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End users and suppliers agree: Advanced process

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1. GREG MCMILLAN STAN WEINER PE controltalk putman net IE LAM A LITLE ANNOYED AND THE 68 CONTROL TALK Stan What process did you recently tackle where process models could not be identified Michel Last year we worked in a nickel plant on a semi autogenous grinding SAG mill The SAG mill process uses steel balls and large rocks for grinding The load consisted of ore steel balls and water In addition to stabilizing the process and increas ing production rates the control sys tem must protect the lining by ensur ing the rocks fall on other rocks and not the lining The controlled vari ables were density inferential mea surement power weight bearing pressure and recirculation flow The manipulated variables were speed feed and water flow The disturbance variables were ore size ore hardness and crusher opening A camera pro vided the mean size the percent be low 4 inches and below 1 inch The detailed population of ore sizes was not known Greg What solution did you use to eliminate manual control when pro cess models are not possible Michel Since the operators could control the process manually rule based models would work Since process performance varied signifi cantly from shift to shift we worked closely with operations to find the best operator logic and put it in the form of simple linguistic rules with relative grading via a fuzzy logic control program Fuzzificatio
2. I know it s true I saw it on ControlGlobal com Continued on page 17 Search this site Tips www controlglobal com thismonth GO Don t Compromise on Safety Make sure automation project procure ment strategies save money and still avoid unnecessary risks Wireless eBooks Four free downloadable ebooks on the ins and outs of an industrial wireless strategy Color Science and Good HMI Design Picking the right color scheme can make or break your HMI design To download any or all of these white papers and others go to www Control Global com whitepapers y m gt m _ O m m U ControlGlobal E News Multimedia Alerts White Paper Alerts Go to www controlglobal com and follow instructions to register for our free weekly e newsletters NOVEMBER 2012 www controlglobal com 15 WORKHORSE i Rely on Magnetrol s unfailingly hard working liquid level switches in the field Magnetrol mechanical buoyancy switches work hard and keep on working through extreme media conditions challenging applications and even generations of instrumentation protessionals who have entrusted their operation s safety and performance to Magnetrol In fact so many of our customers depend on Magnetrol s legendary reliability they wouldn t dream of switching from our mechanical buoyancy switches Find out why instrumentation experts count on Magnetrof workhorses
3. First 100 MHz handheld Scope and 3000 count DMM First 50 MHz handheld Scope and 3000 count DMM THE LEGACY OF First 200 MHz Color handheld oscilloscope First 200 MHz isolated CAT III safety rated hand held oscilloscope First 500 MHz handheld oscilloscope First 200 MHz 2 or 4 Channel CAT IV safety rated handheld oscilloscope After 20 years Fluke ScopeMeter industrial scopes still lead now with 500 MHz bandwidth and 5 GS s sampling speed The Fluke 190 Series II extends your troubleshooting arsenal showing you waveform shape timing distortion and disturbance in greater detail than ever before Two and four channel models fit any application measuring signals from 60 MHz to 500 MHz ScopeMeter test tools are number one in ruggedness the only completely sealed drip proof dust proof IP 51 rated scopes Watch ScopeMeter 190 II Scenario Videos PLL KE www fluke com scopemeter500 2012 Fluke Corporation AD 4252291A_EN TOPJOB S DIN Rail Mount Terminal Blocks Measure Up with e No torque PUSH WIRE spring pressure connection technology e Smudge tree oil resistant multi line vinyl f e Maintenance ree wiring Wire it once and a forget it i E Gir eg Bi e More jumper combinations to get the job TEH done DOR j TAH marker strip j _ a a i h z P3 q i p as Pe pe iak E a i E r j C Pe Saal Ei F ii oe
4. position feedback The actuator shaft would move even though the closure member did not Diagnostics and re sponse test metrics from the positioner said things were not too bad The smart positioner was basically lying Nearly all control loops in the chemical industry depend upon the manipulation of flow by the use of a final ele ment such as a control valve It s generally taken for granted that when a controller changes its output there s an actual change in the position of the closure member of the valve plug ball or disk However the specification of control valves doesn t adequately emphasize the very basic require ment that the positioner respond in a timely manner or even at all and this has resulted in shortcomings that introduce variability into the process Before the advent of smart HART and fieldbus position ers feedback measurements of position were rare because a separate position transmitter had to be installed and wired The user generally wasn t aware that differences in valve ac tuator and pneumatic positioner design were the source of cycling in the process Typically besides traditional factors such as size and ma terials of construction control valve specifications have fo cused on minimizing leakage through the valve at shutoff and emissions to the environment from packing Too often to reduce project costs plants pick on off valves to address re quirements This can create performance p
5. ae B e Built for corrosive thermal cycling and vibration prone applications Ep ma se TOPJOB S Try it in your toughest application Request your free tool kit at www wago us tough htm cO INNOVATIVE CONNECTIONS H a PE Ta bi lan SAE Finding Faults Giant Swedish mine counts on an integrated EAM system to make fault reporting and predictive maintenance easier by Nancy Bartels Some 50 km north of the Arctic Circle in the Lapland re gion of Sweden is a giant hole in the ground It s 3 km long 1 5 km wide and 250 m deep This is the Aitek copper mine About 15 km from the town of Gillivare it is one of the larg est open pit mines in Europe Owned by the Boliden Group www boliden com which THE EQUIPMENT LIST The modernization project at Aitek is appropriate to the size of the mine itself ABB www abb com has provided e 650 motors for conveyors pumps fans crushers grinders and process equipment e 230 drives and variable speed drives to control the electric motors e Two 22 5 MW gearless mill drives to power grinding mills e Two 2 x 5 MW dual pinion drive systems for ring gear mill drive RMD mills e Four 1 4 MW permanent magnet motors for slurry pumps e Process control system Extended Automation System 800xA e 23 distribution transformers for drive systems e Three 80 MVA power transformers for substation e Gas insulated switc
6. 72 Emerson Process Mgt Wireless 3 Endress Hauser 000 6 7 A EEEE E S O E ire ache re ke ee 45 Honeywell a ee anai 1 14 Gad Controls a toc 3 ois oe daorn kok oe EEX 65 Lumenite Control Technology 48 Magnetrol International 16 Maple SYStCING 0 easta an ean x 4585 44 Martel Electronics 1 240206 0 oeea sae 49 Maverick Technologies 2 4 vasasneeveue 7 Metik secsi posritis eons ER ERAT 65 Meriam Process Technologies 40 Mitsubishi Electric Automation 39 Moore Indis iets 2 65 ayudiwanse a eeu oe 23 National Instruments 10 NovaTech Process Solutions 20 Omera EA ECNE oc 2c0ccaed ew niana 3 Orion Mist inents 64 52 04 ou eneg aa 32 Pepper Fute reenso ven ne dhedtdey bas 2A Phoenix Contact ssesorsdsspidrad iTia aoe 2 OR e 47s E E 49 05 38 Samson COMO srsreissss tert ESEAS 53 EEEE EE E EE E E can een 22 Siemens Process Automation 58 Nea AMEE noc nena ted dubdacuren ges 37 O a oat pe EESTIT ETETEN 46 WEG Electrice MOto esras cu ode ode Sens 55 VON ENEE EEEE EE 27 Moore 320 351 352 353 363 372 382 383 c N O o gt a 2 16 ive ontact Polly Dickson pdickson putman net 630 467 1300 ext 396 CLASSIFIEDS A We Love to Buy PLC DCS Sensors Drives Motor Control from Allen Bradley to Xycom Industrial Automation WWW Santaclarasystems COM Peed AUTOMATIO
7. As is typical in open pit operations it s very dusty It s also very cold and dark much of the year and outdoor equipment has to withstand temperatures as low as 45 C 49 F in winter The reliability of motors drives and other equipment is para mount in such conditions another reason early fault detection is critical At Aitek maintenance is supported not only with the EAM system but also with the document management system which is integrated with Sys tem 800xA This gives operators access to drawings instructions manuals and other documentation to enable quick and correctactions In March 2011 Aitek also began using the asset monitor func tion in System 800xA to support its pre dictive maintenance activities The asset monitors focus on critical parts of the operation that are essential for reliable and profitable operation of the mine One of these is the gearbox of the large mills Asset monitors signal the need for maintenance on them de tect anomalies and take corrective ac tion before a critical situation arises Aitek uses one of the extensions available for System 800xA Snapshot Reports to keep track of maintenance issues Preconfigured reports are ex ecuted on a regular basis to collect process and maintenance data The 800xA standard functions and other system extensions like Asset Monitor ing can provide general and specific report functionality The flexibility of Snapshot Reports g
8. It has an excellent reputation within the industry and is the clear global leader in this niche highly dif ferentiated market This acquisition further broadens our position in the highly attractive materials test and measurement equipment market and makes us a leader in a growing indus try segment notes Frank Hermance Ametek s chairman and CEO Driving market growth in both de veloped and emerging markets is the need for more sophisticated test and measurement techniques due to the in creased variety and complexity of tire designs the globalization of tire manu facturing capacity and more stringent quality requirements says Hermance Micro Poise is well positioned to take advantage of that growth It has a large installed equipment base at many of the world s leading tire manufactur ers and is the only industry supplier of all key test and measurement tech niques with products that offer best in class accuracy repeatability and cycle times Micro Poise joins Ametek s Elec tronic Instruments Group ABB Reports Solid Performance in Uncertain Market ABB reported steady orders and higher revenues in the third quarter of 2012 despite a challenging macroeconomic environment as the company ben efited from what it said was its well balanced market exposure especially the improved access to the North American automation market gained through recent acquisitions Power orders were lower than t
9. THE PATENTED AURORA MAGNETIC LEVEL Taa Tie INDICATOR FROM ORION INSTRUMENTS nit i CO es Ug _ PROVIDES HIGH VISIBILITY LOCAL P OF THE LIQUID DENSITY AND PE 54o m papi DIELECTRIC THEREFORE PROVIDING YOU A SAFETY NET OF REDUNDANCY ALL IN A SINGLE DEVICE O O f c oO 1 i gt A7 a h o i INDICATION WHILE SUPPLYING REAL z d a TIME GUIDED WAVE RADAR DIGITAL z gt a D FEEDBACK TO THE CONTROL ROOM O 3 E z i H 5 THIS COMBINATION OF APPLICATION a iU i e PROVEN TECHNOLOGIES RELIES ON A i wv COMPLETELY DIFFERENT PROPERTIES w ES O 4 gt an 5 wo q Magnetic Float GWR Probe amp TOETOE Oil amp Gas Production Wastewater Treatment Oil amp Gas Refining Pulp amp Paper Chemical Processing Mining Tm Power Generation Military ore _ os ECLIPSE SUITS WAVE FARA eat ahah Cag FHS a PN INS THUMEWNTS Aar WY ety e ie i A ba NOW ms gt SIL Certified www orioninstruments com 2105 Oak Villa Boulevard e Baton Rouge Louisiana 70815 866 55 ORION HART is a registered trademark of the HART Communication Foundation FOUNDATION fieldbus is a trademark of Fieldbus Foundation Orion Instruments Orion logotype Magnetrol logotype Eclipse Reveal and Aurora are registered trademarks of Magnetrol International Inc COMMUNICATION PROTOCOL f RESOURCES fam Level O
10. for unmatched dependability longevity and trouble free performance in the field Contact your MagnetroF representative today P Magnetrol your preferred partner at the RIGHT LEVEL for ma FA 1 800 624 8765 info magnetrol com years S amp S PutmanMedia IN MEMORY OF JULIE CAPPELLETTI LANGE VICE PRESIDENT 1984 2012 555 W PIERCE RD SUITE 301 ITASCA ILLINOIS 60143 executive team s e S President amp CEO JOHN M CAPPELLETTI CFO JANE B VOLLAND VP Circulation JERRY CLARK 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 Western Regional Sales Manager LAURA MARTINEZ 310 607 0125 Fax 310 607 0168 lmartinez putman net Northeast Mid Atlantic Regional Sales Manager DAVE FISHER 508 543 5172 Fax 508 543 3061 dfisher putman net Inside Accounts Manager POLLY DICKSON pdickson putman net Subscriptions Circulation JERRY CLARK JACK JONES 888 644 1803 foster reprints Corporate Account Executive CLAUDIA STACHOWIAK 866 879 9144 x 121 Fax 219 561 2019 claudias fosterprinting com editorial team Editor in Chief WALT BOYES whoyes putman net Executive Editor JIM MONTAGUE jmontague putman net Senior Managing Editor Digital Media KATHERINE BONFANTE kbonfante putman net Managing Editor NANCY BARTELS nbartels putman net Senior
11. inside a vertical tube In a real ap plication it would be measuring the height of some liquid in a storage or processing vessel probably nota tube or pipe Click on http www youtube com watch v RRlenELOSnU The second Level Measurement Lab Check shows how to use the 13 A transmit Pneumatic Calibration ter to measure water level inside a plastic tube and report that level as a 3 15 psi air pressure signal to a re mote receiver gauge This lab dem onstrates the basic operation of any pneumatic signaling system where a variable air pressure represents some other variable in this case water level In the past most industrial instruments worked like this using 3 15 psi pneumatic signals to repre sent pressures levels temperatures flows and even some analytical vari ables Click on www youtube com watch v gybq5lkvO_Y NOVEMBER 2012 www controlglobal com 33 End users and suppliers agree Advanced process control is a powerful and effective tool but implementation and maintenance need to be simplified by Dan Hebert PE By now virtually every industrial process in the world is under automatic control so the logical next step is advanced process control APC APC has already been implemented in many fa cilities albeit with varying degrees of success But when APC works the results can be nothing short of spectacular Dr James Ford senior consult
12. justments need to be made to the APC algorithms and mod els Without this on going maintenance the original APC application will lose effectiveness often to the point where it must be decommissioned Without Maintenance Benefits Fade Away Whether model based or some other underlying technol ogy any APC implementation will lose its effectiveness over time if it s not properly maintained Maintenance doesn t re quire as much effort as initial implementation step testing isn t generally required for example but adjustments must nevertheless be made to maintain effectiveness Richard McCormick automation engineer and industry consultant with Mick Automation in Quebec City Canada says MPC maintenance is and will continue to be the big gest issue Degradation of performance over time after start up is seen everywhere thus benefits decrease over the years he points out Automatic monitoring tools for MPC applications are oriented for detecting things like models mismatch the percent of the time constraints are hit and other measurements to flag and identify causes for MPC performance degradation over time Lack of experienced personnel for good support remains the biggest challenge for users This is one reason why using specialized firms seems to be popular Mick Automation implemented MPC on FCC polym erization units in the late 1990s and it took a couple of Tired of Programming PLCs The ST 72 Contro
13. optimization offerings our capabilities in feedstock data management and re finery supply chain optimization will allow us to provide a unique end to end solution across the full oil sector rolglobal com NOVEMBER 2012 ware business right Matthew Webster CEO of Spiral Systems value chain said Matthew Webster chief executive officer Spiral Software The business will continue to be managed by Spiral Software s existing executive team adding employees to Invensys operations in the United King dom and North America No financial terms for the deal were announced Automation Market Downshifts in 20 2012 According to Allen Avery of ARC Ad visory Group after several quarters of strong growth following the global re cession automation market expansion has slowed decidedly Whereas previ ous quarters saw double and high sin gle digit growth rates the second quar ter of 2012 saw a paltry 2 7 growth in supplier revenues While they continue to execute many projects around the globe sup pliers cited several reasons for the more modest growth These include both economic uncertainty in the United States and Europe and a cooling down of the once white hot Chinese econ omy New order activity also fell off somewhat for some suppliers as the re bound effects from the global recession have waned and they convert their or der books into revenues However sup pliers still reported robust activity in th
14. I O change Great So another wiring schedule Another marshalling design And another cabinet Just make it all go away YOU CAN DO THAT Electronic marshalling eliminates the rework the redesign and the headaches With DeltaV Electronic Marshalling Emerson lets you make I O changes where and when you need DELTAV them without costly engineering and schedule delays Our new DeltaV CHARacterization Module CHARM completely eliminates the cross wiring from the marshalling panel to the I O card regardless of signal type so you re no longer held to predefined specifications All those wires gone All that time and engineering gone See how easy it can be by scanning the code below or by visiting IOonDemandCalculator com y EMERSON Process Management The Emerson logo is a trademark and a service mark of Emerson Electric Co 2012 Emerson Electric Co EMERSON CONSIDER IT SOLVED
15. Technical Editor DAN HEBERT dhebert putman net Contributing Editor JOHN REZABEK Columnists BELA LIPTAK GREG MCMILLAN STAN WEINER Editorial Assistant LORI GOLDBERG design amp production team VP Creative Services STEVE HERNER sherner putman net Associate Art Director BRIAN HERTEL bhertel putman net Senior Production Manager ANETTA GAUTHIER agauthier 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 le Thi eNO OS MY Pa O 2 a Ph CONTROL ONLINE Blog Posts You Might Have Missed Among the real stars of ControlGlobal com are some of our most popular bloggers Greg McMillan and Joe Weiss Greg not only is half of the Control Talk team and occasional fea ture writer but the brains behind the Control Talk blog not to be confused with the monthly column of the same name which covers modeling and control In the last few weeks Greg has been providing his readers with checklists for control issues In his Checklist for Cascade Control Greg calls cascade control an effective way of providing better feedback and feed forward con trol The peak error in the primary loop can be reduced by more than an order of magnitude for disturbances originating in the secondary loop The nonlinearity of a control valve can be remove
16. What would happen if you used instead of cycle time or response rate the concept of workflow Suppose you could spread the cost of this workHow based program ming across a number of companies by using Software as a Service SaaS and cloud comput ing Now small companies could afford to use the tools too We ll be talking about this revo lutionary concept more in the future SMLC will help define smart manufactur ing for the future If you re interested in the fu ture of manufacturing come join in EDITOR S PAGE WALT BOYES EDITOR IN CHIEF whoyes putman net smaller companies just cant afford to implement the systems and Support structures necessary to use Smart manufacturing technologies NOVEMBER 2012 www controlglobal com 9 Unbeatable Control Precision and Flexibility Lowering cost increasing productivity and shortening design times are just some of the challenges industrial engineers face The graphical system design approach a offers ie combines productive software and reconfigurable 1 0 RIO hardware to help you flexibility through FPGA meat these challenges This off the shelf platform customizable to solve any control pega gs and monitoring application integrates motion vision and O with a single software you program the way you development environment to build complex industrial systems faster think graphically gt gt Accelerate your productivity at ni com indus
