IEN: How are manufacturers using existing technologies in new ways?

Pemberton: Industrial users are moving toward wider application of variable speed drives in lieu of flow control valves for fluid handling systems. Historically, control valves have been the standard for flow control in industrial process pipes. Variable speed drives (VSDs) have been used in various pump applications where conventional control strategies did not work well or for the purposes of reducing energy consumption. Today, with escalating energy cost and lower drive prices, there is a trend toward wider use of VSDs as the primary flow control element. VSDs allow pumps to run at slower speeds with trimmed impellers resulting in significant improvements in pump reliability and the associated mean-time-between-failure (MTBF). In new applications variable speed drives are often less expensive to purchase and install than flow control valves. Subsequently, when combined with lower energy and maintenance cost, the total life cycle cost (LCC) of a give pumping system can be significantly reduced.

IEN: What are the major challenges facing development of these systems? How can they addressed?

Pemberton: There are many barriers to the adoption and application of new technology. In the case of variable speed drives, the issues encompass cultural change, multi-discipline nature of the application, lack of capital funds as well as a lack of staff and time. By far, the biggest issue is the change in culture required when retrofitting variable speed drives into applications historically operated by valves. There is always a perceived risk, even though the technology is proven, that the changes will adversely affect operations and reflect negatively on the person(s) responsible for making the changes.

IEN: What innovations are in store for users?

Pemberton: In the case of variable frequency drives, manufacturers are beginning to embed intelligence about the rotating asset that the drive is connected to in the process. For example, Goulds Pumps offers an intelligent drive named PumpSmartTM that monitors changing conditions in both the pump and process. The intelligence embedded in the drives microprocessor provides mechanical fault protection and will alarm or slow down in order to protect the pump from conditions such as cavitation, closed valves occur and low flow. We will see this trend continue and can expect to see smart equipment such as compressors, blowers, etc. emerge alongside the intelligent field devices that exist today, i.e., smart transmitters and valve positioners.

IEN: How are software and equipment being improved in this area?

Pemberton: Historically we have placed sensors throughout industrial processes to monitor parameters such as flow, pressure, level and temperature. Conversely, the use of sensors to monitor rotating assets such as turbines, pumps, compressors, etc. have been limited to high capital cost items often for the purpose of securing insurance. Today, with the widespread use of smart field devices, PC based systems, Microsoft standard software, and fieldbus communication, traditional process control and asset management are merging into one system that can monitor and control the process as well as, in many cases, the production assets themselves. Asset Management is the fastest growing area in industrial control and holds the promise of allowing real-time monitoring of assets to increase the use of predictive and preventable maintenance techniques. Asset management software allows advanced diagnostics, JIT parts orders, operator decision support as well as automated documentation of process and regulatory data. Plants in the future will be able to run the process and only shut down when necessary to make major repairs and not on regular schedules for preventative maintenance procedures. This will increase plant availability and flexibility resulting in improved bottom line results..

IEN: How can companies integrate smart systems with legacy/traditional parts of the enterprise?

Pemberton: Some legacy systems have to be replaced or significantly upgraded to incorporate the data from smart equipment, although many proprietary systems have data communication ports allowing the data to be communicated over a variety of fieldbus technologies and utilized within the existing system's data structure. Often the cost of integrating new technology into existing is doable and relatively inexpensive.