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Delegates that register before 30th March to benefit from “Early Bird” registration fee

Online registration is now open for Emerson’s first Global Users Exchange in Europe (www.EmersonExchange.org/emea). The three-day event, aimed at existing and potential users of Emerson Process Management products and services, is being held from 29-31 May 2012 at the Hotel Maritim, Düsseldorf, Germany. Delegates can either book for the full conference programme or choose to attend specific days based on the agenda of events.

Delegates booking the full conference will have access to all conference presentations, courses and technical exhibition, meals, exhibition reception and networking events. In addition, delegates that register before 30th March will benefit from a reduced “Early Bird” registration fee.

“Interest in the European Global Users Exchange has been high and the response to the call for presentations has exceeded our expectations with over 300 abstracts being received,” said Bob Sharp, President, Emerson Process Management Europe. “We know that delegates will be looking for ways to improve energy efficiency with enhanced automation, meet new regulatory requirements, increase yields, or simply get more out of their automation investments, and many of the presentations will follow these themes.”

Tailored to meet the needs of users in Europe, the Middle East and Africa, the three-day conference will start at midday on Tuesday 29th May and finish on Thursday 31st May. Delegates will be able to choose from around 100 themed presentations with some being simultaneously translated into German and Russian. The programme also includes industry forums, technology exhibits on both evenings and networking events where delegates can meet fellow automation professionals and process industry experts.

Shaped by users, for users – the Emerson Global Users Exchange provides a platform for customers to share their learning by delivering presentations to their colleagues. The event is managed by a Board of Directors, comprising users from a range of industries, who shape the conference content and guide the direction of the users group at large.

For more information, including how to book a delegate place and details of the conference programme and venue, please visit: www.EmersonExchange.org/emea

Dantorque subsea actuator weighs in at 9 tonnes and ties in to existing 91 cm diameter pipework on Trinidad

The National Gas Company of Trinidad and Tobago Limited is using the largest Dantorque™ actuator ever produced by Emerson, to help expand its gas distribution network on the Caribbean nation of Trinidad and Tobago. The actuator, which is 2.4 metres tall and 1.64 metres in diameter, will be used to isolate the gas being supplied from Trinidad’s northern offshore gas fields, in the event of an emergency situation.

The multi-million dollar project covers a range of valve automation products from Emerson, including a Dantorque subsea gear operator and one smaller spring return actuator, three Shafer™ subsea actuators and 11 Shafer gas-over-oil actuators installed on the offshore platform and land portions of the pipeline.

The development of new gas fields off the northeast shores of Trinidad required new pipelines to be connected to the existing pipeline infrastructure, which is all in the south. The tie-in to the large 91 cm diameter existing pipeline required a spring return actuator with ROV (Remote Operated Vehicle) override capability. To meet this requirement, Emerson supplied a DTUS 171/1350 Dantorque actuator which has a spring-ending torque of 102,500 Nm and weighs 9 tonnes.

The National Gas Company of Trinidad and Tobago Limited (NGC) has been a long-time user of Shafer rotary vane actuators and gas-over-oil actuators. The Dantorque actuator met all of the requirements for optimum envelope dimensions and diver-assisted installation and retrieval capability.

The Dantorque DTUS actuator converts the linear motion of a spring into rotation through helical spline gearing technology. The mechanical spring return package is based on the Belleville (disc) spring principle, which is well proven. Through this unique combination of the helical gearing mechanism and the Belleville disc spring principle, the Dantorque DTUS provides an extremely compact package for the amount of torque being produced.

Rosemount^® wireless conductivity transmitters help prevent discharge of chemicals into local environment

Korsnäs Gävle is using Emerson Process Management’s Smart Wireless conductivity and temperature transmitters to collect critical leak-detection monitoring data at its board and paper production unit at Gävlebukten, Sweden. Improved monitoring enables the company to verify its compliance with environmental monitoring legislation.

