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1. p GHT 5 Isomerisation Name of the units C Control Valves for maintenance C Control Valves repaired in Workshop during TA Hydrogen 2 HDS CONTROL VALVE REPAIR DURING TURNAROUND Figure 1 Using HART diagnostic data ahead of time MOL saved between 20 000 and 70 000 per turnaround MARCH 2013 45 The new ST100 Series Gas Flow Meter So perfect it s like you designed it yourself Inspired design Inspiring performance Informative graphical LCD readout interchangeable analog and digital bus communications flow rate total flow temperature pressure highest integrity enclosure dual sensor systems calibration options easy and accurate installation The ST100 your process gas flow meter wish list turned into reality FLA inter COMPONENTS e INTERNATIONAL LLC Visit FluidComponents com ST100 today for a self toured demo 1 800 854 1993 m 1 760 744 6950 ASSET MANAGEMENT 800000 TTT TTT TTT eee eee 600000 Cost 400000 200000 nis Maintenance cost without diagnostics 8 Crane optional Breakdown of the activities Bl Diagnostic experts I Valve technicians repair test Bl Mechanic staff remove disassemble reassemble Maintenance cost with HART diagnostics CONTROL VALVE DIAGNOSTICS USING HART Figure 2 Maintenance without diagnostics costs more than three times as much as that done using dia
2. As for Ceuta Canosa says the fa cility is already planning to use the CALIBRATION MAN ON THE GROUND HOUSE CALL ALL PACKED UP Figure 1 Germ n Canosa Murcia says the on site Figure 2 A specialist from Endress Hauser system cut calibration time at the Ceuta plant from months to days service again next year when the next three year calibra tion is required This time we will expand the on site services to include the calibration of the temperature sen sors within our flowmeters This will increase the service handles calibration complexities on site saving down time and shipping expenses Figure 3 The Endress Hauser on site calibration kit ships in three flight cases bringing calibration directly to the sensors cost but it will guarantee us more accurate temperature measurements M Nancy Bartels is Control s managing editor Katherine Bonfante Controls senior digital managing editor also contributed to this story MONITOR VISCOSITY SIMPLY SENSE MIXER MOTOR HORSEPOWER WITH UNIVERSAL POWER CELL EASY INSTALLATION e No holes in tanks or pipes e Away from sensitive processes VERSATILE e One size adjusts to motors from small up to 150hp POWER SENSOR Du S e Works on 3 phase fixed or variable 5 frequency DC single phase power SENSITIVE e 10 times more sensitive than just sensing amps CONVENIENT OUTPUTS e For meters controllers computers 4 20 milliamps 0 10 volts
3. a trademark of Chote 22 other trademarks trace names and Service marks belong to thaw resoective companiei LESSONS LEARNED Continued from page 16 Only d p indicators were provided and they were located in the control room requiring long lead lines One of the lead lines detected the high pressure reference from the condensate pot At Fukushima soon after the cooling water pumps stopped the condensate temperature in the uninsulated pot reached boiling point and boiled off Once the lead line to the high pressure side of the level indicator emptied the indicator over reported the water level in the reactors by several meters which gave the operators a false sense of security Reliable Ex Core Level Measurement There are at least three ways to eliminate the level measure ment error caused by the boiling off of the condensate from the wet legs These are 1 Use different type level detectors 2 Move the condensate pot wet leg and d p cell outside the primary containment 3 Keep the existing system but de tect the height of the reference leg and if it drops compen sate for that drop Choices 1 and 2 require plant shutdown while 3 can easily be implemented without shutdown and without much expense Figure 2 Figure 2 shows how the actual weight of the remaining condensate in the wet leg AWL is measured and how that is subtracted from the normal reference wet leg RWL The calculated difference AL is
4. Round 2 Begins The ballot for 65C 714 Committee Draft Vote CDV which relates to standard IEC 62734 Ed 1 Industrial Communication Networks Wireless Communication Network and Com munication Profiles ISA 100 11a has failed The process begins to look like a reprise of the Fieldbus Wars of the 1990s although one hopes not as acrimonious The country by country voting results are interesting in that of the 22 votes cast 19 Par ticipating Member countries approved the standard with 12 in favor 63 2 and seven against 31 8 The discrepancy in the voting numbers is caused by the fact that there are also five Observing Members among the 22 that count in the second criterion of overall voters With the approval criteria being 2 3 approval of all Participating Member countries 12 19 63 2 and 4 approval of both Participating and Observing Members 7 22 31 8 the ballot was rejected under both criteria In addition to the vote results themselves the National Committees NC provided about 194 comments of which 42 were editorial with the balance requiring a technical resolu tion The Working Group IEC 65C WG 16 is responsible for resolving these comments It held a meeting in January to begin the com ment resolution process At that meeting 98 comments have been accepted and will be di rectly incorporated into the next revision of the document Fifty nine comments were ac cepted in principle in par
5. s training courses are published on a robust and engaging eLearning platform Each course is fo cused on either a measurement technol ogy such as variable area vortex ultra sonic or mass flow or on a more general topic such as the basics of gas measure ment or pipeline leak detection The online Krohne Academy is ven dor agnostic and not specific to indi vidual products and or industries No special knowledge is required but it is useful to have basic technical un derstanding of process measurement Training is free and there is unlimited use of the learning platform which is available in English German French and Chinese Online registration is available at https academy online krohne com Course participants can use the acad emy courses at any time of the day and at their own speed Learning progress eval uation and certification of attainment is available Participants can even engage and interact with Krohne technical ex on specific issues 456 Signal Combinations in a width of just mm No that s not a typo The new 857 402 Universal Signal Conditioner really supports up to 456 signal combinations as well as raises the bar with industry leading features such as e Wide input range 0 3 mA to 100 mA or 60 mV to 200 V Signal clipping for proper output operation preventing errors MRS potentiometer for full scale adjustments no limits Auto reset fusin
6. 2 055 Ele Mil Prou sma 1 248 n m toT Dac CORO UCIS eec EE 146 Paper mann SOZ TOA IMCL ON eee manam n n 60 000 On site Hands on You choose A blended training approach to help you keep up with today s challenges Customize your training experience through the unique offerings provided to you through our Process Training University Whether it be on site on line or in the classroom choose a training package that is tailored to meet your needs Find out more about Endress Hauser s unique training www us endress com training Endress Hauser People for Process Automation TCE I4 3111 31 0 It s time to try AutomationDirect P Head Mounted and DIN Rail Mounted Programmable Universal Temperature Transmitters RTD and Thermocouple New to the ProSense line are head mount hockey puck style and DIN rail mount temperature transmitters Non programmable units offer the convenience of being pre configured for specific RTD or thermocouple inputs with a variety of popular temperature ranges Programmable units offer the flexibility to be user configured with free software for a broad selection of thermocouple and RTD types custom temperature measurement ranges sensor fault conditions and other parameters Non programmable models starting at 69 00 Models for thermocouple Types J K or T Models for RTD Type Pt100 3 wire Select from a va
7. Russia one of the largest thermal power stations in Europe Emerson the main automation contractor for the project completed the upgrade during a four month shutdown Unit 5 of the Surgut 2 power plant owned and operated by E ON Russia will now take advantage of Emerson s PlantWeb digital automation architec ture with the Ovation expert control system which was designed specifi cally for power applications In addi tion to upgrading the Unit control system instrumentation control valves and other related equipment Emerson also modernized controls for the fluid end of the turbine set reconstructed trolglobal com MARCH 2013 Starting Serial Ending Serial Model Manufacture Dates Number Number Fluke 376 Sept 2010 Feb 2011 Fluke 375 Sept 2010 Mar 2011 Fluke 374 Oct 2010 Feb 2011 Fluke 373 Oct 2010 Oct 2012 the model and serial numbers listed above Any serial number preceded or followed by the letter R is not af fected by this recall notice Fluke is warning owners of these meters to stop using them immedi ately and return them to Fluke for repair Fluke asks users to send only the clamp meter any test leads boxes 14270001 15909999 14270001 16079999 14270001 16579999 14270001 21950000 manuals that are sent with the unit will not be returned To contact Fluke for information on how to have the units repaired either go to www fluke com 37x recall to reg ister the affected product
8. LOAD CONTROLS x INCORPORATED WWW LOADCONTROLS COM CALL NOW FOR YOUR FREE 30 DAY TRIAL 888 600 3247 Electronic Pressure Switch Try this NEW compact and versatile switch Low cost Field tested 5 ms response time Discrete and continuous output 4 20mA or 1 5VDC Well suited for hazardous locations MEASUREMENT AND CONTROL Engineered to Order with Off the Shelf Speed Irma DAN HEBERT SENIOR TECHNICAL EDITOR 52 dhebert putman net Automation suppliers and solutions Droviders bring a deep understanding of process automation and IT to the table Should You Manage IT from Off Site Many process plants and process automation departments struggle with IT issues par ticularly those closely related to process control and monitoring While some larger plants and companies have sufficient IT staff conversant in automation issues most do not leaving automation professionals to fill the gap One source for assistance is off site ser vice providers These firms run the gamut in terms of the services and assistance they pro vide from basic data backup to full remote monitoring and support Data backup tasks are performed in house at many process plants but some facilities find it tempting to neglect or postpone them because day to day operations may continue unim peded for months or even years with no data storage failures But inevitably a failure
9. Mighty MINI s strong features to ensure their project s success Super slim design only 6 2 mm wide Jaw dropping energy efficiency consuming as little as 25 mA Fast implementation with T bus power bridging system Reduced wiring time and errors thanks to the easy to use V8 adapter When you re confronted by enemies of quality let Mighty MINI s built in powers save the day by isolating converting and conditioning distorted analog signals This reliable little super performer isn t even afraid of hazardous duty fearlessly going to work in CID2 areas Learn more call 1 800 322 3225 or visit www phoenixcontact com mightymini INSPIRING INNOVATIONS gt k CA LIBRATION Long Distance Calibration Calibration is complicated at best Add problems of long distance timing and customs regulations and things get really tricky by Nancy Bartels Ceuta is one of those odd corners of the globe a polit ical anomaly cast up after centuries of political storm Approximately 7 sq mi 18 sq km territory on the north coast of Africa just west of Morocco it lies about 12 mi 20 km across the Strait of Gibraltar from Spain Its stra tegic location has made it a contested bit of real estate all the way back to the Carthaginians At various times it has been under Roman Byzantine Moorish Berber and Portuguese control Since 1580 it has been claimed by Spai
10. New Product Announcements PepperlrFuehs asas mt 24 Sales Aid For Your Field Force Phoenix Contact Pck OE eee Q 09 X096 LES S Q S 48 Ei PR Materials amp Media Kits Red Lion Controls 42 Direct Mail Enclosures Reed Exhibition 18 M Customer amp Prospect er Communications Presentations jll acd oe au IO TEUER IIR WI SSO Op O O E SS Samson Controls L Gt Sk NUR TUE NP ND is 54 8 Conferences amp Speaking Engagements Sierra Instruments 55 Recruitment amp Training Packages SOR ok ek ea Oo ee For additional information please contact United Electric Controls 53 Foster Printing Service the official reprint provider for Control 30 Call 866 879 9144 or Wago TIT 232 sales fosterprinting com Winsted cas wd aoe ees wwe Reed 4 Our safety experts talk safety Our operators talk control But when it comes to keeping our people and plant safe we all need to speak the same language Eliminate uncertainty reduce your risk with DeltaV SIS Emerson s smart safety instrumented system provides an integrated intuitive set of engineering tools and software that enables your team to handle configuration alarms and device health DELTAV SIS monitoring while maintaining the systems separation required by IEC 61511 and 61508 standards The DeltaV
11. amounts It works with a single valve and pump in automatic or manual mode or with two valves for two stage batching Endress Hauser 888 ENDRESS www us endress com GOING SOLO Solo 24 VDC powered pro cess temperature controllers are available in four standard DIN sizes These single loop units are equipped with a dual ment display and offer dual four digit seven seg output control and a built in auto tune function Flexible control modes include PID ramp soak on off and manual operation Free configuration and monitoring software is available Automation Direct 770 889 2858 www automationdirect com MARCH 2013 57 58 CONTROL EXCLUSIVE EN 9th Generation Thermox WDG Flue Gas Combustion Analyzer For more than 40 years we have been a leader in combustion gas analysis says Mike Fuller divison VP of sales and marketing and business development for Ametek Process Instruments and we believe the WDG V is the combustion analyzer of the future 6 WDG analyzers are based zirconium oxide cell that provides a reliable and cost effective solution for measuring excess oxygen flue gas as well as CO and methane levels This information allows operators to obtain the highest fuel efficiency while lowering emissions for NOx CO and CO The zirconium oxide cell responds to the difference be tween the concentration of oxygen in the flue gas versus an air reference assure complete combust
12. and on our YouTube Channel We have published unique web content ranging from B la Lipt k s ebook on distillation to Greg McMillan and Stan Weiner collected Early Years of Control Talk all the while publishing new product releases and news as we get them We are proud of what we have accomplished and we are proud to be rec ognized by the Neal Award jury whether we win or not The most important thing though is that we continue to work every day at making the Control Global com experience better for our readers and our clients As editor in chief I want to take this time to congratulate the entire team especially Katherine Bonfante and Sarah Cechowski our digital editors Under Katherine s leadership the ControlGlobal com website continues to grow more impressive all the time Search this site Tips www controlglobal com thismonth Why Migrate a Legacy DCS www controlglobal com wp _ downloads 130205 rockwell migrate dcs html Safety Instrumented Systems Essentials www controlglobal com wp_ downloads 130128 Essentials eBook html Flowmeter Accuracy Specifications WWW cCOntrolgqlhobal whitepapers 2013 130122 siemens flowmeters accuracy html Thermowell Calculation Standard www controlglobal com multime dia 2013 rosemount thermowell calc standards html No More TAFLAs http community controlglobal com content enough taflas Podcast RCAs and Top 50 Awards www controlglobal com mu
