First major upgrade of popular DCS platform post-acquisition
Using Valmet’s D3 distributed control system (DCS) automation platform, industrial processors can now integrate numerous reliability and performance enhancements in the first significant update following its acquisition from NovaTech Automation last year.
The latest D3 version 16.3 from Valmet, a worldwide provider of process technologies, automation and services, showcases the company’s ongoing commitment to enhancing the widely used DCS and provides a comprehensive automation solution for process industries. This includes system-wide redundancy, robust I/O modules, advanced process controllers, fast Ethernet connectivity, efficient human-machine interface (HMI) tools, and customizable application programming for batch and continuous processes.
The update includes a variety of improvements, bug fixes, security and usability enhancements, and new features that increase the automation platform’s reliability and performance.
To maintain a secure and reliable automation environment, it is necessary to update to the newest server and desktop operating systems. D3 v16.3 is among the initial major DCS versions to support Windows Server 2022. Windows Server 2019 is also supported for the system servers. Operator consoles and small display servers use Windows 10 Enterprise LTSC 2021 or LTSC 2019.
Valmet D3’s core HMI system, the ProcessVision Console (PVC), has also been upgraded with additional features, further improving user-friendliness. Engineers, technicians and operators use PVC to control industrial processes, view and troubleshoot detailed system and IO information, as well as monitor trend data.
The PVC supports “display edit” functionality for Faceplate, Current Trend and Historical Trend groups, and changes can be converted to D3 Architect configuration input files. The PVC also supports a floating toolbar that offers operators a simpler, easier way to make process control changes and navigate their displays. The toolbar also provides easy access to the Console Settings Editor to personalize the look and feel of the PVC and to PAAC displays to view and control dynamic alarm management behavior.
Integrating Valmet’s PID Loop Optimizer into D3 is one of the most significant value-added improvements. For example, proportional integral derivative (PID) tuning parameters can affect how a valve will behave (i.e., whether it reacts aggressively or slowly to the changing process). Correct tuning can impact the material, the process, how much energy is consumed, and how tightly it is controlled.
Unfortunately, in many plants, process engineers must essentially estimate PID tuning numbers. To resolve this issue, Valmet replaced a third-party software solution and integrated its own PID Loop Optimizer. The optional layered product supports tuning PID and pulse repetition frequency (PRF) loops and can be launched from Valmet ProcessVision.
By having the PID loop tuning software directly embedded in the D3, the operator can call up the loop tuning software directly from their workstation and it will analyze the performance of the loop and make recommendations for tuning that can be copied or downloaded directly back to the controller.
Operators can tune PIDs with confidence with accurate parameters for the required process response. Mistakes are reduced since no math and no manual copy-pasting are required. The software recognizes the controller, its algorithms and all unit conversions, so loop-tuning activities are expedited. Operators have total control over the tuning selection and can even tune specialized loops like cascade, pH control and level controllers.
In addition to the PID Loop optimizer, two new prompts have been added to the digital input (DIN) block type to support an alarm delay when the alarm is triggered and upon a return to normal. Alarm delays can be placed on the change from normal (CFN) and change of state (COS) alarms.
D3 v16.3 also supports the newest controller in its PCM4 line, the PCM4100A.
The PCM4100A has a five-slot backplane rather than the four-slot backplane of the PCM4100, providing room for an additional I/O card. The additional PCI slot allows up to four I/O cards to be installed in a non-redundant controller or up to three I/O cards in a redundant controller configuration. Otherwise, the PCM4100A has the same dimensions, power requirements and I/O type support as the PCM4100 (first introduced in 2002), allowing it to replace any existing Valmet PCM4100 in the same chassis.
For more information, visit https://www.valmet.com/d3.
New combustion analyzer for high-particulate applications
AMETEK Process Instruments has introduced its next-generation high-particulate combustion analyzer, the Thermox WDG-V HP. This series of advanced analyzers is used to reliably measure excess oxygen, combustibles and hydrocarbons in industrial applications. Building on the proven WDG-V platform, the WDG-V HP brings predictive artificial intelligence (AI) diagnostics and design redundancies that increase reliability to keep operators safe. Serving global markets, the WDG-V HP is certified for use in ATEX/IECEx Zone IIC T3 Gc and North America Class I Division 2 hazardous areas.
Used for safe combustion control and emissions monitoring, the new analyzer adds the capability to measure hydrocarbons, including methane (CH4), and even alternative clean fuels such as methanol (CH3OH) and hydrogen (H2) at percent levels as a standard feature to monitor for excess fuel and loss of flame during startup, light-off and during normal operation.
The WDG-V HP integrates the close-coupled convection design for combustion control in high-particulate environments, with the ability to monitor all three measurements in one analyzer for the full visibility of combustion process safety and optimization.