Water from heat exchangers at the Gävlebukten plant is carefully monitored prior to its return to the sea. Small internal leaks may result in the discharge of hazardous chemicals into the local environment. Any leak of acids, bases, or salts will raise the electrical conductivity of the water and is easily detected using a conductivity sensor. A renovation project within the utilities section meant that I/O supporting existing instrumentation was to be removed. Korsnäs Gävle therefore needed an alternative way to transmit the required measurements to the main control room.

“Initially we considered installing new cable runs, but the process would have taken too long and would have delayed the planned renovation project,” said Peter Hallenberg, Project Leader Process Automation, Korsnäs Gävle. “The application presented a great opportunity for us to install and evaluate Emerson’s Smart Wireless technology, which takes advantage of the IEC 62591 (WirelessHART^®) communication standard.”

The Smart Wireless solution that Korsnäs Gävle installed includes a Rosemount^® Analytical 6081-C transmitter connected to a conductivity probe. The transmitter sends the measurement data via a Smart Wireless Gateway to the existing control and data acquisition systems, where it is used to ensure compliance with the environmental monitoring legislation.

Korsnäs Gävle also needed to establish new continuous monitoring of emissions from aerated basins and ponds. Twenty-two new sensors measuring pH, dissolved oxygen, and water temperatures had to be installed and connected to the central monitoring system. There were no available cable runs, and new cable infrastructure presented a considerable challenge and cost at €200 per metre.

To meet this challenge, Korsnäs Gävle installed six Rosemount wireless transmitters, each with four available inputs, to relay data from the analytical sensors. The wireless instruments provide the necessary data to meet the environmental requirements.

“Less than two months after ordering the Smart Wireless devices, the whole system was fully operational. That is very fast for implementing 30 new measurement points,” said Hallenberg.

“Now that the network is in place,” he added, “we have also found that adding additional devices becomes very simple.”

Specifically, Korsnäs Gävle has installed seven Rosemount 648 wireless temperature transmitters to automate the monitoring of water temperatures in  wastewater pits that feed the aerated basins and ponds. A further eight Rosemount wireless transmitters will be installed to identify plugged filters on two wood chip digesters within the main processing section of the plant.

Ovation^™ expert control system will enable precise and reliable combustion control

Emerson Process Management has been awarded a contract for the retrofit of the Unit 3 turbine at Senelec Cap des Biches power station in Senegal. The upgrad e to the new Ovation^™ controls will enable a number of operational benefits, including more precise and reliable combustion.

Located 23 km east of Dakar on the edge of the Atlantic, Cap des Biches is an important power station in Senegal with a rated output of 82 MW. The project is part of a national plan to revamp production capacities in Senegal with EDF CIT (Centre d’Ingenierie Thermique) appointed as technical advisor.

Emerson is appointed Main Contractor for the project covering the audit and evaluation of the existing control systems, scheduling for the dismantling of equipment to be replaced, design of the Ovation system, engineering drawings, FAT test plan and commissioning procedures. Emerson’s scope also includes installation, commissioning and operator training.

Emerson was awarded the contract following the successful completion of Units 1, 2 and 4 by Innovative Control Systems (ICS), which is now part of Emerson Process Management’s Power & Water Solutions group.

“Emerson was awarded this contract on the basis of its industry experience, turbine-retrofit expertise, and ability to provide a complete automation solution,” said Moussa Diagne, Production Director for Senelec. “Emerson has already upgraded three gas turbine units for Senelec and we know from these experiences that it has the best technologies to help Senelec meet the growing need for reliable energy in Senegal.”

The project covers the installation of the Pratt & Whitney Gas Turbine 3 (22MW) and new turbine controls and instrumentation. Emerson is also responsible for the installation of the refurbished gas engine including mechanically coupling it to the existing turbine elements on site. Emerson will replace the existing PLC-based control system with its Ovation expert control system with redundant controllers for overall control of the system. An Ovation supervisory system will replace the existing operator interface.

