Partnership a roadmap to increase automation of its operations in Mexico.

Braskem Idesa Works with Emerson to Drive Operational Excellence, Achieve Sustainability Goals!

A strategic partnership with Braskem Idesa to provide digital automation technologies and engineering services across its operations to meet business performance metrics and achieve its sustainability goals has been announced by Emerson.  Braskem Idesa is a joint venture between Brazil-based Braskem, the largest producer of thermoplastic resins in the Americas, and Grupo Idesa, one of the biggest petrochemical companies in Mexico.

A multi-year digital transformation roadmap will leverage Emerson’s extensive petrochemical industry expertise and broad portfolio of advanced automation technology and software solutions to drive not only operational excellence but also support Braskem Idesa’s goal of reducing greenhouse gas (GHG) emissions scope 1 and 2 by 15% by 2028 and achieving full carbon neutrality by 2050.

“We identified several key financial and performance benchmarks and brought Emerson on board to participate in the creation of a detailed digital transformation strategy for achieving Top Quartile results,” said Stefan Lepecki, Braskem Idesa’s CEO. “Having a well-defined path forward has given us the confidence to pursue our sustainability and performance goals, with advanced, integrated technologies that help us support market demands.”

Taking advantage of Emerson’s Operational Certainty methodology, the roadmap provides a framework for scalable improvements in some of the four key transformation work streams:

• Information management, including creating a data architecture for real-time KPIs and decision-making. • Physical loss control, with enhanced energy management and loss control systems. • Production and energy optimisation with advanced control technologies. • Reliability and energy efficiency using data analytics, continuous emissions monitoring systems, LED lights and fugitive emissions reductions.

These work streams align with Braskem Idesa’s three-pronged strategy for the reduction of GHG emissions through energy efficiency, renewable energy use and low carbon intensity process technologies; renewable feedstocks and post-consumer recycling; and capturing carbon emissions to use as raw materials, value-added chemicals and as an alternative to future carbon taxes.

“Successful leaders are realising that sustainability initiatives are also good business,” said Mark Bulanda, executive president of Emerson’s Automation Solutions business. “Reducing waste and unnecessary raw material consumption, lowering energy costs and driving profitability, all while improving environmental sustainability, is absolutely possible with the right focus and resolve.”

•  See "Forward Focus..."  - the theme of the Emerson User Group Conference commencing 24th October 2022 in Grapevine (TX USA).

@EmersonExchange @EMR_Automation @Emerson_News @BraskemIdesa @HHC_Lewis #PAuto #Mexico

PoE for Coriolis for process efficiency.

The first Micro Motion Power-over-Ethernet (PoE) Coriolis flow measurement device for the food and beverage, life sciences and chemical industries has been introduced by Emerson. Their 1600 Coriolis Transmitter is designed to be a scalable solution for facilities wanting to make a gradual transition to remote flow data collection, monitoring and configuration.

“The Micro Motion 1600 transmitter offers customers a purpose-fit device in both form factor and capabilities for the demands of the food & beverage and life sciences industries as they strive to achieve more efficient, reliable and sustainable operations,” said Melissa Steigler, food and beverage industry director at Emerson.

With traditional Ethernet, optional PoE and an additional licensable configurable output, the 1600 delivers a powerful solution for customers looking for a flow measurement device that will grow with their process and is easily integrated into a control system.

PoE can deliver power and data over a single Ethernet cable, which means no new cabling will need to be installed, saving customers up to 50% in installation and maintenance costs. The Micro Motion 1600 transmitter can use just PoE or have a separate direct current (DC) power input, depending on wiring availability. The smallest PoE Coriolis transmitter on the market, the 1600 is available in aluminium or hygienic stainless steel. The compact size and lightweight design are an added space-saving benefit for skid designers.

The transmitter is equipped with a multi-language four-line local operator interface (LOI), a suite of advanced software solutions including Smart Meter Verification, Data Historian, Concentration Measurement and Advanced Phase Measurement, as well as an additional licensable channel that can be configured for analogue, frequency or discrete output and a USB-C service port. The reliable, high-quality data it collects allows for greater process efficiency, which minimises product and process waste, reduces emissions by giving visibility to entrained gas events, and results in a more efficient consumption of power.

