Enhanced perimeter defense solution simplifies network security for DCSs

Emerson, a global software and engineering leader, is improving perimeter security for the DeltaV™ distributed control system (DCS) (FIG. 1) with its new NextGen Smart Firewall, a purpose-built control system firewall designed to provide easy-to-install and easy-to-maintain perimeter security for all industries. More ruggedized construction, increased bandwidth and role-based access provide users with increased performance and more granular access control.

Manufacturers must secure their networks without the complexity that would otherwise add administrative overhead to already busy operations teams. Emerson’s NextGen Smart Firewall features a user-friendly HTML5 web-based user interface, easy-to-understand setup menus and pre-defined DeltaV application rules. The ease of use helps DeltaV administrators and control engineers with no security or information technology (IT) expertise create secure connections for DeltaV applications.

A critical element of Emerson’s vision of boundless automation architecture is secure connectivity between systems in the plant and across the enterprise. The company’s NextGen Smart Firewall delivers intuitive setup and interfaces to provide plants with access to a much wider array of technologies—from control, to reliability, to sustainability and more—without the need to maintain a dedicated IT presence.

Gigabit connections support improved performance for applications that require higher bandwidth. The ruggedized construction is well suited for harsh manufacturing environments. Emerson’s NextGen Smart Firewall’s advanced features include:

1. Virtual private networks—Increasing flexibility and security for geographically dispersed networks
2. Network address translation—Protecting network IP schemes and conserving addresses
3. More granular user roles—Administrators have full control, engineers may add or modify application rules, and auditors have read-only access to logs.

For more information, visit NextGen Smart Firewall.

New portable gas detector for personal monitoring

Dräger has released its new portable X-am 5800 multi-gas detector (FIG. 2), which simultaneously measures up to six gases, depending on the sensors installed. It represents a new addition to the Dräger X-am series, which already includes the X-am 2800.

The newly developed Catalytic Ex-Sensor (CatEx SR) is robust and can be used for measuring flammable vapors, such as petrol, diesel and nonane, and the gases methane (CH₄), propane (C₃H₈) and hydrogen (H₂). It has an automatic full range option available for CH₄, allowing for gas measurements of up to 100 vol%. Furthermore, the sensor is particularly resistant to contamination from silicone or other harmful substances.

It is possible to equip the X-am 5800 with a greater number of different sensors for the measurement of toxic gases, such as chlorine, ammonia (NH₃), H₂, cyanide and many other dangerous gases. The optional "Toxic Twin" function, for example, triggers a special alarm when carbon monoxide (CO) and hydrogen cyanide are present together in the ambient air.

Dräger develops and produces the sensors in-house, including the electrochemical sensors; so, these sensors are perfectly matched to this device. With the external X-am pump, the X-am 5800 can also be used for clearance measurements, as can the X-am 2800, which was launched in 2022.

The X-am 5800 can be used with the Dräger Gas Detection Connect cloud-based software solution, which digitalizes asset management and facilitates live data transmission. Here, the gas detector transfers the data via Bluetooth to a smartphone, which then sends it to the Dräger Gas Detection Connect Cloud. With the automatic test station, Dräger X-dock, data can also be transferred to the same cloud backend without a smartphone. Users can safely access their data at any time using an internet browser.

A new sturdy clip, combined with the device's small size and low weight, makes the X-am 5800 easy to carry. The large buttons make it is easy to operate, even while wearing gloves. Important information, such as measured gas values, alarms and the time, are easily viewed on the large display. A green status light indicates that the device is ready for operation. User guidance is language free. The X-am 5800 is approved for Ex zone 0 and has been tested in accordance with ingress protection class IP 68.

When developing the X-am 5800, Dräger placed particular emphasis on sustainability. This means Dräger X-am series accessories, such as the battery charger, X-dock test station or calibration adapter, can also be used with the new X-am 5800. The durable Dräger sensors—as well as the rechargeable (and easily exchangeable) energy supply—ensure the long service life of the device. The technical documentation and packaging have been designed to use as little paper as possible. When ordering more than two devices as part of a kit, the number of operating instructions is kept to a minimum. Dräger will also take back used devices and ensure they are professionally recycled.

Visit www.draeger.com for more information.

Greenhouse gas emissions management software

KBC (A Yokogawa Company) has launched an emissions management solution, Visual MESA^® Greenhouse Gas Emissions Management, for industrial process plants. Whether cloud-based or onsite, this technology integrates the emissions management workflow across the entire plant to simplify reporting and reduce Scopes 1 and 2 emissions. Visual MESA Greenhouse Gas Emissions Management software uses real-time emissions data to pinpoint critical operational areas that can improve the accuracy and frequency of greenhouse gas emissions (GHG) reporting. This information enables plants to take strategic decarbonization actions, minimize emissions and achieve sustainability targets.

Industrial plants are encouraged to report their GHG emissions. Typically, this task is done using GHG Protocol standards with quarterly or annual averages, which can be a tedious and time-intensive process. However, operational sites need accurate and continuous monitoring. Real-time monitoring of emissions throughout the plant, from raw materials to disposal, enables operators to identify gaps and take immediate action to meet emissions reduction targets.

