Technology Innovations Conference 2016

Christian McDermott, Voovio

The purpose of ER is to simulate, with extreme accuracy, industrial facilities and equipment that workers operate, and to overlay all the relevant information that they need to understand, practice and execute processes flawlessly. Examples of working projects will be demoed live to show how Voovio:

• ensures all SOPs are executed without errors
• maximizes productivity in operations and maintenance tasks
• reduces operations, maintenance and training costs

Richard Hanner, aeSolutions

This presentation discusses critical decisions and activities that take place during the Front-end Loading phase of Safety Instrumented System (SIS) design in accordance with ISA84/IEC61511. These decisions, when made correctly, present an opportunity to improve the longer-term viability of achieving the intended risk reduction, reduce the costs of late-stage design changes, construction, and SIF maintenance. We will discuss the importance of these critical items, their impact on system design, engineering, construction, and maintenance costs, as well as strategies for addressing these items when limited information is available. Examples of critical decisions will be discussed, that span from the processing of the Risk Assessment output to testing philosophies.

Don Mack, Siemens

A Safety Instrumented System (SIS) is designed to reduce the likelihood of hazardous risk by decreasing the frequency of unwanted accidents. The amount of risk reduction that an SIS can provide is represented by its safety integrity level (SIL). The SIS is designed to detect when the process reaches a hazardous condition and respond accordingly to move the process to a safe, thus preventing the unwanted accident from occurring. Studies indicate however, that over 50% of all SIS failures are related to human error. While many SIS systems boast having SIL 3 certification, it’s often the human interactions that render many of these well intended systems to be essentially non-existent. A safety interlock matrix is a proven tool that will help reduce the human errors throughout the entire safety lifecycle of the SIS.

Lourdes Reyes, Schneider Electric

According to a recent ARC Advisory Group study, it was reported that operator error is the leading cause of significant plant incidents. In the process industries, these incidents account for the highest dollar loss per incident, resulting in 42% of unscheduled plant shutdowns.  The process industry now faces the enormous challenge of replacing an aging workforce with a computer-savvy, gaming generation over the next five years. 

It’s been shown that people learn best by doing, as opposed to lecture or demonstration.   The airline industry for years has recognized the need for simulator training so that pilots can experience hazardous situations and learn from their mistakes while in a safe, virtual environment.  Advances in computer speed as well as process simulation now allow rigorous, first-principal simulation models to be used for operator training. 

With an Operator Training Simulator (OTS), operators can practice starting-up the unit and responding to emergencies, during which their every move can be measured against a benchmark for scoring.   Instead of opening and closing real valves, their actions open and close virtual valves in the simulation model.   Outside operators can also be included via the use of a 3-D virtual reality environment, where they walk around in a true virtual world.  This virtual world is linked with the same rigorous dynamic model, allowing for board and outside operators to coordinate like they do in the plant.  Virtually all companies in the process industries are extremely lean, so options like training program development as well as cloud-based execution can be important to minimize the demands on management and IT as an OTS program is rolled out.

Aaron Cook, Aetos Group

The more we understand about the condition of our infrastructure the better we can maintain it and keep processes running. Part of the challenge is accessing the equipment easily, safely, and cost effectively. Robotics have come of age to give actionable data and go where it is not possible or unsafe for a human. It is proven to be a safer and more cost effective alternative to traditional methods.

By Bob Swanson, Siemens
Join this session to learn about how process industries have and will benefit from innovation in the utilization of real-time data access in collaborative 3D immersive environments. Discover how an immersive training simulator can enable customized, scenario-driven 3D workflow simulations for HSE training, emergency drills and SOP rehearsals. Join us to learn more about key knowledge retention, enhancing operational safety and efficiency with advanced, 3D virtual reality visualization software.

What attendees will learn (about 5 bullets)
1. Why immersive training is so effective
2. How Visualization is implemented
3. How this technology helps in plant operations
4. What benefits other companies have gained

Spencer Absher, Mynah Technologies

Life Cycle Dynamic Simulators provide excellent business returns for process plant operations. Appropriate use of dynamic simulators has been proven to be a valuable tool for both new process investments and control modernization. The investment in dynamic simulation can be easily justified based upon Capital Project Execution and Operational Excellence Initiatives benefits in the process industries. Mimic simulation software was designed for the implementation of life cycle dynamic simulation for DeltaV and is the clear choice for implementation of this valuable technology.

By Russ Davis, Mistras Group

Asset integrity encompasses all of the equipment and instrumentation that is integral to the process. Ensuring that this equipment is safe to operate today and in the future is critical to a safe, reliable and environmentally responsible facility. This presentation will evaluate the potential damage mechanisms that detrimentally affect plant equipment and instrumentation. The presentation will demonstrate comparative analysis of the most effective and efficient testing and inspection methods for detecting and evaluating those damage mechanisms.
A focus on holistic inspection methodologies and a discussing of the latest innovations and how these methods integrate into the comprehensive reliability program will be presented. The methodologies include:
• Advanced NDE methods
• Advanced accessibility methods
o UAV’s/Drones and Robots
o Rope access inspection
The goal of this presentation will be to present an array of advanced NDE and accessibility methodology for ensuring the integrity of the plant as well as lowering the risk of operations and demonstrate regulatory compliance.

