Plant Operations and Maintenance
Display Screen Improves Industrial Performance
The Simatic IPC377E basic panel PC offers a platform specifically developed to optimize cost for PC-based applications in industrial environments. It has an antiglare, scratchproof, and chemically resistant screen, and it combines the performance of an industrial PC with analog-resistive single-touch operation. The PC is a preconfigured turnkey solution for economical implementation of human-machine interface (HMI) applications, for the acquisition and networking of production and energy data in production environments (such as assembly workstations, warehouses, and logistics systems), or standard applications in the image-processing field. It is easy to integrate into existing machines, and it is available with a 12-, 15-, or 19-in.-diagonal display screen.
Real-Time Visualization Reduces Plant Errors
The SIMCA updates in the Umetrics suite optimize process control in manufacturing facilities. The software now uses advanced data analytics and visualization to improve plant operations and efficiency. It has an intuitive and flexible graphical interface to handle complex data. Projects can be uploaded directly to an online server for real-time visualization of the process. The software quickly detects and analyzes deviations from normal operating conditions. It detects changes in set parameters and enables remedial action before production is affected, ensuring that product quality remains consistent. The detection and control capabilities of the software help to maximize resource efficiency, minimize operational costs, and increase confidence in product quality.
Transmitter Technology Tracks Measurement Accuracy
Liquiline CM44 and CM44R transmitters incorporate Heartbeat technology with memosens pH and conductivity sensors. The diagnostic continuous-analysis system recognizes related events during operation. Heartbeat monitoring minimizes the probability of a sudden breakdown or failure of the measurement and can help to define when maintenance is needed. The monitor tracks the quality of the calibrations and integrates a maintenance timer to ensure optimal sensor performance. The verification system allows a measurement to be assessed without removing the sensor or shutting down the process, and a qualitative function checks the entire measurement loop for sensor and transmitter performance. The verification results are documented as reports that can be used when regulatory, quality, or safety documentation is needed. The transmitters can be connected to programmable logic controller (PLC), supervisory control and data acquisition (SCADA), or distributed control systems. Data from these control systems can be used for process optimization and predictive maintenance.
Endress + Hauser
Drum Transporter Enhances Operational Safety
The FTA drum-handling unit can load, unload, palletize, and store steel drums of nearly any size or configuration. The parrot-beak clamping system and cushioned-belt cradles allow the attachment to fit onto any standard lift-truck’s fork. The unit provides a secure grip and transports the drums safely to and from any location. It is available in models designed to simultaneously handle 1–4 drums as large as 2,000 lb per drum. Available options allow the units to work with open-top and closed-head drums, and different coatings are available to withstand various environmental conditions.
Automation Control Improves Productivity
The DeltaV cybersecurity-certified automation control system enhances plant operation, connectivity, and productivity. This update to the system features redesigned architecture that improves productivity through extensive access to production and equipment data, improved usability, and greater security. The system’s characterization module (CHARM) technology enables it to be installed closer to field devices, which reduces wiring and overall installation costs. Smart commissioning technology reduces commissioning time to as little as 10 min. The live operator interface is easy to understand and modify. The human-machine interface (HMI) comes pre-engineered with the best practices for user experience, to improve situational awareness and decision-making speed. The graphics system is transferable across desktops, laptops, and mobile devices.
Materials and Chemicals
Lightweight Thermoplastic Yields Uniform Products
These short-fiber thermoplastic materials have mechanical strength exceeding that of long-fiber thermoplastic (LFT) materials. The KyronMax structural thermoplastic compounds are injection-moldable replacements for metals that overcome the process and design limitations associated with LFT polymers. The short-fiber technology gives the polymer some of the beneficial properties of metals and enables consistent and uniform final products. Complex parts can be molded with a wall thickness as low as 0.015 in. (0.038 cm). The KyronMax polymers are 20% lighter and 20–50% stronger than LFT polymers. They can exhibit tensile strengths above 51,000 psi (352 MPa) and a flexural modulus above 6,500,000 psi (44,816 MPa). The technology is currently available in various thermoplastic formulations, including polyamide (PA), polyphthalamide (PPA), polyphenylene sulfide (PPS), polyetherimide (PEI), and polyether ether ketone (PEEK).
