Through The: Looking Glass
Through The: Looking Glass
Through The: Looking Glass
LOOKING
GLASS
A pragmatist's view
of how emerging
technologies
will revolutionize
tomorrow's controls.
MARCH 2015
ASSET MANAGEMENT
MOVES BEYOND CMMS
CT1503_01_cvr.indd 1
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f e at u r e s
30 / control Systems
of the Future
Through the looking glass of emerging
technologies. by William L. Mostia
W E B
E X C L U S I V E S
a t
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 ), 1501 E. woodfield Rd., Ste. 400N, Schaumburg, IL 60173. (Phone 630/467-1300; Fax 630/467-1124.) Address all correspondence to Editorial and Executive Offices,
same address. Periodicals Postage Paid at Schaumburg, IL, and at additional mailing offices. Printed in the United States. Putman Media 2015. All rights reserved. The contents of this publication may not be reproduced in whole or part
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Frontier/BwI,PO Box 1051,Fort Erie,Ontario, Canada, L2A 5N8.
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CT1503_05_07_TOC.indd 5
3/3/15 9:47 AM
3/3/15 10:13 AM
D E PA RT M E N T S
9 / Editors Page
Cozy up to DHS
Homeland Security wants to help prevent,
respond to and recover from cyber attacks.
On-site
On-line
Hands-on
or in the
Classroom
28 / resources
49 / Technically Speaking
11 / control Online
13 / Feedback
Our readers speak out on Big Data, Internet protocols and NERC CIP.
You choose.
52 / roundup
14 / Lessons Learned
50 Years of Progress
Bla Liptk looks back at how far weve
come and how far we have to go.
54 / Products
19 / On the Bus
55 / control Talk
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22 / In Process
Editor Education
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EDITORS PAGE
cozy Up to dhS
s we go to press, the U.S. Congress is threatening to suspend funding for the Department of Homeland Security (DHS). Some
members are even calling for its dissolution.
But assuming its still around when you read
this, you might consider enlisting DHS in your
efforts to improve cybersecurity.
Many of you folks think cybersecurity is all
about technology, said Gregory Touhill, retired brigadier general and now deputy assistant secretary of cybersecurity operations and
programs at DHS, speaking to attendees of the
recent ARC Forum. Im here to tell you cybersecurity is not a technology issue; its a riskmanagement issue.
Start by recognizing the full value of your assets. Do you know how much your information is worth? Touhill asked. Businesses too
often fail to account for intellectual property
when determining the value of at-risk assets.
Recognize that cybersecurity is a 24/7 responsibility, and that no single piece of software or other technology offers fail-safe proection against cyber threats. Threats will hunt
you down at home to get access to your work,
Touhill said. Theyll hack your home network
to get a vector.
Its not just nation-state bad actors or individuals who are looking to sell stolen protected information. Hacktivistsfolks who dont necessarily agree with your companys mission or
core values, may look to damage a company,
Touhill said. Then there are those in your own
organization who are simply stupid, he said.
Many industrial control systems were not
designed for security. Companies are adding
potentially vulnerable capabilities like remote
access, wireless and mobile, with no dedicated
on-site cybersecurity expertise. They may need
help fitting these into a security strategy.
With that in mind, on Feb. 12, DHS announced a new Critical Infrastructure Cyber Community C Voluntary Program. Pronounced c-cubed, C is a public-private
Paul Studebaker
Editor in chiEf
pstudebaker@putman.net
Businesses too
often fail to account
for intellectual
property when
determining the
value of at-risk
assets.
M a r c h / 2 0 1 5 www.controlglobal.com
CT1503_09_Editorial.indd 9
3/3/15 9:46 AM
3/3/15 10:13 AM
CONTROL ONLINE
SHORTER
SHOP-FLOOR TO
TOP-FLOOR TRIPS
CUT ENERGY
CONSUMPTION
LOW-INFO
VOTERS IN
YOUR SIS
INTELLIGENCE
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End Users Come Together to
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CT1503_11_web.indd 11
11
3/3/15 9:48 AM
Magnetrol works.
So this works.
So this works.
The chemicals you provide are critical to consumers lives. Level and flow control is
critical to efficiently and safely processing those chemicals. For control solutions that
work, trust Magnetrol. We have been providing level and flow instrumentation to
the chemical industry for decades. And we offer the most advanced measurement and
control technology available today.
You can rely on MAGNETROL to keep your process
running efficiently and safely. So your customers
can rely on you.
