Activity

  • Role of Digital Valve Controllers in Modern Process Safety

    Jim Cahill
    Valves used in process safety applications remain static for much of their existence in a manufacturing or production process. Digital valve controllers can play an essential role in ensuring these valves operate as they should when called upon in an abnormal situation. For safety valves used in throttling applications, digital valve controllers enable precise control through accurate valve positioning to avoid process…

  • Protecting Tanks and Minimizing Emissions in Changing Pressure Conditions

    Jim Cahill
    Storage tanks can safely hold thousands of barrels of product, but they are sensitive to overpressure and vacuum conditions, which can lead to product loss or excess emissions. Our article in the March 2025 issue of Valve World , titled “ Hazardous storage tank pressure protection and emissions control ,” discusses protective equipment that ­promotes operational safety while minimizing environmental impact, even in storage…

  • Optimizing Water Usage in Ore Mining Operations

    Jim Cahill
    Water is a fundamental resource for ore mining. It’s used in many processes, including grinding and classification, as well as flotation. Effectively managing its use enhances the efficiency and reliability of the mining operation. A white paper, High-Performance Control Valves for Water Addition Processes in Ore Mining , highlights the importance of valve selection in reducing operational and maintenance costs, waste…

  • Recommended LNG Process Valves, Actuators and Regulators

    Jim Cahill
    Over the past several years, liquefied natural gas (LNG) shipments worldwide have established a truly global market for natural gas. It’s a fascinating process to take natural gas, separate out any liquid condensates, dry the gas, and cryogenically cool the gas into the liquid phase. The LNG is loaded for transportation on ships to its destination for regasification into the gas phase. Click to enlarge The valves…

  • Enhancing Safety with Advanced Pressure Relief Valve Technologies

    Jim Cahill
    Pressure relief valves (PRVs) play a critical role in manufacturing and production processes by preventing unsafe overpressure conditions. They also affect regulatory compliance, process reliability, and the plant’s economics. Historically, these devices, independent from the control systems, went unmonitored and required manual inspection to identify leaks and other issues. These leaks can pose safety hazards, environmental…

  • Calculations for Sizing Control Valves

    Jim Cahill
    A Fisher brand technical paper on Valve Sizing Calculations shows the traditional and standardized calculations for properly sizing pressure regulators and valves. The traditional method uses equations designed by Emerson based on the performance of these valves and regulators. The paper explains that improper sizing can be both expensive and inconvenient. A too small valve will not pass the required flow, and the process…

  • Diagnosing Pressure Relief Valve Bellows Issues

    Jim Cahill
    I found an “oldie but goodie” article in Valve Magazine , Introduction to Pressure Relief Devices – Part 1 . The author highlights the origin of pressure relief valves (PRVs) from numerous boiler explosions in the early 1900s. The purpose of PRVs are: …to open to relieve excess pressure, reclose and prevent further flow of fluid after normal conditions have been restored The author shares various PRV design types…

  • When is a SIL Suitability Rating Required for Final Control Elements?

    Jim Cahill
    Update and bump: A LinkedIn post on this subject went viral, so I thought it would be worth sharing Riyaz Ali ‘s thoughts on this subject again. Abstract Final Control Elements (Control valves or Safety Shut Down Valves) are the key components of any close loop control system, whether it is used for Basic Process Control Systems (BPCS) or for Safety Instrumented Systems (SIS). Financial constraints derive different…

  • Adopting New Tailings Standards for Mine Sustainability Podcast

    Jim Cahill
    Miners have always faced the challenge of how best to safely and sustainably manage the vast amounts of uneconomic material left over from the mining process, known as tailings. A new global standard charts a path for the industry to further improve its management practices. In this podcast, Emerson’s Steve Brewer joins me to discuss some of the challenges in adopting the new standard and the role of valve technology…

  • Supercritical Control Valve Selection

    Jim Cahill
    Supercritical fluids are often found in carbon capture, ethylene, and hydrogen refining processes, and they pose unique equipment selection challenges, particularly for control valves. Our article on pages 45-50 in the February issue of Hydrocarbon Engineering , titled “ Demystifying Control Valve Selection ,” discusses key supercritical fluid applications, and it provides guidance for sizing and selecting control valves…

  • Hydrogen, Helium and High-Pressure Gas Pressure Relief Valve

    Jim Cahill
    Hydrogen as an energy carrier continues to be investigated as a form of energy for a more sustainable world. This tiny molecule poses challenges in its use and distribution. Anderson Greenwood Type 84 pressure relief valve A recent Emerson press release, New Emerson Pressure Relief Valve Optimizes Safety and Performance in Critical Gas Applications describes the Anderson Greenwood Type 84 valves, which deliver leak…

  • How To Assemble and Disassemble High Pressure Isolation Valve

    Jim Cahill
    How many times have we tried to assemble or disassemble something trying to follow written instructions that are unclear or perhaps confusing? Or watching a YouTube video trying to follow somebody’s oral instructions. I came upon this “how to” video for the assembly and disassembly of a Sempell VA400 high pressure isolation valve . The 3:43 YouTube video, Sempell VA400 High Pressure Isolation Valves – Assembly and Disassembly…

  • Selecting a Valve Positioner for Performance and Savings

    Jim Cahill
    Digital valve controllers, like this Fisher FIELDVUE DVC7K Digital Valve Controller from Emerson, employ a variety of sensors and electronics to ensure even very large valves reach their commanded position despite variable interferences. LNG facilities and pipelines rely on valve positioners to provide precise and reliable flow control. My article in the January 2025 issue of LNG Industry on pages 35-38, titled “ Wise…

