Italian Pharma co selects Emerson to enable a digital transformation…

FIS – Fabbrica Italiana Sintetici, a leading active pharmaceutical ingredients manufacturer, has selected Emerson to digitize operations and work processes at three manufacturing sites in Italy. With these $20m (€16.1m) contracts, Emerson will provide automation technology to help create a fully electronic manufacturing environment for increased efficiencies, quality and regulatory compliance.

“It is vital that FIS develops the right relationship to help it expand operations in a measured and prudent manner,” said Franco Moro, general manager of FIS. “Working with Emerson provides FIS with a trusted partner as we digitize work processes and invest in automation to improve production and efficiency.”

As part of its growth strategy, FIS constructed a new $123m (€100m) unit at its Termoli site, doubling capacity to produce active pharmaceutical ingredients. Emerson will implement its Syncade manufacturing execution system at the Termoli site, as well as the Montecchio facility, providing automated workflows and paperless procedures and record-keeping. Paperless manufacturing improves production efficiency and offers widespread benefits in compliance, product quality, inventory and document control, which are critical in the highly regulated pharmaceutical industry.

These two leading companies have partnered before; Emerson provided its DeltaV distributed control system to monitor and control manufacturing at the Termoli site in 2017. As part of this latest agreement, Emerson will expand the automation system to incorporate additional measurement and control instrumentation. By standardising on DeltaV across its Termoli, Montecchio and Lonigo sites, FIS aims to improve efficiency and ensure consistent operations.

“This project reinforces Emerson’s strong relationship with FIS, and, as a trusted advisor, we will continue to support its business objectives on a long-term basis,” said Mike Train, executive president of Emerson Automation Solutions. “Our expertise will help FIS further automate work processes and boost profitability across these three sites as part of a company-wide digital transformation strategy.”

The contracts are part of a 10-year strategic framework agreement signed with Emerson for the supply of its DeltaV and Syncade systems, measurement instrumentation and control valves, as well as a 10-year service agreement that covers the control systems at all three sites plus the new MES systems at Termoli and Montecchio.

Advertisements

Algae control at Sellafield 

LG Sonic, a leading international manufacturer of algae and biofouling control systems, has installed multiple LG Sonic Industrial Wet Systems at the Sellafield  nuclear power facility in the UK. This led to a significant improvement in the clarity of the water and the visibility into the storage ponds. As a result of these ultrasonic processing systems there has been an exceptional reduction in blue-green algae and chlorophyll levels in the treated storage ponds.

Sellafield, a nuclear fuel reprocessing and nuclear decommissioning site, handles nearly all the radioactive waste generated by the 15 operational nuclear reactors in the United Kingdom. In 2015, the UK government started a major clean-up of the stored nuclear waste facilities in Sellafield because of the bad condition of storage ponds. One of the main causes of these bad conditions  was poor visibility in the water due to algae growth.

The Solution: Ultrasound technology

To improve water visibility in the storage ponds, four LG Sonic Industrial Wet systems were installed. The systems have 12 ultrasonic programmes to effectively control different types of algae, and are able to treat algae in a relatively short time. GPRS control allows the user to monitor and change the ultrasound programme remotely. Furthermore, status updates and alerts are received when power outages occur.

In only three weeks after the installation of the LG Sonic ultrasonic systems, there was a significant reduction in blue-green algae count and chlorophyll levels. As a result of the this reduction, the water started to clear and it was possible to see vessels and containers in the storage ponds that in recent years were only visible when using a tethered underwater mobile camera device.

Over 10,000 LG Sonic systems have been installed worldwide, including many on the current European FP7 projects.

unnamed (1)

A recent picture of a storage pond

MVDC Power Transmission

Azeez Mohammed, president & CEO of the GE Power Conversion business discusses how MVDC technology is creating a more secure and higher-capacity grid for the future. Thanks to the MCDC technology, Scottish Power Energy Networks’ Angle DC project – first of its kind in Europe – will provide a 23% power capacity increase for supplies to Anglesey. Similar technology is being used in offshore wind applications, giving up to  15% cost savings.

