Text 21. Ubiquitous sensors

Turning data into knowledge starts with the ability to collect the right data across the plant and enterprise. In this regard, advancements in sensor technology will play a critical role in shaping the plants of the future. As sensors become smaller, more rugged and more reliable, they can pave the way for some truly exciting capabilities to mine for more-meaningful process data.

Some specific areas to watch include:

• Microelectromechanical sensors (MEMS). For decades, the concept of using “smart dust” to monitor variables was considered more science fiction than reality. Today, however, industry is truly on the cusp of being able to take advantage of this technology, which could be directly inserted into process liquids to derive unprecedented detail about unit functionality.

• Wearable sensors. At many plants wearable sensors already play a valuable role in tracking individuals. Taking this technology a step further by adding fire-and gas-detection capabilities will enable supervisors to know if workers are potentially in danger. For example, is the mobile operator in an environment where hydrogen sulfide content is rising or where oxygen or nitrogen content is changing?

• Flying sensors. This safety-enhancing technology is becoming a reality today. If a facility experiences a problem, operators can dispatch a remote-controlled flying device to visually inspect the affected area. These devices can include sensors that, e.g. can detect gas leaks.

• Video as a process input. Many plants already have cameras pointing at their flare stacks. Going forward, video will provide more than images – color analysis capabilities will allow operators to use video as an alarm point and variable, for instance, for changes in flare composition.

• Embedded sensors. Work is currently underway to develop such devices, which perhaps represent the Holy Grail of process sensing technology. One example is embedding a sensor on a tray in a column to relay information such as liquid loading, temperature and pressure.

These advancements provide more than just additional data points – rather, they furnish more-specific data that truly give operators a greater understanding of how processes are functioning. This type of knowledge ultimately can help operators continually improve production while maintaining a safe environment.

Text 22. Unifying automation layers

The lines between plant automation levels are becoming increasingly blurred every day – business functions, advanced applications and control system platforms are more interconnected than ever before. As a result, more manufacturers are designing programs that link entire enterprise and, therefore, connecting raw material availability to demand variability.

This strategy will play a major role in delivering specific information to the right people within an organization, along with the right amount of function and control. It starts with gathering data in a common database, establishing standards (e.g. for look and feel) and then distributing those data to various parts of the organization. The idea here is to eliminate time spent by different departments sorting through information that isn’t of value to them.

Specific examples of this unification can be found today in the batch manufacturing industries, such as specialty chemicals and life sciences. Integrated batch solutions, for instance, can deliver increased reliability with batch execution at all levels on a control-level redundant platform. It’s also proven to improve plant efficiency by reducing batch cycle times; this can lead to an annual 1% increase in throughput.

Likewise, great opportunities now exist for pharmaceutical manufacturers to bring manufacturing execution systems into the control rooms to help improve productivity, decrease errors and enable paperless plant operations that significantly reduce regulatory-compliance-related costs.

Going beyond plant boundaries

Plants of the future need better connectivity across the enterprise if they’re truly to drive business results. Wider-spread adoption of common databases and platforms is essential for this trend to take hold. Now, different departments have dissimilar views on operating parameters, including alarm and shutdown points. Building a common database will enable groups within the organization to better collaborate to establish standard limits for processes and operate them in a safer manner.