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Emerson Chosen as Automation Partner for World’s Largest Hydrogen Refueling Station for Commercial Vehicles Dec 24, 2022
Korea Hydrogen Green Energy Network (KOHYGEN) has chosen global technology company Emerson’s advanced automation solutions to help ensure the safety and reliability of its pioneering hydrogen infrastructure initiative, which recently marked the completion of the world’s largest hydrogen refueling station for commercial vehicles. The project is an important step toward the two organizations’ goals of reducing emissions, driving investment in hydrogen and accelerating the transition to a net-zero global economy. “We’re committed to building smart, safe hydrogen refueling infrastructure by leveraging IT-based integrated operations, using large capacity, high-efficiency charging systems and, most importantly, strengthening design safety standards,” said KyungSil Lee, KOHYGEN’s chief executive officer. “Emerson is helping us secure abundant clean energy for Korea and the world.” The JeonjuPyeonghwa Hydrogen Refueling Station is the first of 35 high-capacity gas and liquid hydrogen refueling stations KOHYGEN plans to construct across Korea by 2025. The first station has a charging capacity of 300 kilograms per hour, which can fuel up to 15 buses and trucks per hour, or over 100 per day–12 times more than an average capacity hydrogen station. To further lay the foundation for a stable hydrogen supply chain, Emerson and KOHYGEN are collaborating on technical standards for future high-capacity commercial refueling stations and similar projects. KOHYGEN plans to expand its hydrogen supply platform to service hydrogen-powered aircraft, ships and other diverse forms of transportation. “In line with Emerson’s ‘Greening By’ sustainability strategy, we’ve worked on a range of hydrogen projects globally, applying our expertise and innovative technologies to scale hydrogen consumption and make renewable energy a reality,” said Mike Train, Emerson’s chief sustainability officer. “Partnering with KOHYGEN is another critical step forward in diversifying our global energy mix.” In addition to deep domain experience across the hydrogen value chain, Emerson is providing core technologies, including temperature transmitters, flowmeters, pressure transmitters, programmable logic controllers (PLC) and valves, to deliver the high level of performance necessary for developing a commercially viable hydrogen charging model that can expand Korea’s domestic hydrogen market and serve as a template in other countries. KOHYGEN is a special purpose company held jointly by nine energy industry leaders: Korea District Heating Corporation, Hyundai Motors, GS Caltex, S-Oil, Hyundai Oilbank, SK Energy, SK Gas, E1 and Air Liquide Korea. About Emerson Emerson is a global technology and software company providing innovative solutions for the world’s essential industries. Through its leading automation portfolio, including its majority stake in AspenTech, Emerson helps hybrid, process and discrete manufacturers optimize operations, protect personnel, reduc...
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ABB Partners with Boliden to Reduce Carbon Footprint of Its Industrial Products Dec 17, 2022
ABB is working with Boliden, the Swedish mining and smelting company, to build a strategic co-operation to use low carbon footprint copper in its electromagnetic stirring (EMS) equipment and high-efficiency electric motors. The aim is to reduce greenhouse gas (GHG) emissions while driving the transition to a more circular economy. The partnership with Boliden forms an integral part of ABB’s strategic ambition to reduce the environmental impact of raw materials used in its products by replacing them with lower carbon alternatives. Apart from using recycled copper, ABB has committed to increase the use of recycled electric steel (e-steel) and recycled aluminum. The move is also an important step in closing the circularity loop that has already seen ABB designing its motors to be up to 98% recyclable, with the remaining 2% of materials available to be incinerated for heat recovery. Recycling copper, aluminum and steel offers energy savings of between 75 and 95% compared to virgin production. “As a part of ABB's 2030 sustainability strategy, our target is for 80% of our products and solutions to be covered by a circularity approach. The work with Boliden is an important step towards this goal,” said Ola Norén, head of Metallurgy Products, Process Industries, ABB. “By taking stock of the delivery by the end of this year we’ll ensure that all our metallurgy products use recycled hollow copper conductors from 2023.” “We want to enable a more sustainable and resource-efficient future, and with this collaboration our customers can not only decarbonize by upgrading to energy efficient motors but will also be able to install ABB technology that has an improved environmental footprint thanks to Boliden’s copper,” said Ulf Hellstrom, managing director at ABB Motion, Sweden. “This is an excellent example of the circular economy in practice.” The co-operation includes ABB placing the first order for Boliden’s certified recycled copper through Finnish metals manufacturing specialist Luvata. Hollow conductor wire made from the material will be used in ABB’s EMS products for both steel and aluminum manufacturing. Furthermore, as of 2023, ABB will purchase Boliden’s low-carbon and recycled copper to cover the demand for its IE5 Ultra-Premium Efficiency SynRM and e-mobility motors produced in Europe. The two companies have also signed a memorandum of understanding that will see ABB supporting Boliden in identifying inefficient low-voltage motors across its operating units. These motors can then be replaced with high efficiency motors within ABB’s take back upcycling framework, with the old motors recycled to provide raw material for Boliden’s recycled copper. Copper is a vital material for manufacturing industrial electrical equipment, but its production is energy intensive. To address this, Boliden has developed low-carbon copper that is mined using fossil-free energy and also produces copper using secondary raw material from recycled products. The carbon footprint...
