Process optimisation by Real-Time Control!

23/08/2014
Major installation at English sewage treatment works.

Wessex Water, an English water authority,  is investing around £20m at its Taunton sewage treatment works to improve the facilities for wastewater and sludge treatment in a project that is due for completion by the end of March 2015. The upgrade to the works under the DWF (Dry Weather Flow) Improvements Scheme will increase the site’s treatment capacity whilst also improving the efficiency and quality of the treatment process, lowering energy costs and reducing the site’s carbon footprint.

Prior to the implementation of the DWF Scheme, the STW was comprised of an inlet pumping station and balance tank, coarse and fine screens, grit removal (detritor), primary settlement tanks, a conventional ASP & biological filter beds, final & humus tanks and final effluent lagoons. The construction work involves the creation of a new four-lane ASP to replace the existing 16 biological filters. To facilitate this, one of the lagoons and four of the filters are being taken out of service to create space for the new works, and this has allowed all development to remain within the existing site boundaries enabling most works to be constructed under permitted development rights.

tauntonProcess optimisation of the new ASP stage will be achieved through implementation of Hach Lange’s Real-Time Control (RTC) system, which monitors influent ammonium concentration and dissolved oxygen concentrations along the aeration lanes, providing more efficient control of the fine bubble diffused aeration. The measurement of other quality parameters in the process train provides feedback to the RTC. A reduction of up to 15% energy usage is anticipated as a result.

Balfour Beatty has provided the civil works and Nomenca Ltd is responsible for the supply, installation, commissioning, and performance testing of the mechanical and electrical components of the new works. Contracts Manager Trevor Farrow says, “Nomenca’s reputation is built on a track record of successfully delivered projects, and the relationships that we develop with both clients and suppliers are key to this success. We have already worked with Hach Lange’s instrumentation on a wide variety of projects, so we are confident that this project will be a further success.”

As Project Manager for Wessex Water, Garry Orford says: “The drivers for this works upgrade include an increased treatment capacity requirement and a tightening of the consent, taking in to account longer-term requirements that may be implemented in AMP6. We have already implemented Hach Lange’s RTC process optimisation systems at our Holdenhurst plant – 175,000 PE – near Bournemouth, and this has delivered energy savings of around 25% so we are confident that we can repeat this success at Taunton – 85,000 PE.”

taunton2Following completion of the new works, the site will meet the following consent conditions:

  • Dry Weather Flow (DWF)   30,595 m3/d
  • Sanitary parameters BOD:SS:AmmN 15:30:3 mg/l

In addition to the upgrade of the sewage treatment facilities, a third anaerobic digester (AD) is also being built at the Taunton works. “This will increase our capacity to generate renewable energy and further reduce our electricity bill,” according to Garry Orford. “The power generation of the AD plants is fairly stable, but the energy demand of the treatment plant varies according to the load, so there will be occasions where we can sell energy back to the grid, and others where we will continue to have a power requirement. It is essential therefore that we use this power as efficiently as possible.” 

Real-Time Control in industrial processes is commonplace. However, wastewater monitoring represents a greater challenge because of its physical and chemical variability. Historically, wastewater monitoring technology was prone to drift (especially galvanic dissolved oxygen monitors) and required a high level of maintenance, so RTC was not feasible. However, the latest sensors offer much higher levels of reliability than was possible in the past, with substantially lower levels of maintenance and recalibration. This has been a major factor in enabling the development of RTC in wastewater treatment. In addition, many of the latest sensors provide a ‘health status’ output in addition to the readings. As a result, if any problems arise they can be quickly remedied, and control systems can ignore data from sensors that are not performing to their target specification.

Monitoring technology
The capital outlay for the addition of RTC to a treatment plant is relatively small; the most significant extra cost is the requirement for extra sensors plus the RTC unit. The Taunton build includes the installation of the latest sensors for dissolved oxygen, ammonium and turbidity, controlled by an sc1000 network, providing reliable data on the influent, and from within the treatment process.