3/3/15 10:14 AM
Emer
G N I K A E P S YL L A C I N H C E T
FEEDBACK
editorial team
Editor in Chief: PAUL STUDEBAKER
pstudebaker@putman.net
Executive Editor: JIM MONTAGUE
jmontague@putman.net
Senior Managing Editor, Digital Media: KATHERINE BONFANTE
kbonfante@putman.net
Managing Editor: NANCY BARTELS
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Contributing Editor: JOHN REZABEK
Columnists: BLA LIPTK, GREG MCMILLAN,
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INTELLIGENCE
IN NUMBERS
End Users Come Together to
Pick Winners of 23rd Annual
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GREGORY BRYANT
carl.henning@profinet.com
M A R C H / 2 0 1 5 www.controlglobal.com
CT1503_13_Feedback.indd 13
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3/3/15 10:09 AM
LESSONS LEARNED
liptakbela@aol.com
hen I started to work as a process control engineer in the late 1950s, the toilet
float and the thermostat were considered
to be automation. At that time, the main job
of the instrument department in a plant was to
clean plugged pressure taps and stuck control
valves, while our control panels were full of
pushbuttons, blinking lights and manual loading stations.
My Past
I taught process
control in the
chemical
engineering
department at Yale,
not because Yale
didnt like
automation, but
because the faculty
didnt know
what it was.
14
www.controlglobal.com M A R C H / 2 0 1 5
CT1503_14_16_Lessons.indd 14
3/3/15 10:11 AM
Tank overfill.
In the best case, you have to clean up.
In the worst case, you end up in court.
Want to sleep well at night?
The Emerson logo is a trademark and a service mark of Emerson Electric Co. 2012 Emerson Electric Co.
Emerson_RTG_API2350_Choice_awards_ControlM_7x10_2015.indd 1
3/3/15 10:14 AM
2015-02-19 09:49
Lessons Learned
the design phase of the plant that is the key to safety, not dependence on the action of panicked operators. The choice
is not between depending on humans or machines. The
choice is between trusting the judgment of two kinds of peoplethe operator or the HAZOP team.
For absolute safety, what is needed is override safety control (OSC), which cant be turned off or overruled by anything or anybody. When the plant conditions enter a highly
accident-prone, life-safety region, the uninterruptible, safe
shutdown of the plant must be automatically triggered.
The functioning of OSC must be so designed that it cant
be stopped by cyber attacks because it is not connected to
the Internet at all. It cant be overruled by the operators and
cant be modified or turned off by them. In short, once the
OCS is activated, the plant must be shutting down under
the preplanned, totally automatic HAZOP control, and
nothing and nobody can prevent that.
www.controlglobal.com M a r c h / 2 0 1 5
CT1503_14_16_Lessons.indd 16
3/3/15 10:11 AM
To enter, go to
alliedelec.com/
HowDoYouTest
1.800.433.5700
Allied Electronics, Inc. 2015. Allied Electronics and the Allied Electronics logo are trademarks of Allied Electronics, Inc. An Electrocomponents Company.
* Test & Measurement products from Rigol, Fluke, Keysight, FLIR, or Extech. Products may vary.
3/3/15 10:14 AM
Beyond Control.
The NEW Research Control SRD positioner does
everything you expect any valve positioner to do,
plus more. The SRDs comprehensive diagnostics tool
continuously monitors for fugitive emissions, delivers
real-time performance statistics, and facilitates both
proactive and reactive process management. Available
with integrated network communications, the SRD is
compatible with Research Control valves and most other
pneumatically-actuated valves.
Visit www.badgermeter.com/Smart-Valve-Positioners or
call 877-243-1010 for more information today.
3/3/15 10:15 AM
ON THE BUS
hy is it, after weeks of seemingly troublefree plant operation, the phone rings on
the holiday weekend when the goose is
in the oven and the table is set for dinner? Fortunately for me, the crew on shift was prepared
to muddle through until normal business hours
after the weekend. They just wanted to know
whether the problem they were seeing was
likely to cause a spurious trip of some production-critical pumps. Dinner was saved thanks
to the fact that we had proven years ago that a
bad indication from a suction pressure transmitter would hold last value, and the associated interlock wouldnt trip. While a persistent
bad indication would defeat a necessary protection that prevented significant mechanical
damage, the disruptions were fleeting enough
to remain a mere annoyance.
When the issue was investigated on the next
normal business day, it was immediately apparent that the segment was failing due to waterlogged and corroded terminals in an intermediate terminal box. The little enclosure was
designed to be weather-tight, but weve all seen
how simple it can be to defeat a systems accommodations for preventing moisture entry.
When a limit switch cover is removed to
make an adjustment, a frail-looking O-ring
flops out. Its easily misaligned or omitted when
the cover is reassembled. How many covers
have you found loose, missing gaskets or simply open to the environment? Just condensation of moist air from the warmer seasons can
be enough to begin corruption of circuit boards
and terminations. In all but the most arid climates, anyone who has spent any time servicing instruments knows the experience of removing the cover of a troubled instrument and
having a cup of water drain out.
The most experienced troubleshooters,
such as Emerson Process Management Distinguished Technologist Marcos Peluso, agree
that defects and oversights in the physical
layertwisted-pair copper, power supplies, ter-
minals, conduit systems and enclosuresaccount for over 90% of the problems encountered in field device networks, even 4-20 mA.
