The value of Specialist Automation Suppliers

Engineers around the world are looking at how to benefit from the various solutions to the IIOT on offer: the article posted on 2 February entitled “How DCS Vendors see their IIOT future” covered the approaches being adopted by some of the major DCS vendors. This follow-up article, written for and first published in South Africa, in the Technews South African Instrumentation & Control Journal, March 2017, covers the approach of some of the smaller, specialist suppliers to their own selected sectors of the process industries.

While the major DCS suppliers try to work out how to provide revenue earning services from the growth of the IIOT, there are many specialist engineering product and systems suppliers who are investing in making their products easier for engineers to use in networks, and operate within the IIOT.

Most of these specialists are primarily focussed on the production of their valves, sensors, controllers or drives: this is their business – and they need their products to work with any interface the customer requires. Their expertise in interfacing their own products is the best available, they have an in-house systems knowledge base and capability. Most now offer this capability to their would-be product users as a service – offering a custom designed system incorporating the products. So look to these suppliers to offer the best engineering at an economic price, within their specialist field.

Typically these single-minded companies were set up by a design engineer with a good original product idea, and this has been developed and refined over the years. Often the company is family owned – and engineering / R&D investment takes precedence over profit distribution. Some such companies still exist in the USA, and a few in the UK, like JCB and Rolls Royce. Several specialist engineering product examples are found in suppliers originating from Germany, Scandinavia and middle Europe, where the culture seems to have encouraged their survival.

Beckhoff Automation

Arnold Beckhoff started his company in 1953: Beckhoff Automation now has a turnover of Euro 620 million, and employs 3350 people. The company implements open automation systems based on PC control technology, scalable from high performance Industrial PCs to mini PLCs, I/O and fieldbus components, plus drive technology and automation software. Supplying systems to many industries, Beckhoff works with and supplies components for over 15 major fieldbus systems. Motion control solutions solve single and multiple axis positioning tasks, and their servomotors offer combined power and feedback over a standard motor cable.

The Beckhoff TwinCAT 3 engineering and control automation software integrates real-time control with PLC, NC and CNC functions in a single package, and then all Beckhoff controllers are programmed using TwinCAT in accordance with IEC 61131-3. While the built-in TwinCAT condition monitoring libraries allow the on-site controllers to monitor the status of the sensors, to reduce downtime and maintenance costs, it also allows wider comparisons with connections to such cloud services as Microsoft Azure or Amazon Web Services. Other data connections are available, for example a smartphone app enables immediate local and mobile display of a machine‘s alarm and status messages.

Bürkert Fluid Control Systems

Bürkert was founded in 1946 by Christian Bürkert: it now has sales of Euro 412 million and employs over 2500 people. The product base is gas and liquid control valves, systems for measuring and controlling gases and liquids, plus sensors for monitoring such fluids, extending to complete automation solutions and fluid systems – this capability is known as their ‘Systemhaus’. While their products are now applied across many industries, their particular specialisations have been in sanitary, sterile and hygienic applications (food, beverage, biotech and pharmaceuticals), micro applications (medical, inkjet and beverage mixing/vending), and water treatment industries.

From the UK operation, Bürkert provide locally engineered solutions and systems for their pharma, food and brewery customers in particular. Locally made craft beers are a major growth area in the UK, and most start small, with no real automation. One example was Stroud Brewery, who needed to expand production by a factor of 5x, and preferably not increase their staff numbers: Bürkert designed a PLC system and intelligent control panel, which automated the temperature control of the cold and hot liquor tanks, and in the mash pan. In addition a system for controlling the run-off rate from the mash tun simply uses three separate Bürkert level sensors.

Bürkert also have developed their own ‘Device Cloud’, they call this ‘mySITE’. This collects data from Bürkert sensors around the world, using an on-site interface known as mxConnect – which can also accept data inputs from other sensors.

National Instruments

National Instruments was only started in 1976, in the USA, by Dr James Truchard and a colleague, who are still involved in the business. Now sales are $1320 million, and they have 7400 employees worldwide. Their declared Mission is to “equip scientists and engineers with systems that accelerate productivity, innovation, and discovery” – and their focus has always been to supply research establishments and engineers with open, software-centric platforms with modular, expandable hardware. This gives its own logistics problems, with 35,000 customers served annually.

It is difficult for me, as an outside observer, to relate the NI systems to an oil refinery or chemical plant application: but it comes into its own when the data handling grows in complexity – for example in pharmaceutical and biotech applications, and the sort of plants where engineers have a major input in monitoring the application. Mention cyclotron or Tokomak, CERN or the Large Hadron Collider, and NI and its LabView are embedded in their engineering control systems. All 108 collimators on the LHC are position controlled using LabView.