IMG_0056The LDO sc dissolved oxygen sensor employs an optical luminescence method for calibration-free and drift-free measurements. Once the construction work is complete there will be four new lanes, each with three zones, so a total of 12 LDO probes will monitor dissolved oxygen.

In addition, two SOLITAX ts line dip probes will measure Mixed Liquor Suspended Solids (MLSS) content in the aeration lanes and the solids content of the Returned Activated Sludge. The RTC at Taunton will also control sludge retention time, which enhances plant efficiency. The suspended solids probes employ a patented dual scattered light method with a built-in wiper, to provide colour-independent measurement of solids without a requirement for calibration. Ammonium measurements will be undertaken at both the entrance and exit of the aeration lanes with two AMTAX sc instruments; high-precision analysers that continuously collect samples via an air-bubble cleaned filter probe. The ammonium analysers will be mounted directly over the filters to minimise the distance travelled by samples.

Real-Time Control
The Hach Lange RTC is implemented on an industrial PC which communicates with an sc controller network and the local PLC. The RTC system determines the most efficient aeration level and continuously feeds DO set points to the PLC which controls the blowers. This means that under RTC, DO set points are no longer ‘fixed’, instead they ‘float’ according to the load. The RTC modules continuously deliver set points to the PLC, which applies them to the process. This ensures that response to changing conditions is immediate. The algorithms employed by the N-RTC (Nitrification Real Time Controller) are mainly based on the Activated Sludge Models of the International Water Association.

The N-RTC also constantly reads the NH4-N concentration at the outlet of the aeration lane. This value provides a feedback control loop and ensures that the DO concentration is fine tuned to achieve the desired ammonium set point at the end of the ASP. In this way, the N-RTC control module combines the advantages of feed forward and feedback control, which are (1) rapid response, (2) set point accuracy and (3) robust compliance.

Aeration to achieve the biological oxidation of ammoniacal compounds to nitrate is the most energy intensive process at activated sludge plants because blower power consumption can represent over 50% of total costs at some plants. However, in addition to the advantages of the process optimisation system, four new Sulzer high speed HST-20 turbo-compressors are being installed by Nomenca, following trials on similar units by Wessex Water. These machines employ a control system that manages both the number of blowers to run, and the speed of the blowers, which will further improve energy efficiency.

Summarising, Garry Orford says: “Wessex Water has an ambitious long-term objective of carbon neutrality, and these improvement works projects provide us with useful opportunities to make a significant contribution to that goal.”


Industry 4.0 unplugged!

22/08/2014
Electrical component manufacturer, REO, has written a blog post about the four biggest industrial revolutions – the development of mechanization using water and steam power, the introduction of electricity in manufacturing environments, using electronics and IT to further automate manufacturing and finally, Industry 4.0.

Industry 4.0 is a big concept and a hugely popular buzzword across manufacturing. It originated at the Hannover Messe a couple of years ago, when Siemens defined it as the computerisation of manufacturing, including transition to higher levels of interconnectivity, smarter plants and communication between equipment.

industry4The first industrial revolution was the development of mechanization using water and steam power – in fact Reo mentioned their visit to its birthplace recently. This was followed by the introduction of electricity in manufacturing environments, which led to mass production. The digital revolution happened during our lifetime, using electronics and IT to further automate manufacturing.

Industry 4.0 is the fourth step in this series of revolutions. Although it is still, relatively speaking, in its infancy, the idea relies on sophisticated software and machines that communicate with each other to optimise production.

Furthermore, today’s smart plants are expected to take decisions regarding production efficiency and safety autonomously. Industry 4.0 is more about machines doing the work and interpreting the data, than plants relying on human intelligence – as was the case until now.

Thanks to the capacity of Industry 4.0 ready devices to process big data, they are able to offer statistics and trends that allow manufacturers to make their production lean and more fuel efficient. Saving electricity and water are key requirements for modern plant managers and they can achieve their eco-friendly goals by using smart plant connectivity.

Seamless integration
REO offers a number of products that integrate seamlessly into an Industry 4.0 plant environment.