Elastomer Improves Breathable Foam Durability
The HyPur-cel product line now includes open-cell, breathable polyurethane foams with a variety of physical and performance properties. The new formulation of the R series contains elastomer polymer components. The series exhibits cyclic fatigue resistance and virtually no loss in firmness or resistance to compression. The materials demonstrate ultra-low stress relaxation and low hysteresis loss. A variety of densities and firmness options are available. The material is suitable for high-performance energy-return applications such as gaskets.
Lightweight Structural Foam Is Thermally Stable
Rohacryl is a polymethacrylimide (PMI) structural foam that is based on acrylic chemistry. The foam core material is lightweight, easy to shape, and has strong mechanical properties. It is thermally stable and remains so even when cured at high temperatures. Because it contains no chlorofluorocarbons (CFCs), it is environmentally friendly. The material is designed for composite applications in the aerospace, electronic, and medical industries.
Moldable Resin Is Stable at High Temperatures
Lexan CXT resins are injection-moldable polycarbonate copolymers. They have an index of refraction greater than 1.6, and more than 89% of visible and infrared (IR) spectra can pass through a 1-mm-thick piece of the material. The resins have Vicat B120 softening temperatures up to 190°C and glass transition temperatures up to 195°C. High transparency, thermal stability, and malleability prevent deformation and discoloration and make the resin appropriate for use in the electronics, consumer and industrial products, and healthcare industries. The materials can be produced at a faster rate and at lower costs due to shorter cycle times, fewer production stoppages, and lower rejection rates. Greater dimensional accuracy enables components with more complsex geometries, thinner and longer walls, and better textural definition.
Gel Coating Serves as an Electrical Insulator
MasterSil 170 gel is a two-component gel system designed for potting and encapsulation. After the components are mixed, the gel has a low viscosity of 1,000 cP and a working life of 2–4 hr for a 100-g batch. The solvent-free gel does not require air to crosslink and cures at 75°F. As it cures, it has a low exotherm and low shrinkage. The gel is easy to dispense and, after coating, it is highly resistant to water and does not crack under severe thermal cycling. It has a low refractive index of 1.42 and performs well as an electrical insulator, making it suitable for coating and protecting sensitive electronic and optical components against thermal stresses. It can be applied in thicknesses greater than 1 in. The shelf life of the unopened material is six months at 75°F.
Flexible Caulk Is Chemically Resistant
The A1104 AFLAS fluoroelastomer caulk has a high abrasion resistance and resists alkalis, aminos, and other high-pH chemicals. It is highly resistant to oil and fuel and can withstand temperatures up to 400°F (205°C). It can bond to most substrates, including metals, concrete, glass, ceramics, other elastomers, and some plastics. The material can protect substrates from acidic corrosion by chemical spills, vapors, and process liquids. The caulk can also repair concrete cracks, seal expansion joints, coat metal supports and housing, and seal tank lids and pipe penetrations. The liquid formulation can conform to any space or gap, which improves the seal of molded O-rings and gaskets.
Software Improves Troubleshooting of Small-Scale Operations
PanelView 5310 is a graphic terminal for design, operations, and maintenance in small applications. The software enables the reuse of control alarms without the need to create more human-machine interface (HMI) tags, which reduces configuration time. The auto-diagnosing buttons interact with a controller at the operating input/output (I/O) speeds to help reduce downtime and improve productivity. Troubleshooting is straightforward and can be done directly from the panel. The software integrates easily with other softwares and can test-run projects in the development environment. Virtual network computing (VNC) connectivity allows users to remotely monitor operations via a smartphone, tablet, or personal computer.
