3D TRASAR® Boiler Technology for Refineries and Petrochemical

Refineries and petrochemical plants have some of the most challenging boiler feed water systems, and boiler reliability is critical to plant operations. If a boiler is shut down unexpectedly, it can impact the on-stream availability of an entire process unit and result in reduced production.

Since changing conditions impact different parts of the boiler system...often very quickly...3D TRASAR Boiler Technology is critical. Nalco completes a thorough audit (mechanical, operational, and chemical) of your boiler systems in order to understand the gaps and make recommendations specific to your operational goals. This approach is designed to drive the results, reliability, and cost savings that all refineries and petrochemical plants expect.

3D TRASAR Boiler Technology

There are many different variables that can affect the total system performance of a steam system boiler including feed water quality, chemical treatment program, contamination events, and operational factors. These variables can cause system stresses that manifest themselves as operational problems: pre-boiler corrosion and economizer failures, boiler tube scale, boiler carryover, and fouling of critical downstream equipment such as turbines. 

The 3D TRASAR program detects system variations, then determines and delivers the correct program dosage. Nalco continues to improve the technology, making it the industry standard for monitoring and control that delivers measurable results. The technology can be customized and upgraded to ensure your system has the amount of desired control when you want it. It also has web accessibility and easy reporting capabilities in one, easy to install package. http://www.youtube.com/watch?v=uVEfU8x9A6I&feature=player_embedded

The Deliverables 3D TRASAR Boiler Automation delivers value by:

• Improving boiler reliability
• Optimizing energy and water usage
• Reducing green house gases
• Reducing the total cost of operations

The technology provides real time diagnostic capability, reduces scaling potential, reduces pre-boiler corrosion potential, and reduces carryover potential.

3D TRASAR Internal Treatment Control 

Nalco continues to improve tracing technology, making it the industry standard for monitoring and control that delivers measurable results. Boiler internal treatment control is achieved with various sensor technologies coupled with the most advanced boiler internal treatment chemistry. Upsets that could cause scaling or corrosive conditions automatically triggers control actions which brings the system back to safe parameters, maintaining clean boiler tubes 24 hours a day, 7 days a week.

3D TRASAR Pre-Boiler Corrosion Control 

The Nalco Corrosion Stress Monitor (NCSM) minimizes preboiler corrosion by measuring and reacting to the net oxidation/ reduction potential of the bulk feedwater, at the actual boiler operating temperatures and pressures. The NCSM detects changes in oxidation/reduction stress, determines the corrective action and responds in real-time by changing oxygen scavenger or metal passivator feed to protect the system. It is now possible to detect and react to the conditions inside the preboiler system under actual operating temperatures and pressures, allowing 3D TRASAR technology to deliver superior boiler system performance.

3D TRASAR Boiler Cycles Management 

Nalco’s 3D TRASAR Boiler Automation also helps optimize and control boiler blowdown. The outcome is increased heat efficiency, reduced energy requirements, increased water reuse, asset preservation, and improved utilization of fuel to heat your boiler.

3D TRASAR Information Management 

We offer a data driven process for continuous improvement. 3D TRASAR Boiler Technology continuously monitors key system parameters and KPIs which can then be analyzed from the convenience of your control room (DCS), on-line or by downloading to a laptop computer.

ROI Case Studies:

• 3D TRASAR Technology for Boilers reduces pre-boiler corrosion & unplanned boiler shut downs in a West Coast Refinery resulting in $4.8 MM in savings.
• Refinery improved sustainability, saving $372,000 per year in energy and water savings by optimizing boiler blowdown via 3D TRASAR boiler blowdown management.

Sensors take the heat

Greenwich University researchers are to work with Oxsensis on the development of sensors that can measure pressure and temperature at more than 1,000C.

Greenwich University researchers have won a SPARK award to work with Oxfordshire-based Oxsensis on the development of sensors that can simultaneously measure pressure and temperature at more than 1,000C.

Prof Chris Bailey, who leads the Computational Mechanics and Reliability Group in the School of Computer and Mathematical Sciences at the university, will use computer modelling techniques to predict how the sensors and their components would operate under different conditions of fluid flow, temperature and vibration.

The research will help Oxsensis with the design, assembly and installation of the sensors, which operate deep inside combustion engines.