Automation solutions like recognition systems for product checking and sorting can be used to provide status reports. The information received from them can be sent straight to the quality department who can stop production if faults have been discovered.

In addition, these recognition systems come with a program written as an instruction list, operating sequence or ladder diagram, as specified in the IEC 1131 standards. This makes them ideal for the track and trace requirements of the pharma industry, as well as those of food manufacturing plants.

Vibration measurement instruments can also be integrated into smart plant strategies. The Reovib BK032 is a monitoring unit for vibratory feeders for instance. By using this measuring device in conjunction with an accelerometer, vibration levels can be easily monitored and introduced to a database.

In the Reovib control system, an acceptance window can be set, defining adjustable maximum and minimum limits. If either of these values is exceeded, a corresponding relay will operate. During the unstable, start-up phase a time delay can be set so that spurious readings are ignored. The unit has a built-in sensor power supply for direct connection, which means that REO’s measurement instruments not only collect data, but also react to it and take action as per the input programs.

What does the future hold?
REO believes that Industry 4.0 will ultimately represent a significant evolution in manufacturing and industry. Furthermore, geographical and data boundaries between distinct factories will soon become a thing of the past, with smart plant concepts joining-up sites located anywhere around the world.

Of course, the company recognises that their own products are only a very small part of this bigger picture. Furthermore, they have never set out to design an ‘Industry 4.0’ compliant device, just as customers never ask for an ‘Industry 4.0’ application.

Instead, the may be said to be part of a trend in the electrical industry that SIEMENs identified at Hannover. But this particular trend is an exciting one and they are keen to see how it develops, as are we all!


Labhair liom! Speak to me! Parle-moi! Languages in marketing automation!

18/08/2014
With a work force that boasts 20 different nationalities and 17 languages, the industrial automation spares supplier, European Automation is keen to show its support for any programme promoting learning new languages. Indeed, its recent linguistic placements and support for the British government initiative encouraging businesses to identify the benefits of employing postgraduate language students, is reflected in its endorsement of the European Day of Languages

Our planet has over 7 billion people who speak between 6,000 and 7,000 different languages. In Europe alone there are more than 225 indigenous languages, which only amount to three per cent of the world’s total. “Now how bad do you feel that the extent of your multilingual capabilities is speaking louder and more slowly when abroad and extensive use of hand signals?” In celebration of all these tongues and dialects, the 26 of September is European Day of Languages.

LTnahEEuropean Day of Languages promotes linguistic diversity as a tool for achieving greater intercultural understanding and encourages events designed to showcase the benefits of multilingualism.

European Automation knows all about the importance of speaking the lingo when it comes to international business. 82 per cent of their sales currently come from exports and thus it’s essential that we not only speak in terms that our customers understand, but also remain aware of cultural differences.

LTnahE_Logo“With a work force that boasts 20 different nationalities and 17 languages, we feel that we’re not doing too badly on the linguistic and cultural diversity fronts. We regularly organise days celebrating different nationalities – these consist of staff bringing in different foods, playing music and generally getting into the spirit of multiculturalism.”

Their special days are not too dissimilar from the range of events promoting the learning of languages scheduled across the continent for European Day of Languages. Those who wish to be involved the can organise their own event and submit it to the European Day of Languages’ page; there’s even a prize for the most innovative idea. Here is the full list of what’s going on and how you can enter! 

sprachrLanguage can often be a barrier for companies looking to export and can seriously impede a company’s growth. When our customers call from different parts of the world, they are put through to a native language speaker with relevant cultural knowledge. This eliminates communication problems and creates an authentic relationship between our customers and our sales team. Needless to say, in any language, the benefit of this is huge/énorme/riesig/ollmhór/огромный… well, you get the gist.

Therefore the need for more language specialists in companies like European Automation is crucial.

On May 6, British business secretary Vince Cable announced a new initiative, which encourages companies to identify and employ postgraduate students with relevant language skills for key overseas markets. European Automation strongly supports the initiative and have actively sought to nurture local linguistic talents.

