Emerson invests $100m in new flow research centre

Emerson is to invest more than $100 million in Boulder, Colorado, to significantly expand manufacturing space, and create a new innovation centre focused on research, new product development and industry training for its advanced flow measurement products.

David N. Farr, chairman and chief executive of Emerson commented: “This US investment significantly expands our ability to serve as industry leaders, helping customers in essential industries optimise their operations with the latest technologies. Our new facility demonstrates our continued commitment to customer-driven innovation and high-tech manufacturing, as well as our focus on attracting the best and brightest talent to work for Emerson.”

Emerson is recognised globally for its advanced flow measurement technologies and diagnostics that help leading global customers in the life sciences, food and beverage, chemical, power and energy industries. The new innovation centre will drive innovation and new product development to enable customers in these critical industries to realise performance improvements in production, reliability, safety and sustainability.

“As an entrepreneur, I saw first-hand how Colorado’s talent and market strengths can fuel innovation,” said

Colorado Gov. Jared Polis commented: “As an entrepreneur, I saw first-hand how the talent and market strengths in Solorado can fuel innovation. This investment in Coloradans and our state is a bold statement about our economic power and the bright opportunities that lie ahead.”

Artist’s impression of the new Emerson facility in Boulder

The nearly 180,000 square foot (16,700 square metres) expansion includes a new, 85,000 sq ft (7,900 sq m) laboratory, and a manufacturing facility to design and develop products, technologies and software that measure and control the flow of material in any manufacturing process.

The facility will offer a hands-on Interactive Plant Environment that simulates real-world industrial manufacturing conditions for worker training and upskilling to help reshape the future workforce. This ‘experiential’ training facility will provide Emerson customers with hands-on access to the most advanced products and technologies, including flow, temperature, level, pressure and wireless instrumentation, valves and regulators, as well as Emerson’s leading control systems and Plantweb digital ecosystem. Emerson’s flow measurement portfolio includes Coriolis, magnetic, vortex, multiphase, differential pressure and ultrasonic meters – meters that show the Micro Motion, Rosemount, Roxar and Daniel brands.

The new factory complex will have charging stations for electric vehicles and bicycle parking areas, plus include green landscaping, energy efficiency and water conservation programmes. Work is expected to commence on site in spring 2020.

Emerson currently has 630 employees in Boulder, which is the home of its Micro Motion business. Micro Motion was founded in 1977 as one of Boulder’s earliest start-ups and invented the first Coriolis flow meter. Emerson acquired Micro Motion in 1984 and has continued to invest in design, engineering and attracting technical talent.

Last year, Emerson announced a collaboration with Colorado State University to build the Emerson Brewing Innovation Centre, where students get hands-on experience using the latest automation technologies.

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

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.

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.

Rosemount 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.

Similarly, 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!

Another 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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Hybrid Laser Continuous Gas Analyser

Emerson has announced the release of the Rosemount CT5100 continuous gas analyser, the world’s only hybrid analyser to combine Tunable Diode Laser (TDL) and Quantum Cascade Laser (QCL) measurement technologies for process gas analysis and emissions monitoring. The CT5100 is the latest offering in the Emerson CT5000 series, providing the most comprehensive analysis available as it can detect down to sub ppm level for a range of components, while simplifying operation and significantly reducing costs. Unlike traditional continuous gas analysers, the CT5100 can measure up to 12 critical component gases and potential pollutants simultaneously within a single system – meeting local, national, and international regulatory requirements.

The CT5100 was first shown at the Emerson European Exchange in Brussels, last month, and is one of several new developments to be launched this year, following the acquisition of the company Cascade Technologies, of Stirling in Scotland in December 2014.

The CT5100 operates reliably with no consumables, no in-field enclosure, and a simplified sampling system that does not require any gas conditioning to remove moisture. The new gas analyser is ideally suited for process gas analysis, continuous emissions monitoring, and ammonia slip applications.

“The increase in regulatory requirements worldwide, along with the decrease in experienced personnel in industrial plants, have paved the way for the emergence of a new generation of faster, more accurate, and easier-to-use measurement technologies,” said Ruth Lindley, product manager for QCL analysers at Emerson. “The CT5100 represents an important next step in that direction, providing unmatched sub-second response time for precise, reliable measurement of complex gases and emissions to ensure regulatory compliance and prevent costly fines or unexpected shutdowns.”

The CT5100 is a unique combination of advanced technology, high reliability, and rugged design. Its ‘laser chirp’ technique expands gas analysis in both the near- and mid-infrared range, enhancing process insight, improving overall gas analysis sensitivity and selectivity, removing cross interference, and reducing response time. The laser chirp technique produces sharp, well-defined peaks from high resolution spectroscopy that enable specificity of identified components with minimum interference and without filtration, reference cells, or chemometric manipulations.