•  See "Forward Focus..."  - the theme of the Emerson User Group Conference commencing 24th October 2022 in Grapevine (TX USA).

@EmersonExchange @EMR_Automation @Emerson_News @MicroMotion @HHC_Lewis #PAuto #Food

Spherical image capture.

Teledyne FLIR Integrated Imaging Solutions is pleased to announce the all new Ladybug6— the latest addition to its field proven Ladybug series. Ladybug6 is the leading high-resolution camera designed to capture 360-degree spherical images from moving platforms in all-weather conditions. Its industrial grade design and out-of-the-box factory calibration produces 72 Megapixel (MP) images with pixel values that are spatially accurate within +/- 2 mm at 10-meter distance.

Key Features: • Captures 72 Megapixel images with spatial accuracy of +/- 2 mm at 10-meter distance • Frame rates of up to 29.9 FPS at 4K resolution, 15 FPS at 72 MP • Wide operating temperature range of -30° C to 50° C • IP65 rating with industrial grade IP67 rated connectors • Support for additional Global Navigation Satellite Systems • Excellent color response, low noise, and a high dynamic range • Captures, compresses, and transmits 8-bit or 12-bit pixel data • Feature rich and user-friendly Ladybug SDK • All-metal body with 2-year warranty.

“The new Teledyne Ladybug6 is designed for mobile mapping and all-weather inspection projects requiring excellent image quality and high resolution,” said Mike Lee, Senior Product Manager at Teledyne FLIR. “With the addition of Ladybug6, we are now pleased to offer a wider variety of spherical cameras with higher resolutions ranging from 30 MP to 72 MP.”

The new Ladybug6 builds on Teledyne’s machine vision heritage with increased image resolution, enhanced on-board processing, and robust IP67-rated connectors. Building on the field proven Ladybug5+, the Ladybug6 captures, compresses, and transmits 8-bit or 12-bit pixel data delivering outstanding images across a wide range of lighting conditions with excellent color response, low noise, and a high dynamic range. Designed from the ground up to capture images from moving platforms in outdoor environments, the Ladybug6 features a wide operating temperature range (-30° C to 50° C), support for additional Global Navigation Satellite Systems, and trigger control by hardware or software with advanced APIs for complete camera control.

Ladybug6 cameras are engineered to deliver high-accuracy, high-resolution, and dependable results for applications such as HD mapping, asset management, roadside inspection, panoramic street image production for street view, road surveying, heritage scanning, building management, among several others.

@flir @mepaxIntPR #PAuto #Inspection

Smallest robot.

ABB's smallest ever industrial robot, offers new possibilities for faster, more flexible and high-quality production of wearable smart devices. With its compact size, class-leading payload and unrivaled accuracy, the new IRB 1010 offers electronics manufacturers the opportunity to increase their production of devices including smart watches, earphones, sensors, and health trackers through automation.

“The market for wearable smart devices is accelerating rapidly, with projections estimating double digit growth between 2022 and 2028,” said Rui Liang, Managing Director of ABB Robotics’ electronics business line. “To meet this growth, companies are demanding compact robotic solutions that are suited to narrow production spaces in electronics manufacturing lines and that can accurately handle the small components used in wearable devices. As the most accurate robot in its class for 1.5kg payloads, our IRB 1010 meets these demands, enabling companies to maximize output and productivity while maintaining the highest levels of product quality.”

The IRB 1010 is designed to suit the narrow spaces and special purpose machines typical of electronics production environments. With a reach of 370mm and a footprint of 135mm by 250mm, the IRB 1010 is 30 percent smaller than ABB’s current smallest robot, the IRB 120. These compact dimensions increase the number of cells that can be fitted into production spaces, enabling manufacturers to boost output through higher density factory layouts. Capable of handling loads up to 1.5kg, the IRB 1010 has the highest payload in its class, with the ability to lift up to three times more weight than comparable robots. This increased payload capacity – coupled with a larger diameter air hose that provides added power for vacuum suction – enables simultaneous handling of multiple objects, allowing more objects to be processed per hour. It also opens opportunities for new applications including film peeling, material handling, assembly, gluing and inspection.

