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Emerson's cutting-edge dust collector monitoring solution. (Image source: Emerson)

Emerson, a global leader in industrial automation, has introduced a sophisticated dust collector monitoring and control solution aimed at improving operational efficiency, cutting maintenance costs, and ensuring environmental compliance across multiple industries.

By integrating proven mechanical and automation technologies, this intelligent system delivers real-time diagnostics and seamless compatibility with existing plant systems, enabling operators to optimise performance and prolong equipment life.

Industries including cement, mining, chemicals, food production, and power generation manage materials that generate substantial dust and particulate emissions. These airborne particles threaten worker safety, equipment reliability, and environmental standards, making effective dust collection systems essential.

Conventional dust collectors use filters that require periodic cleaning with compressed air and eventual replacement, which can lead to expensive maintenance and unexpected downtime if not properly monitored.

Emerson’s innovative solution addresses these issues through automation. By employing advanced algorithms and predictive diagnostics, it optimises filter cleaning, identifies faults early, and reduces energy consumption. Extending filter life by up to a year can save businesses as much as US$18,000, while avoiding downtime that may cost thousands per hour.

A robust automation suite

The solution combines a range of Emerson’s trusted products, such as ASCO™ pulse valves, AVENTICS™ air flow sensors, Rosemount™ pressure sensors, and PACSystems™ programmable logic controllers (PLCs). These components enable precise control of pulse valve operations and automated cleaning cycles across multiple filter lines.

Additional features include Movicon.NExT SCADA for remote monitoring, alerts, and reporting, and QuickPanel+ human-machine interfaces (HMIs) that provide real-time diagnostics and early fault detection. The system also incorporates ASCO P152 particle concentration sensors to detect low dust levels and filter issues, alongside differential pressure monitoring with optional 4-20 mA compatibility.

“With this world-class and easily implemented solution, we aim to help our end users achieve greater operational efficiencies and gain valuable insights that reduce reactive maintenance, lower the risk of downtime, minimize energy consumption, and extend equipment life while addressing the knowledge gap by providing easily accessed information for operations personnel,” said Samuele Oliva, product marketing manager for dust collectors and alternative energy with Emerson’s discrete automation business.

Delivering operator benefits

Emerson’s solution provides several key advantages. Optimised pulse valve usage extends the lifespan of valves and filter bags, reducing compressed air waste and safeguarding equipment. Predictive maintenance capabilities monitor compressed air, pressure, temperature, dust levels, and energy usage, allowing early intervention to prevent costly failures.

The system’s scalability, with licensing based on pulse valve count (up to 500), makes it adaptable to facilities of varying sizes. Its Floor-to-Cloud connectivity ensures seamless integration with existing automation systems, offering a comprehensive operational overview and supporting compliance with environmental regulations.

In addition to cost savings, the solution advances sustainability by lowering energy and compressed air consumption. Smart filter cleaning reduces waste, while early detection of failed filters helps avoid regulatory penalties. These features align with increasing industry demands for environmentally responsible practices.

Trina Storage's Elementa 2 Pro – a 5.015 MWh energy storage system designed for ultra-long lifespan, superior efficiency, and maximum safety. (Image source: Trina Storage)

Trina Storage, a prominent global provider of energy storage solutions, has rolled out its newest product—the Elementa 2 Pro 5MWh energy storage system—across key markets in Europe, Asia-Pacific, and the Middle East & Africa

The product launch has drawn significant attention from industry stakeholders, underscoring its high performance and further establishing Trina Storage’s capacity to support grid stability and meet varying energy requirements worldwide.

The Elementa 2 Pro builds upon the proven success of the original Elementa 2 line, introducing the latest advancements in cell technology and system architecture. It offers a high-efficiency, intelligent, and adaptable energy storage solution for a wide range of applications.

Durable, compact, and high-performance

As energy demand continues to grow and grid reliability becomes increasingly vital, efficient use of space is more critical than ever. Trina Storage has responded with the Elementa 2 Pro 5MWh, a solution designed to meet both performance and spatial challenges in modern energy infrastructure.

At the core of the system is a 314Ah cell with an industry-leading cycle life of 15,000, ensuring both durability and long-term economic value. The unit’s side-by-side and back-to-back compact configuration minimises its physical footprint, making it ideal for installations in urban and industrial settings. A noise suppression system keeps operational noise at just 70dB, addressing concerns in sensitive locations.