The KBC Visual MESA Greenhouse Gas Emissions Management software monitors emissions and energy consumption from plant operations using digital data sources. With the technology’s advanced features, the software provides actionable recommendations to decrease energy and emissions while automating the official emissions reporting. Key capabilities of the GHG emissions management software include:

1. Real-time carbon emissions monitoring eliminates delays in reviewing time-sensitive data.
2. Real-time energy optimization provides alternative scenarios to optimize energy and emissions savings as well as meet sustainability targets.
3. Actionable recommendations for operations analyze and visualize emissions data campus-wide, allowing for quick and confident decision-making in critical areas.
4. Auditable carbon reporting following tracks all data to its source, calculates average or total Scopes 1 and 2 emissions throughout the facility to monitor GHG emissions on a daily, monthly and yearly basis, and uses any of the seven GHG Protocol reporting standards (Corporate Standard, GHG Protocol for Cities, Mitigation Goal Standard, Corporate Value Chain [Scope 3] Standard, Policy and Action Standard, Product Standard and Project Protocol).
5. Factor-based emissions calculations automate the emissions accounting and reporting process, allowing engineers and accountants to focus on higher value activities.

Visual MESA Greenhouse Gas Emissions Management software effectively monitors, manages, analyzes and visualizes Scopes 1 and 2 emissions data in real time across the entire plant, providing swift and accurate decision-making on critical areas affecting emissions.

For more information, contact your local KBC (info@kbc.global) representative, or visit https://www.kbc.global/.

Easy-to-operate level measuring devices

Endress+Hauser has launched its new generation of Micropilot 80 GHz radar sensors: FMR60B, FMR62B, FMR63B, FMR66B and FMR67B.

The new generation of sensors comes equipped with integrated assistants (wizards) that operate via multiple HMI formats, including the SmartBlue app. Besides tried-and-tested digital communication protocols like HART, other digital protocols such as Profibus and Ethernet/APL will be included in the near future. The measurement performance of the new radar chip combined with the smart Heartbeat Technology monitoring function helps to increase productivity. The new Micropilot generation offers solutions that make individual customer processes simpler, safer and more productive.

The range of new-generation 80 GHz radar sensors (FIG. 3) for level measurement provides solutions for virtually any radar application. Thanks to the compact device design, it can be used in confined installation situations. Suitable versions are also available for challenging process conditions such as aggressive media or extreme temperatures.

The commissioning and operation of the radar devices are straightforward and intuitive. Users are guided through the process by wizards, thus preventing errors and enabling the devices to be successfully commissioned with limited experience or training. Thanks to a Bluetooth interface, the devices can be conveniently controlled remotely via the SmartBlue app from Endress+Hauser. In conjunction with Heartbeat Technology, processes can be monitored continuously, and verifications performed in < 3 min while the process is running. The HistoROM mobile data memory transfers measuring point parameters without error when the electronics are replaced. The device is repaired quickly and smoothly without requiring specialized user knowledge.

Systematic errors, unintentional operating errors and process anomalies all pose risks to plant safety. The new Micropilot radar family meets all safety requirements and has been developed following IEC 61508, utilizing Endress+Hauser's 20 yr of safety integrity level (SIL) expertise; it can be used in SIL2 or SIL3 applications with homogeneous redundancy.

Instrument-led sequences also guide the user step by step through commissioning, parameter configuration or SIL proof testing, thus preventing systematic errors and increasing safety. As a result of the existing Bluetooth interface, function checks or changes to settings can always be performed remotely from outside the danger zone via the SmartBlue app. The innovative communication option, Ethernet-APL, also allows the device to be monitored and operated for the first time via an integrated web server. The new color display ensures safety at a glance by changing from green to red in the event of an error, thus providing a quick status overview.

Another function that eliminates systematic errors is the automatically generated checksum (CRC), generated from all the safety-related parameters and noted in the test report. Changes to an individual parameter can be identified from the checksum, making it possible to immediately determine if a parameter has been changed, significantly speeding up inspections.

The new 80 GHz electronics utilized in the FMR6xB were developed in-house and provide exceptional measurement performance. In addition to the measurement performance, Heartbeat Technology developed by Endress+Hauser enables productivity gains, providing reliable diagnostic and monitoring data and enabling predictive maintenance due to its constant monitoring of anomalies, such as foam or buildup.

Device verifications can be performed in < 3 min without removing the device or interrupting the process. The patented radar accuracy index (RAI) combined with Heartbeat Verification now enables traceable verification according to DIN ISO 9001 for the first time, resulting in a considerable reduction in the effort and costs associated with calibration and documentation and significantly extending calibration cycles.

Thanks to easy integration into asset management systems and smart self-diagnostics, unplanned plant shutdowns are largely avoided and production output increases.

To learn more online, visit FMR60B, FMR62B, FMR63B, FMR66B and FMR67B.

