Displaying items by tag: Emerson

DeltaV™ PK Controller simplifies capital projects, readies organisations for operational benefits of IIoT

Emerson is launching the DeltaV™ PK Controller, making the advanced automation of its DeltaV distributed control system (DCS) available to fast-growth industries traditionally less reliant on large-scale automation. The next-gen controller provides scalable automation control to all process industries, particularly parts of the life sciences, oil and gas, petrochemical, and discrete manufacturing industries that have relied on complex, non-integrated programmable logic controllers (PLCs) with limited operational capabilities. The fit-for-purpose DeltaV PK Controller is the process industry’s first controller that manufacturers can scale down for skid units or scale up to be natively merged into the DeltaV DCS in a larger plant.

Today, these industries tend to use PLCs for smaller applications, which can create disconnected ‘Islands of Automation’, and limits plant production improvements. The DeltaV PK Controller is the first controller to truly bridge small and large control applications. Organisations can leverage the DeltaV PK Controller for effective, easy-to-implement standalone automation control akin to a PLC but with the features of a full-scale DCS, including advanced batch production, recipe management, execution, and historisation. Users can then choose to leave the DeltaV PK Controller standalone, or natively merge it into their DeltaV DCS. This capability eliminates operational complexity and dramatically improves the performance, safety, and efficiency of their entire project and operational lifecycle.

DeltaV PK Controller

“The DeltaV PK Controller delivers a business-effective solution for organisations of all sizes to improve automation control and integration,” said Jessica Jordan, Emerson product manager. “The controller is capable of powerful standalone control for advanced automation on skids today while still being able to easily integrate into a full-scale DCS for total plant production control.”

The DeltaV PK Controller is the latest addition to Emerson’s Project Certainty initiative, targeting radical transformation in capital project execution. The new controller will simplify capital projects by enabling OEM skid-builders to design and produce skids in the same way they do today, while eliminating the costs, time, and risks associated with integrating a PLC into their control system.

The DeltaV PK Controller was designed from the start with connectivity, particularly into the IIoT, in mind. The scalable controller leverages an assortment of communication protocols, including the first Emerson controller with a built-in OPC UA server. It is also the first Emerson controller with six Ethernet ports and can operate using any Emerson DeltaV I/O type, including DeltaV Electronic Marshalling, traditional marshalled I/O, wireless I/O, and integrated safety instrumented systems. In addition, it has built-in protocols to communicate with Ethernet devices such as drives and motors. Together, these features make connectivity easier at every stage and help plants achieve operational benefits of cloud-based tools and analytics through the IIoT. The DeltaV PK Controller also features built-in redundancy for controllers, communication, and power supplies, allowing organisations to improve uptime without adding to complexity or footprint.

For more information, visit www.Emerson.com/DeltaVPKController.

For more information on Emerson’s Project Certainty initiative, visit www.Emerson.com/Project-Certainty

About Emerson

Emerson (NYSE: EMR), headquartered in St. Louis, Missouri (USA), is a global technology and engineering company providing innovative solutions for customers in industrial, commercial, and residential markets. Our Emerson Automation Solutions business helps process, hybrid, and discrete manufacturers maximise production, protect personnel and the environment while optimising their energy and operating costs. Our Emerson Commercial and Residential Solutions business helps ensure human comfort and health, protect food quality and safety, advance energy efficiency, and create sustainable infrastructure. For more information, visit www.Emerson.com

CHO-Power, part of the Europlasma Group, is using Emerson Process Management’s digital automation technology to control a new waste and biomass fed power station at Morcenx in southwestern France. By providing flexible and accurate control of an innovative gasification process, Emerson’s Ovation^™ expert control system is enabling the plant to operate at maximum efficiency.

The new Morcenx gasification facility will generate 12 MW of power from 150 metric tonnes per day of industrial and wood waste, making it the most powerful plant of its type worldwide. The efficient use of waste and biomass fuel helps the plant support European energy guidelines promoting the use of continuous-source renewable energy with low CO₂ emissions. Start-up was in autumn 2012, and the plant was commissioned to the grid at the beginning of 2013.

The Morcenx power station is the first of its type to use an innovative and highly efficient gasification principle based on patented 'Turboplasma' equipment to transform waste into syngas. The 1200°C temperatures generated from the plasma torch produce a very pure syngas that is used to drive the turbine and generate electricity.  In addition, 18 MWth of hot water from the cooling system is used to heat a vegetable greenhouse and a wood drier.

“We selected Emerson’s Ovation system because it provides the levels of flexibility and control needed to cope with the varying characteristics of biomass fuels,” said Yannick Ferriere, project manager, CHO Power. “Also critical was Emerson’s extensive project management experience with biomass power generating plants, as well as its technical support including engineering, configuration of the Ovation system, training, start-up assistance and maintenance.”

The Ovation system, together with AMS Suite predictive maintenance software and smart instrumentation, is part of Emerson’s PlantWeb^™ digital plant architecture that provides both advanced control and asset management capability for the Morcenx facility.

The Ovation system will perform data acquisition and monitor and control all major plant components to provide improved unit stability, responsiveness and thermal efficiencies; tighter overall control of plant operations; and a more concise view of key plant and turbine parameters. The system provides embedded advanced algorithms and proven control routines that continually adjust the combustion process to compensate for the varying characteristics of biomass fuels. This maximizes both boiler and plant efficiency. The Ovation system interfaces with the GE steam turbine, gas treatment system and gas engine using Profibus-DP communications. 

An Ovation SIS (safety instrumented system) provides SIL-3 protection for the boiler systems. Complying with the stringent international standard IEC 61511, Ovation SIS employs digital intelligence and diagnostics to provide an integrated complete-safety-loop approach that helps increase process availability, reduce lifecycle costs and ease regulatory compliance.

Emerson also provided a broad range of instrumentation for the power station, including Rosemount^® temperature, pressure and flow transmitters; Fisher^® control valves; and Rosemount Smart Wireless temperature transmitters. AMS Suite software will enable maintenance and operations personnel to predict equipment issues to better maintain and protect the machinery.

“We are delighted that Europlasma has chosen our automation technologies for this innovative power facility,” said Bob Yeager, president of the Power & Water Solutions business unit of Emerson Process Management. “Our technologies, services and support have made a significant contribution to this project, which will develop into a key part of Europe’s renewable generating capacity.”

A detailed market study by CHO Power shows that 650 new advanced gasification power plants will have to be built in Europe by 2030 to meet EU renewable energy targets. Of these 107 would be required in the UK and a further 126 in France.