Abstract: A real-time control system includes a faulty variable identification technique to implement a data-driven fault detection function that provides an operator with information that enables a higher level of situational awareness of the current and likely future operating conditions of the process plant. The faulty variable identification technique enables an operator to recognize when a process plant component is behaving abnormally to potentially take action, in a current time step, to alleviate the underlying cause of the problem, thus reducing the likelihood of or preventing a stall of the process control system or a failure of the process plant component.

Abstract: A coaxial sensor array system configured for prediction of leaks in a water distribution network based on data acquired from coaxial sensor array including: at least one hydrophone; a hydrophone mount configured to house the at least one hydrophone; a pressure transducer configured to measure pressure of a water column within which the plurality of hydrophones is submerged; a pressure transducer mount implemented as a lead-free brass disc configured for fitment of the pressure transducer; an electrical connector configured to connect communication cables to the pressure transducer; a sensor housing configured to house the at least one hydrophone and the pressure transducer; and an end cap configured to seal a back end of the coaxial sensor array system and further configured to allow communications to pass through into a watertight shielded flexible conduit.

Abstract: A process characteristic parameter determination system uses a process model and a tuning module to accurately determine a value for a process characteristic parameter within a plant without measuring the process characteristic parameter directly, and may operate on-line or while the process is running to automatically determine a correct value of the process characteristic parameter at any time during on-going operation of the process. The process characteristic parameter value, which may be a heat transfer coefficient value for a heat exchanger, can then be used to enable the determination of a more accurate simulation result and/or to make other on-line process decisions, such as process control decisions, process operational mode decisions, process maintenance decisions such as implementing a soot blowing operation, etc.

Abstract: A real-time control system includes a simulation system to implement a predictive, look-ahead function that provides an operator with information that enables a higher level of situational awareness of the expected transitional events of future steps within the control program or sequence logic. The simulation system enables future steps and transitions to be monitored before they actually occur, which enables the operator to recognize and potentially take action, in a current time step, to alleviate the underlying cause of the problem, thus reducing the likelihood of or preventing a sequence stall of the control program.

Abstract: Testable, redundant pneumatic control assemblies and related systems and methods are described herein. An example pneumatic control assembly described herein includes first, second, and third parallel supply channels between a compressed air supply and valve header, first, second, and third parallel vent channels between a vent and the valve header, and first, second, third, fourth, fifth, and sixth logic valves. The first and sixth logic valves are disposed in the first parallel supply channel and the first parallel vent channel, the second and third logic valves are disposed in the second parallel supply channel and second parallel vent channel, and the fourth and fifth logic valves are disposed in the third parallel supply channel and third parallel vent channel. The pneumatic control assembly also includes a first, second, and third solenoid valves to control certain ones of the logic valves.

Abstract: A real-time control system includes a fault detection training technique to implement a data-driven fault detection function that provides an operator with information that enables a higher level of situational awareness of the current and likely future operating conditions of the process plant. The fault detection training technique enables an operator to recognize when a process plant component is behaving abnormally to potentially take action, in a current time step, to alleviate the underlying cause of the problem, thus reducing the likelihood of or preventing a stall of the process control system or a failure of the process plant component.

Abstract: Methods and apparatus to optimize ramp rates in combined cycle power plants are disclosed herein. An example method disclosed herein includes predicting a first setpoint for a gas turbine in a combined cycle power plant over a prediction horizon and predicting a second setpoint for a steam generator over the prediction horizon. The example method includes identifying a first steam property of steam generated by the steam generator in the combined cycle power plant based on the second setpoint. The example method includes comparing the first steam property to a second steam property of steam associated with a steam turbine in the combined cycle power plant and dynamically adjusting at least one of the first setpoint or the second setpoint based on the comparison.

Abstract: A U-I/O card improves on traditional I/O cards by enabling configuration of each I/O channel on each U-I/O card to operate according to a desired signal type (e.g., AI, AO, DI, or DO). Thus, each I/O channel of a given U-I/O card may be coupled to any type of field device. The U-I/O card thus simplifies I/O network design, wiring, configuration, commissioning, redesign, and rewiring. The U-I/O card also improves space efficiency in marshalling cabinets and eliminates inefficient use of I/O cards relative to traditional I/O cards.

Abstract: A process characteristic parameter determination system uses a process model and a tuning module to accurately determine a value for a process characteristic parameter within a plant without measuring the process characteristic parameter directly, and may operate on-line or while the process is running to automatically determine a correct value of the process characteristic parameter at any time during on-going operation of the process. The process characteristic parameter value, which may be a heat transfer coefficient value for a heat exchanger, can then be used to enable the determination of a more accurate simulation result and/or to make other on-line process decisions, such as process control decisions, process operational mode decisions, process maintenance decisions such as implementing a soot blowing operation, etc.

Abstract: A mixer support assembly for use in an integrated cover and mixer apparatus and anaerobic digester system incorporating same provided. The digester system includes a tank with an integrated cover and mixer apparatus which provides a completely or substantially gas tight enclosure for the collection of biogas. The integrated cover and mixer apparatus includes a cover, a mixer, and a mixer support assembly for supporting the mixer. The mixer support assembly includes a float ring and a support body that is selectively removable from the float ring. The support body is attached to the float ring by way of a clamping arrangement.