New benzene-specific monitor for tighter international regulations

ION Science has launched a new, dramatically upgraded version of Titan—Titan 2—maintaining its position as the only fixed benzene-specific monitor in the world. In accordance with recent legislative changes, Titan 2 (FIG. 4) offers enhanced stability and sensitivity, supporting ION’s continued mission of protecting lives and preserving the environment.

Benzene is a toxic, carcinogenic gas representing a serious threat to many workers, as well as the environment. It is vital that staff are protected by monitors that can continuously measure benzene at the low levels required by increasingly stringent international regulations. Titan 2 delivers accuracy and sensitivity in benzene detection and is ideal for use in a variety of sectors, such as oil and gas, bulk storage facilities, chemical manufacturing and processing, and asphalt production.

Users of the original Titan will be familiar with the instrument’s accuracy and performance; however, Titan 2 features core enhancements, such as a new rugged manifold, a piezoelectric micro pump for enhanced stability, a lower limit of detection, and updated PC software for easier management and control.

An occupational exposure limit (OEL) for benzene of 100 ppm was originally recommended in 1946. Following further associations with leukemia, the OEL was reduced to 50 ppm and then to 1 ppm as the 8-hr time weighted average (TWA) exposure limit (U.S. OSHA, 1987). However, further health problems have been reported at levels below 1 ppm, so there is pressure in many countries to lower the limit further. For example, NIOSH recommended an airborne exposure limit (REL) of 0.1 ppm (10-hr TWA) and 1 ppm during any 15-min work period. Similarly, the current EU 8-hr TWA for benzene is 1 ppm (3.25 mg/m³). However, from April 5, 2024, the long-term exposure limit will be reduced to 0.5 ppm and will be cut again from April 2026 to just 0.2 ppm.

Titan 2 meets regulatory requirements driving the need for greater sensitivity. Thanks to innovative technology in conjunction with industry-leading photoionization detection (PID) sensor technology, Titan 2 has a reduced likelihood of cross-sensitivity and can detect benzene rapidly at levels as low as 0.02 ppm. At the other end of the scale, it can detect benzene at up to 20 ppm, delivering high speed and high sensitivity.

Titan 2 captures a gas sample once every 60 sec. The sample is then conditioned within a further 60 sec to allow precise benzene measurement, ensuring a consistent flow of real-time data. The piezoelectric micro pump in the latest version delivers enhanced pressure and flow accuracy to ensure a rapid response and unrivalled reliability.

Titan 2 also features visible alarm capability, triggering an alert when benzene concentrations reach either of two operator-configurable levels. Twin relay outputs enable the user to integrate the unit with existing site alarm systems, while easy-to-use firmware allows a simplified calibration procedure. For analysis of readings captured by Titan 2, both 4-20mA and RS485 MODBUS communication protocols can be utilized.

A proven, robust separation method ensures specific readings for benzene, with an easy-to-read display. An internally regulated heating system ensures stable operation even at extreme temperatures, and the new robust housing reduces contamination risk and allows for extended use in the harshest environments.

Titan 2 has been designed to comply with international safety standards, including ATEX and IECEx, making it safe for use in any environment, as well as featuring an IP65 Ingress Protection rating. ION Science’s PID technology has been independently verified as the best-performing on the market, according to the company, providing reliable, accurate solutions backed by outstanding product support. Importantly, and unique to Titan 2, the new MiniPID T2 10.0 eV Sensor features a patented design to nullify potential humidity interference, while ensuring a fast response, the highest levels of sensitivity and market-leading reliability.

The Titan 2 service module is designed to be backwards compatible; so, in conjunction with a simple firmware upgrade, it now provides existing Titan customers with a quick and convenient upgrade opportunity.

For more information, visit https://bit.ly/44tqfDz.

Successful deployment of new generation submersible tank inspection robot

Square Robot has announced the successful outcome of a joint development program with ExxonMobil to design, build and deploy a submersible autonomous robot (FIG. 5) capable of entering above-ground storage tanks through a side entry “launcher” to inspect the internal surfaces of the tank while the tank remains in service. A key feature of the robot and application is the ability to safely enter more volatile liquids, such as gasoline, stored in tanks with an internal floating roof.

The final phase of the development program was executed when a robot was deployed into a 140-ft diameter above-ground storage tank containing 150,000 bbl of gasoline at ExxonMobil’s Baton Rouge facility. Representatives from both companies witnessed the successful deployment, survey and recovery of the robot in full compliance with the original design objectives.

This groundbreaking service is a world first, offering significant environmental, health and safety benefits. The service eliminates the release of hydrocarbon vapor and waste associated with taking a tank out of service, and reduces personnel risk by avoiding confined space entries. Additionally, with the tank remaining in service and operational, the total cost associated with traditional inspection services is dramatically reduced, adding value to tank owners while arming them with a comprehensive data set regarding the state of their asset so that more informed decisions can be made as part of their integrity program.

For more information, visit www.squarerobots.com. HP