It`s Not Easy Being Clean

Transcription

2010 Salary Survey
Tunneling for Data
at Kimberly-Clark
On the Web
Andrew Bond Reports on
Process News in Europe
Fort FISCO Secures
Intrinsic Safety
It’s Not Easy Being Clean
JUNE 2010
Sustainability will happen when we all learn a new economic calculus.
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CT1006_FPA.indd 4
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June 2010 • Volume XXI! • Number 6
f e at u r e s
S
a
l
a
r
y
s
u
r
v
e
y
59 / Feeling It
The effects of the 2008-9 economic implosion ripple
through our latest salary survey. by Nancy Bartels
S
o
f
t
w a
r
e
65 / Network Tunnel Links
Control and Vision
Swiss paper mill uses OPC DataHub to integrate realtime data for better quality management.
by Bruno Maurer
I
n
t
r
i
n
sic
S
a
f
e
t
y
68 / FISCO is Fortified
Intrinsic Safety
More power means more devices can be connected to a
single H1 port—especially now that FNICO is part of the
FISCO standard. by Ian Verhappen
W E B
E X C L US I V ES
Andrew Bond’s European Report
www.controlglobal.com/1006.Bond.html
Cover Story
50 / It’s Not Easy Being Clean
Sustainability will happen when we all learn a new
economic calculus.
by Katherine Bonfante
CONTROL (ISSN 1049-5541) is published monthly by PUTMAN Media COMPANY (also publishers of CONTROL DESIGN, CHEMICAL PROCESSING, FOOD PROCESSING, Industrial Networking,
Pharmaceutical Manufacturing, and PLANT SERVICES ), 555 W. Pierce Rd., Ste. 301, Itasca, IL 60143. (Phone 630/467-1300; Fax 630/467-1124.) Address all correspondence to Editorial and Executive Offices, same address. Periodicals Postage Paid at Itasca, IL, and at additional mailing offices. Printed in the United States. ©Putman Media 2010. All rights reserved. The contents of this publication may not be reproduced in whole or part without
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Post International Publications Mail Product Sales Agreement No. 40028661. Canadian Mail Distributor Information: Frontier/BWI,PO Box 1051,Fort Erie,Ontario, Canada, L2A 5N8.
J u n e / 2 0 1 0 www.controlglobal.com
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an advertising supplement to
JUNE 2O1O
I/O at Your
Fingertips
Focus on HumanCentered Design
Yields New Way
to Think About I/O
CT1006_Emerson.indd 1
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Process automation just got easier.
Again.
Introducing the DeltaV S-series. A fresh look on usability down to the smallest detail–from the new,
patent-pending hardware that minimizes installation complexity and maximizes plant availability, to the
more intuitive operator displays, to built-for-purpose smart security switches that minimize your lifecycle
costs. The re-designed DeltaV system embeds knowledge, reduces complexity, and eliminates work–
bringing a new level to the now-familiar DeltaV standard: Easy. www.EmersonProcess.com/DeltaV
The Emerson logo is a trademark and a service mark of Emerson Electric Co.©2010 Emerson Electric Company
5/24/10 12:07 PM
Contents
Q&A with Emerson’s Peter Zornio
Innovation’s New Frontier . . . . . . . . . . . . . . . p4
I/O on Demand
The New Paradigm . . . . . . . . . . . . . . . . . . . . . . . p6
Electronic Marshalling
Redefining the Project Path . . . . . . . . . . . . . p10
Conventional I/O
Redesigned for How You Work . . . . . . . . . . p14
Wireless Mesh Networks
The Ultimate in Flexibility . . . . . . . . . . . . . . . p16
Field Device Networks
The New Game in Fieldbus . . . . . . . . . . . . . . . . p18
Safety Instrumented Systems
Flexibility without Compromise . . . . . . . . . p20
IOonDemandCalculator.com
Calculate Your Project Savings . . . . . . . . . p22
ControlGlobal.com/IOonDemand
the early reviews are in . . . . . . . . . . . . . . . . . p23
3
special advertising supplement ● JUNE 2010
5/24/10 12:08 PM
Q&A with emerson’s peter zorNIO
Innovation’s New Frontier
O
workers are coming in; and what specialists are left
are stretched ever more thinly. Further, new plants are
coming online in rapidly growing markets in far-away
places where the operators may have little familiarity
with computers and electronics. HCD principles can
make it easier for them to come up to speed and help
them operate with fewer errors.
Anecdotally, we had a customer come to Austin and
say, “Your technology must pass the 20/20 rule for it to
be useful to me.” He explained that to solve any particular problem, he may have to “pick from 20 people,” and
whoever is picked must be able to solve the problem “in
20 minutes.” Only technology built for ease-of-use can
solve this problem.
ver the past 30 years, the automation
industry has made incredible strides in
technology. The capability and functionality
of today’s digital automation systems arguably have
advanced to a point where they have outpaced the
ability of many end users to take full advantage of the
technology they already have in place.
So it is, says Peter Zornio, Emerson Process
Management chief strategic officer, that the next
step change in automation innovation will come,
not from adding new features and functionality, but
from subtracting complexity—making automation
technology easier to use; easier to implement and
manage; easier to bring to bear for business benefit.
Control recently caught up with Zornio to discuss
Emerson’s commitment to human-centered design
(HCD) and how it continues to reshape the company’s offerings, notably its new DeltaV S-series
digital automation system architecture, and what the
company calls “I/O on Demand,” which is intended
to do nothing less than reinvent how I/O gets done
in the process industries.
Q: How has human-centered design changed
Emerson’s development process?
A: As we investigated how to improve usability, we
began to work with Carnegie Mellon University, the
leader in human-centered design for industrial applications—which itself has only been around as a
discipline for the past 15 to 20 years. We developed
a better understanding of what we needed to do. We
made organizational changes and investments, such as
creating our own Human-Centered Design Institute.
And today, we’ve put more than 60 key staffers through
immersion training in HCD principles.
From an Emerson product development perspective,
human-centered design has meant that instead of interviewing customers only to understand how they use or
interact with a product, we interview and observe them
to understand what they do in their work and how they
interact with others. We’ve created personas for various positions to illustrate how people actually use and
interface with the technology. This has helped us better
understand how to design the technology around them.
In the end, our HCD goals became three-fold: to
eliminate work, to remove complexity and to embed
knowledge.
Q: How did Emerson identify human-centered
design as an important driving force in the
company’s development efforts?
A: We actually identified “usability” as a key strategic
imperative about five years ago. We conducted surveys
of our customers and found that their challenges
increasingly revolve around people. The “old” challenges of the past—global competition, optimizing
production and complying with regulations— are all
still there, but the people challenge has come into focus
for our customers as key to running safe, reliable and
highly productive plants.
Users face a productivity paradox: There’s more
technology than ever, and plants are trending toward
larger and more complex processes. Meanwhile, experienced worker are retiring; fewer, less experienced
JUNE 2010 ● special advertising supplement
4
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‘I/O on Demand is all about
affording customers the greatest
degree of flexibility with the least
amount of effort and risk.’
We used to talk to our customers about the need to
change their work practices to get the maximum benefit
from technology—but as it turns out, no one’s available
to rewrite those work processes. So step one is making
things easier by engineering the work out of the process.
Second, for the work that cannot be eliminated, we’re
striving to remove complexity: Make it simple as possible, and make the technology do the hard part. Our
third aim is to embed within the technology the knowledge of those experienced people who are leaving—or
who perhaps were never there in the first place.
Q: One recent outcome of Emerson’s focus on
human-centered design is “I/O on Demand,”
a concept revealed at last fall’s Emerson Exchange
in conjunction with the DeltaV S-series launch.
Can you explain more about what makes this new
approach to input/output so revolutionary?
A: At its core, I/O on Demand is all about affording
customers the greatest degree of flexibility in their
I/O decisions with the least amount of effort and
risk. Regardless of I/O type chosen—traditionally
wired, bussed or even redundant wireless—users can
add and begin using input and output points natively
and with far less engineering, design and field work
than previously possible.
But it’s not just choice of I/O type. On demand
means flexibility in time and place too. Our electronic
marshalling solution, for example, allows users to execute
projects far more quickly—gracefully accommodating
those inevitable last minute changes and reducing timeto-production. Our SmartWireless offering essentially
allows incremental “wireless I/O” to be distributed seamlessly throughout the plant, wherever and whenever the
need for a new measurement point is identified.
We’ve also used HCD principles to change the game
in Foundation fieldbus—streamlining segment engineering and installation effort, as well as eliminating many
of the potential installation problems having to do with
power, grounding and termination issues. Another way
in which we allow users to further leverage their I/O
investment is in the seamless communication of DeltaV
SIS (safety instrumented system) information to the basic process control system (BPCS). In this way, information from safety I/O can be used to allow the BPCS to
make more informed control decisions.
More than a collection of HCD-driven enhancements, I/O on Demand represents a fundamental
transformation of Emerson’s PlantWeb architecture.
An integrated, wireless infrastructure gives plants a
flexibility to respond to changing needs during its
entire life cycle. Fieldbus has become easier to implement and even more cost-effective. And electronic
marshalling has revolutionized how conventionally
wired projects get done. It’s the first real update to a
35-year-old engineering practice.
5
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I/O on demand
The New Paradigm
E
Across the process industries, sustainability and
related environmental concerns show no sign of abating, especially as they relate to conserving increasingly
expensive energy and limiting greenhouse gases. New
regulations are being extended to include the protection of personnel and equipment. Control system
security also is becoming more important, as the
perceived threat of cyber incidents mounts.
Meanwhile, increasing scale and complexity
constitute a growing challenge. On the one hand,
plants are getting larger. Petrochemical plants, for
instance, have become petrochemical complexes.
This makes sense for efficiency reasons, but the entire
operation becomes more complex because of unit
interdependencies. Projects, too, are getting bigger and schedules are getting compressed. Hence
more engineering work is getting pushed onsite for
completion, sometimes with a marked effect on final
project timing, cost and quality.
Against this backdrop are a record number of
industry professionals at retirement age, who as they
leave are taking a wealth of experience with them.
Further, some industries are pursuing strategic workforce reductions. Centralized facilities, for example,
are being developed in order to move more people out
of hazardous or unsafe areas. The oil and gas industry
is particularly adept at creating unmanned facilities,
so when someone is sent onsite to troubleshoot, a
true generalist—not a specialist—is required. And in
growth markets, plants often are being built where
there is essentially no ready-trained work force. Further complicating matters, few experienced people are
interested in relocating to these remote locales.
So, we’re left with fewer, less experienced people
dealing with ever more complex processes and technologies. “It’s a perfect storm,” said Steve Sonnenberg,
Emerson Process Management CEO, in his keynote
address to the Emerson Global Users Exchange late
last year in Orlando as he prepared to unveil the latest
iteration (version 11) of the company’s DeltaV digital
automation system, the S-series.
ver since the first direct digital control system
was applied some half-century ago, input/
output (I/O) has been essential to process
automation system architecture. And for just as long,
the engineering of that I/O has been complex, and the
fruits of that labor rigid and inflexible.
First, take the specification of conventional rackmounted I/O cards, each of which uses shared circuitry
to deal with a specific number of similar input or output
channels. Then add to that the design of associated
controllers, marshalling cabinets, junction boxes and wire
runs, and it’s no surprise that the typical project incurs
significant change-order expenses as inevitable late-stage
design tweaks wreak havoc on delivery schedules.
Foundation fieldbus and other bus technologies
essentially moved some I/O functionality out into the
field devices themselves—easing the need for conventional I/O—but fieldbus segments are complex, and
little reduction in engineering effort has been realized
relative to conventional I/O practices.
The American Heritage Dictionary defines paradigm
as “a set of assumptions, concepts, values and practices
that constitutes a way of viewing reality for the community that shares them.” And in the case of I/O, the
prevailing paradigm is that I/O is hard; I/O is inflexible.
But what if it wasn’t so difficult? What if constant revisions to I/O specs didn’t hamstring your project schedule? What if existing I/O spares didn’t limit your ability
to deploy new measurement points? What if I/O was
more readily available, in any flavor needed, anywhere
you needed it, and at any stage during a project—even
after you’re up and running?
That’s the essential value proposition of I/O on
Demand, Emerson Process Management’s new way of
thinking about I/O.
The Process Landscape
To better understand the genesis of the I/O on Demand offering, it’s useful to first consider the broader
context of the process industries and the increasingly
global business environment in which they compete.
6
5/24/10 12:09 PM
‘One of the goals of humancentered design is to eliminate
unnecessary work.’
From HCD to ‘I/O on Demand’
Emerson Process Management decided some years ago
that human-centered design (HCD) had to be a major
part of the answer to this conundrum and set out to
ensure that its process automation offering helps to
accomplish three primary goals: eliminate work (where
possible), reduce complexity for its users (let technology
do the hard part), and embed knowledge (where needed).
“Frankly, automation suppliers have not designed
products built around the actual ways projects are
executed and the ways plants are run,” says Sonnenberg.
“Advancing products features is important, but designing
products around how people use them is critical.”
Task analysis, notes Peter Zornio, Emerson chief strategic officer, confirms that automation design is engineeringintensive (Figure 1). “That’s all work,” he says, “and one of
the goals of HCD is to eliminate unnecessary work.”
I/O on Demand (Figure 2) is essentially the
result of Emerson’s HCD development approach
applied to I/O. It consists of a collection of new
technologies as well as a range of HCD improvements all aimed at affording customers the greatest
degree of flexibility in their I/O decisions with the
least amount of effort and risk.
Controller
Work
• I/O lists and controller sizing
• Power, grounding, and fusing design
• I/O design
• Spares sizing
• Cabinet design
• Conduit and cable layout
• P&IDs
• Process narratives
• Installation package
I/O
“I/O on Demand is ‘what you want, where you
want it, when you want it,’” continues Zornio. “This
is an automation breakthrough that eliminates the
intensive pre-engineered work associated with I/O.”
Electronic Marshalling Streamlines Work
While I/O on Demand promises usability and
labor-saving improvements for almost any choice
of I/O approach, perhaps the most transformative
innovation for project work is the practice of electronic marshalling.
For conventionally wired instrumentation, electronic marshalling allows users to land field cabling
wherever there is an available terminal block in the
marshalling cabinet—regardless of signal type or
control strategy. Each terminal block is set up to
receive a single-channel characterization module,
or CHARM, which includes the A/D converter and
associated signal characterization for that point’s
particular type of analog or digital I/O signal. Each
I/O point is then digitally communicated via the
marshalling cabinet’s DeltaV backplane—and can
be associated with any control strategy in any of the
system’s DeltaV controllers.
Marshalling
Work
• Cabinet design
• Jumpers and
terminations
• Wiring diagrams
• Cable layout
Junction
Box
Work
• Junctoin Box design
• Jumpers and
terminations
• Wiring diagrams
• Cable layout
Figure 1. The traditional approach to engineering and installing input/output points is
a complex, time-consuming and inflexible process.
7
5/24/10 12:09 PM
I/O on demand
“44% of process control inputs can be wireless with
no difficulty, and for a greenfield plant that’s a savings
of 7% overall,” says Duncan Schleiss, Emerson vice
president of platform strategy. “Getting rid of wires
eliminates most activities associated with wiring design
and installation,” Schleiss adds. “Poof! Cabinets, wire,
terminations, cable tray design, fusing, installation
drawings and a host of other activities are simply gone.”
(For more details on the wireless aspects of I/O on
Demand, see article on p 14.)
The effort and cost savings potential is enormous,
because the manual cross-referencing of each incoming pair of wires with the appropriate I/O card
is effectively eliminated—along with the requisite
“spaghetti” wiring, extra terminal blocks and cabinet
space. Further, because signal characterization is done
on a single-channel basis, flexibility to accommodate
late stage design changes is greatly enhanced. On a
typical capital project, Emerson estimates that electronic marshalling could result in 32% reduction in
‘Advancing product features
is important, but designing
products around how people
use them is critical.’
DeltaV controllers, a 40% reduction in cabinet footprint, and a whopping 90% reduction in intra-cabinet
wiring relative to conventional I/O practices. (For
more details on the electronic marshalling aspects of
I/O on Demand, see article on p 10.)
Reducing Fieldbus Effort and Cost
Emerson’s HCD effort also took a hard look at
Foundation fieldbus and found that substantial improvements could be made in how fieldbus is done.
“Foundation technology requires third-party power
supplies and power conditioners—along with the
necessary engineering and wiring and cabinet space,”
Schleiss explains. “And if you wanted to get at the
bus diagnostics, you had to jump through OPC and
RS485 hoops in order to get the information into the
control system.”
“With DeltaV S-series and I/O on Demand, we’ve
integrated the power circuitry with the H1 card
itself,” Schleiss says. “Third-party power conditioners
and dedicated power supplies—and the engineering
that went with them—are a thing of the past.”
Citing a recently completed project consisting of
Redundant Wireless Boosts Flexibility
A second important aspect of Emerson’s I/O on Demand approach is the addition of redundancy to the
company’s Smart Wireless infrastructure offering. Redundancy will allow an increasing number of traditionally wired I/O points to go wireless—for incremental
monitoring as well as for closed-loop control, Emerson
believes. This will have a profound impact on the design of new facilities as well as the ability of brownfield
plants to easily implement new measurement points
and asset management strategies.
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5/24/10 12:09 PM
Figure 2. Emerson Process
Management’s I/O on Demand
approach represents significant usability enhancements
for conventionally wired,
bussed, or wireless connectivity to field devices.
some 2,500 Foundation fieldbus segments, Emerson
estimates that total project cost could have been
reduced by some 7% using the new I/O on Demand
approach. “Five thousand H1 power conditioners, 32
H1 power cabinets, along with their design and documentation, and all that factory and on-site wiring,”
lists Schleiss. “All gone!
“But we also integrated diagnostics. So now the
maintenance staff can wait for the DeltaV H1 card to
notify them of a problem on the physical layer, such as
low voltage or high current. Easy! It’s all integrated!”
(For more details on the fieldbus aspects of I/O on
Demand, see article on p 18.)
Safety I/O Leverages HART Data
Emerson also has addressed flexible I/O considerations in the modular, distributed architecture of
its safety instrumented system, DeltaV SIS. Fully
configurable I/O for any type of signal, the ability to
add incremental logic solvers at any time, and scaleability from 16 to 30,000 I/O points all contribute
to increased flexibility, improved robustness and the
elmination of single points of failure.
Further, the integration of DeltaV SIS with the
DeltaV basic process control system (BPCS), allows users
to leverage SIS I/O information to make better operations decisions. (For more details on the safety aspects of
I/O on Demand, see article on p 20.)
Error-Proofing Conventional I/O
Even the DeltaV system’s “conventional” I/O hardware has evolved to make life easier with the new
S-series. Patent-pending heat dissipation technology
allows for a completely enclosed shell (no vents). This
prevents particles—or an errant screw—from entering
a card and short-circuiting electronics.
And the new S-series hardware also offers “easyon-hard-off” installation, which means there are no
screws needed to install a card onto the backplane, yet
releasing one requires pushing an out-of-the-way release
button on top of the card. (For more details on how
conventional I/O practices have been improved using
HCD principles, see article on p 14.)
In the final analysis, I/O on Demand spans both
revolutionary new technologies as well as the sum-total
of myriad human-centered design innovations—all
in the name of shifting the I/O paradigm. Now, I/O
doesn’t seem quite so hard, does it?
9
5/24/10 12:10 PM
electronic marshalling
Redefining the Project Path
A
need not be engineered beyond knowing an approximate total I/O count?
Electronic marshalling does all these things. As a
result, it effectively removes I/O from the critical path
of many projects—decoupling process design from I/O
architecture decisions, as well as eliminating the rework
costs and project delays that were once the inevitable
consequence of late-stage design modifications.
“The new I/O on Demand capability of Emerson’s
DeltaV S-series allows users to add or change I/O types
whenever they make project design changes, no matter
where the I/O is located,” notes Larry O’Brien, analyst
for the ARC Advisory Group. “This reduces project costs
and, even more important, reduces time to startup.”
cornerstone of I/O on Demand is electronic
marshalling, a new approach to an industry
practice that until now has changed little over
the past several decades.