13. including layout graphics placement navi gation procedures alerts and alarms user identifica tion and other security requirements ZEN LLLI W NENNK LL rs www rittal us s OPERATOR PERFORMANCE that the water wastewater systems oper ate hundreds of pumps valves actuators water quality and other equipment which are monitored by more than 1200 I O LL WT Im FT E EE E E ELE im 5 FEE points and networked via Modbus TCP E P 3 IP a high speed Ethernet backbone with twin servers and remote radios and 100 live video security cameras at its pump ing stations All of this data comes into an unmanned cubicle where it s been man aged by GE Intelligent Platform s GEIP Proficy iF ix software and then reports e mails and alerts are pushed out to DPW personnel on their laptops tablet PCs and smart phones Also about two years ago Waterford DPW added Proficy Workflow software which automates more processes serves as Graphic courtesy of PAS Inc an electronic user manual and performs Figure 2 An optimized overview of a large power plant doesn t look like an abstract exception based reporting which notifies graphic of a power plant Instead PAS uses prioritized trend data and human factor prin users of problems so they don t have to go ciples to make important abnormal conditions and alarms stand out clearly find them For ex
14. local business or global enterprise you ll find Freelance will suit all your process needs Ask our users because we did They said You can depend on Freelance Rely on it Plan now for Automation amp Power World 2013 Orlando March 25 28 2013 For information www abb com a amp pworld 2 22 Power productivity for a better world March 2013 Volume XXVI e 5 COVER STORY 36 Operator Performance Pumps Up Prioritized data improved HMI displays proactive alarm planning and other tools all can enhance operator performance The trick is knowing how much of each you need by Jim Montague WEB EXCLUSIVES A S 5 MANAGEMENT 45 Wireless May Make Valves Easier to Maintain How to use wireless to manage your valve assets by Walt Boyes Reader Faves Stories You Liked the Most The Safety Instrumented Function An S Word Worth Knowing www controlglobal com articles 2003 A3 Can We Use Control Valves for Safety Shutdown www controlglobal com articles 2003 446 html C A LIBRATION Manage PLC Programs to Meet FDA Requirements www controlglobal com articles 2005 385 html 49 Long Distance Calibration Calibration is complicated at best Add problems of long distance timing and customs regulations and things get really tricky by Nancy Bartels w 3 8 CONTROL ISSN 1049 5541 is published monthly by PUTMAN Media COMPANY also publishers of CONTROL DESIGN CHEMICAL PROCESS
15. new transmitters e On Demand Help Menus and teachable device specific short cuts e More than twice the battery capacity of any handheld communicator e Manage device information through PC connection e Integrated multi language support www yokogawa com us Continuing a Tradition of Excellence 4 j 4 y j w E k A o M k EM t A j P A j ae 7 J 474 Advanced Nuclear Level Technology Sets New Stanqard VEGA s ProTrac radiation based measurement technology delivers reliable non contact level measurements and sets the standard for modern design With ProTrac users get Smallest and lightest detector available for easy installation Single encapsulated electronics for superior durability On board adjustment and display module for tool free commissioning Advanced software wizards provide fast and intuitive setup Safe and reliable operation for SIL2 applications design certified to IEC 61508 WWW Vega americas com americas vega com Looking Forward 1 800 FOR LEVEL in VEGA Americas Inc vega_americas IN PROCESS power and frequency control and coordination It also pro vides real time monitoring of equipment and timely notifi cation of abnormal situations and helps determine equip ment health so technicians can schedule maintenance and repairs more efficiently Implementing a
16. s www endress com Promass flowmeters installed on its facilities gensets But installing flowmeters is only part of the solution Those meters have to be calibrated in Ceuta s case ev ery three years And here s where things get a bit more complicated MARCH 2013 49 From 4 3 to 15 displays Maple Systems has an HMI to fit your automation needs Features include Bright LCD touchscreen Rugged durable construction High speed operation Serial and Ethernet Com ports Built in video ports 12 and 15 Support for over 100 controllers Easy to use full featured programming software As always Maple Systems provides complimentary technical support and the best value in the industry Visit our website for details CALIBRATION Germ n Canosa Murcia elec trical maintenance technician at Endesa in Ceuta explains The calibration of these flowmeters is extremely important because first the Spanish electricity system op erator Red El ctrica of Spain SA requires testing on certain flowme ters to ensure adequate performance and these have to be calibrated every three years We also have to properly calculate fuel consumption and CO emissions to comply with Spanish and European Union regulations Fi nally we have an internal directive of the company to keep track of these things Figure 1 But regulatory and corporate de mands aside the calibration of the 11 Ho
17. the height of the lost conden sate in the wet leg Under emergency conditions by adding this amount AL to the level reported by the d p cell NL the corrected level CL is obtained Both signals NL and CL should be sent to the control room to provide the opera tors with the needed information concerning the conditions in the reactor Any number of d p cells LT can be added to the reactor and the closer they are vertically the more ac curate their readings will be In Core Level Measurement The ex core level measurement will approximate the in core level only so long as the fuel rods are covered by water but once the ex core level drops below the suction of the jet diffusers it will not Therefore direct in core measurement is also needed In many cases such as Fukushima they were not provided One method of in core level measurement is to correlate it with the gamma radiation distribution inside and outside the reactor The vertical gamma radiation distribution is re lated to water level because water is more of a moderator than steam On the other hand because gamma radiation is also a function of the neutron flux and of the speed of water recircu lation special correction models and algorithms are needed to obtain the water level from gamma radiation distribution Other possible ways to detect in core level or steam water ratio are based on the thermal or electric conductivity or neutron modulation differences between
18. will oc cur and it will be hugely disruptive if proper backup procedures haven t been followed Off site data storage firms can provide the discipline of regularly scheduled backups offloading in house resources from this tedious task Firms such as Amazon Google and Rack space provide these services at very low prices albeit with correspondingly low levels of spe cialized support particularly for customers in niche markets like the process industry For comprehensive IT support tailored to their specific needs process plants that primar ily rely on one supplier for most of their auto mation hardware and software may wish to engage this preferred supplier for offsite IT as sistance When this option is chosen process automation and IT professionals can expect a much higher level of service but at substan tially higher costs Major automation suppliers have large numbers of personnel dedicated to servicing the automation IT sector and they bring a much deeper understanding of process automation If your plant uses automation hardware and software from a variety of suppliers and you need a higher level and a greater range of ser vices than are provided by the typical data backup firm an automation solutions provider could be your best option Our company provides five basic services MARCH 2013 from our PlantFloor24 Operations Center backup and recovery software updates and patch management incident management r
19. world s first flowmeters for the EtherNet IP network Coriolis and Electromagnetic seamless integration into Rockwell Automation Integrated Architecture M and PlantPAx Process Automation System expanding the flow of real time data across the manufacturing enterprise With just a few mouse clicks you have the ability to integrate configure and commission in minutes not hours typical with other networks Measurement information from flowmeters into the control system aid real time decision making for increased quality and output Endress Hauser People for Process Automation DEPARIMENTS 9 Editor s Page It s about Being Your Authority Ways we try to be your trusted source for automation information 13 On the Web ControlGlobal com Up for Neal Award It s nice to be recognized by a jury of our peers 15 Feedback Readers weigh in on past articles 23 Lessons Learned How Automation Could Have Saved Fukushima It can overcome the human factors during a serious disruption 25 On the Bus Why Couplers Aren t Commodities One size does not fit all and it makes sense to know exactly what you need 26 Without Wires ISA100 11a Round 2 Begins Achieving a wireless standard will take persistence and participation from end users 28 In Process Fluke recalls clamp meters Emerson goes big at Russian power plant fear of failure stymies STEM careers and other March 2013 e Volume XXVI e Nu
20. 013 57 OPERATOR PERFORMANCE Photo by Bill Fritz at Waterford DPW and alarms stand out clearly A whitepaper by PAS on these high performance HMI principles and the EPRI project is located at http tinyurl com a8tdjIn Besides improving HMIs and displays enhancing perfor mance also means assisting the physical eyeballs viewing those screens especially when their owners attention fal ters and they get tired Limiting work hours and potentially dangerous fatigue has long been mandated for airline pi lots first responders truck drivers and other professions but it s not as well known or established in many process op erations where many managers and operators rely on too many overtime hours and consecutive workdays To remedy these dangerous situations the U S Dept of ransportation s Pipeline and Hazardous Materials Safety Administration s www PHMSA dot gov latest rules took ef fect in September 2012 and they require pipeline operators Figure 1 A staff member at Waterford DPW consults several operating platforms at the same time including water wastewater process controls and security cameras with help from GE Intelligent Platform s to use display graphics that employ human factor designs Proficy Vision and Proficy Workflow software provides progressive exposure of detail Displays designed from a stack of schematic designs will not have this They ll be flat like a computer hard disk wit
21. CH 2013 t gt 40 AEI D Just as there are many ways to improve process controls and automation there are many useful ingredients that go into improving operator performance And just like mixing up a nutritious fruit smoothie or protein shake the best recipe for optimal operator performance means finding the tools and methods you need most and will suit you best These components include better prioritized data and alerts simplified displays and software improved ergonom ics targeted training and simulations new policies on alert ness and physical fitness and numerous software tools and proactive procedures All can help enhance operator perfor mance and improve the safety and productivity of process applications and lately they re being followed by a bunch of other helpful tools and software For instance Dave Strobhar chief human factors engi neer at the Center for Operator Performance www operator performance org reports it s testing the semantic procedure analyzer SPA which is learning software that recognizes and flags terms updates all applicable documents and makes it easier for operators to organize and update routine and emergency procedures SPA was developed by Penn State University with contributions from center members Chevron www chevron com and Yokogawa Corp of Amer ica www yokogawa com us The center also just developed its display metrics toolkit DMT that lets operators measure their performan
22. EATE INNOVATIVE SOLUTIONS REGISTER TO ATTEND AT WWW INTERPHEX COM AD6 INTERESTED IN EXHIBITING CONTACT PETE ZEZIMA AT 203 840 5447 INNOVATION INTELLIGENCE PASSION DRE INFORMATIC INTERPHEX 2015 MORE INFORMATION INTERNATIONAL CONTRACT d BioPharm BioProcess WPhariit iitical Online The Science amp Business of BioPharmaceuticas N T E R NATIONAL CORPORATE 68 SPONSORED BY INDUSTRY PHARMA PARTNERS I PARTNERS Pharmaceutical oo n groc now you Any screen size Any Sorters Moor Text Gadgets Line Header Page Navigation Push Button mooth Fil Smooth Monitor and Control Gadgets 0 00 ft LED Q Check Box Horizontal Gauge 100 4 images Harizomnial Sidor 5 00 GC Ooo Hg Taxi Y i x 3 so Value Input Drag and drop touchscreen ready gadgets and page objects onto your screens to quickly build clear visual high performance HMis Scan this QR code with your smartphone to learn more Responsive design is built gracefully to fit any device labels images live video tri browser Anywhere Securely monitor and control your system from anywhere anytime on any device Mo browser plug ins or controls are needed Ever Make changes quickly a
23. ING 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 2013 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 SUBSCRIPTIONS Qualified reader subscriptions are accepted from Operating Management in the control industry at no charge apply for qualified reader subscription fill in subscription form 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 BWT PO Box 1051 Fort Erie Ontario Canada L2A SNS MARCH 2013 5 Endress Hauser Inc 2350 Endress Place Greenwood IN 46143 inquiry us endress com WWW us endress com Service 800 642 8737 Unlock process potential with EtherNet IP enabled instruments The
24. IPTAK GREG MCMILLAN IAN VERHAPPEN STAN WEINER Editorial Assistant LORI GOLDBERG Ea Q 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 qe cle This A e 4 3 o amp The Top 50 Automation Companies Ive been following your list for several years Its always an excellent summary One company to consider is Sick optical sensing products Its annual report indi cates it did about 900 million last year TOM KNAUER Tom_Knauer sti com While I was studying your report about biggest companies in automation market I couldn t find some big players for ex ample Sick or Balluff In 2011 Sick had about 902 of income How do you get companies to your report burys poczta fm Editors Note Our 50 list is always work in progress Companies are added or subtracted as their fortunes change We always welcome recommendations about companies we may have missed For a com plete explanation of the criteria we use for inclusion go to p 38 of the December 2012 issue or go to www controlglobal com arti cles 2012 top 50 how do we do it html