Advanced cooling and safety features

To maintain peak performance, the Elementa 2 Pro features a hybrid cooling system that keeps cell temperature variance within ≤2.5°C, even under extreme conditions. In colder climates, auxiliary power needs are cut by 30%, improving the system’s overall energy efficiency.

Safety is engineered into every layer of the design. The Elementa 2 Pro uses electric vehicle-grade cells, tested rigorously to ensure they meet the highest safety standards. It incorporates a three-tier electrical protection system and an emergency shutoff, providing robust safety coverage from the cabinet level to the PCS and EMS components.

Intelligent control and streamlined maintenance

In addition to its hardware strengths, the Elementa 2 Pro is equipped with advanced smart management features to simplify operations and cut down maintenance efforts. It offers 1:1 NTC temperature monitoring, enabling real-time oversight of individual cells and allowing for rapid anomaly detection. Its four-tier or master-slave BMS setup ensures optimal performance in parallel multi-cabinet installations.

The system also supports remote upgrades and live monitoring with a single click, reducing the need for on-site interventions and increasing O&M efficiency by up to 90%. This intelligent automation significantly lowers operating costs while enhancing reliability.

A milestone in clean energy innovation

Having earned international acclaim for the Elementa series, Trina Storage has leveraged its extensive experience from global projects to develop the Elementa 2 Pro. This latest system is tailored to meet the changing needs of the energy storage market with a solution that is both robust and forward-looking.

"The launch of the Elementa 2 Pro 5MWh system marks a significant milestone in Trina Storage's commitment to innovation and sustainability," said Wei Deng, Head of Global Product at Trina Storage. "We are confident that this advanced solution will help accelerate the global transition to clean energy."

Also read: Trinasolar advances South Africa’s energy transition

Clear and durable component labelling on solar farms isn't just a regulatory tick-box; it's fundamental for passing inspections, ensuring on-site safety, and enabling efficient maintenance.

Non-compliant or illegible labels can lead to failed inspections, delays in critical repairs, and increased risks for personnel.

Adhering to standards like IEC 62548-1:2023, IEC 61730-1:2023, and IEC 62109-1:2010 is crucial for smooth project handover and long-term operational integrity.

Brady brings to the market labels that are tested and verified to not only comply with applicable standards, but also withstand the conditions they are exposed to in installations over the long term.

Reliable identification solutions streamline your workflow and ensure compliance.

Properly labelled PV modules, inverters, junction boxes, and cabling allow for quick identification during inspections, saving time and preventing potential roadblocks.

Clear labelling also enhances safety by providing immediate information for lockout/tagout procedures and troubleshooting.

Furthermore, well-identified components enable maintenance teams to locate and address issues rapidly, minimising downtime and maximising system performance.

The reliability of your identification system should never be compromised.

All compliant solar farm identification labels are printed on Brady’s durable label materials, engineered to remain attached and legible for years, especially in demanding outdoor environments. These materials are designed to resist fading and peeling, ensuring long-term readability.

Brady’s solar farm identification labels have undergone rigorous testing in their laboratories, including the IEC 61730-2:2023 durability test, confirming their resilience.

Choosing the right identification partner simplifies this critical aspect of solar farm development. Opting for solutions designed for the harsh outdoor environment ensures longevity and legibility of labels, even under extreme conditions.

A comprehensive offering should provide durable labels and efficient printing options tailored to the specific needs of solar installations.

By implementing compliant and robust identification practices, electricians and contractors can ensure successful project completion, improve site safety, and facilitate efficient long-term maintenance of solar farms.

Investing in durable and regulation-adhering labelling is a direct investment in the project's success and operational efficiency.

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Download our free Guide to compliant solar farm identification for practical insights into effective solar farm labelling.

This guide illustrates where specific identification labels should be applied and presents solutions for fast and accurate labelling in the field.

Discover how to easily provide the right information to inspectors, first responders, and maintenance teams with compliant and reliable solar farm identification labels.

Discover more about identification solutions for Solar farms now.

BRADY Corporation in Middle East
www.brady.eu
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Ampacimon, for example, has developed its GridLife suite of grid monitoring tools including PDEye.

There are broadly three types of maintenance strategies, explains Javier Ortego, director of BlueBox Technology at Ampacimon:

Reactive or breakdown is a strategy of responding to a failure after it has occurred and when repairs are needed to restore function.

A preventative or scheduled maintenance strategy requires periodic inspections and regularly timed interventions.

Any defects are corrected as they are detected or components are replaced at scheduled intervals.