Indeed, classical marshalling is at the heart of a
labor-intensive, relatively inflexible work practice that
also is subject to the whims of late-stage process design
modifications. Changes in process design drive changes
in control system inputs and outputs required, and
proceed to cascade through all that detailed engineering work—from reworking drawings to control system
partitioning to building new cabinets. Late design
changes are inevitable, but they add cost, time, and
most important, risk to any project. The practice of
wired marshalling only intensifies these problems.
But what if the nature of any single I/O channel
could be changed at will, at any time during a project? What if a new pair of wires needed only a place
to land and could be digitally bound to any controller in the system? What if all marshalling cabinets
and junction boxes were of a “standard” design and
Out with the Old
In the typical project of today, field home run wires are
landed on the right-hand terminal strips in the marshalling cabinet shown in Figure 1. The terminal blocks
then must be cross-marshalled to the appropriate I/O
card and controller on the left-hand side of the diagram,
Figure 1. Traditional marshalling
involves the landing of field wiring
on terminal blocks followed by
the manual cross-marshalling of
each signal pair to the appropriate I/O card and controller on the
other side of the cabinet.
10
5/24/10 12:11 PM
Figure 2. Electronic marshalling allows field wiring to be
landed on any available terminal block in the cabinet;
each channel is then individually characterized and
digitally mapped to the desired controller.
24V DC field power injection
Single-channel A/D converter with character
(CHARM - characterization module)
Hidden digital bus provides
resulting in a rat’s nest of wiring that is both difficult to
manage and difficult to modify.
With electronic marshalling, wires from the field
still are landed on the right-hand set of terminal blocks
as shown in Figure 2. But there are no cross wires. All
of that work, design and engineering simply goes away.
That’s because with electronic marshalling, each individual channel is characterized to become the appropriate I/O type—analog input, digital output, etc.—
simply by plugging in the appropriate A/D converter
module called a characterization module, or CHARM.
So when it comes to instrumentation installation, land the wires anywhere, characterize the signal
with a CHARM, drag and drop it to the appropriate
controller in the host system and off you go! Any I/O
can be used with any controller in the system—meaning that all of the I/O can be bound to the control
system much later in the project. Overall system costs
are lower because internal cabinet cross-wiring is
eliminated, cabinet footprint is reduced, I/O channel
assignments are simplified and factory-acceptance test
(FAT) activities are trimmed.
An Inside Look
The DeltaV CHARM IO card (CIOC) itself has been
designed for ease of use, both in physical installation
(Figure 3) and its software tools. Components snap
together with secure DIN-rail latches and interlocking
carrier connectors; a series of 96 I/O channels can be
connected to a DIN-rail in a matter of minutes. Each
I/O card can serve I/O signals to any four controllers in
the system with 50 ms updates for fast, reliable control.
The CIOC architecture is fully redundant, starting with the two I/O cards on a carrier. The carrier has
redundant communication modules for primary and
secondary network connections. There are two 24-VDC
input power connections. The carrier connects to the
CHARMS base plates and provides redundant power
and communication buses to the CHARMs. Everything
is redundant down to the individual channel.
11 CT1006_Emerson.indd 11
5/24/10 12:11 PM
mistakenly inserted. CHARMs also can be partially
ejected to a locked position, disconnecting the field
wiring from the system to perform field maintenance
actions or to remove power to a field device. Activating
the CHARM latch ejects the CHARM to the stand-by
position. Closing the latch locks the CHARM in place
and isolates the field wiring for field work.
No tools are needed to remove a CHARM or
CHARM terminal block from the CIOC (Figure 3).
Upon initial insertion, CHARMs are sensed by the
system, automatically creating the I/O definition in
the DeltaV configuration database. Also, upon initial
insertion of a CHARM, each terminal block is “selfkeyed” so that the wrong type of CHARM cannot be
‘Emerson’s DeltaV S-series
allows users to add or change
I/O types whenever they make
project design changes.’
Figure 3. Detail shows how a series of
characterization modules, or CHARMs,
are used to individually condition and
convert each I/O signal—HART
diagnostics included.
Ground bottom of rail for shields
Two or four wire devices supported
Wire banks in pairs for easy wiring
“No tool” easy eject mechanism to
release CHARM terminal block
One HART v7 modem
per channel for fast
communications
“No tool” easy eject mechanism to
release CHARM for hot work
12
5/24/10 12:12 PM
‘The electronic marshalling
junction boxes come in a
one-size-fits-all design.’
Figure 4. Redundancy is built into each CHARM IO card,
including the power supply and communication link.
Redundant Ethernet
(copper or fiber)
Redundant 24V DC power supply
(for CHARMS, CIOC, and field devices)
Redundant CHARM IO
Card (CIOC)
What Cabinet Design?
Because electronic marshalling senses the individual
character of each I/O channel to its plug-in CHARM,
the design of marshalling cabinets can be greatly simplified. Indeed, Emerson’s standard electronic marshalling cabinet comes with no options (none are required)
and with all rails and components installed. The only
missing parts are the CHARMS and corresponding
CIOCs, which means that I/O from field can be wired
up at any time—and be electronically marshalled later.
And because all components of the CIOC are rated
for installation in Class 1/Division 2 or Zone 2 hazardous locations and feature extended operating temperature ranges and G3 environmental ratings, electronic
marshalling can be done in field-mounted junction
boxes. Using standard Ethernet infrastructure hardware,
I/O can be added to a remote enclosure located miles
away from the controllers and control room. This further
reduces the footprint of the central equipment room
as well as reducing the overall wiring infrastructure of
traditional multi-core instrumentation cable.
Like its electronic marshalling cabinets, Emerson’s electronic marshalling junction boxes also come in a one-sizefits-all design: Simply run a CAT5 or fiber-optic Ethernet
back to the controller cabinet, and now the marshalling
cabinets disappear altogether. This means even fewer design
tasks, less footprint, less wire and fewer wiring problems.
All told, the use of electronic marshalling in junction
boxes has the potential to eliminate scores of hours of engineering, design and installation work while improving
the ability of a project to accommodate late-stage engineering changes while minimizing rework and schedule
impacts. The traditional marshalling cabinets and I/O
cabinets are effectively gone, along with design and
installation tasks related to such tedious details as fuses,
spares, jumpers and terminations, wiring diagrams and
cable layout—not to mention the design of the cabinets
and junction boxes themselves.
5/24/10 12:13 PM
conventional I/O
Redesigned for How You Work
E
The new cards also offer “easy-on-hard-off” installation, which means there are no screws needed to install
a card onto the backplane, yet releasing one requires
pushing an out-of-the-way release button on top of
the card. Further, S-series I/O cards are automatically
“auto-sensed” when added to the system. This helps
makes maintenance error-proof, ensuring that any
replacement I/O card is of the proper type. A guide
prevents bent pins and cards easily snap in place.
System availability is addressed with S-series I/O
by allowing the online addition of new components
without shutting down. Controllers, I/O cards, field
devices and workstations can be added while the
host system is powered and running—any system
can be upgraded or expanded on-the-fly with no
downtime. System uptime is also enhanced through
the available redundancy of system components, including controllers, control and field interface power
supplies, controller Ethernet communications and
many field interface cards.
ven as it has helped I/O to escape its old constraints, the practice of human-centered design
has been used to make important usability
enhancements to conventional I/O as well.
In the Emerson DeltaV architecture, HCD is embodied in the new DeltaV S-series I/O cards, which
carry forth the electronic functionality of the company’s proven M-series I/O, but are re-engineered to
deliver a new level of easy, error-proof installation
and operational robustness.
“The S-series I/O cards use the same electronics and
software that has been proven for more than a decade in
the M-series hardware,” says Duncan Schleiss, Emerson
vice president of platform strategy. “And, by the way,
customers can upgrade to the DeltaV version 11 without
needing to upgrade to S-series I/O.”
Installation Error-Proofed
One HCD-driven improvement is the S-series’ patentpending heat dissipation technology, which features
a plastic cover over the top air vents to prevent items
from dropping down into the card from above and
shorting out the circuitry.
Modular and Compatible
Importantly, both S-series and M-series I/O hard-
S-series I/O interfaces snap to 8-wide I/O carrier with
integrated 24 VDC bussed field power distribution.
Redundant controllers with system
power supplies on 2-wide carriers.
Rails slide together
easily and securely.
14
5/24/10 12:13 PM
Latched installation delivers
tight connections every time.
Guide prevents bent pins
and card snaps in place.
Screw fastening
eliminated. No
broken cards due
to overtightening.
With snapclamps the
correct
tightness
is assured.
Cards remain
securely in
place.
Venting system
prevents debris/
objects from
entering.
‘Both S-series and M-series I/O
hardware can coexist in the
same DeltaV system with no
trade-offs or incompatibilities.’
ware can coexist in the same DeltaV system with no
trade-offs or incompatibilities. And while it doesn’t
offer the single-channel modularity of Emerson’s
new electronic marshalling approach (see story, p
10), the S-series does allow users to specify the exact
number of I/O cards, 8-wide carriers, power/controllers and 2-wide carriers needed—and the flexibility
to add more I/O as the system grows.
The DeltaV system supports a full range of
analog, discrete, digital bus, thermocouple and
RTD field devices. DeltaV control hardware is built
rugged and f lexible to mount almost anywhere and
is designed for extreme field installation conditions,
including: Class 1/Division 2 areas, CENELEC
Zone 2 areas, and ISA-71.04-1985 Airborne Contaminants Class G3.
All DeltaV I/O cards are rated for extreme operating temperature ranges of -40 °C to 70 °C (-40
°F to 158 °F) and can be mounted in field junction
boxes, significantly reducing equipment footprint.
Shared remote I/O is available for Zone 2 installations. Unlike other remote I/O, DeltaV remote I/O
can be shared among several controllers for a greater
range of applications and installation flexibility.
5/24/10 12:13 PM
wireless mesh networks
The Ultimate in Flexibility
T
he advent of the wireless instrument network—which in effect moves I/O functionality out into the field device itself—offers
perhaps the ultimate in I/O on Demand flexibility.
Indeed, once a mesh-based wireless infrastructure is
in place, incremental I/O points actually lead to a
stronger, more robust wireless network.
So not only does the new I/O point come along “for
free,” it actually improves the communications reliability
of those wireless measurement points around it.
“Wireless has been adopted at thousands of customer
sites globally,” notes Bob Karschnia, vice president,
wireless, for Emerson Process Management. “Plants
using wireless have realized savings and become smarter
through simpler engineering and construction, flexible
start-up, faster deployment and project completion, and
the ability to respond to changing automation needs.”
But customers have been asking for more, relates Peter Zornio, Emerson chief strategic officer. “In particular,
they’ve requested gateway redundancy and the ability to
install gateways in hazardous areas. We’ve solved both of
these issues with the new DeltaV system.”
redundantly with the DeltaV network (Figure 1). This
new approach divides the functionality of the existing
1420 Wireless Gateway into two elements, allowing the
remote link to be installed in hazardous environments.
“This gives a lot of benefits by increasing availability,
reducing both installed cost and footprint, and is more
forgiving,” says Duncan Schleiss, Emerson vice president
of platform strategy. “As with our previous wireless solution, it lowers life-cycle costs and removes the need for
engineering drawings.”
Figure 1. The DeltaV
system architecture
now offers fully
redundant wireless
remote links that can
be installed
in hazardous
environments.
Redundancy + Hazardous Area Installation
Redundancy and hazardous area installation—together
with Emerson’s new PID algorithm, which makes possible closed-loop control over Wireless HART—will allow more traditionally wired I/O points to go wireless,
Emerson believes. This promises to have a profound impact on the design of new facilities as well as the ability
of brown-field plants to implement new measurement
points and asset management strategies.
“Full redundancy protects the wireless network from
any single point of failure by allowing primary failover
to ensure that data always is delivered even if there is a
malfunction,” Karschnia says. “The new full redundancy
furthers strengthens Smart Wireless technology as a complement to wired and bus approaches on capital projects.”
Wireless redundancy in the new DeltaV architecture takes the form of redundant remote links, which
communicate via RS485 with redundant Wireless I/O
Cards (WIOCs). The WIOCs, in turn, communicate
16
5/24/10 12:14 PM
Wireless PID Enables Closed-loop Control
The latest DeltaV and Smart Wireless offering can also
do closed-loop PID control over wireless. At bioprocess
technologies supplier Broadley James, wireless pH and
temperature transmitters control a single-use disposable
bioreactor. “We conducted batch runs using mammalian
cell culture,” says Scott Broadley, Broadley James president. “The observed pH and temperature control using
wireless measurements was equivalent to that achieved
using wired transmitters.”
Similar results were seen at another installation,
this one at the University of Texas, Austin, stripper and
absorber control is being done using WirelessHART
transmitters. Column pressure control and heater stream
flow control over wireless provided the same dynamic
response and comparable performance as wired transmitters, according to Frank Seibert, technical manager
of the UT Austin separations research program. Both
installations use the enhanced PID algorithm available
with the DeltaV S-series.
What makes this possible, explains Randy Balentine, DeltaV product marketing manager for Emerson
Process Management, is the new control algorithm.
“We knew WirelessHART devices and the way they do
non-periodic updates, and we understood how we could
accommodate that in the PID algorithm and function
block,” he says. The technology is available to address
most control applications, with scan rates as fast as one
second, supported by devices, gateway and the DeltaV
digital automation system.
Trials at the University of Texas, Austin, have demonstrated the use
of WirelessHART devices for closed-loop distillation control.
“Yesterday, you couldn’t do PID wirelessly,” says
Balentine. “Today, that’s no longer the case.”
All these wireless enhancements mean that more and
more wireless points can be implemented wirelessly—
and the savings can add up quickly.
“Up to 44% of process control inputs can be wireless with no difficulty, and for a greenfield plant that’s a
savings of 7% overall,” estimates Schleiss. “Getting rid
of wires eliminates most activities associated with wiring
design and installation—Poof! Cabinets, wire, terminations, cable tray design, fusing, installation drawings and
a host of other activities are simply gone.”
‘44 % of process control inputs
can be wireless with no difficulty
and for a greenfield plant that’s
a savings of 7% overall.’
5/24/10 12:15 PM
field device networks
The New Game in Fieldbus
W
reduced wiring costs and better information access
promised by fieldbus. While fieldbus reduced the
number of I/O cards needed back at the control room
or junction box, it still required third-party power
supplies and power conditioners. And, if you wanted
the ability to access fieldbus diagnostics directly in
the control system, more third-party devices, software
and integration work were needed. Further, installing
fieldbus properly came with its own set of “gotchas.”
In the end, using fieldbus instead of point-to-point
wiring did little to reduce the time and effort needed
to engineer and implement I/O points.
hile it doesn’t obviate the need for wires
altogether, Foundation fieldbus and other
bus technologies do reduce the need for
traditional rack-mounted I/O cards by moving the
I/O function into the field devices themselves.
In a typical fieldbus topology, a number of these
digitally communicating devices—whether speaking
Foundation, Profibus, ASI-bus or any of a number of
other protocols—can coexist on a single pair of wires,
communicating not only process variable or status
information, but a wealth of other secondary information as well. In the case of Foundation fieldbus, up to
16 devices can be daisy-chained along a single pair of
wires, and the traditional I/O cards that would have
been needed are replace by a rack-mounted H1 card to
manage communications between the control system
and the devices along that given segment.
But a funny thing happened on the way to the
HCD Meets Foundation
Enter Emerson’s human-centered design (HCD) initiative, which took a hard look at Foundation fieldbus
in the course of its DeltaV S-series development work,
and found that substantial improvements could be
Ethernet
RS485
Figure 1. The old way of doing Foundation fieldbus required
an array of third-party devices and software.
18
5/24/10 12:16 PM
Figure 2. The new way of doing
Foundation fieldbus in the DeltaV
S-series system includes integrated
diagnostics and power circuitry
built right into the H1 card.
made in how fieldbus gets done, according to Duncan
Schleiss, Emerson vice president of platform strategy.
“By applying the principles of HCD, we have changed
the game in fieldbus again,” Schleiss says.
Foundation fieldbus technology requires thirdparty power supplies and power conditioners, engineering, wiring and cabinet space. Also, to get at the
bus diagnostics, you have to jump through OPC and
RS485 hoops in order to get the information into the
control system.
With DeltaV S-series and I/O on Demand, Emerson has integrated the power circuitry within the H1
card itself, explains Schleiss. This eliminates difficult
segment power design, installation and troubleshooting tasks. The additional cabinet footprint associated
with use of external segment power supplies is also
eliminated. Third-party power conditioners and
dedicated power supplies and all the engineering that
went with them are no longer necessary. They have
become a thing of the past.
Citing a recently completed project consisting of
some 2,500 Foundation fieldbus segments, Emerson
estimates that total project cost could have been
reduced by some 7% using the new I/O on Demand
approach. “Five thousand H1 power conditioners,
32 H1 power cabinets, along with their design and
documentation, and all that factory and on-site wiring,” lists Schleiss. “All gone!”
All This and Diagnostics, Too
“But we also integrated diagnostics,” Schleiss says. “So
now the maintenance staff can wait for the DeltaV H1
card to notify them of a problem on the physical layer,
such as power consumption or a missing terminator.
Easy! It’s all integrated!”
The DeltaV digital automation system also works
natively with other popular digital communication buses, such as Profibus DP and DeviceNet for integration
of motor starters and drives, and AS-i bus for low-cost,
simple installation of discrete devices, such as pushbuttons, on/off valves and proximity sensors.
“The DeltaV system provides native support for
configuring busses with no need for third-party configuration tools,” Schleiss says. “And Ethernet I/O devices
are easily connected through virtual I/O modules.”
Further, fieldbus devices are auto-sensed when
connected to the DeltaV system network and automatically added to the system configuration, Schleiss
adds. “As a result, engineering and commissioning
effort is dramatically reduced.”
5/24/10 12:16 PM
SAFETY instrumented systems
Flexibility Without Compromise
I
propriately. Specifying the I/O hardware requires only
two pieces of information—the total number of I/O
and whether (and where) redundancy is required. Redundancy allows for the on-line replacement, on-line
upgrade and on-line proof-testing. However, DeltaV
SIS logic solvers are SIL 3-rated in both simplex and
redundant configurations. There are no time-out issues should a redundant pair fail.
n addition to a fundamental rethinking of how
input/output gets done in process control and
monitoring applications, Emerson’s I/O on
Demand approach has transformed the ability of
users to f lexibly deploy modular, distributed safety
applications while ensuring the robust isolation of
safety functions and the elimination of single points
of failure.
Further, the transparent integration of DeltaV SIS
with DeltaV automation systems used for basic process
control system (BCPS) applications allows the leveraging of safety I/O data to make better informed process
control decisions.
Modular and Scalable
With the DeltaV SIS architecture, users can add I/O
capacity in increments of as few as 16 fully configurable
I/O points—up to a maximum of 30,000 points in a
single system. Because the I/O is directly connected to
the logic solver, memory and processing power increase
whenever I/O is added; this negates any concerns over
the abillity to effectively run the configured logic,
regardless of system size.
Each DeltaV SIS logic solver is in effect a container for a small number of SIFs, and there can be no
unplanned interaction between them. This is very different from the traditional approach where hundreds of
SIFs are all placed in a single safety PLC, and the effect
of changing a single register or the addition of a SIF
could affect all of the logic.
fully Configurable I/O
Starting with upfront design and engineering tasks,
complexity is greatly reduced by the use of fully
configurable I/O in DeltaV SIS. This configurable
I/O functionality allows users to design applicationspecific safety instrumented functions (SIFs) without
limitations on I/O type per logic solver or the added
complexity of I/O card wiring. This simplifies both
engineering and maintenance.
Field devices are wired to the logic solver as
needed, and the I/O channels are then configured ap-
Figure 1. Within the scalable DeltaV SIS
architecture, multiple SISnet domains can
be used to distribute safety applications
throughout a facility.