Transforming Power Grids for an Efficient Future

With a fast-growing global population and increasing levels of industrialisation, demand for electricity is expected to soar 60% between now and 2040. That means power grids will be called on to transmit more power, more efficiently. And to do so, they’ll have to adapt to an evolving energy landscape.

Today’s grid is still structured around transmitting electricity from a handful of large, centralised power plants running on coal, oil, gas and nuclear. While these will continue to dominate the mix for years to come, renewables are increasingly making their presence felt – and are expected to supply a third of global power by 2040.

With renewables growth comes an increasingly diverse distribution network – from remote and offshore generation sites to microgrids. All must be brought together to ensure we continue to have a reliable, resilient power supply. The challenge now is that the majority of power grids are made up of decades-old infrastructure that’s simply not – yet – up to the task.

Laying the foundations

Creating a future-proof power grid means fusing time-honoured knowledge with forward-thinking technology. For over 100 years, GE electrical engineers have recognised that DC electricity transmission is more efficient than AC. Now, DC is becoming more prominent – both at the beginning and end of the grid. DC is produced by wind turbines and solar PV and used by everything from smartphones, laptops and electric cars to the data centres that keep our digital world up and running. However, having to convert back and forth between AC and DC along the way leads to wasted energy through resistance and heat.

AC may have won the “War of the Currents” that raged between the Edison Electric Company (which favoured DC and would become General Electric) and Westinghouse (which favoured AC) in the 1890s. This was due to its ability to easily step up voltages to the higher levels needed to transmit it over long distances and back down again for safe usage. But today, new power conversion and transmission technology means it is becoming more cost-effective to use DC to transmit at higher voltages, with less energy losses. The same attractive cost story applies when it comes to integrating new, often remote, DC-producing renewables into the wider grid network.

At the GE Power Conversion business, we’re developing the use of DC to enable more efficient power transmission to and from remote areas – both onshore and offshore.

Strengthening the Anglesey power supply

At the GE Power Conversion business, we are delivering Europe’s very first medium-voltage direct current (MVDC) link as part of the Scottish Power Energy Network Angle DC project in Anglesey and surrounding North Wales area. A growing demand for electricity in the region, combined with increasing volumes of renewable generation, is putting the existing 33-kilovolt AC links between the isle of Anglesey and the Welsh mainland under strain.

Converting the existing AC connection to MVDC could help it to carry more than twice the power and do so more efficiently. GE MVDC technology is providing a critical project asset, as it allows for the creation of a more-secure, higher-capacity grid without the need to overhaul existing infrastructure or install new power distribution assets.

Instead, GE will install MVDC power modules at the two existing substations in Bangor and Llanfair PG, where the AC to DC conversion will be performed. GE MV7000 power electronic inverters will transmit the power via the existing 33-kilovolt AC overhead line and cable circuit, increasing the power available to Anglesey by 23% to meet its future needs without additional environmental impact. What’s more, the DC equipment will assist in the provision of further grid support, as the inverters are able to support the AC voltage at each substation.

This MVDC technology works in much the same way as our high-voltage direct current (HVDC) projects, but on a smaller and simpler scale. For example, a comparable HVDC system would operate at 320-400 kilovolts DC, whereas the Angle DC project will operate at 27 kilovolts DC—demonstrating how this technology can be scaled to fit a variety of customer needs.

Lowering the cost of offshore power

From wind turbines stationed far out at sea to solar farms in inhospitable deserts, renewable generation networks are often found in hard-to-reach places. Getting the power generated to a centralised grid via AC can waste energy and keep renewable electricity costs higher than they need to be.