“The CT5100 modular design and patented ability to chirp up to six lasers in one enclosure provides greatly expanded measurement capability as well as superior analyser availability and lower maintenance costs,” said Dave McMillen, North America business development manager. “Start-up and commissioning is quick and maintaining the analyser requires minimal technician time and material cost.”

For more information on the CT5100 analyser, go to www.EmersonProcess.com/GasAnalysis/QCL. Surprisingly, the CT5100 replaces the older CT5200 model, which is now made obsolete.

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Emerson Enardo relief valves get WirelessHART communications

Emerson acquired Enardo, a manufacturer of pressure and vacuum relief valves based in Tulsa, Oklahoma, in late 2013. This week saw the launch of a new wireless enabled version of the Enardo pressure and vacuum relief and safety valve used on storage tanks in the oil and gas, petrochemical and pharmaceutical industries.

By adding the Smart Wireless monitoring system operating over the Emerson WirelessHART network, the safety valves, normally located on the top of large storage tanks, can easily signal to operators in the control room that they have been triggered to either relieve a pressure or vacuum condition. Such situations can arise as a result of changes in temperature, liquid level, or both, and relief valves are essential to prevent tank over or under-pressure conditions that could lead to structural failure. Enardo pipe-away, vent-to-atmosphere, in-line and end-of-line relief valves are typically installed on storage tanks to control evaporation and fugitive emission losses that result from flammable and hazardous petroleum vapour-producing products. Knowledge of the actuation of such a safety valve enables an immediate response, where needed, to prevent problems which can be related to safety, emissions, and the quality of a tank’s content.

Steve Attri, product manager at Emerson for the Enardo valves, commented: “Until now, PVRVs have remained un-monitored, with none of the feedback loops commonly seen in other pressure control devices. As the tank’s primary pressure control device, this wirelessly-monitored solution can be invaluable.”

Enardo manufactures tank and terminal safety equipment, including hatches, vent, pressure and vacuum relief valves and flame arrestors used in the oil and gas, petrochemical, chemical and other industries. Enardo in-line and stack vent valves have been the oilfield industry standard for more than 80 years.

Prior to the acquisition by Emerson, Enardo had sales of $65m a year, and employed 140 people. It now operates within the Regulator Technologies business, previously known as Fisher Regulators, within Emerson Process Management.

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Emerson acquires Spectrex

Emerson Process Management has announced the acquisition of Spectrex Inc, a leading US-based manufacturer of flame and open path gas detectors. With this addition, Emerson will have the most comprehensive line of flame, gas and ultrasonic leak detector solutions used for safety monitoring in the industry.

Spectrex will join the Rosemount portfolio of measurement and analytical technologies, joining the capabilities already available with the gas leak detection systems acquired in Groveley Detection (nickdenbow.wordpress.com/2013/06/24/1345/) in June 2013.

For nearly 34 years, Spectrex has been the leader in flame and open path gas detection. It developed the world’s first ultraviolet-infrared (UV/IR) and triple infrared (IR3) flame detectors and was first to introduce xenon flash lamps in open path detector design, increasing detectors’ resilience to atmospheric conditions while reducing power consumption. These innovative advancements in safety monitoring provide a powerful solution for customers in the oil and gas, petrochemical, chemical and power industries.

“We are very excited about adding the Spectrex product line to our flame and gas detection portfolio,” said Tom Moser, group vice president of Emerson Process Management’s measurement and analytical technologies. “Emerson is committed to helping our customers protect their employees, facilities, and the environment, and we are now better positioned to serve that need.”

Spectrex and its staff are located in Cedar Grove, New Jersey, with sales and technical support offices in Houston, the United Kingdom and Taiwan.

Editor’s note: I tried to launch the UK sales of the first UV/IR detection system ever developed (so I was told at the time) which was made by Armtec in New Hampshire. That was in about 1983. Maybe Spectrex bought up Armtec? All inputs will be welcomed!

Emerson acquires Cascade Technologies

The acquisition is intended to expand Emerson’s gas analysis portfolio, adding laser-based measurement analysers and systems for enhanced industrial emissions monitoring, production efficiencies and regulatory compliance.

Emerson has announced that it has acquired Cascade Technologies Ltd, based in Stirling in Scotland, UK, a leading manufacturer of gas analysers and monitoring systems using their Quantum Cascade Laser (QCL) technology. This innovative technology measures multiple gases simultaneously, helping companies improve industrial emissions monitoring, production efficiencies and environmental compliance.

Emerson is expanding its analytical measurement capabilities by adding this innovative laser technology to its Rosemount Analytical gas analysis portfolio.  QCL technology provides a step change in gas analyser performance through its increased sensitivity, speed of response, and fingerprinting capability. These technology advances in the gas analysis market space provide a powerful solution for customers in various industries such as petrochemical, food and beverage, marine, automotive and pharmaceutical. Terms of the acquisition were not disclosed.