Prof Bailey said: 'The aerospace and car manufacturing industries are demanding improved sensors because next-generation engines are getting much hotter. At the moment, no sensor can work reliably above 800 degrees.'

The two partners will start working together this month.

Oxsensis, which was formed in 2003 as a spin-out from Rutherford Appleton Laboratory, is developing sensor technology based on the micromachining of super-resistant materials such as single-crystal sapphire (melting point >2,000C) together with innovative fibre-optic interrogation techniques that give high sensitivity and immunity from electro-magnetic interference effects common in turbo-machinery such as gas turbines.

The SPARK awards, which started in 2002, are given to higher education institutions that help small and medium businesses tackle a problem of direct relevance to them. They also aim to encourage longer-term relationships between educational and business organisations.

The SPARK awards are organised by the Integrated Products Manufacturing Transfer Network, one of the Knowledge Transfer Networks of the Technology Strategy Board, jointly with the Innovative Electronics Manufacturing Research Centre (leMRC) of the Engineering and Physical Sciences Research Council.

http://www.omron.co.id/application_solutions/category_details.asp?app_id=E484

http://www.omron.co.id/application_solutions/category_details.asp?app_id=E484

ABC Formula/Conversion Table for Wastewater Treatment,Industrial, Collection and Laboratory Exams

A Methodology for Commissioning Control Loops

Several years ago our company recognized the need to integrate system commissioning into our construction process in order to consistently meet the owner and design team's needs and expectations. Below is a summary of the process we have developed by trial and error over the last 8 years.

1. Design Review: Review of drawings and specifications to verify the following: Coordination between trades; code compliance; equipment selection and capacities; control sequences for all equipment; and control system component specifications.

2. Submittal Review: Review of HVAC equipment and control system submittals to verify the following: equipment capacities, types and features; control system architecture; and control system component accuracies, ranges, signal types, ratings, and failure modes.

3. Commissioning Plan: Name and telephone number for all participants in commissioning process schedule of activities; HVAC pre-start and start-up checklists; analog device testing and calibration sheets; digital device testing and set point sheets; functional performance test sheets for all DDC control loops; testing and calibration procedures for all devices.

4. Equipment Start-up: 

A. Pre-Start Activities: Confirm device wired to the appropriate voltage source; heater elements installed in motor starter devices; shipping restraints removed; device rotates freely; adjust pulleys, belts, couplings; safety devices installed; and disconnect switches installed.

B. Start-Up Activities: Confirm that noise and vibration levels are acceptable; Confirm source voltage is acceptable all phases; record actual and rated amperage; and check device rotation

5. Critical Input Calibration: A. Analog Input Devices 

1. Temperature devices without transmitters (Thermistor, resistance type)

a. Disconnect sensing element from loop.

b. Check for failed signal at address.

c. If system shows failed continue to next step. If not, check for shorted wire or a bad software address.

d. Connect decade box or suitable resistance simulation device place of sensing element.

e. Simulate the resistance corresponding to zero, fifty, and one hundred percent of system design rating.

f. Adjust control system software offset or slope and intercept as required to ensure reading with in stated tolerance.

g. Replace sensor element. Make sure the system is receiving the correct signal.

2. Temperature devices with transmitters (RTD type)

a. Assemble required equipment: Decade box, digital VOM, trim screwdriver, and RTD resistance vs. temperature chart specific to the element being tested

b. Adjust the decade box setting so that the transmitter output is 4.00 mA.

c. Record the resistance value and the corresponding temperature.

d. Adjust the decade box setting so that the transmitter output is 20.00 mA.

e. Record the resistance value and the corresponding temperature.

f. Subtract the temperature in step b from the temperature in step c. This is the transmitter span. Adjust the transmitter span potentiometer as required to allow the actual span to match the required span. Repeat steps b and c to confirm.

g. Set the decade box to the resistance corresponding to a 4.00 mA output.

h. Adjust the zero potentiometer as required for the transmitter to produce a 4.00 mA out put signal.