Emerson will also supply and install a new excitation system, vibration monitoring system, fire protection system and instrumentation, including integrating these systems into the Ovation system. Emerson will also retrofit existing mechanical equipment for dual fuel conversion, enabling the unit to run on gas or diesel fuel oil. Also included is the installation of new gas conversion equipment and a gas generator. The schedule for the project is 22 weeks.

Bob Yeager, president of the Power & Water Solutions division of Emerson Process Management said, “We are delighted that Senelec has chosen Emerson’s project management services, digital plant networks and advanced control systems to help provide higher levels of plant availability, reliability and environmental compliance.”

ASCO Numatics solenoid valve, pressure switch and non-return valve used in an innovative patented braking system that improves safety, comfort and control when towing caravans and trailers

Modern trailers, caravans and horseboxes are designed to be stable and safe to tow, they feature a specially designed chassis with suspension and efficient brakes. Even so, as any experienced caravanner will tell you, a reduction in speed and change in driving style are essential when towing, and this applies particularly when braking.

The normal caravan over-run braking system relies on the tow vehicle’s brakes and deceleration to compress the tow hitch and apply the caravan brakes. This means there is a delay before the caravan brakes are applied. Now a new system is available that applies the caravan brakes as soon as the stop light circuit on the car is energised. Braking is quicker and more effective.

The new system is installed on the trailer and uses pressurised air to operate an actuator that applies the trailer brakes using the existing rods and linkages. The air supply from the on-board compressor is controlled by an ASCO Numatics sub-miniature solenoid valve. This is used to direct air to the brake actuator when the towing vehicle’s brake circuit is energised and release the pressure when circuit is de-energised. An ASCO Numatics pressure switch limits the maximum pressure in the system preventing it from locking the caravan wheels. Pressure is maintained in the system using an ASCO Numatics non-return valve which prevents air being released back through to the compressor.

Called Insync Brake Assist (IBA), the innovative braking system was developed by experienced caravanner Charles Irving and is now being manufactured and marketed by Insync Systems Ltd. “The sales and technical teams at ASCO Numatics have really helped to get the IBA into production,” said Charles Irving. “They provided excellent application advice and technical support and ASCO Numatics now supply a custom kit of parts with the pressure switch pre-set to our specification. This makes it easy to supply IBA kits to our team of installers located across the UK.”

The ASCO Numatics valve is ideally suited to this demanding application. It features a stainless steel core tube which provides exceptional resistance to humidity and corrosion. With a service life of up to 20 million cycles, the valve is designed for applications that require fast (5-10ms) and frequent operation. The valve being used on the braking system is a 3/2 style with 12v DC operating coil. The pressure switch limits the pressure in the braking system. With an operational life of 1 million cycles, it can be adjusted over the range from 1 to 5 bar. The pressure switches supplied for the IBA are factory preset by ASCO Numatics.

“We worked closely with Charles Irving to ensure we provided the right valves and pressure switch for the job,” said Steve Barford, Senior Process Specialist, ASCO Numatics.” We know that many trailers and caravans are left unused for months and it was critical that the devices being used would respond immediately when required. ASCO valves have an outstanding reputation for quality and reliability and we are confident that our products will meet the challenges of this unusual application.”

The IBA consists of a small control box mounted inside the caravan. This houses the compressor, ASCO Numatics control valve, pressure switch and non-return valve. Electrical connections provide 12v power and inputs from the brake and reversing circuits. Pneumatic pipes connect the control box to the brake actuator assembly, which is clamped to the caravan chassis using specially fabricated brackets. The system is designed to fail safe in the event of a power failure, deactivating the IBA and allowing the over-run braking system to operate as normal.

Three day event in Düsseldorf, Germany aims to help Emerson users improve efficiency and reduce costs with enhanced automation

Emerson announces the first Global Users Exchange in Europe. Themed “Exchanging Ideas. Creating Solutions”, the three day event will run from 29-31 May 2012 at the Hotel Maritim, Düsseldorf, Germany. Tailored to meet the needs of users in Europe, the Middle East and Africa, delegates will learn about best practices and see how colleagues are meeting new regulatory requirements, increasing yields, improving efficiency and reducing costs with enhanced automation.