Now, similar technology behind the MV7000 converters used for Angle DC has also been successfully trialed for use in remote power networks. Our PassiveBoost solution will enable DC power transmission, opening up the potential to boost electrical output from these remote sites while also reducing power costs.

PassiveBoost is an MVDC converter which provides a straight replacement, with the same footprint and volume, for the AC transformer inside every wind turbine. This helps to facilitate a direct connection to an efficient MVDC power collection grid, resulting in a lower cable cost and no need for an expensive and complex DC breaker. A 6 megavolt-ampere converter was designed and tested at the GE power test facility in the UK. There, it successfully demonstrated the capability of generation, distribution and protection at MVDC, highlighting efficiency levels that could bring a 15% cost saving for offshore wind electricity by significant reductions in component count, cabling costs and removal of need for offshore platforms.

Greater grid control through data-driven insights

To drive further efficiency across the power grid, GE can also offer VISOR 2.0, an asset management tool that provides remote connectivity to key assets. This not only enables an improved service response time, but also access to real-time support and advice in the event of a fault or problem. By pairing this tool with the GE Data Historian, which collects, processes and stores data, customers can more easily review the capabilities of their MVDC system. Its ability to capture and analyse data about asset performance means customers can then develop optimum control algorithms for the distribution system, helping to ensure the grid is always functioning as effectively as possible.

As electrification within all industries gathers pace and the burden on existing energy distribution networks increases, we’re ready to put our expertise into action where it’s most needed.

 

Diabetes plant for Novo Nordisk chooses Emerson

Another Novo Nordisk greenfield pharmaceutical project has chosen Emerson Automation Solutions to achieve a fast project start-up: this Emerson release gives the following information.

Emerson advises: “Global healthcare company Novo Nordisk has awarded Emerson a $40 million automation systems and services contract for a new US-based drug manufacturing facility to help battle the global diabetes epidemic. The largest project in its history, Novo Nordisk’s new $2 billion plant in Clayton, North Carolina, will leverage Emerson Project Certainty methodologies and automation technologies to help ensure the plant achieves a tight project construction schedule to meet a construction target of 2020.

The new 825,000-square-foot production facility will help the Danish drug company increase manufacturing capacity and meet its goal of doubling production of diabetes drugs over the next decade. According to the Centres for Disease Control and Prevention, more than 29 million Americans are living with diabetes, with another 86 million living with prediabetes.

“Our extensive experience in the life sciences industry and integrated offering for capital projects and automation perfectly positions us to help Novo Nordisk deliver its largest project in history,” said Mike Train, executive president, Emerson Automation Solutions. “Together we can design and deliver this world-class manufacturing facility to be ready on time, and to quickly deliver these important diabetes medicines.”

Novo Nordisk will implement elements of the Emerson Project Certainty approach to help reduce project complexity and achieve the tight project schedule. This transformational approach leverages automation technology, which serves as a central nervous system in a plant, and new methodologies, to reduce costs and complexity and accommodate late-stage project changes.

Novo Nordisk selected Emerson’s integrated portfolio of automation technologies and services, including its DeltaV distributed control system (DCS) and Syncade manufacturing execution system (MES). Emerson will also provide smart automation technologies including valves and measurement instrumentation.”

ABB automation increases capacity 10x for Tate & Lyle food additive plant

When Tate & Lyle acquired Biovelop, a Swedish manufacturer of oat based food ingredients in 2013, the factory in Kimstad, Sweden was modernized and expanded by installing automation systems, variable speed drives, motors, motor control cabinets  and valve positioners from ABB Automation. In 2016 the remodeled plant celebrated the first anniversary of operations with the new systems and significantly increased production capacity.

The global market for specialty food ingredients, including health and wellness products, is growing, with annual sales of $51 billion and annual growth rate of 4-5%. Oat ingredients have been actively involved with this trend as they offer some key nutritional and functional benefits. In particular, oat contains beta glucan, a soluble fiber that has been shown to lower cholesterol and reduce post prandial glycaemic response – claims that have been approved by the European Food Safety Authority (EFSA). In fact, it was these properties of the grain that made the sector an attractive one to Tate & Lyle, and triggered the decision to diversify its portfolio into this sector.