They recently rewarded three Newcastle College (GB) linguists a two week placement at European Automation after they beat off fierce competition. All three had to apply for the placement by interviewing first in English and then in their chosen second language, earning themselves the chance to put their skills to the test in the working world.

According to the research that sparked the initiative to recruit more multilingual postgraduate students, as much as €60 billion (£48 billion)  is lost in international sales because of poor language skills and cultural ignorance. Talking louder and enunciating (whilst pointing, always remember to point!) may be fine to communicate with the hotel barman in Lanzarote, but it certainly isn’t good enough for businesses looking to succeed when exporting abroad.

“So what have you got planned for the September 26? Why not take a leaf out of our book and embrace a different culture, or more than one for that matter, in the spirit of European Day of Languages.”

ag_caint

 


Demand for accurate, lightweight test & measurement sensors set to increase!

07/08/2014

Test and measurement is a prerequisite for constant innovation and improvement in the development and manufacturing space. In turn, monitoring various operating conditions such as acceleration, pressure, temperature, magnetic field and frequency range while performing test and measurement tasks automatically necessitates a variety of sensors. As innovations in testing methods gather pace, the development of sensors used in test and measurement applications too will pick up.

tandmNew analysis from Frost & Sullivan, Sensors in Test and Measurement, finds that the market earned revenues of €820m ($1.10 billion) in 2013 and estimates this to reach €1,14 billion ($1.53 billion) in 2020. The aerospace and defence as well as automotive industries will generate the maximum revenue due to the large number of applications involved, and the high cost of sensors used. Meanwhile, the installation of wind turbines, owing to the intensifying focus on renewable energy, will present opportunities for sensors in testing wind turbines. Product testing in consumer electronics is another avenue that promises high growth.

“As product design and development become more complex, the need for highly accurate, sophisticated sensors for test and measurement applications will increase,” said Frost & Sullivan Measurement and Instrumentation Senior Industry Analyst Sankara Narayanan. “The shift to smaller, lighter structures will also drive the demand for smaller, lighter electronic components, including sensors.”

However, innovations in core sensor technologies have not kept pace with developments in other areas such as instrumentation and sensor packaging. To expand market scope, proven experience of having met the requirements of demanding test and measurement end markets will be critical. Further, easy-to-use, dedicated sensor solutions that provide state-of-the-art measurement and monitoring will be mandatory irrespective of the end market.

It is important for sensor manufacturers to offer a wide configuration of sensors to support multiple applications. Maturing into a one-stop shop by supplying test equipment and associated software along with sensors will help vendors appeal to a larger consumer base.

“Moreover, sensors used in test and measurement are put to extreme working conditions involving high temperature and pressure,” noted Sankara Narayanan. “Therefore, manufacturers must be able to deliver both on-site and local technical, repair and calibration services to stamp their authority in the global market.”


Wash, Rinse, Dry: Cleaning mass-produced automotive parts!

04/08/2014
High quality components keep vacuum cleaning plant running smoothly

The Multiclean-D-4-4-F full vacuum plant from Höckh is a true giant among washing machines. While the drum of a household washing machine can hold six kilograms at any one time, an industrial washing machine recently delivered to a German customer can take two 600 kg loads of metal parts for the automotive industry.

Festo’s  technology keeps the twin-chamber cleaning plant running smoothly.

The Multiclean-D-4-4-F full vacuum plant from Höckh is a true giant among washing machines.

The Multiclean-D-4-4-F full vacuum plant from Höckh is a true giant among washing machines.

In metalworking, greases and special emulsions protect cutting tools against wear. While this is good for the machines, it leaves a residue on the metal parts and must be removed before further processing. Assembly processes or surface treatments such as galvanising or painting require clean parts. Depending on the application, aqueous cleaning solutions or solvents can be used.

Solvents are preferable to aqueous cleaners for oily mass produced parts for the automotive industry as they are quick, economical and resource-saving. A new twin-chamber perchlorethylene-based cleaning plant from Höckh Metall-Reinigungsanlagen GmbH has raised the bar with operation under full vacuum.