“The acquisition of Cascade Technologies is an exciting step as we further strengthen our gas analysis portfolio,” said Tom Moser, group vice president of Emerson Process Management’s measurement and analytical businesses. “Our customers depend upon Emerson to solve their toughest analytical measurement problems. We are now better positioned to serve that need.”

Dr. Iain Howieson, chief executive officer of Cascade Technologies, added: “Joining a global leader like Emerson represents an incredible opportunity for business growth. The Emerson global presence and market leadership will have an immediate impact on the adoption of cutting edge QCL gas analysers and monitoring systems.”

New Emerson fork viscosity meter

The direct insertion Micro Motion Fork Viscosity Meter is designed for demanding applications where accurate, fast-response viscosity and density monitoring is required.

Emerson Process Management has released the Micro Motion Fork Viscosity Meter, the next generation of the market-leading Micro Motion 7827 and 7829 direct insertion viscosity and density meters.  Incorporating the same rugged and reliable tuning fork design as its predecessors, the Fork Viscosity Meter is built to tackle demanding process applications such as oil fired heater combustion control, HFO blending/production and pump protection.

In applications where accurate, fast-response viscosity and density monitoring is required, this direct insertion meter is the ideal choice. It helps solve the problems customers face on a daily basis, such as reducing oil fired heater combustion emissions, minimising cutter-stock usage in HFO blending and reducing contamination risks on multi-product pipelines.

The Fork Viscosity Meter incorporates a hazardous area approved head-mounted transmitter that has the flexibility to connect to control systems via a wide range of digital and analogue protocols. Because it supports 4-20mA, HART, WirelessHART, Foundation fieldbus and RS485 Modbus, system integration and start-up /commissioning costs are significantly reduced.

An additional benefit of the Fork Viscosity Meter is the capability to accept and process external signals from other field instrumentation such as temperature, pressure and mass or volumetric flow devices.  The input of these external measurements enables the meter to calculate and output enhanced process measurements, minimising the need for extra cables and so reducing installation costs.

The Fork Viscosity Meter also incorporates a new diagnostic capability called ‘Known Density Verification’ that checks the meter for measurement alarm conditions, sensor integrity and the presence of coating, erosion or corrosion. This new technology expands the availability of diagnostics information in critical viscosity and density measurement applications which can result in significant maintenance costs and cycle time reductions.

Emerson and Spectro alliance over oil analysis

Emerson Process Management and Spectro Incorporated have announced an exclusive alliance to combine technical innovation and expertise to deliver expanded best-in-class oil analysis solutions. By integrating Emerson’s industry-leading oil analysis applications for the industrial process industry with Spectro’s extensive oil analysis product line and expertise, users gain more meaningful and accurate information on the health of their machinery, helping to prevent costly machine repairs.

Under the new agreement, Spectro gains rights to a suite of Emerson-developed and patent protected Intellectual Property in the field of oil analysis for predictive machine maintenance. Included in this portfolio of IP are Emerson’s AMS Suite oil analysis software module as well as the CSI 5200 Machinery Health Oil Analyzer, the multi-functional analyser that is uniquely capable of detecting most lubricant-related problems in gears, pumps, compressors, turbines, engines, hydraulics, and process machinery.

With effect from October 1, 2012, Spectro will become the exclusive, world-wide supplier of the CSI 5200 Machinery Health Oil Analyzer product and services offering.

“Emerson and Spectro will work closely as we continue to develop leading technology solutions for the process industry,” said Ron Martin, Vice President and General Manager of Emerson’s Asset Optimization and Lifecycle Care business. “By aligning with Spectro to deliver advanced oil analysis solutions, we can better provide our customers with predictive diagnostics to make more informed decisions about their assets.”

“The relationship with Emerson opens the door for customers to expand their predictive maintenance programmes by accessing the expertise available with Spectro’s extensive oil analysis product line, industry knowledge and global distribution network,” said Brian Mitchell, President and CEO of Spectro Inc. “This means that Emerson customers can now take advantage of the same long-term technology solutions and growth path currently available to Spectro customers worldwide.”

Spectro specializes in analytical instrumentation and software for machine condition monitoring. It is one of the largest global suppliers of oil and fuel analysis instruments to industry and the military. Industry clients include petrochemical, mining and power generation companies, as well as commercial testing laboratories. Spectro’s extensive product offerings include spectrometers for wear metal analysis, lubricant degradation and contamination analyzers, particle analysis instruments and complete turnkey systems for oil or fuel analysis laboratories, all managed by its SpectroTrack software platform. For more information, see www.spectroinc.com

Emerson ‘ultra-supercritical’ power station contract in China

Emerson Process Management has received a $2.72 million contract to install its Ovation expert control system at Huadian Lingwu Power Plant units 3 and 4, which are the first 1,000-MW, ultra-supercritical units in China to utilize air-cooling condenser technology. The air-cooling condenser technology, typically used in subcritical power plants located in areas where water is scarce, is now also gaining traction in supercritical and ultra-supercritical units that are increasingly specified in response to environmental regulations.