20
5/24/10 12:17 PM
Figure 2. The integrated
but separate architecture
of the DeltaV SIS and BPCS
platforms ensures that safety
information is available
through familiar and intuitive applications, yet meets
IEC 61508 and IEC 61511
requirements for physical
separation and independence of safety and control.
For complex applications that may require multiple
SIFs acting on the same final element, input data is
shared among multiple logic solvers so that cause-andeffect logic can easily be implemented in a single SIS
module. Given this flexibility, the DeltaV SIS system is
well-suited to the full range of safety applications, from
small burner management applications to large emergency shutdown (ESD) and fire and gas applications.
The DeltaV SIS system architecture also enables SIS
applications to be geographically distributed in local
junction boxes across a plant or facility. This ability is
especially appealing for large plant complexes as well as
for applications such as distributed oil and gas wellheads
and pipelines (Figure 1).
“The DeltaV SIS modular, distributed architecture
enables users to custom-fit the system to their SIS application with the flexibility to locate safety logic and I/O
near the process,” says Larry O’Brien, ARC Advisory
Group analyst. “This SIF-based approach isolates safety
instrumented functions, eliminates single points of
failure, and simplifies change management.”
Integrated Safety and Control
To facilitate better decision-making, plant operators
have one common operating environment for both
the BPCS and SIS when using the DeltaV control
and safety platforms. This integrated view (Figure 2)
includes alarm handling, time synchronization, user
security and device health monitoring. Meanwhile,
the DeltaV SIS power supplies, communication channels, hardware and real-time operating systems are
physically separate and independent of the control
system, maintaining the separation required by IEC
61508 and IEC 61511 standards.
“Not only is DeltaV SIS itself modularly scalable,
but it can be transparently integrated with DeltaV
systems used for process control,” explains Duncan
Schleiss, Emerson vice president of platform strategy.
All DeltaV SIS information is communicated to
the control network via the DeltaV controllers. This
eliminates work that is traditionally required to map
data between the two systems with two different
engineering and operations environments. It also
eliminates the time and cost of training personnel to
use two different systems. “The DeltaV SIS system
delivers the benefits of total integration and total
separation,” Schleiss adds, “without the tradeoffs
associated with the two extremes.”
5/24/10 12:17 PM
I/O on Demand Calculator
Calculate Your Project Savings
B
ecause I/O on Demand represents a significant shift in how most types of I/O are
engineered and implemented, it can be a
challenge to decide just what options to use in a
particular project. And while plant practices and application requirements may dictate the mix of I/O on
Demand platforms chosen, figuring out how much
money you could save relative to the traditional way
of doing things just got a whole lot easier.
Enter IOonDemandCalculator.com, a new website
created by Emerson Process Management to help you
estimate project cost savings—and impact on project
schedule—based on the mix of electronically marshalled,
wireless and fieldbus I/O you expect to deploy.
Also, because certain choices will have different
implications for the ability of a project to accommodate late-stage revisions without delaying the schedule,
you’ll be asked to estimate:
• The number of I/O typically affected by change orders.
• The number of people engaged in the project.
Once these essential project parameters have been
entered into the calculator, you can estimate the project
costs savings and the impact on delivery schedule for
different mixes of I/O on Demand platform options
relative to a conventionally wired and marshalled system.
The essential options include electronically marshalled in
a central control room, electronically marshalled in field
junction boxes, fieldbus and wireless.
Sample Calculation
Take, for example, a project with a total I/O count of
5,000, 20% spare I/O capacity and average controlroom-to-junction-box and junction-box-to-field-device
distances of 200 m and 20 m, respectively.
If 20% of I/O are electronic marshalled in the
control room, 30% are electronically marshalled in
field junction boxes, 30% of I/O points are implemented using wireless and 10% using fieldbus, the
I/O on Demand Calculator indicates that you stand
to save $8.11 million in project costs relative to conventional wiring practices.
Further, if 500 I/O points (10% of the total) are
estimated to be subject to change orders, and 100 people are working on the project, the I/O on Demand
Calculator indicates that this mix of I/O on Demand
platforms can potentially eliminate 44.9 man-project
days and 1,867 man-hours of work.
While these initial project cost savings are nothing
to sneeze at, it’s important to note that they do not take
into account the longer-term benefits afforded by electronic marshalling and a wireless infrastructure.
Indeed, once a project is done, the I/O on Demand
savings have only just begun.
I/O on Demand = Less Wires
The essential information you’ll need to know includes:
• The total number of I/O required.
• Average facility distances, from the control room to the
field junction boxes and from the field junction boxes
to the devices.
• Percentage of spare I/O capacity desired.
Visit IOonDemandCalculator.com to estimate how
much you could save on your next capital project.
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5/24/10 12:17 PM
ControlGlobal.com/IOonDemand
The Early Reviews Are In
S
ince it was first introduced at the 2009 Emerson Global Users Exchange, much has been
written about I/O on Demand and its potential to revolutionize how the process industries do
I/O—especially in the context of project work. Following are excerpts of the articles and reviews that
have rolled out over the past several months. Visit
ControlGlobal.com/IOonDemand for direct links to
the full stories excerpted below.
“Emerson charms user group with
introduction of DeltaV S-series”
“Cabinets, wire, terminations, cable tray design,
fusing, installation drawings and a host of other
activities are gone! Single-channel CHARMS and
controller independence allow the first real updates
to 35-year-old engineering practices.” Highlights
of the 2009 Emerson Global Users Exchange as
reported by Walt Boyes and the rest of the editors of
Control. Visit ControlGlobal.com/IOonDemand for
direct link to their full report.
“Eliminates much of the cost associated
with installing conventional I/O”
“I/O on Demand fits well with Emerson’s overall theme
of making advanced technologies easily accessible and
easier to use for a wide range of industries,” writes Larry
O’Brien, analyst with the ARC Advisory Group. “ARC
believes that I/O on Demand and the concept of electronic marshalling can offer cost savings in new projects,
but also offers a good solution for control system migration projects. Significantly, it avoids a simple functional
replacement of conventional I/O, which can be very
difficult to justify in today’s world of constrained capital
and tight operating budgets. I/O on Demand effectively
eliminates much of the cost associated with installing
conventional I/O.” Visit ControlGlobal.com/IOonDemand for direct link to full story.
“DeltaV S-series is no ivory-tower rethink”
“By putting usability and productivity at the heart
of product design, Emerson meets two vital needs of
Emerson’s Duncan Schleiss holds a single-channel Characterization
Module, or CHARM, at the company’s October 2009 launch of I/O
on Demand and its new DeltaV S-series.
today’s global environment: skills shortages in emerging markets and an aging experienced workforce in
the developed world,” writes Jim Pinto, automation
industry observer. “DeltaV S-Series is no ivory-tower
re-think. Emerson insiders tell me that they worked
the design every step of the way with a large petrochemical customer. Bravo, Emerson team, for yet
another engineering and market coup!” Visit ControlGlobal.com/IOonDemand for direct link to full story.
“Emerson overturns 35 years
of industry thinking on I/O”
“Selectively previewed at last year’s Emerson Exchange in Washington, [electronic marshalling]
essentially eliminates the need for a physical path
from signal source to controller,” writes Andrew
Bond of the Industrial Automation Insider. “Instead,
new single-channel CHARacterization ModuleS or
CHARMS relay I/O information via the Ethernet
backbone to any controller and provide singlechannel integrity and flexibility down to the channel
level. Not only does this approach drastically reduce
engineering time, but it also ensures that changes
to the original design can be readily accommodated
without rewiring.” Visit ControlGlobal.com/IOonDemand for direct link to the full story.
5/24/10 12:18 PM
DeltaV IO on Demand Ad_for supplement:Layout 1
5/13/2010
10:54 AM
Page 1
Last minute project changes?
Forget the pain. Calculate the gain.
The DeltaV™ system’s breakthrough I/O on Demand takes the time, expense and risk
out of last minute project changes. Wireless, FOUNDATION fieldbus, Electronically
Marshalled or traditional I/O–the choice is yours. I/O on Demand eliminates steps and
gives you the flexibility to easily handle unforeseen changes. Prove it to yourself. Plug
in your project’s parameters and see the savings possible across the life of the project at:
IOonDemandCalculator.com
The Emerson logo is a trademark and a service mark of Emerson Electric Co.©2010 Emerson Electric Company
5/24/10 12:18 PM
June 2010 • Volume XXI! • Number 6
D E PA RT M E N T S
33 / Editor’s Page
Great Expectations.
35 / Feedback
Our readers weigh in on the Deepwater
Horizon disaster.
37 / On the Bus
To answer the PLC or DCS question, you
might want to be checking things out with
peers whose situations are similar to yours.
70 / Ask the Experts
Our experts discuss preventive valve maintenance, mathematical models for water
treatment, and how process automation
specialists can get respect.
IN PROCESS
72 / Roundup
Get your pressure instrumentation products here.
76 / Products
The latest process automation technology.
38 / Other Voices
Could cyber-terrorists attack your facility?
Maybe, but that’s not the attack you should
be most worried about.
79 / Control Talk
The flowmeter lab at the new
Emerson Innovation Center.
McMillan, Weiner and friends take on loop
performance.
PRODUCT RounDUP
43 / In Process
Emerson opens its Global Innovation
Center and other process news.
49/ Resources
Online loop-controller information.
81 / Ad Index
Check these pages.
82 / Control Report
Jim Montague on Arkema’s homemade display screens that remove bottlenecks in its
processes.
Yokogawa’s EJX930
multivariable transmitter.
Circulation aUdited june 2010
Chemicals & Allied Products................................................................................12,548
Food & Kindred Products.....................................................................................12,638
Paper & Allied Products..........................................................................................3,470
Primary Metal Industries.........................................................................................5,445
Electric, Gas & Sanitary Services............................................................................3,116
System Integrators & Engineering Design Firms.....................................................8,912
Rubber and Miscellaneous Plastic Products...........................................................4,403
Stone, Clay, Glass & Concrete products.................................................................2,057
Textile Mill Products...............................................................................................1,361
Petroleum Refining & Related Industries.................................................................3,877
Tobacco Products.......................................................................................................115
Total circulation.....................................................................................................63,006
CT1006_05_31_TOC.indd 31
31
5/24/10 2:58 PM
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CT1006_FPA.indd 32
5/24/10 3:05 PM
EDITOR’S PAGE
Great Expectations?
“Absolutely, it is our responsibility,” said BP CEO Tony Hayward in an NPR interview.
“We will absolutely be paying for the cleanup operation. That’s our responsibility and
we accept it fully.”
BP and all the other oil companies are in a bad situation. An ex-
decisions by both BP and Transocean have conspired to make BP the villain of offshore oil production. There is talk of halting all exploration
off the coast of the US. There is talk of punitive
penalties against BP. There is virtually no understanding in the press or on the part of the
general public of what has happened. We’re beginning to learn what happened, and BP has
completely bypassed the $75 million cap by
spending over $500 million and counting as
this editorial goes to press. Yet there are people
who believe BP, and by inference, all oil companies are somehow “guilty” of this “environmental catastrophe.”
Since 2005, when a catastrophic and preventable accident destroyed a significant part
of the BP refinery in Texas City, Texas, BP’s
upstream and downstream units have devoted
funding and real change management to making, as Hayward has put it, “safety our number
one priority.” Quietly and without fanfare, BP
has revised training programs, safety systems,
safety planning and implementation. The DuPont safety system is the standard of the industry, and it has been adopted wholesale by BP. So
what went wrong?
What BP can’t change is the fact that subsea
drilling is dangerous. In the case of the current disaster, all of the safety systems failed,
including the last best hope—the blowout preventer. The odds of this happening in a company with a good, if new, safety culture are so
low as to be immeasurable. And both BP and
Transocean were lulled by the fantastic safety
record of the rig.
So what does this tell us? It tells us, that offshore development, like the refineries, involves
a set of complex systems, and can’t be defended
from risk by linear engineered systems. All
safety systems, whether SIS in manufacturing
or fire and gas safety in offshore environments,
Walt boyes
Editor in chief
wboyes@putman.net
tremely low probability of failure scenario, coupled with what appear to be bad
are designed to manage acceptable risk, not remove it entirely.
Yes, the sinking of the BP drilling rig has
produced a significant ecological threat. But
should we use this as an excuse to stop offshore exploration and development?
Not until somebody comes up with a fuel
source that doesn’t require hydrocarbons.
Wind and solar energy are capable of replacing a maximum of about 10% of our need for
oil for fuel. Battery technology has not significantly improved in the last 20 years. Hydrogen
is always just over the horizon.
Some say that we need to stop exploration as a
deliberate choke hold on our need for oil. That’s
arrant nonsense. The only way we’re going to
curb our need for oil is to produce vehicles and
power plants that do not use oil. Nuclear plants
generating hydrocarbon-free electricity to run
electric vehicles would go a long way to keep us
from running out of oil. Oil ought to be used
as a chemical feedstock for things like clothing,
building materials and shelter—not fuel.
We want our gasoline, our nylon, our styrofoam plates and all the other things we make
from oil, but we aren’t willing to accept the
consequences and mitigate them.
Even when a company like BP does everything it can think of to minimize risk from its
activities, things can still go wrong. It is good
that Mr. Hayward has committed his company
to paying for the cleanup operations. But it is
not so good that we, our government and the
media are at his throat without accepting the
responsibility that we too have for what has happened in the Gulf of Mexico.
Oil ought to be
used as a chemical
feedstock for things
like clothing, building materials and
shelter—not fuel.
CT1006_33_EDIT.indd 33
33
5/21/10 2:50 PM
336 Volts of Green Engineering
MEASURE IT – FIX IT
Developing a commercially viable fuel cell vehicle has been a significant challenge because
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0834 Green Engineering Ford.indd 1
CT1006_FPA.indd 34
12/15/09 3:27:29 PM
5/24/10 3:05 PM
555 W. Pierce Rd., Suite 301 • Itasca, Illinois 60143
G N I K A E P S YL L A C I N H C E T
FEEDBACK
administrative team
President & CEO: John M. Cappelletti
Vice President: Julie Cappelletti-Lange
VP, Circulation: jerry clark
What Should Have Happened
at Deepwater Horizon
publishing team
Group Publisher/VP Content: Keith Larson
klarson@putman.net
Midwest/Southeast Regional Sales Manager: Greg Zamin
gzamin@putman.net
630/551-2500, Fax: 630/551-2600
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310/607-0125, Fax: 310/607-0168
lmar tinez@putman.net
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dfisher@putman.net
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888/64 4-1803
foster reprints
Reprints Marketing Manager: Jill Kaletha
1-866-879-914 4 ex t. 121, Fax 219.561.2019
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editorial team
Editor in Chief: WALT BOYES
wboyes@putman.net
Executive Editor: JIM MONTAGUE
jmontague@putman.net
Digital Managing Editor: Katherine bonfante
kbonfante@putman.net
Managing Editor: nancy bartels
nbar tels@putman.net
Senior Technical Editor: Dan Hebert
dheber t@putman.net
Contributing Editor: JOHN REZABEK
Columnists: Béla Lipták, Greg McMillan, Stan WeineR
Events Director: Andy Wuebben
Editorial Assistant: Lori Goldberg
design & production team
Group Art Director: Steve Herner
Art Director: Derek Chamberlain
sherner@putman.net
dchamberlain@putman.net
Associate Art Director: ToM Waitek
t waitek@putman.net
Jesse H. Neal Award Winner
eleven ASBPE editorial Excellence Awards
Twenty-five ASBPE excellence in graphics Awards
ASBPE 2009 Magazine of the year finalist
FOUR ozzie awards for graphics excellence
Two of our regular contributors have
weighed in on the Deepwater Horizon
oil spill in our SoundOff! blog (http://tinyurl.com/2b29538). From Béla Lipták:
“I would never allow ANY critical shut-off
valve to be installed without a remote trigger. Same with the dead man switch. The
same with mine operation without methane monitored escape alarm, etc, etc.”
John Cusimano of exida, (www.exida.
com) sent the following comment:
“[Why aren’t] BOPs designed and certified to IEC 61508 (SIL 3 or better)? None
are listed in the Safety Automation Equipment List (http://tinyurl.com/2d3dspk), nor
was I able to find any on Google. IEC 61508
has been the international standard for functional safety since 1998. Numerous valves and
actuators, including hydraulic actuators, have
been certified, yet these super-critical valves
that are the last defense to prevent a catastrophe like the Deepwater Horizon don’t seem
to have any functional safety certification.
“The literature I’ve seen lists the following certifications: API RP 500B, API RP
14F, NEC Article 500, NFPA 476, UL,
CSA, FM, NEMA, CENELEC, BASEEFA, British Standards
“This excellent paper (http://tinyurl.
com/2g3sglz) discusses application of IEC
61508 and IEC 61511 in the Norwegian
Petroleum Industry. Section A14.2 discusses BOPs.
“From this picture of the Deepwater
Horizon BOP (http://tinyurl.com/2dtdrjy),
it appears to me this valve was configured
to be Normally Open (NO). To be failsafe, shouldn’t it have been designed to be
Normally Closed and held open by a signal from the platform? Clearly this thing
wasn’t designed to be fail-safe. BP engineers say even the E-Stop didn’t work.
“‘We don’t know why it didn’t work,’
says BP spokesman William Salvin. ‘We
know automatic systems did not close it;
we know workers hit the manual switch
before evacuating the rig; and we have
been trying since hours after the incident
to activate the blowout preventer, and that
has not been successful.’
“Unfortunately, if no one is specifying
SIL-rated BOPs, then no one is going to
get them.”
Rush to Judgement
This in response to Walt Boyes’ May 5
SoundOff! post on the oil spill (http://tinyurl.com/2cguj9g): Until someone comes
forward with solid evidence of why the Blow
Out Preventer system
failed to trip properly, I
recommend withholding judgement on BP’s
post accident behavior. I’ll concede that at
the moment, they appear to be doing many
of the correct things.
Right now, we haven’t heard much from
anyone who might know what the condition the well is in under 5000 feet of water. For all we know, they could have stumbled upon extreme conditions that nobody
could have predicted.
Ultimately, the drilling rig risks are entirely BP’s. On the other hand, this caliber of oil-spill risk was not theirs to take. If
evidence suggests they cut corners on the
BOP maintenance, it could be the end of
the company.
Until we hear or see evidence of what
went wrong, I recommend suspending judgment of BP’s culpability.
Jake Brodsk y
Correction
An error appeared in a news item in
May’s InProcess. It should have read as
follows: “Houston-based Vize, LLC, supplies a complete line of magnetic level
indicators (MLI), engineered bridle solutions and accessories. An important
addition to the Ohmart/VEGA family,
Vize product lines complete Ohmart/
VEGA’s full offering of level measurement technologies. Ohmart/VEGA and
Vize share the goal of understanding individual process and application needs,
to supply a solution that is safe, accurate,
and low-maintenance.”
CT1006_35_FDBACK.indd 35
35
5/21/10 2:53 PM
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CT1006_FPA.indd 36
5/24/10 3:06 PM
ON THE BUS
Birds of a Feather
The other day, the long-discussed and oft-debated topic of “PLC or DCS” came up
again on the ISA email listserv “control.” The subject has been debated on the list numerous times—maybe someone out there keeps assigning it as a term paper or senior
project, and his or her students end up posing the question to our group.
convergence, i.e. PLC ≈ DCS, has its advocates, and the case has grown stronger in recent years. There’s even a camp proclaiming
PC (Windows box) ≈ PLC ≈ DCS. The arguments are not without merit, but the focus is on
functionality: My “Y” can do everything your
“X” does. But, good intentions, especially when
executed by novices, can have unintended consequences. The hard part is making sure it
doesn’t do what you don’t want.
The hydrogen plant near me, I’m told, is a
clone of an earlier plant. The former was built
to serve, we’ll say, a pancake syrup plant. In its
earlier incarnation, it was controlled by PLCs.
Now, it has a PLC for pressure swing adsorption (PSA), but uses a scaled-down DCS for
the rest. Why the change? The second plant,
while nearly identical in capacity and footprint,
serves a plant from a “large process industry”
culture that was willing to pay for the more
costly DCS. The former plant was unmanned;
the latter has at least one operator on duty 24/7.