National Grid UK, which controls the distribution and transmission of electric power round the country, has adopted a control system based on the NI CompactRIO for the whole network. With many new power generating sources, HVDC connections, variable inputs from solar and wind farms, and the phasing out of major fossil fuelled plants, National Grid found that traditional measurement systems did not offer adequate coverage or response speed to handle these new challenges and risks. They adopted a platform, based on the CompactRIO, to provide more measurements – and also adapt with the evolving grid for generations to come. This interconnected network includes 136 systems, with 110 permanently installed in substations throughout England and Wales and 26 portable units that provide on-the-go spot coverage as needed.  The associated software systems provide their engineers with customized measurement solutions that can be upgraded in the future as new grid modernization challenges arise.

In terms of IoT developments, NI has just opened an Industrial IoT lab at the NI Austin HQ in the USA, to focus on intelligent systems that connect operational technology, information technology and the companies working on these systems. Many other companies are co-operating in this venture, like Cisco and SparkCognition, and the lab intends to foster such collaboration to improve overall interoperability. In addition NI has partnered with IBM and SparkCognition to collaborate on a condition monitoring and predictive maintenance testbed: this will use the SparkCognition cognitive analytics to proactively avoid unplanned equipment fatigue and failure of critical assets.

(c) Nick Denbow 2017

How DCS Vendors see their IIOT future

Engineers around the world are looking at how to benefit from various IIOT offerings: the survey below covering the approaches being adopted by some of the major DCS vendors was first published in South Africa, in the Technews South African Instrumentation & Control Journal, February 2017. Next month a similar article will cover the approach of some of the specialist suppliers to the process industries.

The last year saw all the major DCS and process control systems suppliers re-assess their business positioning, in the face of the turndown in capital spending as a result of the continuing recession and fall in commodity prices, led by oil. Their problem is that their main business cycles between feast and famine, as it is dependent on investment project business. Harry Forbes of ARC Advisory Group notes that automation companies will do nearly anything to protect their installed user base, because that’s where they believe future revenues will come, and come more easily than winning projects. So the way to survive the famine is to provide on-going services to these asset owners, to maintain the business relationship, and be better positioned when capital investment returns. Plus they stop competitive suppliers gaining a foothold via similar service contracts.

The current area of interest for most manufacturing plants is IIOT, and so the automation vendors have been focusing on this, plus Big Data and analytics, offered by remote ‘cloud-based’ services. The different suppliers come from different market positions, and so their approaches, while offering the same, are tailored in different ways.

Emerson Automation Solutions

Peter Zornio of Emerson expressed his very clear view of this market back in April at their Global User’s Exchange in Brussels. Emerson is involved in the IIOT: this does not include the ‘Smart Cities’ that Siemens and ABB talk about, nor Industrie 4.0, which extends from production back up into design concepts – IIOT is just ‘Manufacturing’. I believe Emerson also recognise that their process control systems cannot be a part of IIOT, they must be fenced off, with firewalls etc, to prevent cyber-security worries, and blocked from external inputs. But this does not stop them transmitting information outwards, and the whole Emerson approach of ‘Pervasive Sensors’ – their major new topic for 2015 – is now an important feed, into IIOT analytics.

The resulting offering is a cloud-based service developed in co-operation with MicroSoft, using their Azure IoT Suite of cloud services. Having worked with MicroSoft for over 20 years, their Windows 10 IoT technology will be incorporated into both the DeltaV and Ovation control systems and in data gateways to serve plant data to the Azure IoT Suite. Emerson will then provide the data analysis services that feed back information and recommendations to the relevant plant personnel, for example about plant performance or equipment maintenance. Zornio described this as a remote service similar to the ‘Monitoring Centre’ typical of the electricity generation industry, or the ‘iOps centre’ typically described in the oil and gas industry – which shows the areas of focus for the Emerson control system business.

Since then, Emerson restructured their widely separated divisions, Process Management and Industrial Automation, into one business, Emerson Automation Solutions, under newly appointed president Michael Train. This brings in some of the factory automation aspects covered by the old Industrial Automation Division, and extends the potential for the same IIOT monitoring into other areas of the manufacturing plant, such as power supplies, packaging and even discrete manufacturing. However, as part of their restructuring, Emerson has sold off significant parts of what was their Industrial Automation business, bringing in significant amounts of cash. In December the Network Power business, serving mainly data centre and telecommunications customers, was sold to Platinum Equity for $4Bn: the business will be rebranded ‘Vertiv’. Then, just this month, the deal to sell the alternators, drives and motors businesses known as Leroy-Somer (France) and Control Techniques (UK) to the Nidec Corporation was finalised: their combined annual sales were $1.7Bn, but of more relevance now to Emerson, the resulting cash payment received from Nidec is $1.2Bn. So Emerson Automation Solutions has probably earmarked part at least of that $5.2Bn of cash for some interesting, relevant acquisitions, maybe in this IIOT services area.