Productivity is further enhanced by the inclusion of six braking systems, which allow the robot arm to remain in its position even when stopped. By eliminating the time needed for the robot to recover its position after a stop or pause, production can be resumed more quickly, enabling the IRB 1010 to do more in less time than other robots in its class. Key to the IRB 1010’s high accuracy is ABB’s OmniCore™ E10 controller, which offers class-leading position and path repeatability of 0.01mm. With its slimline design, the controller is well suited to small part assembly in applications where production cell sizes need to be minimized. The controller offers the flexibility to meet changing requirements, with built-in digital connectivity and over 1000 additional functions enabling easy scalability.

Consuming up to 20 percent less energy compared to ABB’s previous IRC5C controllers, the OmniCore E10 also enables manufacturers to cut their energy costs and improve energy efficiency. Robot Control Mate makes programming simple.
Programming the IRB 1010 is made simple with ABB’s Robot Control Mate. Available as an add-in to ABB’s RobotStudio® programming software, Robot Control Mate enables users to move, teach and calibrate the IRB 1010 from their computer or mobile tablets without the need for programming skills.

This simple programming, together with the small size of the IRB 1010, also opens new possibilities for educational applications. The IRB 1010’s compact design makes it suitable for installation on classroom desktops, while its ease-of-use enables both teachers and students to quickly master the skills needed for programming and operation. The addition of the IRB 1010 complements ABB’s comprehensive range of articulated industrial robots, with includes a full range of small, medium, and large options, including a growing family of collaborative robots that can be safely deployed alongside workers.

@ABBRobotics @ABBgroupnews @NapierPR #Pauto #Robotics #Electronics

Three million valves and seven reasons...

A customer in China has recently purchased the 3 millionth Fisher™ FIELDVUE™ digital valve controller for use in the water treatment pressure control valve in their membrane plant. A digital valve controller helps regulate and monitor the opening and closing of a control valve, and it also provides a wealth of information with respect to valve status and health. 

Although this is a significant milestone for the company they point out that  the top seven reasons why process plant personnel specify, purchase, install and use Fisher instruments are more important.

1. First, a FIELDVUE digital valve controller enables remote monitoring of control valve position. Florida Power & Light installed FIELDVUE digital valve controllers on 90 of their Fisher control valves are used to control natural gas and steam flows associated with the turbines. Plant operators in the control room now receive valve position feedback, allowing them to verify the operation of each valve. Accurate control valve position enables tighter control to setpoint, increasing efficiency and improving operations.
2. Second, in an offline mode, a FIELDVUE digital valve controller can be used to create a signature for a new valve. This signature captures details on packing friction, air usage, valve travel, and other parameters—all of which can be compared to future valve signature test results. Often a comparison will quickly highlight developing issues, such as instrument misalignment, air supply issues and actuator leaks.
3. Third, FIELDVUE digital valve controllers can proactively monitor valve performance while the valve is online and controlling the process, revealing if a valve is failing to reach commanded states or is exhibiting excessive air usage or abnormal friction, for example. This information can alert maintenance staff of developing issues, and in many cases diagnostic software can offer a list of possible causes, helping technicians quickly isolate and resolve the problem.
4. Fourth, FIELDVUE digital valve controllers can detect trigger events, and then capture valve profile and performance data before, during and after the event. This data may not keep an event from happening, but the information is often critical to quickly isolate the root cause of the problem and to identify any failed components so they can be repaired quickly.
5. Fifth, FIELDVUE digital valve controllers are often used in critical applications, such as on anti-surge and safety interlock valves. In these and other applications, the digital valve controllers enable partial stroke testing to ensure the valve will perform as required during abnormal conditions, and they can also be used for partial proof testing to extend intervals between required full proof testing.
6. Sixth, historical data from the digital valve controller can be combined with other upstream and downstream process information—such as surging pressures or swinging flows—to uncover operational problems. FIELDVUE digital valve controllers can also expose how a valve is performing related to parameters and factors such as supply air pressure, positioner tuning, or mechanical sticking.
7. Seventh, FIELDVUE digital valve controllers enable secure remote valve monitoring provided as a service by third-party experts, whose efforts unload often limited plant personnel. Based on instantaneous and trended data, it is possible to detect abnormal conditions leading to many developing problems. However, this data is only useful if it is gathered in near-real time and is accessible by specialists with the tools, skills and time to interpret it. Emerson provides these services, using its Fisher ValveLink™ software to perform scheduled online testing of each valve as it operates.