“We have seen a more than tenfold increase in capacity with the same number of shift operators compared to four years ago,” said Annika Werneman, Tate & Lyle plant manager. “It’s a huge change in such a short time, and it means that we’ve gone from a low-level facility to one that can deliver high quality product to our customers globally.”

Advanced automation technologies in the plant run critical food processing equipment -including pumps and decanters: material handling machinery is also used to transport the dry food products. ABB delivered automation equipment that included 85 variable speed drives (VSDs), with power ratings ranging from 0.37 kW to 55 kW, as well as ABB MNS 3.0 motor control cabinets and low voltage motors. ABB also delivered 44 Digital Electro pneumatic positioners (TZID-C) , which use the Hart protocol to communicate with the control valves.

“We needed a process that was highly automated and could run 24 hours, seven days a week, all year long,” Werneman continued. This meant building a system that enabled Tate & Lyle engineers to digitally interact with the system, commission (start) devices, and diagnose performance deviations or failures from anywhere in the world. This not only helps ensure operational consistency, but also reduce the total cost of ownership by enabling staff to manage the processes without being physically present at each site.

Such interactivity was enabled by the ABB fieldbus automation for the drive controls, providing flexibility as well as remote monitoring of the plant performance. “I like that ABB designed the system so that the fieldbus responsible for device control is split from the fieldbus used for asset management,” explained Leo Dijkstra, power & controls team leader Europe at Tate & Lyle. “This ensures that I can make any changes to the configuration of the devices without the risk of the whole network going down.”

At Tate & Lyle, they place great importance not just on what they do, but how they do it. “We are working continuously wherever we can to reduce the environmental footprint of our operations,” said Dijkstra. ABB was well placed to help as it has developed a portfolio of products and solutions that improve industrial energy efficiency.

“In our pump applications alone, we are using up to 50 percent less energy thanks to the variable speed drives, and these have been running non-stop for the last two years without a single failure,” Dijkstra continued. “What’s more, ABB was so quick to deliver products that we even had the first VSD delivered in just a few days.”

Although the nearest ABB support is only a ten-minute drive away from the Kimstad factory, the fieldbus flexibilities in the drives enable Tate & Lyle to rely on its own staff to handle the ABB equipment remotely. “Our work with Tate & Lyle illustrates the benefits of digitization, which can yield immense productivity and output gains from existing facilities,” said Petter Hollertz, area sales manager at ABB. “The improvements at this plant also show what great teamwork between the equipment supplier and the user can accomplish, as we worked together as true partners on this project.”

E+H acquires Blue Ocean Nova

A new Endress+Hauser press release says the company is further expanding its portfolio of products, solutions and services in the field of process analytical measurement, by  acquiring Blue Ocean Nova AG, a manufacturer of innovative inline spectrometers for monitoring quality-relevant process parameters. 

Blue Ocean Nova will operate under the umbrella of the Endress+Hauser centre of competence for liquid analysis headquartered in Gerlingen, Germany: the 15 employees currently located in Aalen, Germany will be retained. “The intelligent process sensors developed by Blue Ocean Nova will enhance our offering in the field of process analytical measurement, adding a strategic building block,” said Dr Manfred Jagiella, Managing Director of Endress+Hauser Conducta GmbH+Co. KG. As a member of the Group’s Executive Board he is also responsible for the analytics business. 

Innovative concept

EH_blue_ocean_nova

The process sensors developed by Blue Ocean Nova cover the relevant optical spectroscopy regions of UV-VIS, NIR and MIR to analyze liquids, gases and solids inline. The innovative technology allows the spectrometer to be directly integrated into the measurement probe, even in explosion-hazardous areas. The sensors can furthermore be automatically cleaned and easily integrated into process control systems.