Rockwell Automation

Rockwell Automation has a totally different customer profile, perhaps the reverse of that described for Emerson, having great strength in factory automation, food processing and discrete process control in general. Their product portfolio is strong on motor control, actuators, energy management etc, using Ethernet based systems and controllers, which give simple interfaces to remote data systems. Steven Meyer of SAIC reported that the Rockwell South African MD Barry Elliot commented at the Electra Mining Show that the challenge is ‘to do more with the assets the organisation already owns’. He added that “In most cases the data already exists: our challenge is to implement systems that enable us to turn this into actionable information to streamline productivity and efficiency”. Just what the customer audience wanted to hear.

In November Rockwell launched their ‘FactoryTalk Analytics for Machines’ cloud application, based on – the MicroSoft Azure cloud enabled capability – yes, them again! OEMs using Rockwell/Allen Bradley controllers on their machinery can embed a FactoryTalk Cloud gateway device, to interface to this Rockwell remote analytical service.  Back at corporate level, the new Rockwell CEO is Blake Moret, and his attention is also on developing the oil and gas process systems business that was actually doing well in Rockwell, but is smaller than that of rivals like Emerson: so he has acquired Maverick Technologies, one of their system integrator customers. First this give Rockwell access to the Maverick five years of experience in supplying remote operations support as a service. Second, Walt Boyes of the Industrial Automation Insider has pointed out that Maverick has craftily recruited many otherwise retiring process experts from such companies as Dow, DuPont, ExxonMobil and other first tier companies, amassing a couple of hundred very valuable grey heads with continuous process management expertise. These are very useful for remote service support and advice, supplied even from their retirement homes!

ABB and IoTSP

Maybe ABB will have an alternative approach? ABB has a concept described as the Internet of Things, Services and People (IoTSP). They last year joined the Steering Committee of the Industrial Internet Consortium, an organisation founded by AT&T, Cisco, General Electric, IBM, and Intel in 2014. Then in September they recruited Guido Jouret as their ‘Chief Digital Officer’ – he was at one time the General Manager of the Cisco ‘Internet of Things’ division. October, however, brought them back into line with Rockwell and Emerson, when their new ABB Ability offering was announced as standardised on MicroSoft Azure, “expanding the ABB leadership in energy and the fourth industrial revolution”: ABB will take “full advantage of Azure services such as Azure IoT Suite and Cortana Intelligence Suite to capitalise on insights gathered at every level from device, to system, to enterprise, to cloud”. Although ABB say they have had many years of successful collaboration with MicroSoft, from the website it appears Ability is a new venture – looking for applications in transport infra-structure, digital power substations, fleet management services, Smart buildings etc.

Yokogawa

Yokogawa started 2016 with two acquisitions, first ‘Data-as-a-Service’ provider Industrial Evolution Inc, who provide cloud-based plant data sharing services, followed by KBC Technologies, who specialise in offering oil and petrochemical production plants the advanced software needed for process optimisation and simulation. These two were combined to create their new Industrial Knowledge Division. Executive vp Satoru Kurosu commented that “Key strategic objectives of Yokogawa’s Transformation 2017 plan are to expand the solution service business, focus on customers, and co-create new value with customers through innovative technologies and services”.

They then followed up with a strategic investment in FogHorn Systems Inc, a Silicon Valley specialist in fog computing – said to be the solution to faster processing of IIOT data present in the cloud. At the year-end, Yokogawa made a further significant investment into IIOT technology, first with a $900k investment into Bayshore Networks, who specialise in cybersecurity, and have developed the Bayshore IT/OT Gateway for use in the cloud, separating IT Departments from OT (Operational Technology) infrastructure networks. More than that, Yokogawa announced the establishment of a new Architecture Development Division in California, to pursue the development of the core technologies needed to establish the robust and flexible architecture required to improve operational efficiency and productivity when using the IIoT. Their aim is to expand this US engineering centre to over 50 staff in the next five years.