Pelusos colleagues have devised a solution,
at least for 4-20 mA loops that connect to the
top-end 3051 HART pressure transmitter:
Power Advisory diagnostics for advanced loop
integrity. The diagnostic is communicated to
any HART-capable asset management software
and alerts the end user to impending issues
with moisture, cable integrity, terminal corrosion and power supplies. Since these physical
layer disorders usually take some time before
they affect the signal, a weekly report should allow the end user to detect and avert a problem.
But what about the rest of the devices?
Profibus PA and Foundation fieldbus have
had a repertoire of physical layer diagnostics
for nearly a decade, ranging from simple handheld devices such as the Relcom FBT-6 to thefeature-laden Pepperl+Fuchs field diagnostics
handheld and advanced diagnostics module
(ADM). All these tools can alert the user to defects in the physical layer. The Pepperl+Fuchs
units use an embedded expert system to suggest likely causes for the detected symptoms
and recommend remedial actions. But while
they can identify an ailing network, you might
still have challenges determining the precise
location of the defect.
Couplers providing simple short-circuit protection for each fieldbus spur substantially improved the fault tolerance of fieldbus segments.
But Pepperl+Fuchs has designed a new generation of intelligent couplers that can detect and
mitigate degradation or progressive failures owing to water ingress, sloppy terminations, high
vibration, corrosion, cable abuse and device
faults on each individual spur.
If such couplers can perform as promised,
measurement and control professionals using
them can count on more peaceful holidays in
the future. Perhaps the goose of physical layer
defects is finally cooked.
contributing Editor
Jrezabek@ashland.com
Anyone who
has spent any
time servicing
instruments knows
the experience of
removing a cover
and having a cup of
water drain out.
M a R c h / 2 0 1 5 www.controlglobal.com
CT1503_19_OTB.indd 19
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3/3/15 10:21 AM
Without Wires
Director,
inDustrial automation ne t works
iverhappen@industrialautomationnetworks.com
sired functions in the device are disabled. Configuration congruency processes assure that
the multiple databases where intelligent device
configuration data are stored all have the same
data, and that configuration changes propagate
accurately and in adequate time.
Part 2.2: Diagnostics Utilization specifies
multiple work processes related to diagnostics
done by intelligent devices, including establishing an IDM program, training, maintenance of
intelligent devices, scheduling of maintenance,
audit and continuous improvement.
Part 2.3: Procedure Management specifies
multiple work processes not covered in other
parts, including inspection and function testing of intelligent devices to assure that correct
and appropriate manual and automated procedures are used for support of intelligent devices.
Part 2.4: Calibration Management addresses the program activities and work processes for managing calibration procedures,
including inferential (analytical) and physical measurements, such as cover calibration
checks, statistical analysis of calibration checks,
decisions about calibration versus replacement,
and actual calibration requirements.
The last of the Part 2 documents is Part 2.5:
Intelligent Valve Management, covering activities and work processes, including on-line
diagnostics and repair, as well as off-line turnaround, diagnostics and repair processes, including in-line procedures and shop repair related to final control elements.
Part 3: Implementation Guide(s) provides
guidance on implementation of intelligent device management and will be developed upon
completion of the Part 2 documents.
Working groups have been identified for
each of the Part 2 documents, and the first document has been submitted to the IEC as a new
work item under SC65E. For more information
or to participate, contact Charley Robinson
(crobinson@isa.org) at ISA or your countrys
national standards body.
www.controlglobal.com M a r c h / 2 0 1 5
CT1503_20_Wireless.indd 20
3/3/15 10:22 AM
TPC-651T
TPC-1251T
TPC-1551T
TPC-1751T
COMING SOON
www.advantech.com
3/3/15 10:15 AM
In Process
22
Likewise, energy grids will need to become more intelligent, so they can balance and deploy available power, gas
and heat from many sources.
Koeckler adds the answer to these
challenges is Integrated Industry,
which is the smart, digital networking and integration of manufacturing systems and processes. Integrated
Industry is about allowing machines
and workpieces to communicate with
each another, which will allow entire
production lines to autonomously and
dynamically reconfigure themselves,
and make small-batch and one-off
production commercially viable in
large plants.
Manufacturing in Europe, North
America and Asia will all depend on
Industry 4.0, but most companies still
dont know what they need to do to
be ready for it, adds Koeckler. What
they need to do is form close networks
with all stakeholders involved in their
showcase of solutions
As usual, the heart of Hannover Fair
will be its thousands of exhibits and
their solutions to help make manufacturers more efficient. Here are some
highlights of the technologies and
products that will be exhibited:
ABB (www.abb.com) will demonstrate its new range of swirl and vortex
flowmeters that can measure volume
mass energy and flow in one device.