A syrup factory outage may be undesirable, but
that client’s culture was OK with the risk of an
occasional outage, which the latter client found
untenable. Margins on organic chemicals and
the cost of downtime relative to pancake syrup
probably is a big part of the equation.
In a large process industry culture that reveres bulletproof reliability, few have much
patience for beta testing or “science projects.”
As a friend and former colleague loved to say,
“We race to be second.” Let the other guy take
his lumps with Serial No. 1. If it pans out, then
we’ll be close followers. What students and
novices sometimes fail to grasp, is that control
systems, no matter how well-conceived, are often fraught with unintended consequences and
features in early iterations, and may require
years of interaction with sophisticated users before all the bugs are out. This important, but
The idea of
less tangible aspect of a control system’s heritage is absent from the “PLC ≈ DCS” debates.
What user communities have shaped the control systems under consideration? Where can
you find your “flock” where your concerns and
priorities are understood?
A related question I hear a lot is “Should I
choose HART, Profibus or Foundation fieldbus?” A little effort and research could lead to
finding your flock. One good place to look is
free seminars by trade groups. Profibus Nutzerorganisation (Profibus User Organization) has
free seminars worldwide. Go to one, and if you
recognize your peers and competitors attending and/or presenting papers, then you may
have found your home. However, if all the talk
is about soup and syrup and your business is
gasoline, you may want to move on.
The Fieldbus Foundation routinely has free
seminars too. The foundation is unique in
maintaining an end-user council whose members (from companies like Shell, Mitsui, Saudi
Aramco, Reliance, Suncor, Apache Corp. and
others) aim to influence the development and
prioritization of new features. The HART
Communications Foundation regularly participates in industry shows, so you can gauge your
kinship with fellow users there.
Finally, system-supplier/end-user meetings
are an excellent way to find your kin. Again,
you can go and listen to what’s being promised
for upcoming releases. Do they sound like what
you’ve been wishing for your plant? Do you find
the papers presented are about subjects you or
your management find near and dear?
Of course, you can argue that running with
the herd means your results will be—at best—undistinguished, but do you really want to be a pioneer? If you and your company agreed to such an
adventure, I’d be interested in how it worked out.
Write to me at jrezabek@ispcorp.com.
john Rez abek
contributing Editor
jrezabek@ispcorp.com
If you recognize
your peers and
competitors attending or presenting
at a trade group
seminar, then you
may have found
your home.
CT1006_37_OTB.indd 37
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5/21/10 2:56 PM
Other Voices
Could Cyber Terrorists Attack Our Company?
Maybe, but perhaps this isn’t the best question to ask. When cyber-related events cause
outages and plant shutdowns—whether they were caused by accident, employee,
John Cusimano
Director, e xida
securit y services division
jcusimano@exida.com
hacker or terrorist—the first question should be, “What made our system unstable and
susceptible, and what can we do to prevent it from happening again”?
Eric Byers
Chief technology officer
Byers Securit y
eric@byerssecurit y.com
Some recent headlines have read: “Electricity
Grid in U.S. Penetrated By Spies,” “China and
Russia Hack into U.S. Power Grid,” “Russian
Hackers Vandalize BTC Pipeline Data Servers,” and most recently, “CIA Director Says Cyber Attack Could Be Next Pearl Harbor.” With
news like this how can anyone sleep at night?
The reality is that most of what is published
regarding control system cybersecurity in
mainstream media is over-dramatized. While
the scenarios painted in these stories may be
valid, they are often void of detail regarding
these so-called incidents. The result is that the
government, public, media and control system operators can end up focusing on possible
“long shot” perpetrators and not on the very
real day-to-day risks of modern network-based
control systems.
The fact is control system cyber incidents
are real and are occurring on a regular basis
in industries around the world. How do we
know? One way is through a service provided
by the Security Incidents Organization. It
maintains a database called the Repository
of Industrial Security Incidents (RISI, www.
securityincidents.org) that tracks incidents
of a cybersecurity nature that directly affect industrial SCADA and process control
systems. By studying actual incidents, RISI
helps provide a realistic assessment of the
threats and vulnerabilities of our industrial
control systems.
A key finding of RISI is that, while they
have occurred, there haven’t been a tremendous number of deliberate cyber attacks on
industrial control systems. Less than 25% of
the incidents recorded in the database represent intentional attacks on control systems.
The remaining 75% of the incidents were
unintentional.
Whew! Now can we all breathe a sigh of relief? No, not really. While these incidents may
have been unintentional they still resulted in
downtime, production losses, environmental
N/A
0%
General incident type
Outsider
17
47%
Less than 25% of
Insider
19
53%
Intentional
36
22%
the incidents
recorded in the
RISI database
N/A
51
40%
represent
Insider
20
16%
Unintentional
126
78%
Outsider
55
44%
intentional attacks
on control systems.
38
Figure 1. Terrorist and external threats to automation systems are real, but not the only cyber
incidents you should be concerned about.
www.controlglobal.com J u n e / 2 0 1 0
CT1006_38_40_OV.indd 38
5/21/10 2:59 PM
e
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ani
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CT1006_FPA.indd 39
5/24/10 3:07 PM
Other Voices
damage, equipment damage and even injury and death.
Unintentional incidents can lead to the same set of consequences. So, while the threats might be different, the vulnerabilities are the same.
These unintentional incidents range from malware
(viruses, worms, etc.) to network disturbances to software bugs. The point is that, whether or not you believe
your digital control systems may the target of cyber attack, you sure as heck should believe that they are susceptible to a cyber incident.
For example, consider the 44% percent of unintentional
incidents that RISI reported were attributed to an outsider.
The outsider in the case of an unintentional incident is usually the malware author. An energy company in Australia
learned about this the hard way when it was infected with
the W32.CF virus. Even if the virus didn’t “intend” to infect that energy company, the infection forced the company
to restructure all of its 1000 desktops—an expensive proposition. Fortunately, in this case, the virus did not make its
way into the control system. Other companies have not been
so lucky. Either through connections into the business network, VPN dial-up connections for remote support or even
USB drives, viruses have made their way into control system
networks. Operator HMIs, engineering workstations, data
servers, historians, etc. can all be affected. There are numerous incidents recorded in RISI of such infections that have
cost organizations millions of dollars in downtime. Viruses
have even been a contributing factor to more serious incidents by preventing operators from seeing critical alarms in
a timely manner.
Another 40% percent of unintentional cyber incidents recorded in RISI were not even caused by a person, but rather
by faulty equipment or software. These “accidental” incidents have resulted in major operational impacts, such as
the computer glitch that caused a major power outage in
the Phoenix, Ariz., region. In this case, the power provider,
the Salt River Project (SRP), had a system in place to shed
load if it was unable to meet demand. Unfortunately, while
SRP had no problem meeting load demands on the day of
the incident, a computer problem indicated that it did, and,
consequently, triggered a widespread outage. An estimated
92,000 Salt River Project customers were without power for
20 to 30 minutes.
RISI contains many, many more examples of both intentional and unintentional cyber incidents. Each one
provides a valuable lesson that can be used to avoid similar incidents in your facilities. Furthermore, many of
them provide valuable information to manufacturers of
40
automation system equipment on the bugs and vulnerabilities that have been exploited in existing products.
The good news for those willing to address the issue is
that even a modest effort can lead to substantial improvements. Numerous organizations have published standards
and guidelines to help their constituents bolster the cybersecurity of their installed systems. What you’ll find in most of
these is not “rocket science,” but good engineering practices
developed by people in the industry who have learned from
experience. For example, ISA99 has completed its ANSI/
ISA-99.02.01-2009 standard, “Security for Industrial Automation and Control Systems: Establishing an Industrial
Automation and Control Systems Security Program.” This
standard outlines a straightforward approach that companies can adopt to managing the security lifecycle of their
automation systems. Although in a different format, it addresses the same topics as the NERC CIP standards that
have been mandated in the United States for all entities that
own or operate assets that are critical to the reliability of the
bulk electric system.
The best place to start is by performing a control system
cybersecurity assessment on your existing systems. Organizations can perform a self-assessment or hire an experienced third party to assist and provide recommendations.
We recommend end users work closely with their automation system equipment suppliers because their products play
a critical role in the implementation and enforcement of the
technical controls called for in security standards.
A key point in any assessment is not to get stuck on
low-probability, complex “terrorist” scenarios, but rather
to consider the full spectrum of network issues and effects that could harm your operations. For example, what
would happen if an everyday virus was carried into the
control system in a contractor’s laptop? What would be
the impact if that virus caused all the HMIs to fault at
the same time? Would the plant be shut down, or could it
be run “blind,” and who would decide? What would the
process be to diagnose the problem? What procedures
would be used to recover HMIs as fast as possible? What
would the process be to prevent the recovered HMIs
from being infected again?
You can see that the list can get very long, but all of these
questions (and more) are basic ones that need to be asked
for each possible scenario. By creating a well thought-out
“threat model” that names all the pathways into the control
system, all the possible impacts or events and all the possible
consequences, a systematic assessment is both possible and
cost-effective.
CT1006_38_40_OV.indd 40
5/21/10 2:59 PM
When safety is key to
your operation…
Allied offers product solutions that
protect personnel and equipment.
Banner Engineering
Optical Touch Buttons
Allied Stock Number
807-2000
3M
Disposable Respirators
Allied Stock Number
617-6481
Find more safety solutions at:
/safety
THINK ALLIED
SM
Manufacturer
Description
Allied Stock Number
SMC
Soft-Start Valves
499-1983
© Allied Electronics, Inc 2010. ‘Allied Electronics’ and the Allied Electronics logo are trademarks of Allied Electronics, Inc.
CT1006_FPA.indd 41
1.800.433.5700
An Electrocomponents Company.
5/24/10 3:07 PM
System 800xA High Integrity. The gulf between
SIL3 and safety leadership is big ... really big.
Does your SIL3 safety supplier close that gap? Why settle for an out-of-date
safety system architecture? Whether you want a segregated or fully integrated
solution, ABB’s innovative architecture saves you money throughout the lifecycle
of the system. Regardless of your needs, our 800xA High Integrity solution provides
features that go far beyond your average safety system, providing both reliable
safety and business value like only a leader can. We have been at the forefront
of safety automation for more than 30 years. For more information, visit
www.integrateyourinformation.com.
CT1006_FPA.indd 42
5/24/10 3:08 PM
RL-38
IN PROCESS
Emerson Opens Global Innovation Center
Center has testing capacity for huge, high-performance valves.
Go big or go home. That’s the order of the day at Emerson
Process Management’s new Emerson Innovation Center,
Fisher Technology in Marshalltown, Iowa. The company
has invested $30 million in the 136000-sq.-foot research and
testing center built on the site of the original Fisher plant in
downtown Marshalltown.
Emerson Electric Inc.’s COO, Ed Monser, noted that
his company deliberately made a $30-million investment
in Marshalltown to strengthen the technology of Emerson.
“It’s about pride, small-town pride,” echoed Terry Buzbee, president of the Fisher Controls division of Emerson
Process Management. “We want to note that this is also the
130th anniversary of the founding of the Fisher Governor
Co., which was located where the northeast corner of this
building stands now.”
The facility takes up a solid, square city block. The center
required almost 2 million pounds of process piping, more
than 1600 feet of 30-inch and 36-inch pipe, seven underground air storage tanks each more than 150 feet long, and
more than 4500 cubic yards of concrete.
However, the facility’s footprint is not the only big thing
about it. The center is home to the world’s largest “flow lab”
that, for the first time, enables large valves to be tested in
real-world plant conditions to ensure production reliability,
efficiency, environmental compliance and safety before being installed at a customer’s site.
“No other facility in the world can do what our Marshalltown Emerson Innovation Center can do—from seismically
qualifying a 35000-pound control valve to testing a twostory-tall valve that controls the flow of feedstocks for a petrochemical plant,” said Steve Sonnenberg, president of Emerson Process Management.
The center’s flow lab has enough capacity to fill an
Olympic-sized pool in just over eight minutes or a Goodyear blimp in about 12 seconds. Control valves can be
tested at pressures up to 3500 psi, which is equivalent to
providing enough force to support a sport utility vehicle
on a postage stamp. Meanwhile, the center also is home
to a 26000-sq.ft. sound chamber in which Emerson can
develop and verify the noise levels of new devices before
a customer’s plant is built.
Emerson, whose Fisher valves are installed in more than
90% of the world’s nuclear facilities, can provide seismic
qualification of its valves at the new Innovation Center,
which is critically important to making nuclear plants safe
and reliable during earthquakes. Emerson was recently
Every Fisher control valve design undergoes flow testing
in the 2500-sq.-meter flow lab in the newly opened Emerson Innovation Center.
awarded contracts to provide its Fisher control valves for
Westinghouse Electric Co.’s newest generation of nuclear
power plants.
The world’s appetite for energy is driving the development of next-generation nuclear plants, mega-train liquefied
natural gas (LNG) plants, and large oil and gas refineries,
which require larger capacities and highly engineered control valves and instrumentation. The Emerson Innovation
Center was opened partially as a response to this demand
for testing of the large valves and other instruments required
in such operations.
Honeywell to Acquire Matrikon
Honeywell has announced that it has signed an agreement
valued at approximately $142 million USD (approximately
$145 million CAD) to acquire Matrikon Inc. The acquisition
will strengthen Honeywell’s position in the high-growth oil
and gas and power value chains, and increase its global footprint in key regions. The transaction is subject to approval
by Matrikon’s shareowners. Matrikon will be integrated into
Honeywell Process Solutions, which is part of Honeywell’s
Automation and Control Solutions business group.
“Our industrial customers want their plants to run well
in any economy, and Matrikon’s products help do that,” said
Norm Gilsdorf, president of Honeywell Process Solutions.
CT1006_43_46_INPRO.indd 43
43
5/24/10 2:19 PM
IN PROCESS
“Combining Matrikon’s technology
and expertise with Honeywell’s industrial platform expands our offering to
help customers continue to improve
plant performance. This acquisition is
a great addition to our business,” GilsEthernetio_Half_CM.ai
5/5/2010
3:53:29
dorf concluded.
A C R O M A G
E T H E R N E T
The purchase of Matrikon will give
Honeywell applications that monitor
oil and gas well performance and mining equipment performance, as well
as supply chain solutions for mining.
Matrikon’s cybersecurity and alarm
PM
management solutions also align with
I / O
S O L U T I O N S
Dependable Value.
Honeywell’s solutions for process safety
and security.
Founded in 1988, Matrikon specializes in technology to manage production, optimize operations and monitor
assets at industrial plants, including oil
and gas, refining, energy, power and
mining companies.
Matrikon’s sales were approximately
$80 million USD for the 12 month period ending in February 2010.
In addition, entities related to Nizar Somji, the president and CEO of
Matrikon, have also granted an option
to Honeywell to acquire their outstanding shares at a price of $4.50 CAD per
share, exercisable at any time after July
12, 2010.
Byres Security Wins
Frost & Sullivan Award
7-YEAR
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Byres Security Inc. (BSI) of Vancouver,
British Columbia, Canada, has been
presented with Frost & Sullivan’s 2010
World Customer Value Enhancement
Award in Industrial Network Security
Solutions. The honor recognizes the
Tofino Industrial Security Solution in
the industrial network security market.
Frost & Sullivan named Byres
Security its 2010 World Customer
Value Enhancement Award winner for its focus on enhancing the
value that its customers receive and
for outstanding achievement in the
areas of leadership, technical innovation, customer service and strategic product development. The award
highlights Tofino’s effectiveness as
a high-mean-time-between-failure
(MTBF) solution specifically designed for industrial control environments that operate seven days a week
with no downtime. It also calls out
the fact that the Tofino solution protects against outside threats as well as
accidental internal threats.
“Winning the 2010 Customer Value
Enhancement Award for Industrial
Network Security is an honor and a tes-
5/24/10 2:19 PM
Process Controllers
HMIs
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Signal Conditioners Temperature
Controllers
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Internet
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pull it all
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Red Lion helps you manage the complexity of your entire environment with simple, highly-functional
and open integration solutions. Seamlessly leverage multiple legacy devices from a single entry point with a
universal software platform and integrated conversion of over 200 protocols. Enable Ethernet communications
on serial devices, data acquisition, web serving, data logging and remote management via mobile devices.
Connect dissimilar devices and access orphaned data that can be used to make your process run more
efficiently. Red Lion controls awaken your technology, create transparency and span the gaps in your process
environment. Call for free catalog at (717) 767-6511 or visit www.redlion.net
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RL-384A Corporate Ad_Control.indd 1
CT1006_FPA.indd 45
12/17/09 4:39 PM
5/24/10 3:08 PM
IN PROCESS
tament to the approach we have taken
with the Tofino Industrial Security Solution. We designed it from the ground
up to meet the needs of industry,” remarked Eric Byres, chief technical officer of Byres Security.
ABB Acquires Ventyx
ABB has agreed to acquire Ventyx for
more than $1 billion from Vista Equity
Partners to become a leading provider
of software solutions for managing energy networks.
Ventyx is a software provider to
energy, utility, communications and
other asset-intensive businesses, offering a broad range of solutions including asset management, mobile
workforce management, energy trading and risk management, energy
operations and energy analytics. The
company also provides software solutions for planning and forecasting
electricity needs
Based in Atlanta, Ventyx has a
large installed base in the U.S. market and Europe, and operates in more
than 40 countries. The company employs 900 people and reported 2009
revenues of about $250 million.
ABB will combine its related network management business within
the Power Systems division with Ventyx to form a single unit for energy
management software solutions.
By providing ABB with broader access to the utility enterprise management market, the acquisition triples
the energy management software
market available to ABB.
“The big advantage for energy
companies, utilities and industrial
customers is that they will now have
a single supplier of enterprise-wide
information technology platforms
and power automation systems,” said
Joe Hogan, ABB’s CEO.
At ABB’s Automation and Power
World event, Enrique Santacana,
president and CEO of ABB Inc., said
the purchase “gives ABB the ability
to help our customers integrate their
applications with smart grids and
truly follow the electrons from the
point of generation to the point of
use and then optimize all the stages
along the way.”
The acquisition is subject to customary regulatory approvals and is
expected to be completed in the second quarter. ABB intends to pay for
the acquisition in cash.
“ We Deliver
ToTal QualiTy.”
Failure is not an option in a Cashco valve or
regulator application. Your business and
our reputation depend on total quality
and reliability.
That’s why every Cashco employee is
involved in our ISO 9001:2000 Quality
Assurance Program. It’s why we test every
unit to ensure 100 percent product
functionality before it leaves the
factory. And it’s the reason the
return rate on Cashco warranted
products is less than one percent.
Holly Fries, Inside Sales Engineer
4 Years Industry Experience
www.cashco com
Innovative Solutions
46CAS-181A.indd
www.controlglobal.com
1
June /2010
Cashco, Inc., P.O. Box 6, Ellsworth, KS 67439-0006, Ph. (785) 472-4461, Fax: (785) 472-3539
11/25/08 11:43:32 AM
5/24/10 2:19 PM
LIQUID LEVEL MEASUREMENT
When the going gets tough,
the tough get an Orion.
Orion level gauges take on the
toughest measurement challenges
in the world’s harshest conditions.
O
rion level controls are built tough. Our Aurora
Magnetic Level Indicator (MLI) combines float-
operated and leading-edge electronic measurement in a
single, redundant indicator. Orion MLIs not only serve
industry’s most demanding applications and environments,
they’re built to thrive in these extremes.
Learn more about new or replacement solutions in
AURORA®
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shown mounted
to an Atlas MLI
liquid level indication at orioninstruments.com.
• Onshore/Offshore Oil & Gas
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6646 Complex Drive • Baton Rouge, LA 70809 • 1-866-556-7466 • info@orioninstruments.com
CT1006_FPA.indd 47
5/24/10 3:09 PM
INTRODUCING THE
Vantage
Combination Measurement System
The VEGAMAG Vantage utilizes VEGAPULS through-air
radar to report level by tracking the float, which is also
coupled to the magnetic level indicator. An optional full
port ball valve provides isolation in order to take the
gauge out of service without interrupting the process.