17. a Bhl P k a ee AETI P WEEN p es a jo P ojele inig EHE fofsjE E jR Hei Beha tatel ea SUPERE rent see pah ee ee ee a 3 bal 1 a L ev ebraws a Built in simulator Program Do more with the completely new and FREE Do more Designer E software DirectSOFT and ladder programs developed with DirectSOFT are not compatible a with these CPUs Download the FREE r software m Choose a Do more starter kit to get going fast You get e Prewired 3 slot base with your choice of Do more CPU e 8 point input simulator module J Starter Kit e 8 point relay output module e Do more Designer software CD ROM e USB programming cable e User manual Coupon for 30 days FREE online video training xK AutomationDirect reserves the right to substitute a larger base at its discretion H2 DM1E START H2 DM1 START with H2 DM1E CPU with H2 DM1 CPU for the details watch overview Or go straight to to buy A _ Sage WAUTOMATIONDIRECT the 1 value in automation Connecting the Manufacturing Dots Since 2010 I ve been part of an organization called the Smart Manufacturing Leader ship Coalition https smartmanufacturingcoalition org SMLC is working to define an overarching operating system for manufacturing Why do we need to do that Can t we just use what we ve got It isn t that simple Among the biggest
18. and will get more intuitive and easier to use A part of this trend is an im provement in performance monitoring and diagnostic tools to help both the engineer and the operator to under stand what the controller is doing and why Some processes require nonlinear techniques and we see this as improv ing in the future as well Robert Golightly APC manager at Aspenlech www aspentech com says Traditional maintenance issues will be eliminated with built in tech nology that automates much of the maintenance cycle and keeps control ler models matched with plant perfor mance all without the need for the level of expertise required today Perry Nordh product manager at Honeywell Process Solutions www honeywellprocess com says Hon eywell has a system in place to help end users implement APC Benefits Guardianship Maximum BG Max is a flexible and comprehensive ser vice program that provides APC per formance management services to help plant managers maximize the re turn on investment from Honeywell s advanced control and optimization so lutions he explains Other APC vendors offer similar support services but users also want vendors to make APC easier for them to use without having to rely on sup plier support Opto 22 doesn t focus on many HMI setup tools or application specific algorithms although many users and vendors sell or share industry specific tools for our PAC Control program m
19. art automation could have pre vented all three of them In this series of articles I will give a brief summary of that chapter History During the last 60 years nuclear energy has be come an important component in the energy mix of mankind It supplies about 5 of the to tal global energy consumption or about 13 5 of global electricity consumption In the United States nuclear energy is the source of about 8 of the total energy consumption or about 20 of the total electricity used Figure shows that after the accidents at Three Mile Island and Chernobyl the building of new nuclear power plants slowed and the per centage of global electricity consumption met by Fukushima Global number of active reactors 435 Ages yr 30 40 138 gt 40 24 Average 27 Under construction 60 28 China 10 Russia 6 India Planned 150 Shut down 138 Decommissioned 17 USA Operating 104 Shut down 28 Decommissioned 13 1960 1970 1980 1990 2000 2010 SS Se Nuclear share of global S electricity consumption In 2012 13 5 USA 20 1960 1970 1980 STEADY SUPPLY DROPPING DEMAND Global installed capacity GW In 2012 413 GW USA 119 GW 1990 2000 2010 Figure 1 Red line in top chart shows number of active reactors the blue dotted line includes planned reactors Red line in bottom chart shows current capacity blue dotted line share of consumption w controlglobal com NOVEMBER 2012 With ris
20. block is con figured to be wired directly to the AO block of a valve CIF shall be the default choice for solv ing PID The PID should be executed in the posi tioner allowing the operator to run the block and hence the valve in manual even when all the other devices in the loop are being serviced e HMI faceplates shall use the output of the loops AI block to display the measured vari able so it remains a live value even when the positioner is being replaced The device mea suring the variable controlled by the PID shall always be on the same segment e The remaining loops cascade masters for example may be configured to run in the host with little loss of performance Any out put being controlled by 4 20 mA for example most variable frequency drives also are sensi ble choices for being solved in the host Exploiting control in the field is never an all or nothing proposition A couple simple guide lines can be employed to help ensure your proj ects have a logical basis for their application Hi NOVEMBER 2012 ww JOHN REZABEK CONTRIBUTING EDITOR JRezabek ashland com Fieldbus would become a more robust truly distributed and innately more reliable platform for rudimentary PID loops w controlglobal com 25 16 wince IN PROCESS Invensys Buys Spiral Software U K petroleum software specialist increases 1 OM s footprint in refining sector Invensys Operations Management IOM _
21. cCc O VER S TORY 34 APC Ain t Easy End users and suppliers agree Advanced process control is a powerful and effective tool but implementation and maintenance need to be simplified by Dan Hebert PE A SSET MANA GEM EN T 47 Finding Faults Giant Swedish mine counts on integrated EAM system to make fault reporting easier by Nancy Bartels VALVES 51 Is Your Control Valve an Imposter Beware the disguised positioner by Greg McMillan WEB EXCLUSIVES Applying Color Science to Effective HMI Design www controlglobal com whitepapers 2012 121009 beer sallman scott nixon hmi html Modifying SIL Certified Equipment Failure Rates on the Basis of Deployment www controlglobal com SIL_Failure_Rates html 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 ad dress Periodicals Postage Paid at Itasca IL and at additional mailing offices Printed in the United States Putman Media 2012 All rights reserved The contents of this publication may not be reproduced in whole or part without consent of the copyright owner POSTMASTER Send address changes to CONTROL P O Box 3428 Northbrook IL 60065 3428 SUBSCR
22. chsrupton to producto Virtualization capabilities let you test drive upgrades to stop pronlems in their track ri ee ee i fi ni ef j i 1 IT ar a b I pb lf you have an aging system ts ime to map a course wiin Honeywell Qur innovation and depth of expertise is unparalleled You can drive superior results Honeywell Your road to the future WALT BOYES EDITOR IN CHIEF CONTROL ONLINE Why You Come to ControlGlobal com whoyes putman net I know it s true I read it on the Internet Well no There is a lot of infor mation on the Internet that is just plain wrong Unfortunately some of the information that is very available on the Internet is also very plausible How ever in an engineering discipline if you aren t careful you can get seriously burned That s where we come in Both in Control magazine and on www control global com we are editors Thats much more than being spell checkers and grammar queens We are fact checkers we are purveyors of knowledge and we are fundamentally the curators of the process automation space What s a curator We think about curators with respect to museum exhibits not magazines or websites A curator is a person who is a content expert responsible for acquisition and interpreta tion of collections of information and material Here we function quite a bit like a museum curator but for the process automation space We colle
23. digital communication standard the idea of field devices solving function blocks was adopted Devices would not just measure something and make a process variable available to a host or translate an analog output to a valve stem posi tion they would have the largely optional ca pability to support and solve a whole repertoire of standard function blocks A function block is an object a small app that performs a very specific duty with a speci hed set of inputs outputs and internal config uration parameters An analog input block or AI performs the basic I O chores of translat ing a raw measurement say a differential pres sure into a meaningful process variable in en gineering units It has a menu of linearization choices that includes square root extraction and some innate alarming capabilities Most of this was nothing new What was new was that devices became autonomous ca pable of accepting inputs solving their block ware and publishing an output without being poked or polled by a centralized host They can communicate with other devices and with the host as peers and are even capable of solving PID for closed loop control The end users who desired this capability were people with process control or a DCS fo cus and they saw a move to an entirely vendor independent digital distributed and determin istic control platform as a logical evolution of the systems of that day Today t
24. divided by the fill or exhaust flow coefficient for the posi tioner I P or booster The response time for large changes is estimated as 86 of the desired change in valve position divided by the slewing rate sec For changes between 1 and 10 the actuator response time becomes relatively fixed except for large valves and dampers It always was rather obvious that large valves were slow because it takes time to fill or exhaust enough air in a large actuator volume to make a change in actuator pressure large enough to overcome the torque or friction load to move the Input signal closure element However until recently it wasn t known Actuator position that the response time of even small valves was dramatically Flow rate filtered slower to the point of almost no response because of the de sign of pneumatic positioners Time seconds Figure 2 p 50 shows how the response time increases to 10 to 100 seconds from 1 to 2 seconds as the size of the step RESOLUTION change in signal decreases below 1 Note that in this plot we Figure 3 Even at mid throttle the flow through Valve B only are primarily seeing the effect of the positioner because the responds to larger than normal changes in the input signals step changes aren t big enough to see stroking time limitations ay A s Q Er aN by gt Vent and Regulator Systems for Dissolved Gas Flotation Throughout the wastewater i
25. over a four year pe riod says Tom Lyndrup staff engineer in Enterprise s Advanced Process Control group However two years later that s exactly what I m doing 34 www controlglobal com NOVEMBER 2012 And despite his initial doubts Lyndrup is succeeding especially in projects where APC replaces existing controls In some cases 24 hours after a new APC routine started up we achieved higher total production than the day be fore despite a change in feed composition that normally results in lower rates For more on Enterprise s APC ac complishments see the sidebar Justifying APC at www controlglobal com CT1211_JustifyingAPC html Tom Kinney product manager at Invensys Operations Management www invensys com says MPC moves the operating process closer to multiple constraints simultane ously to realize the maximum profit from an operating unit Units typically pay for themselves within six months and equip companies for ongoing financial productivity qual ity or other strategic advantages Given these success stories why isn t APC implementa tion more widespread APC Is Incredibly Hard If you saw the movie Moneyball or read the book you probably remember Billy Beane telling Scott Hatteberg how easy it would be for him to switch from catcher to first base For confirmation Beane looks to infield coach and colleague Ron Washington
26. slight adjustments and work with control en gineers to make slight adjustments A production record was achieved in the first week The average use of energy per ton has decreased by 8 and the tonnage per day has increased by 14 Greg Fuzzy logic has uses beyond control of mining processes Top 10 Reasons to Use Fuzzy Logic Control on Your Children 10 Model predictive control did not work kids interactions requires too much dy 9 Decoupling all your namic compensation 8 There too many states of nonlin earity for an adaptive tuner 7 You can write your own rules 6 You can claim to be an expert 5 You can add and subtract rules at will 4 Your children will be baffled 3 It gives you a warm fuzzy feeling 2 You can throw away your child psychology books 1 Your children won t move back in after graduation W AD INDEX ADVERTISER PAGE NO DD ceres ree eE e E yeas ee at Alhed Electonics dy kno tend a x oem acon 2 CLD co ae a ee ere eee 472 ARC Advisory Group a an anaana 57 Automation Direct 0 44 4 s06 5200 e04 o 8 Badoer Meters irse sicbateyeas ed baw Gus 50 Banner Engineering esseis 504620 iasan 28 CNC Oi os hose Gis Cac es Rade S GA E Ses 34 Davis Ins HUMES s 0005 30 Emerson Process Mgt Micro Motion 43 Emerson Process Mgt Rosemount 19 Emerson Process Mgt Saab dics 44 rosis sal Emerson Process Mgt Systems
27. used to ef fectively reduce noise in the rate of change calculations Greg An FLC I designed was used on a large waste pH neutralization system to minimize reagent use The FLC worked quite well for decades but when the control engineer who implemented the FLC in the DCS left the plant the control engineer who in herited the system did not know how to maintain or improve the FLC The process engineers never could figure out what the FLC was doing and just knew the reagent cost was less when the FLC was in automatic What did you do to help FLC analysis trouble shooting and performance assessment Michel We could see what rules were firing when and how often It turned out that 20 of the 500 rules were do ing most of the work We also had on line metrics of process performance We paid particular attention to inter faces Metallurgists had to be able to modify targets constraints production goals and limits The control engineers must be able to easily adjust rules and tweaked weights Stan How long did it take to commis sion and what were the benefits Michel The FLC was on advisory control for three days Operators could see the FLC was anticipating their ac tions During the next four days the FLC was on automatic during the day and the shapes and ranges were modi fied On the eighth day the FLC was used continuously and has been op erational ever since Every week met allurgists validate rules make
28. who doesn t miss a beat when he tells Hatteberg It s incredibly hard According to end users some vendors sound like Beane particularly when they are trying to sell them on overly complex APC implementations that turn out to be incred ibly hard to implement and nearly impossible to maintain Dan Cox director of engineering at AOC Resins www aoc resins com in Collierville Tenn has reservations about off the shelf APC Most APC products don t work well in our batch environment he says This is in contrast to the vendor s claims but I still feel this is the case The amount of engineering required for model predictive con trol MPC or neural nets tends to outweigh the benefit So AOC Resins implements APC with custom coding and reaps the fruits of its labors For more details read the sidebar Roll Your Own APC Lou Bertha engineer at RDI Controls www rdicontrols com in Lower Burrell Pa is also skeptical In my experi ence APC is a marketing term big DCS companies use to sell a bunch of preconfigured subroutines that either pro vide generic or process specific routines such as soot blow ing compensated gas flow calculations etc he says Ad vanced is questionable Sometimes these canned routines are just an easy way to develop a system since the specific routine has been developed but typically end users can not adjust these routines for their specific application The iro
29. 001 Control Valve allows it to be used in a wide variety of applications The V2001 gives superior control in the lower cost services such as HVAC and low pressure plant utilities as well as the more rugged requirements seen in most industrial processing plants The V2001 comes with an integrally mounted positioner which not only eliminates all cumbersome linkages and brackets it also allows internally ported connections to the actuator so that no external tubing is required This versatile control valve which is readily available for fast shipment gives you the user many advantages all at a truly affordable price E Integrally mounted positioner E Multiple trim sets E Options for noise abatement trim m Class IV or VI shutoff E Forged yoke and bonnet Call or visit our website to see how affordable it is to make all your control valve problems disappear SAMSON CONTROLS INC USA Internet www samson usa com Phone 281 383 3677 Fax 281 383 3690 CANADA Internet www samsoncontrols com Phone 905 474 0354 Fax 905 474 0998 MEXICO Internet www samson com mx Phone 728 285 2001 Fax 728 285 2028 AUIIO4ZEN VALVES 4 in segmented ball valves with metal seals diaphragm actuators and standard positioners If you re looking just at the actuator you can estimate the pre stroke dead time and stroking time from an individual fill or exhaust parameter for the actuator type and volume
30. 3 6767 Customers First Integrity Always 45 Years of Excellence New Solutions Every Day BANNER IN PROCESS spans apparel and accessories computers and electronics machinery textile and fabrics and transportation equip ment among others As the U S chemical industry expands NGL conver sion into a higher volume of downstream products the posi tive impacts could flow through the value chain into other manufacturing sectors particularly given that chemicals are used in an estimated 90 of all manufactured products said Anthony Scamuffa U S Chemicals leader for PwC Not only could the abundance of NGLs help drive reduced pricing for derivative products it could also potentially drive domestic re shoring activity and possibly bring about a favor able shift in the U S balance of trade as ethylene capacity comes on line Major oil and gas companies and upstream commodity in dustry participants are evaluating their business models and actively moving forward to take advantage of emerging shale gas opportunities Some are considering whether to restart mothballed assets invest in greenfield projects form strate gic alliances and expand and upgrade existing assets Many of these companies are also executing large capital projects identifying engineering and construction resources and es tablishing strategic sourcing agreements with NGL providers Further downstream specialty chemical entities are st
31. 60143 mail at nonprofit rates Check one Full Name and Complete Mailing Address of Publisher Editor The purpose function and nonprofit status of this organization and the and Managing Editor exempt status for federal income tax purposes Publisher Keith Larson 555 West Pierce Road Itasca IL 60143 e Has Not Changed During Preceding 12 Months Editor Walt Boyes 555 West Pierce Road Itasca IL 60143 13 Publication Title Control Managing Editor Jim Montague 555 West Pierce Road ItascalL 14 Issue Date for Circulation Data Below September 2012 60143 Average No Copies Each Issue During Preceding 12 Months No Copies of Single Issue Published Nearest to Filing Data Extent and Nature of Circulation Total Number of Copies Net press run Legitimate Paid and or Requested Distribution By Mail and Outside the Mail 1 Outside County Paid Requested Mail Subscriptions Stated on PS Form 3541 Include direct written request from recipient telemarketing and In ternet requests from recipient paid subscriptions including nominal rate subscriptions employer requests advertiser s proof and exchange copies 45 972 46 101 2 In County Paid Requested Mail Subscriptions Stated on PS Form 3541 Include direct written request from recipient telemarketing and Internet requests from recipient paid subscriptions including nominal rate subscriptions employer requests advertiser s proof and exchange copies 3 Sales Through Dealers an