In February 2017 Yokogawa published their own release describing how these businesses will work together, and introducing another co-operation with Telit IoT Platfoms LLC, who are said to offer “offers unmatched expertise, resources, and support to make IoT on-boarding easy – reducing risk, time to market, complexity, and costs for asset tracking, remote monitoring and control, telematics, industrial automation, and predictive maintenance across many industries and vertical markets worldwide”. The most interesting aspect of their approach is that they seem to be moving towards “Plug-and-play” technology expanding to enable sensors to automatically join and adapt to plant networks, plus cloud reporting and condition monitoring, making the plant engineer’s job a lot simpler!

Obviously Yokogawa have major ambitions to develop and offer IIOT cloud data services with the best in technology and cybersecurity, all with a reduced customer detailed input.

Developments in South Africa

With so many major suppliers stepping up to offer cloud based IIOT data analysis and reporting services, what do the plant managers do? Steven Meyer’s report on the recent conference on the topic organised by the African branch of the Manufacturing Enterprise Solutions Association highlighted the recent PricewaterhouseCoopers report showing that South African companies plan to spend around R6Bn per year, until 2020, to implement the ideas of the fourth industrial revolution. In a keynote speech, local PwC director Pieter Theron made the telling comment that companies will need to find the right collaboration partners in order to improve their business efficiency through the technologies of the fourth industrial era – very few have the capability to go it alone.

These comments ring true for many large businesses all around the World: and it is clear that there are several interesting potential partners for these potential IIOT users to evaluate!

Yokogawa IIOT Collaboration plans

The following Yokogawa Press release announces that for future IIOT developments Yokogawa will work with Microsoft Corporation, FogHorn Systems Inc, Bayshore Networks Inc and Telit IoT Platforms LLC, to integrate their technology into an industrial IoT (IIoT) architecture for the delivery of new services. With this architecture, Yokogawa aims to transform its business model, expand its business scope, and help its customers run their businesses more efficiently.

Outline of the Tie-up

IIoT technology is now ready for practical use thanks to advances in network technology, the availability of low-cost, large-capacity data communications, and the shifting of corporate information systems to the cloud. However, the use of IIoT technology presents many technical challenges in such areas as sensing, automation, and security, and it is also costly to build such systems and develop the necessary applications. With its wide range of expertise in fields ranging from sensor technology to control logic and applications technology, Yokogawa will be able to help its customers address issues they face in their business by providing end-to-end solutions that incorporate sensing, control, and cloud-based processing.

Through this architecture, business process applications can be configured to enable the use of “plug-and-play” sensors, by providing the ability to automatically detect sensors and other instruments connected to the network, make appropriate settings enabling them to work immediately, sensing clouds with automatic provisioning for the efficient utilisation of cloud platforms to detect and connect sensors and other devices to the cloud and dynamically making the necessary changes for the exchange of data, database clouds, historian (data storage) clouds, and application development environments to work together. These four companies each possess technologies that will be key components of this IIoT architecture.

This undertaking will be led by the Yokogawa Architecture Development Division, based in California, which was set up in November 2016. Yokogawa’s IIoT architecture will integrate the cloud-based Microsoft Azure IoT Suite, FogHorn’s fog computing software, Bayshore’s layer 7 security technology which operates at the application (top) layer in the open systems OSI reference model, and Telit’s communication modules, sensor on-boarding, and device management.

Regarding this business tie-up, Tsuyoshi Abe, a Yokogawa vice president and head of the Marketing Headquarters, commented as follows:

Yokogawa has drawn up a long-term business framework and formulated a vision statement that reads, “Through ‘Process Co-Innovation,’ Yokogawa creates new value with our clients for a brighter future.” The IIoT architecture that Yokogawa will develop under this agreement will revolutionise the way in which value is delivered in sensing and plant information management. By working with these four companies, Yokogawa will rapidly establish its IIoT architecture. Under the corporate brand slogan of “Co-innovating tomorrow,” we will seek to expand partnerships such as these with leaders in each industry.

The Four Companies and their Technologies

– Microsoft Corporation

Microsoft is a worldwide leader in software, services, devices and solutions that help people and businesses realise their full potential. The cloud-based Microsoft Azure IoT Suite platform, which provides businesses with globally scalable, preconfigured IoT solutions, will enable Yokogawa to connect their devices, analyse previously-untapped data, and integrate business systems. The Azure IoT Suite provides the functions required for the construction and utilization of Yokogawa’s IIoT architecture.