Constructed in a 2” schedule 40 pipe as standard, the
Vantage’s small profile fits into nearly any mounting
arrangement. The Vantage is ideal for processes with low
dielectric constant values, flashing, foaming, or in light
hydrocarbons.
Key Specifications
•
-328 to 842°F (-200 to 450°C)
operating temperature
•
Up to 2,320 psi (160 bar)
operating pressure
•
Visual indication from up to 200 ft
•
SIL2 Qualified (IEC 61508/61511 Standards)
•
Compliant with ASME B31.1/31.3 Standards
877.411.VIZE | info@vizellc.com | www.vizellc.com
CT1006_FPA.indd 48
5/24/10 3:09 PM
RESOURCES
Loop Controller Resources
Control’s Monthly Resource Guide
Every month, Control’s editors take a specific product area, collect all the latest, significant tools we can find,
and present them here to make your job easier. If you know of any tools and resources we didn’t include, send
them to wboyes@putman.net, and we’ll add them to the website.
METHODS AND BEST-PRACTICES
Control Guru
www.controlguru.com
The Controlguru.com eBook is an online textbook that covers proven methods
and best-practices for optimizing the performance of PID controllers. This free
resource focuses on PID control and related architectures such as cascade, feedforward, Smith predictors, multivariable
decoupling and other classic and advanced process control strategies. Topics
are explored in the context of real-world
production processes, and step-by-step
procedures for analyzing and correcting
underperforming PID controllers are
based on techniques that are widely used
in industry. The site’s table of contents
can be found at www.controlguru.com/
pages/table.html.
PID CONTROLLER TUNING
Control Station Inc
860/872-2920 www.controlstation.com
All production processes are inherently
unique and dynamic, and tuning loop
controllers should be based on the user’s objective for controlling a given
process. This white paper introduces
an easy-to-follow and step-by-step procedure both for analyzing the dynamics of common industrial production
processes and for tuning the associated
loop controllers to achieve the desired
level/type of performance. The paper
covers testing and data requirements
that are needed to accurately model a
dynamic process in closed-loop. Methods from the white paper are applied to
a level control example. The link can
be found at http://controlstation.com/
page/46-white-papers.
LOOP TUNING TUTORIAL
E xpertune
262/369-7711 www.exper tune.com
This site contains a basic PID tutorial,
covering subjects such as, definitions
of proportional, integral and derivative, control loop tuning, fine tuning
rules, and starting PID settings for
common control loops. It also has links
to more advanced papers and articles
on a variety of loop control subjects, including loop optimization, and a list of
webinars and other classes. The direct
link is www.expertune.com/tutor.html.
CONTROL OF DC MOTORS
IK Alogic
+33/555-103-363 www.ikalogic.com
This tutorial, “Closed-Loop Speed
and Position Control of DC Motors,”
explains the meaning of closed-loop
control, and how to apply it in your
projects. It compares closed- and openloop control, two-shaft encoders, the
controller itself, and provides a sample C source code for a 89S52 microcontroller. A direct link to the tutorial
is found at www.ikalogic.com/tut_
closed_loop_spd_ctrl.php
covers other matters, such as choice,
selection, installation and commissioning of controls. The direct link is at
http://tinyurl.com/2ecsfct
FEED-F0RWARD CONTROLLERS
Universit y of Connecticut,
School of Engineering
www.engr.uconn.edu/
“Cascade vs. Feed Forward for Improved Disturbance Rejection” is a
white paper discussion of the most popular architectures for improved regulatory performance—cascade control
and feed-forward with feedback trim.
Both architectures trade off additional
complexity in the form of instrumentation and engineering time in return for
a controller better able to reject the impact of disturbances on the measured
process variable. Neither architecture
benefits or detracts from setpoint tracking performance. This paper compares
and contrasts the two architectures. A
comparative example is presented using a jacketed reactor simulation. A
direct link is at www.engr.uconn.edu/
control/pdf/isa04-1.pdf
CLOSED-LOOP CONTROL FUNDAMENTALS
CONTROL LOOPS AND DYNAMICS
Spir a x Sarco
800/575-0394, www.SpiraxSarco.com/us/
An explanation of each component
of a control system, including valves,
actuators, sensors and controllers, as
well as an introduction to methods of
control and system dynamics, including simple control loops and feedback
systems. This is Chapter 3 of a larger
tutorial on basic control theory, which
PAControl.com
w ww.pacontrol.com
This free PDF is a workbook on basic
control of temperature, flow and filling
level. It contains exercises and worksheets, chapters on the fundamentals
of closed-loop technology, dynamic responses of systems, commissioning and
maintenance and more. The direct
link is at www.pacontrol.com/download/process-control-systems.pdf
CT1006_49_RESOURCE.indd 49
49
5/21/10 3:02 PM
Sustainability is not new. In the paper and plastics industries, recycling has been a way of life since the 1960s. For years, even decades,
some manufacturers have been involved with cogeneration, alternate
energy, water reuse/recycling and chemical reuse, and many more
companies are following their example. What is new is the insistence
from the public, the economic community and the government that
we must be sustainable now. Add to that the growing understanding
that sustainability efforts can drop quickly to the bottom line,
and you have much more than a feel-good marketing effort. Now you’re talking about a sensible
business strategy that’s a win-win for manufacturers, their customers and the environment.
50
CT1006_50_57_CVRSTRY.indd 50
5/25/10 9:37 AM
by Katherine Bonfante, Digital Managing Editor
The Economic Calculus
At the Siemens User Summit in 2008, Bruce Taylor, then
with Suncor Energy USA Inc. (www.suncor.com), described
the sustainability task that its executive management set for
him. They asked Taylor and his team to produce a viable energy management system. The first challenge they addressed
was not on the plant floor, but in the accounting department.
“We started building awareness that energy is not a fixed
cost,” said Taylor. “There was an ‘abundance’ energy mentality with aggressive focus on production growth. Our energy and carbon dioxide costs were not fully valued. Our
energy budgets would more than double if fuel internally
consumed was assigned a cost. There was distributed accountability for energy management, and there was a lack
of linkages between targets and performance.”
Taylor continued, “Just from shaping behavior, we can
impact a 3% to 5% annual improvement in energy costs,
culminating in a cumulative improvement of 25% to 30%
in carbon footprint.”
How is the new mentality different from the old? There’s
no entry in a cost-accounting rollup for saving the environment or moderating global climate change.
What happened is best described by a concept called the
“economic calculus.” As with the air and water pollution
control drives that erupted in the 1960s after the publication of Rachel Carson’s The Silent Spring, the economic
calculus was widened to permit those costs to be incorporated into the ongoing operating costs of an enterprise.
No company today would think twice about including
air or water or solid waste pollution controls and mitigation
strategies in a new or rehab plant design. The management
support Taylor received is a clear indication that the economic calculus is widening once again, this time in favor
of sustainable manufacturing.
More New Math—Sustainability Drivers
“Energy is a hot topic right now, mainly because of the volatility of energy costs,” says Marcia Walker, global market
development manager for sustainable production at Rock-
well Automation (www.rockwellautomation.com). “For the
past 12 months, energy costs have gone down. However,
industry professionals are preparing for the future, and they
want to able to keep energy costs under control, especially
because energy is the largest variable production cost.”
The cap-and-trade policies under discussion now have
also put energy costs in the spotlight. Whatever the final
shape of these policies, manufacturers want to be ready—
and controlling energy costs is part of that preparedness.
From an environmental perspective, when manufacturers
are able to control carbon emissions, they also are able to
control energy usage and save on their energy costs. Most
manufacturers today continue using coal- or gas-fired energy processes with big emission footprints—and big emission footprints cost more than small ones.
Environmental policies have a financial impact. For example, getting rid of industrial waste often is, in the end,
more costly than implementing green practices. Furthermore, local communities are discouraging industrial
plants—usually through taxes or fees—from dumping industrial waste into landfills.
That financial penalty encourages creative waste disposal.
Many process plants send their industrial waste to re-use facilities. Here businesses use someone else’s “garbage” for raw
material. More than a dozen years ago, Fluke Corp.’s (www.
fluke.com) George Bissonnet showed Control’s editor in
chief, Walt Boyes, that the circuit board and spent chemical
recycling business he developed was actually a profit center.
Safety compliance is another strong driver in sustainability. This is based, one assumes, on the proposition that a
safe plant is more sustainable than one prone to damage
from unsafe practices. Study after study has shown that
safety compliance, both in traditional workplace safety and
in process safety management produces higher profit levels
over time than ignoring safety issues does.
Walker adds, “[The process industries] are looking at
things through a new lens. They want to improve their environmental performance, not just for responsibility reasons,
but also for financial reasons.”
51
5/25/10 9:37 AM
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5/24/10 3:09 PM
Manufacturers also have a responsibility to shareholders
to maximize profits. As T. J. Rogers, chairman of Cypress
Semiconductor (www.cypress.com) says, “If you want businesses to do something, show them the money.” This is another example of that widening economic calculus.
wireless
innovatI/On.
■ Analog, Discrete,
Temperature and Serial I/O
What Is Sustainability Anyway?
Rockwell’s Walker explains that sustainability consists of making operations cleaner, safer and more energy efficient. “[Rockwell Automation] buckets sustainability into energy efficiency,
environmental applications and safety. Energy, environment
and safety are the three main components of it, with energy being the component that surprises people the most,” says Walker.
Going green is not about doing just one thing—reducing waste, reducing energy cost, minimizing the carbon
footprint or reusing materials in the production processes.
Green practice in process automation is about mixing and
matching sustainability efforts, creating the perfect balance
at the plant level, not only benefiting end users’ return on
investment, but also benefiting the environment as a whole.
“It’s a bit surprising that sustainability is being treated as
something new,” said Mark Lee, Coca-Cola’s director of
commercial product supply engineering at the Rockwell Automation Manufacturing Perspectives event in 2008. “It’s really just good business practice.”
For Lee and other end-user executives, sustainability in
many ways does represent a rebadging of the manufacturing
professional’s stock-in-trade: a continuous improvement process aimed at increasing efficiency, reducing waste, easing
environmental impact and boosting workplace safety.
“Sustainability is part of the relentless pursuit of waste
elimination,” Lee said. “It’s part of being a world-class manufacturing organization.”
Siemens Industry’s (www.siemens.com/entry/cc/en/) marketing manager, Ken Keiser, adds, “Sustainability is a way to
use green technology to help both the environment and the
company. Instead of ripping out and throwing away systems,
customers can lengthen the life cycle of the equipment they
have by just changing a few key components and using as
much of what they have as possible.”
■ Transceiver pairs to replace
a single signal cable
■ Scalable networks collect
thousands of signals
■ FlexPower options include
battery, solar and DC
■ Integrated Site Survey for
wireless link status
■ 900 MHz and 2.4 GHz
license-free radio
■ Multi-layer security protocol
■ IP67, Intrinsically Safe and
Class I Div 2 models
Getting There from Here
It’s easy to see that the pressure is on to “go green,” but the
best way to respond to that pressure isn’t so easy to discern.
Few in the process industries have a clear strategy for doing
so. Deciding which green initiatives make most sense for a
particular operation, much less how to implement those initiatives is a complex decision. But help may be on the way.
In 2008, the Aberdeen Group (www.aberdeen.com) conducted a survey of manufacturing companies about their
specific sustainability initiatives. The findings revealed that
the companies that have the best sustainable production
For white papers, application
information and other educational content:
www.bannerengineering.com/wireless
Sensing unplugged™.
© 2010 Banner Engineering Corp., Minneapolis, MN
BA-1943A Wireless Ad_1-2_Control.indd 1
1/20/10 10:55 AM
5/25/10 9:38 AM
performance also tend to have the best performance in other
areas such as financial performance.
Rockwell Automation used these findings and partnered
with Aberdeen to launch its Sustainability Assessment Tool
in January of this year. “This tool allows automation professionals to answer questions specific
to their sustainability needs,” says
Walker. “Not only can a sustainability
assessment tool guide industry professionals to view their entire processes
at a glance, but it gives them the opportunity to identify their biggest target for improvements. Assessment
tools and processes give professionals a guide or starting point towards
meeting their sustainability goals.”
Walker adds that an in-depth process sustainability assessment can help identify the potential return on investment for many businesses. These specialized assessments help determine whether the initial
company involvement requires just a capital investment,
a personnel investment or a combination of both. Assessments can pinpoint the duration of the sustainability process and how much capital investment to expect in return.
Control system integrator Indesco (www.indesco-usa.
com/home.html), Louisville Ky., has been using the tool to
help its customers achieve their sustainability goals.
“To become sustainable in the process automation industry, you can’t
just change the focus on one single
piece of equipment,” says K.W. (Bill)
Holladay, president of Indesco. “It’s not
just about that one process. It’s about
all that can help improve your carbon
footprint or become more sustainable,”
he says. “Rockwell’s Sustainability Assessment Tool doesn’t tell you that you
have to replace this or that component. It doesn’t tell you
that you have to drag out this new technology, and put it
in. What the tool does is help you look at the company as
a whole, comparing you to what is going on in the industry
5/25/10 9:38 AM
and measuring you against other companies that are being successful.”
Live Monitoring
Indesco’s vice president of sales, Thad
Parrott, says that live monitoring is essential for achieving sustainability
goals. “When our customers use live
monitoring systems, they know within
one month what’s working and what’s
not. The reason they know this is because they have been able to tweak
things each week as the process goes
along,” says Parrott.
As Holliday says, “Monitoring processes is a big thing. You can’t fix what
you can’t see.”
Take the case of General Mills. “We
were told in 2005 to reduce our energy
footprint by 15% in five years,” explained
Dave Spryshak of General Mills in November of 2009 at Rockwell’s annual
Automation Fair. “We discovered that
the single biggest energy consumer in
our plants was the HVAC system.”
Spryshak’s team discovered that by
applying process control principles to
the control of airflow in plant buildings, the company could improve air
quality indoors and out, and reduce
electricity use 17% to 49%. Gas usage
was reduced 14% to 63%. In one case,
Spryshak was able to reduce electricity consumption 3 MW, and saved $1.5
million in a single year.
The project team used cascading
loop control for air volume, an enthalpy algorithm to use the least-cost
energy source, multiple room-space
recipes, and used CO2 measurement to
determine room occupancy and derive
airflow requirements.
General Mills has modified 16
plants and is rolling out the changes
across the rest of its enterprise.
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getting more into it.
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How to Implement Sustainable Measures
Ray Zimmermann, of RJZ LLC, a sustainability and energy optimization consultant, who also spoke at Automation
Fair, outlined the overall plan for “going
green” in a process plant. First, he said,
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Total Energy Consumption by End-Use Sector
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Industrial
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“You have to change the corporate culture to make sure that energy-saving projects will continue to perform properly.”
He added that top-level management buy-in was critical to energyoptimization project success, and
that it was necessary to make it a
company priority, establish structure
and committees, identify key personnel at each level of management and
establish an energy mission—that is,
integrate energy into overall company strategies. Then, establish objectives for energy accounting and
data requirements, and develop a
plan to heighten communication and
make energy a visible priority.
After that, Zimmermann said, select
partners with experience, set leadership
priorities and move forward to study
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Changing the Lightbulbs
Sometimes, it really can be that simple—if changing the bulbs at 300 facilities is simple. Osram Sylvania
(www.sylvania.com) and its parent
company, Siemens Automation AG,
(www.siemens.com) have partnered
to design different energy-efficient
lighting technologies, as well as statewide recycling programs to reduce the
amount of carbon emission produced
in the process automation industry.
These programs and green practices
allow Osram Sylvania and its participating customers to reduce the
amount of glass, metal, mercury and
fluorescent substances used in Osram
Sylvania’s lighting products.
One company currently benefiting
from Osram Sylvania’s green products,
such as the Quicktronic family of ballast and lighting controls—the T12, T8,
T2 and T4 fluorescent lamps—is Norfolk
Southern Corp. (www.nscorp.com/nscportal/nscorp), the Virginia-based rail
transportation company.
Norfolk’s primary goal was to become sustainable throughout its processes, and with Osram Sylvania’s help,
it retrofitted more than 300 of its locations, and is anticipating an annual energy savings of 50 million kWh and an
annual CO2 emission reduction of approximately 76 million pounds.
5/25/10 9:39 AM
Get more
done
Sustainability—Trend or Fad?
Sustainability right now seems like
a fad, but it isn’t. Currently, sustainability programs are taking over corporate goals, and everyone wants to
accomplish sustainable practices for
their own reasons.
“Three to four years ago when people started talking about sustainability they would just shrug it off,” says
Walker. “Many thought sustainability
was just a fad.”
The process industries today are
seeing an increase in the number of
employees that are hired to perform
sustainability-related jobs, and these
companies annually publish corporate
responsibility reports.
Corporate human-resources departments also play an important role in
making sure green initiatives are part of
business plans. Employees want to work
for environmentally responsible corporations, and businesses want to hold a
strong sustainability performance because they use this to attract new talent.
Financial officials know that when
carbon trading comes along, this will be
a costly process for corporations. In order to reduce energy costs, reduce emissions and remain profitable, industry
must find ways to make money. Trading
emission credits could be the way to go.
Growing government pressures and
tougher environmental and safety policies act as regulators pushing sustainability initiatives as the norm, as the
economic calculus widens yet again.
Marketing also plays a role in setting
sustainability practices as a trend. Consumers today demand green products
and stockholders are putting pressure
on manufacturers to deliver and meet
popular demands, while operating in
a sustainable fashion, and with a lower
carbon footprint. As Kermit the Frog
used to sing, “It isn’t easy being green.”
However, 10 years from now, sustainable practice will be woven into
daily operations, and running a green
plant will be the only way to remain in
business and profitable.
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3789051A_Control.indd 1
57
4/14/10 5:15 PM
5/25/10 9:40 AM
CONTROL-7.875x10.5.pdf
1
5/25/2010
2:58:01 PM
C
M
Y
CM
MY
CY
CMY
K
CT1006_FPA.indd 58
5/25/10 3:29 PM
This year’s salary survey tells the
tale of the Great Recession’s impact
on process automation professionals. If last year’s story (www.controlglobal.com /ar t icles/ 20 09/Salar y -
Survey0906.html) was one of rising
anxiety in the light of bad news on
the horizon, this year’s reflects the
reality that had yet to become completely apparent in early 2009. While
not an unmitigated disaster, 2009
was a tough year for folks in process
automation, according to the 1500
readers who responded to our salary
survey this year.
Payday: Not Bad, But Not as Good as It Was
$91K to $100K
(11%)
$71K to $80K
(12%)
Under $30K
(10%)
$61K to $70K
(10%)
$51K to 60K
(8%)
$81K to $90K
(12%)
More than $100K
(27%)
36-45
(26%)
$41K to $50K
(5%)
$30K to $40K
(5%)
$2K to $4K
(34%)
$5K to $7K
(7%)
$0K to $1K
(54%)
$8K to $10K
(3%)
More $10K
(3%)
Figure 1. Process automation still
More than 55
pays well. More than 70% of those (20%)
surveyed make more than $60,000 a
year, up from 50% last year. Twentyseven percent make more than
$100,000, but that number is down
from 36% a year ago.
26-35
(18%)
18-25
(2%)
45-55
(33%)
Figure 2. Raises have taken a real
hit. This year, 54% of respondents
report a raise in the zero to $1000
range, a mirror image of last year’s
percentage, when that same number
got raises between $2000 and $4000.
Only 34% got those kinds
of raises
Salary/Benefits
(19%)
this year. Last year, 16% reported
raises in the $5000 to $7000 range.
This year, that number is down to 7%,
down 9%.
Yes (
Appr
(14%
6% to 10%
(22%)
More than 15%
(16%)
Under 2%
(25%)
11% to 15%
(9%)
2% to 5%
(27%)
250
200
Challenging
Work
Figure 3 Bonuses are down
too, from
(42%)
68% last year to 57% this year—and
a quarter of those reporting say their
bonus was between 0% and 2%.