What attendees will learn:
The attendees will learn an overview of advance asset integrity inspection and testing methodologies as well as new methods for accessing plant equipment. Attendees will also learn about analyzing the process stream to determine potential damage mechanisms and the most effective and efficient methods for detecting and evaluation of the damage.

Scott West, Aegex

Chemical manufacturing facilities require real-time data and communications to accelerate productivity, boost efficiency and improve safety, but not all mobile devices can enter hazardous locations (UL C1D1). This seminar will address the gains in safety and productivity from employing intrinsically safe mobile hardware and software solutions in hazardous locations.

Replacing clipboards with intrinsically safe Windows tablets allows personnel in all hazardous locations to utilize real-time data. IS devices provide real-time collaboration and predictive analytics to decrease accidents, improve maintenance and avoid production downtime. Reducing production downtime by one hour per year can increase earnings by more than $100,000 per year.

J. Adam Lyman, Henkel Corporation

Pivotal to the success of reliability and predictability in industrial equipment, ceramic based polymer composites can be used to increase efficiency and reduce down-time in aggressive industrial applications. Preventive and scheduled maintenance maximize the life and structural integrity of large and small metal components such as mixing vessels, pumps, hoppers, housings, tanks, chutes, pipes, and centrifuges where these heavy-duty parts are often exposed to aggressive slurries, sand aggregates, particulates, and large stones that can cause damage and abrade even the hardest reinforced steel substrates.

Ceramic based polymer composites help to protect industrial equipment in aggressive environments from mechanical and chemical attack, helping to maintain efficiency and reduce unexpected failures. Technologies in the ceramic based polymer composite products have consistencies ranging from ultra-smooth and high gloss to large beaded compounds. The coatings can be applied to a wide variety of geometries by troweling, pouring, brushing, or spraying.

Chuck Jenkins, GE Oil & Gas Digital Solutions

This topic is covered in two seminars back to back.

PART 1 of 2 OBJECTIVES:
-Assessing the Potential Value & Linking Strategy to Performance
-Understand the potential value of Enabling Condition Based Maintenance
-Understand where Asset Strategy is crucial to Asset Performance

SEE NEXT LISTED SEMINAR FOR PART 2 OBJECTIVES.

BACKGROUND FOR BOTH PART 1 & PART 2
Are you effectively capturing and utilizing all of the data available in the age of the ‘industrial internet’, or drowning in it? In order to achieve optimal efficiencies across operations, enterprise-wide visibility has become essential. An enabled Condition Based Maintenance strategy connects the massive data from machines to workflow processes and analytics, allowing experts to collaborate and make smarter decisions. By developing Intelligent Asset Strategies and using those strategies to proactively Operate and Maintain our Product Assets, we can leverage the technology advancements available to Industrial businesses today. This requires bridging the gap between Informational Technology and Operational Technology (IT and OT) and connecting them to dynamic intelligent asset strategies.

Holistic views connect IT and OT by aggregating and learning from data and then enabling on condition maintenance. Problems are identified, evaluated and integrated early in their development and into workflow systems to facilitate efficient maintenance and operational excellence. The results are smarter, more insightful decisions that move decisions from being reactive to proactive, culminating in significant financial benefits.

Chuck Jenkins, GE Oil & Gas Digital Solutions

This topic is covered in two seminars back to back. See previously listed seminar for PART 1 of 2 OBJECTIVES.

PART 2 0f 2 OBJECTIVES:
-Understanding the Role of Data & Systems Integration
-Understand how data integration plays a key role O&M effectiveness
-Understand how systems integration allows for effective work management

BACKGROUND FOR BOTH PART 1 & PART 2
Are you effectively capturing and utilizing all of the data available in the age of the ‘industrial internet’, or drowning in it? In order to achieve optimal efficiencies across operations, enterprise-wide visibility has become essential. An enabled Condition Based Maintenance strategy connects the massive data from machines to workflow processes and analytics, allowing experts to collaborate and make smarter decisions. By developing Intelligent Asset Strategies and using those strategies to proactively Operate and Maintain our Product Assets, we can leverage the technology advancements available to Industrial businesses today. This requires bridging the gap between Informational Technology and Operational Technology (IT and OT) and connecting them to dynamic intelligent asset strategies.