– FogHorn Systems Inc

FogHorn Systems is a Silicon Valley-based startup that has been deeply involved in developing core software for fog computing and owns advanced technology in this field. Yokogawa invested in the company in July 2016. Fog computing is an architectural concept designed to avoid communication congestion by establishing a “fog” distributed computing layer between the cloud and devices in the field. Fog computing eliminates communication delays and fluctuations by locating the processing of certain data near the field devices and sending only essential information to the cloud. This technology is expected to lead to a number of new IoT applications.

– Bayshore Networks Inc

Founded in 2012 and headquartered in the Washington D.C. metropolitan area, Bayshore develops industrial cybersecurity solutions offering visibility, control, and protection for operational technology infrastructure and applications. The firm has a number of strategic partners in the IT sector and has gained a reputation for its expertise in IIoT cybersecurity. Yokogawa invested in this company in November 2016.

– Telit IoT Platforms LLC

Telit is a leading enabler of end-to-end IoT solutions. The company offers the industry’s broadest portfolio of integrated IoT products and services, including cellular communication modules, IoT connectivity plans, and IoT platform services. As a pure-play IoT company for over 15 years, Telit offers unmatched expertise, resources, and support to make IoT onboarding easy – reducing risk, time to market, complexity, and costs for asset tracking, remote monitoring and control, telematics, industrial automation, and predictive maintenance across many industries and vertical markets worldwide.

For Editorial comment, see the next article about DCS vendors and their IIOT plans….

Yokogawa invests in IIOT cybersecurity

Yokogawa has made some significant investments in the resources needed to develop future techniques for IIOT cybersecurity, first with a new engineering centre to be established in California, and second, by investing US$900,000 into Bayshore Networks, as a partner in a current round of venture capital funding.

New IIOT Division

The new Yokogawa Architecture Development Division in California will pursue the development of the core technologies needed to establish the robust and flexible architecture required to improve operational efficiency and productivity when using the IIoT. The new division will function as a unit of the Yokogawa Marketing Headquarters Business Development Centre, and will keep up with the new technologies being developed every day in the IIoT sector – as well as facilitate close co-ordination with partner companies. The West Coast of the USA is therefore the correct location for this work. The division will be staffed by engineers from Yokogawa who have an extensive knowledge of Yokogawa systems and services, and locally recruited engineers who are conversant in a range of IT fields. The first employees of the division have been located at the local engineering office of a partner company since November 2016, but their own offices are scheduled to open in April 2017. Subsequently, the division will add functions for planning services that use the IIoT and cloud computing, and it is expected that the number of staff will be increased to around 50 over the next five years.

Investment in Bayshore

A parallel press release from Yokogawa explains that there has also been a $900k strategic equity investment into Bayshore Networks, a company established in 2012 that has gained rapid recognition for its expertise in cybersecurity.

Mike Dager, CEO of Bayshore, commented “Yokogawa shares our vision for a secure industrial internet of things enabling new applications that will increase safety, optimize processes, and drive efficiencies. We are proud and excited to partner with such a renowned global leader in industrial controls.”

This Yokogawa investment is part of the recent US$6.6M Series A funding for Bayshore, arranged by Trident Capital Cybersecurity, and its existing angel investors.

Trident Capital

Trident Capital Cybersecurity is a venture capital firm that invests in early-stage companies leveraging emerging technologies in cybersecurity. The firm is a spinout of (or maybe the successor to) Trident Capital, which in 1998 became one of the pioneers of cybersecurity venture capital investing. Renowned as the venture capital firm with the most valuable network of cybersecurity relationships, Trident Capital Cybersecurity also relies on input from a 40–person Cybersecurity Advisory Council, consisting of industry CEOs, customers and former top-level government leaders.

“We led the Series A Investment because Bayshore has been recognized as an innovator and early leader in an emerging cybersecurity segment that is largely untapped to date,” said J. Alberto Yépez, managing director of Trident Capital Cybersecurity. “We are honoured to have Yokogawa join us in supporting the development of the cutting-edge Bayshore technology and business.”

The Trident Capital Cybersecurity website claims 28 cybersecurity investments and 16 successful exits. These have included the Solera acquisition by BlueCoat in 2013, the Qualys IPO in 2012, the acquisition of Accertify by American Express in 2010, the Sygate acquisition by Symantec in 2006 and the Signio acquisition by VeriSign in 2000.

The Bayshore technology

The Bayshore cloud-based software, called the Bayshore IT/OT Gateway, provides IT departments with visibility into OT (Operational Technology) infrastructure, networks, applications, machines and workers.  These OT networks are undergoing transformation and require services traditionally available for IT networks, such as secure remote access and analytics. Bayshore provides immediate value by preventing OT process disruptions and enhancing operational efficiency and business continuity.   The software is distinguished by extremely granular inspection and filtering of network flows – all the way down to machine sensor values – and the ability to provide security enforcement and application segmentation and isolation via flexible, rapidly deployed policies.  The Bayshore policy engine is capable of supporting common industrial protocols and quickly adapting to new and proprietary protocols.

