Digital valve controller offers embedded edge computing to streamline workflows, optimize performance
In late 2023, Emerson released its Fisher™ FIELDVUE™ DVC7K Digital Valve Controller (FIG. 1), a new design improving upon 30 yr of field-proven innovation. The DVC7K features Advice at the Device™ technology with embedded computing and analytics that convert raw data into actionable information locally with Bluetooth capability within the device. This means maintenance personnel can receive the data via their phone, tablet or computer wirelessly without having to be in a control room at the plant location. The new valve controller technology improves the performance, reliability and uptime of both on-off and control valves—and by extension an entire process plant or facility—in a wide variety of process industry applications, and provides the information required to create streamlined work processes.
Digital valve controllers are available as accessories for control and on-off valves to provide local analysis of valve data, digital communications with host systems and other features. These features improve uptime by alerting personnel to developing problems, reduce maintenance costs by providing the actionable information required for proactive rather than reactive maintenance, and cut troubleshooting time in the event of an issue by providing recommended corrective actions. For example, a control valve may be reacting slowly to commands requiring it to move, which is often an early sign of impending issues. The DVC7K will recognize this type of condition, alert personnel and provide recommendations to fix the problem.
The DVC7K interprets data to create an optimized path to action by combining patented technology, experience-based algorithms and continuous real-time analytics with flexible connectivity and easy integration. It uses powerful, real-time and onboard edge computing to analyze issues and create actionable information, providing real-time awareness of valve health by analyzing data locally via its onboard diagnostics. If analysis reveals a problem, an alert is created, which can be viewed locally or remotely, providing the information required to create streamlined work processes that save time and money. All alerts include recommended actions to fix the problem, a new feature for digital valve controllers and unique to the industry.
Previously, digital valve controller data had to go to a host system to be processed and prepared for viewing; however, with the intelligence of this system, data is now accessible without requiring access to the host software. All information can be viewed at the DVC7K’s local user interface, nearby via Emerson Secure Bluetooth® wireless technology, or remotely after it is transmitted via a wired digital network to a host, such as a distributed control system (DCS) or asset management system (AMS).
The local user interface provides indication of valve health at a glance via LEDs, and users can drill down from the interface home screen to find more information. Emerson Secure Bluetooth enables access to one or more digital valve controllers at distances up to 30 ft from any device capable of supporting Bluetooth, such as a smartphone or tablet. Whether the information is viewed locally, nearby or remotely, plant personnel can use it to drive awareness of valve health.
With increased remote connectivity and Advice at the Device local diagnostics, flexibility increases, providing the information needed for fast decisions and quick action to address arising issues. The DVC7K can be specified for all new valve purchases, and it can be retrofitted to most existing valve installations, in either case quickly and easily commissioned via the local user interface. With > 3MM FIELDVUE units sold and more than 10 B hr of field operation, long-term reliability and performance is proven in use, a key requirement as Fisher and other Emerson valves are often used in critical process industry applications.
To learn more, visit Emerson.com/FisherDVC7K.
From a programming tool to a hub for the digitalization of data from safety devices
The development of new Industry 4.0 technologies and functions is much faster than the further development of classic process automation equipment. Adding new functions to safety devices requires particular care. The engineering, diagnostics and test tools in the new version of HIMA’s SILworX® will become the hub for the digitalization of data from safety devices (FIG. 2).
SILworX is a safety-related configuration, programming and diagnostic tool developed by HIMA to program and configure all HIMA systems. Fault diagnosis and testing tasks on safety applications are also carried out via the same intuitive user interface. The new version has now been expanded to include Industry 4.0 features. The SILworX software runs on standard Windows PCs in a “software container,” which makes it independent of Windows.
It can be used in combination with all popular antivirus programs. Each time it is started, the software automatically uses cyclic redundancy check (CRC) methods to eliminate incorrect installation data or manipulations. Additional CRCs are used to ensure protection of the project from unwanted changes. Whether in the engineering of large and distributed automation projects or in the diagnosis of faults or in regular testing, the specification, configuration and maintenance of safety devices in process plants require a level of effort and careful attention that should not be underestimated. Traditionally, if new functions are added to components of safety devices, time-consuming recertification has been necessary.
HIMA is taking a new and important step in terms of digitalization with the next version of SILworX to help to reduce this effort through consistent digitalization and new functions to simplify these tasks while still being able to use modern Industry 4.0 functions flexibly.
A distinction is made between core functions for programming safety controllers and Industry 4.0 functions. New functions that are not safety-related can be integrated using modular plug-ins via an interface that does not affect the core safety-rated SILworX functions. This modular structure makes it possible to digitalize automation processes quickly and flexibly, and users can create extensions themselves or use plug-in modules from HIMA or other providers.
This enables planners and plant operators to add new functionality quickly and easily, or to adapt or replace existing functions in a compliant, efficient and future-proofed way. This significantly increases efficiencies in engineering, diagnostic and test tasks by reducing efforts and costs.