25. NO EE ee e E 4 AutomationbDirect 8 Badger Meler sss sewage uwa mapa TM Banner Engineering cos cp tedio 31 Classic H 47 AUTOMATION Siemens Moore Panel Controllers PLC DCS Emerson Process Mgt Fisher 17 FEE Sensors Drives Emerson Process Mgt Rosemount 27 d T iq Motor Control m MEUS E from Allen Bradley to merson Frocess Megt systems Moore 320 351 352 353 363 372 382 383 Industrial Automation Endress Hauser 0 7 Fully Tested Warranty www santaclarasystems com Fei F luid Components a behest Lo ab custorner ser ce CAHN iON Corm di T 21 22 ni m ETE M as 2 LOOKING to s M Contact Seth Kostek at Kobold Instruments 56 ADVERTISE 888 450 0301 x215 Load Controls ies rete re 5 buyer santaclarasystems com Magnetrol 1 0 1 Contact Polly Dickson pdickson putman net 630 467 1300 ext 396 Maple Sy 50 Moore 35 Mynah 1 T3 C I R O L National Instruments 12 Omega Engineering 3 M CUSTOM REPRINTS Orion Instruments 57 ESSERE Cook we 14 REPRINTS ARE IDEAL FOR
26. PROMOTING EXCELLENCE IN PROCESS AUTOMATION CONTROLGLOBAL COM Wireless May Make Valve Maintenance Easier Long Distance Calibration Operator J Prioritized data simpler 5 alarm planning and human factor designed equipment can improve awareness and abilities How much FAECES INTERACTIVE TRAINING TOOLS REDUCE OPER do you need of each TR N D amp LUT OPER f ali 5 MEREVEN FORN 8 INTERACTIVE TRAINING TOOLS REDUCE OPER TOR x 1 L ON THE WEB Reader Faves Automation Stories You Liked the Most gt PutmanMedia MARCH 2013 PLANT first responder anticipator forecaster gatekeeper quality controller opportunist problem solver accident preventer life saver OPERATOR Feel the power Foxboro control systems put the power of information in the hands of your key plant personnel empowering business success that starts at the core of your organization iom invensys com yourtuture Foxboro Copyright 2013 All rights reserved Invensys the Invensys logo Foxboro and Triconex are trademarks of Invensys plc its subsidiaries or affiliates All other brands and product names may be trademarks of their respective owners Pressure Transducers Sensors and Gauges Bet a Pressure Transmitters Lightning Protection Optional Le
27. Process Safety Enjoyed your September 2012 editorial Struck a chord with me One other ele ment that strikes me when we talk about plant safety is the condition of our aging refineries Sometimes even the best main tenance practices fail to manage to keep some of these plants safe They beg for re hts and technology updates BP Whiting is in the throes of a mega expansion leaning on fieldbus Not sure how much refitting is being done on exist ing processes I m sure there are plenty of processes there and in our other U S refin eries that would be safer with investments in modern technology JIM SHIELDS jim shields fluke com Wired vs Wireless I read this article January p 47 www con trolglobal com articles 2013 verhappen wireless html and it was very interesting Thank you There is an another solution that is between these two technologies it s called powerline communication Wherever DC or AC powerline is re quired for the operation of any automa tion module the powerline can be used to convey data between the modules without new wires I My company has used this idea to develop semicon ductors operating as UART transceiv ers over the power line You may trans fer any number of RS232 RS485 bytes into the device and the data will be re ceived by all other devices connected over the powerline Originally the device was designed for automotive therefore it is noise robust Act
28. Q member and professional process engineer said failing and more im portantly trying again is a pivotal skill in problem solving Tf one does not take risk they risk not solving the problem she said As educators professionals and leaders we need to re inforce to teens that every failure is an opportunity to learn and grow Teaching teens that it is okay to take risks and sometimes fail will build their confidence and ultimately their knowledge base of science technology engineering and math Girls Fear Failure More According to the survey 88 of students say they feel the pressure to succeed of which 71 say failing a class makes them feel they have not succeeded Seventy eight percent of girls feel unsuccessful when they fail a class compared to 6476 of boys When faced with a difficult problem to solve only 1176 of students are happy because they enjoy solving problems according to the survey results Fifty eight percent Can rely on wireless to control remote facilities Can monitor temperatures at known problem locations without wiring Can 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 ProcessContr
29. SIS system reduces your training and lifecycle costs by eliminating complex data mapping and multiple databases while helping to ensure that you re meeting safety compliance Learn more about safety processes and best practices by downloading the Safety Lifecycle Workbook at www DeltaVSIS com workbook amp EMERSON Process Management EMERSON CONSIDER IT SOLVED
30. Stahl www r stahl com offers another line of couplers that have low quiescent short circuit current This can be a factor when one is computing the maximum power budget for a segment The 30 mA you save could facilitate adding an additional device or allow test equip ment to be connected without causing commu nication errors Stahl couplers also have special accommodations to limit inrush current when powering up an entire segment and circuitry to tolerate more than one short circuit without an increase in the total current load Cobalt Process https cobaltprocess com doesn t believe in salesmen and caters to savvy end users who know what they want and don t want to pay for marketing overhead Arguably any of the certified couplers will be one of the most reliable components of one s heldbus networks But there are ample features and distinctions that have their appeal for indi vidual users and cultures BM JRezabek ashland com Potting is no better than the Significantly more cost effective technique of conformal coating for ruggedizing couplers MARCH 2013 JOHN REZABEK CONTRIBUTING EDITOR 25 2 WITHOUT WIRES pu IAN VERHAPPEN DIRECTOR INDUSTRIAL AUTOMATION NETWORKS iverhappen industrialautomationnetworks com To directly influence the outcome of this dispute end users should vote with their time by participating in the appropriate standards committees 5 100 11
31. UniSim operator training simulator from Hon eywell Process Solutions www honeywellprocess com to instruct operators how to run its Experion C300 Process Knowledge System PKS and quickly diffuse potentially un safe situations In fact Woodside reports employing UniSim before commissioning prevented at least five process trips THE DIFFERENCE BETWEEN OPERATION CONTROL Only Winsted control room consoles combine the configuration flexibility you need 5 with the robust performance demand From modular to custom Winsted consoles offer an array of options and modifications that optimize aesthetics function and ergonomics Bring your ultimate control environment to life with our FREE WELS 3D console design software Try it now winsted com wels iua OMEN UID CE 4 WINSTED CORPORATION WEB WINSTED COM TEL 800 447 2257 FAX 800 421 3839 Control Room Consoles PERFORMANCE pal The Angel training simulator was identical to our real Angel control room panel and enabled our operators to prac tice on the new C300 system says Dustin Taylor Wood sides process engineer We also used UniSim Design to model the process which provided dynamic process behav ior for training our panel operators UniSim increased the competence and confidence of our staff when dealing with unsafe scenarios plus we reduced the number of trips Andrew Ogden Swift director of technology strategy at Honeywell Proce
32. VE EDITOR 62 jmontague putman net supporters of more and better training will often have to agitate managers into enabling routine but vital instructional programs Get into the Uncomfort Zone I ve probably said it before but after a dozen or so interviews usually begin to notice some common threads and trends Sometimes these repeated themes are indicated as much by what my sources don t say as what they do say For example this month s cover article Operator Performance Pumps Up is all about the multiplying fruit salad of tools and methods for improving opera tors situational awareness and their ability to manage process applications efficiently safely and productively Everyone was talking focused and prioritized data uncluttered and efficient HMIs efforts and rules to reduce fatigue ra tionalized alerts and alarms unified software platforms simulations wearable cameras and video conferencing and even eye tracking cameras and ways to monitor operators atten tion and alertness Oh sure in class and on the job training were mentioned however I got the feeling that everyone was impatient to get done with talking about training quickly and on to the next glitzy technical innovation No one actually said it but it seemed from the lip service it received that training was old fashioned and just plain boring And maybe it is but I still can t think of anything more essential to improving o
33. ample the department Made possible by With the Control Essentials Series KR HN E Written by the editors of CONTROL our new Control Essentials series is designed to provide process industry professionals with an up to date top level understanding of a range of key process automation topics Our intent is to present essential engineering concepts in a practical non commercial fashion Made possible by together with a review of the latest technology and marketplace drivers all in a form factor well suited for onscreen consumption Get in and get out quickly with just the information you need To download your complementary copy Now available at visit ControlGlobal com Essentials ControlGlobal com Essentials built algorithms and templates to indicate if pairs of pumps are alternating correctly at 62 of its pumping stations This allows Workflow to provide alerts when the pumps aren t synched properly so individual visual checks by the operators aren t required anymore It s been our goal for years to get as many applications as possible onto one platform so we don t have to call up so many different types of software says Fritz But we wanted more than snapshots of what s going on so we re installing new Proficy Vision software which brings all our separate software programs into one customizable dashboard and al lows us to bring up and quickly scroll through all our in dividua
34. ansmit live video of device s he working on to experts at a distance and get real time feedback about correct procedures and actions to carry out Many operators are increasingly overwhelmed with data because each is typically being asked to man age more systems says Russ Agrusa president and CEO of Iconics Inc www iconics com Operators must be able to integrate disparate infor mation and software into standard common interfaces They need tools that can dig through big data and allow priority alerts to bubble up to the top Naturally as most human endeav ors migrate to tablet PCs and smart phones some even cooler tools are beginning to pop up to aid operators One of these futuristic collaborative tools is Mobile Voice and Video from Emerson Process Management www emersonprocess com This wearable video conferencing system allows field operators to point a hands free camera at problematic equipment and confer with technical experts at a distance Figure 5 It was developed with com ponents from AudiSoft www audisoft net and Frontline Communications http frontlinecomm com Mobile Voice and Video has full high definition video but it also makes voice communications a priority says Neil Peterson Emerson s senior wire OPERATOR PERFORMANCE less marketing manager This means it can switch to fewer frames per sec ond video based on available WiFi or cellular bandwidth to keep confer en
35. buses Relcom www relcominc com engineered and patented the Spur Guard acompact assembly that could be substituted for pluggable terminals on their wiring blocks Any spur what fieldbus calls a single pair drop to a device fitted with a SpurGuard could sustain a water logged or otherwise short circuited condition without cratering the whole network SpurGuards were expensive so Relcom and its competitors began to design and manufac ture couplers wiring blocks pre fitted with short circuit protection for each spur Since about 2009 end users have been able to choose from a wide selection of couplers that are reg istered and tested by the Fieldbus Foundation www fieldbus org So can couplers be pro cured on the basis of cost only There are distinctions If youre creating a wiring block or brick you have to make choices regarding how many spurs you can wire to each brick Pepperl Fuchs www pepperl fuchs us has one of the wider selections of bricks which can be purchased with 4 6 8 10 or 12 spurs per brick P F and Phoenix Contact www phoe nixcontact com go a step further to optimize scalability in their lines of snap together modu lar coupler hardware Both P F s RM SP line and Phoenix Contact s FB ET lines allow you to build up couplers with between two and 26 spurs A pluggable bus rail extends the bus for up to a half dozen more modules each extend ing the base unit in incremen
36. ce with different graphics which can help them create better tools for individual applications We now have a range of tools and methods for evaluating perfor mance so operators and managers can more easily develop the best solution for them says Strobhar Collaboration Aids Simplification One of the best ways to improve operator performance is to get the operators involved early in designing solutions that can meet the specific needs of their applications When we implement interfaces and control systems we get the operations guys on the team developing the graphics as soon as possible says Keith Jones president of systems integrator Prism Systems Inc www prismsystems com in Mobile Ala So after we program the PLCs and DCSs and bring their data to the HMIs about 80 of the input on what those displays should include and how they should look has already come from the operators Once operators get some real input on changes they become very proud of them Despite these potential benefits Jones adds there can still be a lot of reluctance to change by older entrenched opera tors when Prism is asked to upgrade brownfield applications We ve seen some really horrible HMIs that pack as much information and color onto one screen as possible This was done because HMIs and screens used to be a lot more costly but they make it very hard to pick out what s important ex plains Jones This is why we began following and preachin
37. ces up and running Jim Montague is Control s executive editor The Virtual Plant inthe Cloud MiMiG v3 5 Mareh 2013 Easier Modeling Real Time Dynamics Effective raining M Y N A H www mynah com 1 636 28 2000 F MYNAHTechnologies RESEARCH CONTROL ReCo VALVES 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 2013 Badger Meter Inc RESEARCH CONTROL is a registered trademark of Badger Meter Inc High Performance Solutions ISET MANAGEMENT f Wireless May Make Valve aintenat ce Easier Should you use wireless in managing your e assets by Wa Boyes Asset management is the most difficult thing many companies do far more difficult than actually making the products their processes are set up to make The reason of course is that asset management for predictive and preventive maintenance 15 an add on function in most plants When these plants were built there were enough people available to walk around inspecting assets for potential problems and forty years ago the cost of sim ply replacing all the critical valves or motors every time there was a