Holistic views connect IT and OT by aggregating and learning from data and then enabling on condition maintenance. Problems are identified, evaluated and integrated early in their development and into workflow systems to facilitate efficient maintenance and operational excellence. The results are smarter, more insightful decisions that move decisions from being reactive to proactive, culminating in significant financial benefits.

by James Hoffman, Teikoku USA

Canned motor pumps are being increasingly specified for use with volatile, toxic and heat sensitive fluids to eliminate potential exposure due to leaks into the environment. As canned motor pumps utilize the pumped fluid to provide motor cooling and sleeve bearing operating medium, fluids that exhibit low boiling or high melt point require special pump design considerations. This seminar will review the design options available to handle these temperature sensitive fluids and highlight instrumentation possibilities available in the designs to increase Mean Time Between Maintenance Intervals to the maximum potential.

Attendees will learn the specific fluid properties that require special treatment to take advantage of the entire range of capabilities offered by canned motor pumps for emission-free pumping of those fluids. Pump design attributes will be detailed to establish baseline understanding of the technology and enhancements to safely handle toxic, volatile and temperature sensitive fluids.

Vinay Gadekar Epcon Software
Fluid Flow Simulation has gained prominence over the past decade and has been proven to identify root cause problems in plant wide utility systems. Once the root causes of low flow and pressure are identified, then the fluid flow simulation model provides the means to evaluate options to resolve these root cause problems and identify the optimal solution. Examples of how root causes, such as solids’ build-ups, in piping and piping leaks have been identified will be provided.

by John Gnadinger, Johnson Controls

Part 1 of 2 – Exploring today’s technologies that can provide visualization of a portfolio of buildings for key performance indicators across any subject matter area (e.g. energy, utility, fault detection, space/lease/asset, facility management, etc.), analytics, and workflow management. Using these technologies to help facilitate energy conversation and constant commissioning to ensure savings are consistent.

Attendees will learn about:
– Asset Protection/Technology Advancement
– Fault Detection & Diagnostics / Analytics

by John Gnadinger, Johnson Controls

Part 2 of 2 – Workflow management is key to savings through the tracking of critical events on key assets, and the integration of work order management systems (or other information management systems) ensures consistent handling of asset issues.

Attendees will learn about:
– Workflow Management / Facilities Management
– Portfolio Visualization / Key Performance Indicators
– Diagnostic Reporting

Gary Suchy, Jr., Bilfinger Mauell Corp

Control room design is about understanding how components within a room (video walls, consoles, lighting, etc.) affect each other and the staff that occupy the space. Beyond the scope of architecture firms, proper control room design is done by analyzing and observing how information moves within a control room. At Bilfinger Mauell Corporation, control room design goes way beyond the spatial arrangement of components in a room.

The Design program is Bilfinger Mauell Corporation’s complete control room design service. Our designs are based upon proven data and methods that we’ve developed and implemented over the last forty years. Beginning with a detailed discovery phase, our staff works closely with personnel inside the control center to understand how your staff interacts with information and communicates. Our design group members are ergonomic and spatial planning experts. Each member brings a unique array of skills and professional experience that is unmatched in the industry.

Jean Fischer Bandy, Novatech

There is an old adage that says continuous processes are just batch processes with really long run times. This means that state-based control can be useful for procedural automation of both continuous and batch processes. In addition to step‐wise batch control, state‐based control supports automation of startup, shutdown and exception handling procedures, provides state-specific alarm monitoring with automated response to abnormal conditions and allows a common user interface for continuous and batch processes including production equipment and supporting utilities.

State‐based control can incorporate both manual and automatic actions. It enables the operators to correctly perform long or complex procedures, infrequently used procedures or procedures that require exact adherence and detailed documentation. The process automation can be recipe‐driven to manage things like product formula grade changes or multiple CIP circuits. State‐based can incorporate the ISA‐88 and ISA‐106 hierarchies of Area – Cell – Unit – Equipment, allowing the operators to focus on managing the process instead of controlling individual pieces of equipment.

This presentation will review the benefits of state‐based control with examples of how it can be applied to a variety of processes including the flexible batch procedure approach of ISA‐88 and the concepts of ISA‐106 procedural automation.

by John Cusimano and Katy Voigt, aeSolutions
Companies that operate hazardous chemical processes are addressing, or are beginning to address, industrial control system (ICS) cybersecurity. Or, if they have not, they will soon as regulatory pressures and the next edition of ISA 84/IEC 61511 will make that mandatory. However, a big challenge that industry faces is the alignment and integration of ICS cybersecurity processes with their existing process safety processes. One of the reasons for this is that ICS cybersecurity efforts are often led by IT whereas process safety is led by engineering, operations or corporate safety. Regardless, integration is important not only to avoid duplication of effort but also to provide management with a holistic view of their operational risk that includes both cyber and traditional initiating events.