Forty-nine percent of the bonuses
were between 2% and 10%. But a
surprising 16% got more than a 15%
bonus.
Hiring
(19%)
59
Promotions/
Raises
(19%)
150
CT1006_59_63_SALARY.indd 59
100
5/24/10 2:28 PM
The Numbers Don’t Tell All—Stretched to the Limits and Not Liking It
In our surveys, we provide a place for respondents to add
additional comments about their work. The same themes
usually appear: bad bosses, stingy employers, long
hours, office politics, cuts in salary and benefits, and, on
the other hand, the contented souls who love their work
and companies.
However, this year, two themes took center stage, probably because of the cutbacks caused by the shaky economy and the rolling demographic bomb of retirements—
too much to do and not enough resources to do it, and
concern over who is going to step up to fill the jobs that are
being vacated by the seniors.
• “There’s more work to be done by fewer people.”
• “ Workers are not being replaced, forcing us to run
short-handed. Everyone must work harder, smarter and
cover areas outside their expertise.”
• “I feel driven/pushed/pressured to deliver more and
faster innovations and new products, while not being
given any new resources.”
60
• “ We made some cuts 12 to 18 months ago, and combined
with near-term retirements, we’re getting stretched to the
breaking point. We’re going to need time to hire, but without sufficient turnover time from retirees to the new hires.”
• “ Too much knowledge is walking out the door due to
retirement, layoffs and open positions not being filled,
thus forcing the ones left to carry more burden without added financial gain. Most new help is naïve and
inexperienced.”
• “ Like all companies, we all do more and more work with
less and less people.”
• “ No one in upper management seems to be planning
for training the next generation of engineers. The gap
is getting huge.”
• “No trained people coming up through the ranks.
•“ [We have] issues with finding personnel with the background needed and the lack of apprenticeships for people coming into the market.”
•“I’m always worried about too much outsourcing and not
5/24/10 2:28 PM
More than 55
(20%)
No (47%)
enough new engineers being hired by the refinery.”
•“ We have a noticeably aging work force for which no
replacement bench strength is being developed.”
•“ Training is very often seen as ‘pure costs/good
times for employees’ by most employers, rather
26-35
(18%)
than as good investment in employees.”
•“A lack of training is a serious problem for me. I work in
18-25
a shrinking company that serves a shrinking industry.
(2%)
I do not haveYes
the(53%)
time to get training, and my employer
doesn’t have the money. At the same time, my lack of
training slows me down. It’s an infuriating Catch-22.
Operators at my customer’s factories never have time
for training either, so I have to create systems that one
Appreciation
can operate without training.”
(14%)
Opportunity for
Advancement (13%)
ry/Benefits
(19%)
More than 55
(20%)
with our proven solutions
Job Insecurity
Job Security
(12%)
No (47%)
ES2 Liquid Level Transmitter
new slimline design embodies robust
protection against a full range of
environmental challenges such
as extreme washdown practices,
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extreme humidity.
Other
(1%)
allenging Work
(42%)
26-35
(18%)
ts
%)
18-25
(2%)
Yes (53%)
• Flush mount slimline
design
Hiring
(19%)
Appreciation
(14%)
Promotions/
Raises
(19%)
Opportunity for
Advancement (13%)
simplifies process control integration, inventory
monitoring, and even shares data plant wide via
Ethernet. Now with data logging for reporting and
compliance monitoring.
• Monitor up to 32 tanks
Other
(1%)
• 10.4" color touch screen
HMI display
Figure 4. Job anxiety is up a little this year, with 53% saying they’re
worried about it, up only 1% from last year, surprising in light of
35% who say their companies are laying people off, and only 19%
are hiring. Last year, these two numbers were nearly equal at 37%
laying people off and 38% hiring. Eighteen percent say raises and
promotions have been affected by the economic downturn, down
from 25%Hiring
last year, although that drop may indicate that some com(19%)
panies took
action early in the crisis instead of waiting until this year.
Promotions/
Raises
(19%)
• Suitable for washdown
(IP68 rated connections)
LP3 Tank Level System
Job Security
(12%)
Layoffs
(35%)
• Loop powered
(4-20 mA output)
More Overtime
(14%)
Other
(14%)
%)
g Work
(42%)
Keep
Your
Process
Flowing
More Overtime
(14%)
Other
(14%)
• Data logging and
Ethernet connectivity
To learn more call or visit our website.
800-242-8871
734-662-5691
King Engineering Corporation
Ann Arbor, MI Fax 734-662-6652
CT1006
www.king-gage.com
5/24/10 2:29 PM
18-25
(2%)
5
)
Yes (53%)
Why They Do It
Appreciation
(14%)
Opportunity for
Advancement (13%)
Salary/Benefits
(19%)
Job Security
(12%)
Other
(1%)
Challenging Work
(42%)
Figure 5. In spite of anxiety over job and frustration about what cutbacks have meant,
most process automation specialists aren’t in it just for the money. One chart that
remains remarkably unchanged is the one that ranks what gives our respondents the
most job satisfaction. What they want, more than job security (12%), a chance for advancement (13%), appreciation (14%) or a decent salary and benefits (19%), is challengHiring
ing work (42%). And in response to a question
in our Basic Skills Survey, in spite of all
(19%)
More Overtime
the difficulties, 73% of respondents said they are happy in the automation profession,
(14%)
and another 25% said they were
happy at least some of the time. That same 73% said
Promotions/
Raisesthe profession.
they’d encourage their children to enter
(19%)
Other
(14%)
Sort of—I could be
happier (39%)
No (15%)
Layoffs
(35%)
Profile of a Process Engineer
The people who answered our survey
• Earn more than $60,000 a year (72%)
• Work 40 to 60 hours a week (72%)
• Do not get overtime pay (75%)
•Get three weeks a year or more vacation time (82%)
• Are over 45 (53%)
• Are male (95%)
•Live in U.S. (60%), Asia (15%), Europe,
(13%), Canada (6%), Latin America (5%)
•Are Caucasian (72%), Asian (15%), Hispanic (5%), Black (3%), other (5%)
• Are married (81%), with children (78%)
•Have a college degree (72%), have an
advanced degree (23%)
•Have degrees in everything from electrical engineering (37%) to such diverse
fields as accounting, marketing, food
science and psychology.
•Work in engineering, design and construction (40%), plant maintenance (17%) or
production and plant operations (14.5%)
•Have worked for no more than three
companies during their career (66%)
•Have been in process control longer
than 10 years (67%)
•Works in the oil and gas (19%), chemical
(12%), food and beverage (8%) or other
industries.
The complete Salary and Basic Skills surveys are available online at www.controlglobal.com/1006_salarysurvey.html and
www.controlglobal.com/skills2010.html
62
5/25/10 10:22 AM
Perks and Bennies Down Too
Benefits also are not what they were. This year 90% of respondents reported
having medical benefits, down from 98% last year, and 71% said they had denUnder $30K
tal coverage, down from 89%
last year—an 18% drop. Life insurance coverageMore than 55
36-45
(10%)
(20%)
(26%)
is down 13% from last year at 75%, and disability insurance is down 19% from
$61K to $70K
77%
in 2009 to 58% this year, although these numbers may reflect, in part, a
(10%)
larger group of respondents from outside North America.
$51K44%
to 60K
Only
say their companies offer pension plans, down from 48% last year,
(8%)
and only 55% say they have a 401k plan, down from 90% last year.
As for
other
$41K
to perks,
$50K a few folks report everything from company cars (13%), flex
26-35
time (5%)
(27%) and tuition reimbursement (40%) to overseas housing allowances,
(18%)
an$30K
on-site
gym, and the intriguing entry “meat.”
to $40K
One
(5%) unexplaned anomaly is the 12% who say they can telecommute, while
18-25
45-55
only two respondents report
having a company-supplied cell phone and laptop.
(2%)
(33%)
No (47%)
Yes (53%)
$2K to $4K
(34%)
The Demographic Bomb
der $30K
%)
$61K to $70K
(10%)
$51K to 60K
(8%)
$41K to $50K
(5%)
$30K to $40K
(5%)
NoOpportunity
(47%)
for
Advancement (13%)
Salary/Benefits
(19%)
$8K to $10K
(3%)
More $10K
(3%)
Job Security
(12%)
26-35
(18%)
6% to 10%
45-55
(22%)
(33%)
Other
(1%)
18-25
(2%)
Challenging Work
Yes (53%)
(42%)
More than 15%
(16%)
Figure 6.
Hidden in plain site in our profile of a process engineer is the demo-
K to $4K
4%)
$5K to $7K
(7%)
graphic bomb. Nearly 53% of the respondents to our survey are over 45, and
20% are over 55. At the other end of the scale, only about 2.5% are under 25 and
Appreciation
another11%
18.5%
tounder
15% 35.
(14%)
(9%)
The Skills Gap
$8K to $10K
(3%)
ore $10K
%)
Opportunity for
Advancement
(13%)
Hiring
(19%)
Salary/Benefits
(19%)
250
Promotions/
Raises
(19%)
200
More Overtime
(14%)
Job Security
(12%)
150
% to 10%
22%)
0
Appreciation
(14%)
More than 55
(20%)
$5K to $7K
36-45
(7%)
(26%)
More than 15%
(16%)
11% to 15%
(9%)
Other
(1%)
100
50
Other
(14%)
Challenging Work
(42%)
0
Yes (46%)
Sort of—I could be
happier (39%)
No (15%)
Layoffs
(35%)
Figure 7. Our basic skills survey reflects that anxiety about skills. Fifty-four percent of
those surveyed said they were either unhappy with the level of their basic skills (15%)
or only “sort of” happy, believing that their basic skill level could be better (39%).
Hiring
(19%)
Promotions/
More Overtime
(14%)
5/24/10 2:30 PM
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CT1006_FPA.indd 64
3542778B_810_Control_PlantServ.indd 1
5/24/10 3:10 PM
5/11/10 11:38 AM
Last August, we got a call from Mark Lauterburg, engineering manager at the Kimberly-Clark paper mill in Niederbipp, Switzerland, located between Zurich and Bern, about
an hour’s drive from our facilities at Logicpark (www.logicpark.ch) in Thun. Lauterburg was working on a real-time
quality management system and was having some difficulty
with his OPC servers and reliable data connectivity, so he
contacted us as local distributor for OPC software to help
resolve the issues he was facing. So the following morning I
met him in the mill, and he explained the situation.
“We can store images of every inch of a 3-ton base sheet
reel in an SQL database and refer to it weeks or months later,
but we need to do more,” Lauterburg told me. “To get the
camera system working, we must refer the actual produced
grade, machine speed and other important data from the
distributed control system (DCS).”
To collect data in this integrated way, Lauterburg needed
to connect his camera systems to the production lines’ ABB
System 800xA DCS (www.abb.com). This would allow him
to establish direct, real-time connections between the papermaking equipment and cameras, and enhance the quality of
the stored data.
“The vision quality management system is one of those investments with significant savings potential, and we wanted
to get the most out of it,” explained Lauterburg. “Logicpark
seemed to be quite expert in working with OPC, and we
were confident that they would help us with our data connectivity issues and get everything working.”
Kimberly-Clark is a global market leader in hygiene products, and it owns several manufacturing facilities in Europe.
The Niederbipp plant is one of the newest. It was substantially rebuilt after a fire in 1996 that destroyed much of the
equipment. Because it was recently upgraded with a new
drive and control system, the mill’s tissue-making machines
produce paper at speeds up to 1800 meters per minute. (Figure 1) This kind of production speed requires very sophisticated quality control systems. At these speeds, holes and
other defects in the base sheet are not visible to the human
eye. As a result, highly sensitive camera equipment is required to detect these defects. For this reason, Lauterburg
also recently installed process and quality vision systems
on both production lines. These multi-megapixel cameras,
called “sheet brake cameras,” capture over 1000 frames per
second to help identify, categorize and trace any defects in
the base sheet.
Our company, Logicpark, is a software engineering firm focusing on data management for industrial systems. Founded
in 2003, we implement, support and optimize MES systems,
and offer shop-floor and ERP solutions in conjunction with
our partners. Our staff leverages its experience in computer
science, project and process management, and marketing to
provide comprehensive, enterprise-wide solutions.
Cameras and Control
On the shop floor, Lauterburg introduced me to Jan
Tschudin, Kimberly-Clark’s project engineer, who showed
CT1006_65_67_OBJECT.indd 65
65
5/25/10 4:24 PM
S o f t wa r e a n d I n f o r m at i o n S y s t e m s
me the equipment. When the cameras were installed,
Tschudin had hoped that making the connection would be
straightforward because both ABB’s DCS and the camera
system were OPC-enabled. OPC is an industrial data communication protocol that allows any kind of hardware with
an OPC server to talk to any OPC client software, such as a
SCADA system or HMI. At Logicpark, we make every effort
to implement and support OPC. We do our best to educate
our customers and contacts about OPC, and even created a
special website for this purpose because we feel OPC is an
excellent industrial standard.
Basically, the ABB system had an OPC server and the
sheet brake cameras had an OPC client. It seemed like a
straightforward connection, but the DCS and the camera
system were on two different networks, protected by firewalls. This was the cause of the problem.
“The quality management system runs on a separate
virtual LAN from our factory automation system because
the sheet brake camera system is running as pilot system
at our facility,” explained Tschudin. “The producer of the
sheet brake camera system has been working closely with
us during the installation and afterwards, implementing improvements by remote access from outside the country. We
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Figure 1. Kimberly-Clark’s paper mill in Niederbipp,
Switezrland, was recently upgraded with drives and
control systems that enable its tissue-making machines to
produce paper at up to 1800 meters per minute.
needed clear separation between the two systems, but also to
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66
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YEAR
GUARANTEE
You’ll be in good company…
Certificate No. FM14290
ISO9001:2001
Figure 2.Two OPC DataHubs, one on the paper machine’s
sheet brake computer and another on the mill’s utility
server, are configured with an SSL tunneling connection
that allows the DataHub on the utility server to get data
from the DCS OPC server. When the tunnel is activated,
the OPC DataHub on the sheet brake side gets a complete copy of all the configured OPC points on the DCS.
5/25/10 10:35 AM
BG PiProAd.qxd:Layout 1
4/23/10
3:11 PM
S o f t wa r e a n d I n f o r m at i o n S y s t e m s
“We had been trying to run this
system using DCOM, but it was a
constant source of frustration,” said
Tschudin, “The connection would
be stable for a day or two, and then it
would drop, and we’d have to manually
reconfigure the system to get it working properly. We lost large amounts of
valuable data that way.”
Conduit Between Networks
Fortunately, OPC tunneling eliminates the need for DCOM. An OPC
tunneling solution converts the realtime data stream into TCP before
sending it across the network, and then
turns it back into OPC at the other
end. There are several OPC tunneling products on the market, but not all
of them provide the robust connectivity that Tschudin needed, combined
with the flexibility to configure it for
the unique requirements of his system.
Tschudin and I discussed the pros
and cons of different approaches. He
and Lauterburg had considered using OPC UA, since it is not based on
DCOM technology, and thus eliminates the need for OPC tunneling.
However, the technology was still in
development, and implementation was
low. There were no OPC UA servers
available for their hardware, and they
needed something that would work
with their existing system.
Finally, we chose the OPC DataHub from Cogent Real-Time Systems
Inc. (www.opcdatahub.com) because
it provides a robust tunneling connection and is easy and flexible to configure. We installed one OPC DataHub
on the sheet brake’s firewalled system
computer and configured it as an OPC
server for the sheet brake’s OPC clients. Then we installed a second OPC
DataHub on a utility server on our
own firewalled network. This second
OPC DataHub was connected to the
DCS’ OPC server using DCOM. That
DCOM connection was relatively easy
to configure and reasonably stable because both machines are on the same
network, so we didn’t have to deal with
firewalls there.
Next, we configured the OPC DataHub on the utility server to get data
from the DCS OPC server, and then
configured a tunneling connection between the two OPC DataHubs (Figure
2). We opened one port on each firewall to allow the connection, and for
security reasons, configured the OPC
tunnel to be an SSL connection. When
the tunnel was activated, the OPC DataHub on the sheet brake side gained
a complete copy of all the configured
OPC points on the DCS. With a few
mouse clicks, we configured the necessary points that the sheet brake system
needed, and by lunchtime of the same
day, we had a working system.
Of course, there was some finetuning involved. Initially, we configured the OPC DataHub to read all
the points in ABB’s DCS. Since there
were a lot of points, that slowed down
the start-up time significantly. So, we
changed it to connect only to those
points that the sheet brake system actually needed. This reduced the start-up
time to a fraction of a second. Tschudin
and Lauterburg were pleased with the
quick work, but needed to test the system for several weeks before deciding
to go ahead with the implementation.
The system now has been working
for months, and the benefits are clear.
“With the vision quality management
system connected to our DCS in real
time, we can gather important data,
such as the machine speed, grade number and grade name, when a particular
defect occurs,” said Tschudin. “This is
particularly helpful when we plan for
the use of the paper, such as for facial
tissue, paper towels, paper napkins and
so on. We have now equipped our second tissue machine line with an identical system and have resolved other
problems in the plant by using OPC
tunneling.”
BetaGauge
PI PRO
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.. Accuracy of ±0.05% of F. S.
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. Displays in 18 standard or
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BetaGauge
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Bruno Maurer is head of solutions at Logicpark in
Thun, Switzerland.
67
5/21/10 3:10 PM
The Fieldbus Intrinsically Safe Concept (FISCO) provides
the live working benefits of intrinsic safety (IS) without
many of the limitations associated with IS entity techniques,
such as extensive calculations and restrictive power limitations—two main reasons why FISCO often is selected for
installations in classified areas. In addition, because fieldbus
applications need more complex multipoint connections
than analog “point-to-point” signals, traditional IS entity
calculations were very cumbersome.
FISCO Parametric Values
Parameter
Value
Uo (output voltage)
14 – 17.5 V
Io (output current)
≤ 380 mA
Po (output power)
≤ 5.32 W
Ui (input voltage)
17.5 V minimum
Ii (input current)
380 mA minimum
Pi (input power)
5.32 W minimum
Loop (cable) resistance
15–150 Ω/km
Loop (cable) inductance
80–200 nF/km
Maximum trunk length
1900 m
(6233 ft) max
1000 m
(3281 ft) max
Gas Group
IIB (C/D)
Gas Group
IIC (A/B)
Maximum spur length
60 m (197 ft)
Ci internal capacitance of field devices 5 nF maximum
To overcome these difficulties, the German Physikalisch
Technische Bundesanstalt (PTB) developed the FISCO
model. In its PTB-W-53e report, PTB said that tests proved
that using only one active power supply (load-sharing redundant power supplies are not supported) on the bus, the cable parameters and internal capacitances and inductances
of the devices have no negative influence on the intrinsic
safety of the system and, therefore, can be neglected.
In 2005, the results of this work became a full IEC standard (IEC 60079-27). Fieldbus Non-Incendive Concept
(FNICO) also was published as part of the standard’s first
edition. Table 1 summarizes the limiting conditions of a
FISCO-compliant system.
The IS standard described the requirements for “Ex ia”
for zones 0, 1 and 2 and “Ex ib” for zones 1 and 2. The fifth
edition of IEC 60079-11 added the classification “Explosion
Protection, Ex ic” suitable for use in Zone 2 only. The newest editions specify that FISCO “ia” is suitable for Zones
0, 1 and 2; FISCO “ib” for Zones 1 and 2; and FNICO in
Zone 2.
As the name implies, the FNICO part of the standard was
based on non-incendive principles, and in the second edition IEC 60079-11 will be replaced by FISCO “ic.” Apparatus designed and approved to the FNICO requirements
of the first edition may be used in an “ic” FISCO system,
because existing FNICO installations will be grandfathered
in for continued use today and also after the new edition of
IEC 60079-15 is published, likely in 2011.