3. Pressure Transmitters:

a. Disconnect the sensing element from the transmitter and replace it with a hand-held calibrated pressure simulation device with an accuracy that exceeds the rating of the transmitter to be calibrated.

b. Install a VOM meter in line with the negative terminal of the transmitter.

c. Determine the following values from the manufacturer's data:

(1) PMIN - Pressure at minimum transmitter output

(2) PMAX - Pressure at maximum transmitter output

(3) TMIN - Minimum transmitter output signal (mA or VDC)

(4) TMAX - Maximum transmitter output signal (mA or VDC)

d. Adjust the pressure until the transmitter output equals TMIN. This value is P1.

e. Adjust the pressure until the transmitter output equals TMAX. This value is P2.

f. Adjust the span potentiometer until the transmitter output signal equals the following:

g. Adjust the pressure to PMIN value.

h. Adjust the zero potentiometer until the transmitter output signal equals TMIN.

i. Adjust the pressure to [PMin - P Max / 2 ]  , and confirm that the transmitter output signal is equal to [TMin - T Max /2 ]  .

j. Repeat steps d) through i) as required.

4. Relative Humidity

a. Disconnect wire from negative terminal of transmitter.

b. Connect VOM between the sensor and the signal wire to read current (mA) of the device.

c. Using a hand held relative humidity calibration device, compare the output signal of the transmitter to the expected value.

d. Adjust the zero potentiometer of the transmitter as required so that the output matches the expected value.

5. Digital Inputs

a. Remove the control wiring and verify the control system address.

b. Alternatively open and close the control wiring circuit and confirm the corresponding change of state at the control panel.

c. Record the setpoints.

6. Output Calibration:

A. Analog Output Devices

1. Control valve (pump operational during test)

a. Disconnect control signal and record valve position.

b. Command valve to 0%, 25%, 50%, 75%, and 100% position and observe valve response. Adjust the control signal output device(s), including I/P transducer and/or pilot positions, as required.

2. Control Damper (fan operational during testing)

a. Disconnect control signal and record damper position.

b. Command damper to 0%, 25%, 50%, 75%, and 100% position and observe response. Adjust the control signal output device(s), including I/P transducer and/or pilot positions, as required.

3. Fan Speed Control

a. Disconnect control signal and record fan speed.

b. Command VSD to 0%, 25%, 50%, 75%, and 100% maximum speed and observe fan speed response.

B. Digital Output Devices 

1. Remove the control wire at the termination of the digital output wiring (relay, E/P, contract, starter, etc.) and verify address.

2. Alternatively command the output opened and closed from the control system, and confirm the appropriate response at the controlled device.

7. Functional Performance Testing: 

A. Overview: Functional performance testing is the method by which the control loop logic is tested for proper performance for each controlled system. This is accomplished by revising set points or simulating events and comparing the actual system response to the expected system response.

B. Normal control sequence: Perform a step-by-step test of all the various control logic sequences for each HVAC system by revising setpoints or simulating events (contact closure, etc.) and observing system response.

C. Safety interlocks: Verify that the following interlocks shut down the appropriate equipment when the equipment is operating in either the "hand," "automatic," or "local" control modes: fire alarm, duct detectors, manual safety switches, high or low temperature, and high or low pressure.

D. Overrides: Verify the proper system response to manual override devices, including occupant override switches, life safety override switches, control panel digital switches, and control panel analog output gradual switches.

E. Failure Modes: Remove the control signal and confirm proper position of the analog and digital control devices.

F. Loop Tuning: Upon completion of testing and prior to final acceptance testing, adjust the proportional, integral and derivative gains of each DDC control loop as required to provide stable operation.

8. Acceptance Testing: 

A. Upon completion of the functional performance testing, the operation of each control loop shall be demonstrated for the owner's representative(s).

B. The owner's representative(s) shall include the building engineer(s) assigned to operate this facility, as this test is the first step in owner training.

9. Owner Training: Upon completion of the owner's acceptance the owner's representative(s) and building engineer(s) will be trained in the proper operation of the HVAC system. When system commissioning is properly executed, we have found that warranty costs are virtually eliminated. These savings in warranty costs more than pays for the cost of commissioning. Most importantly, thorough system commissioning ensures a working building and adds value for our customers. This added value can differentiate you from your competition.

 

XCorr Corrosion sensors

Corrosion, in one form or another, can cause high value assets to deteriorate, shortening their useful lives. Corrosion related repairs and replacements drives up costs. Thus Condition Based Maintenance (CBM) strategies are being explored by many organizations in an effort to reduce inspection costs while minimizing the risk of equipment damage from corrosion. Aginova provides several tools to help in scheduling maintenance.