This presentation will discuss the process safety lifecycle and the ICS cybersecurity lifecycle and the key touch points where these lifecycles must synchronize in order for the responsible teams to exchange data and provide a common and holistic view of risk to executive management. We will present the ICS cybersecurity risk assessment process defined in ISA 62443, which many refer to as a cyber PHA or cyber HAZOP, and discuss how this process establishes a key linkage between process safety and cybersecurity.

by Neil Sandford, Koch-Glitsch

Distillation has come a long way since the ancient Egyptian and Greek alchemists, and new advances are still being made. This presentation will focus on recent improvements to the distillation process including divided wall column (DWC) configurations and new higher efficiency distillation tray devices that will help to minimize energy consumption and capital investment in future refineries and chemical plants. Industrial examples will be shown from the refining and petrochemical industries.

by Zarco Olujic, AMACS-Montz

Although dividing wall column (DWC) is a proven technology and fairly well established in practice, and highly appealing regarding energy and capital saving potential, the number of industrial applications is still limited. As elaborated in greater details elsewhere, e.g. Jansen et al., Chemical Engineering, August 2014, 40-48, a DWC is an atypical distillation column and there are certain process and mechanical design and operation-related concerns and potential constraints that may discourage inexperienced practitioners and make them reluctant to consider design and implementation of a DWC in prospective applications.

Indeed, a reliable hydraulic design method is needed to translate performance simulation results into diameter(s) and height of the shell of a new DWC, or to examine appropriateness of an existing column shell in a retrofit case. Internal layout and dimensions of normal and partitioned sections depend on chosen type and size of structured packing and auxiliary equipment. Related calculations must be done with certain rigor if one wishes to arrive at a reliable basis for evaluation of cost-effectiveness of both new DWC designs and retrofits. The present paper aims at filling the existing know-how gap, and addresses all relevant aspects of packed DWC design using engineering tools available in public domain. In cases where screening experiments have to be made, mini-plant and pilot scale equipment solutions are available.

by Andreas Danninger, Raschig

For mass transfer trays standard sized round and rectangular valves have proven their industrial advantages many times. Also large sized valves have been designed for fouling services. Over the past years a new trend is pushing into the market: mini movable or fixed valves. They are getting more and more popular especially for mass transfer columns were operators are looking for high capacities.

Raschig has recently tested its Mini Fixed Valve in the Fractionation Research Inc. (FRI) test column to provide more information about capacity, pressure drop and efficiency to the industry. The seminar discusses results and shows typical applications were high capacity mini fixed valve trays were successfully applied. An industrial example for a grass root design and a revamp case will be presented.

Dan Summers, Sulzer Chemtech

Sulzer Chemtech has recently developed the UFM™ tray and it has received worldwide industry acceptance over the past 3 years. In the past, users had to tolerate reduced turndown capability to get more capacity out of their trayed towers (e.g. Pro-Valve, MVG, SuperFrac etc.). This new movable valve tray targets those applications that need more capacity (than “normal” valve trays) yet still achieves high turndown capability. This presentation will show testing results, extensive experiences where it has been applied, and also document three applications (with feedback) where the superior capacity and performance characteristics of this tray has enabled three different towers to achieve higher than expected capacity and performance. Operating data will be presented and tray efficiency will be discussed.

Alex Makowski, Prozess Technologie

Prozess Technologie will present their new platform, Reveal, for in-line process measurements. The Reveal platform gives a customized solution along with flexibility on how to operate and integrate it. The Reveal gives its users the option to have built-in application modeling or the opportunity to build their own with low maintenance and reduced costs.

Prozess brings real-time process measurement applications into the manufacturing line and out of the lab with a device the size of a shoebox. The Reveal analyzer is fast and accurate with measurements in milliseconds at the molecular level. It’s non-destructive, meaning measurements do not change or destroy samples. Further, the Reveal saves money in materials, work hours, waste disposal and production cycles. And, it ensures adherence to regulatory and quality guidelines. Prozess also specializes in process measurement for hazardous environments.

Yvan Masson, BIAR Sampling Systems

Liquefied gases such as Chlorine, Liquefied Petroleum Gas (LPG) and others are toxic chemical and no exposure is allowed for the operator. Some risks present in traditional sample methods are: (1) Numerous steps require the operator to handle multiple valves in a precise sequence in order to prevent exposure and guarantee a representative sample, (2) There are numerous potential leak points, (3) The nature of some fittings present potential exposure risks and (4) A robust design is difficultly achieved due to small tubing and numerous equipment involved.
To improve the current sample method by simplifying the process, reducing potential leak points and improving the general quality of the equipment, BIAR Sampling Systems has designed and manufactured a proprietary Sample Valve and Sample Clylinder. This innovative product represents less steps than traditional methods and each steps are intuitive. Furthermore, only the desired amount of product is extracted from the process line, thus eliminating the need to recycle unwanted residue.