32. D PROCESS CONTROL years to complete it That was the easy part The major thing after implementation is to maintain this huge ap plication with knowledgeable process engineers and to have the operators understand and believe in the moves made by the optimizer he says When the process en gineer who participated in its design and implementation changed position the application slowly and continu ously degraded to a point where it was decommissioned This is why I would now stay away from this type of opti mization unless you have an impressive and knowledge able staff to maintain it An automation engineer at a major refiner who wishes to remain anonymous says getting a multi variable con trol MVC application running isn t too much of a prob lem Just spend big money to hire an expert he ad vises The problem has always been keeping it running once the expert goes home If the vendors were listening to their customers you would see more support tools for running applications better visibility into why a control ler did something unexpected the ability to identify poor performing models in real time and user friendly tools to update individual models inside a running application Making APC Easier End users are making APC easier by going back to ba sics often implementing APC functionality by creating custom configurations using standard programming tools provided by automation system vendors Tod
33. END PRICE The H2 Series PLC offers features and per formance of high end PLCs for an economical price Us ing DirectLogic DL205 hard ware as a platform it supports Do more all base units discrete and analog I O modules avail able for the DL205 PLC but with four times more program memory nine times more data memory and operates at speeds up to 20 times faster than current DL205 CPUs Automation Direct 800 633 0405 www automationdirect com SEAMLESS PC PAC INTEGRATION The WinCPU seamlessly in tegrates with Mitsubishi s iQ Platform It mounts directly to the back plane of the iQ Series controller and is ideal for users who require synergy among high level comput ing multi level processing and non traditional control It features a 1 66 GHz Atom processor and solid state memory SSD and offers tight in tegration between control and computing technologies Mitsubishi Electric Automation 847 478 2100 www MEAU com a ROUNDUP EMBEDDED PCS Multi core enabled CX2000 devices are equipped with CX2000 s housing concept combines a Intel processors metallic basic housing with front panels made of a spe cial screening plastic and can handle environments with temperatures ranging from 25 C to 60 C The basic CPU module has one DVI port four USB ports and two in dependent Ethernet ports Beckhoff Automation 952 890 0000 www beckhoffautomation com cx2000 HAZARDOUS AREA PANEL MOU
34. End users and suppliers agree Advanced process control is a powerful and effective tool but implementation and maintenance need to be simplified NOVEMBER 2012 Finding Faults Is a Good Thing Is Your Control Valve an Imposter ON THE WEB Applying Color Science to Effective HMI Design Handling SIL Certified Equipment Failure Rates S amp S PutmanMedia Industrial integrity you ll never use Phoenix Contact s Valueline Industrial PCs are engineered by engineers Valueline IPCs are constructed with durable metal casing Each Valueline is fully customizable to fit your application Valueline models like the BPC 1000 series are also budget friendly ruggedly reliable and covered by something you ll most likely never need a 2 year warranty Plus when you include Phoenix Contact s recommended power supply and surge protection with your purchase we ll upgrade you to a 5 year warranty You ll probably never need that one either To learn more about Valueline Industrial PCs call us 1 800 322 3225 or visit www phoenixcontact com valueline OGD OO GD GD OGD OO OD Likontac GD 2012 PHOENIX CONTACT INSPIRING INNOVATIONS Products for Lean Manufacturing al Output 2 e Easy to Use Digital Controller with On Off PID and Ramp Soak H i Ei iae F e Optional Ethernet Control with IE ANY Built In Web Server N3 Ar Ea e 120V
35. IPTIONS Qualified reader subscriptions are accepted from Operating Management in the control industry at no charge To apply for qualified reader subscription fill in subscription form To non qualified subscribers in the Unites States and its possessions subscriptions are 96 00 per year Single copies are 15 International subscriptions are accepted at 200 Airmail only CONTROL assumes no responsibility for validity of claims in items reported Canada Post International Publications Mail Product Sales Agreement No 40028661 Canadian Mail Distributor Information Frontier BWI PO Box 1051 Fort Erie Ontario Canada L2A 5N8 NOVEMBER 2012 5 Proline simply clever Endress Hauser Inc 2350 Endress Place Greenwood IN 46143 Sales 888 ENDRESS inquiry us endress com Service 800 642 8737 Www us endress com Fax 317 535 8498 rit DI IUU Compact without compromise As a direct digital Coriolis flowmeter the Promass 100 opens entirely new perspectives for demanding applications in life sciences biotechnology food and chemical industries m Compact design without limitation of functionality m Ideal for skid mounted process facilities m Simultaneous measurement of mass or volume flow corrected volume density temperature and viscosity Promass I m Seamless integration into process control and asset management systems via EtherNet IP and Modbus RS485 HART and PROFIBUS DP currently in preparation Modern web
36. N Siemens Moore Panel Controllers Fully Tested 1 Year Warranty Phone 584 241 6010 Fan 484 2414014 WA elemana oom customenseanice i clasiculeninie com SANTA CLARA SYSTEMS Contact Seth Kostek at 888 450 0301 x215 buyer santaclarasystems com United States Postal Service Statement of Ownership Management and Circulation Requester Publications Only Publication Title CONTROL Publication Number 1049 5541 Filing Date 9 30 2012 Issue Frequency Monthly Number of Issues Published Annually 12 10 Owner Putman Media Inc 555 West Pierce Road Itasca IL 60143 John M Cappelletti 555 West Pierce Road Itasca IL 60143 Julie A Cappelletti Lange 555 West Pierce Road Itasca IL 60143 Jenny G Cappelletti 555 West Pierce Road Itasca IL 60143 Annual Subscription Price 96 00 Nicholas G Cappelletti 555 West Pierce Road Itasca IL 60143 Complete Mailing Address of Known Office of Publication Melody L Cappelletti 555 West Pierce Road Itasca IL 60143 555 West Pierce Road Itasca IL 60143 11 Known Bondholders Mortagees and Other Security Holders Owning Contact Person Jeremy Clark or Holding 1 Percent or More of Total Amount of Bonds Mortgagees or Telephone 630 467 1300 Other Securities If none check box None Complete Mailing Address of Headquarters or General Business 12 Tax Status For completion by nonprofit organizations authorized to Office of Publisher 555 West Pierce Road Itasca IL
37. NT HMIS Pepperl Fuchs has received UL Class I Division 2 ATEX Zone 2 and IEC Ex Zone 2 certification on its 15 in and 19 in industrial panel prod ucts including the PC8200 series Panel PCs and KM8200 and RM8200 Series remote monitors Its stand alone operator workstations are rated for General Purpose Class I Division 2 Class I Divi sion 1 ATEX IEC Ex Zone 2 and ATEX IEC Ex Zone 1 Pepperl Fuchs 330 486 0002 www pepperl fuchs us LITTLE PC WITH BIG TEMPERATURE RANGE Valueline industrial PCs now include the VL BPC Mini a miniature embedded box PC The first model available is a wide temperature version that operates between 40 C and 65 C 40 F to 149 F It has a fanless design in a compact DIN rail mountable package In addition it has high shock and vibration ratings which makes it suitable for rugged applications Phoenix Contact 800 322 3225 www phoenixcontact com MULTI TALENTED INDUSTRIAL COMPUTER NPE X1000 is an industrial computer that can be used as a telemetry module mod bus gateway proxy router or an SNMP agent It s a com plete ready to use platform including hardware installed Linux operating system free ware tools and programming libraries for C C There are eight serial ports 6 RS 232 2 RS 485 and CAN audio HDMI USB and Ethernet interfaces Techbase 48 58 345 39 22 www a2s pl DOUBLE SPEED PACS Allen Bradley ControlLogix 5570 series PACs
38. Operation _ ae W e 12 A 1440 W Nominal fi an Fa y 15 A Max Capacity Br Visit omega com cni cb120sb AW l 3 Yi 1 Rh NN i l I sll MM il 7 li I ita f TL ES 4 Adjustable DC Speed Control OMDC 15DVE 152 Permanent Magnet DC Motors OMPM DC Starts at Visit omega com omdc 15dve 1 2828 82 6 6 342 omega com ETET INNA ait ARLTLT AASA LALA i 1 E TALALATATALALALA A 3 i i Signal 50 Warning Tower Lights OMSL Series Starts at 70 Visit omega com omsl_series Y OMEGA COPYRIGHT 2012 OMEGA ENGINEERING INC ALL RIGHTS RESERVED AT aN ata AN j l ii Dar uan j i i d F Operator Effectiveness In order to keep your plant running safely and at its optimum level your operators need to be equipped to recognize abnormal situations and handle them through effective decision making Advanced alarm management easy navigation to plant wide actionable information dogged attention to human factors in the control room and integrated training simulation will elevate your operators performance to new heights That s the Power of Integration Join the conversation at www processautomationinsights com Plan now for Automation amp Power World 2013 Orlando March 25 28 2013 Power and productivity For information www abb com a amp pworld for a better world November 2012 Volume XXV Number 11 CONTENTS FEATURES
39. T User Interface SMART Architecture SMART Functionality is the ultimate paperless digital recording system GP models are portable bench units ideal for lab test applications GX is a panel mount system designed for process environments Both feature a highly responsive and intuitive touch screen operator interface and scalable modular I O e Text messages can be handwritten or e Save data to high capacity SD media typed on the touchscreen to satisfy e Print reports to a network printer batch recording needs e Change settings and view real time e A swipe of the screen shows trend data with a web browser history e Order the channels you need today purchase and install additional I O a modules when you need more It s SY quick and easy ADB1201 For more information www Smartdacplus com 800 258 2552 vigilantp ant YOKOGAWA www yokogawa com us The clear path to operational excellence Can rely on wireless to control remote facilities Can monitor temperatures at known problem locations without wiring Can I collect remote tank level data without costly trenching and conduit Can control remote well pumps without line of sight sures cross wireless network In process and industrial automation you need accurate monitoring consistent uptime and real ROI Be sure With the Banner SureCross Wireless Network Visit BannerEngineering com ProcessControl Or call 888 37
40. a pH loop directly throttles a reagent valve on a static mixer this change in slope on the valve characteristic compensates for a change in process gain for pH that is inversely proportional to flow A quick opening trim characteristic provides initially a very high process gain followed by a very low process gain This nonlinearity is accentuated in the installed characteris tic and is generally undesirable because it magnifies resolu tion problems near the seat and causes an excessive loss of sensitivity even at mid range throttle positions Pinch valves and isolation valves designed for on off service tend to have this characteristic Turning on a Dime or at Least a Quarter Dead time and response time quantify dynamic response The dead time Td is the time to a first change in closure member position after a change in signal The response time T86 is the time required for the position to reach 86 5 of its final value and includes the dead time These parameters are defined in the ISA standard and report for the test and measurement of the response of the complete control valve assembly 0 O c re O w w v 7 r re 2 w v a Step size RESPONSE TIME Figure 2 Various positioners on small actuators all exhibit much longer times for smaller step changes Versatile Dependable Affordable The versatile design of the SAMSON Type V2
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42. ant at Maverick Technolo gies www mavtechglobal com says that Maverick s engineers recently implemented a set of model based controls for BASF www basf com in Geismar La The application was on a series of fixed bed catalytic reactors in which the reaction was highly exothermic while the catalyst was very heat sensitive Ford ex plains Figure 1 p 34 The temperature had to be kept high enough to promote the reaction but just a short high temperature excursion could rap idly deactivate this very expensive catalyst Several APC algo rithms were used to implement the solution in a Foxboro DCS The project was very successful especially at controlling the reactor temperature profile during bed catalyst changes con cludes Ford The controls implemented by Maverick outperform the best of my operators even with me at the console instructing them exactly how to handle a change out says David Weatherford technologist at BASF They saved us a lot of money in catalyst costs and paid back the investment in a couple of months Enterprise Products www enterpriseproducts com in Hous ton Texas is an energy company that operates pipelines 25 nat ural gas processing plants 20 NGL and propylene fractionators and import export terminals When I took on my new role I didn t think Id be able to justify replacing advanced regulatory controls which I d developed and supported
43. ar post of recent weeks has been Lessons Learned from Aurora He begins On the SCADASEC list Ed Beroset stated the following Tve attended a number of security conferences at which speakers would gravely intone that we have not yet learned the lessons of Aurora Tve found that there s a very wide range of interpretations as to what those might be My questions for this group are 1 what is the lesson of Au rora and 2 what has been done about it and 3 what s left to do In response to Ed there are a number of lessons learned specifically from Aurora To read the entire post go to http com munity controlglobal com content les sons learned aurora In his post Legacy Control System Cybersecurity Reliability Test Bed Joe reports There has long been a strong desire to find solutions for secur ing industrial control systems that go beyond simply exposing problems and risks What is so difficult about finding solutions The answer is technology use and compliance Solutions exist for some parts of the control system that have been adopted adapted from the IT community To read the complete post by Joe go to http community controlglobal com content legacy control system cybersecurityreliabil ity test bed Hi Updated every business day the Control Global online magazine is available at no charge Go to www controlglobal com and follow instructions to register for our free weekly e new
44. art ing to feel the effects of natural gas and NGL prices on their business models Moreover as the commercial distribu tion of ethane and ethane based raw materials increases it could trigger new innovations and investment in new tech nologies Research and development initiatives leveraging ethylene based chemistries that replace petroleum based products may predominate Companies might also look for longer term sourcing relationships and partnerships with raw material suppliers to help with developing new products Based on industry reports we estimate U S chemicals industry has invested 15 billion in ethylene production in creasing capacity by 33 As these investments take hold yielding more supply the United States could become a ma jor global low cost provider of energy and feedstocks said Garrett Gee director of chemical advisory services at PwC We re already seeing increased investment activity among multinational companies in building the infrastructure to export liquefied natural gas LNG products As manufacturers replace petroleum based raw materials with products based on ethylene their cost structures should also change significantly as well as supply and demand for certain products This pattern may be repeated for other petroleum based raw materials many of which are used in building construction adhesives paint coatings plastics packaging and carpeting If the changes brought about by s
45. be to reduce faults But in fact unreported faults don t get addressed In the past using the old solution opera tors tended to avoid the complicated time consuming reporting process and simply didn t report all the faults they observed Now because System 800xA provides a common visual interface for a diverse assortment of systems applications and equipment operators simply click on the object shown on their HMI that they want to report choose create fault report input the problem and submit the report which FLT 2011 C MS with Motor Starter When Measuring Continuously or Point to Point 4 20m lt A Industrial Level Transmitter Lumenite Control Technology wwwiumenite conv level ASSET MANAGEMENT Figure 2 The integrated report application from Maximo makes it simple for operators to report faults as they are discovered right from their HMI screens then becomes available in Maximo where the maintenance staff can see complete and correct information and take action immediately The integration of Maximo and Sys tem 800xA ensures early fault detection which has increased the number of faults reported five fold according to Aitek It gives operators the ability to inform the maintenance department about prob lems while they re still small and before they can cause a breakdown or an un planned shutdown The mine and its equipment runs 24 7 every day of the year in extreme conditions
46. can re duce the amplitude of the limit cycles significantly For pH control the resolution of a reagent valve can deter mine the number of stages of neutralization needed A fine adjustment valve in parallel with a coarse adjustment valve simultaneously manipulated by a model predictive control ler can extend the sensitivity and rangeability of a reagent system enough to eliminate a stage Throttle Your Valve Problems A control valve package is only as good as its weakest link whether it s the actuator positioner feedback mechanism packing or valve design If the control valve and actuator are similar to those used for isolation valves you re a candi date for significant limit cycles sustained variability in your process This is particularly a problem with packaged equip ment skids where control valves are chosen based on piping specifications and lowest price rather than on loop perfor mance Cost effective solutions exist For example a sliding stem valve designed for minimal seating friction and packing friction coupled with a dia phragm actuator and a smart positioner can reduce resolu tion and dead band to better than what you can achieve with a standard variable speed pump Figure 4 shows that even operating near the seat a sliding stem control valve with a digital positioner can respond to changes as small as 0 1 I Greg McMillan is a member of the Process Automation Hall of Fame Editor s note This artic
47. ct information articles white papers prod uct and news announcements blogs tweets special projects videos podcasts ebooks and more and we present them to you in an easily available format sorted edited curated for your use Sometimes we find this information and sometimes we commission new works We can do this because we have put together a group of subject matter ex perts to work on our collections people like Greg McMillan Stan Weiner B la Liptak Joe Weiss John Rezabek Dan Hebert Jim Montague Nancy Bar tels Katherine Bonfante a host of other end users and knowledgeable vendors and finally your humble servant The difference between what you can find on Google about 45 million re sults for process automation and what you can find on ControlGlobal com and in Control magazine is the value we bring to you actionable information that you can use and that you can trust We aren t just passive accumulators of information We go out and find what you need to know We broke the Stuxnet story back in 2010 and have followed it all the way We have curated a large body of material on cybersecurity We followed the wireless standards imbroglio to try to keep you from being con fused and we did it from the inside by actively participating in the standards process We provide deep content on field devices networks wireless final control elements controllers and control systems and we do it in a way you can trust