Designed with the operators in mind, the WDG-V HP offers a more serviceable and robust enclosure, ensuring superior ingress protection and easier access to the probe and filter.
For more information, visit www.ametekpi.com.
New level of reliability for industrial heat trace installations
Emerson is bringing added reliability to heavy-duty industrial heat trace deployments with its Nelson AXPC Connection Kits, engineered to fulfill the increased safety requirements of National Electrical Code (NEC)/Canadian Electrical Code (CEC) hazardous location codes.
Compatible with ¾-in. national pipe thread (NPT) conduit entries, Nelson AXPC Kits (FIG. 1) contain everything needed to create the safest, most reliable and fully protected heat trace wiring connections in multiple configurations, as well as to verify the heating cable circuit's operation. The kits protect petrochemical plants, food and beverage manufacturers, and power generation facilities from fluids freezing in their pipes, valves and tanks in cold weather.
Nelson AXPC Connector Kits are constructed to withstand extreme conditions that would compromise a standard heat trace connector. Their non-metallic, impact-resistant polyester enclosures are rated IP66 and NEMA 4X, making them suitable for use in highly corrosive environments. The enclosures also feature reinforced standoffs to prevent cracking, along with being carbon-impregnated so static charge cannot build up.
The enclosures offer the additional advantage of being both larger and modular in design to ensure easier, faster installation and service. DIN-rail mounted terminal blocks help when maintaining the connection, while spring-clamp terminals simplify wiring with no need to tighten screws. The kits fit all wattages of Nelson LT-J, LT-JT, HLT-J, XLT-J and CLT-JT Series self-regulating heater cables.
In addition to the AX Series for NEC and CEC installations, Nelson offers its EX Series version for IEC global hazardous requirements.
For more information, visit https://www.emerson.com/global.
Web-based SaaS application optimizes oil and gas operations
KBC (a Yokogawa Company) has released KBC Acuity™ Process Twin Pro, a web-based software as a service (SaaS) application. This AI-powered application leverages rich data analytics and optimization methods to automatically monitor and update the company’s Petro-SIM® digital twin solution to ensure consistent value is delivered. From one centralized platform, KBC Acuity Process Twin Pro technology provides meaningful insights to help refiners accelerate decision-making and facilitate efficient asset management and operational effectiveness (FIG. 2). These aspects are crucial to achieve growth, scalability, sustainability and profitability.
According to the company, the oil and gas industry faces volatile prices, rising costs and sustainability concerns. The Industrial Internet of Things (IIoT), combined with first-principles models and engineering expertise, enables real-time monitoring and data-driven strategies to support operational effectiveness.
Key benefits of the KBC Acuity Process Twin Pro technology include:
Health index monitor: Proactively alerts users of any inaccuracies and risks in one or more assets across sites to prevent outdated digital twins from being used for unit optimization and profitability studies.
Automated workflow: Performs calibrations and tuning studies within the application to profile candidate cases based on quality and prediction analysis to facilitate efficient data handling while increasing employee productivity and engagement.
Perfect digital twin: Fine-tunes the model’s parameters, enhancing the digital twin’s accuracy long term. By reducing dependency on domain expertise, it empowers users to make well-informed decisions.
Cloud collaboration: Provides a scalable and centralized platform to monitor, maintain and visualize multiple assets that simplifies asset management, planning and sharing best practices across all business units.
KBC's new application operates within the KBC Acuity Industrial Cloud Suite and seamlessly integrates with the Petro-SIM process simulator and real-time optimization (RTO) systems. With KBC’s expertise and first-principles modeling and simulations, the new solution accelerates digital transformation and provides sustained value.
For more information, visit www.kbc.global.
Hybrid cooling system for sustainable heat rejection
Kelvion is reshaping the market to boost thermal efficiency and empower customers to operate sustainably and energy-efficiently. The company’s new hybrid cooling system (FIG. 3) is designed to deliver exceptional thermal performance while minimizing environmental impact. This system offers an ideal balance between water and energy consumption while setting a new standard in the heat rejection industry.
Designed to bridge the gap between standard adiabatic coolers and cooling towers, the hybrid offers two cooling modes: dry and wet. In dry mode, heat is exchanged with ambient air via its sensible enthalpy (the measurement of energy in a thermodynamic system). For wet mode, the system waters the coil and uses both the water sensible and latent enthalpy via an adiabatic effect where air evaporates the water. This allows the system to work with ambient dry bulb temperatures well above process fluid outlet temperatures.