The European event will follow the same format as the October 2011 Emerson Global Users Exchange held in Nashville, USA. The event will include workshops, presentations, industry forums, short courses, technology exhibits and product roadmaps. Delegates will be able to choose from themed presentations in English, German and Russian.

“We are delighted to announce the details of the first Global Users Exchange for our many users across Europe and others who will join us from other regions,” said Bob Sharp, President, Emerson Process Management Europe. “The Emerson Global Users Exchange is much more than an industry-leading technical conference. It is a community of manufacturing leaders committed to extracting the most from their automation investment and sharing their learning with each other.”

The event also provides an opportunity for delegates to understand what their peers, other suppliers and customers in the industry are doing to compete in these dynamic times. Attendees will be provided with a unique opportunity to touch and experience the breadth of innovative Emerson technologies – all in one place.

An important element of the event is the opportunity it provides to network with other delegates and industry leaders to make the right connections. Delegates will also be able to meet with the experts behind the technologies and learn how innovative technologies can be put to work.

The Emerson Global Users Exchange organisation is now looking for users to share their experiences and expertise with their process automation peers by giving a presentation, workshop or short course at the event. Presenting at the Global Users Exchange provides a unique opportunity for users to showcase their company and its successful operational practices.

For more information about the event, including how to submit presentations, the conference programme and venue please visit: www.emersonexchange.org/emea

Quick Ship programme provides a reduced lead time for Fisher^® valves, and a lead time of less than three days on selected valve assemblies and parts

Emerson Process Management announces that its Quick Ship programme has now been extended to cover selected Fisher^® valves, assemblies and parts. Fast  delivery of replacement products and spare parts is critical to keeping any plant running at maximum efficiency and Emerson’s Quick Ship programme supplies critical products and spares on reduced lead times so that customers can minimise costly down time.

Initially launched to cover Rosemount^® temperature and pressure transmitters, then extended to include Rosemount and Micro Motion^® flow products, Emerson has now established a dedicated Fisher Europe Quick Ship team that will check the availability of parts and manufacturing resources to meet the customers requested lead time.

The premium Quick Ship programme offers customers a reduced lead time for Fisher valves, and a lead time of less than three days on selected valve assemblies and parts. The Quick Ship option is available on Fisher sliding stem valves up to 6”, rotary valves up to 10” and butterfly valves up to 12”.

Quick Ship orders follow a different route through order processing and on to the dedicated Quick Ship workshop and team, in order to meet the agreed delivery time. To ensure that Quick Ship orders are fulfilled within the shortest possible timescale, Emerson has made a significant investment in the resources and infrastructure at its facilities in Székesfehérvár, Hungary.

As part of the Quick Ship programme, Emerson’s new Installed Base Tool offers major customers on-line access to their installed valves based on tag and serial numbers. This allows customers to select parts for individual valves with prices and lead-times. The tool also enables 24/7 on-line ordering of parts.

The Installed Base Tool is being further developed to allow customers to upload valve information including certificates, pictures, history, diagnostics reports and even schedule maintenance or service calls directly.

“The start-up of the Fisher Europe Quick Ship programme has already helped many customers get replacement products and parts on site quickly,” said Hans Nieuwpoort, the Fisher Europe Quick Ship Programme Director. “This programme means that more of our customers have speedy access to critical replacements – minimising plant downtime and lost revenue.”

For full details of products available through the Quick Ship programme, please contact your local sales office or email hans.nieuwpoort@emerson.com

Rosemount^® 5300 and 5400 Series level transmitters can now be installed in Modbus and LevelMaster applications

Emerson Process Management announces that the Rosemount 5300 Series Guided Wave Radar (GWR) and 5400 Series non-contacting level transmitters now  include the ability to communicate via the Modbus communications protocol. The addition of Modbus enables the transmitter to emulate LevelMaster – sometimes known as ROS or tank – protocol. This broadens the application range for these devices even further and enables them to be retrofitted into existing Modbus and LevelMaster networks.