Li internal inductance of field devices
10 µH maximum
Energy Access
Device temperature classification
T4 (135 °C/275 °F)
The FISCO approach is inherently a system concept, as
68
CT1006_68_69_FISCO.indd 68
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Intrinsic Safety
there is only a single source of possible energy (the fieldbus
power supply) into the flammable atmosphere, and all other
devices and equipment must not put energy on to the bus—
hence, the low capacitance and inductance limits for the
field devices. The T4 temperature rating also is not a significant constraint, since this temperature is well below the T6
rating for most hydrocarbon industry gases.
Despite this, it is possible to connect separately powered
devices to a FISCO network, provided the bus terminals
remain passive and do not present more than the internal
inductance and capacitance limits defined in Table 1 to
the network.
FISCO power supplies must comply with the Uo, Io, Po, Ci
and Li parameters of Table 1. However, there is no specification
relative to the maximum permitted external capacitance Co
or inductance Io. All FISCO power supplies can be either linear or trapezoidal output for category “Ex ia” installations (Gas
Group A through D in North America), while for gas group “Ex
ib” (Gas Group C/D in North America), a rectangular output
power supply can be used to make higher energy levels possible. Most FISCO units are trapezoidal, as that allows for more
energy than linear, which is what must be used for IS barriers
and isolators
It should also be noted that FISCO power supplies can, in
many cases, also be used as repeaters to boost a signal and
get an additional 1000-meter or 1900-meter extension of the
network. Alternately, they can also be wired in parallel to
make more effective use of a single H1 port by increasing
the number of devices to which it is connected.
However to determine if you need to use a repeater, you
need to determine the maximum trunk length as a function
of system load. Using the following formula, combined with
the mandatory FISCO documentation for manufacturer,
model, IEC classification, certificate number and temperature range prescribed by the standard, you can determine
the segment design constraints with minimal effort.
Vd = Vp – [ ∑n1 Id + IHH + (ISC – Idmin) + IF ] x R
where R = Ω/km x length of cable and
Vd = voltage at “lumped load” device
Vp = voltage at power supply terminals
Id = current requirement for device d
Idmin = network device with minimum current draw
ISC = spur short-circuit current draw of the field device
coupler
IHH = current budget for handheld communicator (typically 10 mA)
IF = current draw of the field device coupler
These values can be obtained from the manufacturer’s
data sheets.
Therefore, the calculation will consist of the following steps:
FISCO Alternatives
A commonly used alternative to FISCO and FNICO is the
“Fieldbus Barrier or High-Energy Trunk” concept which uses
an “Ex e” trunk. This means it is not “live workable” to provide the option of higher voltage and current levels from the
fieldbus power supply (typically 24V to 28V and 350 mA to
500 mA). This enables both more devices to be connected to
the network and longer trunk lengths because of the higher
starting voltage. The resulting high-energy trunk powers the
fieldbus barrier, which contains the necessary electronics,
such as isolation and IS circuitry, to make each of the spurs
IS/FISCO-compliant. The high-energy trunk effectively separates the FISCO power supply into two parts, with the powerconditioning circuitry in the power supply and the IS circuitry
located in the fieldbus barrier in the field. Rather than the H1
trunk connecting these two sets of circuits being on a circuit
board, it is replaced with the H1 trunk cable.
Another new technology in development by PTB and others,
as an alternative to FISCO is dynamic arc recognition and termination (DART), which uses active electronics at both ends
of the trunk cable to monitor for the potential creation of a
spark, and isolate the circuit from the power before it reaches
a level that could cause a spark and hence ignition. More on
DART is at www.technology-dart.com/en/index.php.
1. Verify that the sum of the device currents is less than
the available current available from the FISCO power
supply
2. Confirm that the lengths of the trunk cable and spurs is
less than the maximum in Table 1
3. If you suspect that you may be approaching the lower
limit of 9-volt operating voltage due to voltage drop in
the trunk, substitute the necessary values in the formula above. Also, if the formula results in Vd ≤ 9 volts,
it may be necessary to perform a detailed calculation
to confirm the actual estimated voltage at each device.
Fieldbus power supply companies all offer free downloadable calculators to do these calculations.
I believe you can now see how FISCO really is fortified
IS—more power means more devices can be connected to a
single H1 port. This is especially true now that FNICO is
part of this standard, is easier to use because it supports “live
working,” and is easy to design because, if you remain within
the design parameters, then the calculation consists of simply
completing a table and, perhaps for insurance purposes, performing a simple worst-case “lump sum” calculation.
Ian Verhappen is an ISA Fellow and Cer tified Automation Pro fessional. He blogs
for ControlGlobal.com as “ The Great Kanduski” and operates Industrial Automation Net works Inc. He can be reached at iverhappen@gmail.com.
CT1006_68_69_FISCO.indd 69
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ask the expertS
Getting Respect and Preventive Valve Maintenance
“Ask the Experts” is moderated by Béla Lipták, process control consultant and editor of the Instrument Engineer’s Handbook
(IEH). The 4th edition of Volume 3, Process Software and Networks, is in progress. If you are qualified to contribute to this volume, or if you are qualified to answer questions in this column or want to ask a question, write to liptakbela@aol.com.
Q
In the past, you’ve written a lot about the need for a
larger role and the added recognition that our process control profession deserves. You also talked
about applying the principles of process control to other
processes like the economy, the control of rivers, or the
global energy future. You wrote about the role universities, publishers, technical societies and conferences could
play in gaining that recognition, but to my knowledge you
never talked about the steps we could/should take to get
there. Why not?
George Crowelly
geocrowelly@aol.com
A
The answer is simple George—I did not, because I
don’t know. It is much easier to identify problems than
to give a recipe for fixing them! It is easier to say that
process control can increase safety by monitoring the methane concentration in mines, designing safe software for acceleration control in cars, designing deep-sea oil wellhead
shutoff valves (the same as we design all critical safety shutoff valves) by partially stroking them periodically to check
out the functioning of the loop, or guarding the cooling systems of nuclear power plants, which could be the next logical targets of the terrorists.
Yes, these problems are easy to solve because, as presetned so far, they all involve only engineering. What’s
much more difficult is to spread the news that there is
a new profession that can solve these problems and do
more. Accepting and understanding this takes time. It
also takes time to convert our engineering societies, conferences and publications from being adverising forums
to becoming the wells of new knowledge, or to take back
process control from the “dot com types” and return it
to people who understand the processes they control. It
might take a lot more accidents at our 40-year-old refineries, aging nuclear power plants and even older mines,
before people realize that it is our profession that can not
only fix them, but can also meet the challanges of the
coming post-industrial age.
Bél a Lipták
liptakbela@aol.com
70
Q
I would like to ask about the preventive maintenance
(PM) of SIS valves in our plant. Our shutdown valves
have no bypass and therefore, scheduled maintenance
requires a plant shutdown. Yet we have no plans to install
bypass systems due to their high cost.
As a result, the operation and maintenance departments
asked to move these SIS valves from the preventive maintenance category, and move them into the shutdown maintenance category to have 100% compliance in PM rather than
deferring PM of SIS valves to shutdown.
I would like to have your opinion on this issue. Is it acceptable if these SIS valves will receive their scheduled maintenance during shutdown? Am I right that safety measures
will not be affected, since they should be done in shutdown
only anyway?
Fahad S Al-Howimil
E HowimilFS@united.sabic.com
A
These questions came up during the evolution of ISA
SP84 standard, starting in 1982. As you know, this standard, co-adopted with the IEC 61511, is a qualitative
approach to availability numbers for SIF. That means, the
transmitter, the logic solver and the final control element
(S/D valve) will function when called on to shut down the
process unit safely. The availability calculation for the Function-SIF takes into account components, design, completeness of testing and the frequency to meet SIL level requirements. There is a Technical Information (TI) as part of ISA
standard SP-84-2005 with details on how to test and maintain these S/D valves per standard. In general, these valves
account for 45% of the availability number. In other words,
your deficiency in design and testing frequency will increase
the risk level manyfold. You have three choices:
• Declare that these systems are not safety instrumented
systems or functions. This will have non-compliant regulatory or insurance-related consequences
• Talk to the valve manufacturer about how to add test
features, so that you can test them periodically (bump test
for 8% to 10% movement) to ensure its functioning. You do
not need bypass valves to do this. There are several prepackaged test kits, such as ASCO and others, on the market to
accomplish this.
CT1006_70_71_ATE.indd 70
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ask the expertS
• Set up your DCS or asset management system to do
partial-stroke testing online to validate the valve function.
This is commonly done in systems similar to yours where
valves are considered critical, but not available for testing
on a periodic basis. This will require some additional components to be added to the existing valve and software setup
to collect data.
If it is any comfort, the ISA SP 91 committee is reviewing
a draft addressing the situation where the valves are not SIF,
but are classified as critical S/D valves. In that case, testing,
training and documentation shall be followed similar to SIF,
but not rigorously quantitatively. This will enable operating
units to meet basic safety needs to own and operate, which
will satisfy regulatory and insurance needs.
Please check with ISA web page (www.isa.org) for some
papers on this topic. I recall an engineer in your company
who gave a paper on this very topic eight years ago in one
of the ISA conferences. Check your company archives, too.
R am.G.R amachandr an
ramacg@cox.net
A
The short answer to your question is yes, you can move
the SIS valve testing to the shutdown maintenance list,
but at a cost.
SIL availability calculations are performed to determine
how frequently a shutdown device will be called on to act,
but fail to do so. The higher the SIL rating, the lower the
likelihood of failure on demand. These availability calculations are based on the dangerous undetected failure rate of
the device and the frequency of testing.
You can lengthen the testing frequency (as you suggest),
but the likelihood of the valves failing to close on demand
will be increased. The question you have to answer is this:
Will these valves still satisfy their SIL requirement under
the new testing schedule?
People have devised ways to get around this issue with
some success. One option is partial-stroke testing. This operation is performed with the use of solenoids and limit
switches, which allow you to partially close the valve while
in operation. This proves out the SIL control system, the
wiring to the valve and the solenoid, but it doesn’t really
guarantee that the valve will fully close and seal upon demand. Still, it does check the functioning of a large part of
the loop, and that may be enough to satisfy the SIL availability requirement.
HUNTER VEGAS
hvegas@avidsolutionsinc.com
A
The interval between testing valves depends on the
performance required. You did not state the original
and proposed test intervals, and so your question can’t
be answered qualitatively (other than saying that the “safety
measures” definitely will be affected by such a change).
Was a calculation done to justify the change? What recommendations (if any) might the valve manufacturer have
for test intervals? Automated partial stroking is often an effective means to extend the required manual full-test intervals. There are over a dozen manufacturers of the systems
required to implement such solutions. Note that failure rates
can change depending on frequency of valve movement and
testing. The standards, technical reports and many books
describe and show how to perform such calculations; it is
nothing more than simple algebra.
Paul Gruhn, PE, CFSE,
pgruhn@sbcglobal.net
Q
I am working in a power plant in Kosovo. As there is no
possibility here of finding good literature on the control of processes I am writing to you. Can you provide
me with a mathematical model description for water treatment plants—especially for the part of a water treatment
plant were I will try to implement predictive control.
Lutfi Bina
lutfi_bina@yahoo.com
A
In process control, two general types of models are
used—first-principle models and black-box models developed from the operational data. For linear, modelpredictive control, black-box, parametric (ARX, ARMA,
state space) or non-parametric models (step responses) are
applied. The typical procedure for building a model is applying pseudo- random excitations, collecting data and generating and validating the model
Most MPC product providers have tools for building models. You also can use Matlab Process Identification Toolbox.
You also can read more on developing models at www.
easydeltav.com/BOL/10.3/index.html
Also, a practical general overview on building models
and model application for tuning and MPC control can
be found in Instrument Engineers’ Handbook (IEH), Vol. 2,
Chapters 2.13 to 2.17. You can also read in the same volume
in Chapter 8.39 about wastewater treatment controls.
Willy Wojsznis,
willy.wojsznis@EmersonProcess.com
CT1006_70_71_ATE.indd 71
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ROUNDUP
The Pressure Instrumentation Shop
Review the latest pressure instrumentation technology here.
72
SUBMERSIBLE PRESSURE TRANSMITTERS
MULTIVARIABLE TRANSMITTER
PT4500 and PT4510 submersible pressure transmitters are optimized for detecting the level of water or other
media with similar density
in challenging industrial
environments, including in
wastewater and irrigation systems, as well as tanks containing gas or diesel. PT4510 was
designed for low-level applications of up to 400 in., while the
PT4500 is available in ranges up to 100 psig.
Turck
800/544-7769; www.turck.us
EJX930 multivariable transmitter handles static pressures to 4500 psi. It gives five
measurements from one device, including fully compensated mass flow, static pressure, external temperature,
capsule temperature and amplifier temperature. EJX930 is also available with fieldbus
and supports AR, IS, SC, IT and PID function blocks and
the software download function.
Yokogawa
800/888-6400; www.yokogawa.com/us
ECONOMICAL PRESSURE TRANSMITTERS
STAINLESS-STEEL PRESSURE GAUGES
The base accuracy of the
Model 261 gauge and absolute pressure transmitter in
the 2600T series is ±0.1%.
Span limits for these models range from 1.2 in. H2O
to 8700 psig and 2.25 mm
Hg to 435 psia with standard
4-20mA and HART protocol. Configure the transmitter and
setup parameters via the LCD display, a HART handheld
communicator or a PC.
ABB
215/674-6580; www.us.abb.com
Brooks S122/C122/F122 series 2-inch stainless-steel
gauges were designed for demanding high-purity applications. With an accuracy of 1%
of full scale, the gauges offer
a reliable and efficient way
to monitor pressure locally.
They come in a variety of process connections, pressure
ranges and socket orientations. They are good for oxygen
service to ANSI B40.1 level IV specifications.
Brooks Instrument
888/554-3569; www.brooksinstrument.com
SOLID-STATE ELECTRONIC PRESSURE SWITCH
SMART PRESSURE TRANSMITTERS
One Series solid-state electronic pressure switch features a response time five
times faster than a transmitter at half the installed cost.
One Series with a built-in integral digital display and 4-20
mA output can effectively replace a switch, a gauge and a transmitter in one package.
One Series is the ideal upgrade to any mechanical switch,
gauge or transmitter.
United Electric Controls
617/926-1000; www.ueonline.com
The ST 3000 transmitter
line features enhanced and
advanced on-board diagnostics for both Foundation
Fieldbus and HART 5 and 6.
The series includes absolute
pressure, differential pressure, gauge pressure, flangemount, high-temperature gauge and in-line gauge pressure
transmitters, providing pressure, level and flow measurement for a wide range of applications.
Honeywell
800/343-0228; www.honeywell.com/ps
CT1006_72_74_RNDUP.indd 72
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ROUNDUP
COMPACT GAUGE VALVE
WIRELESS PRESSURE
Swagelok’s compact gauge
valve is available with either
a ½-in. or 12-mm Swagelok
tube fitting end connections
and is made of 316 stainlesssteel. The valve is rated for
temperatures up to 450 °F
(232 °C). A soft-seat stem
with PCTFE stem tip is available, and users can choose
from UHMWPE, PFA or PEEK packing. The valve is rated
for pressures up to 4000 psig (275 bar).
Swagelok
www.swagelok.com
Sitrans P280 transmitter for
pressure measurement and
Sitrans TF280 transmitter
for temperature have a WirelessHART interface as well as
a graphical display with backlight functions, and are easy
to operate via pushbuttons.
An integrated battery supplies the transmitters with power
for up to five years, with a display that shows the exact number of remaining days.
Siemens
www.siemens.com/wirelesshart
GAS-POWERED CURRENT-TO-PRESSURE TRANSMITTER
DUAL-INPUT DIFFERENTIAL MANOMETER
Moore’s IPX2 current-to-pressure transmitter is approved
for use with natural gas as its
pneumatic supply, allowing
it to be installed at booster,
gas-gathering and compressor stations and pipeline feed
applications It is CSA-, FMand ATEX-approved. It has intrinsically safe, non-incendive,
explosion-proof, and dust-ignition-proof apparatus certifications and a NEMA 4X environmental protection rating.
Moore Industries-International
818/ 894-7111; www.miinet.com
Omega’s new series of manometers feature dual display
and dual pressure inputs.
Pressure is displayed in one
of four user-selectable units
(psi, mbar, in. H2O, and mm
H2O). Software is included
that allows users to display
the data in a graphical format or export the data to Excel or
text files for further manipulation. This CE-complaint product is ideal for automotive, HVAC and R &D/lab use.
Omega Engineering
888/826-6342; www.omega.com
PRESSURE AND AIR VELOCITY MANOMETER
SUBMERSIBLE LEVEL TRANSMITTER
MP120 is a compact, rugged, easy-to-use manometer.
In addition to pressure measurements, it also measures
air velocity via a Pitot tube.
The backlit LCD display is
easy to read in either light or
dark environments. MP120
offers built-in calculation for velocity, up to 4 in H2O pressure range, up to 8000 FPM air velocity range, 0.1 resolution
and accuracy of ± (1% rdg. + 0.2 mbar).
E-Instruments
215/750-1212; www.E-inst.com
Microlevel is the smallest
level transmitter in its class,
boasting 0.63-in. diameter,
and provides standard features that exceed the higher
priced competition. It comes
standard with ±0.25% FS
(±0.1% optional) total error
band over the range of 0 °C to 50 °C. It is available in custom pressure ranges up to 375 ftWC and dual outputs (4-20
mA analog + RS485 digital).
Keller America
800/253-5537; www.kelleramerica.com
73
5/21/10 3:18 PM
ROUNDUP
74
EXPLOSION-PROOF CURRENT-TO-PRESSURE TRANSDUCER
HIGH-ACCURACY PRESSURE TRANSDUCER
Type-595XP explosion-proof
current-to-pressure I/P transducer is small and lightweight, yet less sensitive to
shock, vibration and position
change than other I/Ps. It is
ideal for hazardous environments in remote locations. A
low mass control circuit provides reliable linear output in
difficult applications at an economical cost. FM- and CSAapproved and ATEX-compliant.
ControlAir
603/886-9400; www.controlair.com
KPSI Model 501 SDI-12
transducer meets the requirements of the U.S.
Geological Survey Office
of Surface Water accuracy
specifications for stage monitoring. It offers accuracy of
+0.05% FS total error band
and repeatability and a measurement level accuracy of
+0.01 ft H2O and on-board surge protection. It is 100%
SDI-12 datalogger-compatible.
Pressure Systems
800/328-3665; http://pressuresystems.com/500.html
DIFFERENTIAL PRESSURE SCANNER
COMMUNICATION, CONFIGURATION, CALIBRATION
Ethernet wet/wet liquid
pressure scanner, Model
DSA3307, can accept two to
16 differential all-media pressure transducers. It contains
a microprocessor and 16-bit
A/D. The microprocessor
converts the transducer analog data to engineering units. Sampling and throughput
speeds are user-configured from 1 Hz up to 500 Hz/channel/sec. Available pressure ranges are from 1 psid to 300 psid.
Scanivalve Corp
800/935-5151; www.scanivalve.com
Handheld DPI 620 advanced
calibrator incorporates full
HART capability. It is weatherproofed to IP 65 and contains a complete library of
registered HART device descriptions to support more
than 1000 sensors. It has a
full-color, high-resolution touch interface, large internal
memory, and retains the pressure-generation and measurement capability of the existing DPI 620 calibrator.
GE Sensing & Inspection
www.gesensinginspection.com
HVAC DIFFERENTIAL PRESSURE INDICATOR & TRANSMITTER
OUTDOOR DIGITAL PRESSURE GAUGE
699 Series differential pressure indicators and transmitters are designed for use with
air and non-corrosive gases.
They are ideal for monitoring
low air velocities in air conditioning systems, measuring
low differential room pressures in laboratory and process clean-room applications, and
other low-pressure monitoring applications. They are available in three configurations.
Clark Solutions
978/568-3400; www.clarksol.com.
Specifically engineered for
outdoor conditions, IP67rated PG7 digital pressure
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0 psi to 10000 psi, at ±0.25% accuracy of full scale. It gives
accurate readings even with pulsating pressures—typically a
major disadvantage with vibration-sensitive dial gauges.