38. com panies have decided to use Zigbee instead of WirelessHART Even a SCADA company exemys www exemys com head quartered in Argentina but selling worldwide has standardized on Zigbee for its substation and pumping station wireless mesh networks So even though MOL and others have shown that there are significant reasons to use wireless mesh networks the end users remain skeptical Walt Boyes is Controls Editor in Chief ink 8 h ultimately lower costs Whether specifying new or searching for a replacement Cashco control valves and regulators define industry standards for quality dependability and environmental responsibility The 2296 features the new C27 actuator that can be coupled to any one of several assemblies or valve body models This allows you to use a single actuator design for multiple products This in turn helps customers reduce inventory levels and VW W Cashco com Innovative Solutions Gashco Control Call today and ask for one of our sales representatives Learn first hand why we say our quality is only surpassed by the service we provide Model 2296 cas a b pm a n E 4 6 Cashco Inc P O Box 6 Ellsworth KS 67439 0006 Ph 785 472 4461 Fax 785 472 3539 Mighty MINI o dD O 0 dD OD OCD OO C 2toN Ad 2012 PHOENIX CONTACT Around the world control engineers and electrical engineers count on
39. e flow path through the WDG V was completely redesigned so it provides the fastest response of any extractive combustion gas analyzer and it has the ability to predict a pending sensor failure and monitor flow charac teristics to the sample cell The redesigned combustion analyzer features an improved aspirator with larger orifice sizes low How sample alarm that monitors combustion gas flow and indicates low sample flow automatic verification of cell and detector integrity ensuring proper accuracy and operation and cell and detector age track ing for proactive calibration or service scheduling The WDG V can be installed as either a standalone n MARCH 2013 Ametek s WDG V flue gas combustion analyzer meets SIL 2 standards for safety instrumented systems analyzer with analog HART discrete and Modbus RS 485 bi directional communications or supplied in a typical sensor controller configuration with the addition of an AME Vision HMI that provides a graphical display and membrane key pad Modbus TCP IP Ethernet connection embedded web enabled interface and USB data collection port The WDG V builds on the success of the WDG IV by adding key customer valued features Fuller says The in tuitive color graphical user interface on the AMEVision host module which provides Modbus TCP IP web enabled in terface and USB data port is an Ametek Thermox first The diagnostics that predict the lifetime of the sensor and
40. e required calibration is carried out Figures 2 and 3 At the end of the process a Certificate of Calibration of unit under test UUT and the master meter s Swiss Cali bration Services SCS certificate is delivered At Ceuta says Canosa First our maintenance people dismantled the flowmeters and then cleaned and decontaminated them Then the Endress Hauser engineers con nected the flowmeter to the testing computer and checked and verified its calibration If the calibration tests showed that the measurements were not as specified the engineers reca librated the system until the correct accuracy was achieved The cali bration takes between one and two hours The entire process including disassembly assembly and calibra tion does not exceed more than three of four hours per flowmeter Canosa continues The advan tages of on site calibration are evi dent In just four or five days we had calibrated all the Howmeters We also saved money by not having to pay for the transport and the special tax and customs procedures involved in ship ping them back to the manufacturer Endesa has not limited its use of Endress Hauser s services to Ceuta The Coriolis flowmeters in service in its diesel plants in Melilla just up the coast from Ceuta on the Balear ics in the Mediterranean and in the Canary Islands about 62 mi 100 km off the coast of western Africa have also benefited from the on site calibration service
41. e we ve compiled with our readers Lipt k and McMillan answer ques tions every month in Ask the Experts and Con trol Talk Ask the Experts has answered over 390 questions from concerned automation pro fessionals since it was launched Greg McMil lan profiles and interrogates an automation au thority every month This is also the reason we do not allow ven dor authors in Control and restrict them to white papers and vendor notes on Control Global com It is certainly true that people in the vendor community have great knowledge and understanding of applications prob lems in the process automation space But shar ing their understanding and knowledge with us comes at the potential price of favoritism to ward their employer or their employer s favorite technologies We provide one exception to this policy If the author in question has achieved induction into the Process Automation Hall of Fame we believe that his authority in process automation is unquestionable and his or her insights trump employment Google respects authority and when you see Control or ControlGlobal com high on the re sponse page in the search engine that means that Google respects our authoritativeness as a magazine and combined multimedia informa tion outlet We chose the name ControlGlobal com spe cifically to take a North American print mag azine and turn it into a global resource for process automation We ve succeeded pretty wildly Mo
42. eal time control system monitoring and on line control system edits says Kirk Norris the senior vice president for strategic manufactur ing solutions at Maverick Technologies www mavtechglobal com an automation solutions provider based in St Louis Backup and recovery services provided by hrms such as Maverick and by automation sup pliers are much more in depth than those pro vided by the likes of Google because of their domain expertise Software updates are critical for process plants and each update requires decisions to be made with respect to acceptance and imple mentation If updates are ignored then known bugs will remain often causing significant op erational problems and raising security issues But blind acceptance of updates can be trou blesome too as an update to one program may cause it to cease functioning at points of inter action with other software An automation supplier or an automation solutions provider can provide valuable assis tance by testing updates on hardware and soft ware similar to that installed and running in your plant We re able to replicate our clients entire automation system at our PlantFloor24 Opera tions Center We can then test software updates and make sure that each doesn t cause unin tended outcomes After testing we can work with the client to remotely update their sys tems explains Norris In a similar fashion automation suppliers and automation solution provid
43. ed to convince man agement of the resource requirement Stan How can you reduce the time horizon to reduce test time and pro vide better short term resolution of fast dynamics for a given number of data points over the horizon Mark Regulatory design impacts the settling time of the MPC controller An example is having the setpoint of a temperature cascade control loop for a distillation column as a manipulated variable Controlling levels associated with large holdups in the MPC can also reduce the settling time although this is normally done to provide better con straint control If you don t need to han dle the level control for constraint con trol coordination keeping the level in the regulatory control system is fine If a process variable has a very large time constant modeling the variable as inte grating instead of a self regulating can dramatically shorten the time horizon Depending on the particular MPC the integrator approach may take up a DOF in the LP or OP optimizer Greg I have found that treating loops with a large time constant as near integrators can shorten the tun ing test time by 96 making tests less vulnerable to disturbances and less disruptive Stan For PID loops we have auto tun ers and adaptive control How do you tune an MPC once it goes online Mark You may need to revisit con straint priorities but hopefully you ve got most of these priorities right in the simulator The tuni
44. ers can provide related automaton IT services such as incident management real time control system moni toring and online control system edits ASK THE EXPERTS Loop Drawings for Smart Instruments This column is moderated by Bela Lipt k http belaliptakpe com automation and safety consultant who is also the editor of the nstrument and Automation Engi neers 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 liptakbelaQ aol com I am looking for information on loop drawings for smart instru ments and sample drawings If you could point me in the right direc tion it would be appreciated PAUL BULMER pbulmer mpcconsulting net Loop drawings for smart instru ments are the same as for analog loops except for the communi cation links between the components Figure 1 The loop component sym bols are given in ANSI ISA5 1 2009 As to the need for loop diagrams there is disagreement In the view of American engineering design firms loop drawings are not really necessary are a luxury because if the P amp ID flow sheets are sufficiently detailed then the information that the loop drawings provide can be obtained from the in strument index specifications I O lists and wiring diagrams piping diagrams logics cable schedules etc This view has evolved because the main goal of these firms
45. es SIMON LUCCHINI Simon Lucchini fluor com R Control system deliverables are E moving away from the realms of ISA based conventional drafting as tw are more and more driven by the self documenting software tools used Engineers do not need to do as built drawings as a separate exercise Loop drawings content is driven by the client maintenance person who is using it In most cases it could be too simple as the diagnostics tool and one does not really need reference to loops as there are not too many wires to trace in the field or in the system cabinets Clients are moving away from indi vidual loop drawings and are content with segment drawings irrespective of the fieldbus technology used Clients are demanding more value for the money they spend and want to limit engineering costs as the hardware has been already made commercially off the shelf COTS L Rajagopalan Fluor com As far as I am aware there are E no international standards yet for f Ml smart instrument loop draw ings You can either follow the ISA standard S5 1 or the client s standard However a cover sheet is required to explain all the symbols used in the drawings Smart instruments connected to an asset management system require additional components depending on what protocol is used e g Foun dation fieldbus Profibus Profinet HART Wireless HART DeviceNET ControlNET ASi etc binney4family internode on n
46. es for business to business media and they honor excellence in editorial and de sign in business to business publications Just to be a finalist is a real honor Control has won a Neal Award before but this is the first time that our pioneering website has been recognized We were one of the very first to rec ognize that a website was not a magazine We moved in 2004 to make our website different and special not just a copy of the paper magazine That s JESSE H NEAL AWARDS _ Est 1955 x most extensive sources of process automation knowl why we renamed it www controlglobal com We decided in 2004 that we would make Control Global com an authoritative reference for process auto mation on a global scale We were the first in the pro cess automation space to begin a white paper library hosting at last count over 1200 white papers one of the edge in the world We were also the first to pioneer promoting OEMs white papers so that the word would get out to the readers of Control and Control Global com about technologies the OEMs embrace We were one of the first to carry an editorial daily blog Soundoff We now host several blogs including the influential Unfettered blog by Joe Weiss the internationally respected cybersecurity expert and Control Talk by pro cess automation guru Greg McMillan We were the first to carry video edito rial and some of our videos have drawn thousands of views both on our own site
47. et The insurance cost would be high after a fire or an accident that occurs to any plant that has no loop drawings The responsibility is the owners if he or she takes the risk The World s Most Accurate thermal Mass Flow Meter e Accuracy 0 5 of Reading e Multivariable Mass flow rate temperature amp pressure e Revolutionary QuadraTherm four sensor design DrySense no drift sensor with lifetime warranty e qTherm living learning Brain manages all inputs e Dial A Pipe Change pipe size e Dial A Gas Change gas type e qTherm Gas Library 18 gases amp mixtures growing amp improving mmm s j SIERRA sierrainstruments com c3 North America 800 866 0200 Europe 31 72 5071400 Asia Pacific 8621 5879 8521 22 NEW FROM KOBOLD PAS and PAD Pressure Transmitters Features High reference accuracy 0 075 of calibrated span Long term stability High rangeability 100 1 HART communication Continuous self diagnostics Automatic ambient temperature compensation e EEPROM write protection Fail mode process function e Static model PAS Differential model PAD Specifications Output 4 20mA 2 wire Max media temp 248 F e Connection 1 4 1 2 e PAS Pressure range 14 7 21 7 PSIG 0 8700 PSIG e PAD Pressure range 0 3 6 WC 60 6000 PSIG Areas of Application Heavy duty industrial needs Filtration monit
48. ferences for further study The di rect link is at www ni com white pa per 3639 en PRESSURE INSTRUMENTATION BLOG American Sensor Technologies Inc AST has released a new blog for pressure instrumentation and related items AST hopes to keep customers up to date with the latest product up dates inform visitors of new develop ments within the sensor industry and educate the marketplace on how sen sors are being used and applied AST has begun posting to the blog with top ics ranging for oxygen pressure trans ducers to eliminating diaphragm seals The direct link to the blog is at www astsensors com blog HOW TO MEASURE PRESSURE This free tutorial from the NI De veloper Zone series covers the ba sics of pressure measurement Topics 34 www controlglobal com MARCH 2013 THE BIG BOOK OF PRESSURE INSTRUMENTATION The Open Book Project offers a free downloadable 655 page PDF Les sons in Industrial Instrumentation by Tony R Kuphaldt c 2008 Pages 289 347 of this book cover pressure instrumentation including continu ous pressure measurement mechani cal and electrical pressure elements force balance and differential pressure transmitters and pressure sensor ac cessories The direct link to the book is at http openbookproject net books socratic sinst book liii 0v2 pdf PRESSURE MEASUREMENT FUNDAMENTALS This handbook from Ametek covers the basics of pressure measurement i
