At the Emerson Exchange held last week in Denver US, Steve Sonnenberg President of
Emerson Process, spoke about the volatility of oil prices and the current adversity in industrial markets. Sonnenberg believes this is truly a time to not only look at capital projects differently but for Emerson customers to make dramatic and transformative improvements and not incremental steps. Sonnenberg told the audience of over 3000 attendees “this is not a time to be satisfied with being as good as everyone else.”
Following Sonnenberg's keynote presentation such transformative improvements were being realized by Pete Sharpe, Director of Industry Solutions. Pete presented a perfect example of how to make a transformative step by applying technology to reduce energy costs. With the help of funding from the US Department of Energy (DOE), Emerson as part of the Smart Manufacturing Leadership Coalition (SMLC)
https://smartmanufacturingcoalition.org/, has been participating in the development of a open, cloud-based solution that is capable of saving significant energy for fired heater and blast furnace applications within typical industrial processes. In parallel Emerson has developed its own solution to help customers monitor and track energy use across a site or sites.
Emerson Remote Energy Management The DOE grant targeted $8MM over a three-year period for prototyping of a Smart Manufacturing Platform with the goal to demonstrate the viability of moving near real-time advanced manufacturing applications to the cloud. The Smart Manufacturing platform had to be able to provide quantifiable energy savings and include a commercialization plan for future applications or projects. DOE project funding requirements dictated the creation of a prototype that would accelerate technology deployment, reuse manufacturing applications, while halving the cost.
The SMLC working with DOE funding was able to leverage the guiding principles and vision of the organizations partners to build a platform for cloud-based real-time monitoring and analytics. SMLC chose Rackspace as the cloud service provider, however other Emerson work has been considering
Microsoft Azure for infrastructure and cloud services and Hadoop for distributed data computing in the future. In principle, the solutions were intended to by cloud based, secure, low-cost, require no IT support for end users, utilize a utility model. The platform was also required to access plant data and include a workflow engine for managing multiple steps and directing site resources.
For prototyping the Smart Manufacturing Solution, SMLC chose two commercial test beds. Each site employed the use of sensors, models and operating strategies to reduce waste heat. A Praxair steam-methane reformer furnace as a continuous process test bed and General Dynamics munitions furnace for a discrete manufacturing test bed. In both cases the prototyping is underway and has demonstrated the DOE test requirements to reduce software costs, simplify deployment and save energy cost.