Due to its innovative technology, the hybrid system can achieve a lower environmental footprint than an adiabatic system, while consuming significantly less water compared with a cooling tower. It can be tailored to suit specific applications, especially in hot and very hot climates, and consider climate conditions and the availability of water. Whatever the system, the aim is to use as little energy and/or water as possible.
The main benefits of the hybrid include:
Automatic switch from dry to wet mode
Superior water distribution system ensures uniform wetting of entire coil
Efficient water recirculation system
Special coating for fin protection
Ideal balance between water and energy consumption
Auto drain system and advanced water control management.
The new hybrid system is part of Kelvion’s new “Rethink Thermal Efficiency” campaign to highlight how rethinking heat-generating industrial processes—and using the right solutions to suit the climate and availability of resources—can support the reduction and reuse of waste heat, and help companies to save on energy costs and be more sustainable.
For more information, visit https://thermal-efficiency.kelvion.com/.
An evolution in the rapid, onsite detection of microbial contamination in diesel fuel
Conidia Bioscience has launched FUELSTAT® One, a new test kit to join the FUELSTAT® range designed to rapidly detect microbial contamination in diesel fuel to prevent operational downtime and safety issues (FIG. 4). FUELSTAT One can be used throughout the fuel supply chain, from storage terminal to fuel tank, offering a comprehensive overview of the fuel's quality.
FUELSTAT One is a simple, rapid lateral flow test conducted on either free water or fuel phase samples to detect a broad range of microorganisms. It provides a fully quantitative contamination value in just 20 min–30 min. Similar to how a COVID-19 lateral flow test identifies markers of infection, FUELSTAT One detects markers of bacteria and fungi that can grow in fuel, potentially causing operational downtime, corrosion and severe safety issues.
Microbial contamination in fuel poses significant risks to safety and performance. Microorganisms such as bacteria, fungi and yeast can proliferate in fuel tanks, leading to biofilms and sludge formation, which can clog fuel filters and obstruct fuel lines, causing engine malfunctions or failures. Additionally, microbial activity can produce corrosive byproducts that degrade fuel tanks and components. Contaminated fuel can also reduce engine efficiency and increase emissions. Regular monitoring, maintenance and proper fuel storage practices are essential to ensure fuel cleanliness and maintain reliability, safety and efficiency.
The introduction of FUELSTAT One represents a significant advancement in microbial detection in diesel fuel and redefines the industry benchmark. Just like the established FUELSTAT Plus test kits, which detect fuel-degrading micro-organisms in minutes, the new FUELSTAT One test kits enable a single person to conduct tests at the tank using just four drops of fuel sample, following step-by-step video test instructions via the app.
These tests are conducted onsite, therefore complying with ASTM D6469 guidance for testing for contamination within 24 hours. No laboratory is required, avoiding time delays and associated expenses.
FUELSTAT test kits are supported by a FUELSTAT® Result app that provides instant test results and a PDF report that can be shared worldwide. Registered users can manage results from all tests conducted by their team globally, in real time, at the touch of a button.
Quantitative test results obtained using FUELSTAT One across assets and locations enable the identification of hotspots and trend analysis to inform future fuel maintenance procedures.
For more information, visit www.conidia.com.
Next-gen flame detector to enhance fire safety, performance, range and reliability
The ability to quickly distinguish between a fire or false alarm not only helps to keep workers safe on the job, but can also protect against costly facility shutdowns. As the industry's first optical flame detector with Bluetooth® connectivity, the FL5000 MSIR Flame Detector by MSA Safety Inc. gives process, plant and safety engineers a next-generation solution to flame monitoring, fire detection and response.
Having this connectivity allows users to wirelessly link to the flame detector for configuration and to perform diagnostic tests, allowing for faster setup, easier detector status checks and quicker access to event logs. Additionally, the FL5000 Flame Detector (FIG. 5) features communications capabilities for automatic integration with plant processes and safety systems, making it easy to help further enhance the overall safety operations of a facility.
Designed for demanding industries including chemical and oil/gas production, refineries and storage, the unique FL5000 Flame Detector offers users a wide array of advanced safety features and solutions, including its:
Multiple infrared (IR) detectors and an advanced flame detection algorithm that leverages the intelligence of three artificial neural networks (ANN) that process signals to determine potential hazards
The ability to distinguish between dangerous real flames and common false alarm sources, such as lightning, sunlight reflection and other radiation sources, to help protect facilities while also avoiding false alarms and unnecessary process or plant shutdowns
Factory mutual (FM) performance verification for 22 of the most common fuel types used in the petrochemical and other process industries
The ability to detect fires up to 310 ft (95 m) away
Built-in self-check system: every 2 min, the detector's electronics perform an optical and electrical check to ensure the path is clear and the electronic circuits are operational.
For more information, visit FL5000 MSIR Flame Detector. HP