As always, there’s lots of upbeat customer activity on the Island of Puerto Rico. Most recently, Vivian Freytes and team has focused much of their attention on Tecnología inalámbrica (Wireless technology) applications. The benefits cover a wide spectrum and extend PlantWeb predictive intelligence into areas that were previously out of physical or economic reach, opening the door for new possibilities in process improvement. Remote locations, physical obstructions, and the high cost of engineering and integrating new technologies are no longer the barriers they were.
One customer looked for utility area solutions to replace existing pressure and temperature gauges for 4 to 20 mA transmitters. The application provides greater efficiency to the process while monitoring air with acetone residues needing to be stripped out. Temperature and pressure conditions need to meet the right conditions to properly separate the acetone. If it’s not done properly, time is wasted and costs will rise. In this case, installation and integration was seamless while overall costs were dramatically reduced.
Another wireless customer needed to improve temperature monitoring and documentation systems in raw material active ingredient storage areas. Storage compliance requires raw material to remain within specific storage temperature limits. Not complying becomes a quality issue. Our wireless solution with AMS wireless SNAP-ON technology provided an easy way to install transmitters in the desired location without the need of wiring while providing actual process readings and alarms when conditions are out of specification. The benefit is clear – more for less with real time monitoring and documenting of temperature limits.
The team is actively pursuing many other possibilities for wireless applications on the island. They include the following:
Vibration Monitoring
The problem involves monitoring of rotating equipment. Rotating equipment (pumps, blenders, agitators, etc.) would be monitored for vibrations that would provide an indication of equipment failure or potential failure.
An example would be CIP (Clean In Place) pumps, along with Return Pumps, that are used between batches to clean out the system. The CIP application is one where once a product batch is complete they utilize these pumps to clean out the system. Mechanical problems with the CIP pumps sometimes cause problems in the subsequent production of the next batch of product causing the rejection of the entire batch. High vibration levels on the equipment indicates developing problems that can now be fixed before they result in the rejection of finished product.
Storage Room /Freezer Monitoring
The problem involves prohibitive wiring costs for conventional transmitters used to monitor storage rooms distributed across a production facility. Wireless transmitters also provide solutions to the inherent problems associated with portable freezer/cooler units.
This application involves the monitoring of critical parameters for products stored throughout large multi-building sites. The storage room data is required for reporting to the Food and Drug Administration as well as internal quality control. Typical monitored parameters include pressure, temperature, humidity, visible and UV light, airflow, CO2 and the open / shut status of doors. Freezer parameters monitored would include low-stage and high-stage compressor amperage, internal chamber temperature, and door open/close status. The data collected is intended to provide early indication of refrigerant leaks or door seal issues, which lead to freezer failures.
Portable Equipment
The problem involves the management of moving platform measurements. There is a need to continually re-configure process systems to account for instruments that move with portable process skids (pumps, filtration, CIP/SIP packages).
For disposable bioreactors, this would include WirelessHART transmitters for pressure, temperature, pH, and dissolved oxygen measurement. The flexibility of being able to work on reactors without disconnecting cables can provide on-going benefit by reducing downtime and maintenance. Also, the accuracy and reliability the pH and dissolved oxygen measurement may be improved since battery power wireless transmitters are not as susceptible to ground loops that often plague a wired installation.
Mobile Worker Productivity
The problem involves operators who work on the plant floor outside of the traditional control room and need visibility into the current state of the process. The solution is to provide a DeltaV client on mobile devices for operators working outside the control room. This is also applicable for remote data collection applications where an operator manually records data from a gauge or chart.
As customers on the island continue to pursue cost effective solutions and avoid expensive and lengthy installations, Vivian and team will be there offering alternatives that cut through the maze of challenges. Thanks Vivian!