Access 3D Modeling via the Cloud
SimScale uses the leading engineering software for 3D geometric modeling and is constantly evolving to meet industry needs through a cloud- and web-browser-based system. It has no hardware or software footprint, which helps to keep its cost low. Because SimScale runs on the cloud, the system has multi-user access, tools for collaboration, easy scaling for computing sources, and automated maintenance. This model increases the accuracy of simulation results in both finite element analysis (FEA) and computational fluid dynamics (CFD).
Simplified Data Handling Eases IIoT Implementation
The updated groov software embeds Industrial Internet of Things (IIoT) technologies, protocols, and drivers directly into its web and mobile visualization tools. Engineers, technicians, and developers can use the software as a comprehensive set of tools in development and industrial environments. The additional functions in the software combine visualization, data handling, security, and connectivity into a single appliance and ease IIoT implementation. The updates combine a trusted hardware platform with resilient communication architecture to provide flexibility in automation and supervisory control and data acquisition (SCADA). Data can be sent to a central server or a broker on-site or stored in the cloud. The software eliminates complex networking architectures like virtual private networks (VPNs), firewall configurations, and remote desktop software. Groov acts as a complete computing appliance, so a PC is not required.
Improve Training with Virtual Reality
This augmented-reality (AR) and virtual-reality (VR) cloud-based simulation system improves training for plant personnel. The software uses a self-contained holographic computer and a mixed-reality headset to simulate various plant scenarios. The system allows employers to safely train new employees and help them to experience the impacts of their decisions. The AR/VR simulation improves information retention and reduces the length of technical training. The software can also track and test employees’ progress as part of a formal competency management system.
Progress Indicators Optimize Process Performance
R19 capsule-based software provides a visual representation that enables engineers and scientists to gain insights into production data. The software runs complex calculations in parallel across several central processing units (CPUs) with a single server, provides administrative tools to optimize performance, and can increase control and visibility with real-time progress indicators. The system’s features are scalable for use in any size operation. The software is designed specifically with the oil and gas, pharmaceutical, chemical, energy, mining, food and beverage, and other process industries in mind.
Environmental, Health, and Safety
Explosionproof Lighting Has a Long Lifespan
The EPL-HB-50LED-RT-WLM high-bay light emitting diode (LED) provides 4,333 lumens of high-quality light while drawing only 50 watts. It has a color temperature of illumination of 5,600 K and a color-rendering index of 75, which allows it to produce colors and details much more accurately than traditional high-pressure sodium or mercury vapor bulbs. It is offered with either a 60-deg. or 120-deg. beam spread and can be operated on 100–277 VAC, 50/60Hz. A low-voltage version of this LED fixture operates on AC/DC voltages of 11–25 V. It is made of powder-coated copper-free aluminum and has the highest ingress protection rating against dust and liquid (IP67). The LED withstands high-pressure jets and temporary submersion, and is resistant to vibration and impacts. A special heat-dissipating design paired with LED technology helps this unit achieve a 60,000-hr rated lifespan and 80% lumen retention. The light is equipped with a wall-mounting system and abrasion- and chemical-resistant cable with flying leads for easy electrical connection. This lamp is compact, lightweight, and has a low-profile design with Class I Div. 1 and 2, and Class II Div. 1 and 2, ratings. It is suitable for elevated lighting at work sites with flammable materials, manufacturing plants, and other hazardous locations.
Automatic Self-Cleaning Dust Collectors Run Continuously
This stand-alone dust collector removes airborne dust from upstream processes, which protects operators, improves plant hygiene, and reduces material waste. Process-generated dust can be vented onto filter cartridges through hard piping or flexible connections. An automatic reverse-pulse filter cleaning system uses compressed air to clean the filters at timed intervals. The unit consists of a 2.5-ft3 (70-L) collection hopper with a flanged slide-gate valve and automated controls, a 6-in.-dia. (15 mm) side inlet port, dual filter cartridges, and a 2-hp (1.5-kW) fan motor. The housing and support structure are made of stainless steel and the controls and fan motor comply with National Electrical Manufacturers Association (NEMA) 4X standards for water resistivity. The design and features of the dust collector allow it to run continuously and efficiently and to be cleaned and sanitized completely between product runs.
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