Coating degradation (CDS)

orrosion Protection Compounds (CPCs) or paints are routinely applied on military assets for prevention of corrosion. When exposed to the elements (water, light and salt) these coatings degrade and therefore have to be reapplied. Typically these are applied at fixed time intervals that can sometimes be too soon or too late. The CDS measures the coating degradation in terms of impedance (measured in ohms) and phase angle.
Therefore CDS can be used to determine the condition of the coating. The photograph above shows a sensor head developed by SwRI® which when coupled with the appropriate electronics measures the coating impedance. The photograph shows a complete packaged solution using CDS, T and RH.
SPECIFICATION
Impedance range* 100 ohms to 10 Mohms.
Phase angle 0 to -90.
Frequency range 100Hz to 105Hz.

Water detection (WLS)

Number of wetness cycles as well as the corrosivity of the environment can be measured using the IDS. The photograph to the left shows a corrosivity sensor where one of the electrodes is copper and the other is an iron-chrome alloy. A DC potential is applied across the two probe leads and a current response measured. The ratio of potential to current is inversely proportional to the corrosion.
When both electrodes are made out of the same material such as copper the sensor detects the presence of moisture and can be used to measure the number of wetness cycles. The sensor can be used to measure corrosivity or detect moisture. The IDS sensor in combination with Temperature and RH gives a better picture of the corrosivity of the environment.

SPECIFICATION
Fixed potential applied and resistance measured.
Resistance range – Two orders of magnitude.

Corrosivity measurement (MAS)

Multi Array Sensor probe is a passive electrochemical sensor where there is no applied voltage. As an immediate benefit, there are no issues associated with sensor control. It is a true corrosion rate monitor able to measure uniform and localized corrosion.
This MAS probe sensor is unique in that it does not rely on electrolyte solution to bridge the gap between the probe elements (although electrolyte must be present at anode and cathode sites). Each element is connected together through a common wire within the electronics package.
In this manner anodic (corrosion) and cathodic sites can develop at the elements as on an actual metal. A typical circuit to measure the low currents is shown in the figure to the left. Note MAS probe is the only sensor in the market that can measure pitting corrosion.

Damage Assessment (DAS)

Damage Assessment Sensor (DAS) is perhaps the simplest of all, and requires the monitoring of a property that is related to the volume of material present. It is similar to an ER probe, a coupon like specimen is utilized, but this specimen is position where the resistance to current passing through the coupon is measured (typically a wire).
As the wire corrodes, it’s conductor cross sectional area decreases, causing the resistance to rise. This elevation in resistance can be tracked over time to yield corrosion rate. ER probes are sensitive to other factors which influence resistance (Temperature), and must therefore be accounted for. Eventually, the wire coupon corrodes through and no current is passed. The damage assessment sensor builds in redundancy to the electrical resistance sensor by simultaneously monitoring a multitude of wires each with a different thickness. As the smaller diameter wires corrode through, a definitive “calibration point” is measured with which to check the crude measure of corrosion rate.
This sensor has been tested in the laboratory. Field trials are planned in Q4 2007. More details will be provided after the field trials.

Ultrasonic Wall Thickness measurement sensor

Aginova is developing a new generation of Wireless Wi-Fi® Ultrasonic Wall Thickness measurement sensors. The sensors can operate on a pipeline at up to 300°C in continuous operation (ambient temperature outside pipe).
It becomes now possible to:

• Continuously monitor thickness of pipes
• Suppress human intervention
• Access unreachable pipelines
• Get a correct picture of the pipelines corrosion state

OPC Overview

OPC (OLE for Process Control)

is a series of standards specifications. The first standard (originally called simply the OPC Specification and now called the Data Access Specification) resulted from the collaboration of a number of leading worldwide automation suppliers working in cooperation with Microsoft. Originally based on Microsoft's OLE COM (component object model) and DCOM (distributed component object model) technologies, the specification defined a standard set of objects, interfaces and methods for use in process control and manufacturing automation applications to facilitate interoperability. The COM/DCOM technologies provided the framework for software products to be developed. There are now hundreds of OPC Data Access servers and clients available.

Adding the OPC specification to Microsoft's OLE technology in Windows allowed standardization. Now the industrial devices' manufacturers could write the OPC DA Servers and the software (like Human Machine Interfaces  HMI ) could become OPC Clients. 