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AI-Based Autonomous Control Dec 10, 2022
As process control technologies advance, one concept gaining prominence is autonomy. When contrasted with conventional automation, one of the main differentiators of autonomy is applying artificial intelligence (AI) so an automation system can learn about the process and make its own operational improvements. Although many companies find this idea intriguing, there is understandable skepticism. The system’s capability is only as good as its foundational algorithms, and many potential users want to see AI in operation somewhere else before buying into the idea wholeheartedly. Those real-world examples are beginning to emerge. Yokogawa’s autonomous control systems are built around factorial kernel dynamic policy programming (FKDPP), which is an AI reinforcement learning algorithm first developed as a joint project of Yokogawa and the Nara Institute of Science and Technology (NAIST) in 2018. Reinforcement learning techniques have been used successfully in computer games, but extending this methodology to process control has been challenging. It can take millions, or even billions, of trial-and-error cycles for a software program to fully learn a new task. Since its introduction, FKDPP has been refined and improved for industrial automation systems, typically by working with plant simulation platforms used for operator training and other purposes. Yokogawa and two other companies created a simulation of a vinyl acetate manufacturing plant. The process called for modulating four valves based on input from nine sensors to maximize the volume of products produced, while conforming to quality and safety standards. FKDPP achieved optimized operation with only about 30 trial-and-error cycles—a significant achievement. This project was presented at the IEEE International Conference in August 2018. By 2020, this technology was capable of controlling entire process manufacturing facilities, albeit on highly sophisticated simulators. So, the next question became, is FKDPP ready for the real world? From simulation to reality Yokogawa answered that question at its Komagane semiconductor plant in Miyada-mura, Japan (Figure 1). Here, much of the production takes place in clean room environments under the tightly controlled temperature and humidity conditions necessary to produce defect-free products. The task of the AI system is to operate the heating, ventilation, and air conditioning (HVAC) systems optimally by maintaining required environmental conditions while minimizing energy use. It is understandable that an actual application selected for this type of experiment would be of modest scale with minimal potential for safety risks. This conservative approach may be less dramatic than one at an oil refinery, but this does not reduce its validity as a proof of concept. At first glance, operating an HVAC system autonomously might not seem complex. But the HVAC systems supporting the tightly controlled clean room environment account for 30 percent of the total ener...