These capabilities are built from the ground up for Industrial Internet and provide Bayshore customers with future-proof, cloud-based solutions that are complementary to legacy hardware-based industrial firewalls. Designed for IT perimeter security, firewalls look for IP addresses and ports, which means they block attacks according to standard Internet parameters.  Because industrial cyber-attacks are typically based on granular machine instructions that alter sensor values, the unique Bayshore technology is well positioned to detect industrial attacks that are often overlooked by other security technologies.

Bayshore has strategic alliances with leading technology companies including AT&T, BAE Systems, Cisco Systems, and VMware. It is currently based in New York, but intends to relocate the HQ to Bethesda, Maryland. No engineering base is quoted as existing in California.

2017 Business plan comes together

satoru-kurosu-med

Earlier, Yokogawa had announced the completion of the acquisition of Soteica Visual Mesa (SVM), the leading energy management technology provider, which will be integrated into KBC Advanced Technologies (acquired in April 2016) alongside “Data as a Service” (DaaS) provider Industrial Knowledge (acquired December 2015). Satoru Kurosu, executive vice president and head of Yokogawa’s Solutions Service Business Headquarters, commented that these moves delivered on a number of the key objectives of the Yokogawa Transformation 2017 mid-term business plan: “Key strategic objectives of Yokogawa’s Transformation 2017 plan are to expand the solution service business, focus on customers, and co-create new value with customers through innovative technologies and services.”

(c) ProcessingTalk

Alfa Laval sees marine market growth in ballast and SOx

Readers of this blog will recall the Alfa Laval launch on their “PureBallast” water treatment system for marine vessels way back in 2007. The IMO international convention for the ‘control and management of ship’s ballast water and sediments’ was the legislation that would drive the adoption of such systems world-wide: at last this convention became legally binding on shipping and ship-owners worldwide on 8th September 2016. Inevitably there is a 12 month time lag before it will be legally enforced, and then, hopefully, tankers will not be allowed to ply their trade without having an approved ballast water treatment system fitted.

Ballast water treatment market

Peter Leifland, current president of the Marine & Diesel Division of Alfa Laval presented some interesting views of this market in support of the recent Alfa Laval Capital markets Day presentation to analysts and stockbrokers.

Leifland commented that “With the ratification in place, the market for retrofit installations is expected to start to move.”  Alfa Laval expects that 35 000 ships will install a ballast water treatment system between 2017 and 2025. This is split between 15 000 newly built ships and 20 000 retrofit installations. The average order value per ship for the Alfa Laval chemical-free solution is EUR 200,000 – 225,000.

The Alfa Laval system fully complies with IMO standards and requirements, but as ever different countries can impose further approval and performance requirements and testing, effectively policing their own waters so that only ships with their approved systems can trade in their waters. This means more approval testing, fees, and even design changes for suppliers like Alfa Laval. They have their PureBallast system nearing completion of the long testing procedure needed by the US Coast Guard to check that it meets with their USCG criteria.

Shipboard sulphur oxide emissions (SOx)

The IMO convention for the reduction of sulphur oxides (SOx) emissions from ships has been ratified and since 2015 it has been implemented in some Emission Control Areas (ECAs). This IMO regulation will become global by 2020, requiring that that emission levels will be cut to 0.5%.

Leifland commented that Alfa Laval estimates that 5 000 ships, new as well as existing, will install a scrubber solution in the period 2017-2025.” Given the continuing development of new solutions, Alfa Laval’s average order value per ship is expected to be EUR 1 million. Leifland sees these two developing markets as a useful opportunity, during a period where “falling ship contracting is impacting our order intake”.

Postscript 27 December 2016: 

Alfa Laval PureBallast 3 receives U.S. Coast Guard type approval

Peter Leifland, President of the Marine & Diesel division in Alfa Laval, reports that:

“I am very pleased to receive this type approval, as it confirms the reliable performance of our ballast water treatment system. We now have a system approved by both US Coast Guard and the International Maritime Organization”.

Alfa Laval PureBallast 3 has received US Coast Guard type approval for usage in all water salinities, including fresh water. It follows upon two and a half years of compliance testing, according to the strict demands of the Environmental Protection Agency’s “Environmental Technology Verification” (EPA ETV) testing protocol. The tests were performed at DHI’s test facilities in Denmark, supervised by DNV GL as the independent inspection laboratory.