The benefit to the software suppliers was the ability to reduce their expenditures for connectivity and focus them on the core features of the software. For the users, the benefit was flexibility. They don't have to create and pay for a custom interface. OPC interface products are built once and reused many times, therefore, they undergo continuous quality control and improvement. 

The user's project cycle is shorter using standardized software components. And their cost is lower. These benefits are real and tangible. Because the OPC standards are based in turn upon computer industry standards, technical reliability is assured. 

The original specification standardized the acquisition of process data. It was quickly realized that communicating other types of data could benefit from standardization. Standards for Alarms & Events, Historical Data, and Batch data were launched. 

Current and emerging OPC Specifications include: 

Specification	Description
OPC Data Access	The originals! Used to move real-time data from PLCs, DCSs, and other control devices to HMIs and other display clients. The Data Access 3 specification is now a Release Candidate. It leverages earlier versions while improving the browsing capabilities and incorporating XML-DA Schema.
OPC Alarms & Events	Provides alarm and event notifications on demand (in contrast to the continuous data flow of Data Access). These include process alarms, operator actions, informational messages, and tracking/auditing messages.
OPC Batch	This specification carries the OPC philosophy to the specialized needs of batch processes. It provides interfaces for the exchange of equipment capabilities (corresponding to the S88.01 Physical Model) and current operating conditions.
OPC Data eXchange	This specification takes us from client/server to server-to-server with communication across Ethernet fieldbus networks. This provides multi-vendor interoperability! And adds remote configuration, diagnostic and monitoring/management services.
OPC Historical Data Access	Where OPC Data Access provides access to real-time, continually changing data, OPC Historical Data Access provides access to data already stored. From a simple serial data logging system to a complex SCADA system, historical archives can be retrieved in a uniform manner.
OPC Security	All the OPC servers provide information that is valuable to the enterprise and if improperly updated, could have significant consequences to plant processes. OPC Security specifies how to control client access to these servers in order to protect this sensitive information and to guard against unauthorized modification of process parameters.
OPC XML-DA	Provides flexible, consistent rules and formats for exposing plant floor data using XML, leveraging the work done by Microsoft and others on SOAP and Web Services.
OPC Complex Data	A companion specification to Data Access and XML-DA that allows servers to expose and describe more complicated data types such as binary structures and XML documents.
OPC Commands	A Working Group has been formed to develop a new set of interfaces that allow OPC clients and servers to identify, send and monitor control commands which execute on a device.

The DCOM Architecture

DCOM is an extension of the Component Object Model (COM). COM defines how components and their clients interact. This interaction is defined such that the client and the component can connect without the need of any intermediary system component. The client calls methods in the component without any overhead whatsoever.

Figure 1: COM components in the same process

In today's operating systems, processes are shielded from each other. A client that needs to communicate with a component in another process cannot call the component directly, but has to use some form of interprocess communication provided by the operating system. COM provides this communication in a completely transparent fashion: it intercepts calls from the client and forwards them to the component in another process.

Figure 2: COM components in different processes

When client and component reside on different machines, DCOM simply replaces the local interprocess communication with a network protocol. Neither the client nor the component is aware that the wire that connects them has just become a little longer.
Figure 3 shows the overall DCOM architecture: The COM run-time provides object-oriented services to clients and components and uses RPC and the security provider to generate standard network packets that conform to the DCOM wire-protocol standard.

Figure 3: DCOM: COM components on different machines

Components and Reuse

Most distributed applications are not developed from scratch and in a vacuum. Existing hardware infrastructure, existing software, and existing components, as well as existing tools, need to be integrated and leveraged to reduce development and deployment time and cost. DCOM directly and transparently takes advantage of any existing investment in COM components and tools. A huge market for off-the-shelf components makes it possible to reduce development time by integrating standardized solutions into a custom application. Many developers are familiar with COM and can easily apply their knowledge to DCOM-based distributed applications.

What is OPC Server Development?

An OPC Sever is a software application that acts as an API (Application Programming Interface) or protocol converter. An OPC  Server will connect to a device such as a PLC, DCS, RTU, etc or a data source such as a database, HMI, etc and translate the  data into a standard-based OPC format. OPC compliant applications such as an HMI, historian, spreadsheet, trending  application, etc can connect to the OPC Server and use it to read and write device data. An OPC Server is analogous to the  roll a printer driver plays to enable a computer to communicate with an ink jet printer. An OPC Server is based on a  Server/Client architecture.