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Exploring Local, Remote and Distributed I/O Dec 03, 2022
Process and factory automation controllers connect to sensors, instruments, valves and other equipment through input/output (I/O) cards or racks that are either collocated within the same cabinet (local) at the controller/CPU or installed farther away (remote). Defining the difference between local and remote I/O is straightforward, but the defining differences between remote I/O and distributed I/O can have their nuances and are further confounded by each vendor’s definitions or marketing collateral, just as many automation vendors prefer a name like process automation controller (PAC) over programmable logic controller (PLC). The most used I/O type is local I/O. It is most often from the same vendor as the controller/CPU, since it is ordinarily directly connected to the controller/CPU by integrated racks or cages that hold 4-, 8-, 16- or 32-point I/O cards. Some local I/O expansion racks, or bricks, as they are often referred to, can be separate from the main CPU and connected over a digital bus or highway via twisted pair wires or Ethernet cables, albeit installed within the same physical cabinet. Since local I/O is typically intended to be installed within the same enclosure as the controller/CPU, environmental operational characteristics and hazardous area approvals are not as robust as remotely installed I/O. Remote I/O characteristics Next comes the challenge of outlining the different characteristics between remote I/O and distributed I/O, especially since many vendors refer to them interchangeably. If we use history and release to market timelines as a basis, remote I/O was first and thus less flexible, capable and smart as compared to later released distributed I/O. Initially, remote I/O was nothing more than local I/O reconfigured and housed to be remotely installed from its corresponding controller/CPU Communication was no longer along a backplane but now designed to convert its connected analog I/O signals to a digital format that was transmitted back to the host controller over proprietary buses or highways. Remote I/O is limited in scope and does not contain a complex or advanced CPU or processor to handle math, complex control, and peer-to-peer communication with other remote I/O modules, or allow the connection of additional I/O modules. While operational characteristics and hazardous approvals exceed that of most Local I/O products, it is still somewhat more limited than its advanced cousin, distributed I/O. Distributed I/O characteristics Distributed I/O harnesses all the capabilities of remote I/O and more. It is likely, but impossible to determine, that distributed I/O derived its name from “distributed control.” As the name suggests, distributed I/O is a more complex piece of equipment that can be distributed throughout a process plant or automation facility without the concern of continuous communication with its host controller/CPU. This is because most distributed I/O products contain an advanced CPU and often real-time o...
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New Emerson Compact Controllers Increase ROI for Machine Builders Nov 26, 2022
PACSystems RSTi-EP CPE200 family saves money and time with built-in security, open protocols and high performance out of the box. Emerson, a global software, technology and engineering leader, today announced the release of its PACSystems™ RSTi-EP CPE 200 programmable automation controllers (PAC). This new family of compact PACs helps original equipment manufacturers (OEM) successfully meet customer requirements by minimizing the need for specialized software engineering talent. CPE 200 controllers will deliver large programmable logic controller (PLC) capability in a small, cost-effective, IIoT-ready form factor so machine manufacturers do not need to sacrifice performance for price. The controllers offer open communications through native, pre-licensed support for OPC UA Secure and other common industrial protocols for flexible connectivity over high-speed Gigabit Ethernet. IEC 61131 programming languages and C, the world’s most popular and easiest-to-use programming language, help engineers write and run the high-performance algorithms that enable proprietary production strategies and advanced automation technologies.
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Emerson’s New I/O Interface Nov 26, 2022
Emerson, a global software and engineering leader, has released DeltaV™ IO.CONNECT, a new subscription software service designed to help plants simplify modernization with an open architecture pathway that makes it possible to transition to more efficient control schemes without the need to completely overhaul existing infrastructure. In a traditional plant with tens of thousands of I/O points and many controllers, this can save hundreds or thousands of hours of labor and up to 40% of the capital required for a total rip-and-replace upgrade. Many plants still using control systems from 20 or 30 years ago are unable to reap the benefits of modern, digital technologies that optimize operations and improve sustainability. Modernizing those systems is complicated by the extensive time, labor and capital expense required to convert the old wiring, terminations and other infrastructure they are built upon, leaving plants “locked in” to legacy control technologies and expensive service contracts. DeltaV IO.CONNECT provides a faster, easier, more cost-effective path to replacing any legacy system with a new DeltaV distributed control system while leaving existing I/O infrastructure in place. The solution is provisioned as a subscription software component of Emerson’s Guardian™ Support offering, helping plants remain always up-to-date, driving strategic goals and meeting business needs with future-proof operation. No legacy vendor software is required for configuration and maintenance of I/O. By preserving existing I/O and leaving wiring intact, plants can reduce new system transition time by over 90%, keeping production on pace, reducing risks and minimizing downtime. Once the interface is installed and the plant is running new control technologies, technicians can update I/O on their preferred schedule while the plant runs, shifting what used to be a capital expenditure to the operations budget and driving immediate return on investment through improved process control performance. “Many best practices for better visibility and improved performance are out of reach for the numerous plants still running legacy equipment today,” said Claudio Fayad, vice president of technology for Emerson’s process systems and solutions business. "Moreover, many of the oldest systems are reaching the end of their product support lifecycles, forcing some plants to modernize on a very tight schedule. DeltaV IO.CONNECT empowers industrial plants to choose a digital control system with all the advanced automation features they need, while still scaling at their own pace to better manage transition-related outages and capital expenditures,” said Fayad. DeltaV IO.CONNECT will be on display at the Emerson Global Users Exchange, Oct. 24-28, 2022 in Grapevine, Texas.