49. full scale high performance control system and ensuring its full availability for launch during a four month shutdown was a real technical challenge said Stepan Okunkov manager of CIS Power amp Water Solutions Engineering Center of Emerson Process Management But we were able to achieve this goal through the excellent teamwork between Emerson and Surgut 2 power plant specialists from E ON Russia The Surgut 2 station uses natural gas coming from the Tyumen Region s oil fields Based on annual output the plant is one of the biggest thermal power stations in the world producing more than 35 billion kWh per year Are Teens Afraid of STEM Careers Are Parents to Blame While 95 of teens agree that risk taking is required for innovation in science technology engineering and math ematics or STEM careers 46 say they are afraid to fail or are uncomfortable taking risks to solve problems according to an ASO survey conducted by Kelton Global The survey which was fielded in January in advance of National Engineers Week Feb 17 23 reveals that students pressure to succeed may be driven by parents of which 81 say they are uncomfortable if their child does not perform well in sports extracurricular activities or social situations Of those parents 73 say they feel uncomfortable when their child gets bad grades While nearly half of students are afraid or uncomfortable about failing Cheryl Birdsong Dyer AS
50. g OPERATOR the Abnormal Situation Management Consortium s www ASMconsortium net principles on prioritizing data and us ing minimalist style graphics and quad display systems But even though monitors are cheaper and more effective now it s still hard to sell operators on them and management doesn t want to increase their burden or add more training Jones reports that some HMI software can allow users to keep the look of their old custom screens but this can make them harder and more expensive to upgrade in the future so it s better to make the jump to common standard HMI function blocks and configuration tools such as Siemens In dustry s www usa siemens com Simatic PCS 7 and HMI Plus software If we can convince a user to change to stan dard HMI then we can begin to clean up the graphics and do training on them says Jones Jones adds that PCS 7 has conversion tools for migrating tag databases and hardware defined tasks from old PCs and unsupported software to new systems which can greatly re duce the costs of HMI and DCS upgrade projects We can even leave some old hardware in place and run it in parallel with a new HMI system for awhile explains Jones Then if mistakes are made we can make a punch list and check them by comparing the old and new systems Enhancing the HMI If one of the best ways to aid operators is to fix what they re looking at are there common
51. g to protect against overloads Extended temperature range 25 C to 70 C Dare to compare and visit us online at www wago us usc htm AGO INNOVATIVE CONNECTIONS L You Haye Real ey ud Wireless Network Module NET Concentrator System for More Remote Locations Remote I O Has Never Been More Rugged and Reliable When it s time to clean up your real mess the 10 100Base T Ethernet and Redundant MODBUS NET Concentrator System is your real solution RS 485 Communications Our flexible remote I O lets you use powerful new Just Four or Thousands of Fully Isolated Input advances like Ethernet the web and wireless Output Points Per Network to interface something old with mA V RTD ohm mV something new or something Pot Discrete and Relay I O new with something old Industry Best 20 bit Plus since real world Resolution instruments can t always be installed in peaceful places its rugged industrial design Advanced Math Functions PID Control and Data Logging protects against RFI EMI ground Peer to Host or loops vibration and Peer to Peer Architectures harsh temperature conditions 40 C to 2 40 to 185 F Integrated MODBUS Master Capability for Gathering Process Data from MODBUS Slaves Whether you re managing a local process or need to e OPC Server Available collect data from locations across the globe our NET Concen
52. gnostic data You can see what has happened since we standardized on HART and Foundation fieldbus transmitters and began to enable HART valve position ers Bereznai says We gather infor mation before the turnaround using the HART diagnostic data and by do ing this we save between 20 000 and 70 000 per turnaround So we are more predictive and proactive and less reactive Figure 1 Bereznai continues If you look at Figure 2 you can see the breakdown of costed activities relating to valves The costs are significantly higher without di agnostics than with HART diagnostics He adds Were replacing our ana log positioners with HART and were experimenting with WirelessHART Were in the early stages of using Em erson Process Management s THUM WirelessHART adapters to get diagnos tic information out of HART devices without wiring them to multiplexers We have 20 units in a test application He says his team also worried about and other types of interference So they conducted some nearly destructive testing With the instrument live and broadcasting they arc welded directly to the instrument housing and found no detectable interference from the welding Bereznai believes that the signifi cant cost differential between wiring the diagnostics laden HART cable to a new multiplexer and using the THUM adapters will mean that they can keep their existing devices longer Valve diagnostics are
53. h Google Images for instrument loop drawings for several styles of loop diagrams JOHN DRESSEL john dressel fluor com In my experience loop drawings A are a must have They help tech nicians in troubleshooting If you are using software like InTools for de sign they are easily done H S GAMBHIR Harvindar S Gambhir ril com We need to get more folks think ing lifecycle cost rather than just their portion of the lifecycle GEORGE ERK georgerk1930 gmail com For more answers from our experts in cluding Thomas C McAvinew Dick Caro Bill Hawkins and John Rezabek go to www controlglobal com 1303_ ATE html pm ROUNDUP Loop Controllers on Parade Technology for the heart of your processes ACCURATE DUAL LOOP PID CONTROLLER Adam 4022T dual loop PID controller is a serial based controller with an accuracy of 0 15 It s an ideal con troller for temperature and other process variables in heating and cooling applica tions and in environmental testing In addition it can be installed on a standard DIN rail inside a cabinet and it can withstand ambient tempera tures up to 60 C Advantech 888 576 9668 www advantech com UNVERSAL CONTROLLER The UDC3200 controller is capable of 0 2 universal accuracy and includes a fast scanning rate of 166 ms This V4 DIN controller can be pro grammed using a pocket PC and can be used in wash down applications Universal spare parts make
54. h one folder for all the hles T his doesn t provide optimum situation awareness and control A four level hierarchy including operation over view unit control unit detail and support and diagnostics displays is desired For example Figure 2 is an operation overview from a large power plant We often hear But it doesn t look like a power plant Correct Does your automo bile instrument panel look like a diagram of your engine The display is designed so important abnormal conditions Rittal The System Faster better worldwide reduce operator fatigue by limiting consecutive hours and days worked to a more normal weekly schedule establish thorough alarm procedures document and learn from inci dents and pay fines up to 1 million or more per violation according to Ian Nimmo president of User Centered De sign Services Inc www mycontrolroom com More process facilities are investing in control room man agement CRM and human factor principles and they re taking countermeasures against fatigue such as deploying 24 7 style chairs brighter lighting and better temperature control providing exercise equipment and enforcing regular breaks explains Nimmo They re also monitoring hours worked by operators and calculating the relative risks of RITTAL PRESS STOCK MOD gt SHIP Thousands of enclosures Hundreds of sizes Next day shipping FRIEDHELM LOH GROUP incidents which is going to f
55. her solutions for improving operator performance Implement ing muted color displays ergonomic furniture exercise equipment near the control room or co joined easily accessible software platforms just has to be easier than pounding new skills into often resistant human heads right This preference is reinforced by the fact that engineering in general and process control in particular aren t exactly famous for calling on or nurturing people skills And while process control and automation are all about having de vices take over formerly manual tasks countless optimization safety related and quality control jobs remain for operators to do and they need the training and skills to perform them As a result training needs advocates who will quantify and promote its efficiency and finan cial benefits And these supporters of more and better training often will have to agitate their managers into enabling routine but vital in structional programs I know that bugging my sources into giving me interviews and informa tion can be very irritating but I believe it still has a positive outcome So while software and components may replace operators someday it s not today For now slick HMIs ergonomic workstations so phisticated alerts and alarms and situational awareness software are the gravy and they still need a bed of meat and potatoes training CLASSIFIEDS AD INDEX ADVERTISER PAGE
56. hermocouple is a few inches above the tip In case of this sensor if water covers both TCs the temperature difference ATw will be lower than the temperature difference ATs when both are covered by steam If all nuclear power plants used the correct level measure ment design shown in Figure 2 their safety would be much improved MARCH 2013 25 TRUSTED PROTECTION Pepperl Fuchs Inc Twinsburg Ohio 330 486 0002 www pepperl fuchs us Gaining Trust Comes With Consistency And Proven Reliability As a market leader of solutions for hazardous areas Pepperl Fuchs has built trust and confidence into every element of our product portfolio With over 60 years of hazardous location and intrinsic safety protection experience we ve established ourselves as a trusted partner in the process industry Our versatile isolated barriers for DIN rail and termination board applications together with our cost effective zener diode barriers have made us the world s leading supplier of intrinsic safety barriers With a global sales and support organization we are able to provide any plant with an adaptable range of interface and network products for advanced process control For intrinsically safe solutions go to www pepperl fuchs us JPEPPERL FUCHS PROTECTING YOUR PROCESS p ON THE BUS Why Couplers Arent Commodities When fieldbus pioneers expressed concerns about single points of failure in simple two wire
57. in View IV wind farm and implemented Iconics www iconics com Gene 51564 SCADA system and Hyper Historian which are net worked via open protocols such as OPC take in data from Modbus TCP IP and MHI CNET interfaces and provide AES operators with immediate and aggregated data for monitoring and reporting Genesis64 s global aliasing func tion also allowed the wind farm s staff to configure controls for one turbine and then quickly import the same I O and other settings in the other 48 turbines inc j automation 2013 Red Lion Controls Inc All Rights Reserved better together networking HMIs amp Panel Process Controllers Meters Visual Management Visit better redlion net to learn how our industrial automation and networking products work together to connect monitor control 1 717 767 6511 info redlion net better redlion net Protocol Ethernet Switches amp Wireless Devices Conversion Red Lion has been delivering award winning industrial automation products to customers worldwide for over forty years Now these innovative products are even better when paired with industrial networking from N Iron and Sixnet the pioneers in Ethernet and cellular M2M solutions for industrial environments red lon Photo courtesy of Emerson Process Management Figure 3 A field technician equipped with Mobile Voice and Video from Emerson Process Management can capture and tr
58. innovator B and level control expert to learn more ahout the ECLIPSE Model 706 Eclipse magnetrol com e 1 800 624 8765 info magnetrol com Unbeatable Control Precision and Flexibility T d To PI 2 2 2 GET Lowering cost Increasing productivity and shortening design times are just some of the challenges industrial engineers face The graphical system design approach combines productive software and reconfigurable O RIO hardware to help you meet these challenges This off the shelf platform customizable to solve any control and monitoring application integrates motion vision and O with a single software development environment to build complex industrial systems faster Accelerate your productivity at ni com industrial control platform 800 453 6202 NI LabVIEW system design software offers ultimate 5 flaxibilitythroughFPGA programming simplifies coda reuse and halps you program the way you think graphically Si CONTROL ONLINE ControlGlobal com Norminated for Neal Award WALT BOYES EDITOR IN CHIEF whoyes putman net As you are reading this the Control team is waiting to find out if we have won a Jesse H Neal Award for ControlGlobal com We are one of the four final ists in the category of Best Website for publications in the under 3 mil lion revenue range The Neal Awards are often called the Pulitzer priz
59. ion the flue gas should contain several percent oxygen The optimum excess oxygen concentration is dependent on the fuel type natural gas hydrocarbon liquids and coal The WDG V mounts directly to the process flange and is heated to maintain all sample wetted components above the acid dewpoint Its air operated aspirator draws a sample into the analyzer and returns it to the process A portion of the sample rises into the convection loop past the combustibles and oxygen cells and then back into the process This design gives a very fast response and is perfect for process heaters It features a reduced drift hot wire catalytic detector that is resistant to sulfur dioxide SO degradation and the in strument is suitable for process streams up to 3200 F 1760 The role of combustion analyzers in control and safety functions is evolving rapidly Fuller says Maximizing fuel efficiency while reducing emissions from combustion pro cesses requires the use of aggressive operating setpoints that dictate the need for additional layers of safety for risk reduction He adds The WDG V was designed to meet the SIL 2 standard so that it can be a key part of a safety in strumented system SIS The WDG s aspirator design has always provided a reasonable response time but our custom ers needed tighter control on combustion parameters This means faster response even with flame arresters installed Fuller goes on Th
