson engineers worked collaboratively with Covestro to seamlessly integrate the MPC software into the existing DeltaV distributed control system that manages the batch process. The MPC utilises variables, such as temperature and pressure, to manage reflux flow efficiently. The DeltaV system defines limits and performs start and stop operations for the MPC, eliminating the need for operator intervention that could potentially lead to batch variations.

“By collaborating with partners such as Emerson that share our commitment to sustainability, Covestro aims to achieve added value from carbon used through the value chain,” explained Adrian Belda, manufacturing engineer at Covestro. “Model predictive control from Emerson is a tailored solution that provides the optimal control profile for our batch production process. The MPC gives us the flexibility to increase process efficiency, while considering process safety conditions and guaranteeing product quality.”

Since the deployment of the MPC on one of four reactors, Covestro has achieved significant improvements, including better management of steam rectification, which ensures glycol does not negatively impact downstream operations; reduced reflux water use; and significantly shortened reaction duration. These enhancements have not only increased energy efficiency, but by allowing more batches to be completed, will increase throughput by an estimated 1% annually.

“As organisations strive to achieve ambitious sustainability targets while navigating ever-tighter regulations and global competition, they are looking for ways to drive increased efficiency across their operations,” said Claudio Fayad, vice president of technology for Emerson’s process systems and solutions business. “DeltaV PredictPro helps production teams lock in best practices, so they can be sure the efficiencies they have engineered are performed every time, regardless of who is in the control room.”

Covestro is now exploring the possibility of replicating the approach on similar reactors and integrating boiler control into the MPC solution, which would present further opportunities to reduce energy consumption and help meet its sustainability goals.

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* How process control helped in solving this Covestro operational challenge.

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Delivering scalable recipe authoring and execution technologies for life sciences companies.

DeltaV™ Workflow Management, a next-generation software designed for life sciences companies in early-stage development has been introduced by Emerson. The new software continues Emerson’s expansion of capabilities of the evolving DeltaV automation platform to offer more scalable options to suit the needs of smaller life sciences innovators. For companies with limited IT infrastructure, DeltaV Workflow Management provides a cloud-based, software-as-a-service solution for simple recipe authoring, execution and electronic data capture.

In high-growth life sciences companies, such as those making advanced therapy medicinal products for hard-to-treat diseases and personalised medicines, manufacturing facilities still heavily rely on manual processes and record-keeping for bench-scale operations and recipe authoring. Many do not have robust IT departments, nor staff experienced in the complex coding necessary with traditional manufacturing execution systems.

The software removes this layer of complexity by transitioning recipe workflow data from manual records to digital ‘paper on glass’, providing a simple and scalable solution that helps accelerate the drug development process with no coding experience required. The software also generates searchable digital records that are easily organised and exported, and data that can be more easily analysed and reported. In addition, this digital shift minimises the contamination risks associated with paper records in sterile clean rooms.

“DeltaV Workflow Management enables innovation for both start-ups and established labs that demand speed and simplicity in early-stage drug development,” said Nathan Pettus, president of Emerson’s process systems and solutions business. “Recipes relying on standard, full-blown manufacturing execution systems can take years of experience and months to create and fully automate. With this new software, the timeline is reduced to days, providing companies with a head start toward commercialisation and getting new therapeutic medicines into the pipeline faster.”

Within DeltaV Workflow Management, users employ simple drag-and-drop elements to create steps for a recipe and automate workflows that meet Good Manufacturing Practice standards. Within those steps, they can add new parameters and e-signature requirements for quality control and regulatory compliance, run product recipes, authorise users for specific tasks and create digital batch records.

DeltaV Workflow Management expands and complements the user options for digital recipe development and execution already provided by Emerson’s DeltaV MES – the newest evolution of the Syncade MES. Users now have additional flexibility to match digital recipe solutions to their business needs, underscoring Emerson’s commitment to continuing enhancement of and investment in a portfolio of manufacturing execution solutions for organisations at any scale.

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