  • Selecting a Valve Positioner for Performance and Savings

    Jim Cahill
    Digital valve controllers, like this Fisher FIELDVUE DVC7K Digital Valve Controller from Emerson, employ a variety of sensors and electronics to ensure even very large valves reach their commanded position despite variable interferences. LNG facilities and pipelines rely on valve positioners to provide precise and reliable flow control. My article in the January 2025 issue of LNG Industry on pages 35-38, titled “ Wise…

  • Maximizing Reliability with Emerson’s “The Big Three” Diagnostics in Digital Valve Controllers

    Jim Cahill
    Revolutionizing Valve Maintenance In industrial operations, ensuring reliability and reducing downtime are non-negotiable goals for maintenance teams. Emerson’s FIELDVUE Digital Valve Controllers, equipped with “The Big Three” diagnostics , offer a transformative approach to achieving operational excellence. These diagnostics— Supply Pressure Alert, Drive Signal Alert, and Travel Deviation Alert —are tailored to provide…

  • Engineering Superior Valve Solutions for the World’s Largest LNG Project Podcast

    Jim Cahill
    Liquefied natural gas (LNG) production facilities require rugged, reliable valves for safe, efficient, and sustainable operations. It’s also critical to reduce complexity and use the right valves for the application across the facility’s lifecycle, from initial engineering through construction, commissioning, operations, and ongoing maintenance. Emerson’s Andrea Sutti and Massimiliano Franco join me in the Emerson Automation…

  • How to Size Compressor Anti-surge Valves

    Jim Cahill
    Anti-surge valves protect centrifugal compressors from potentially catastrophic damage, but they are typically grossly oversized for common operating conditions. My article in the December 2024 issue of Automation.com , titled “ The Art of Compressor Anti-surge Valve Sizing and Selection ,” discusses an approach to anti-surge valve sizing that takes into account all operating modes to prevent valve damage and premature…

  • Transitioning to Blue Hydrogen Production

    Jim Cahill
    As demand for hydrogen rises, steam methane reforming (SMR) and autothermal reforming (ATR) have become increasingly vital. Both SMR and ATR are typically grey hydrogen processes, meaning they release significant carbon dioxide (CO 2 ) and other emissions. However, my article in the Winter 2024 issue of Global Hydrogen Review , titled “ From Grey to Blue ,” discusses how each of these processes can be adapted to produce…

  • Rugged, Reliable Valves for Sustainable Chemical Manufacturing

    Jim Cahill
    At the Valve World 2024 Conference , Emerson’s Knut Riegel presented Selecting Valves for Chemical Process Applications. His presentation addressed the chemical industry’s role in Germany, key principles to meet the needs of this industry, and the engineered valve solutions to address these needs. Valves are essential in chemical manufacturing and play a central role in the drive for greater sustainability. Sixty…

  • Valve Solutions for Tailings Disposal and Water Management Challenges

    Jim Cahill
    Our article in the October 2024 issue of North American Mining , titled “ How Valve Solutions Improve Tailings Disposal and Water Management ,” is the second installment in a two-part series explaining how innovative valve solutions can be used to improve mining operations. Part two focuses on tailings disposal and water management/chemical makeup. Contending with dewatered tailings As part of their conservation…

  • Butterfly Valve Designs for High Performance and Long-Term Reliability

    Jim Cahill
    High-performance butterfly valves are a common solution for equipment isolation and other on/off applications across a wide range of chemical and petrochemical processes. My article in the November 2024 issue of Valve World , titled “ Choosing butterfly valves for complete shutoff ,” discusses key design features of these valves to help users evaluate the best alternatives for their applications. Common applications…

  • Boosting Efficiency and Safety: The Power of Digitalization in Greenfield LNG Projects Podcast

    Jim Cahill
    The liquefied natural gas industry is active in building new greenfield facilities. These new facilities have the opportunity to take advantage of technological advances in automation and the digitalization of work processes. Valves, actuators, and regulators play a crucial role in this challenging cryogenic process’s overall safety, efficiency, and reliability. In this podcast, Emerson’s Riyaz Ali and Tom Mullins share…

  • Control Valve Considerations in Lithium Battery Applications

    Jim Cahill
    In the global effort to reduce greenhouse gas emissions, lithium batteries will play a critical role in powering electric vehicles, and by providing storage to offset the variability of green energy sources, such as solar and wind. Our article in the November 2024 issue of Processing , titled “ Control valve selection for the lithium battery value chain ,” describes how capable control valves address challenging conditions…

  • Valve Services for LNG Startup and Commissioning Podcast

    Jim Cahill
    Some of the largest greenfield projects going on throughout the world are liquefied natural gas (LNG) plants. These huge projects liquefy natural gas for transport across the globe. Regasification plants take in the LNG and convert it back into natural gas for distribution throughout the pipeline network. In this podcast, Devin Cloud with one of Emerson’s Impact Partners , John H. Carter , and their ControlWorx Premier…

  • Revolutionary Approach to Pressure Relief Valve Monitoring

    Jim Cahill
    Monitoring pressure relief valves helps producers and manufacturers maintain safe and sustainable operations. In this 12-minute YouTube video, Elevating Safety & Efficiency: Emerson’s Revolutionary Approach to Pressure Relief Valve Monitoring , Emerson’s Ricardo Garcia demonstrates how this monitoring works and introduces the innovative bellows leak detection solution. Transcript Hi, I’m Ricardo Garcia , product…

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