There are many OPC Server Development toolkits available for developing your own OPC Server; MatrikonOPC's Rapid OPC Creation  Kit (ROCKit) is one of it and enables quick OPC Server development. ROCKit offers a flexible and affordable solution that  enables programmers to fully control their own product.

OPC ROCKit packages the complete OPC interface into a single DLL, eliminating the need to learn the complexities of Microsoft  COM, DCOM or ATL. A developer simply writes the communication protocol routines for the underlying device and ROCKit takes  care of the OPC issues.

Features include:

- Fully compliant with OPC DA 1.0a, 2.05 and 3.0 specifications.
- Free threading model on Windows NT, 2000 and XP platforms.
- Supports self-registration, browsing, data quality reporting, and timestamps.
- Can be used as a stand-alone server or as a service.
- In-proc server design for high-performance communication.
- Sample application code and comprehensive documentation illustrating how to use the ROCKit.
- OPC Explorer client that exercises the OPC COM interface for testing and debugging your server.
- The interface to the Device Specific Plug-in application code is separate from the OPC COM interface code. This means that  future OPC source code updates are simply plugged in, while your own protocol code remains untouched, resulting in minimal  engineering effort.

What are Realtime Operating Systems RTOS?

A real-time operating system (RTOS) is a class of operating system intended for real-time applications. Such applications include embedded (programmable thermostats, household appliance controllers, mobile telephones), industrial robots, spacecraft, industrial control (e.g. SCADA), and scientific research equipment.

A RTOS facilitates the creation of a real-time system, but does not guarantee the finished product will be real-time; this requires correct development of the software. A RTOS does not necessarily have high throughput; rather, a RTOS provides facilities which, if used properly, guarantee deadlines can be met generally ("soft real-time") or deterministically ("hard real-time"). A RTOS will typically use specialized scheduling algorithms in order to provide the real-time developer with the tools necessary to produce deterministic behavior in the final system. A RTOS is valued more for how quickly and/or predictably it can respond to a particular event than for the given amount of work it can perform over time. Key factors in an RTOS are therefore minimal interrupt and thread switching latency.

A significant problem that multitasking systems must address is sharing data and hardware resources among multiple tasks. It is usually "unsafe" for two tasks to access the same specific data or hardware resource simultaneously. ("Unsafe" means the results are inconsistent or unpredictable, particularly when one task is in the midst of changing a data collection. The view by another task is best done either before any change begins, or after changes are completely finished.)

General-purpose operating systems usually do not allow user programs to mask (disable) interrupts, because the user program could control the CPU for as long as it wished. Modern CPUs make the interrupt disable control bit (or instruction) inaccessible in user mode to allow operating systems to prevent user tasks from doing this. Many embedded systems and RTOSs, however, allow the application itself to run in kernel mode for greater system call efficiency and also to permit the application to have greater control of the operating environment without requiring OS intervention.

What are Manufacturing Execution Systems?

A Manufacturing Execution System (MES) is system that companies can use to measure and control production activities with the aim of increasing productivity and improving quality.

A Manufacturing Execution System MES is a shop floor control system which includes either manual or automatic labor and production reporting as well as on-line inquiries and links to tasks that take place on the production floor. MES includes links to work orders, receipt of goods, shipping, quality control, maintenance, scheduling, and other related tasks.

The ISA has defined standards regarding the structuring of MES and its integration in a larger company-wide IT architecture. ISA-95 "Enterprise-Control System Integration" defines a layer model looking at the integration aspects between ERP, MES and the production control level. It is supported by several vendors in the MES area. ISA-S88 "General and Site Recipe Models and Representation" defines a process state model for the batch industry.

What is CMMS Software?

Computerized maintenance management system (CMMS) software and enterprise asset management (EAM) software is used to manage  maintenance operations on capital equipment and other assets and properties. CMMS software and EAM software helps maintenance  personnel and departmental managers make better decisions for the allocation, maintenance, scheduling and disposal of  equipment and properties.