The systems from Blue Ocean Nova are utilized in the food & beverage, oil & gas, chemicals and life sciences industries for applications such as concentration and moisture measurements and for measuring relevant quality parameters. The technology enhances the Group’s portfolio, which already encompasses Raman spectroscopy, tunable diode laser absorption spectroscopy (TDLAS) and process photometers.

Extensive experience

Blue Ocean Nova was founded by Joachim Mannhardt and Stefan Beck in 2015, bringing extensive product development experience in the field of industrial spectroscopy and process analytical measurements to the company. “Endress+Hauser opens the door to international markets and customers for us,” explains Stefan Beck. Joachim Mannhardt adds: “We’re convinced that our technology will be an ideal enhancement to Endress+Hauser’s optical portfolio.”

Endress+Hauser acquired Blue Ocean Nova effective 31 October 2017. Both parties agreed not to disclose the details of the transaction. Joachim Mannhardt and Stefan Beck will remain on the management team of the innovative company. “With this acquisition, we are continuing to pursue our strategy of strengthening the process analytical measurement portfolio and in the future supporting our customers from the lab to process,” says Manfred Jagiella.

 

600,000 flowmeters measure beer and lager flow

Titan Enterprises has established a long-standing working relationship with Vianet plc (formerly Brulines) for the supply of beer flowmeters for pub and bar automation projects. Over the last 20 year period Titan have delivered, and Vianet has installed, over 600,000 of these meters for beer and other bar flow measurement and automation applications.

Brulines, was formed in 1993 with the intention of providing pub chain owners with data on their bar activity via an electronic point of sale (EPOS) system. After trialling several other flowmeters, the company sought a solution to resolve flowmeter bearing lifespan problems and to overcome the unreliability of the optical detection method in beer.

beer-meter

The beer flowmeter

Following a collaborative approach to developing the solutions needed for the Vianet customer base, Titan Enterprises proposed an adapted version of its 800-series turbine flowmeter as the design included durable sapphire bearings proven reliable for many thousand hours operation, and a Hall effect detector which was not subject to problems with discolouration inside the pipe. After successful tests, a trial order for 400 units was placed in 1997, which after the subsequent field trials, was followed by an order for >5000 meters which were all delivered to the clients required timescales.

To ensure the flowmeter was ‘fit for purpose’, Titan additionally adapted the cable type as well as the body and increased the length to 10 metres. These adaptions enabled Brulines installations to be maintained in beer cellars with differing wire runs to the control panel without any junction boxes.

Twenty Years of Collaboration

With the widespread reliability of this product, Vianet turned again to Titan Enterprises in 1999 to develop for them an “intelligent” flowmeter (IFM) for their enhanced iDraught retail product. The specification for the IFM required that it should additionally measure temperature as well as determining the type of fluid in the line to detect line cleaning cycles which are essential for the dispensing of a good pint.

At the time, Titan did not have the technology to provide sensing electronics at a reasonable price so we produced a revised version of the beer flowmeter with the capability of being matched to a PCB designed, manufactured and installed by a third party.

After trialling and testing, this new IFM was introduced in June 2000 and supplied to Vianet at the rate of up to 3500 units a week. Mark Fewster, product manager at Vianet commented “Titan’s supply chain has always delivered to our quality and timescale needs”.

IoT Developments

ifm latest

An intelligent flowmeter design

Since this first IFM introduction, close collaboration between the two parties has resulted in 5 iterations of the product with revised features as end user requirements have developed and evolved with the growth of the IOT (Internet of Things). Drawing upon this close working relationship, over a long period of time, Titan continue to work with Vianet on new solutions and offerings as the Vianet customer offering further develops.

This Titan Enterprises application story is based on a report in the Autumn issue of Flowdown, the regular news bulletin published by Trevor Forster, MD of Titan, from their Dorset, UK base.