Owned by Huadian Lingwu Power Generation Company, the plant is located in Yinchuan City in northwest China. It currently consists of two 600-MW, coal-fired units (units 1 and 2) that have utilized Ovation technology since they went into commercial operation in 2007. Units 3 and 4, expected to begin commercial operation in August 2010 and December 2010, respectively, are being built to spur economic development by serving the growing electricity needs of industry in the region.

This growth is part of the broader increase in power demand in China. China’s National Development and Reform Commission stated earlier this year that the country’s electricity consumption rose nearly six percent in 2009. According to the country’s National Energy Administration, in the first quarter of 2010 alone China’s electricity consumption rose 24.19 percent year-on-year to 969.5 billion kilowatt-hours.

As part of its automation solution, Emerson will supply a total of 67 redundant Ovation controllers, 20 workstations and more than 70 Fisher control valves to Huadian Lingwu Unit 3 and Unit 4. At each unit, an Ovation control system will perform data acquisition as well as monitor and control the air-cooled condensers, Donfang boiler, sequence control system, electric control system, modulation control system, furnace safety supervisory system, flue gas desulfurization (FGD) system, feedwater pump turbine and balance-of-plant processes. Each Ovation system will also interface to Hitachi steam turbine controls. In addition, Emerson Ovation technology will monitor and control systems common to both units using multi-networking technology. All told, the Ovation control systems will manage a total of approximately 28,000 I/O points.

“We already know firsthand about the advantages of Ovation technology, based on our experience at units 1 and 2,” explained Lead Engineer Wu Lianwen, Huadian Lingwu Power Plant. “We based our decision to select Ovation for units 3 and 4 on our personal experience with the technology, as well as Emerson’s extensive expertise automating 1,000-MW, ultra-supercritical units, and their significant resources in China.”

Emerson is the global leader in the automation of large ultra-supercritical and supercritical power generating facilities. In fact, the Ovation system has been selected to automate 30 of the 50 1,000-MW, ultra-supercritical units in China. Ultra-supercritical plants use advanced technology that allows operation at elevated steam temperatures and pressures. Ultra-supercritical technologies have become more prevalent in China because they can boost the efficiency of coal-based electricity generation by more than 45 percent, while maintaining superior environmental performance.

“Emerson’s involvement at the Huadian Lingwu Power Plant demonstrates how we bring our global resources and industry-leading technologies together for the benefit of our customers,” said Bob Yeager, president of the Power & Water Solutions division of Emerson Process Management. “We are gratified by the organization’s continued confidence in Emerson’s people and technologies.”

Emerson to buy Chloride: ABB backs out

5 June: The Emerson bid to acquire Chloride in the UK originated with talks in early 2008, that came to nothing. However, Emerson sees Chloride as the European lead HQ for its network power systems business, and is still persistent,  despite the rejection of its £723M offer, 275p a share, made at the end of April. But all the plans of David Farr, Chairman and CEO at Emerson, fell apart, when Chloride reported underlying profits at the top end of city expectations: but surely Farr knew that they were in this good position and should have been delighted to see his expectations confirmed! Chloride has been growing fast in supplying un-interruptible power supplies to provide security to keep major companies operating through power cuts. This is not just a growing market in the developing regions, like India and China, but also happening across the US and Europe, as power supplies become less reliable, and continuity of supply more important.  But Chloride has also expanded with new offices in Kazakhstan, Azerbaijan, Vietnam, South Korea and the Philippines.

While Emerson canvasses major shareholders to assess what price would be attractive, the share price continues upwards, past 286p, and even at this level the institutions are still buying in. So Emerson will have to dig deeper, unless the pressure on the pound generated by anti-British sentiment in the US over the BP problems comes to their rescue.

8 June: ABB joins the party! Or should that be the fray? ABB have made a counter offer to buy the Chloride Group, pitched at 325p a share, giving a total offer value of £860Million and topping the Emerson bid. This offer has been recommended for shareholder acceptance by the Chloride Board. The stock market obviously expects another bid, with the current share price standing at 342p.

15 June: It seems that industry analysts predict there will be no counter-bid by Emerson to top the ABB offer, so it seems that the stock market appetite for a battle was just the over-enthusiasm whipped up by greedy investors.

30 June: A new offer from Emerson of 375p a share, almost USD1.5 billion, sent Chloride’s share price up 37p to 385½p, amid expectations ABB will hit back with a higher offer.

1 July: ABB announce that in the interests of taking a disciplined approach to such acquisitions, a higher offer from ABB would not be appropriate.