Computerized maintenance management software includes features such as work order generation, event logs, scheduling of  preventive maintenance checks and services, and downtime analysis. CMMS software also allows users to plan equipment  maintenance activities to coincide with the schedules of employees such as technicians, mechanics, and operators. Maintenance  management reporting may also be included. CMMS software can be industry-specific or designed for a range of industries such  as transportation, energy and utilities, manufacturing, engineering, and automation.

Enterprise asset management software is designed to improve operational productivity and processes, and track, manage, and  extend the life of critical assets. With EAM software, corporate managers and executives can monitor the status of plants,  buildings and facilities or develop a plan for inventory control. EAM software features include modules to define assets,  track asset usage, maintain asset documents (i.e., warranties, lease agreements, and contracts), and flag assets for  maintenance or other event triggers.

The strongest feature set of CMMS software and EAM software is the ability to integrate the two products into a single  maintenance and management solution. Such integration permits more efficient interaction between various departments within  an organization. For example, when an asset is reported as damaged, service requests can be entered into the system and an  alert immediately sent to maintenance personnel. Mechanics or engineers can then inspect the asset, open work orders, and  alert purchasing agents of any need for the procurement of parts, tools, or other materials to perform repairs. Managers can  run regular reports to identify areas of repeated failure or those assets that cost the most to retain and repair. This  permits the proper distribution of budgeted funds, or implementation of better maintenance and management processes.

What is a P&ID Piping and Instrumentation Diagram?

A Piping and Instrumentation Diagram - P&ID, is a schematic illustration of functional  relationship of piping, instrumentation and system equipment components.

P&ID shows all of piping including the physical sequence of branches, reducers, valves,  equipment, instrumentation and control interlocks. The P&ID are used to operate the process  system.

A P&ID should include:

- Instrumentation and designations 

- Mechanical equipment with names and numbers 

- All valves and their identifications 

- Process piping, sizes and identification 

- Miscellaneous - vents, drains, special fittings, sampling lines, reducers, increasers and  swagers 

- Permanent start-up and flush lines 

- Flow directions 

- Interconnections references 

- Control inputs and outputs, interlocks 

- Interfaces for class changes 

- Seismic category 

- Quality level 

- Annunciation inputs 

- Computer control system input 

- Vendor and contractor interfaces 

- Identification of components and subsystems delivered by others 

- Intended physical sequence of the equipment .

P&ID should not include:

- Instrument root valves 

- control relays 

- manual switches 

- equipment rating or capacity 

- primary instrument tubing and valves 

- pressure temperature and flow data 

- elbow, tees and similar standard fittings 

- extensive explanatory notes .

What are Automatic Guided Vehicles AVGs?

An automatic guided vehicle (AGV), also known as a self guided vehicle, is an unmanned, computer-controlled mobile transport unit that is powered by a battery or an electric motor. AGVs are programmed to drive to specific points and perform designated functions. They are becoming increasingly popular worldwide in applications that call for repetitive actions over a distance. Common procedures include load transferring, pallet loading/unloading and tugging/towing. Different models, which include forked, tug/tow, small chassis and large chassis/unit load, have various load capacities and design characteristics. They come in varying sizes and shapes, according to their specific uses and load requirements. 

  

AGVs have onboard microprocessors and usually a supervisory control system that helps with various tasks, such as tracking and tracing modules and generating and/or distributing transport orders. They are able to navigate a guide path network that is flexible and easy to program.

Various navigation methods used on AGVs include laser, camera, optical, inertial and wire guided systems. AGVs are programmed for many different and useful maneuvers, such as spinning and side-traveling, which allow for more effective production. Some are designed for the use of an operator, but most are capable of operating independently.

Corporations that use AGVs, often factories, warehouses, hospitals and other large facilities, benefit from the many advantages AGVs have to offer. One of the most beneficial is reduced labor costs. AGVs do not tire like human workers, and when their batteries are drained, charging the AGVs easily replenishes their energy. Loads that AGVs carry are far heavier than any single human could manage, which makes transporting heavy objects quick and simple. AGVs help give companies a competitive edge because they increase productivity and complete the job in an effective and time-efficient manner. They are flexible and can be adapted to many different needs. Also, using AGVs reduces damage to products and increases safety among workers.

  

Currently, AGVs are fairly pricey, and this discourages some companies, but in truth, the money is quickly earned back through reduction of other costs. Manufacturers of AGVs are working on reducing costs and making the units easier to understand to attract more potential buyers. Research on these vehicles is on-going, and new developments on software and movement techniques are frequently being made.