The new transmitters feature an integral HART^® to Modbus converter (HMC). This enables up to four external HART transmitters of any type to be connected, and their signals communicated via the Modbus network. 

The devices can be configured using Emerson’s Radar Master software, point-to-point via HART communications, or remotely by using HART Tunnelling over the Modbus network. Configuring remotely eliminates the need for technicians to climb up vessels, enhancing safety.

Rosemount 5300 and 5400 Series level transmitters are designed to withstand the harsh conditions found in the oil and gas industry. They are robust, accurate and reliable, providing users with ‘fit and forget’ real-time level and interface measurement.

ASCO Numatics introduces a new generation of stainless steel cylinders specifically designed to withstand the extreme conditions experienced in the food industry. Quick and easy to install, CIX cylinders feature stainless steel covers, tube and rod, no retention areas and a special front cover design. They are  suitable for use in saline or lactic environments which are subject to frequent wash-downs using cleaners and active detergents.

CIX cylinders can be fitted with IP69K magnetic positioning detectors and feature special seals which are resistant to very high pressure jets. The seals can be replaced quickly and easily without disassembling the cylinder. This reduces the time required for maintenance by 70 per cent – minimising machine downtime and maintenance costs.

PlantWeb™ digital architecture with Ovation™ control system to provide flexible and accurate control of critical combustion process

Foster Wheeler has chosen Emerson Process Management’s PlantWeb™ digital plant architecture with the Ovation™ expert control system and AMS Suite  predictive maintenance software, to control a new biomass boiler at the Polaniec Power Station in Poland. When operational in 2012, this will be the world’s largest 100% biomass-fired boiler.

Foster Wheeler is building the 190 MWe biomass-fired circulating fluidised-bed (CFB) boiler island for plant owner GDF Suez, one of the world’s leading energy providers. Poland has been investing in biomass power generation to achieve a target of producing 15 per cent of its total energy consumption from renewable sources by 2020.

“The Foster Wheeler circulating fluidised-bed technology provides solutions for effective CO₂ reduction in power generation through large-scale 100% biomass utilisation,” said Jarosław Mlonka, President & CEO of Foster Wheeler Energia Polska. “Emerson’s proven automation technology will help overcome the difficulties of burning agricultural biomass efficiently by providing reliable, accurate and efficient boiler control.”

Emerson’s Ovation system features embedded advanced algorithms and proven control routines that continually adjust the combustion process to account for the varying characteristics of biomass fuels.

Emerson’s scope of supply is based on an Ovation system to handle 6000 I/O. This includes Ovation SIS (Safety Instrumented System) for boiler protection and burner management. Project documentation will be generated using the Ovation Documentation Builder smart tool. Emerson will also supply automation services including complete project management, engineering and installation.

Also included is Emerson’s AMS Suite, which will speed configuration and commissioning of boiler instrumentation. When the plant is operational, AMS Suite will enable maintenance and operations personnel to predict equipment issues to better maintain and protect the machinery.

The boiler island and biomass handling plant will be built next to the existing units at GDF Suez’s 1,800-MW coal-fired power station, which already uses an Ovation control system. Following further modernisation of the station’s existing turbine, its output capacity will increase from 190 to 205 MW.

Designed for high reliability and easy maintenance, the boiler will burn wood chips in combination with 20 per cent of agricultural derived fuel such as straw pellets or crushed briquettes, sunflower pellets, fruit husk pellets, and crushed palm kernel shells.

The annual biomass requirement of the new unit will be approximately 1 million tonnes, and it is expected to generate 1.2 terawatt hours (TWh) of clean energy per annum. The plant is designed to ensure that emissions will be well below those required by the EU Large Combustion Plants Directive.

“Biomass utilisation will play a significant role in Europe’s energy future,” said Bob Sharp, European President, Emerson Process Management. “Emerson’s automation technology is perfectly placed to support power generation developments by providing advanced automation and control functions to maximise both boiler and plant efficiency.”