When integrated into the production cycle, it increases part throughput significantly. Up to ten crates filled with pressed and stamped parts pass through the system every hour in a three shift operation. State-of-the-art valve terminal technology from Festo contributes to this excellent performance.

Everything in one chamber
The capacity of the huge washing machine for metal parts is simply enormous. In addition to rapidly cleaning large volumes of metal parts in either a 65° or 98° wash with liquid or vaporous perchlorethylene, the system also dries the parts using a vacuum after they have been washed. And all of this in less than 15 minutes per crate.

Before that, the pressed parts are transported in bulk. Forklift trucks move the parts in crates measuring approx. 900 x 800 x 850 mm and with a total weight of between 500 and 600 kg. To select the right program, the system operator simply scans the bar code on the accompanying ticket. As soon as he has left the loading area, automatic feeding begins and the crate is transported to the next free process chamber. To achieve the required capacity of 10 batches per hour in a three-shift operation, the process has been divided between two chambers.

The door of the giant washing machine drum is closed by a standard cylinder.

The door of the giant washing machine drum is closed by a standard cylinder.

The loading gantry then loads the rotating crate holder and a Festo standard cylinder DNG with a stroke of 180 cm closes the sliding door of the process chamber vacuum tight. When it reaches the last few centimetres, a clever toggle lever mechanism ensures it is firmly closed.

When the door reaches the last few centimetres, a clever toggle lever mechanism ensures it is firmly closed.

When the door reaches the last few centimetres, a clever toggle lever mechanism ensures it is firmly closed.

10 batches per hour
Depending on the parts type, this is then followed by an individual cleaning programme, which can be made up of various modules such as evacuation of the process chamber to process vacuum, pre-washing in the spray process, flood cleaning (full bath) from tank one, post washing in the spray process, flood cleaning (full bath) from tank two, vapour degreasing with solvent vapour and vacuum drying. A limit value encoder monitors the drying process so that only completely dry, solvent free parts are removed from the process chamber.

When the door reaches the last few centimetres, a clever toggle lever mechanism ensures it is firmly closed.

When the door reaches the last few centimetres, a clever toggle lever mechanism ensures it is firmly closed.

The cleaned parts then pass through a cooling tunnel on the unloading roller conveyor so that the crates can be packed directly for shipment. To achieve maximum flexibility, the system was designed as three separate modules.

For cleaning there are two identical, completely independent cleaning modules with process chamber, twin tank, distillation plant, pumps and filters. Because of standalone operation, one module can be switched off in the event of maintenance or low capacity utilisation and the system can continue to operate at half capacity. Both cleaning modules are connected to a central supply module, which houses the vacuum pumps as well as the activated carbon absorber for process air preparation.

The entire vacuum performance of over 1,000 m³/h can be divided into variable ratios between the two process chambers if required. This ensures a very high throughput for the size of the chamber and the complexity of the process of 10 batches per hour.

Reliable process engineering
This demanding process is kept running smoothly by a variety of Festo components. These include valve terminals type CPX/MPA with Profibus control. These valve terminals look after all of the process engineering, activate the angle seat valves and the actuators, ensure the crates are locked and control the liquid transport and the vacuum.

Thanks to ‘intelligence on the terminal’; the cleaning plant from Höckh does not require any additional multi-pin cables. The MS series service unit ensures correct and reliable compressed air preparation. The latest Festo technology also offers a condition monitoring option. Values such as maximum, peak and average consumption as well as effective and apparent power are displayed.


Accelerating development of smart, power-efficient IoT applications!

28/07/2014
Delivering intelligent connectivity starting at the network edge

B&B Electronics has introduced its Wzzard™ Intelligent Sensing Platform.    Wzzard is an easy to use, complete wireless sensor connectivity platform for the rapid deployment of scalable, intelligent, reliable Internet of Things (IoT) networking in remote and demanding environments.   Wzzard was designed to help integrators, VARs and service providers efficiently develop and deploy secure, smart, self-powered, and scalable IoT applications.