A preventative strategy is designed to correct failures before they occur but can result in potential faults being missed or elements being replaced when they are still functional.

Predictive maintenance is a data-driven, proactive strategy that relies on continuous data recovery and analysis to accurately forecast potential failures before they occur and allow timely intervention.

While partial discharge monitoring can be used as part of a preventative maintenance strategy with more sophisticated analysis partial discharge monitoring can also be deployed as in important element in a predictive maintenance operation.

Ampacimon, for example, has developed its GridLife suite of grid monitoring tools including PDEye.

This serves as a central monitoring platform for all the different sensors and monitoring units installed across the grid by detecting defects in insulation using permanently installed equipment such as sensors.

Installed on the cloud or on-premises it can be connected to the asset management system to accurately monitor the system for partial discharge and enable automated diagnosis across all the various asset classes, including cables, transformers, substations and switchgear, generators and motors, and gas-insulated substations.

Developed for optimal reliability, PDEye automatically generates instant real-time warnings from this sensor data with a 98% accuracy.

This level of precision reduces maintenance costs but coupled with an advanced artificial intelligence analytics tool, the platform not only identifies faults and their location but also provides an evaluation of any detected defects.

This AI modelling provides a diagnosis for the technical teams, identifying the defect type, any patterns, their criticality, and other parameters allowing it to categorise multiple defects automatically through clustering. This analysis considers any localisation, sensor ratio, wave parameters, and the phase-resolved partial discharge pattern and delivers an accurate list of defects from just a single measurement.

The system recognises these diverse defects in all insulation types, including XLPE, air, oil, or SF6. This precise AI modelling not only reduces the need for expert analysis but allows non-expert technicians to rapidly assess the condition of any assets and quickly plan and execute any necessary preventive actions. It can therefore enable a predictive maintenance approach to be adopted.

The future of an ageing grid

By detecting and taking action to address potential problems before they occur, grid reliability is improved. In addition, by acting early the cost impact of any emerging problems is mitigated.

For an ageing asset base where reliability is already likely to be affected, advanced grid-enhancing technologies like partial discharge monitoring coupled with AI analytics are tools that serve a multitude of important functions.

Indeed, a recent Credence Research report on the Middle East Grid Modernisation Market found that the market is anticipated to reach US$2.6bn by 2032, at a CAGR of nearly 15%.

It’s a market largely driven by increasing investments in smart grid technologies and digital transformation in the power sector as well as the influences of renewable energy integration.

Partial discharge monitoring allows companies to be aware of the health of their assets and make better decisions about maintenance and repair.

And, while it is worth noting that any defect that does not originate in the main insulation is not detectable by partial discharge monitoring, it can nonetheless serve as an important tool in the grid operator’s arsenal.

This is the last part of Ortego's op-ed. Click here to read the first and second parts.

There are two ways of monitoring partial discharge events.

Partial discharge (PD) in electrical grids is a localised electrical discharge that only partially bridges the insulation between conductors, without causing a complete breakdown.

It typically occurs in high-voltage systems, such as power grids, transformers, cables, or switchgear, where the insulation is subjected to strong electric fields.

Javier Ortego, director of BlueBox Technology at Ampacimon, explains how PD can be detected:  

Partial discharge monitoring can be applied to assets running at voltage of 1 kV or more can be applied at any stage of an asset’s life, even during commissioning.

However, it is particularly relevant to older assets that are at a higher risk of failure, especially those elements that are system-critical and which need to be rigorously monitored.

Key methods of monitoring

There are two ways of monitoring partial discharge events, off-line when the line is not energised, or online when the line is in use.

Off-line monitoring can take place during commissioning or if the line is de-energised when there is no load and therefore no noise.

Because the line is in use, online measurements can be more challenging as signal noise is generated that can interfere with the accuracy of any measurements.

For example, high-intensity noise can obscure the pulses derived from small partial discharge problems and make them difficult to detect.

In addition, it can make it harder to pinpoint the location of a particle discharge even if it is detected, the location is a key parameter to address any faults found.

There are also several possible monitoring strategies including punctual measurements that are performed at a specific time and usually last less than an hour, temporary measurements that can last perhaps hours or days and permanent measurements that monitor assets at all times and may be installed for months or years.

Finally, having obtained relevant data from the partial discharge monitoring, the interpretation of the signals is complicated and requires experienced personnel to derive actionable results.

This is the second part of Ortego's op-ed. Click here to read the last part

The first part is published here. 

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