Automation Products Group
888/525-7300; www.apgsensors.com.
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Product introductions
76
DUAL-CORE EMBEDDED COMPUTER
FAST SWITCHING RELAYS
UNO-3084 is a fanless embedded automation computer with front-accessible
I/O design. It has an Intel
Core 2 Duo L7500 1.6 GHz
processor, 2GB DDRII RAM
(expandable to 4GB), a GMA
X3100 graphics engine, dual
DVI-I ports with support for up to three displays, dual
IEEE-1394b interfaces, 2 x RS-232/422/485 ports, and 2 x
10/100/1000 Base-T RJ-45 ports with teaming function support and 5 x USB 2.0 (one internal) ports.
Advantech Corp.
800/205-7940; www.advantech.com/ea.
Weidmüller has added four
versions to its Microopto
family of opto-couplers or
solid-state relays designed
for applications, including
switching and amplifying
actuators, signal inversion
and converting TTL signals.
They offer extremely fast response time, reliability, compact
size and low power use. The four products are Microopto
Solenoid, Microopto 1CO and two Microopto TTL converter devices. All are CE- and cULus-approved.
Weidmüller
(804/ 379-2593; www.weidmuller.com
TEXTING CONTROLLER
SAFETY-ENHANCED VORTEX FLOWMETER
With the introduction of a
GSM modem, Phoenix Contact’s Nanoline controller provides easy control capability via
text messaging from anywhere
in the world. The modem uses
the cell-phone GSM network,
sending text messages via the
SMS protocol. The GSM modem’s phone book can store up to
eight phone numbers that can be configured to send program
messages and/or fault or warning messages. The Nanoline is a
small, flexible controller for simple applications.
Phoenix Contact
800/322-3225; www.phoenixcontact.com/usa_home.htm
Rosemount 8800D criticalprocess, vortex flowmeter is
designed to increase plant
availability and enhance
safety. Its vortex sensor is isolated from the process, making it possible to maintain the
vortex sensor without requiring a process shutdown, greatly increasing process availability.
It eliminates the need to shut down the process to maintain
a vortex sensor, and has the ability to verify the health of the
transmitter by simulating the vortex flow signal.
Emerson Process Management
www.emersonprocess.com/rosemount
SHIELDED LINEAR-POSITION SENSORS
UNIVERSAL REMOTE I/O MODULE
Temposonics linear-position
sensors have a super-shield
housing (SSH) option for use
in harsh environments. Available in an integrated package
with R-and G-Series sensors,
the SSH stainless steel housing is hermetically sealed,
meeting the requirements of protection modes IP 68 and IP
69K. The housing provides protection against corrosion and
penetration of dirt and water, making it ideal for outdoor use
or high-pressure, wash-down applications
MTS Systems Corp
919/677-0100; www.mtssensors.com
Safety Manager Remote I/O
module is designed for harsh
environments. By using softmarshalling, the Honeywell
Safety Manager Remote I/O
module can be mounted close
to the process unit, eliminating the need for marshalling
panels and home-run cables, reducing or eliminating field
auxiliary rooms. Each channel of the universal, high-density
module can be individually configured to a different I/O type
It is SIL 3-certified by TÜV Rhineland.
Honeywell Process Solutions
www.honeywell.com/ps
CT1006_76_78_PROD.indd 76
5/21/10 3:20 PM
A
SIMPLIFY CONTROL SYSTEM BUILDING
CAT5e ETHERNET PATCH CABLES
AMRN/AMRX (for Modbus/
RTU) and AMTN/AMTX
(for Modbus/TCP) controls
packages provide a fast, easy
way to interface with any
Modbus slave connected to a
PC’s serial or network ports.
The packages are easy-to-use
ActiveX. AMRN and AMTN are Windows Forms Controls
(.NET) that provide a quick way to communicate with slave
devices connected to a PC’s serial or Ethernet port. Free
evaluation versions are available.
Acromag
248/295-0865; www.acromag.com.
Cat5e Ethernet patch cables
are available in eight colors
and 3- foot to 50-foot lengths.
The straight and crossover
patch cables support up to
1000 Mbps, and are designed
to reduce the effects of electromagnetic interference by
incorporating a single metal foil shield which wraps around
the entire set of four twisted shielded pairs. The robust RJ45
connectors are also shielded against electrical interference.
Prices start as low as $5.
Automation Direct
770/889-2858; www.automationdirect.com/ethernet
DIAMOND PROTECTION
TDR LEVEL TRANSMITTER
Diamond-SIS High Integrity Protective System is a
low-cost, stand-alone logic
solver certified for use in applications up to Safety Integrity Level (SIL) 3. It provides
overpressure protection for
scenarios where the opening
the pressure relief valve poses unacceptable risks. It’s an SIL
3 logic solver with 2oo3 voting, providing the user with a
fault-tolerant logic solver independent from the process control and unit safety instrumented system.
SIS-TECH
281/922-8324; www.sis-tech.com.
Impulse Series continuous
TDR level transmitter uses
time domain reflectometry
(TDR) to provide accurate
measurement of total level,
distance or volumetric outputs. It gives continuous
level measurement of liquids
at ranges up to 50 ft. (15 m), with a two-wire 4-20mA, HART
output signal. It is made of 316SS and Hastelloy C for use in
hazardous (Class I, Div. 1) environments with either intrinsically safe or explosion- proof installation requirements.
Ametek Drexelbrook
215/674-1234; www.drexelbrook.com
CT1006_76_78_PROD.indd
Add-On_C_June10 o.indd 77
1
5/21/10 10:51:47
3:21 PMAM
5/19/10
COMMUNICATION FOR LEGACY SYSTEMS
REDUCE SENSOR IMPACT FAILURE
N-Tron has introduced six
new products designed for
legacy serial communications in industrial environments. ESERV-11T/12T and
ESERV-M12T Series bridge
the gap between older serial
and contemporary Ethernet
protocols, allowing organizations to preserve their investment in programming and equipment, while moving forward with advancing technology. Both have connectivity options for 10/100BaseTX and multimode fiber applications.
N-Tron
251/342-2164; www.n-tron.com
BunkerProx is a rugged,
“self-bunkering” M18 inductive proximity sensor designed to survive longer in
abusive welding applications
without external protection. Also, BunkerProx has a
strong, massively thick housing that boosts the ability to withstand repeated mechanical
impact. A frontal impact deflection ring helps protect the
high-temperature ceramic face from impact damage during
part loading and unloading.
Balluff
800/543-8390; www.balluff.com
WIRELESS SENSORS FOR ENERGY MONITORING
NO-FUSE SURGE PROTECTION
Hobo ZW Series, a family of
wireless data nodes for centralized monitoring of energy
use and environmental conditions in buildings, reduces
the cost and complexity of
data collection by measuring,
recording and transmitting
real-time energy use and environmental data from dozens
of points to a central PC. They form a self-healing, wireless
network to transmit logged data and can measure temperature, relatively humidity, kilowatt hours, CO2, AC voltage,
amps, gauge pressure and more.
Onset
800/564-4377; www.onsetcomp.com.
Surge-Trap Type 1 surge protective device (SPD) meets
requirements for UL 1449
Third Edition, and is ideal
for indoor applications. It features TPMOV technology,
making it a “no-fuse” surge
suppressor that doesn’t require the use of additional fuses or over-current protection.
It can be installed upstream or downstream of the main disconnect. Surge-Trap Type 1 SPD product line offers a wide
range of voltage configurations and satisfies National Electric Code (NEC) 2008 SPD requirements.
Ferraz Shawmut
(978) 462-6662; http://us.ferrazshawmut.com.
FIREWALL FOR OPC
STOP BACKFLOW
Triconex Tofino Firewall for
OPC will harden industrial
safety systems against network accidents and attacks.
It is the first firewall that
protects integrated applications based on OPC Classic.
It is now available for Invensys customers using the Triconex TCM with the embedded OPC solution. It provides
security features developed specifically for Triconex and its
embedded OPC Classic server to protect against malicious
attacks and other threats to network operations.
Tofino
250/390-1333; www.tofinosecurity.com
Tideflex CheckMate inline
check valve is ideal for backflow prevention and mitigation of odors. In outfalls,
stormwater, CSO and SSO
applications, CheckMate’s
custom-engineered design
eliminates costly backflow
from oceans, rivers and interceptors. It has very low headloss, especially beneficial in
low-lying areas. Its 100% fabric and elastomer construction
eliminates corrosion problems, and its unibody construction
eliminates components that catch debris, corrode or fail.
Tideflex
412/279-0044; www.tideflex.com.
CT1006_76_78_PROD.indd 78
5/21/10 3:21 PM
C O N T R O L TA L K
What’s Going On with Loop Performance?
Greg McMillan and Stan Weiner bring their wits and more than 66 years of process control experience to bear on your questions, comments, and problems.
Write to them at controltalk@putman.net.
Stan: There are a lot of diverse processes and
applications out there. We all tend to think our
loop performance problems are unique.
Greg: But a deeper understanding of concepts
will guide you through the thousands of details
to the source of the problem and the most effective solution.
Stan: We’ve picked Mark Coughran, a senior
industry consultant in Global Industry Solutions at Emerson Process Management in Austin, Texas, and previously a research specialist
in the Research and Test Department at Fisher
Controls in Marshalltown, Iowa, to be our
guide.
Greg: For you as a troubleshooter, what are the
most common performance problems?
Mark: I am seeing integrator loop tuning and
slope of the installed characteristic is the valve
gain. The control valve is the principal source
of nonlinearity and limit cycling in control
loops. Split-ranged valves and integrating processes are particularly susceptible to valve response problems.
Greg Mcmill an
Stan weiner, pe
controltalk@putman.net
Stan: Dead band, stiction and characteristic
nonlinearity are generally greatest near the closed
position. The transition between cooling and
heating for temperature control and acid and base
reagent for pH control requires operation near
the closed position of all valves at the split-range
point. I have seen a lot of loops cycling across the
split-range point, wasting energy and reagent. So
what I am hearing is we have a double hit. What
processes have an integrating response?
Mark: Batch temperature, bioreactor process
variables (dissolved oxygen, pH and temperature), some gas pressures, level, dissolved solids
valve response problems in all of the process industries in plants all over the world.
Stan: Why are these problems so prevalent?
Mark: First, valve specifications generally do
not have entries for valve performance requirements. The tuning for integrating loops also is
different and counterintuitive. Finally, plants
are being built where there is no expertise.
Greg: What valve response parameters are
most critical for loop performance?
Mark: The key parameters are valve dead band
from backlash and shaft windup, resolution
limits from stiction, and the installed characteristic that is the result of the inherent valve
characteristic, fluid properties and the process
pressure at the valve inlet and outlet. Dead
band and resolution are lost motion, and the
CT1006_79_80_CTTALK.indd 79
79
5/21/10 3:23 PM
C O N T R O L TA L K
and impurity concentrations in processes with large recycle streams have
integrating responses. Composition,
temperature and pH loops in continuous processes with a large dominant
process time constant have a near-integrating response. To shorten tuning
tests dramatically, these extremely slow
self-regulating processes can be tuned
as integrating processes.
Greg: These are important loops in
terms of process yield and efficiency,
since analyzers provide direct measurements, and temperatures provide
inferential measurements of process
composition. How about an example
of a typical tuning mistake?
Mark: A drum level loop was cycling
with a controller gain of 1 and a reset
time of 20 seconds. The settings that
proved best ended up being a controller gain of 12 and a reset time of 2000.
Greg: This is consistent with my experience that loops with integrating processes are running with a significantly
smaller than desirable controller gain
and a reset time at least an order of
magnitude too low. I have had success
increasing the reset time by a factor of
10 as a quick fix until an auto tuner can
give results. This is a move in the more
stable direction. If the reset time is not
greater than 300 seconds, and the controller gain is not greater than three,
then the tuning settings are probably
too low. More than two significant figures is wishful thinking.
Mark: If the controller gain is too low,
you become more sensitive to reset
action. The product of the controller
gain and integral time must be greater
than four divided by the integrating
process gain ( See Equation 10 in
www.controlglobal.com/articles/2010/
LevelControl1002.html). Thus, you
can reduce slow rolling oscillations
and overshoot by increasing the controller gain. This is counterintuitive
80
because we are taught that a lower gain
and slower tuning provides a smoother
over-damped response.
Some integrating processes, such as
header pressure and jacket temperature
control, have a lead time where the initial rate of change is much faster than
the eventual rate of change of the process variable. The tuning rules for integrating processes are not well known,
and the tuning rules to deal with a lead
time are particularly rare. Most of the
tuning rules in the literature are for selfregulating processes with a first order
(single lag) plus dead time response approximation. The user doing trial-anderror tuning finds it especially difficult
for integrating processes.
Stan: In an inverse response where the
process variable first moves in the opposite direction of the final response, you
have to back off on the controller gain.
Drum level, column sump level and
furnace pressure can have an inverse
response. In modern plants, the degree
of inverse response has decreased. Preheating feed water and air by flue gases
for energy recovery has reduced the inverse response for boilers and furnaces.
For column sump level, the inverse response is only seen when steam is manipulated to control level, not a preferred
control scheme unless the bottoms flow
is too small for level control.
Mark: I have seen a lot of loops where
the filter time was too small or too large.
If the filter time is too small, noise
causes the valve to move, which selfinflicts a disturbance and wears out the
packing. If the filter time is too large,
the loop may oscillate, since integrating
process performance and tuning is particularly sensitive to the additional lag.
Stan: What do you recommend projects do for these important loops?
Mark: I recommend that users request
the supplier to provide the dead band,
resolution, response time and installed
characteristic for control valves. These
lost-motion and response parameters
should be the results of small steps
in valve signal (e.g. 0.5%) per the current test methods established by the
ISA-75.25.01-2000 (R2006). The user
should plot the integrating process
gain, which is the product of the control valve gain, process variable gain
and measurement span gain, versus
controller output. The control valve
gain is the slope of the flow versus
stroke plot of an installed characteristic curve. The process variable gain is
the slope of a plot of the ramp rate of
For Greg and Stan’s list of the
Top 10 Things You Don’t Want
to Hear in a Project Definition
Meeting, go to www.controlglobal.com/1006CT.html.
the process variable versus valve flow
provided by the process engineer for
various setpoints, and the measurement span gain is 100% divided by the
process variable span used by the controller. The resulting integrating process gain must have dimensions of %
PV per sec per % flow (units of 1/sec).
The user should use tuning rules for
integrating processes to estimate tuning settings, and decide if gain scheduling is needed for changes in the gain
with operating point. Once the loop is
commissioned, auto tuners and adaptive controllers should be used to identify the actual integrating process gain
and dead time for the expected range
of setpoints and load disturbances.
Greg: The installed characteristic and
lost motion near the seat determine the
real rangeability of the control valve as
estimated by the equations on slide 21
of Deminar #2 posted April 22, 2010 on
http://modelingandcontrol.com/. Deminar #2 and its posted review also provide a more in-depth discussion of dead
band (backlash), resolution (stiction)
and the resulting limit cycles.
CT1006_79_80_CTTALK.indd 80
5/21/10 3:23 PM
C L A SSI F IEDS
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CT1005_81_Class.indd 81
81
5/24/10 4:09 PM
F
co
CONTROL REPORT
Pictures for Polymers
If a few windows into your process application are good, then more will be better—especially if they’re easier to set up and network. You just have to be brave and persistent
Jim Montague
e xecutive Editor
jmontague@putman.net
Once our engineers
saw the graphics
we were making
and began to use
them, we got a lot
better buy-in from
everyone..
82
enough to build displays that focus on the values you truly need. Luckily, a few good
tools can help.
For example, Arkema Inc.’s refrigerant, polymer and hydrochloric acid
plant in Calvert City, Ky., had used Bailey Network90 controls in its Kynar polymer facility
since 1988 and has expanded and upgraded
them several times since then, including moving from panel boards to a distributed control
system (DCS). The facility now has eight process control units (PCUs) and 51 controllers,
and its latest upgrade involved going to ABB’s
800xA for its Harmony DCS in 2008.
The plant makes several grades of Kynar
polymers and a monomer, and these highgrade plastics are used to give elasticity to
paints and impart rust-proofing and sun-resistance capabilities to other coatings, according
to Michael Smith, Arkema’s senior staff plant
instrument engineer. Smith presented “Recent
800xA Applications at Arkema Calvert City” on
May 20 at ABB Automation and Power World
2010 at the George R. Brown Convention Center in Houston.
“In my Kynar area, we needed added windows into our units, but the previous system
only allowed eight windows per server, and this
wasn’t enough for what we needed to do,” says
Smith. “We needed 800xA because it wouldn’t
be limited in the client-server part of the HMI.
So we began to move on this project in 2008,
and this set the stage for adding ABB’s AC800M
controllers to our network as well.”
Smith adds that Arkema’s latest polymer application upgrade consisted of two main components—updating the de-ionized (DI) water
system for making polymers and a $16-million
renovation of its sprayer-dryer system for turning the product into powder before shipping.
“Though we had a bottleneck on our Kynar
process, we were a little overwhelmed to try
to upgrade the whole sprayer-dryer system at
once. So while we were in a six-month construction period, we did pre-engineering and
graphics for the DI system before taking on the
larger project,” explains Smith. “On the DI water system, we replaced old PLCs, learned and
implemented AC800M controllers and S800
IO, used the PC device library, tied into the
800xA system and created the graphics.”
Likewise, to network its new 800xA system
and controls, Smith reports he and his staff decided to use Profibus and Ethernet. “We used
Profibus for networking because it can talk to
our MCCs, so we didn’t need other networking
protocols, and we can see all our tabs and parameters on one screen,” he says.
Also, he added, the AC800M controllers
and S800 I/O slid easily into the existing panels in the field near their DI water units. “The
DI water application is fairly simple, but its regeneration phase can get a little complicated,”
says Smith. “However, once our engineers saw
the graphics we were making and began to use
them, we got a lot better buy-in from everyone.
“Engineers often feel pretty iffy about doing these kinds of graphics, but 800xA helped
with a lot of pre-steps, such as color pallettes,
and made it easy to add symbols and devices
later on. In fact, it only takes about half a day
to make a pretty complex screen, but then you
can just copy it over for other process units.”
Similarly, because its other two spray dryers
were on the Harmony DCS, Arkema needed
the same look and feel for the third one using the AC800M controller and S800 remote.
“We needed to connect to the downstream process interlocks in our material-handling system
and to avoid cramming powder into our downstream system. So we set up a Harmony PCU
Gateway (HPG) connection to the AC800M to
interlock those downstream signals.”
As a result, Smith says Arkema was able to add
its third spray dryer without needing any more
operators and also saved $500,000 on its $16-million budget for the project. Nice view.
CT1006_82_CR.indd 82
5/24/10 10:15 AM
“Even with all of my experience in
the industry, AutomationXchange
provided opportunities for me to find
solutions to advance my machines
that I was not aware of before.”
Dr. Thomas Pool
Manager of Electrical Engineering
KLIKLOK-WOODMAN
SM
SM
Solution Provider Profile
Maverick Technologies is a next-generation engineering,
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For more information on attending AutomationXchange,
contact Andy Wuebben, Executive Director, at 952.224.7640
CT-CD_AUTO_AD2.indd
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Shouldn’t you know your safety
loops from the inside out?
With a smart safety instrumented system you can. DeltaV SIS. Smart.
DeltaV SIS is the only logic solver to digitally diagnose and automatically proof test components of your entire safety loop.
No more second guessing–the health of each element in the safety loop is continuously monitored. This valuable
information is easily accessed by operators without data-mapping and multiple databases. DeltaV SIS shuts down your
plant when needed for safety, but keeps you running safely when components fail–reducing spurious trips.
DeltaV SIS is the first to use predictive intelligence and device diagnostics to enable safer facilities, improve availability,
lower life-cycle costs, and ease regulatory compliance. For more insight, visit: www.DeltaVSIS.com
The Emerson logo is a trademark and a service mark of Emerson Electric Co. ©2010 Emerson Electric Company
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It`s Not Easy Being Clean

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