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49. d FLC Michel Ruel is back to talk to McMillan and Weiner about PID control and beyond 69 Ad Index Check these pages 70 Control Report Valero s Good Examples Independent refiner keynote at ISA Auto mation Week 2012 shows how advanced process control can produce big gains Chemicals amp Allied Products Food amp Kindred Products System Integrators amp Engineering Design Firms 9 261 Primary Metal Industries 5 232 Electric Gas amp Sanitary Services 4174 Petroleum Refining amp Related Industries Pharmaceuticals Rubber amp Miscellaneous Plastic Products 3 499 Paper amp Allied Products oli Stone Clay Glass amp Concrete Products 1 855 Textile Mill Products 1 219 Tobacco Products 137 Total Circulation 60 020 Endress Hauser People for Process Automation Building on our successes together in the United States Endress Hauser is expanding in the US nearly doubling our manufacturing capacity and increasing our training and Support capabilities Why Because we believe a the best support for our customers comes from manufacturing our products close to where we ship them and having our support and services nearby Today more than 90 of products we ship to our US customers are built right here in the US and that figure continues to increase in the skills and work ethic of our US workforce Our people are the foundation on which we build high quality innovative prod
50. d Gionet process control engineer at Agrium Carseland Nitrogen Operations www agrium com in Denver Colo uses an Invensys Connoisseur advanced process control application http tinyurl com 9mgq3xp with an MPC configuration and a linear programming optimization layer that provides target information to the constraint controller In the midst of all the advanced APC software Gio net uses some straightforward controls too For example we run an advanced servo control cascade incorporating feed forward control Dead time compensation is faked with an adaptive first order filter block We currently have one important PID loop running a self tuning algorithm I might be too liberal in terms of what most control engineers consider advanced control but keep in mind that cascade control was once considered advanced con trol he says Meriam Delivers the Best Performance for Your Money and So Much More e Over 100 years of experience manufacturing process measurement instrumentation e Superior accuracy over widest temperature range e Rugged design to handle tough environments e Accurate reliable and repeatable measurements e Instruments are easy to use and maintain the first time e Ergonomic product design saves time and a e Updates available at www meriam com increases productivity e Personal in house customer support e A complete product line perfect for a wide variety of applications e Expert in hou
51. d from the primary control loop Flow feed forward and ratio con trol can become more effective To read the entire post go to http com munity controlglobal com content checklist cascade control The other hit is Checklist for Batch Reactor Temperature Control Greg says Tight reactor temperature con trol enables the optimization of ca pacity and yield What happens up front in the reaction sets the stage for downstream processing and what ul timately ends up in the final product Generally increasing reactor tempera ture will increase reaction rate capac ity but if the temperature is too high side reactions may develop reducing reaction selectivity yield Oscilla tions and errors will prevent operating closer to the optimum temperature This checklist offers questions to im prove reactions by addressing the heat ing and cooling system design ther mal lags split ranged discontinuities tuning reactant feed and the need for a measurement of fouling and conver sion To read the entire checklist go to http community controlglobal com content checklist batch reactor tem perature control Our resident expert on cybersecu rity is Joe Weiss He is a principal at Applied Control Solutions and an au thority on cybersecurity and control systems In his Unfettered blog he crusades for better more effective se curity of critical infrastructure and process control systems Joe s most popul
52. d the company responsible for the onshore section of pipe was responsible for that particular section of the pipeline and vice versa Consequently that section of pipe was neglected and finally failed DR RAYMOND WRIGHT ray wright fse global com Smart PIG systems are used to collect pipeline data that are analyzed offline to identify defects and poten tial dangers to the integrity of the pipeline No PIG system initiates any safety action as the data collected is not capable of taking the decision Pipeline defects arise over time and require comparison between periodic records for correlation Hence I do not see a direct link between smart PIGs and safety systems There are other pipeline monitoring systems for leaks that use patented software to identify any leaks failures early and initiate warnings or shutdowns L RAJAGOPALAN L Rajagopalan Fluor com NOVEMBER 2012 www controlglobal com 61 ROUNDUP Ss PLCs and Industrial Computers What you need when you need the machinery to think and do the job ALL IN ONE HMI AND PLC Perspecto CP TV merges an HMI and a PLC into one package The CP TV of fers an all in one solution for logic and visualization It features five sizes of TFT touchscreens and a selec tion of ports Ethernet Mod bus TCP CANopen USB RS 232 and RS 485 The IEC 6113l compatible software is the all in one development tool for logic programming and graphic screen editing Wago 800 DIN RAIL w
53. ding failure of the pipe There are also na tional and international standards that state the mini mum thickness and other required parameters to deter mine the condition of the pipe and trigger a repair or replacement There may be abnormal circumstances that warrant additional inspections pipe hit by anchor dragged by ship potential damage from earthquake etc These nor mally would be evaluated by visual inspection as a first step If the PIG is traveling through a steel pipe then the transmission of a data signal will be impeded by the pipe acting as a shield and by the depth of the pipe un derground or under water So while it may be advantageous to receive real time data it may not be practical If data is being lost because of electronic failures then perhaps the integrity of the electronics inside the PIG could be improved with bet ter diagnostics and or redundancy but it is likely this has already been implemented in modern PIGs De sign and certification of the data collection systems to IEC61508 may help to improve the integrity of the electronics however the cost of this would need to be weighed against the benefit if existing PIGs already have high reliability You can review what happened at Veranus Island www dmp wa gov au 7202 aspx This pipeline failure is interesting A section of the pipeline between offshore and onshore was neglected because the company re sponsible for the offshore section of pipe believe
54. dors mixed with good engineering principles can yield excellent results but a high degree of end user ex pertise is required NOVEMBER 2012 55 ADVANCED PROCESS CONTROL SP Reactor 2 outlet Operator entry sere temperature control model based APC DOES CATALYTIC REACTORS SP Reactor 6 outlet py Operator entry temperature control piim model based Reactor 3 outlet temperature control model based Reactor 3 intlet temperature control Smart PID Courtesy of Maverick Technologies Aik i l To purification amp recovery Rx Rx Rx Rx 3 4 5 6 Figure 1 APC was used with great effectiveness by system integrator Maverick Technologies to improve control on a series of fixed bed catalytic reactors MPC on every process in a refinery or chemical plant are over he says Too many failures The future will see a renewed in terest in APC solutions tailored to fit each specific control prob lem and will rely on a combination of traditional advanced reg ulatory control inferred properties and MPC techniques when appropriate and justified Maintaining APC s full effectiveness is also difficult APC AERO DERIVATIVE ADVANCED CONTROL What s APC and what s just a collection of clever programming blocks Lou Bertha of RDI Controls www rdicontrols com isn t sure and he s the one who put together an APC system to control an aero derivative combustion turbine The process
55. e AspenTech s www aspentech com DM Cplus APC software to improve unit stability balance and optimize feed rate and reduce steam and power usage In the NGL Fraciona tor liquid recovery unit improved quality in creased recovery rate and minimized feed dis turbances resulted in a fuel gas savings of about 200 000 per year Similar improvements were made in the propane recovery units and depro panizer units Results were even more impressive at a GALP Energia hydrodesulphurization plant in Portugal where APC generates savings of about 1 2M 1 54 million per year The As penlech APC software in use there controls sulphur in the final product to below the spec limit reduces hydrogen in the hydrotreater and hydrodesulphurisation units and saves fuel gas in pre heating furnaces We offer core MPC technology for both linear and non linear applications and prod ucts for developing inferential measurements explains Robert Golightly APC product mar keting manager at AspenTech On top of the APC technology we offer a range of optimiza tion products including composite technology supporting very large applications and full real time optimization based on our modeling prod ucts Aspen Hysys and Aspen Plus He adds that AspenTech can provide ser vices in the form of augmentation to existing staff or turnkey services Sometimes such help is needed because APC requires specialized skills not always available wit
56. e key power oil and gas and mining sectors The order backlogs that suppli ers have accumulated are still healthy indicating that growth should con tinue for the foreseeable future Shale Gas Supports Rosy Outlook for U S Chemicals Industry The expansion of the shale gas market could potentially drive significant ben efits to the U S chemicals industry in cluding decreased raw material and en ergy costs according to a new report by PwC USS titled Shale Gas Re shaping the U S Chemicals Industry In fact another recent PwC report esti mated that the potential impact of shale gas on U S manufacturing could en able U S manufacturers to lower their raw materials and energy costs as much as 11 6 billion annually by 2025 Before natural gas from shale can be transported efficiently and sold commercially impurities must be ex tracted The byproducts of this process known as natural gas liquids NGL include hydrocarbons such as ethane butane and propane The chemical in dustry uses NGL s to produce a variety of derivative products that ultimately become raw materials for multiple manufacturing sectors In the case of ethane they convert it to ethylene the most significant single chemical in terms of volume and value and then a range of downstream products A sam pling of manufacturing sectors that ul timately benefit from greater capacity and more attractive pricing of NGLs SMART CF SMAR
57. e process theme was later empha sized by Jim Simmons from DuPont who described the fieldbus learning curve triggered by his company s pur chase of a Siemens PCS7 control sys tem He sung the praises of fieldbus and Profinet in particular Through that project I have become a fieldbus proselytizer within DuPont I believe any new control system installation should have to justify not using field bus technology W Using wireless here and there is one thing But using it across my entire operation There s no one could trust to do that See more do more and be more profitable with the most trusted partner in wireless Emerson Emerson is your proven partner with Smart Wireless in more customer sites and with more operating hours than anyone else in the process industry Smart Wireless has the widest range of technologies to expand your vision into more places across your operations And its self organizing mesh network delivers the highest reliability available It is simply the most intelligent secure and cost effective operation wide wireless option available See how Smart Wireless can empower your bottom line N at EmersonProcess com SmartWireless N EMERSON Process Management The Emerson logo is a trademark and a service mark of Emerson Electric Co 2012 Emerson Electric Co EMERSON CONSIDER IT SOLVED LIQUID LEVEL MEASUREMENT fF THE ORIGINAL INNOVATORS
58. ed Valero s upgrade of the control systems control room and networking infra structure at its Benicia Calif refinery Denise Plaskett Valero s principal applications engi neer for control systems presented Continu ous Evolution Layering Experion on Top of TDC describing how she and her colleagues designed and carried out the renovation in cluding moving more than 2000 I O points testing new local control networks and dealing with timing issues that required all integration and cutover to the new system to be done on line while working around unit turnarounds over several years Pretty dramatic Nothing like good stories Hi 24 7 365 Any platform Any industry Anywhere It s here The world s first full service platform independent 24 7 365 hardware software and total process support solution Move ahead of the competition Improve asset management Reduce operational costs Augment staff with a broad deep resource pool It s all possible through our revolutionary PlantFloor24 solution We combine customized service options with around the clock support of our U S based operations center all backed by the expertise of MAVERICK Technologies an ISA Strategic Partner We never sleep so you can For our video and technical papers visit PlantFloor24 com To talk about a custom program for your plant call 888 917 9109 Premier MAVERICK isa strategic Systems Integration Another
59. enhance data acquisition and monitor ing applications that log manipulate and exchange large amounts of data SoftPAC is programmed with the PAC Project software A control program developed for one PAC can be run on another one with almost no modification Like hardware based PACs SoftPAC can be used with any Opto 22 Snap I O unit that uses an Ethernet based I O processor SoftPAC runs under Microsoft Windows 7 32 bit or 64 bit or Windows XP 32 bit operat ing systems and supports operation on multiple cores and processors Opto22 800 321 6786 softpac opto22 com MONITOR PRESSURE THE EASY WAY Ashcroft DG25 digital pres sure gauge provides a five full digit LCD in ranges up to 25 000 psi Available in ac curacies of 0 5 and 0 25 FS this new design boasts a minimum battery life of 2000 hours Standard features in clude an IP67 enclosure se lectable units of measure a 20 segment bar graph indicator min max tare and a list of agency certifications A backlight and rubber protective boot are also available Ashcroft 800 328 8258 www ashcroft com LEVEL AND TEMPERATURE IN ONE SENSOR The AST45PT liquid level sensor for hydrostatic level and temperature measure ment provides two indepen dent 4 20mA output signals for a level and a temperature signal With measurement ranges from l psi 27 68 in water column to 100 psi 230 67 ft water column the AST45PT appeals to a wide range of applications AST of f
60. erioration of loop performance The decou pler can also deal with stronger interactions A simple decoupler uses the output of one PID as the feed forward for the other PID and vice versa For interactions between more than two controlled variables or for more than one con straint MPC is advisable Greg The advent of adaptive tuners has re cently automated the identification of process models and scheduling of tuning MPC pro cess model identification was an automated and essential feature from the beginning of MPC technology Stan Oil gas petrochemicals and commod ity chemicals are produced by large continu ous processes with well known process mod els where a 0 1 increase in process efficiency or capacity provides enormous benefits MPC with the integrated LP for process optimization is the obvious solution What industries don t have process models and why Michel I have found that many processes in the mining industry can t be modeled The process interrelationships and dynamics in the processing of ores are not defined due to the predominance of missing measurements and unknown effects PID loops are often in manual not only for the usual reasons of valve and measurement prob lems but also because process dynamics between a controlled and manipulated variable radically change including even the sign of the process ac tion reverse or direct based on complex multi variable effects that can t be quantified
61. ers five temperature ranges and eight cable length options to make integration simple American Sensor Technologies 973 448 1901 www astsensors com 1 NOVEMBER 2012 BALL VALVES FOR PRECISION PROCESS CONTROL New V Series modulating ball valve for achieving pre cision process control is de signed to control pressure temperature flow and level The valve body is available in carbon or stainless steel with NPT socket weld tri clamp and 150 or 300 flanged end connections Sizes available are 2 in through 8 in Control signal options include 4 20 mA and 3 psi to 15 psi V Series modulating ball valves are characterized to meet your custom flow requirements Assured Automation 800 899 0553 www assuredautomation com ELECTOMAGNETIC FLOWMETER PHONE HOME The Proline Promag L800 battery powered electromag netic flowmeter is ideal for use in remote sites in water and wastewater systems The flowmeter has an integrated GSM GPRS cellphone sys tem that allows data to be transmitted as an email over the cell phone network It is available in sizes from 2 in to 24 in operates at pressures up to 232 psi and works with liquids having a minimum con ductivity 250 pS cm Maximum flow rate is 33 ft sec Endress Hauser 888 ENDRESS www us endress com promag 400 800 ODUCT INTRODUCTIONS PLASTIC ELECTROMAGNETIC FLOWMETER The new plastic body FMG800 series is a battery powered corrosion resistant electro
62. es the rock at 4 m s to the concentrator NOVEMBER 2012 www controlglobal com 47 ASSET MANAGEMENT plant where two 22 5 MW gearless mills grind it down to sand at the rate of 4400 tons per hour Then the sand goes into flotation tanks filled with reagents foaming agents compressed air and chalk where 500 000 liters of water are added each hour separates out the valuable copper This treatment gold and silver ore which floats to the top The resulting chalcopyrite concentrate which is 25 copper is then transported by train to Boliden s smelter in R nnsk r 400 km away An operation this size has a lot of mine equipment to be maintained In addi tion to the new concentrator surface crusher and the 7 km conveyer between them the site has pipelines to its water rec lamation stations pumping stations a welding shop a truck garage administration buildings and a recycling station The operation is controlled by a System 800xA from ABB www abb com and to support maintenance of the A BIG DAILY GRIND Figure 1 One of two 22 5 MW gearless mill drives that power the grinding mills at the Aitek facility designers integrated a Max imo enterprise asset management EAM system from IBM www ibm com with it Finding Faults Among the goals Boliden had for the system was to increase the number of reported faults in the system At first glance this seems counter intuitive one would think the goal would