The SwirlMaster comes in standard
(FSS430) or extended (FSS450) versions with ABBs swirl technology that
enables very short upstream and down-
www.controlglobal.com M a r c h / 2 0 1 5
CT1503_22_26_InPro.indd 22
3/3/15 10:22 AM
Moore
M
oore IIndustries:
ndustries: L
Layers
a y er s o
off P
Protection
rotection T
That
hat C
Cant
ant b
be
eC
Cracked
ra c ke d
Protect your valuable processes by turning to Moore
Industries dependable line of FS Functional Safety
Series instrumentation. You can condently install our
FS Functional Safety products and know they will do their
jobs every time. Built to last in rugged environments, our
instrumentation will:
3/4/15 9:04 AM
IN PROCESS
Cybersecurity Needs
to Be a Team Sport
www.cashco com
www
Innovative Solutions
Cashco, Inc. P.O. Box 6, Ellsworth, KS 67439-0006 Ph. (785) 472-4461, Fax: (785) 472-3539
24CAS-226A.indd
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M A RC H / 2 015
1/12/15 11:08 AM
3/3/15 10:23 AM
In Process
posed by the theft of intellectual property or the exposure of client or personnel information can destroy a business.
Currently in the commercial sector, the average length of time between
when a security breach occurs and
when the affected business detects that
breach is more than 240 days, Touhill
said. Thats unacceptable. Id like
to know [as a business owner] when
theyre coming through the gate, not
when theyre going out the gate.
Getting all employees to understand
that cybersecurity is a 24/7 responsibility and that no single piece of software
or other technology is a fail-safe protection against cyber threats is essential,
according to Touhill.
Are you training your workforce to
take the same cybersecurity precautions
at home as they do at work? Touhill
Sharing passion.
Cooperating as partners.
Finding solutions.
You are the expert in your field and
Pepperl+Fuchs will treat you as one.
Working as partners, we share our
knowledge and experience with you.
The result is an innovative solution that
moves you toward the future.
www.pepperl-fuchs.com
M a r c h / 2 0 1 5 www.controlglobal.com
CT1503_22_26_InPro.indd 25
25
3/3/15 10:23 AM
IN PROCESS
GET
CONNECTED!
MACTeks family of
HART modems...
USB
RS232
Bluetooth
WWW.MACTEKCORP.COM
OR CALL 609-801-0039
HART and WirelessHART are registered trademarks of
the HART Communication Foundation.
2014 MACTek Corporation All Rights Reserved
CT1503_22_26_InPro.indd 26
times does your company practice [dealing with] a major disaster with your IT
infrastructure?
The time to generate a response
plan to a hack is not the morning of an
attack, Touhill noted.
Nanoline Contest
Winners Announced
A team from Benton Central Jr./Sr. High
School in Oxford, Indiana, has won Phoenix Contacts (www.phoenixcontact.com)
2015 Nanoline Contest. The grand prize
is a trip to Louisville, Kentucky, in April.
Team members include Blake Stawsma,
Justin Shultz, Wil Barce, Kyle Laramore,
Bryce Nehrig and Nate Post. The team
designed and built the Fully Automated
Nanoline T-Shirt Cannon, which runs
on Phoenix Contacts Nanoline Controller and uses the intuitive, flowchart-based
nanoNavigator software to control the application. The group will travel to Louisville in April, where they will observe the
final rounds of the VEX Robotics World
Championship.
www.controlglobal.com M A R C H / 2 0 1 5
3/3/15 10:23 AM
3/3/15 1:23 PM
RESOURCES
In the Loop
Controls Monthly Resource Guide
THIS SYSTEM IS CLOSED
This is a basic tutorial on closed-loop
control systems. It covers the basic definitions and descriptions of how closedloop systems work, a discussion of
closed-loop summing points and how
to use them, transfer functions, multiloop closed-loop systems and closedloop motor control. The direct link is
www.electronics-tutorials.ws/systems/
closed-loop-system.html.
ELEctronIcs tutorIaLs
www.electronics-tutorials.ws
CASCADING CONTROL
A brief blog post by Jacques Smuts, author of Process Control for Practitioners
(http://amzn.to/16sFjEM), covers cascade control basics: what it is, how to
manage it, its advantages and disadvantages, when you should use it, and
when you shouldnt. The direct link
is at http://blog.opticontrols.com/archives/105.
optIcontroLs
www.opticontrols.com
A SEVEN-STEP PROGRAM
The performance of industrial control
loops directly affects company profitability and operability in several ways.
It affects the stability, robustness and
safety of the process. In addition, it
plays a role in the cost, efficiency and
maximum rate of production, and influences the quality of the product.
TUNE-UP TIME
This free guide offers a best-practices
approach to PID controller tuning. It
shares a simplified and repeatable procedure for analyzing the dynamics of
a process and for determining appropriate model and tuning parameters.
Included are basic terminology, steps
for analyzing process dynamics, methods for determining model parameters,
and other valuable insights. The direct
link is at www.yokogawa.com/us/technical-library/white-papers/pid-tuningin-distributed-control-systems.htm.