 

2M EM Flowmeters in 40 years

Since 1977, Endress+Hauser has produced over two million electromagnetic flowmeters. The company claim this is more than any other manufacturer, and that E+H is the market leader in electromagnetic flowmeter technology. “This magic number stands for high-quality measuring technology and, above all, satisfied customers in all kinds of industries,” says Bernd-Josef Schäfer, Managing Director of Endress+Hauser Flowtec AG, the center of competence for flow measuring technology.

The Endress+Hauser success story as a manufacturer of electromagnetic flowmeters began in the middle of the 1970s. In order to enter the water and wastewater market which was emerging at that time, E+H purchased the company ‘Flowtec’ in Bern, in 1977, and moved it to a new location in Reinach (Basel-Landschaft, Switzerland). This is where Endress+Hauser started to produce flowmeters with just three employees, in a former military barracks.

EH_MID_01

The 1977 production unit at Reinach

Then, work was done on an on-demand basis. “Whereas today,” says Bernd-Josef Schäfer, “our production spans six sites around the globe – in Switzerland, France, the USA, China, India, and Brazil – and boasts state-of-the-art logistics. This infrastructure is what has enabled us to produce two million electromagnetic flowmeters to date in accordance with required quality standards.” These two million electromagnetic flowmeters could measure a volume corresponding to four times the flow rate of the Amazon. Each production site also features precise calibration facilities which are regularly checked by national accreditation bodies and which guarantee consistently high measuring quality for each individual device.

Constant innovation for customer satisfaction

The company’s success, which spans almost 40 years, is due to many factors. In particular, its inventive talent has enabled Endress+Hauser to keep offering its customers new, groundbreaking devices capable of measuring all kinds of fluids, such as water, milk, acids, alkalis, or ore slurry, with the greatest accuracy. With clever innovations such as the precision measurement of difficult fluids (Autozero, 1981), microprocessor control (Variomag, 1984), two-wire technology (Eximag, 1987), or the operating matrix (Tecmag, 1990), Endress+Hauser has always managed to stay one step ahead of the competition.

EH_MID_03

In 1985, 800 and 2000mm bore flowmeters were produced for monitoring drinking water supplies delivered around Algiers

In 1993, all of these device variants were brought together to form a single product family under the name of “Proline”. Alongside this family, however, Endress+Hauser also produces flowmeters for very particular applications – for example, filling bottles at one-second intervals.

Looking to the future with Proline

Since 1993, the Proline device family has undergone constant development to ensure that it meets the prevailing requirements in a wide range of industries. Following the second generation launched in 2000, the third and most recent Proline generation (2012) offers a multitude of unique functions and device properties. This means that system operators will not only be able to retrieve measurement and diagnostic data via display, WLAN, web server, or fieldbus, but will also be able to monitor the process comprehensively and, if necessary, check the functioning of a flowmeter during operation.

EH_MID_04

One modern production line for Proline electronics units

Bernd-Josef Schäfer sees the future of Endress+Hauser optimistically: “Innovations such as these enable us to align our product portfolio consistently with the needs of every industry. We are looking ahead to our three-millionth electromagnetic flowmeter with great confidence.”

This E+H release was first published by Eoin O’Riain in Read-out.net in Ireland

Emerson shows off their latest instruments

The Emerson European Exchange User Meeting in Brussels in April 2016 presented their approach to large automation projects, ‘Project Certainty’, as the main thrust of the conference and press event associated with the meeting. This approach will be reported separately: this view of the instrumentation developments on show was the topic of my column about this event, published in the SA I&C Journal in June 2016. The story is shown below.

The Emerson European Exchange

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Maybe half the audience for the first Emerson presentations

The Emerson ‘Global User’s Exchange’, for their customers and potential customers in Europe, Middle East and Africa, was held in Brussels in April. As with all the leading Automation, Control and Instrumentation suppliers in the world, Emerson Process Management has developed this style of single company Expo, because it is difficult to present their whole product range and capability in any commercial, third party exhibition: there would not be enough space. Indeed even in their own dedicated display hall, not all their product capability was on show.

The same is true of the presentations and keynote speeches. The Emerson business is so big, based on large automation projects, that these have to be the main focus of the management comments. The fascinating detailed product and technology developments in temperature, analytical or corrosion instrumentation also on show, did not get top billing, but they were there, in the background.