60. is to minimize the number of man hour consuming documents and thereby gain a competitive edge by tightening budgets through limiting engineering costs In other offices and in other parts of the world such as Asia the criterion is total cost which includes not only design but also operating mainte nance and insurance costs and from that perspective loop drawings are desirable because they make the loops easy to understand as you do not need to look at several documents Those hrms consider the generating of loop diagrams valuable and use ISA5 4 as s r r ww Electrical lead serial link Kes Internal DCS serial software communications link lt 7 P amp ID DOCUMENTATION Combination of two services Multivariable Tx Figure 1 Communication link symbols One Series Transmitter Switch for the Power Industry Monitors pressure or temperature Provides analog 4 20 mA signal Programmable switching capability Smart self diagnostics SIL 2 suitable Partner with the Best ask THE ERPERTS O the basis although it has not been updated for over a de cade and does not give examples for fieldbus loops For this group of engineers it would be useful if ISA5 4 covered the protocols used e g Foundation fieldbus Profibus Pro finet HART Wireless HART DeviceNET ControINET ASi etc So it seems that the main cause of the elimination of loo
61. it easy to maintain while on board diag nostics and plug in circuit boards simplify troubleshooting and repair Honeywell Process Solutions 800 343 0228 www honeywellprocess com AUTOMATIC OR MANUAL POWER Russelectric on site power control systems are equipped with dual PLC controls for automatic generator set start ing and stopping status and alarm annunciation synchro nizing and priority load con trol If both PLCs were to fail a manual control allows personnel to synchronize and paral lel the generators onto the bus and add and shed loads They are UL listed and meet ANSI IEEE and NEMA standards Russelectric Inc 781 749 6000 www russelectric com DISPLAY AND ALARM SIMULTANEOUSLY 51 72 simultaneous controller provides display and alarm functions for up to 64 channels and I O It uses a simple menu driven setup is wireless capable and displays data on its color LCD It has four RS 485 serial ports for si multaneous Modbus master slave operations and multiple masters five standard SPDT alarm relays and four indepen dent alarm levels per channel RC Systems 409 986 9800 www rcsystemsco com CONTROL BY THE BATCH RA33 batch controller senses and dispenses liquids into containers or process ves sels in food chemical phar maceutical oil and gas and other process applications It monitors flow temperature and density controls valves and pumps and dispenses programmed recipe
62. ket like space between the shroud and the reactor wall and is pumped downward by rods are covered a jet dispenser not shown It travels down ex core outside the core and then rises up in core As it rises the fuel rods heat it and the wa by water ter boils and therefore swells Condensate ale gt Steam Narrow span Cooling level transmitter waler Control rod Emergency Fuel rods shutdown rod Core shroud Wide span level transmitter THE PROBLEM WITH THE 0LD WAY Figure 1 This traditional system uses condensate pot compensated d p transmitters In such a system if the condensate in the reference leg is lost boils off the level transmitters will over report the level MARCH 2013 Automation Could Have Saved Fukushima In the previous articles described how automation could have prevented the Three Mile Island and Chernobyl accidents Now will do the same for Fukushima but be cause of its importance will devote more than one article to it In this first article will concentrate only on the measurement of the water levelin the reactor If the Fukushima In most nuclear power plants the ex core level is measured by two differential pressure transmit ters Figure 1 One has a narrow span range LI and the other a wide one LI W The is a better indicator of the surface of the boiling water while the LT W detects the total ex core hy dros
63. l programs that we couldn t see all at once before Now our office managers and 56 field staffers can view water operations on the SCADA system HVAC data vehicle lo cations and status security camera feeds work orders and other information at the same time Figure 1 So if there s a water main break they can trace it with GIS isolate it faster check affected pump rates and tank levels find the closest person and vehicle tell operators which valves to close and get specification data into the right hands more quickly Don Busiek GEIP s general manager for manufacturing 198 KT a OPERATOR PERFORM ANGE software adds that Proficy Vision was just released in January and while it renders several types software on one screen its counterpart Proficy Mobile software will allow users to access SCADA data on tablet PCs and smart phones This all about understanding how operators navigate and what they need and then coming back and providing the right data to them at the right time says Busiek Apart from all the displays and technical solutions another of the best ways to empower operators is still good old thor ough in class or on the job training which is often aided by online curriculum and simulations For instance to prepare for commissioning and start up on its Angel platform on western Australia s Northwest Shelf Woodside Energy Ltd www woodwide com au recently de cided to use
64. ltime dia 2013 podcast top 50 rca 2013 html Zombie ISA Automation Week http community controlglobal com content isa automation week rises grave pauto isaautoweek isa ControlGlobal E News Multimedia Alerts White Paper Alerts Go to www controlglobal com and follow instructions to register for our free weekly e newsletters 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 newsletters MARCH 2013 13 PENTAIR tyco 9 PENTAIR Flow Control How do you create a global company built for the future By combining two powerful histories in pursuit of a bold vision to help companies around the world contribute to healthier safer if environments Building on the achievements of Pentair and s Flow Control businesses comprised of Valves amp Controls Thermal Controls and Water amp Environmental Systems the new Pentair deliy rs exceptional depth and expertise in filtration and processing flow management equipment protection and thermal al pge ment fa From water to power From energy to construction From food service to residential We re 30 000 employees strong combining iny r tive thinking with disciplined execution to deploy solutions th fat it hell better manage and utilize precious resources a ensure operational success for our customers world
65. ma Design In the case of Fukushima the design was even worse because no transmitters were used at all Continued on page 23 Manually inputting the control signal feels pretty primitive I need to get back in automatic mode for better efficiency YOU CAN DO FISHER You can automate your control signal using the Fisher Control Disk valve from Emerson Process control loops containing butterfly valves are often placed in manual mode due to poor control performance This results in operators constantly monitoring and adjusting the control signal significantly reducing efficiency With a control range comparable to a segmented ball valve the Control Disk valve enables control closer to the target set point This allows you to leave your control loop in automatic mode regardless of process disturbances With low maintenance requirements and sizes up to NPS 36 it s time to put the Control Disk valve in your loop Visit www Fisher com automatic to watch an animation video or download a brochure amp EMERSON Process Management The Emerson logo is a trademark and service mark of Emerson Electric Co 2013 Fisher Controls International LLC D352200X012 MZ8 EMERSON CONSIDER IT SOLVED IT HAPPENS AT IN I ERPHEX ARE YOU IN APRIL 23 25 2013 JAVITS CENTER NEW YORK NEW YORK EE NER E LE Misi i EE P X BRINGING TOGETHER KEY PHARMA AND BIOTECH PROFESSIONALS WITH SUPPLIERS TO CR
66. mber 5 CONTENTS 34 Resources Contents under and about pressure 22 Technically Speaking Off Site IT Off site firms often provide a better solution than in house alternatives 93 Ask the Experts Loop drawings for smart instruments 57 Roundup What s new in loop controllers 58 Product Exclusives Ametek unveils fifth generation flue gas combustion analyzer Pepperl Fuchs reveals a new 91 efficient field power supply 60 Control Talk MPC The Past Present and Future Part 2 McMillan Weiner and Mark Darby of CMiD solutions talk more about MPC applications 62 Control Report Get in the Uncomfort Zone Old school training and other irritations are the true path to improved operator performance and process optimization 63 Ad Index process automation news Check these pages CIRCULATION AUDITED JUNE 2012 11 430 Petroleum Refining amp Related Industries 3 417 Chemicals amp Allied 1 10 731 Rubber amp Miscellaneous Plastic Products 2212 Systems Integrators amp Engineering Design Firms 9277 Miscellaneous Manufacturers 2 141 250050000 5 073 Stone Clay Glass amp Concrete Products 1 758 Electric Gas amp Sanitary Services
67. n and is now a Spanish autonomous city But Ceuta is no backwater It is a very modern city with daily high speed ferry service to and from Cadiz in Spain It is a free port and oil industry retail and tour ism drive its economy Its population of some 78 000 gets its electricity from the Spanish electric power provider Endesa Generaci n www endesa com Endesa generates 33 of Spain s electricity and has 25 plants spread over the Iberian Peninsula plus five in the Balearic islands in the Mediterranean nine in the Ca nary Islands and two in Ceuta and Melilla a similar city on the north coast of Africa near the Moroccan border The power plant in Ceuta has an installed capacity of about 100 MW provided by nine diesel generators and a gas turbine Like most electricity providers today Endesa s objec tive is to optimize its competitive position by producing electricity at a minimum cost all while maximizing the availability of its equipment ensuring the safety of its employees and respecting the natural environment This is a tall order given that Endesa has electrical generat ing facilites spread out all over the Iberian peninsula the southwestern Mediterannean and out in the Atlantic Ocean off the west coast of Africa Part of fulfilling this tall order means that keeping track of greenhouse gas emissions for regulatory and sus tainability purposes is a big issue for Endesa This effort is supported by Endress Hauser
68. ncluding deadweight pressure tes ters the calibration of deadweight testers monomnieters secondary com parison pressure standards and se lection of pressure measurement The PDF is free and standards downloadable but registration is re quired The direct link is at http ti nyurl com 740dkox PRESSURE TRANSMITTERS FOR DUSTY SERVICE One of our readers asked our team of experts I need your help in installa tion of a pressure transmitter for dusty service We re working on blast furnace stack pressure measurement It s full of dusty particles We suggest a scheme wherein we are purging the impulse tube constantly with low pressure ni trogen and also blasting nitrogen at regular intervals using solenoid valves Please suggest any alternate option or your opinion on the same Read the answers at http tinyurl com bc3olqq TRANSDUCERS I P transducers are versatile instru ments that use an electrical control sig nal to proportionally regulate gas pres sure The most common application is in valve actuation but they can also be used in many other situations As more processes become automated I Ps are being used more and more in place of manual regulators Overall I Ps are relatively simple devices but there are numerous factors to take into account before selecting one This eight page white paper should provide you with a complete understanding of the factors involved in making the correct p
69. nd deploy automatically with web server based architecture Peper Tuis Pi Bras 1 2140 a View your screens on any device with bem a modern web browser from an iPod M touch to a web enabled HDTV Any device size any manufacturer No per user licenses and no tag limits i Everything scales Graphics buttons ands everything All software is included No plug ins no downloads Nothing else to buy or install Build clean effective operator interfaces using only a web browser View them on any device with a modern web browser What could be simpler With groov from Opto 22 now you can Learn more today at www groov com Or talk with our helpful engineers at 800 321 6786 22 m Automation made simple CT MAR2013 Your operator interface has changed Forever Can you Develop your HMI entirely within a web browser View it on any modern PC smartphone tablet or even HDTV Securely access it from your network or over the Internet Build screens with a library of touchscreen ready gadgets Use the lastest web standards HTML5 CSS3 SVG with no plug ins Eliminate programming and server commissioning Deploy changes automatically Now you can 43044 Business Park Drive Temecula California 92590 3614 U S A Local 951 695 3000 Toll free 800 321 6786 www opto22 com or wwW groov com FF THE c w proc
70. ng 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 amp at EmersonProcess com SmartWireless N EMERSON Process Management The Emerson logo is a trademark and a service mark of Emerson Electric Co O 2012 Emerson Electric Co EMERSON CONSIDER IT SOLVED 28 IN PROCESS Fluke Recalls Digital Clamp Meters Improperly fastened circuit assemblies can cause shock electrocution or burn hazards Fluke Corp is voluntarily recalling certain Fluke 373 374 375 and 376 digital clamp meters manufactured between Sept 1 2010 and Oct 51 2012 The printed circuit assembly in these units may not be properly fas tened to the test lead input jack This may result in inaccurate voltage read ings including a low or no voltage reading on a circuit energized with a hazardous voltage presenting a shock electrocution or thermal burn hazard This Fluke digital clamp meters with voluntary recall involves Emerson Upgrades Automation at Russian Power Plant Emerson Proces Management has completed an automation upgrade for an 800 MW unit at Russias Surgut 2 Power Plant in Chelyabinsk
71. ng process then becomes one of setting weights to get the right trade off between tightness of CV and MV movement Note that you can t tune your way around a poor model which you might do in PID for inadequate knowledge of process dy namics You can t just increase move suppression T he steady state part can still give you grief It is not unusual during online tuning to realize you have model problems causing you to revisit your model choices Stan What can you do in the MPC to deal with changes in dynamics and problems with measurements and final control elements until fixed Mark Most MPC packages allow cus tomization for example the capabil ity to switch a model or write to model and tuning parameters and this is often used Process gains or a multiplier can typically be accessed Static transforma tion of controlled and manipulated vari ables is also a standard feature a pop ular option is piecewise linearization functionality You can turn off a section of the MPC where a controlled variable or manipulated variable is unavailable Stan Some MPCs can execute as fast as one second creating opportunities to use MPC for decoupling and opti mization of relatively fast loops where a PID execution time does not need to be less than one second Greg Go to www controlglobal com 1303 ControlTalk html for more advanced control myths MARCH 2013 61 CONTROL REPORT REN JIM MONTAGUE EXECUTI