Yokogawa corporation of america
www.yokogawa.com
If you know of any tools and resources we didnt include, send them to ControlMagazine@Putman.net with
Resource in the subject line, and well add them to the website.
28
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CT1503_28_Resources.indd 28
3/3/15 10:31 AM
Temperature, Process
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User-Friendly, Simple to Configure
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Visit
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Humidity + Temperature
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CN243 Series
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Sensor included!
Visit omega.com/ith
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COPYRIGHT
INCALL
ALLRIGHTS
RIGHTSRESERVED
RESERVED
COPYRIGHT 2015
2011 OMEGA
OMEGA ENGINEERING,
ENGINEERING, INC.
Visit omega.com/cn63300
omega.com
Prices listed are those in effect at the time of publication and are subject to change without notice. Please contact OMEGAs sales department for current prices.
3/3/15 10:19 AM
CONTROL SYSTEMS
OF THE FUTURE
CT1503_30_38_CoverStory.indd 30
3/3/15 10:51 AM
CT1503_30_38_CoverStory.indd 31
31
3/3/15 10:51 AM
Public Cloud
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Condition Orange!
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Local Cloud
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visibly. better.
www.hwll.co/controlroom
2015 Honeywell International, Inc. All rights reserved.
3/3/15 10:19 AM
On the other hand, one of the corollaries to Parkinsons Law is, Data
expands to fill the space available for
storage. Sensors are becoming more
pervasive and cheaper as well smarter,
offering more data. Digital bus communication will become the norm even
within legacy systems. Wireless is ex-
425.745.3229
www.maplesystems.com
CT1503_30_38_CoverStory.indd 34
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Monitor Mounts
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Download our free WELS 3D software that lets you design, visualize and cost
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M a r c h / 2 0 1 5 www.controlglobal.com
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and/or cloud, and extract useful information for plant operators, engineers, supervisors and managers, as well as people
at the enterprise level. Data analytics also will be used to analyze video for security and safety in collaborative operations
and in support of artificial intelligence (AI) applications and
operator online and personal advisors.
Data analytics are already availableone example is
Honeywells Maxpro VMS for safety and security (Figure
2)but wider use is expected when the flood of data begins to overwhelm the existing systems. Once the data analytics have massaged, manipulated and crunched the data,
and analyzed, collated and organized the information, they
must present it to the operator or other plant personnel using
graphics and visualization tools. Processing speed will be of
the essence where real-time information is required.
Ai Beyond Siri
Weve become familiar with AI in the form of smart, virtual personal assistants (SVPAs), which entered the market
in 2011. Examples include Apples Siri and Microsofts Cortanasoftware agents that can perform tasks or services for
an individual. In process control, operator SVPAs will be
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For meters, controllers, computers
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bl
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ow
M
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CT1503_30_38_CoverStory.indd 37
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tial to provide operators with a continuously available headsup display of important data and additional information.
Microsoft recently announced its answer to Google Glass,
called HoloLens, which will be bundled with Windows 10
for release to developers this year (sidebar, page 35). This device has the potential to revolutionize the operator interface
by providing data visualization and a collaborative operating
environment for operators, engineers and corporate experts,
as well as trusted third parties and vendors.
ACKNOWLEDGEMENTS
Valuable insights were conttributed for this article by:
Bernie Anger, general manager, GE Intelligent Platforms
Jonathan Crane, chief commercial officer, IPsoft
Dave Cronberger, customer solutions architect, Cisco
Adrian Fielding, Andrew Stuart, Paul Hodge and Paul
McLaughlin, Honeywell Process Systems
Brent Leimer, market manager, Winsted Control Room
Consoles
Pierre Skonnegard, control room designer, CGM
Susanne Timsjo, manager, software architecture and
user experience, ABB
Bob Voss, director, applications research, Panduit
technologiesaugmented and virtual reality, artificial intelligence, cloud and fog computing, and data and predictive
analyticsare poised to change the industry.
William L. Mostia, PE, fellow, SIS-TECH Solutions,
is a frequent contributor to Control.
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3/3/15 10:53 AM
Asset MAnAgeMent
by Jim Montague
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Asset MAnAgeMent
40
streamlined by software
While asset management is historically
costly, time-consuming and labor-intensive, improvements in software and
hardware are making it more approachable for a wider circle of users applying
it to more varied projects that go beyond maintenance to each new level of
optimization and sustainability.
For example, Mohawk Fine Papers
(www.mohawkconnects.com) in Cohoes, New York, recently saw its energy
costs balloon by 30% over a few years,
and redoubled its efforts to reduce its
energy consumption with better asset
management. Energy makes up 60% of
Mohawks operating and maintenance
costs, and our motor and pump assets
consume 75% of that energy, says Paul
Stamas, Mohawks vice president of IT.
So management needed visibility into
data on the factory floor for better decision making, and we needed an EAM
system that integrated energy into our
asset management strategy.