These are seven of the leading reasons Emerson believes that FIELDVUE digital valve controllers are used so widely in process plants, with end users realizing benefits as described in the following three applications.

 

A herbicide plant in Iowa reduced annual maintenance costs by $230,000 (ca €234k) by using FIELDVUE digital valve controllers with advanced control valve diagnostics to transition their plant from reactive to predictive maintenance. In one case alone, the plant saved nearly $100,000/hour  (€101k/h) by detecting and addressing a developing control valve issue before it shut down the unit.

 

A paper mill in Louisiana was suffering routine boilers trips due to damper positioning problems. Upgraded FIELDVUE digital valve controllers with advanced diagnostics eliminated these trips, avoiding losses of $18,000 (€18.3k) an hour due to unscheduled outages.

 

A combined cycle power plant was reworking all critical valves during every outage to maximize uptime when the plant returned to service. After upgrading to FIELDVUE digital valve controllers and implementing diagnostic alert software, the plant was able to focus their outage repair efforts more efficiently. The plant saved $68,000 (€69,2k) in one outage alone and has experienced year-to-year cost reductions of $33,500 (€34.1k). Similar programs in the company’s other plants have generated average savings of $1,200 (€1.22k) per valve.

 

"These reasons and results show why process plant personnel have often specified FIELDVUE digital valve controllers in the past and why many of them will continue to do so in the future," said a spokesman.

•  See "Forward Focus..."  - the theme of the Emerson User Group Conference commencing 24th October 2022 in Grapevine (TX USA).

@Emerson_News @EMR_Automation @FisherValves  #PAuto

Analysers for monitoring low-TOC values.

Total organic carbon (TOC) is an important quality parameter in the various manufacturing and process environments that depend on ultrapure water. When TOC content is too high, it can adversely impact the performance of water treatment systems, compromise high-precision machinery, or contaminate batches. The CA78 and CA79 online TOC analyzers from Endress+Hauser provide continuous and precise monitoring to ensure stable operations, regulatory compliance, and high-quality products.

Real-time water quality assessment for minimal product contamination.

These TOC analyzers utilize proven UV-oxidation and differential conductivity measurement, the most-established method for reliable TOC trace analysis in ultrapure water. The fast response time (t90) of 50 seconds enables quick control system and personnel reaction in the event of water quality deterioration, reducing contamination, product loss, and costs. Complete measuring point management.
The analyzers’ user-friendly modular design and easy accessibility to components simplify maintenance and minimize operating costs. Additionally, Endress+Hauser’s worldwide service network provides end users with complete measuring point management throughout plant lifecycles, including installation qualification and operational qualification.

CA78 in the power & energy, semiconductor, personal care product, and disinfectant manufacturing sectors.
The CA78 TOC analyzer supports safe operations in many applications, including but not limited to:

• Protecting turbines and other expensive power plant equipment. • Manufacturing semiconductors and additional microelectronics. • Ensuring product quality in the personal care industry. • Assuring the efficacy of disinfectants.

The CA78 is configurable to meet various requirements in the power and semiconductor industries. For example, the standard version is the right choice for measuring ultrapure water in semiconductor production, providing high-precision measurement in water with conductivity values up to 2 µS/cm. Meanwhile, the instrument option for measurement in water with conductivity values closer to 10 µS/cm is perfectly-suited for deionized water in power plants. When multiple TOC measuring points are required, the 3-channel configuration allows for multiple streams to be run through one analyzer, which reduces capital expenditures.

Pharma-compliant CA79.
The CA79 TOC analyzer meets or exceeds all requirements of the US and European Pharmacopoeias, enabling manufacturing activities in accordance with FDA 21 CFR Part 11. Depending on the instrument configuration, online calibration and system suitability tests (SSTs) can be initiated with the press of a button, and these records are automatically stored onboard.