In addition to plug-ins, the new version of the engineering tool also simplifies collaboration in automation projects: The new “Multi-file project” option enables projects to be saved as a library of related files for the different parts of the project, with version control embedded into each component. These can be imported individually into external versioning tools and later reassembled into a project. This makes team collaboration on large projects much easier and more efficient.
The “Comparator Plus” function helps to make the engineering and modification of safety systems more efficient, while reducing the work needed to demonstrate change management throughout the safety lifecycle. Changes between different versions of safety logic and functionality are graphically compared and documented in an intuitive manner.
Of particular interest to plant operators is the ability to implement automatic testing of all of the loops of the safety instrumented system (SIS), as well as the communication to the basic process control system (BPCS) and the field device level. The HIMA Smart Safety Test enables logic tests, automated recurrent testing, partial stroke tests, transmitter tests and stress tests for the BPCS. The tests and documentation of their results are carried out automatically.
To learn more, visit www.hima.com.
Accurate and reliable temperature measurement solutions for induction and heat treating applications
AMETEK Land, a leading manufacturer of highly accurate infrared pyrometers, scanners and thermal imagers, is supporting industries—including manufacturing, automotive, aerospace and construction—with highly accurate and reliable temperature measurement solutions for induction and heat treating applications (FIG. 3).
Induction heat treatment is a highly versatile technique widely used to alter the mechanical properties of materials including metals and alloys. However, accurate temperature control is crucial to achieve the desired temperature and material properties, and to control both the heating process and induction generator.
AMETEK Land offers a wide range of dedicated pyrometers, line scanners and thermal imagers to optimize these heating and processing applications.
One key solution is the SPOT+ range of pyrometers. These smart infrared pyrometers offer advanced industrial connectivity and visible light process video, making non-contact temperature measurements accurate and flexible, especially in the harshest of environmental conditions.
Thermal imaging cameras and systems also play an important role in industrial processing and furnace applications, forming a crucial component for visualizing, controlling and documenting the induction heating and heat treatment process.
The company’s advanced cameras and systems, including the MWIR-640 and LWIR-640 imagers, and the NIR-2K, working with the IMAGEPro advanced processing and control software, help to meet the increasing demand for improved product quality, process efficiency, energy saving, predictive maintenance and emissions reduction.
For more information about AMETEK Land’s solutions for induction heating applications, visit here.
High-performance, multi-purpose, adjustable speed drive for greater efficiency, easier engineering, quicker setup, improved sustainability
With SINAMICS G220, Siemens has launched a new high-performance drive to join the SINAMICS drives family. Recently introduced to the North American market, SINAMICS G220 is an innovative multi-purpose, adjustable speed drive with built-in Clean Power technology, which reduces harmonics by up to 97% without the need for an AC line reactor or DC choke. SINAMICS G220 is significantly more efficient in terms of space utilization and operation, and it makes the system engineering and its integration into a production or processing machine much easier (FIG. 4).
SINAMICS G220 is also the first drive to join the Siemens Xcelerator portfolio, the Siemens-wide business platform for digital transformation. SINAMICS G220 drives are an integral part of the TIA Portal and feature a digital twin in Startdrive, the drives commissioning tool from Siemens. This allows the behavior of the drive to be tested and optimized before the hardware is available.
SINAMICS G220 has an integrated web server for commissioning that eliminates the need to install software or an app on a PC or mobile device. This saves time and makes drive setup intuitive and user-friendly.
These new drives are also equipped with an Industrial Internet of Things (IIoT) module. This means that SINAMICS G220 can easily be integrated into cloud and edge applications, increasing the transparency of the applications and enabling remote monitoring and accessibility of the drive system. Machine availability can even be optimized and system uptimes can be further improved.
In the area of cybersecurity, SINAMICS G220 comes standard with state-of-the-art security integrated, providing highly secure communication, integrity and authenticity checks to protect against tampered firmware. Additionally, the drives offer user management and access control (UMAC) within TIA Portal.
SINAMICS G220 drives come with a range of modular and flexible hardware options as well as software and safety integrated functions, which can be easily adapted to user-specific application requirements. For example, SINAMICS G220 is also available in UL Type 12 (IP55) wall-mount design and a special conformal coating option is also available for the operation of a drive in the harsh environments where the presence of corrosive gases such as hydrogen sulfide (H2S), sulfur dioxide (SO2) or ammonia (NH3) is unavoidable. Thanks to the superior quality of its components and robust hardware design according to UL 61800-5-1, the drive is built to ensure a long service life.
When it comes to integrated safety, SINAMICS G220 meets hardware-based SIL 3 functional safety requirements. Thanks to its built-in media and S2 system redundancy, maximum system availability is guaranteed and the continuity of critical processes is maintained.