72. ng would convey some sense of pro cess functionality There should be some indication of the related components Often there would also be a simpli hed process sketch Furthermore many loop drawings do not even show the power supply details pertaining to the 4111 Cedar Blvd Baytown TX 77523 20 393 9677 www samson usa com SAMSON GROUP www samsongroup net SAMSON CONTROLS INC samson samson usa com SAMSON over 100 years experience in manufacturing high quality control valves m Modular design and assembly B Low maintenance and low total cost of ownership E Positioners with HART9 FOUNDATION fieldbus and PROFIBUS technology German and American engineering and manufacturing CERA SYSTEM DAIR TORQUE e SAMSOMATIC GMBH LEUSCH STAR LINE VETEC Ventiltechnik GmbH 01126 i x Term b401 780 HIGH ACCURACY FOUR SENSOR MASS FLOW METER Defore possible Af H1 cards Live workable trunk Field junction box REDUNDANT FISCO SEGMENT DIAGRAM COMPONENTS Figure 2 An example of a segment diagram that serves the function of a loop diagram instrument e g how to isolate the 24V DC from an instrument what are the fuse ratings It makes me wonder if anyone actually uses loop drawings anymore A lot of this arises from the con straints imposed by drawing automa tion tools instrument databas
73. ntains 300 miles of sanitary sew ers and sends the township s wastewater 30 miles away to De troit for treatment Bill Fritz PE Waterford s public works director reports OPERATOR PERFORMANCE There are a few basic steps needed to upgrade human machine interfaces HMIs and their software so they can contribute more fully to helping operators and their appli cations Keith Jones president of system integrator Prism Systems reports these are some of the most crucial e Involve operators up front discuss why an upgrade is important secure buy in and allow input on planned changes e Decide on what HMI platform to use and seek profi ciency in it by aligning with a system integrator and supplier partners e Renew focus on overall business goals understand required operations and define or redefine displays and graphics functions to best serve those tasks For example don t make displays that merely recreate P amp IDs but instead evaluate the manufacturing pro cess to determine what operators truly need to know ask them what screens they use most and build HMIs based on that data Draft a project team and then cross pollinate by send ing at least one person from the end user s side to the system integrator s side and vice versa Hold regular visits and face to face and WebEx meet ings to update participants on the project s progress and seek new input Develop HMI project scope plan and acceptance schedule
74. ol Or call 888 373 6767 Customers First Integrity Always 45 Years of Excellence New Solutions Every Day BANNER IN PROCESS of girls say they feel uncomfortable or afraid when facing a difficult problem in school In comparison only 3476 of boys feel uncomfortable or afraid when asked to solve challenging schoolwork ASQ CEO Paul Borawski says We need to teach today s students how to take risks and fail so they feel comfortable when faced with challenging work If stu dents are going to cure the next deadly disease solve the energy crisis or end world hunger they have to be prepared to fail and learn from those failures About the Survey The ASO STEM survey was con ducted Jan 3 11 2013 among 511 American youth ages 12 17 and 391 parents using an email invitation and an online survey Margin of error was 5 for the parent sample and 4 3 for the youth sample Krohne Offers Online Academy Krohne Inc has announced the avail ability of the Krohne Academy featur ing web based training on measure ment technologies and other topics of interest to process measurement per sonnel The audio enhanced interac tive training courses are ideal for pro cess measurement personnel who work with different measurement principles on a daily basis as well as students and others who wish to update their knowl edge of measurement techniques and applications in technical installations The academy
75. online as part ofthe recall or call 877 564 7180 for in formation and to request a postage paid mailing envelope for the unit BIG POWER The 800 MW unit at the Surgut 2 Power Plant in Chelyabinsk Russia one of the largest thermal power stations in Europe and equipped the Unit 3 control room provided engineering and installation services certified compliance with re quirements of Russia s System Opera tor of Central Dispatch Administration of the Unified Energy System and as sisted with unit start up As part of the project Emerson also installed AMS Suite predictive maintenance software The new integrated system enables automated operation of the entire power unit including electrical con trols for turbine generators and pumps boiler and burner controls and unit 1 2 TR me th ener oot um 17 rye Vu A yd 15 Ajam La Lio crip pes gemi LL tup Nam nc 6 LOW Norm Lev ra Yokogawa s First DD Direct Intrinsically Safe Handheld HART Communicator e Reads manufacturers DDs in their native format without the need for translations e HART compliant modem communicates with any registered or unregistered HART Device e Features an ergonomic handheld design e Enhanced 4 3 diagonal anti glare touchscreen with color graphic display no stylus required e Full QWERTY keyboard for commissioning
76. orce some to hire more staff Besides providing more human factors graphics process managers also need to conduct a risk assessment to make sure their operators can handle the number of alarms they re going to get Then they need to take a holistic CRM ap proach evaluate the roles and responsibilities of their opera tors and define exactly what they re supposed to do in spe cific situations including normal and abnormal operations and in emergencies While software and computers of all types are indispensable to manufacturing in general and process control and auto mation in particular the downside is an increasingly im penetrable jungle of software applications and packages that don t share data fast enough or allow operators to access in formation they need to make crucial decisions Fortunately some solutions are coordinating different types of software and bringing them into more manageable formats For instance Waterford Townships Dept of Public Works DPW http twp waterford mi us Departments Pub lic Works aspx uses many types of process control main tenance documentation asset management and enterprise software to operate its water collection distribution and wastewater systems which cover 36 square miles in Mich igan and serve about 75 000 residents The water system pumps and treats about 8 million gallons per day of ground water from 20 wells at 12 plants and 100 remote sites and the wastewater system mai
77. oring Automotive Robotics Im Visit our new website at www koboldusa com or call 412 788 2830 ASK THE EXPERTS i ISA needs a universal language and in terpretation on loop drawings GERALD LIU P ENG gerald liu shaw ca I have witnessed a real move away A from loop drawings in the last 10 to 15 years This has paralleled the overall tightening of budgets both for capital projects which has trans lated to shedding any optional design documentation such as loop drawings and for plant maintenance and engi neering support which has translated to reduced E amp I technician and con trols engineering staffing levels and higher turnover In a lean plant environment loop drawings are more of a luxury mostly duplicating information found else where even though elsewhere means at least four other documents P amp ID I O wiring diagrams piping diagrams instrument spec sheets and possibly SAMAs logics cable schedules and instrument lists At the same time in some plants there has been a greater adoption of SAMA diagrams some times better referred to as control functional diagrams loosely based on the old SAMA standard but updated and adopted to control of industrial processes I agree as well that loop drawings are particularly useful especially to plant personnel because one must not refer to a number of other documents to get the whole picture of a loop as histori cally p
78. p drawings is economic and can be short sighted because having them serves not only operational and maintenance convenience but also can improve safety and thereby lower insurance costs BELA LIPTAK liptakbela aol com Figure 1 shows the P amp ID representation that I have been using based on latest version of ISA5 1 and Fig ure 2 is a sample of a segment diagram which can be considered to be a replacement for the loop diagrams that I use when presenting certified training for the Fieldbus Foundation There is a trend toward using database driven loop dia grams or their equivalent This is well and good for the large facilities however there are far more smaller operations that continue to rely on the printed word or manually created CAD drawings for installation commissioning and trouble shooting It may save a few pennies now but if you need to recon struct a loop during or after an incident or at the proverbial 3 a m on Saturday morning the lost production revenues quickly exceed the cost of preparing the minimum level of documentation We need to get more folks thinking total lifecycle cost rather than just their portion of the lifecycle IAN VERHAPPEN iverhappen industrialautomationnetworks com I have not seen a true loop drawing in over 15 years They are now merely a wiring drawing in another form and are more geared to construction commissioning rather than operations maintenance A true loop drawi
79. perator performance or the appropriate actions of any one in a critical situation Training has always been essential to steadily building the skills that everybody needs to mas ter their crafts including athletes soldiers mu sicians firefighters emergency medical techni cians EMTs and physicians to name a few Repetitive practice and drilling gradually com bine neural pathways in the brain and these links allow participants to carry out complex actions faster and more efficiently than some one who hasn t practiced those skills More re cent research shows that sleep and dreaming af ter practice helps set these new skills in mental concrete so they can be called on later But as worthwhile and relatively inexpensive as training is it s still boring a time sucking job that requires patient and methodical in struction by teachers and willingness to prac tice repetition and evaluation by students On screen courses and simulations can help but MARCH 2013 I suspect most of those annoying hours still have to be put in and frequent refreshers will be needed later The firefighters and EMTs that I used to cover were forever drilling on all the scenarios they might encounter so they wouldn t risk wasting precious seconds during a fire or medical emergency Faced with training s perceived drudgery many operations supervisors process engi neers system integrators and managers can be forgiven for wanting some ot
80. rantees that the system will keep operating even during a power sup ply failure Each 24 VDC 15 A power supply module plugs directly into a 3 or 6 position backplane which allows a maximum capacity of 45A or 90A of continuous uninterrupted power The entire system is rated for P20 protection class in ac cordance with EN60529 and has an operating temperature rating of 25 C to 45 C at a relative humidity of less than 9576 non condensing Input voltages from 90 VAC to 250 VAC or 90 VDC to 300 VDC are permissible Current required is 15 A Output voltage is adjusted via an easy access backplane mounted The PS3500 series field power supplyoffers N 1 and redun dancy to ensure a low mean time between failures potentiometer The system is rated Class I ATEX Zone 2 and Division 2 certified by Underwriters Laboratories To make the most use of the PS3500 users should add a diag nostic module to the backplane This module adds the most protection possible and it should be used with all mission critical loops It s also rated Class I Division 2 Groups A B C D T4 and Class I Zone2 Groups T4 The power supply diagnostic module permits real time input and output power monitoring with a complete suite of diagnostics and fault indication with configurable warn ing and alarm levels Its bus output is RS 485 HART and is suitable for integration with the plant s asset management system with its EDDL and DTMs It
81. re than half of the visitors to Control Global com come from outside North Amer ica We even have a small Spanish language information channel Control en Espa ol We are always researching ways and partnerships to do more in other languages and other cultures We delight in accepting articles from all over the world We have had articles authored ev erywhere from Cleveland to China to Iran and we want more We are determined to provide you with the most authoritative information resources that you can use to do your job every day wherever in the world your job may be Drop me a line and let me know how you think were doing WALT BOYES EDITOR IN CHIEF whoyes putman net The authorities writing for us have more than 3 5 man years of experience in process automation between them MARCH 2013 9 The dawn of a new standard level control Prepare for a total ECLIPSE of current level and interface control solutions With superior signal performance powerful diagnostics and a full line of overfill capable probes Magnetrol s ECLIPSE Model 706 guided wave radar transmitter delivers unprecedented reliability From routine water storage applications to process media exhibiting corrosive vapors foam steam buildup agitation bubbling or boiling the ECLIPSE Model 706 will take your operation to a new level of 2 satety and process performance 4 Contact Mlagnetrol the guided wawe radar
82. recommendations for improv ing those screens and other HMIs No doubt Poor basic control performance is rampant including poor tuning and poorly maintained valves says Bill Hol lifield principal alarm management and HMI consultant at PAS Inc www pas com and co author with Hector Perez of the High Performance HMI Handbook This is like sending a race car driver out on the track with lousy brakes Neither the operator nor the process can perform well with poor ba sic control Fortunately many alarm systems are being fixed and alarm management has become well accepted How ever alarms are a small part of the overall operator HMI and so high performance HMIs based on new principles for creating screens are needed to correct poor widespread and ingrained HMI practices A proper HMI increases operators situation awareness and their ability to detect and success fully resolve abnormal situations Hollifield adds that PAS recently worked with the Elec tric Power Research Institute www EPRI com to proof test these high performance HMI concepts at a large coal fired power plant using several operators and a full simulator The tested HMI included proper hierarchy and embedded knowledge and we found that operator results were better when handling significant abnormal situations adds Hol lifield Besides showing useful information instead of just raw data displays should be designed in this hierarchy that MARCH 2
83. riety of pre configured measuring ranges 4 20mA analog output signal 2 kVAC isolation cULus CE RoHS He ain models starting at 89 00 Thermocouple Types J K T E N R S U B C D L RTD Types P1100 Pt500 Pt1000 Pt50 Ni100 Ni500 Ni1000 Cu50 Cu100 2 3 or 4 wire 4 20mA analog output signal 2 kVAC isolation cULus CE ROHS A _ ave quick and easy TSD25 Series Temperature Switches all models 89 75 A r WP Compact temperature switch with simple setup using mechanical adjustment dials di rM Temperature setting range 4 to 284 F 20 to 140 C and UB Extremely durable housing with 316 stainless steel wetted parts purchased separately TTD25 Series Temperature Transmitters all models 126 00 High accuracy 2 wire temperature transmitter Integral 1000 ohm Class A platinum RTD sensing element 4 20mA analog output signal Temperature ranges of 0 100 C or 0 300 F Thermowells RTD sensors Go online or call to get complete information request your free catalog or place an order Order Today Ships Today kun e glis ae Py kumita A Heiden WAUTOMATIONDIRECT the 1 value in automation SSS EDITOR S PAGE Its About Being Your Authority Elsewhere in this magazine l ve written about being a finalist for the Jesse H Neal Awards While finding another place to pat ourselve