Abstract: The described methods and systems enable iterative plant design. These methods and systems may be utilized to test multiple P&ID designs and control strategies before a plant is constructed, enabling engineers to test physical layouts and control strategies for the particular unit, facilitating optimal design of the plant and control scheme for controlling the process. The described methods and system thus facilitate optimal design of optimal physical layouts and control strategies.

Abstract: A water conditioning composition includes water; at least one gluconate compound; at least one carbonate compound; a non-ionic preservative; and a phosphate buffer. For example, the composition can include 87-95 wt. % water; 0.5 to 1.5 wt. % gluconate compound; 3 to 8 wt. % carbonate compound; 0.5 to 1.5 wt. % non-ionic preservative; and 0.5 to 2.5 wt. % phosphate buffer.

Abstract: Methods and apparatus to optimize ramp rates in combined cycle power plants are disclosed herein. An example method disclosed herein includes predicting a first setpoint for a gas turbine in a combined cycle power plant over a prediction horizon and predicting a second setpoint for a steam generator over the prediction horizon. The example method includes identifying a first steam property of steam generated by the steam generator in the combined cycle power plant based on the second setpoint. The example method includes comparing the first steam property to a second steam property of steam associated with a steam turbine in the combined cycle power plant and dynamically adjusting at least one of the first setpoint or the second setpoint based on the comparison.

Abstract: Systems and approaches for error detection detect discrepancies in industrial equipment by comparing a particular asset to similar industrial assets running in parallel to the particular asset. An error detection unit detects a difference between an estimated and actual output of the asset. Based on the magnitude of the difference, the error detection unit determines whether an input value of the particular asset is similar to input values of the plurality of industrial assets and whether an output value of the particular asset is similar to output values of the plurality of industrial assets. If the input value of the particular asset is similar to the input values of the plurality of industrial assets and the output value of the particular asset is not similar to the output values of the plurality of industrial assets, then the error detection system sets an alarm.

Abstract: A system and method for operating a remote plant simulation system is disclosed. The system and method uses a light application at the plant to collect relevant data and communicate it to a remote plant simulation. The remote plant simulation uses the relevant data, including data from the actual process, to create a process simulation and communicate the display data to the light application operating at the plant where it is displayed to a user. The remote system offers the advantage of offering decreased cost and improved simulation as the equipment cost, operator cost and set up cost is shared by a plurality of users. Further, the data may be stored remotely and subject to data analytics which may identify additional areas for efficiency in the plant.

Abstract: A rotating drum screen method for separating solids from thin stillage obtained from ethanol fermentation, the thin stillage comprising one or more of solids and suspended solids. Thin stillage is chemically treated with an anionic polymer to form stable particles of one or more of solids and suspended solids. Introducing the treated thin stillage into a rotating drum screen system. The drum screen includes a filter screen that retains at least a portion of the solids within a hollow portion of the drum screen and which produces a liquid effluent that is discharged from an outer surface of the drum screen. The retained solids are removable from the drum screen via a solid discharge end. A head box is disposed within the hollow portion of the drum screen and has a plurality of fluid flow channel dividers dividing and directing an influent stream outwardly against the drum screen.

Abstract: A mixer support assembly for use in an integrated cover and mixer apparatus and anaerobic digester system incorporating same provided. The digester system includes a tank with an integrated cover and mixer apparatus which provides a completely or substantially gas tight enclosure for the collection of biogas. The integrated cover and mixer apparatus includes a cover, a mixer, and a mixer support assembly for supporting the mixer. The mixer support assembly includes a float ring and a support body that is selectively removable from the float ring. The support body is attached to the float ring by way of a clamping arrangement.

Abstract: A control system uses a feedforward neural network model to perform control of a steam turbine power system in sliding pressure mode in a more efficient and accurate manner than a control scheme that uses only a multivariate linear regression model or a manufacturer-supplied correction function. Turbine inlet steam pressure of a steam turbine power generation system in sliding pressure control mode has a direct one-to-one relationship with the electrical energy load (output) of the steam turbine power system. This new control system provides a more accurate representation of the turbine inlet steam pressure, such that the power generated by a power plant is more closely controlled to the target (demand). More particularly, the feedforward neural network model prediction of the turbine inlet steam pressure more closely fits with the actual turbine inlet steam pressure with very little error, and thereby providing better control over the electrical energy load.

Abstract: Methods and apparatus to optimize turbine ramp rates are disclosed herein. An example method includes predicting a setpoint for a turbine rotor over a prediction horizon. The example method includes predicting a surface temperature profile of the turbine rotor for the prediction horizon based on the predicted setpoint via an empirical data model. The example method also includes predicting a first stress profile for the turbine rotor based on the surface temperature profile. The example method includes performing a comparison of the first stress value to a second stress value and dynamically adjusting the setpoint based on the comparison.

Abstract: A water conditioning composition includes water; at least one gluconate compound; at least one carbonate compound; a non-ionic preservative; and a phosphate buffer. For example, the composition can include 87-95 wt. % water; 0.5 to 1.5 wt. % gluconate compound; 3 to 8 wt. % carbonate compound; 0.5 to 1.5 wt. % non-ionic preservative; and 0.5 to 2.5 wt. % phosphate buffer.