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I have to declare that I need to understand a product or technology to become enthusiastic about it, and in general I have found instrumentation easier to understand than automation software. Emerson has always put an emphasis on instrumentation, and invested in this by developing or acquiring innovative new techniques and companies in the area – moreso than most of the other majors. Then by adding their own knowledge power, they add interfaces and capability, such as HART and Wireless communications, manufacturing technology, housings and mods for industry-wide approvals. So I am an Emerson fan. But because technology grows, it does become harder to understand the way these instruments actually work! For me, a visit to the Emerson Expo is like opening a treasure chest, filled with ideas and enthusiastic people available to explain their latest kit.

Wireless interfaces link everything

The Emerson dedication to WirelessHART communications with all instrumentation, as a standard option, opens up the possibility of adding modern technology sensors into existing plant and processes without the major hassles of adding new cables.

Emerson 12-3-1550855bRosemount temperature sensors have had a wireless capability from ‘Day 1’ of the wireless era: and various companies made such wireless sensors capable of being clamped or strapped to the outside surface of a pipe, to make them totally non-intrusive, and easily re-positioned. The Rosemount engineers have gone one step further, recognizing the measurement errors possible with an external sensor affected by the environment. They have developed X-well technology, available with a clamp for pipe ODs between 0.5” and 48”, which incorporates a layer of thermal insulation 13mm thick and covering a 12” length of the pipe (this is not shown in the picture). All this helps to bring the temperature sensor measurement closer to the actual pipe contents temperature, but in addition the electronics senses the ambient temperature, and uses a thermal conductivity algorithm to make a further correction, before transmitting the data over the wireless link.

WirelessPressureGaugeSimilarly, Rosemount lateral thinking has applied wireless technology and piezo-resistive pressure measurement to the pressure gauge. This modern design of an ancient instrument replaces the original Bourdon tube measurement element with a modern sensor capsule, which uses the battery power to drive a needle around a 270 degree scale on a 4.5” indicator. Then the WirelessHART connection transmits the actual process pressure to a central monitoring system. This new indicator gauge is much safer than the old design – with two layers of process isolation from the gauge body it can withstand a 150x overpressure, and is much less affected by plant vibration.

Emissions Monitoring

One of the most advanced product ranges demonstrated in Brussels came from Cascade Technologies, of Stirling in Scotland, which was acquired for Rosemount Analytical at the end of 2014. Cascade have developed some clever laser based systems for gas analysis, for example for Continuous Emissions Monitoring (CEM) systems, which allows them to measure for multiple gas types simultaneously. In the words of one of the experts they effectively have up to 9 lasers operating at different frequencies in one analyser, enabling monitoring for a similar number of gas concentrations. Similar systems have been used to monitor up to a total of 20 gases simultaneously. Their enthusiastic engineers were saying that following the Emerson involvement in the company they would be launching four new products this year – in fact the next one of these was reported on here, in a ProcessingTalk.info review, last month!

Enardo_950_w-bracketAnother essential, but older, safety and emissions monitoring product range has been updated by the addition of an Emerson WirelessHART data link. In 2013, Emerson acquired Enardo, a Tulsa-based manufacturer of mechanically operated pressure and vacuum relief valves, which are used to protect storage tanks for oil/gas, petrochemical and pharma plants – Enardo is now part of the Fisher Regulators business. These valves relieve the tank vapour pressure when the tank is filled, or the temperature rises, or allow air to enter as the tank is emptied, preventing any pressure damage to the tank walls. But safety concerns and modern emission regulations require the valve actions to be monitored: and with no existing wiring installed to transmit such signals, the WirelessHART systems provide a simple solution.

Corrosion monitoring

It was way back in 2009 when Emerson acquired Roxar of Norway, who then specialised in systems for monitoring offshore wells and oil pipelines. The technology involved in the Roxar sensors has developed a long way: they don’t just use ultrasonic detectors to measure the sound of sand and grit hitting the pipe walls! The ER corrosion sensors use a probe with a thin, exposed electrical conductor embedded in an insulator, inserted in the pipe wall. Corrosion of this element changes the resistance of the conducting path, which is monitored. Various designs are available, to adjust the sensitivity of the sensor. LPR probes are Linear Polarisation Resistance probes, which are electrochemical, so require the presence of a conductive liquid, like water, to function. The current response achieved when a small (10-20mV) known polarisation is applied between the electrodes exposed to the liquid, gives the corrosion rate, using electrochemical theory. These Roxar sensors with their CorrLog electronics are now available with WirelessHART communications, making them much easier to apply to any pipework area that is considered at risk from corrosion – and for modern plants using different sources and compositions of feedstock, the corrosion rates can vary significantly from one batch to the next.

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