What is Robotics? - Robotics Industrial

Robotics is the science and technology of robots, their design, manufacture, and application. Robotics requires a working  knowledge of electronics, mechanics, and software and a person working in the field has become known as a roboticist.

Although the appearance and capabilities of robots vary vastly, all robots share the features of a mechanical, movable  structure under some form of control. The structure of a robot is usually mostly mechanical and can be called a kinematic  chain (its functionality being akin to the skeleton of a body). The chain is formed of links (its bones), actuators (its  muscles) and joints which can allow one or more degrees of freedom. Most contemporary robots use open serial chains in which  each link connects the one before to the one after it. These robots are called serial robots and often resemble the human  arm. Some robots, such as the Stewart platform, use closed parallel kinematic chains. Other structures, such as those that  mimic the mechanical structure of humans, various animals and insects, are comparatively rare. However, the development and  use of such structures in robots is an active area of research (e.g. biomechanics).

Robots used as manipulators have an end  effector mounted on the last link. This end effector can be anything from a welding device to a mechanical hand used to  manipulate the environment.

The mechanical structure of a robot must be controlled to perform tasks. The control of a robot involves three distinct  phases - perception, processing and action (robotic paradigms). Sensors give information about the environment or the robot  itself (e.g. the position of its joints or its end effector). Using strategies from the field of control theory, this  information is processed to calculate the appropriate signals to the actuators (motors) which move the mechanical structure.  The control of a robot involves various aspects such as path planning, pattern recognition, obstacle avoidance, etc. More  complex and adaptable control strategies can be referred to as artificial intelligence.

Any task involves the motion of the robot. The study of motion can be divided into kinematics and dynamics. Direct kinematics  refers to the calculation of end effector position, orientation, velocity and acceleration when the corresponding joint  values are known. Inverse kinematics refers to the opposite case in which required joint values are calculated for given end  effector values, as done in path planning. Some special aspects of kinematics include handling of redundancy (different  possibilities of performing the same movement), collision avoidance and singularity avoidance. Once all relevant positions,  velocities and accelerations have been calculated using kinematics, methods from the field of dynamics are used to study the  effect of forces upon these movements. Direct dynamics refers to the calculation of accelerations in the robot once the  applied forces are known. Direct dynamics is used in computer simulations of the robot. Inverse dynamics refers to the  calculation of the actuator forces necessary to create a prescribed end effector acceleration. This information can be used  to improve the control algorithms of a robot.

Handbook of Industrial Robotics

About the Handbook of Industrial Robotics, Second Edition:

"Once again, the Handbook of Industrial Robotics, in its Second Edition, explains the good ideas and knowledge that are needed for solutions." -Christopher B. Galvin, Chief Executive Officer, Motorola, Inc.

"The material covered in this Handbook reflects the new generation of robotics developments. It is a powerful educational resource for students, engineers, and managers, written by a leading team of robotics experts." - Yukio Hasegawa, Professor Emeritus, Waseda University, Japan.

"The Second Edition of the Handbook of Industrial Robotics organizes and systematizes the current expertise of industrial robotics and its forthcoming capabilities. These efforts are critical to solve the underlying problems of industry. This continuation is a source of power. I believe this Handbook will stimulate those who are concerned with industrial robots, and motivate them to be great contributors to the progress of industrial robotics." -Hiroshi Okuda, President, Toyota Motor Corporation.

"This Handbook describes very well the available and emerging robotics capabilities. It is a most comprehensive guide, including valuable information for both the providers and consumers of creative robotics applications." -Donald A. Vincent, Executive Vice President, Robotic Industries Association

120 leading experts from twelve countries have participated in creating this Second Edition of the Handbook of Industrial Robotics. Of its 66 chapters, 33 are new, covering important new topics in the theory, design, control, and applications of robotics. Other key features include a larger glossary of robotics terminology with over 800 terms and a CD-ROM that vividly conveys the colorful motions and intelligence of robotics. With contributions from the most prominent names in robotics worldwide, the Handbook remains the essential resource on all aspects of this complex subject.


SHIMON Y. NOF, a recognized expert in robotics research and applications, is Professor of Industrial Engineering at Purdue University's School of Industrial Engineering.