What attendees will learn:
(1) The importance of representative sample
(2) Overview of traditional sampling methods
(3) Risk to avoid with traditional sampling methods
(4) How to improve safety while making the sampling process simpler and more efficient
(5) Sampling best practice

by Barry A. Perlmutter, BHS

This presentation will discuss lab testing, pilot testing and scale-up for converting chemical processes to continuous filtration technologies from batch filtration operations. The overall scheme can be used by process engineers to develop optimum continuous pressure or vacuum filtration solutions for high-solids slurry applications.

In this first process a liquifed gas slurry is used to produce a specialty chemical. A liquefied gas is a clean, colorless gas that is easy to liquefy and transport. It is gaseous at normal temperature and pressure, but changes to a liquid when subjected to modest pressure or cooling. The most important point is to keep these gases, under pressure, so they behave as a liquid during filtration, cake washing and drying. The presentation discusses the process testing in the laboratory and in the field to evaluate continuous pressure filtration as an alternative to batch pressure filtration.

In this second process, the objective is to replace the current batch centrifuge with a technology that would be suitable for conversion to a continuous process. The initial lab tests suggested a vacuum belt filter would achieve cake quality equal to or better than the current centrifuge with a major reduction in processing time. The decision, after the lab testing, was to select a vacuum belt filter for pilot testing.

The presentation includes technology descriptions, discussion of specifications and general guidelines for performance guarantees. 

by Rick Gill, DrM

Whether new or used filtration equipment is considered for process expansion or R&D scale up, there are numerous considerations that should be investigated to ensure that pilot plant or commercial plant scale up is successful. In order to make these expansions reliable, consider testing the suspension(s) as a part of a systematic approach to determine the filtration process window.

Variations in solids concentrations can be the most underrated variation in determining what technologies can be best utilized. Part of the utilization determination should also take into account both capital and operating cost as well as various “environmental” issues such as personal protection

by Jeffrey Luby, Edwards Vacuum

As the size and complexity of vacuum systems increases the financial and technical challenges of them do so also. Accurate modeling allows system optimization in advance of engineering efforts and potentially negates the need for inefficient and costly empirical iterations. This paper describes a unique computational modeling technique for vacuum systems which incorporate any number of primary and secondary pumps and other pertinent elements. Examples are shown to illustrate the accuracy and efficacy of the technique.

by Andreas Kobus, SIHI

Increasing pump capacity with a need for better vacuum levels has, historically, required rotary lobe blowers ahead of a conventional backing pump. The combination, although effective, is encumbered by restrictions to compression ratio and is, therefore, oHen used in a multiIstage, “stacked” arrangement; ahead of conventional oil sealed or liquid ring backing pumps. The inherent inefficiencies of the rotary lobe blower lends to high energy use with a heavy footprint within the production environment. SIHI”boost” vastly improves efficiencies with minimal footprint. The new design boasts high speed spindles to achieve deep vacuum and eliminates the need for a “stacked” blower configuration. A high compression ratio capability reduces the backing pump requirement to 1/10th that of a pump used within a rotary lobe blower system. Significant energy savings, reduced maintenance and lower “up front’ investment make SIHIboost a sound decision for optimized return on investment.

by Tom Dardis, Gardner Denver

This seminar outlines the savings in operating cost and reduction in greenhouse gases by combining the strength of a liquid ring pump with that of steam ejectors, with a focus on Chemical Process and Refinery applications. Steam jet ejector vacuum systems have been the standard approach for desired performance levels in distillation columns and some reactor applications. By pairing a liquid ring vacuum pump with steam jet ejectors, a “hybrid” system can improve performance while reducing operating costs, maintenance requirements and the generation of greenhouse gases. The addition of the liquid-ring vacuum pump allows the entire vacuum system to handle additional backpressure while maintaining stable operation during off-design process conditions. This flexibility in process conditions allow hybrid vacuum systems to provide reliable performance while reducing system downtime and unscheduled maintenance. Hybrid vacuum systems can be installed in new applications, or as an upgrade to an existing all-ejector system. Case studies will be presented to show the economic and performance benefits of a liquid ring/SJAE hybrid vacuum systems.

What attendees will learn
How liquid ring vacuum pumps work and how they can improve performance of an all ejector vacuum system and save energy/operating costs.

by Christian Halupa, Teikoku USA

With increasing requirements for plant safety and owner risk management, liquid cooled canned motor pumps are being increasingly specified to eliminate operating emissions and process fluid leaks in the event of mechanical failures. Since canned motors are liquid cooled, Nationally Recognized Testing Laboratory (NRTL) underwriting is subject to special application under the National Electric Code (NEC) to provide suitability for use in hazardous area locations. This seminar will offer design considerations used by an NRTL in certifying the technology for underwriting and labeling.