63. etup allows us to develop and modify these subroutines to provide greater flexibility than the fixed rou tines in other systems Bertha explains You don t need to be a computer science major to figure out and modify these routines to suit your needs Whether or not these are considered APC is in the eye of the beholder but the tracking and coordination between PIDs and setpoints makes it a fairly advanced setup says Bertha Wwww vega americas com americas vega com 1 800 FOR LEVEL VEGA offers the VEGAPULS through air radar and the VEGAMET signal conditioner for easy inventory management The system delivers actionable inventory data direct to an office PC and with a convenient local display unsafe climbing of silos is eliminated The Easy Inventory Management System supplies the following benefits Provides overfill protection with automated alarming and quoting Measures level over entire height of the silo Continuously measures during the filling process Sends e mail for reorder point Looking Forward ADVANCED PROCESS CONTROL Figure 2 System integrator RDI Controls uses standard software tools provided by Opto 22 to create its own APC routines to control combustion turbines Courtesy of RDI Controls suppliers are changed Adding new equipment can signif cantly change the process as can normal deterioration of existing equipment As changes occur within the process corresponding ad
64. grate mission critical applications with ruggedized computing and networking devices Learn how SEL can improve your system operations at www selinc com ops Unlock Your Smart HART Device s Hidden Secrets HART Loop Interfaces LEA COMMUNICATION PROTOCOL e Convert HART to 4 20mA Signals e Break Out Up to Three Analog Signals eo 6 e Provide High Low Process Alarm Trips Contact Closure 3i 54346 e Convert HART to MODBUS RTU ee DEGC e Monitor HART Instrument Diagnostics e Work with Every HART Compatible seseo ETTA Transmitter and Valve e Set Up in Minutes Using FREE Configuration Software HART Digital Signal Carrying Primary Second Third and Fourth Variable Process Data and Instrument Diagnostic Information 4 20mA Representing the Primary Variable Mass Flow HART am S43 ur So 4 20mA Proportional to 3rd Variable P irae 4 20mA Proportional to 4th Variable T can be Connected Anywhere Along High Alarm in Response to 4th Variable T the 4 20mA Loop __ HART Transmitter Diagnostics Fault Alarm or Additional Process Alarm HIM Smart HART Loop Monitor Breaks Out Data from Smart HART Instruments Smart HART x4 Multivariable Mass Flow Transmitter T gt Flow www miinet com HART WORLDWIDE e www miinet com H United States info miine
65. hale gas take hold in the chemicals industry they will also create a need for specialty steels reactors pumps valves fit tings control systems storage tanks and other equipment as ae PROCESS well as the services of engineering and construction firms Another possible outcome is that chemical products will increasingly become a substitute for more expensive materials such as met als glass wood leather and textiles The significant increase in NGL production could drive change across the U S chemicals industry but the full potential of the market will depend on a number of factors According to a New York Times article by Michael Levi in August August 16 www nytimes com 2012 08 16 opinion the case for these tors include domestic tolerance for ex natural gas exports html fac panded hydraulic fracturing and its waste products as well as the political and economic ramifications of export ing LNG added Scamuffa The im plications of the shale gas boom for the chemicals sector also vary by company so management teams need to consider their individual situation and business options including the risks and oppor tunities presented by the abundance of shale gas Courtesy of SustainablePlant com Authors Honored for Alarm Management Book Eddie Habibi and Bill Hollifield have been recognized as the recipients of the Raymond D Molloy Award presented by ISA Publications Department for the best se
66. have en hanced memory and process capabilities that help enable seamless integration with motion drives They have a 1 GB secure digital card and USB port an on board dis play for enhanced controller diagnostics and run time in formation and a new energy storage module that eliminates the need for lithium batteries Rockwell Automation 414 382 2000 www rockwellautomation com PLC MASTER MasterLogic PLCs can be deployed in a standalone mode without any human machine interface They can also be used as an additional controller with Honeywell s Experion Process Knowledge System PKS architecture and are compatible with Honeywell s portfolio of process control systems With integration they can control multiple processes with one common operator interface Honeywell Process Solutions 800 343 0228 www honeywell com ps hfs NOVEMBER 2012 www controlglobal com 63 64 PRODUCT INTRODUCTIONS SOFTWARE BASED PAC INCLUDES PC BASED CONTROL AND DAQ SoftPAC is a software based programmable automation controller PAC ideal for use with computationally intensive applications and those that must log manipulate and exchange large amounts of data SoftPAC is part of the SNAP PAC family of standalone and rack mounted PAC controllers SoftPAC takes advantage of a PC s computational speed to quickly execute complex logic and calculations It also takes advantage of a PC s file handling and networking capabilities to
67. he year earlier period which included a large offshore wind order Exclud ing that order power orders rose 10 driven by utility and industry invest ments in power transmission Automa tion orders were up 13 flat organic driven by demand for improved indus trial productivity mainly in Europe and North America and in the mining and marine sectors The operational EBITDA and op erational EBITDA margin were lower than in the strong third quarter of last year mainly due to the execution of lower priced power orders from the backlog but were higher than 2Q 2012 The operational EBITDA mar gin in Power Products was steady com pared to the second quarter of 2012 Cost savings for the group amounted to about 280 million in the quarter The stronger U S dollar continued to nega tively impact ABB s reported results An increase in divisional cash flows was more than offset by cash outflows NOVEMBER 2012 www controlgloba m 29 IN PROCESS from hedging corporate exposures as a result of the stronger U S dollar We re encouraged that we could grow the business and sustain profitabil ity well within our target corridor despite a challenging macro environment said Joe Hogan ABB s CEO We continued to execute on cost reduction and grow the service business two of our key strate gic initiatives The geographic rebalanc ing of our automation business towards North America for example through Instr
68. here are still a lot of folks who use heldbus for I O only But many of the pro cess control specialists who experimented with heldbus solved PID have caught on to the vi sion of the architects of SP50 that fieldbus would become a more robust truly distributed and innately more reliable platform for rudi mentary PID loops In growing numbers us ers are deploying fieldbus employing this long dormant capability to not only have fully digital I O but also a fully digital and distributed con trol system vendor neutral and independent of the host Many systems people may never land a wire or lay their hands on a positioner or buy a transmitter but they realize that the reliabil ity of their control schemes hinges on these devices no matter where PID is solved And if one can also solve PID with improved deter minism speed and integrity there s nothing to lose and much to gain by exploiting it But there will always remain many loops for which control in the field CIF isn t an option Fitting compressor speed controls or complex schemes requiring nonlinear controls adaptive gain scheduling or complex cascades into the relatively generic repertoire of fieldbus func tion blocks might be a struggle If you re leading a project you d like a simple and straightforward bit of guidance to help your consultant EPC easily choose the logical appli cations for CIF or control in the host such as e Whenever the output of a PID
69. hgear 170 kilovolt for substation e Harmonic filter system for the complete plant e 201 cubicles of low voltage switchgear 400 690 volts for distribution of power across the site ASSET MANAGEMENT operates mines and smelters in Sweden Finland Norway and Ireland the mine recently completed a massive expan sion and modernization project The price tag for Aitek s up grade was 790 million but it s enabled the mine to double its production capacity extend its life until 2030 and add molybdenum to its list of metals produced Aitek s ore is not especially high grade It s 0 25 copper 0 1 g gold per ton and 2 g of silver per ton but still worth the investment in digging it up It s not just the market value of the minerals that makes the investment worthwhile The up grades Boliden has installed are expected to reduce life of mine cash costs from 0 80 per pound to 0 43 per pound and have raised production rates from 4 3 tons per man hour to 5 5 tons per man hour Efficient trouble free operation is crucial to Aitek s long term success Crush Shake Stir Once a week at Aitek a blast produces enough ore for the operation to process 106 000 tons each day The unpro cessed ore is loaded onto 100 ton trucks which deliver it to a crusher deep in the pit The crusher reduces the ore to 30 cm boulders which are then transported by underground conveyors to a storage area above ground From there a 7 km conveyor mov
70. hin process plants or companies Because of this lack of familiar ity many plants that could benefit from APC haven t done so despite many success stories LG Chem s Daesan Ethylene plant in South Korea was plagued by disturbances making quality and throughput control difficult The plant had to deal with feed quality variations de coking activities naptha tank switching ev ery three days furnace switching every day and changing ambient conditions To solve the problem LG Chem s engineers implemented Aspen APC software across all sec tions of the plant to stabilize plant operation re duce losses maximize throughput and minimize energy consumption Aspen controller software was installed on the furnaces and the C2 splitter another controller coordinated all the other con trollers and a simulator was used to provide infer ential measures of composition and severity and to determine the gains for the controllers The effort reduced losses by about 35 across all disciplines throughput went up 2 and energy consumption went down 1 5 AspenTech was one of the originators of APC software for general purposes in the process in dustries so their vision of the future is worth not ing Based on the changes we have seen over the last five years my expectation is APC will be come more accessible to non experts predicts Golightly The inclusion of knowledge best practices and workflow automation within the p
71. http iom invensys com has acquired Spiral Software www spiral soft com a privately held company headquartered in Cambridge U K Founded in 1998 Spiral Software pro vides integrated solutions ranging from crude assay management to refinery supply chain optimization enabling cli ents to make the best possible choices in trading and refining crude oil Spi ral s crude oil knowledge management tools help companies track the quality of feedstocks and predict their refining behavior Fully integrated refinery plan ning and scheduling help optimize pro duction plans based on real time crude demand and market pricing as well as the refinery s own capacity and supply chain constraints This acquisition complements our existing refinery wide optimization strategy and leverages our SimSci Es scor modeling and optimization offer ings for the hydrocarbon processing in dustry said Ravi Gopinath president of IOM s software business Spiral Software provides the only integrated refining industry solution designed from the ground up bringing together feedstock data management planning and scheduling This means that our SimSci Esscor offerings will now fully support and optimize the entire refin ing value chain from crude trading to supply chain distribution including lifecycle modeling from design to start up to performance optimization Combined with Invensys Opera tions Management s existing refinery
72. igation DEBASIS GUHA Debasis Guha ranhill worley com my Although I am not an expert in pigging systems pipeline integrity and continuous leak detection is best performed by specialized software pro grams Intelligent PIGs are used to collect and store data in their memory because transmitting data while they travel through the pipeline requires a lot of bat tery power PIG tracking transmitters and receivers are available from a number of vendors However these are restricted to information about the PIG s location rather than data transmission If Harry is interested he can contact PPSA www ppsa online com and get more in formation on the latest developments from PIG manu factures and end users RAY BINNEY binney4family internode on net Pigging is usually not the only non destructive peri odic test carried out on the pipe Usually there will be an inspection frequency set to examine some or all of the pipe from the outside especially for major pipelines The combination of periodic pigging and external ex amination should be sufficient to trend the integrity of the pipe in normal circumstances provided that the frequency of these inspections is set within a reasonable time frame This time frame will be affected by the type of material flowing in the pipe corrosive clean dirty service etc All the data from the combination of these inspec tions is generally trended to provide adequate warning of an impen
73. ing costs and tighter budgets need to get more out of my temperature instrumentation and my crews YOU CAN DO THAT ROSEMOUNT Use the enhanced Rosemount 644 Temperature Transmitter s modular design to save money and boost productivity With higher performance goals and increased budget pressures you re forced to do more with less That s why we enhanced the Rosemount 644 Temperature Transmitter with a unique modular design that enables customized functionality at each process point so you only buy what you need And its insightful diagnostics and superior accuracy ensure your crews spot trouble sooner take action faster and hit your production targets spot on Find out how you can customize a temperature solution to fit your budget at Rosemount com temperature 73 EMERSON Process Management The Emerson logo is a trademark and a service mark of Emerson Electric Co 2012 Emerson Electric Co EMERSON CONSIDER IT SOLVED PUESSONS LEARNED Le Containment Rupture disk Relief valve 7 A Pressurizer Boiler J Electric power Cooling Generator Reactor THREE MILE ISLAND PRESSURIZED WATER REACTOR Figure 2 The primary pump 1 circulated the primary water while the secondary water was circu lated 4 by the secondary water pump until its suction valve was accidentally closed nuclear power dropped from 18 in the early 1990s to 13 5 by 2012 Some na tions have decided
74. ing software says Tom Edwards Opto 22 s www opto22 com senior technical advisor The tools that users and vendors provide for the PAC Con trol programming software are primar ily in the form of subroutines which are imported into PAC Control and incorporated into a control program Opto 22 provides subroutines as free integration kits on the website Other subroutines are shared by customers in the online OptoForums he adds APC will become available any time everywhere because the ba sic operations data and software are easily available at the DCS and PC level says Saravanan Prabakaran so lutions consultant at Yokogawa www us yokogawa com The implementa tion and maintenance cost of APC will become cheaper The tools that will be available for APC implementation will help in easy implementation The optimal solution is elusive but perhaps the most promising path is to start with the simplest APC pos sible one that delivers an acceptable percentage of theoretical benefits but without stultifying complexity Users and vendors alike must keep in mind that implementing APC is just a start because without proper maintenance any solution will soon lose its effective ness Even with complex APC technol ogies simpler is often better I Dan Hebert PC is Control s senior technical editor An extended version of this story is at www controlglobal com CT1211_Coy erStory html
75. ion was based are continually changing to one degree or another in every process plant In a refinery for example a switch might be made in the product mix in response to customer demand Raw mate rial input properties can vary significantly particularly if In multiple engine configurations they need each engine to control its fuel flow to maintain precise speed and load control of the generator Multiple modes of operation and tracking complicate things further We can put one engine in a test mode which allows direct control of engine speed or have one engine shut down due to engine problems while the other engine maintains the specified generator setpoints Bertha notes The system uses advanced control techniques such as cascade con trol loops with and without feed forward adaptive tuning anticipatory con trol adjustments and multiple controller coordination and tracking Opto22 allows us to develop user defined subroutines which can range from simple to complex says Bertha These subroutines are developed in the same flow diagram scripting language used to de velop the control logic Since Opto22 provides both higher and lower level commands we have the ability to develop the blocks or subrou tines such as rate limiters function generators monitors Modbus commands and so on to suit our needs But is this APC Some of these blocks may be considered standard on some DCS type systems but the Opto22 s
76. is basically a jet en gine exhausting into a power turbine with the power turbine coupled directly to a generator The system must control and limit multiple jet engines coordinate the speed to 3600 rpm to synchronize with the electrical grid and ad just load when online Each of the engine controllers positions the fuel control valve to provide the required liquid or gas fuel requirements and that s where it gets interesting With two engines operating the system will determine which engine is the master The slave engine will get an engine speed cascaded setpoint from the master Either engine controller can be the master and the control logic seamlessly switches masters as operational modes dictate The system is controlled with four Opto 22 rack mounted Snap PAC R series controllers with I O modules Controllers are installed on each of the engines The controllers communicate with each other peer to peer to ensure overall operational requirements are met Both systems have multiple PID controllers including cascaded control loops which all vie for control of the fuel control valve explains Bertha Tracking and coordination between these controllers can be come quite complex because we need the controllers to respond imme diately when needed and not have to wind down 36 NOVEMBER 2012 will only work as designed for a limited period of time as the underlying process conditions on which the original imple mentat
77. issues manufacturing companies say they are fac ing are integration of data across their supply chains and workforce development to replace retiring workers Data integration is extremely hard to do For example one of the attendees at the October SMLC meeting noted that she needs to get par ticle size distribution and elemental concentra tion and moisture for her input feedstock and what she gets is a paper or electronic copy of a paper certification It isn t the same thing so the company has to have wide acceptance brackets for its feedstocks which leads directly to non optimal performance It s sometimes possible to build brittle application program interfaces APIs but as another participant said They last as long as the people who wrote them are employed there It s critical to im prove this kind of data transfer because if it isn t competitive to make the products here in the United States they will be made elsewhere Workforce development is another sore point It s clear that there s a workforce short age especially in the technically literate job area If we want to keep manufacturing here we need to have people who want those jobs and who qualify to work in them Large companies can afford workforce develop ment and training They can support integrated supply chains to the extent their suppliers will let them But small and medium sized companies just can t afford to implement the syste