SINAMICS G220 ensures the improved sustainability of processes through robust, safe, secure and efficient design and operation. This new drive contributes to a sustainable future along its entire lifecycle from design to delivery thanks to the carbon-neutral production sites and paperless delivery system. This new drive is suitable for all industries, but especially chemical, oil-and-gas, food-and-beverage, pharmaceutical, marine, automotive and tire manufacturing.
For more information, visit www.siemens.com.
New tool automates plant configuration
The new Project Builder for Aucotec's Engineering Base (EB) software platform can make plant configuration even easier for planning professionals. The tool extends the Advanced Typical Manager (ATM) for EB, which can be used to define cross-discipline, function-oriented modules that make structuring and configuring plants very efficient (FIG. 5). Individually configurable, the Project Builder now automatically instructs the ATM on the appropriate selection of typicals. The combination of tools increases the quality of the plant configuration and safeguards knowledge.
Until now, project planners either had to have in-depth knowledge of typicals and their complex designations themselves or call in experts to select the right ones. The Project Builder, on the other hand, can be configured for each plant type using conditions and rules, so that it has the necessary expertise on the "right" typicals for defined projects. As it also knows the components of the ATM modules, it automatically knows where each one fits. This not only speeds up the "clicking together" of plant projects of all kinds, but above all increases data quality, eliminating misinterpretations of cryptic typical names. At the same time, specialists who know all the typicals—including their functions and cryptic designations—inside out are no longer needed.
The new configuration tool is not only configurable using rules. Users can also define their own user interface to suit their preferred workflow and individual requirements. For project types or individual user interfaces, every configuration can be saved and used repeatedly. This accelerates project processing even further and archives important knowledge, significantly reducing the workload of the specialists.
The configurator creates the project independently, then the ATM fills it with the appropriate typicals according to the “instructions” from the Project Builder. The new tool then takes over again and (depending on the configuration) can automatically start follow-up actions, such as generating terminal block diagrams, creating tables of contents or customizing the documentation structure. The Project Builder guides its users step-by-step through the plant configuration in an easy-to-understand manner. Each click takes them one level further until a field or an entire plant is fully defined and mapped in the data model. The tool also provides information about the consequences of a certain selection, for example: “If this point is clicked, only this constellation is possible in the next step.”
To learn more, visit www.aucotec.com.
Updated Veritas methane measurement and verification protocols to help reduce emissions
GTI Energy has made a leap forward in measuring and verifying methane (CH4) emissions with the release of the updated Veritas Version 2 Protocols. As measurement and detection technologies become increasingly available, Veritas Version 2 offers a simplified framework to evaluate and respond to the mounting volume of data on CH4 emissions. The updated protocols, rigorously tested by industry stakeholders, provide a more streamlined, refined and standardized approach to accurately measuring, and thereby reducing, global CH4 emissions.
The Veritas Version 2 Protocols complement ambitious global commitments to reduce CH4 emissions, including the Oil and Gas Decarbonization Charter introduced at COP28, where 50 companies representing more than 40% of global oil production pledged to zero-out CH4 emissions by 2050. The updated protocols also support government, regional, state and federal regulations for emissions—such as the U.S. Environmental Protection Agency (EPA) rule to reduce CH4 emissions from oil and natural gas operations in the U.S.—and empower industry stakeholders to meet these commitments.
GTI Energy is committed to providing stakeholders with transparent and credible tools for creating measurement-informed CH4 emissions estimates, which are vital to inform actions needed to meet ambitious climate goals. By aligning with global CH4 commitments and government guidelines, the Veritas Version 2 Protocols will help industry meaningfully reduce CH4 emissions this decade and enable the role of natural gas in low-carbon and low-cost energy systems, the company said.
The Veritas Version 2 Protocols have been consolidated from six to three, with a single “upstream” protocol that combines production and gathering and boosting; a “midstream” protocol that combines processing, transmission and storage, and LNG segments; and a “distribution” segment that remains a standalone protocol. The streamlined approach ensures the technical detail remains consistent with the original protocols and maintains accuracy and reliability of the information.
GTI Energy is one of two U.S.-based stakeholders participating in an international working group aimed at establishing a universal approach for measuring, monitoring, reporting and verifying greenhouse gas (GHG) emissions across the natural gas supply chain to drive global emissions reductions. GTI Energy will contribute observations, best practices and lessons learned from the Veritas Initiative.
GTI Energy also announced collaborative efforts with the Oil & Gas Methane Partnership 2.0 (OGMP 2.0) to develop a new methodology, expected in February 2024, for participants in both Veritas and OGMP 2.0. This methodology will provide stakeholders with a detailed path for meeting the requirements of OGMP 2.0 using Veritas protocols. This collaboration marks a major milestone in harmonizing CH4 emissions measurement and verification standards, fostering greater consistency and comparability of global emissions data.
To learn more, visit veritas.gti.energy. HP