Regular SSTs ensure compliance with the pharmacopoeias’ regulations for TOC values. And with a compact, stainless-steel housing, the CA79 integrates seamlessly into ultrapure water installations, ideally situating it for use in applications subject to the stringent hygiene requirements of the life sciences industry. 

Complete portfolio for multiple industries.
With the introduction of the CA78 and CA79 analyzers for low-TOC measurement ranges, Endress+Hauser is rounding out its liquid analysis solutions for critical parameter measurement.

The CA78 supplements Memosens CLS15E contacting conductivity sensors, Liquiline System CA80SI silica analyzers, CA76NA sodium analyzers, and SWAS panels for reliable, low-maintenance solutions in a variety of sectors. The CA79 complements the Memosens CPS61E pH sensor, Memosens COS81E oxygen sensor, and Memosens CLS82E conductivity sensor for critical parameter measurement in pharmaceutical production environments.

These analyzers each store critical process, calibration, and sensor data locally, with transmission to a central process control and documentation hub, which is especially important in highly-regulated industries. This plethora of high-precision instruments provides end users with a complete portfolio of sensors, photometers, and TOC analyzers, and now all of these measurements can be monitored and managed at a single source.

@Endress_US @Endress_Hauser @Endress_UK #PAuto

Ultra-fast changing for ultra-fast car.

A team of students from Eindhoven University of Technology has succeeded in developing an all-electric, ultra-fast charging prototype race car. Set to roar into action at the Le Mans 24-hour endurance racing event in France, the team leveraged the advantages of Danfoss technology to solve its fluid conveyance challenges.

All-electric racing cars are not new, but how does the endurance motorsport segment join the green revolution, where events require the rapid recharging of race cars? Enter InMotion, a student team from Eindhoven University of Technology in the Netherlands which set out to develop an all-electric race car with ultra-fast charging capabilities.

Electric refueling.
To help take InMotion’s fast charging technology (called electric refueling) from concept to reality, the team reached out for technology sponsors. PowerFlex, an expert supplier of hose solutions based in Weesp, Netherlands, stepped up to the challenge. The company is a long-term Danfoss Power Solutions distribution partner.

“We saw huge potential in their ambitious project,” said Ruggero Grillo, marketeer at PowerFlex. “We believed in their goal, their underlying technology and their passion, so we were proud to support them and help accelerate the motorsport sector’s transition to a green energy future.”

The PowerFlex team was tasked with helping InMotion identify the optimal fluid conveyance solutions to meet several of The Revolution race car’s key challenges. These included minimizing heat buildup in the 58 kilowatt-hour battery pack during fast charging, enabling quick battery disconnection, and delivering efficient cooling.

Battery pack cooling.

To maintain the optimal battery pack temperature during fast charging, PowerFlex recommended the Danfoss Evercool GH001 multi-refrigerant hose and fittings due to advantages that include near-zero permeation, tight bend radius, wide temperature range, and compatibility with many refrigerants.

In addition, the Danfoss EZ Clip system for hose assemblies gave the InMotion team flexible installation options without the need to invest in costly crimp tooling, while Danfoss Hansen aluminum dry-break ADB couplings were chosen for quick and easy battery connection and disconnection without fluid loss or air infiltration.

Finally, to optimize heat distribution from the race car’s battery pack, PowerFlex provided various Aeroquip by Danfoss Performance Products, including hoses, fittings, and adapters. Throughout the project, the knowledge and experience of PowerFlex was a crucial asset in The Revolution race car’s successful development, providing InMotion with on- and off-site technical guidance, testing, servicing, and more.

“Offering a low weight-to-power ratio, high performance, and racing-level quality, the Danfoss components we chose were designed for exactly this kind of challenge — and they delivered,” stated Grillo.

12-minute charge.
InMotion’s prototype race car is now able to reach an 80% state of charge from near depletion in just 12 minutes. The installed solutions keep the vehicle as lightweight as possible, while also making it easier for InMotion to assemble or reconfigure systems. Importantly, The Revolution endurance race car remains on course to showcase the game-changing potential of fast charging at the world-famous Le Mans.

 @Danfoss @BiesheuvelSport #Automotive