78. ives us the ability to create system reports based on prac tically any personnel group request says P O Lundqvist senior project manager at Boliden Boliden plans to implement the As set Optimization solution at all of its mines when their 800xA systems are upgraded E Nancy Bartels is Control s managing editor BETA LVALIOR ATORS e Dual pressure systems DPC 300A Dual System Pneumatic Calibrator j pp Regulated plant air to 100 psi 7 bar Integral electric pump to 300 psi 20 bar e Pressure accuracy up to 0 025 of full scale e Built in loop calibrator function with 24 VDC power e Ideal for transmitter calibration e Rugged IP67 Case e AC Rechargeable NiMH Cell RESEARCH CONTROL ReCo VALVES V When precision means everything From process industries to research Badger Meter offers both standard and custom designed control valves to help ensure precise performance We design our products to be accurate and effective for the most critical and demanding applications 800 876 3837 www badgermeter com valvefam23 aspx Badger Meter 2012 Badger Meter Inc RESEARCH CONTROL is a registered trademark of Badger Meter Inc High Performance Solutions Is Your E VALVES TIREE SN Mids Beware the disguised positioner By Greg McMillan When I was leaving home for the first time my dad said Be as honest as the day i
79. l shunt resistors A 16 channel dig ital input and six channel relay output module are also available GX and GP20 units support up to 10 modules for a ca pacity of 100 input channels The smaller GP and GX10 models support up to three modules for an input capacity of 30 channels Configuration is done through the touch setting menus on the display GX and GP products are network capable and can send data and PDF formatted reports to other network devices and network enabled printers for automatic generation of printed reports Because the network interface is standard Ethernet the devices support a full range of functions that include web server FTP file transfer email messaging and Modbus TCP client server connectivity The web server functions allow us ers to access real time displays including trend history with their web browser They also can change settings in a browser based environment with no special software For more functionality Yokogawa is offering as a free download GA10 file viewing and configuration software similar to the DAQStandard software that supports the DXA product lines GA10 is a standalone product with some over lapping functions with DAQStandard but it was designed from the ground up to support the GX GP products The viewer supports viewing and downloading of the proprietary secure digital binary data files of the GX and GP with a wide variety of functions including maths reporting and configu ratio
80. le is adapted by the author from one that appeared in Chemical Processing October 2007 r i F 7 ee a wt i l i m F J e E 1 F P et e a 7 f d _ f on i E a a ms Da O PRESENTING THE 17TH ANNUAL ARC WORL FEBRUARY 11 14 2013 e ORLANDO FLORIDA Achieving breakthrough performance requires identifying key improvement targets implementing the correct process improvement tools and generating fresh and unique offerings to meet evolving customer needs The results Reduced costs greater market share and enhanced value across the organization At ARC s World Industry Forum you will discover new innovative processes and technologies that will enable you to significantly and consistently outperform your competition Join us and learn how you can improve e Energy Efficiency e Risk Management Asset Performance e Employee Training e Operational Excellence e Supply Chain Optimization e Information Sharing e Legacy and Aging Infrastructure e Cyber Security e Operations and Maintenance Synchronization Go to www arcweb com events arc orlando forum or call 781 471 1175 Co Sponsored by CONTROL 2012 Siemens Industry Inc SIEMENS Scan to explore the future of flow measurement Because size and safety matter SITRANS FC430 the market s most compact Coriolis solution usa siemens com Coriolis Building on a strong tradition of innova tive thinking Siemens has designed the next generation
81. ller is Your Solution Simple menu driven setup Delivers 16 64 channel display modes Embedded web server for HMI and system integration QVGA Color LCD displays data as trends bar graphs and engineering units Modbus TCP Master Slave Modbus RTU RS 485 e Four RS 485 serial ports allow simultaneous Modbus master slave operation and multiple masters Five standard SPDT alarm relays Four independent alarm levels per channel e Wireless capable e Data logger records values to SD card Learn more Contact Jodi Downing at jdowning rcsystemsco com 1 409 986 9800 www rcsystemsco com MRC SYSTEMS Become One with Your Process ONE SOURCE FOR PROCESS CONTROLS When your process is out of balance operating costs Through open technologies and future proot escalate Harmony is achieved and core KPI metrics designs we provide a migration strategy for our are exceeded when your control systems are in sync control solutions illuminating a clear path forward with your process Mitsubishi Electric s scalable Flexibility reduced risk and unmatched performance range of automation solutions and open connectivity will put you at peace with your process Become options reduce engineering cycles and downtime One with your process using Mitsubishi Electric while improving profitability For more information email process meau com MITSUBISHI ELECTRIC WWW meau com ADVANCE
82. lling ISA book of 2011 Alarm Management A Comprehensive Guide Second Edition The annual award is presented to the book that addresses the needs of automation professionals while meeting the high standards and expecta tions of the ISA Publications Dept The book is designed for engineers in refiner ies and other process plants to help them optimize alarm systems that have been known to contribute to abnormal situ ations rather than assist in preventing them Eddie Habibi is the founder and CEO of PAS www pas com a human reliability solutions provider that serves the power and processing industries Bill Hollifield is PAS s principal alarm management and high performance HMI consultant Alarm Management A Comprehen sive Guide joins a select few success ful publications from ISA that have re ceived this award said Eoin O Riain vice president of the ISA Publications Dept E Ametek Buys Micro Poise Measurement Systems Ametek Inc has acquired Micro Poise Measurement Systems a provider of integrated test and measurement solu tions for the tire industry from Amer ican Industrial Partners a private equity firm for approximately 170 million in cash Micro Poise is headquartered in Streetsboro Ohio and has additional manufacturing operations in Troy Mich Beijing China and L beck Germany It has estimated 2012 sales of approximately 125 million Micro Poise is a great addition to Ametek
83. magnetic flowmeter featuring a built in rate and total indicator With no mov ing parts the magmeter per mits unobstructed flow to minimize flow disturbances and straight pipe requirements It is designed for tracking flow rate and total flow in usage monitoring applications including wells industrial wastewa ter and other water reclamation applications Omega 800 TC OMEGA www omega com HAZARDOUS AREA ANALYZER FLOW SWITCH MONITOR FS10A analyzer flow switch monitor is suitable for continuous flow verification applications that support process analyzer sampling systems operating in hazardous plant areas in the U S Canada and elsewhere The approvals include Nonincendive Class I Division 2 Groups A B C D Class II Division 2 Groups E F G Class IIT T4 Ta 71 C Type 4X The FSIOA s wetted parts are 316L stainless steel with Hastelloy C22 sensor tips Fluid Components International 800 854 1993 www fluidcomponents com EXPLOSION PROOF I P TRANSDUCER ControlAir 950XP explosion f proof I P transducer with nat ural gas option with a bleed rate of only 3 scfh comes in at half the allowable rate under the new EPA HO OAR 2010 0505 rule This model has FM CSA and ATEX approvals for use with natural gas and comes with a tapped exhaust and sealed conduit It is available with preset output ranges of 3 psig to 15 psig 3 psig to 27 psig and 6 psig to 30 psig ControlAir Inc 00 216 3636 www control
84. mes 100 95 75 89 93 Publication of Statement of Ownership for a Requester Publication is required and will be printed in the November 2012 issue of this publication Signature and Title of Editor Publisher Business Manager or Owner Jeremy L Clark VP of Circulation Date 09 30 2012 certify that all information furnished on this form is true and complete understand that anyone who furnishes false or misleading information on this form or who omits material or information requested on the form may be subject to criminal sanctions including fines and imprisonment and or civil sanctions including civil penalties CONTROL REPORT OOOO JIM MONTAGUE EXECUTIVE EDITOR jmontague putman net APC can watch limits at the same time and change operations to more economic targets as feedstocks temperatures and WW VV VV other variables change Valero s Good Examples I ve already mentioned it was nice to attend ISA Automation Week after several years absence but didn t realize how useful 2012 s event would be until the final keynote I m no controls engineer and because l m not hip deep in process lines and PLCs all the time it s good for me to be reminded how these fields actually work Having that understanding gives me points of reference I can use to cover oil and gas and the other pro cess industries So I sat in on Travis Capps presentation It s Not Business as U
85. ms and support structures necessary to use smart manu facturing technologies And these technologies already for the most part exist Mark up languages data conduits like OPC and fieldbus databases low cost sen sors standards such as ISA88 95 99 and 06 and IEC standards such as 61499 all exist They are all tools but not every plant that could use them does Can you integrate all your systems Sure Just buy everything from a single vendor But what if you don t want to do that Worse yet what if you have to start telling your suppliers that they also have to use the same vendor you do What do you think their answer will be Likely it will be Not only no but absolutely not So what to do Think of how a computer op erating system works One of the reasons that modern enterprises work is the predominance of Windows and to a lesser extent Linux and Apple as an operating system Wouldn t it be easier to interconnect supply chains in an open manner using best of breed products if there were an overarching operating system for man ufacturing Of course it would But how do you get that system SMLC is not looking to replace current control systems or even current ERP systems Rather the system to be developed is going to be designed to make interconnection and inter operation easier or even possible Even though SMLC is really still in its in fancy some really interesting ideas have al ready come forward
86. n Data can be converted to Excel using GA10 software For more information contact Yokogawa at www yokogawa com CONTROL TALK Ruel Rules for Use of PID MPC and FLC 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 Greg In the Control Talk columns Show Me the Money Part and 2 Nov and Dec 2009 www controlglobal com articles 2009 Money0911 html www controlglobal com articles 2009 ShowMoney2_0912 html Mi chel Ruel demonstrated to us how to im prove the performance of the basic process control system by fixing valves tuning loops and improving sequences In some cases the capability of the PID was used to perform ad vanced regulatory control ARC A key part of the success was the calculation of benefits and working with the operators to improve PID actions and sequences for start up and abnormal situations Stan When do you need to move beyond PID control Michel Given that process models can be identified model predictive control MPC is advisable if the interactions between controlled variables can t be sufficiently reduced by detun ing or decoupling Detuning where one PID hopefully the least important PID is made about five times slower than the other PID can handle weak interactions A PID decoupler eliminates detuning and the consequential de t
87. n Figure 3 p 52 shows how such a positioner sees a change in position for step inputs of 1 when in fact the flow hasn t changed until the step inputs are 5 For some rotary on off valves made into control valves by putting NOVEMBER 2012 on a digital positioner the actual dead band was 8 even though the smart positioner had extensive data showing the dead band was 0 5 Resolution and dead band add a dead time to the loop beyond that due to the actuator and positioner This can be estimated as the resolution or half of the dead band divided by the rate of change of the controller output Resolution will cause a limit cycle constant amplitude persistent oscil lation in any loop regardless of tuning For an integrating process such as level with a controller with integral action or a cascade control system where both the primary and sec ondary controller have integral action dead band also will cause a limit cycle The amplitude of these cycles is the resolution or dead band multiplied by process gain for the process variable of interest For temperature and pH loops this process gain can be 10 or more and can cause severe oscillations and process problems Whereas problems from nonlinearity and response time are triggered by disturbances and tend to die out if the controller is properly tuned limit cycles are con tinual A digital positioner with good closure member feed back that is tuned with a high gain and rate action
88. n of the controller in puts consisted of rating the measure ments as to members of Lo Lo Lo OK Hi and Hi Hi sets The mem bership can be crisp where there the shapes are rectangles with no overlap More traditionally the member ship consists of symmetrical triangles whose sides intersect at the middle of the side providing equal overlapping For our application we used some Im NOVEMBER 2012 special shapes and weights Decisions were made with If T hen rules be tween each graded process input and a process output An example of a rule is If the power is high and the weight is low then the speed is medium and the feed is low The rules of the best performing operators were nominated and closely reviewed by the process engineer metallurgist Defuzzifica tion consisted of establishing a relative grading of the change in the control ler outputs for each rule by a member ship set The resulting increment or decrement in each output is a velocity algorithm that inherently eliminates windup and the bumpless transition from manual to automatic Weights for each rule and shapes for memberships were determined from a design of ex periments DOE The resulting fuzzy logic controller FLC was commis sioned in the advisory mode Stan What were your controller in puts Michel We used the controlled vari ables and rates of change of controlled variables as FLC inputs A second or der Butterworth filter was
89. na such the de crease of pipe thickness Information obtained from pigging is used only for operator warning Events requiring immedi ate action such as pipe damage due to earthquakes ship an chors or terrorist action have to use other techniques What is feasible though is to transmit the data collected as soon as the PIG is retrieved from the pipe Figure 1 and use computer software to speed the evaluation of and response to that data BELA LIPTAK liptakbela aol com I am not an expert in the use of PIGs but I would say it s situational Use of real time telemetry depends on many factors e g depth of the pipe and substrate above the pipe the type of media behind or in front of the PIG in the pipe length of pipe number of bends etc Acoustic or RF telemetry fiber optic or copper spools at the launcher and on the PIG are just a few examples of how data can be transported in real time Bottom line We need more data to provide a solution Budget timeline and per formance requirements bandwidth data rates etc are an obvious consideration as well KEITH SOMMER keithsommer1 gmail com I don t know that I would agree with Mr Crowney s statement at all Corrosion and ultimate failure of a pipeline is a rather slow process that usually takes months if not years to occur In most cases a degrading pipe will be inspected many times before it ultimately fails providing many opportunities to identify a de
90. ndustry people rely on the full line of VCI tank vents gauge hatches and flame arrestors for complete process control The comprehensive vent offering allows customers to select the technology necessary to tightly control and manage greenhouse gases escaping to the atmosphere View our full line of products online today at www Cashco com Model 3700 Emergency Relief Vent Valve Model 8900 Emergency Pressure Vacuum Vent The engineered modular design of the VCI vent line allows customers to quickly and cost effectively modify units in the field to different body styles and loading techniques as wastewater requirements evolve www cashco com Innovative Solutions Model 3100 Pressure Vacuum Vent Cashco Inc P O Box 6 Ellsworth KS 67439 0006 Ph 785 472 4461 Fax 785 472 3539 Spool type positioners have an extremely slow response to the point of no response for changes less than 0 2 The response time for even good positioners can rise by an order magnitude for small steps HART and fieldbus digital position ers generally have eliminated this posi tioner resolution problem When you also consider that pneumatic position ers tend to lose their calibration and have no position feedback or diagnos tics there s considerable justification in terms of performance and mainte nance for replacing such positioners In the days of analog control a guideline advised using boosters in stead of
91. nfirm on spec performance and forecast calibration needs without interrupting your process It s time you had control of your operation with a clear picture of every flowmeter s health go to EmersonProcess com Verification N EMERSON Process Management The Emerson logo is a trademark and a service mark of Emerson Electric Co 2011 Emerson Electric Co EMERSON CONSIDER IT SOLVED Station station 2 station 4 pressu HMI5070P 7 Hi Res Display 20 50 C 4 122 F Operating Temperature Conformal Coating Galvanic Isolation Aluminum Enclosure UL CE Listed Two Year Warranty Sa Call 425 745 3229 maplesystems com ADVANCED PROCESS CONTROL APC then it makes it impossible to ap ply simpler possibly better or at least more cost effective tools to do the job End users are doing their part to make APC easier and vendors are moving in the same direction Table 2 lists some of the improvements APC vendors could make to keep end users happier Vendors on Board Vendors are very aware that APC needs to be easier and they are responding by adding features that speed and sim plify implementation and by provid ing maintenance tools that alert end users when adjustments to existing ap plications are required Kinney says Invensys is working to make its software easier In general we foresee tools which make it easier to configure and maintain controllers
92. nic thing is what the big DCS houses call APC is what most smaller engineering companies call the next project Ford of Maverick agrees The glory days of implementing ADVANCED PROCESS CONTROL ROLL YOUR OWN APC AOC Resins www aoc resins com says canned APC doesn t work well with its batch processes but it is using Emerson Process Management s www emersonproc ess com DeltaV APC software for certain functions and supplementing Emerson s software with custom code We use fuzzy blocks in certain loops that have changing process gains says Dan Cox director of en gineering at AOC Resins However we don t use them in loops with long dead times DeltaV Fuzzy works well with changing process gains as long as the dead time is under around 30 seconds When control is more compli cated it s simply easier to figure out stuff about the pro cess It s hard to replace an engineer that can do a mass balance and has good APC programming skills AOC develops its own programming Typically we just use Math block within DeltaV he explains The structured text programming language has most com mon functions you would need but their variation on an array is weak If it is too complex we will send an OPC request to a stored procedure in SQL have SQL crunch the number and send the result back From the SQL stored procedure we may invoke a VB script Basically once we get out to SQL via OPC we will use any mea