BBWzzardUnlike a traditional SCADA application where sensors and edge devices are simply passive conduits for raw data, edge decision making delivers a more effective network.  Using iterative control limits and gateway data aggregation to support applications closer to the network edge, the Wzzard Intelligent Sensing Platform brings this intelligence to the network starting at the sensor, creating a more responsive, reliable and efficient network.

There are several key components and technologies that comprise B&B Electronics’ Wzzard Intelligent Sensing Platform, as demonstrated here: B&B Smart Sensing Wzzard Platform

First, Wzzard Intelligent Edge Nodes will connect, via conduit fitting cable gland or M12 connector, to any industry-standard sensor. General-purpose analog inputs, digital input/output and thermocouple interfaces are included. B&B has already integrated internal temperature and accelerometer sensor options, and can integrate other application specific sensors upon request.

The Intelligent Edge Nodes are easily configurable, using Android or IoS smartphones or tablets and the Wzzard app over Bluetooth LE 4.0. They can be configured to communicate only data outside specified thresholds, reducing the cost on cellular networks, as well as to associate other useful information (geo-location, device name, and up-time) with the collected sensor data for upstream analytics applications.   Control time synchronization is used to maximize battery life, exceeding 5 years for many applications.   Nodes are IP67 rated for outdoor use and include both magnetized and screw mount options.

Next is the communications component. B&B chose SmartMesh IP® wireless sensing technology from Linear Technologies Dust Networks.  SmartMesh IP is based upon the wireless IEEE 802.15.4e standard and creates full-mesh networks, sometimes referred to as “mesh-to-the-edge” networks.  SmartMesh IP networks use a triple-play of wireless mesh technologies—time diversity, frequency diversity, and physical diversity—to assure reliability, resiliency, scalability, power source flexibility, and ease-of-use.  At the core the technology is an intelligent mesh network with advanced algorithms and power saving technologies that enable powerful features not available from other WSN providers including:

• Ultra low power consumption

• Deterministic power management and optimization

• Auto-forming mesh technology for a self-healing and self-sustaining network

• Dynamic bandwidth support, load balancing and optimization

• Network management and configuration

• Zero collision low power packet exchange

• Scalability to large, dense, deep networks

wzzard_groupWzzard’s Intelligent Edge Nodes can join the mesh network at any time without gateway interaction.  Nodes attach automatically, and the SmartMesh IP technology dynamically self-configures to re-form the mesh network. To ensure data always reaches the gateway, nodes will determine their optimal RF paths to other nodes and back to the gateway. The SmartMesh IP protocol implemented within the edge nodes includes advanced network management functions and security features such as encryption and authentication. For more information: B&B Smart-Sensing What is Smartmesh

Wzzard also uses the lightweight, publish/subscribe messaging transport MQTT protocol for sensor communications.   MQTT is an extremely simple messaging protocol created for M2M and IoT applications over wireless networks. Its efficient distribution of information to single or multiple receivers, low power usage and minimized data packets make it ideal for mobile or remote locations. Unlike older SCADA protocols such as Modbus, MQTT places few restrictions on the volume or type of data that can be communicated. This facilitates a meta-data approach where multiple IoT applications can act upon the information simultaneously without having to know its origin.

Finally, B&B’s programmable, industrial-grade Spectre router serves as Wzzard’s Intelligent Gateway. Spectre can connect equipment and other devices to the Internet or Intranet over either wired Ethernet or wireless cellular connections. Spectre is built for plug-and-play simplicity with extensive remote management, deployment and customization options.  It is a robust, flexible gateway designed for easy deployment in demanding environments and the cellular version creates secure connections in locations where cable connections are impractical.

Processed information from the sensor nodes is published through the Spectre Gateway up to the customer’s IoT application using MQTT transport protocol.