Attendees will learn what an NRTL considers in assessing liquid cooled motors for suitability for use in hazardous area locations, the testing used to verify suitability and the machine design details that enter into the scope for testing and control to establish suitability for use in NEC hazardous area locations

Kenneth (Ken) S. Jones, Project Integration

This presentation presents the hazards of Arc Flash and the requirements of the National Fire Protection Association’s (NFPA’s) Code 70E for the workplace. NFPA Code 70E provides inspection and testing procedures and practices for evaluating the safety of installed electrical systems in residential, commercial, and industrial facilities. It requires that employees be protected from electrical hazards such as arc flash. This presentation uses discussion and videos to show various aspects of what an arc flash is, how it can be started, what protection methods can be used, and how to potentially lower arc flash incident energies. It also outlines proper methods of compliance per guidance developed by the Institute of Electrical and Electronics Engineers (IEEE).

Jay Juvenal, CV Technologies

Combustible dust explosions are one of the most elusive and dangerous hazards at nearly all industrial facilities manufacturing or handling chemical products. There is no universal gas law for dust and as a result, every application is different and every material presents a different risk. The means of safeguarding against these hazards varies with each application and therefore each situation warrants its own risk analysis. In addition to the hazard themselves, the regulatory environment involving combustible dust is also complex and requires its own level of comprehension. The release of NFPA 652 in October of this year will undoubtedly change the landscape of how these hazards are dealt with.

Marty Sharp, UltraSafe

* Proper sizing and Fit of Safety Harnesses
* Use of New Retractables, Lanyards for improved tie off of options
* Procedures used for avoiding lower level contact in foot level drops
* Safe rescue procedures for over the edge falls
* Brief review of some New Ultra-Safe Products
– Electrical Workers – ARC Rated Harnesses and Lanyards (meets ASTM F887 Specs)
– Welders and Hot Work – Kevlar F.B.H. Harnesses and Lanyards
– Painters Harnesses and Lanyards – clean off with soap and water
– Alumi – Safe Harnesses
– First Anchor up Tie Off System

Eric Predatsch, Linde Engineering

There are many options for reducing odors of which thermal oxidation is one. There are many thermal oxidizer designs used in industry, one of those is Flameless Thermal Oxidation (FTO). The major design characteristics for each type of Thermal Oxidizer are presented. The advantages of the FTO are explained. A selection chart to guide the engineer for all thermal oxidizers is presented.

Raymond Porter, Odotech

Odor is a sensory response to a compound or mixture of compounds. Although some classes of compounds are more odorous than others, the impact of odor on an individual or community can not be predicted on the basis of chemistry alone. To address issues related to adverse odor impacts leading to community complaints, one needs to understand the odor science and the methodologies for sampling, measuring, monitoring, and modeling of odor on the basis of sensory perception. This presentation will review the methodologies for characterizing odors to better define its impacts on the environment and optimize the capital investment required to mitigate its adverse effects.

By Chris M. Finen, P.E., EATON
As a leading power systems manufacturer Eaton’s #1 goal is safety and our anthem in every Eaton facility is “CHOOSE ZERO!” We live and breathe the design, manufacturing, testing, and start-up of electrical systems every day, and fully understand the threat arc flash hazards are to the safety and well-being of our people and our customers. If you are a stakeholder that maintains, designs, or purchases electrical equipment – you should attend this session. We will discuss best practices and recent innovations, and how you can apply a systematic approach to develop a safer environment in your facilities. Eaton personnel are at E-Chem 2016 to share our expertise and make ourselves available, but this is a vital topic that cannot be addressed in a half hour review. Please let us know if you have a need we can address in greater depth. We Are Here to Help!

By Bill Barnette and L.W. Canter, EATON

A facility that is designed with the latest LED technologies will deliver higher productivity, safety records, and directly impacts employee morale. Walk through any production facility, warehouse, office space, or parking garage and the lighting system reinforces one theme – “My company (does or does not) place great value on my ability to see clearly, and perform at the highest level.”

As long-life LED’s reach their tipping point and replace traditional lighting sources, your workers will live with your design choices for many years. Yet no other element of the electrical industry is changing faster, and requires engineers and procurement professionals to stay abreast of the technology improvements. Join us as we review these changes and discuss ways to control energy, support your safety objectives, and improve employee morale and quality of life. No other manufacturer offers LED luminaires in a wider range of applications from Crouse Hinds harsh and hazardous fixtures, to Eaton Lighting’s (formerly Cooper Lighting) office space, warehouse, or outdoor solutions.

Robert Alexander, SKF

SKF would like to present two solutions for contaminated environments. The first is the industry’s first corrosion resistant bearing steel, HNCR. The second product overview singles out the benefits of the SKF sealed spherical roller bearing and the new seal design for the unit.

Ron Sustich, Siemens

Burner Management Systems (BMS) are one of the most wide-spread process safety applications utilized throughout the Chemical, Petrochemical, and Oil & Gas Industries. Historically, there hasn’t been much guidance on the use of automation systems for BMS other than older standards that left much to interpretation. Fortunately, NFPA 85 & 86 has been revised and can now assist you in devising a better, more flexible and cost-effective BMS design.