93. nline 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 GUIDED WAVE RADAR TAKEOVER Although DP transmitters remain the dominant instrument for level measurement their worldwide mar ket share is expected to steadily erode in the presence of growing demand for the newer level measurement technologies Leading the assault is guided wave radar GWR which is among the most versatile tech nologies now being used for liquid level measurement Not only does GWR usually outperform conven tional level measurement technolo gies a GWR radar transmitter is ex tremely compact and easy to install and operate The latest generation of guided wave radar transmitters is a formidable contender as a potential market wide replacement to the uni versally entrenched differential pres sure transmitters Free download at http tinyurl com d67amm 6 THE GREEN BOOK ON LEVEL The 8th edition of The Green Book Flow Level and Environmental Handbook Encyclopedia is now It has more than 1300 pages of the latest information on available flow level and environmental prod ucts from flowmeters and valves to water test equipment and a new sanitary
94. ns available in the modern computing world Most of the work AOC has done involves curve fitting to model acid value and viscosity relationships in prod ucts as they build molecules If we re off the expected curve we adjust by using models to get us back on the curve by adding acids or glycols he explains The math involved here is beyond what makes sense to do in Del taV Because of this we use model data stored in SQL with stored procedures to send results to the control system Cox would like to see some improvements in APC software data exchange Once data can be pushed and pulled with SQL commands you no longer need to have the Emerson guy come in and spend hours on setup he notes Pushing and pulling via OPC is OK but why not embed database functions in the programming envi ronment Flagging data as valid with a IF statement in the control system as it goes to the database would be easier than all the tools that are currently offered to slice the right piece of data The math is not that complex he says Il expect to see more canned packages for equipment that is common in our industry Every chemical plant has thermal oxidizers scrubbers columns and so on This equipment usually comes from a handful of vendors So should be able to choose an Alfa Laval model XXX for example and have an MPC block almost configured to optimize the unit The powerful programming environments provided by ven
95. ocess gain for flow is the slope on a plot of percent flow versus percent valve position travel The plot should reflect the installed flow characteristic not the inherent trim characteris tic This accounts for the reduced pressure drop available to the control valve at higher flows because of the increase in pres sure drop in the rest of the system from frictional losses and a decrease in pump discharge pressure The changing valve drop makes an equal percentage trim more like a linear characteris tic and a linear trim more like a quick opening characteristic The effect increases as the valve pressure drop as a percent of the total system pressure drop is decreased In Figure 1 we see the process gain gets too low for travel above 80 of a sliding stem valve The control loop must make large changes in position to change the flow For simi lar conditions a ball or butterfly with a 60 maximum rota tion would see a corresponding excessive loss of sensitivity at NOVEMBER 2012 about 60 travel a typical problem for high capacity valves If the pressure drop across the control valve is large com pared to the pressure drop in the rest of the system as in pressure letdown reagent surge and vent valves the in stalled characteristic is the inherent characteristic For an equal percentage trim the nonlinearity is extreme process gain can change by a factor of 50 because the slope of the characteristic is proportional to flow If
96. of Coriolis flowmeters for excellence in performance safety and user friendliness the SITRANS FC430 This digitally based flow solution features market leading compactness very high accuracy of 0 1 low pressure loss extremely stable zero point and best in class data update with 100 Hz high speed signal transfer Unique support tools provide direct access to all operational and functional data certificates and audit trails The SITRANS FC430 is amongst the first Coriolis flowmeters to offer SIL 3 certification on the system meeting the highest standards of safety and reliability With the SITRANS FC430 process optimization has never been easier or more innovative Smallest footprint Shortest lay length of any Coriolis sensor in its size class SensorFlash a micro SD card with backup data settings certificates and audit trails uploadable to any PC Robust Sensor Frame with high resistance to process noise and vibrations for excellent 0 1 accuracy Answers for industry TECHNICALLY SPEAKING APC Complex Solution for Complex Problems Advanced process control APC can be a very powerful tool to solve problems not amenable to more basic techniques such as PID control In the right situation APC can deliver benefits that more than compensate for the time and expense required to im plement and maintain these often complex solutions For example Saudi Aramco s six gas plants us
97. on and viewing of data displays The displays can be configured for up to six display modes with up to 20 multi channel views The user interface was designed by human factors engineers who in corporated the latest thinking into the data presentation following color universal design principles The color selec tion for the highly important overview display was chosen to enhance normal data recognition and to capture the user s attention for important data such as alarm conditions All operations begin with the blue Menu button which calls up a screen full of touch menus for all display and operat ing functions Glowing blue during normal operation the Menu button blinks red when there is an alarm condition Operators have several ways to annotate the data and leave messages including pre stored messages custom mes sages and if they like they can enter a freehand annotation al com NOVEMBER 2012 The GP 20 is a member of the new SmartDAC product family of digital data acquisition systems using a pen stylus tool Mouse capability is also built into the GX and GP The new design modular I O archi tecture allows users to add input chan nels and alarm relays in any combination at any time up to the maximum for the product Each module is accessible from the rear of the device A 10 channel uni versal input module supports a full range of thermocouple RTD and DCV sensor measurements as well as mA inputs with externa
98. onsidered ad vanced by most engineers but they al low us to easily add functionality and simplify the overall logic configura tion he says Is this an APC type of system he Will it work when you need it ae protection you also can t afford to be wrong If a chute s packed right It ll work correctly But what about your tank overfill protection device You don t need to climb the tank to test it manually with Drexelbrook s IntelliPoint SIL2 level switch You just push a button in your control room to verify operation i So why take a leap of faith with something less Visit www drexelorook com tankoverfill to learn 800 553 9092 2012 by AMETEK All rights reserved With tank overfill more or call DREXELBROOK asks Depends on your definition of APC If you are looking for advanced from a control perspective then yes if you re looking for canned routines that say they are advanced then no In many cases the more esoteric varieties of APC aren t needed We often make advanced control more difficult than it has to be ymous engineer opines our anon For exam ple I do pass balance control with PID blocks very simple I am con tinually amazed at the number of people who poo poo the idea don t believe it can be done and or insist on writing some fancy code or use an MVC to do what is essentially inte gral only control and very sl
99. ow inte gral control at that The user community has to take greater ownership of technology se lection If you rely on a vendor youre going to get what he is selling If man agement has been sold that MVC is TABLE 1 BENEFITS OF APC 1 More throughput 2 Improved quality 3 Less variability 4 More stable operations 5 Allows operation closer to process limits 6 Can be used to justify capital expenditures 7 Improves and standardizes operator actions TABLE 2 HOW VENDORS CAN MAKE APC EASIER 1 Create templates for popular process equipment and units 2 Create canned routines for common applications 3 Stop promoting the use of overly complex solutions 4 Create tools that allow users to easily create their own APC solutions 5 Provide tools that alert users when application maintenance is needed 6 Integrate APC more tightly with regulatory control 7 Make it easier to exchange data with external APC related applications 8 Provide a forum where users can swap APC programs Manually verifying every flowmeter wastes time and money wish I could just tell which ones need attention YOU CAN DO THAT Mico Motion Monitor flowmeter integrity dynamically automatically and on your schedule ms Emerson s Smart Meter Verification for Micro Motion Coriolis meters is the only automatic P tool that checks the entire meter s performance and integrity in line This allows you to trend data co
100. pera tions more quickly to maintain the most profit able targets and rates In general process units have multiple limits and to avoid violating lim its operators need to be conservative However n controlglobal com NOVEMBER 2012 APC can watch all these limits simultaneously and change unit operations to the most eco nomic target as feedstocks daily temperatures and other variables change Essentially as things change APC can react more quickly to avoid vi olating operating limits So far Capps reports Valero deployed APC on 110 process units out of 210 candidates by the end of 2011 and presently has 15 projects underway Typical benefits can be tens of mil lions of dollars per year for an average sized re finery adds Capps APC utilization has also increased from 55 on a smaller installed base to more than 80 on the larger installed base This isn t the first time Valero gave me a great story I helped Valero s analyzer technology man ager Robert Sherman write Sample Condition ing Systems Need Love Too for the December 2011 issue www controlglobal com articles 2011 sample conditioning systems need love html In it he stressed that process users and integrators must carefully design and match sample condi tioning systems SCSs with application require ments complete application data sheets and de ploy climate controlled shelters At the 2010 Honeywell Users Group meet ing I cover
101. positioners on fast loops With digital process loops and smart posi tioners this no longer is an issue It s essential that every control valve have a smart digital positioner A booster if needed on a large actuator to reduce pre stroke dead time and stroking time should be installed on the outlet of the positioner with the booster bypass ad justed to prevent cycling by allowing the positioner to see a small portion of the actuator volume Achieving Fine Results Resolution and dead band play a cru cial role in valve response and highly depend upon the total valve package Resolution is the smallest change in signal in the same direction that will result in a change in position Pneu matic positioners can adversely af fect this but an even bigger potential problem originates from friction in the packing and seating through a behav ior known as stick slip where the valve closure member doesn t move sticks and then breaks free and jumps to a new position slips Older designs of high temperature and environmental packing as well as manual tightening of the packing beyond specifications can cause the resolution to deteriorate to 10 or worse A more insidious source of resolu tion problems is the high seat or seal friction particularly associated with valves designed for isolation On off block valves aren t control valves and vice versa lf an application must pre vent leakage install an on off valve whose ac
102. riods The second key to safety is to make sure that if cooling fails and the fuel rods melt causing the molten zirconium in their cladding to react with the water and generate hydrogen the generated hydrogen does not explode This requires that it be safely released outside the containments of the reactor building In order for hydrogen to explode it needs oxygen and an ignition source Therefore these must be denied by the design while the hydrogen is being routed to the outside Three Mile Island At 4 a m on March 28 1979 Unit 2 of the 900 MW reactor at Three Mile Island TMI 2 in Pennsylvania experienced a partial core meltdown Between 13 and 43 million curies of radioactive krypton gas were released half the core melted and 90 of the fuel rod cladding was destroyed The maxi mum offsite radiation reached 83 millirems but the radia tion dose received by the community was small The plant was designed by GE for a life of 30 years be gan operation in 1978 and it is still in operation today In fact in 2009 it received approval to continue operation for another 20 years Figure 2 p 18 shows approximately the main equipment and piping of the plant At the time of the accident the controls of the plant were mostly manual and mostly pneumatic So what happened Operators working on a demineralizer at 4 a m accidentally admitted water into the instrument air supply to part of the control system This caused the valve on
103. roblems that can t be fixed simply by adding a smart positioner While installing NOVEMBER 2012 www controlglobal com 51 cs O 5 WwW Xx 2 o z 2 a oe VALVES Valve travel 40 50 60 3 Enitech gain ee ee Z specification 40 60 Valve travel INSTALLED CHARACTERISTIC Figure 1 Process gain becomes too low when travel of sliding stem valve exceeds 80 52 a smart positioner is always beneficial an incorrect feedback mechanism in the valve design can give a false indication of performance To avoid problems always consider five basic valve re quirements linearity dead time response time resolution and dead band They can give crucial guidance and justifi cation for a final element that leads to better control Range ability and sensitivity also are important but as we ll see properly meeting the other requirements will address them Linear in a Nonlinear World To get on a common basis we need to define process gain for a self regulating process as the final percent change in the con trolled variable divided by the percent change in valve position Note that the calibration span of the transmitter for the con trolled variable is a factor Because the changes seen in data historians for process variables are in engineering units they must be converted to percent of scale The maximum allow able controller gain is inversely proportional to the process gain The pr
104. roducts will enable APC deployments in orga nizations where it was previously cost and or re source prohibitive to do so In the near future the traditional maintenance issues will be eliminated with built in technology that automates much of the maintenance cycle and keeps controller mod els matched with plant performance all without the need for the level of expertise required today For a process plant with a number of control loops or just a few high value ones that can t be closely held to setpoint using conventional control techniques APC is worth investigating Recent advances have reduced both the cost and complexity of implementation and mainte nance making APC a viable option in a wider range of applications Hi NOVEMBER 2012 ww DAN HEBERT SENIOR TECHNICAL EDITOR dhebert putman net At a GALP Ener gia hydrodesul phurization plant in Portugal APC generates savings of about 1 2M 1 54 million per year w controlglobal com 59 ask THEERPERTS O O OOOO Real Time PIG Data Transmission Ask the Experts is moderated by B la Lipt k http belaliptakpe com automation and safety consultant who is also the editor of the nstrument and Automation Engineers Handbook IAEH If you would like to become a contributing author of the 5th edition or if you have an automation related question for this column write to liptakbela aol com When pipe inspection gauges PIGs travel through s
105. s long and don t be fooled into us ing on off valves as control valves I was puzzled since I was only going to summer camp Years later I realized that my Dad was warning me about the greatest hoax of the century in the automation business Positioners were put on piping valves and sold as throttling valves Who wouldn t want a lower priced valve that was in the piping spec and had the name High Performance because of an exceptionally low leakage classification The valve could serve as both a throt tling valve and isolation valve What a deal Users did not realize the flow characteristic was some times quick opening and in many cases too flat for large openings Even more insidious was that the backlash and stiction was more than an order of magnitude larger than valves originally designed for throttling service Adding in sult to injury poor precision pistons e g link arm rack and pinion and scotch yoke and less expensive positioners e g spool instead of relay type were used that deteriorated the resolution by a factor of five or more The result was a dra matic increase in nonlinearity dead time response time dead band and stick slip Users were clueless as to the source of the limit cycles and increased process variability Pneumatic position ers offered no position readback Even more deceptive was the fact that many installations of smart positioners had actuator shaft rather than internal closure member
106. se technical support Accutube Averaging Pitot Tubes Handheld Calibrators MFC HART Communicator Pressure Pumps Complete Flow Solutions Digital amp Analog Pressure Transmitters Follow Meriam Online kj 10920 Madison Avenue e Cleveland OH 44102 e PH 216 281 1100 www meriam com e sales meriam com 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 YOU CAN DO THAT ROSEMOUNT Driving overfill prevention technology forward Tank Gauging a aid Emerson s new Rosemount Raptor tank gauging system lets you comply with the reworked overfill protection standard API 2350 4 edition for every type of storage tank The Raptor system includes safety features like SIL certification and a unique radar with two independent gauges level and overfill in one housing Learn more about Raptor and get the latest API 2350 overfill prevention guidance at www rosemount tg com safety cere S EMERSON m Process Management The Emerson logo is a trademark and a service mark of Emerson Electric Co 2012 Emerson Electric Co EMERSON CONSIDER IT SOLVED ADVANCED PROCESS CONTROL Bertha of RDI Controls agrees He used user defined subroutines to con trol combustion turbines While the integration of multiple PID loops was a challenge the individual control loops are fairly simple The blocks we created wouldn t be c
107. server technology for fast onsite device configuration without additional software m Industry optimized sensors for each application Endress Hauser People for Process Automation November 2012 Volume XXV Number 11 DEPARTMENTS 9 Editor s Page Connecting the Manufacturing Dots The Smart Manufacturing Leadership Co alition is trying to make systems work and play well together 15 On the Web Why you should visit ControlGlobal com and why you should come back often plus some of our bloggers greatest hits 18 Lessons Learned Nuclear plants need process automation so we don t have more Chernobyl disasters 295 On the Bus When to Use Control in the Field Fieldbus can be a more robust truly distrib uted and an innately more reliable platform for rudimentary PID loops 26 In Process Invensys expands refinery footprint with Spiral Software buy shale gas market ex pansion and more process industry news 33 Resources The low down on level technologies CIRCULATION AUDITED MAY 2011 CONTENTS 59 Technically Speaking APC is complex but can deliver big results in the right circumstances 60 Ask the Experts Can you get real time data from a pipeline PIG 62 Roundup The latest advances in PLCs and industrial computers 64 Products Yokogawa s new smart recorder and other process manufacturing goodies 67 Control Talk Ruel Rules for Use of PID MPC an