As a result, Mohawk selected InforEAM condition-monitoring software
from Infor (www.infor.com), which has
a web-based architecture, integrates
seamlessly with the companys enterprise resource planning (ERP) system,
and works with its Microsoft SQL Server
2005 database software. Stamas reports
that InforEAM allowed Mohawk to
improve preventive maintenance with
more proactive inspections, calibrations
and repairs, and even worked with SQL
Server to add video files to its work instructions. Because better maintenance
www.controlglobal.com M a r c h / 2 0 1 5
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CMA Actuators
Linear
Rotary
Quarter-turn
www.rotork.com
CVA Actuators
Quarter-turn
Linear
3/3/15 10:20 AM
Asset MAnAgeMent
explains Stamas.
Mohawk also integrated its asset sustainability system with thousands of its
plant-floor sensors to collect more realtime energy data. This data helps us
identify assets that are degrading in
performance and consume excess energy, which triggers alerts and allows
In-chassis
PROFIBUS
at the cost of
A GATEWAY
Master
Slave
A S I A PAC I F I C | A F R I C A | E U R O P E | M I D D L E E A S T | L AT I N A M E R I C A | N O R T H A M E R I C A
CT1503_39_44_Feature2.indd 42
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Simpler Setups
Besides aiding routine operations, some asset management
software can even help out during setup and configuration.
ASSET MANAGEMENT
From plug-and-play Ethernet switches to HMIs and visual management systems with built-in protocol
conversion, our industrial automation and networking solutions will enable you to connect, monitor and
control virtually anything, anywhere at any time. Visit www.redlion.net/connect and discover how to ignite
productivity across your existing manufacturing environments.
M A R C H / 2 0 1 5 www.controlglobal.com
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ASSET MANAGEMENT
lution for Shells Prelude floating natural gas (FLNG) production vessel project, which will operate off the coast of
Australia. With more than 5,000 Foundation fieldbus devices at the Prelude site, many with more than 100 configurable parameters, Shell was concerned about the time it
would take to complete commissioning tasks. Configuring
the devices one at a time is error-prone and laboriousconfiguring one device can take up to an hour, and then configuration for each must be verified.
Consequently, Shell adopted Emersons Asset Management Software (AMS) Suite: Intelligent Device Manager
v. 12.5, which can commission Foundation fieldbus devices
faster. Users can bring devices online with features, options
and alerts they select in a fraction of the time normally required. Emerson expects AMS Suite to reduce commissioning time on smart devices by almost 80%, and allow users to
make online changes to many devices simultaneously. Also,
the softwares Device Manager User Configurations tool lets
users standardize asset configuration and eliminate configuration errors. Users can apply configuration templates to
device placeholders or live devices, so they can be commis-
3 - in - 1
MEASUREMENT
Level Plus
Product Level
Interface Level
Temperature
44
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C A L I B R AT I O N
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Implementing
a calibration
system?
c a l i b r at i o n
N2 blanket
(10 in. wc)
FI
L
H
nitrogen
LT
100% = 23 ft
SG = 1
CT1503_45_48_Feature3_1.indd 46
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c a l i b r at i o n
ACCUTUBES
Thousands
of Effective
Installations
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Diaphragm Seals
Vegas adds that the three main types of dP seal assemblies
pad type, pad type with single capillary and dual capillary
sealcan all cause problems. Pads and seals directly measure pressure, but the diaphragms in them are easily damaged if installed incorrectly. The fill fluid inside the capillaries that transfer process pressure to transmitters can leak
and cause quality problems in the process. These fluids can
become viscous and have slow response due to low ambient
or process temperature and pressure, or boil in high vacuums and high temperatures and ruin the seals.
Seals are fragile and expensive, so you want to be sure
the gaskets are in place before theyre bolted down, and you
always need to be aware of ambient temperature, explains
Espy. Its also important to address up-front how testing and
calibration will be performed to avoid big headaches. Flush
rings are useful for venting and applying calibration pressure, and this means the seal doesnt have to be unbolted to
perform a calibration.
Espy adds that dP seal calibration steps include:
Isolate both seals from process using flush rings;
www.meriam.com
1+ 216.281.1100 | sales@meriam.com
M a r c h / 2 0 1 5 www.controlglobal.com
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c a l i b r at i o n
BetaGauge 330
Pressure Calibrator
with Internal
electric pump
Finally a calibrator that
can handle pressure,
mA, and temperature
with a press of a button.
Calibration calculations:
0% setting = high low pressure @ 0% level = -33.23 in. wc
100% setting = high low pressure @ 100% level = -4.90 in. wc
Steam
36 in.
Steam trace
Conditions:
45 psig, SG = 0.923
LT
Steam drum
Conditions:
600 psig, SG = 0.787
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T E C H N I C A L LY S P E A K I N G
DAN Hebert
Transforming level
measurements into
wireless signals is
only one part of the
equation.
M A r c H / 2 0 1 5 www.controlglobal.com
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m1
(Gv)
tripkovicn@yahoo.com
(Gp) CW
Process
gain
GP = F
GPM
C
GP = 3
m /s
Set pt.