This presentation will quickly bring you up to speed on the latest revisions in NFPA 85 & 86 for Burner Management Systems. Learn how this revised standard can assist you in designing a compliant BMS that minimizes risks and reduces costs, while enhancing safety in process and control facilities.

By Amish Sabharwal & Todd Kubiak, AVEVA

Today, Owner Operators (OOs) are facing the huge challenge of increasing Return On Capital Employed (ROCE) in their capital projects, and reducing the cost of project handovers from the EPCs, while ensuring the asset is safe, reliable, compliant, and operating efficiently. To help tackle these challenges, OOs and EPCs need to build a Digital Asset comprising of their 1D engineering data (mechanical, instrumentation, electrical), 2D engineering records (drawings, datasheets), and 3D models and Laser Scans that are kept “evergreen” through the design, build, and operate phases of their assets. Join AVEVA for this session to learn how we can help your organization create, capture and convert your physical asset into a digital asset.

What attendees will learn:
* what a “Digital Asset” consists of
* the importance of evergreen data
* how we can help your organization create, capture and convert your physical asset into a digital asset

by Derwin Cartmel, Day & Zimmermann

Day & Zimmermann provides laser scanning and 3D data capture technology solutions to create a digital facility integrated into the design phase of capital projects. This provides our customers with a solution that can be deployed at various stages in the lifecycle of the capital or maintenance planning process. Working within a digital facility, the assets can be virtually tagged and dynamically linked to databases to ensure safety, quality assurance/compliance,
maintenance records/planning, and construction planning/progress verification. This solution provides our customers with a tremendous return on their investment, including cost and schedule savings, and the ability to reuse the data to establish work processes on future projects. Other benefits include:

• Reduced field work – increased dimensional accuracy.
• Reduced turnaround time for scanning and data processing.
• Improved quality of engineering deliverables/coordination.
• Improved model reviews with project teams.
• Shortened engineering and construction durations through streamlined work processes.
• Improved constructibility through better visualization of project.

Day & Zimmermann has provided these solutions at industrial facilities around the United States. Join our presentation to learn why 3D technology can help industrial plant owners manage their business, save money, reduce risk, and increase capacity and efficiency.

By Kash Arfa, Emerson Process Management

Due to project excesses, billions of dollars are lost annually in oil and gas exploration and production, hydrocarbon and gas processing, chemical, pharmaceutical, and other process industries. According to industry data, over 65 percent of projects greater than $1 billion fail, with companies exceeding their budgets by more than 25 percent or missing schedules by more than 50 percent. Routinely, they also face operational problems continuing through the second year of operations. This consistently poor project performance can be a serious deterrent to process manufacturers considering new investments. Emerson’s Project Certainty begins with early engagement during engineering and design studies to define project goals and high impact strategies to meet those goals. Despite traditionally accounting for approximately 4 percent of a project investment, automation is revealing unique and repeatable ways to eliminate cost, reduce complexity and accommodate late-stage project changes, beyond the automation discipline.

Tim Heffrom, Lauren E&C

Almost every project can benefit from some level of modularization. But how much? The Construction Industry Institute (CII) IR 283-2 Industrial Modularization outlines key best practices required to successfully execute modular projects. This presentation will provide an overview of the research that has made Planning for Modularization the newest CII Best Practice.

Attendees will learn about the 5 Solution Elements: Business Case Analysis, Project Execution Plan, Critical Success Factors, Standardization Strategy, and Maximization Enablers. Attendees will also receive an overview of the Modularization Toolkit, a set of 4 tools that are available as working documents to assist project teams with the decision process and execution planning for their modular project.

Christine Osborne, ErgonArmor

The silo-ing of engineering disciplines has the unintended consequence of preempting use of time-saving approaches to acid proofing concrete structures. Civil engineers design industrial concrete structures then pass the designs to the architectural finishes team to specify protective linings, foregoing the use of approaches that offer faster turnaround time. This presentation will highlight polymer concrete and anchored thermoplastic lining technologies with unique construction time saving advantages dependent upon integration of civil and architectural design packages.

By Mario Laiseca, Aspen Technology
Aspen Plus is a state of the art process simulator that has been used in the industry to model and optimize a wide range of processes. As part of an entire suite of engineering products, Aspen Plus not only provides pure flowsheet simulation but it can also perform cost estimation, energy analysis and emissions calculations. About 60% of chemical processes involve solids as a feed, intermediate or a final product. To optimize the entire process it is necessary to consider both solids and fluids in one simulation environment in a rigorous way. This presentation will highlight the challenges of modeling processes that contain solids and solid processing equipment, and highlight how cost estimation and energy analysis can be used to identify process improvements. See how you can reduce the energy demand and operating costs of your chemical and solids processes with Aspen Plus.