108. sletters NOVEMBER 2012 17 BELA LIPTAK WN 18 VV iV LESSONS LEARNED liptakbela aol com The key to the Safety of nuclear power plants is to maintain the availability of coolants even if all electric power supplies fail Why Nuclear Needs Process Automation spent the last year reviewing the Three Mile Island Chernobyl and Fukushima ac cidents and found that neither they nor practically any of the 435 operating nuclear plants around the world were designed to provide safe shutdown in case of simultane ous external and internal electricity failure Similarly few of them are protected against hydrogen explosions and practically none can handle regular or cyber terrorist attacks Most are operated in a semi manual mode Many were designed for a useful life of 30 years but have already reached 40 and are still getting extensions In addition neither perma nent waste disposal nor the decommissioning of the plants is resolved For example Cher nobyl occurred in 1986 yet the completion of its decommissioning is planned for 2015 Un der these conditions the question is not if but when and where the next accident will occur In the forthcoming new edition of my hand book I devote a full chapter to improving the safety of nuclear plants through automation and I show that the causes of the three best known nuclear accidents were very similar and that the Chernobyl use of state of the
109. sual Anymore Automa tion in the Refinery of Today at the Orlando Convention Center and got a bracing wake up call about the critical importance of advanced process control APC and the huge gains it can deliver if users are willing to learn and invest in it Capps is Valero Energy Corp s www valero com vice president of energy and gases Capps explained that principles for the Re finery of Today include a common manage ment framework occupational and process safety sound environmental practices stable and reliable operations efficient supply chain management profitability and growth es pecially as North America again becomes a net exporter Valero s framework is its Com mitment to Excellence Management Sys tem CTEMS and its uniform expectations practices and standards are the foundation of its refinery performance measures and assess ments particularly as it strives to achieve first quartile performance in refining mechanical availability and energy efficiency Naturally these goals lead straight to automation and pro cess control and APC With stable and reliable process control in place APC and real time optimization RTO efforts can directly contribute to margin cap ture by using online measurements to optimize processing units and do product blending in real time says Capps Compared to people computers can track more information in real time and use this information to adjust o
110. t where there is a transition from one valve to another The realistic rangeability of a control valve the largest flow di vided by the smallest controllable How is set by the installed characteristic and resolution near the seat Furthermore re peatability isn t as important as the ability of the valve to respond as the process loop will correct for changes in the magnitude of the response Dead band is the smallest change in signal in the opposite direction that will result in a change in position The dead band also is known as backlash or lost motion because it pri marily originates from shaft connections and linkages It s particularly noticeable in rotary valves when there s a trans lation of linear motion of an actuator to rotary motion of the ball or disk Don t count on rotary actuators as a solu tion these actuators typically have been designed for on off service and consequently don t generally provide adequate resolution and dead band specifications The effect is aggra vated by high sealing friction and may result in shaft windup where the actuator shaft twists but the closure member is stuck and then considerably overshoots the desired position when it breaks free Particularly insidious on a rotary valve is a digital posi tioner feedback that uses actuator shaft position rather than closure member position because the positioner can think the valve moves when the ball or disk sticks The response for Valve B i
111. t com Belgium info mooreind be China sales mooreind sh cn MO ORE Tel 818 894 7111 FAX 818 891 2816 Tel 03 448 10 18 FAX 03 440 17 97 Tel 86 21 62491499 FAX 86 21 62490635 ND USTRI ES Australia sales mooreind com au The Netherlands sales mooreind nl United Kingdom sales mooreind com Tel 02 8536 7200 FAX 02 9525 7296 Tel 0 344 617971 FAX 0 344 615920 Tel 01293 514488 FAX 01293 536852 SURVIVAL OF THE FITTEST Endurance To Withstand The Environment Pepperl Fuchs is the clear choice for industrial grade flat panel monitors and workstations Our visualization systems include general purpose and Div 2 monitors to fully integrated Class Div 1 systems Manufactured with industrial rated equipment a full family of high performance visulization solutions includes 10 to 22 inch displays scanners keyboards and other peripherals Our expert knowledge of hazardous area protection and our global support are unsurpassed When you need safe reliable and timely visualization solutions choose Pepperl Fuchs Find high quality operator workstations and monitors at www pepperl fuchs us industrial Pepperl Fuchs Inc cer J PEPPERL FUCHS www pepperl fuchs us PROTECTING YOUR PROCESS a ON THE BUS When to Use Control in the Field Back in the 1990s when ISA s SP50 committee was meeting to debate the specifications and features that would become part of the evolving fieldbus
112. teel pipelines that are routed on the bottom of the ocean or are buried underground the information they collect concerning cracks and leaks is just placed in the solid state memory of the PIG and this memorized data travels with the PIG until it is retreived and the in formation is downloaded I think the safety of the pipelining industry could be much improved if this data which could require the shutdown of pumping or compressor stations could be acted upon immediately How would you approach solv ing this problem HARRY CROWNEY hcrowney aol com HOW PIGGING WORKS Figure 1 The Launching operation is initiated by opening valves 1 2 3 and closing valve 4 Launching is terminated automatically by the PIG passage detector 5 which initiates the reversal of the previous valve positions During a Receiving operation valve 7 is closed 8 and 10 are opened and when the ultrasonic switch 9 signals the PIG s arrival the valve positions are reversed and normal operation resumes 60 www controlglobal com NOVEMBER 2012 At today s state of the art this instant information is not available not only because signals would be impeded by the steel pipe walls and their water or earth cover ing requiring unavailable battery power but also because to day s PIGs are not reliable enough to initiate automatic shut down that can result in excessive pressure surges PIGs today are good only to detect gradual phenome
113. temperature pressure and flow product section with techni cal references This free hardbound handbook has a technical reference section with an overview on flow measurement and aids on selecting a complete flow measurement system unit conversion tables and a glossary Go to greenbook8 for your copy LEVEL MEASUREMENT CHART Find out what level technology is right www omega com literature for every application Download Con trol s very popular level selection guide for your reference Free download Registration required http tinyurl com 93huzqe LAST RESORT LEVEL MEASUREMENT Nuclear level gauges work in nearly any level measurement application However for simple applications no body uses them because they re rela tively expensive and difficult to regu late But when few devices will work with your application or there is no other way to make measurements nuclear measuring products may be the only working option to use In this article you will learn when nuclear level measurements products are good options of measurements to use Free downloadable PDF Registration re quired Direct link is at http tinyurl com 8gte6nl LEVEL MEASUREMENT T V Two YouTube videos on level mea surement subjects First is Pneu matic Liquid Level Measurement Loop This short video shows how a Foxboro model 13A pneumatic dif ferential pressure transmitter is used to measure the level height of water
114. the suction side of the secondary cooling water pump to fail closed in spite of the fact that best practice for cooling service is to have valves fail open The operators did not realize what they had done because the control system did not include the required automatic safety alarms nor was there an automatic interlock to shut down the reactor or to start up a backup cooling system when the secondary cooling water flow stopped The designers of the plant were also responsible because for cooling service they should have specified closed fail ure positions and should have provided automatic scram shutdown of the reactor and automatic starting of emer gency cooling upon failure of the flow of cooling water In the next segments in this series of articles I will describe the events at Chernobyl and Fukushima and will show how those plants should have been automated to protect against the accidents that occurred W CONFISURATION ANG EVENTS PROCESS os ea SECURITY GATEWAY SEL 7 720M gt SWITH A SEL Advanced Solutions for System Operations Save Time Simplify system configuration and analysis using drag and drop interfaces advanced scripting and embedded HMI displays Secure Processes Easily implement industry vetted security for user access and data communications Reduce Errors Organize and manage device configuration consistently throughout the enterprise Apply Dependable Solutions Inte
115. tion is coordinated with the opening and closing of a control valve VALVES If a valve must operate near the seat due to rangeability requirements it s essential to ask the vendor for resolu tion measurements near the seat Don t rely on stated resolution be cause this normally is for the valve at ail i iia J j otors Automation Energy Transmission amp Distribution Coatings Custom Panels application l ji wl Sy A Industry Applications e Cement and Agregate e Food and Beverage e Textile e Mining e HVAC e Metals L Plastics e Pulp and Paper Custom configured e Water and Waste Water to your Specification e Irrigation e NEMA 1 12 3R 4 and 4X cabinets e Quick delivery on preconfigured drives and soft starters e UL 508 certified e Low and Medium Voltage 230 4160 e Made in the USA Transforming energy into solutions www weg net 2012 WEG Electric Corp w am Ww u e Cc oO Ww oO a of VALVES 1 5 in 24000S 0 1 step signal 5 sec per step 5 9 07 70 80 90 Time seconds Signal 100 110 120 130 140 Valve response BETTER THAN A VARIABLE SPEED DRIVE Figure 4 A sliding stem valve with a digital positioner can provide high resolution near seat 56 mid position where the seating or sealing friction is lower High friction and the discontinuity in process gains near the seat cause loops to oscillate around the split range poin
116. to end the use of nu clear energy Germany by 2020 Japan by 2040 yet as of today 60 new plants are under construction and another 150 are contemplated because some argue that the consequences of their use is less dangerous than the continued burning of fossil fuels The Process In fossil fuel burning power plants the fuel is continuously charged from out side the boiler while in nuclear power plants the heat is obtained from fuel stored inside the boiler Therefore the fuel flow to fossil boilers is easy to shut off while in the nuclear process the fuel leaks Decay heat continues to be re leased after shutdown and therefore the cooling of the fuel rods must con tinue The key to the safety of nuclear BE PREPARED Safeguard Plant Personnel and Profitability D 3 Version 14 incorporates ANSI 18 2 Alarm Management and High Performance HMI graphics to keep operators informed not overwhelmed Learn more online at novatechweb com d3v14 Of 4 Novatech You Have Big Ideas We Have a Big Catalog 2013 Allied Catalog Over 110 000 products Over 10 000 new products Over 300 world class suppliers New suppliers include Siemens Corporation and FLIR Commercial Systems 1 800 433 5700 alliedelec com LESSONS LEARNED power plants is to maintain the availability of coolants even if all electric power supplies external and internal simultane ously fail for extended pe
117. trial control platform 800 453 6202 NATIONAL _ Honeywell b The Winning Formula Map a course for process performance lifecycle sustainability and maximum return on your technology investment A Legacy f Innova s tion Classic high performance Cars gain value when maintained over decades Why should your process management system be different You set the pace Plan for the road ahead Enhance performance with Honeywell s continuous evolution approach to innovation and extend your technology investment into the future And if you re ready to upgrade it s the night time to take a hard look at Experion PKS Orion and its revolutionary technology What s Your Roadmap Mapa Winning Course Lead the feild with a powerful automation system that delivers lowest total cost of ownership and helps you achieve top performance throughout Take advantage of new Virtualization Universal l0 and Visualization capabilities with Experion PKS Orion Whether you re on a Honeywell system or a third party control system Honeywell has the technology to help you accelerate production capabilities Honeywell gives you the unswerving performance you depend on maintaining the safe and reliable system you need while modemizing and evolving into the tuture Honeywell Engage Honeywell expertise to engineer a flexible phased modennization with minimal
118. ty of the original paperless recorder Complementing Yokogawa s DXA Advanced R4 series the GX and GP bring some features that are not in the DXA such as the special touchscreen interface field upgradable modular I O SD memory a real time data web monitor and network printer report printing The GX and GP products are the first of a new SmartDAC product family says Steve Byrom data acquisition product manager They incorporate a Smart User Interface Smart Architecture and Smart Functionality design principles The fully modular I O architecture captures all measurement and output functions and held wiring terminations within a com pact field replaceable and upgradeable module This means that customers can buy the functionality they need today and add more capacity when needed The GX10 and GX20 are NEMA 4 rated when panel mounted and feature a 5 7 in touchscreen for the GX10 and a 12 1 in touchscreen for the GX20 The GP10 with the 5 7 in screen and GP20 with the 12 in screen are portable versions designed for use in the lab or on the test bench The technical challenge for our designers Byrom says was incorporating the range of functionality needed along with our high standard for electrical perfor mance into a compact module footprint SmartDAC products use unique and proprietary resis tive touchscreen technology that allows swipe control and finger pinch in out control for fast navigati
119. ucts and cutting edge services Find out more about how we re growing to serve our customers www us endress com expansion ae 2 sma irn e More program memory e More and flexible data type memory e Faster program execution e Easier to use instruction set e Integrated Ethernet on the CPU e Faster I O for counting and motion applications e More and easier to use communications The new Do more H2 series CPUs leverage the existing line of DL205 I O modules and base units to create an incredibly powerful PLC at an incredible bargain Two CPU options are available H2 DMITE H2 DM1E 1 USB port for programming 1 full duplex serial port 1 Ethernet port H2 DM1 1 USB port for programming 1 full duplex serial port e Over 1M bytes total memory includes program data and documentation H2 DM1 e Program monitor debug over any embedded communication port e Supports up to 256 I O locally and thousands more with optional Ethernet remote I O e Supports inexpensive serial port expansion for connection to bar code readers printers etc And each Do more CPU comes with a coupon for a 30 day free trial of online video training rder Today Ships Today l kas omp Fen g ha jph g Soper beers F Copal AP boarre i Ceres Gael Pk ell aphia perl So visit w videos and download the free software to take it for a spin a i W a 4 i ae SS s P ol
120. uments Indispensable tools Then and now 800 398 9925 Davis com 19438 Proven Precise Personal 100 years of Service Test measurement control amp calibration instruments the Thomas amp Betts acquisition is also paying off That gives us reason for cau tious optimism Short term market vis ibility is limited and volatility is high In this environment our near term focus will continue to be on competitive costs and using our strong portfolio and geo graphic balance to tap profitable growth opportunities PI North America Meeting Touts Profibus Gains The 18th General Assembly Meeting of PI North America Sept 26 27 in Scottsdale Ariz celebrated Profibus and Profinet gains in market share Ac cording to Executive Director Michael Bryant The Profibus market is ex pected to grow in 2012 by a further 4 million nodes to reach a total of about 44 million It s reassuring that Profibus continues to flourish even as Profinet is escalating its market share Today every fifth device sold is for Profinet compared to some years ago when it was in 15 During the part of the meeting focused on the process industries Hunter Harrington from the Prof Interface Center in Johnson City Tenn a North American PI Compe tence Center described the Profinet proxy solution that allows sub net works such as Profibus PA HART and Foundation fieldbus to be connected to Profinet Th
121. velop ing problem and correct it prior to disaster Of course this assumes that the pipeline is inspected at all It seems highly unlikely that a PIG sensor would detect an impending failure that had never been sensed in any of the previous inspections and so the ability of the pig to asi rie exrerrs shut down the pipeline immediately rather than waiting for the inspection team to interpret the data and notice the problem would markedly improve safety On the flip side Mr Crowney does not mention the in numerable false shutdowns that would invariably occur ev ery time a PIG sensor malfunctioned or sensed a pipeline abnormality It seems that the resulting pressure surges of stopping and restarting the pipeline for needless interrup tions would cause far more safety issues than the PIG shut down system would avert P HUNTER VEGAS hvegas avidsolutionsinc com Intelligent PIGs nowadays collect all relevant pipeline data Pigging is a process which is deterministic and used on an as when required basis Pipeline leakage or cracks are random phenomenon Moreover PIGs often acquire incorrect or garbage information Any ESD executive action shall be based on a proven system leak detection or pipeline integrity system There fore for shutting down a block valve station or compression station in my opinion an intelligent PIG should not be used However operator alerts can be generated for further action invest
122. ww wago us PAC AND DAQ AT PLC PRICES The Foxboro PAC System provides integrated hybrid control and data acquisition at the price of a PLC It is built for installations with fewer than 3000 I O points and marries high density I O modules with cost effective redundancy options energy efficiency continuous analog logic and sequential control and secure data recording at point of measurement Invensys Operations Management 703 724 7300 iom invensys com NEW INDUSTRIAL PC SERIES The PS4000 Series offers extensive connectivity high performance energy eff cient processor options and quick and easy storage expan sion It features dependable disk less operation Windows XP Professional and Win dows 7 Ultimate operating systems quick and smooth high speed processing with combinations such as Core Duo pro cessors with Windows 7 and PCI Express expansion Pro face 800 289 9266 www profaceamerica com 62 www controlglobal com NOVEMBER 2012 HIGH PERFORMANCE AUTOMATION CONTROLLERS The UNO 2184G is for ap plications requiring lots of graphical processing power UNO 2174G is for industries requiring faster performance but no 3D capabilities The 2184G comes with an Intel Core i7 2655LE processor and the 2174G has an Intel Celeron 847E processor They can support up to 16G DDR3 RAM a dedicated Intel HD graphics processor and are fanless Advantech 800 205 7940 www advantech com ea HIGH END PLC AT LOW

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