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Emerson Helps Simplify, Close Loop on Process Control Nov 19, 2022
DeltaV Feature Pack 3 brings new functionality to help users get the most benefit from their process control technologies Emerson has released Feature Pack 3 for the DeltaV™ Distributed Control System (DCS) to improve process control with added functionality and an improved operations and engineering experience. To make it easier to bring spectral waveform data directly into the control system, Feature Pack 3 adds support for DeltaV Spectral Process Analytical Technology (PAT). DeltaV Spectral PAT connects spectral analyzers directly to the control system to simplify continuous, closed-loop process verification and control for automated real-time quality release. Manufacturers can now easily handle regulatory management while optimizing facility performance and throughput. New updates to DeltaV Live will improve the operations and engineering experience in the DeltaV DCS. The DeltaV HMI features improved runtime diagnostics, robustness, and usability. DeltaV Live Graphics Studio and runtime performance operate up to two times faster than in previous versions. Feature Pack 3 adds DeltaV M-series Zone 2 Remote I/O for increased installation flexibility and easier PLC migrations. DeltaV M-series Zone 2 Remote I/O can be shared amongst several DeltaV controllers for a wider range of applications and increased installation flexibility. It also automatically identifies itself to the control network, eliminating the zero-value time engineers spend creating connections. DeltaV DCS feature packs are delivered at a regular cadence between major DeltaV releases to help users more quickly realize the project and operational savings that come with new features for their control system software. This flexible approach helps organizations make suitable investments in their systems at the right time and deliver maximum return on investment.
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Emerson’s Latest Control System Nov 12, 2022
Emerson’s Latest Control System Update Lays Foundation for Software-Driven, Data-Centric Automation Platform Emerson, a global software and engineering leader, has released a new version of its DeltaV™ distributed control system (DCS). Version 15 of the DeltaV DCS helps plants digitally transform operations through improved production optimization and enhanced operator performance. New software designed to reduce the burden of IT support and modernization spend coupled with expanded analytics will help increase flexibility and speed to market and drive operational improvements. Market forces and public expectation are putting more pressure than ever on manufacturers to drive improved performance and sustainability. Meeting these goals, especially in an era of personnel shortages, means making the most of available data. DeltaV version 15 expands access to critical data to provide every operator with actionable decision support. New infrastructure makes automation easier to set up and maintain while real-time analytics and an improved human machine interface (HMI) help operators improve situational awareness. “As the Purdue Model of control system engineering continues to flatten and more manufacturers need visibility across the enterprise, the control system plays an increasingly important role in providing real-time access to highly-contextualized, democratized data,” said Claudio Fayad, vice president of technology for Emerson’s process systems and solutions business. “Version 15 continues our focus on intuitive, software-defined architectures to help operators and engineers meet the more sustainable, efficient future of process manufacturing.” Project and operations teams rely on virtualization to reduce the hardware and energy footprint of the automation system while simultaneously increasing its availability. DeltaV now supports a hyperconverged infrastructure (HCI) virtualization option that can be deployed in half the time of a traditional virtualization setup. DeltaV HCI is easy to scale and maintain and delivers improved performance. The HCI platform is easily expandable and scalable, allowing users to future-proof their investment, and is the foundation of the DeltaV evolution into a data-centric and software-defined system. Users can increase their speed to market through the new DeltaV Spectral Process Analytical Technology (PAT). DeltaV Spectral PAT integrates two analytics solutions with the DeltaV DCS for real-time closed-loop control. This tighter control helps reduce human error and increase speed to market of quality therapies by moving plants closer to continuous manufacturing of drugs. Enhancements to DeltaV Live, a modern HTML5-based, built for purpose HMI, empower operators with easy access to expert insights for more effective, efficient decisions that drive better performance and help personnel of any skill level. Teams can also unlock anytime, anywhere access to digital twin simulations from across the globe with the new ...
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