By David Thompson of Eastman Chemical Company and Roland Schneefuss of AVEVA
It is more crucial now than ever that projects are completed and assets are maintained as efficiently as possible. Eastman Chemical Company and its peers are sensitive to this need and as a result initiatives across the industry are launching to tackle streamlining the development and use of digital engineering data in its multiple forms. This session will introduce Eastman’s Seamless Engineering Information Global Access (SEIGA) platform. AVEVA will then take a closer look at the benefits of an Integrated Engineering & Design approach.

What attendees will learn:
Eastman’s Seamless Engineering Information Global Access (SEIGA) platform and AVEVA’s approach to Integrated Engineering & Design.

Jim Newman, Bentley Systems

With the advent of the Industrial Internet of Things (IIoT) already upon us, it is important to have strategies in place sooner rather than later to take advantage of the opportunities that IIoT will provide. These benefits will include reduced down time due to the fact that machines can notify engineers about defects and required maintenance; increased quality and reliability; and greater visibility of the manufacturing floor via data analytics, which in turn leads to improvements across the board. With the explosion of data, operators are becoming acutely aware that they can measure every aspect of their production, from energy consumed to asset performance and costs saved. Bentley Systems’ operational analytics software, Amulet, is an intelligent operational platform that converges all available data, real-time and historical, from information technology, operational technology and engineering technology, and transforms it into actionable just-in-time information for improving operational performance using predictive and algorithmic business techniques. It provides its users with context, clarity and confidence into how their operation is performing, where to look and what to do next, resulting in increased plant reliability, energy efficiency and optimization. This seminar will highlight selected success stories showing the growing benefit of IIoT and analytics for owner/operator.

What Attendees Will Learn:
• Understand the analysis tools that every manager should use to turn unstructured and structured data into value for your organization
• See how AssetWise Amulet acts as a bridge by bringing data sources including devices, control systems, sensors, SCADA, networks and applications, together to make smarter decisions
• Learn how embedded calculations, rules and algorithms can transform data into actionable information and predictive outcomes

Jim Newman, Bentley Systems

For owner operators in the process industry, manufacturing plants and supporting infrastructure are critical to success.  Whether it’s bringing new plants into production quickly, confidently managing revamps, and minimizing shutdowns, assets and projects must operate reliably without compromising health and safety standards, and comply with industry and environmental regulations.

Discuss how the latest information management technologies are supporting industrial plants and infrastructure assets throughout the lifecycle. To support ongoing maintenance and asset performance, it is critical to maintain detailed records of all design and engineering activity. Today’s asset lifecycle information management systems provide a common data environment continuously shared across all stakeholders retaining a full history and provenance of engineering information. Couple this with the unprecedented volume of “big data” that’s streaming from the “Internet of Things” (e.g., sensors and meters on equipment, structures, and assets), new asset performance management technologies are transforming all that data into meaningful, actionable information for operational visibility, improved decision support, and enhanced asset performance. The presentation will also show software that automatically creates 3D models from digital photographs—which is increasingly being used to perform continuous surveys and inspections.

Larry Balcom, Schneider Electric

Flowsheet simulation is a key technical tool for modeling industrial processes and improving speed to market. Understanding the key process variables and interactions of an industrial process allow proper equipment design and integration with existing facilities. Correlations and base models developed during the R&D phase can be easily integrated into the flowsheet model which improves technology transfer and maximizes the value of your intellectual property.

Many different process configurations can be easily tested to match the new process to existing facilities. Overall investment can be estimated by identifying additional equipment needed, or expanded capabilities of existing equipment and services. Energy minimization, and heat integration are modeled in the simulation to maximize the efficiency of the process.

Project timelines are streamlined by utilizing dynamic flowsheet simulation to validate detailed designs, test process control logic, and operator interfaces during the project construction phases. Operator training simulation (OTS) can be coupled with the dynamic model to pre-train operators of the new process. OTS pre-training will reduce necessary technical support during process startup, minimize operational errors, and reduce the startup timeline. Flowsheet simulation is often provided to the process operating personnel though simplified input interfaces, frequently built in Excel, to enhance their understanding of the process. Automated simulation models can also be tied directly to the process controls, and provide operators with process alerts, automated diagnose, and improved process performance.

Benjamin Wincure, ProSim

ProSimPlus is ProSim’s robust and easy-to-use process simulator, which is a flexible process engineering software that performs rigorous mass and energy balances for a wide range of industrial plants, including commodity chemicals, specialty and fine chemicals, bioprocesses, etc. Recently, two new innovative simulation tools for an industrially relevant pinch analysis and the exergy analysis have been added to ProSimPlus, to allow both senior and junior engineers to improve the energy efficiency of their industrial plants. This seminar focuses on the use of process simulation to reduce the process energy consumption using these two complementary methods.