(r)
TIC
(Gc)
TT
(Gs)
e
+
c
Sensor
gain
% %
100%
Gs =
=
span F C
The selection goal is control loop stability. This we obtain by making the loop response to load changes as linear as possible
(keeping the loop gain more or less constant).
The gain of any device is the ratio of its output
divided by its input. The loop gain (LG) is the
product of the gains of the loop components:
the process (Gp), sensor (Gs), controller (Gc)
and valve (Gv). Tuning the loop means that if
our goal is quarter-amplitude damping, we adjust the controller gain (Figure 1), so that the
loop gain (LG) will be about 0.5.
Process
fluid (u)
Controller
gain
Gc = %m
%e
Dimensionless
m
+
NeNad Tripkovich
Load
(u)
Valve gain
3
Gv = GPM m /s
% %
Set
point (r)
% GPM F %
=
% % GPM F
= Dimensionless
CONSTANT GAIN
Figure 1: If the process is non-linear (Gp varies with
load), the gain product of the loop (LG) should be
held more or less constant by compensating for
the variation in Gp by using a non-linear valve with
inverse Gv non-linearity.
characteristic (Gv = 1/Gp) so the installed characteristics of the total process will be more or
less linear (TGP = 0.5 to 2.0). Naturally, Gv can
never be the exact inverse of Gp, but as long as
the selected valve characteristic keeps the TPG
within 0.5 and 2.0, instability and limit cycling
can usually be avoided by good controller tuning (assuming TGP = 1.0 when adjusting Gc).
belaliptakpe.com),
automation and safety
consultant, who is
also the editor of
the Instrument and
Automation Engineers
Handbook (IAEH). If you
have automation-related
questions send them to
liptakbela@aol.com.
50
www.controlglobal.com M a r c h / 2 0 1 5
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Liptakbela@aol.com
In order to make the control as stable as possible, you want the loop
response to be as linear as possible.
If you put the loop in manual and move
the output 10%, you want to see the same
10% change in the measurement regardless of whether you moved the output
from 10% to 20% or from 70% to 80%. If
the response is nonlinear, it is difficult to
tune the loop because a gain that works
great at low valve opening will not work
as well as the valve opens further.
Lets say youre controlling flow with a
valve on a long pipe fed by a centrifugal
pump. When the valve first cracks open,
the flow is very low, the pump discharge
pressure is high, and the line loss is very
small. In this case, the control valve is
taking nearly all of the pressure drop,
and a small change in valve position will
result in a big flow change.
Now consider the same when the
valve is 80% open. In this case, the
flow is high, the pump discharge pressure will have fallen, and the line loss
will be much larger. Now the pressure
drop across the valve is much lower, and
a small change in valve position will not
change the flow very much at all.
In this case, an equal percentage
valve is the appropriate choice because
the characteristic of the valve offsets the
effect of the piping. When the valve first
opens, a 5% change will not move the
valve much. However when the valve is
more than 50% open, a 5% change will
move the valve a great deal more. This
inverts the effect of the piping and creates a more linear response for the loop.
Now consider a case where you are
controlling flow, but the pipe is short
and the pump has a fairly flat flow
curve. The valve is now taking the full
line drop regardless of its position. In
this scenario, a linear valve trim would
be a better choice because a 5% valve
position change will affect the flow consistently regardless if the valve is barely
Linear or =% valves have very practical applications, not just theoretical ones. The exact conditions can
be found in many references, for example, Emersons Control Valve Handbook.
(www.documentation.emersonprocess.
com/groups/public/documents/book/
cvh99.pdf).
I came across an application on startup where the =% valve gave poor control because the piping pressure drop
was low. I had to do an inverse characterization in the DCS (which amounted
to gain scheduling). In other words, the
process piping was larger than it needed
to be.
Two classic examples of linear valve
applications are a bypass valve around a
heat exchanger for temperature control
and a trim valve in parallel with a larger
main valve.
Simon Lucchini
Simon.Lucchini@Fluor.com
M a r c h / 2 0 1 5 www.controlglobal.com
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ROUNDUP
52
Deltabar FMD71 level transmitter uses two pressure sensor moduleshydrostatic and
head pressureconnected
electronically to one transmitter. Using a Ceraphire ceramic sensor, the transmitter
calculates differential pressure (DP) from both sensors, and transmits level, volume
or mass via 4-20 mA with HART, eliminating DP measurement problems caused by impulse lines or capillaries.
Endress+Hauser
888-ENDRESS (363-7377); www.us.endress.com
ProSense level sensors include two styles of SLT submersible level transmitters,
which measure liquid levels
by sensing hydrostatic pressure and providing a 4-20 mA
signal. SLT1 has a 1-in. diameter housing and a 0-5 psig to
0-50 psig sensing range. SLT2 has a 2.75-in. diameter PTFE
diaphragm surrounded by a stainless steel, non-fouling cage,
and 0-5-psig to 0-30-psig sensing range.