SeeControl is one of the first IoT platform providers to leverage the Wzzard Intelligent Sensing Platform and MQTT protocols to develop applications. (More information at: B&B/SeeControl Partnership)

“Today, most business analytics can only describe what has happened and why,” said Parthesh Shastri, SeeControl’s vice president of customer success and strategy.  “The industry can move past descriptive to predictive and even prescriptive analytics using IoT technologies such as B&B’s Wzzard that applies edge decision making and processes information collected from sensors before transmitting relevant, as opposed to raw data, up to SeeControl’s SaaS remote management platform. Cloud-based big data analytics is then better able to derive meaning from the data, and prescribe specific courses of action, to drive more intelligent applications.”

Jerry O’Gorman, CEO of B&B Electronics explained, “The Wzzard platform’s technologies, protocols and hardware work together to reduce the complexity, expertise and time it takes for integrators to develop scalable IoT solutions.   We developed Wzzard to facilitate the coming world of connected intelligence, where smart machines and systems will collaborate, inform and make decisions on the intelligence gained from each other with little or no human supervision. Humans will program these smart networks, but then they have the ability to run efficiently and autonomously, sometimes for years, until there’s data reported that requires human intervention.”

Possible Applications:

  • Flood and water level monitoring
  • Smart car parks; vehicle counting, air quality
  • Smart irrigation systems monitoring soil moisture, environmental conditions, leaks
  • Mechanical condition monitoring/preventative maintenance
  • Energy measurements and audits on a per system or machine basis
  • Data center environmental monitoring
  • Tank and lift stations
  • Condition monitoring and optimization in industrial environments
  • Traffic monitoring of over-height vehicles for tunnels and bridges

Celebrating twenty years abnormality!

21/07/2014

This year the Abnormal Situation Management (ASM®) Consortium  is celebrating 20 years of thought leadership in the process industry. The ASM Consortium grew out of a grassroots effort begun in 1989 by ASM to address alarm floods. Honeywell spearheaded the development of a proposal to the US NIST, Advanced Technology Program to form a Joint Research & Development Consortium.

Background on the ASM ConsortiumasmThe ASM Consortium was started in 1994 to address Process Industry concerns about the high cost of incidents, such as unplanned shutdowns, fires, explosions, emissions, etc. The term, Abnormal Situation Management®, was used to describe it. Matching funds from NIST enabled the consortium to spend several years researching and developing highly-advanced concepts to address the problem of abnormal situations. Since then research has continued and increasing effort has been put into development and deployment of solutions that incorporate ASM knowledge.The basis of the ASM Consortium is collaboration and information-sharing. By working together, members achieve far more than they could working alone. Research results are published for members, and often further shared by means of webinars, seminars and workshops. User members also guide Honeywell in selection and development of product solutions that incorporate ASM knowledge. Non-members can benefit from ASM Research as ASM Effective Practices Guidelines for Alarm Management, Display Design and Procedural Practices are available for purchase on Amazon.com.

The proposal addressed the challenging problem of abnormal situation management. In preparing for this proposal effort, Honeywell and its collaborators created the Abnormal Situation Management (ASM) Joint Research and Development Consortium (referred to as ASMC) under the U.S. Cooperative Research and Development Act. In November 1994, the ASM research joint venture began its research with $16.6 million (€12.27m) in funding for a three year study program, including $8.1 million (€6m) from ATP and industry cost-sharing of $8.5 million (€6.29m).

This year, ASM Consortium members have met twice for a week-long Quarterly Review Meetings (QRM) , once at Houston, Texas (USA) in April and then again at Antwerp (B) in June. Along with its normal business, the Consortium discussed plans to celebrate the Consortium’s 20 year of service to the Process Industry. The Quarterly Review Meetings are a platform for the ASM Consortium members to share the benefits gained from the ASM practices and products, and to discuss new challenges faced in plant operations. Members of the Consortium besides Honeywell include industrial manufacturers, a human factors research company, and universities that collaborate to research best practices for managing abnormal situations in industrial facilities.

To celebrate its 20th year, ASM Consortium will be spreading further awareness about managing and mitigating abnormal situations in process industries by publishing journal articles, white papers at leading industry conferences, and a planned video.


Follow

Get every new post delivered to your Inbox.

Join 34 other followers