Automation Direct
800-633-0405; www.automationdirect.com
www.controlglobal.com M a r c h / 2 0 1 5
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ROUNDUP
HIGH-ACCURACY WET/WET DP
PX509HL Series DP transducers are shock- and vibration-rated and provide long
life in containment pressures
up to 10,000 psi. Features include welded, stainless-steel
construction and user-accessible potentiometers for zero
and span, a micro-machined silicon sensor at the core to
provide stable readings with high accuracy of 0.08%, and a
broad compensated range of -20-85 C on most ranges.
Omega Engineering Inc.
888-TC-OMEGA (826-6342); www.omega.com
Sitrans P500 pressure transmitters are designed for custody transfer and compressor applications They are
available in several ranges
to cover all applications and
have a SIL2/SIL 3 safety rating. Their 88-ms speed of
response, 0.14% total performance and five-year 0.05% stability make them suitable for compressor anti-surge and
throughput applications.
Siemens
800-365-8766; www.usa.siemens.com/pressure
M A R C H / 2 0 1 5 www.controlglobal.com
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Product introductions
54
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C O N T R O L TA L K
minimum. The straight run will need to be increased if there are nonplanar elbows, process
equipment or valves upstream. Insertion flow
meters will require greater analysis to get the
sensor at the point in the pipe cross-section that
is at the average pipe velocity.
6. Install radar transmitters with the device
plumb. Make sure the horn or probe is correct
for the service. For coaxial probes, make sure
the standoffs are installed correctly to prevent
false readings. If standoffs are not used, ensure
the probe is not bent to avoid reading contact
points with the housing of the bridal or internal structure of the tank. When using transmitters with horn-type radar, avoid mounting too
close to the sidewall, internal structures, inflow
or sparge lines. Make sure the installation does
not interfere with tank venting. Be sure to run
an echo graph with the tank empty, all of the
dip tubes installed, and the agitator running as
a baseline reading that includes the effect of in-
GreG McMill an
Stan weiner, pe
controltalk@putman.net
Be prepared for shock and awe when you lay out your expectations to your contractors.
M a r c h / 2 0 1 5 www.controlglobal.com
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C O N T R O L TA L K
ternals and geometry for future reference. This is especially important for
detecting problems from coating of the
probe and vortexing of the liquid.
7. Always design wireless systems after a thorough site survey. The number
and locations of transmitters for signal hopping must be more than adequate to make sure transmission is not
blocked when a transmitter is removed
from service. Locations of transmitters
may need to be adjusted. Sales may
not realize how critical this site survey is. Pay attention to future physical
changes to the site and possible parking of tank trucks and service vehicles
that may interfere with the existing
wireless system.
8. Temperature transmitters are designed for multiple sensors, so make
sure the correct sensor is selected and
connected to the appropriate terminals. If there is a mixture of two-wire,
three-wire and four-wire resistance
temperature detectors (RTDs), the
risk of incorrect terminations greatly
increases due to the lack of standardization. Ensure that the probe length
matches the thermowell depth, the fit
is tight, and the tip is bottomed out in
the well. Also use high-temp pipe dope
to avoid thread damage.
9. Make sure the flowmeter element
is installed in the correct orientation
because most flowmeters are sensitive
to flow direction.
10, Install analytical probes within
the limits of the factory cable lengths
between the transmitter and sensor. Attempts to extend the wiring to meet operations or maintenance requests will
result in erratic readings. The factory
cable must be used and junction boxes
not introduced. Substituting cables
and adding junctions causes shielding,
termination, color coding and resistance problems.
11. Avoid installing pH and ORP
probes before process fluids are flowing. Protect the probe from physical
damage and keep the wet cap on the
probe during storage. This wet cap can
56
tem by reducing the sensor time constant or signal filter time needed. For
example, a pH electrode located in a
recirculation line will introduce less
dead time than an electrode in a vessel due to an inherently faster time
constant and by avoiding coatings. A
thermowell or electrode located 25
pipe diameters downstream of a heat
exchanger or static mixer will provide
a more repeatable measurement with
less need for a signal filter. This distance is increased for desuperheaters
and static mixers with gaseous reagents
(e.g., flashing ammonia) to avoid droplets and bubbles, respectively. For
more details on thermowell and pH
electrode installation requirements,
see the books Advanced Temperature
Measurement and Control and Advanced pH Measurement and Control.
www.controlglobal.com M a r c h / 2 0 1 5
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CONTROL REPORT
editor education
Jim montague
e xecutive editor
jmontague@putman.net
Lifting my
head from all the
specialized niches I
cover, I could again
see how process
control fits into
the larger world.
58
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3/3/15 10:20 AM
The Emerson logo is a trademark and service mark of Emerson Electric Co. 2014 Fisher Controls International LLC. D352316X012 MAA2
3/3/15 10:20 AM