84. rod uct selection installation and main tenance When chosen installed and maintained correctly I Ps should pro vide many years of reliable service The PDF is free and downloadable but reg istration is required The direct link is at http tinyurl com b34rben WERE STILL ON THE RISE e p 225 906 2343 e f 225 906 2344 2009 2010 2011 2012 2013 e 70815 toll free 866 55 ORION e Baton Rouge Louisiana e 2105 Oak Villa Boulevard 1 MAGNETIC LEVEL INDICATOR 1 MAGNETOSTRICTIVE LEVEL TRANSMITTER www orioninstruments com A reveal WE THANK THE READERS OF CONTROL MAGAZINE FOR reveal wawamanta com VOTING ORION INSTRUMENTS AS THEIR PREFERRED PARTNER i FOR MAGNETIC LEVEL TECHNOLOGIES PAIEHT FENIR ra Orion logotype Magnetrol logotype and Reveal are registered trademarks of Magn OPERATOR PERFORMANCE Operator Performance Prioritized data simpler displays human factors designed equipmer fatigue reduction efforts alarm p and other tools allimprove awareness and operator how much you need by Jim Montague SPACES E INTERACTIVE TRAINING TOOLS REDUCE OPER ST TRENDS amp SOLUT ERAT X MANE R ORM REAL LES s INTERACTIVE TRAINING TOOLS 1 MES as iF sc 1 Y 56 www controlglobal com MAR
85. rovided on a single loop draw ing Nonetheless loop drawings have become viewed as a luxury by those seeking places to cut design and engi neering costs It s more difficult to as sign a value to the maintenance and reliability costs attributable to inad equate or less effective efficient forms of documentation while it s relatively easy on a capital project to decide it s not needed for installation and saves X design dollars Another trend perhaps a factor in the decline of loop drawings has been reduced participation and influence by plant maintenance personnel on capital projects I recall a time when E amp I tech input carried a fair amount of weight during the design and engi neering phase though Im sure that also varies considerably depending on the corporate culture R H RICK MEEKER JR PE meeker caps fsu edu Loop drawings for smart instru A ments are no different than those for conventional instrumenta tion The difference in the two systems is the digital component of the signal The HART Communications protocol is used by most smart instrument ven dors to impose a digital signal on the 4 20 mA signal This allows additional information to be carried on the in strument wiring matrix The addition of a digital component in the signal also allows other wiring methods such as fieldbus and Ethernet to be used in stead of conventional wiring For examples of loop drawings I suggest you searc
86. s a global standard as will WIA PA the Chinese national standard he ISA100 12 convergence process has been abandoned and if end users buy some of each standard they may actually be setting themselves up for unsafe practices and accidents ISA100 11a devices do not interoperate with WirelessHART devices They are not interchangeable with WirelessHART devices And at this point due to the failure of ISA100 12 there is no intention of making them either interchangeable or interoperable So what happens when a critical transmitter or wireless digital valve positioner fails during an important process condition like an upset Somebody is detailed to run into the stores shed get another transmitter and go put it in At 3 a m in upset conditions it could be very easy to grab the ASSET MANAGEMENT transmitter that is not the one that is going to work in that application This might cause an upset to become a disaster It isn t clear yet how much foothold WIA PA will have either inside or outside of China but the other wireless mesh network standard Zigbee is making a substantial comeback Zigbee was investigated thoroughly by both the HART and ISAI00 teams they had many ofthe same members and found not robust enough for the process industries Unfortunately the U S government decided that Zigbee would be a grand choice for the wireless sensor protocol for the Smart Grid Recently several valve actuator and positioner indicator
87. s alarm output is sin gle Form C relay NO C NC Use of the diagnostic module Schosker says means that maintenance and operations personnel can get early warnings of faults or impending failures from the power supply enabling them to schedule maintenance or switch out the faulty unit before a problem causes unexpected and expensive downtime For more information call 550 486 0002 or go to www peppert fuchs us MARCH 2013 57 GREG MCMILLAN STAN WEINER 60 CONTROL TALK pu controltalk putman net MPC Past Present and Future Part 2 Greg McMillan and Stan Weiner bring their wits and more than 66 years of process control experience to bear on your questions comments and problems Write to them at controltalk putman net Stan In this multipart part series Mark Darby principal at CMiD Solutions is sharing his thoughts on the scope of model predictive con trol MPC applications The focus in Part 2 is on model development and tuning but we are free to roam Mark since models are only as good as the data what are recommendations for testing Mark You need to test at not only the nominal operating point but also near expected con straint limits Pre tests are an accepted prac tice to get step sizes and time horizons We also need to verify that the scan time is fast enough and the trigger level is small enough for data historians and wireless transmitters We prefer that compre
88. s on the back is nice that s not what lam writing about here 6 want to talk about authority and what it means in a time when anyone can be an expert as long as they have an Internet access account and a burning desire to share their opinions I want to talk about ControlGlobal com and authority It is our goal to become your authority for process automation Authority is a serious issue today The Inter net s basic anonymity means it s easy to set up as a pundit about just about anything and no body s the wiser if you sit your skivvies or are wearing a suit And often nobody is the wiser at least for a while if you actually don t know what you are talking about but sound or read really good doing it Essentially authority means that the people who read your stuff do think you know what youre talking about It really is something that is difficult to counterfeit for long Pretending to be an authority in the process automation field is hard to do because the pretenders are easy to spot That s why we have so many real authorities writing for Control and ControlGlobal com Between B la Lipt k Greg McMillan Greg Shinskey Dick Caro Ian Verhappen John Rezabek Joe Weiss our newest blogger Dan Miklovic our publisher Keith Larson and me we have more than 375 man years of process automation experience What this gives us is the ability to answer questions authoritatively describe applications and share the knowledg
89. shutdown was relatively small and shutdowns were rela tively frequent But that is no longer the case Staff reductions have limited the number of people able to walk around the plants Run ning the plant at over 100 of capacity and lengthening the times between planned shutdowns has made preventive re pair or replacement of assets such as valves and motors prob lematic and expensive And with longer times between shut downs unplanned shutdowns due to deferred maintenance have become both more frequent and more expensive We bought the very first version of AMS 1 0 from Emer son www emersonprocess com in 1999 says Gabor Berez nai head of the automation and electrical department for MOL the Hungarian refining corporation whose Danube Refinery was the 2012 HART Plant of the Year We have AMS PRM from Yokogawa www yokogawa com and Hon eywell s www honeywellprocess com asset management software as well Bereznai says that the Danube refinery site has 40 000 in struments 30 000 of which are HART devices In addition the refinery has somewhere between 3000 and 4000 HART valve positioners First MOL connected all its HART devices through hardwired HART multiplexers to its various DCSs Then the plant began to transition toward predictive mainte nance and away from replacing all the valves when a shut down occurred 80 60 Number of valves e I 2
90. ss Solutions adds are several ap proaches to training operators including classroom on the job and using standard and custom simulators The key to proper simulation is defining the competencies needed for operators to perform their roles effectively while designing training solutions to achieve required competencies similarly Glenn Goldney global programs manager for Rockwell Automations www rockwellautomation com Global Workforce Solutions GWS division adds that Operators have been a very neglected population Not only is there a widespread skills shortage but their job descrip tions are hard to define because of their multiple crafts and roles and even those existing job descriptions are changing rapidly This is why training is more important than ever for developing and retaining talent This is why GWS also helps users segment their job structures and redistribute some responsibilities so everyone can be more effective For instance we recently helped Alyeska Pipeline Service Co www alyeska pipeline com develop a custom job interac tion and e learning solution for operators at its emergency back up power plant in Valdez Alaska which serves transfer facilities at the end of the Trans Alaska Pipeline Likewise AES Wind Generation a subsidiary of AES Corp www aes com in North Palm Springs Calif re cently installed 49 of Mitsubishi Heavy Industry s MHI l megawatt wind turbines at its Mounta
91. ssion and filters be removed so we can get raw data A separate data collection to get around these limitations is commonly used Greg For us the pre tests which we called bump tests were separate steps to one manipulated WE ARE GOING 10 UN INTO THE ROOM MARCH 2013 variable at a time We often would find im provements that needed to be made in instru ments or control valves before we did the tests to build the model Stan What automated testing is being used Mark Manual methods are still used but automatic testing approaches are increasingly being applied T hese use random sequences such as a pseudo random binary sequence or generalized binary noise Closed loop testing approaches based on a preliminary model are also being applied as a means of keeping the process in an acceptable range and re ducing the effort involved in plant testing both for the initial application and to update the MPC model for changes in equipment or operating conditions Closed loop testing continues to be an active development area Stan If the testing and some of the model analysis are automated what does the process control engineer need to do Mark The intent of these enhancements is to simplify the tasks of the control engineer not remove his involvement The control en gineer is required to make decisions regard ing test specifics such as move sizes and fre quency and determining when tes
92. stics PS3500 power supplies provide 1 or N N redundancy high immunity and industry leading efficiency for the most demanding environments Featuring adjustable output volt ages between 22 5 VDC and 30 VDC the product has built in alarm outputs a fanless design hot swappable module re placement and boasts an efficiency of up to 91 according to the company s product specifications Pepperl Fuchs product manager Robert Schosker says Pepperl Fuchs needed a robust and clean power supply to support our other product lines such as fieldbus FieldCon nex and HART These two product lines require clean effi cient and reliable power because signal quality is important due to their digital communications Modern continuous processes operate for long periods without downtime and most field instruments have a power supply or their power is supplied by the output loop Digital smart field instruments have extremely long useful lives with very low mean time between failures MTBFs The power supplies also must have similarly low MTBFs These demanding conditions necessitate N and redundancy Shosker said N l redundancy means that multiple power supply modules N have a backup power supply module That s the 1 All modules within the con figuration share the load If one module fails the working modules are able to continue load sharing with no system degradation This is simple and affordable and gua
93. t and the remaining 37 were rejected by the committee The next step will be to revise the CDV to incorporate the changes and then distribute a second CDV probably in the April May time frame If this CDV is approved normally after a five month balloting period a Final Draft International Standard FDIS ballot can be conducted to ward the end of this year therefore the ear liest that ISA100 1la can be published as an IEC standard is early 2014 ISA100 11a is still an ANSI approved standard however it is also likely that the comments adopted by the IEC committee will be incorporated into the next revision of the ISA document As the Canadian chairman for TC65 and a member of Canada s SC65C committee under MARCH 2013 which this standard falls I found it interesting that 62657 2 Industrial Communica tion Networks Wireless Communication Net works Part 2 Coexistence Management in cir culation over roughly the same time frame was approved with comments and will be registered as an FDIS in May this year There were a total of 25 ballots received for this CDV with seven ab stentions 22 P Members voting 20 affirmative 90 9 and two negative votes Work also is ongoing in the area of coexis tence by the major control systems suppliers that will have a positive impact on wireless held or sensor network reconciliation This group known as the Heathrow team may also work towards resol
94. tatic head mass of water in the reactor the weight of the collapsed water column These level transmitters are installed with condensate pots that connect these reference legs wet legs to the high pressure side of the d p cells These level transmitters are inverse acting if the level rises the transmitter out put drops because the hydrostatic head of the condensate in the reference leg is always higher than the weight of the water column inside the reactor Therefore the transmitter outputs are zero when the water level is at its maximum and zero level generates a maximum output signal The reliability of this measurement depends on the assumption that the wet leg is full of conden sate and at ambient temperature During an ac cident these assumptions can be wrong because the condensate in the reference leg can overheat or drain Even under normal operating condi tions the more bubbles that form the higher will be the apparent actual level but the lower its den sity and therefore the detectors will under report the level Inversely as the steaming rate drops the density increases and the actual level drops while the level reported by the transmitters in creases Therefore these level measurements are either unreliable or useless The operators after a while notice that and start to disregard them or even disconnect the automatic level controllers and try to manipulate the level manually The Fukushi
95. the low How sample alarm that monitors combustion gas flow at the sensors set the WDG V apart from previous generations And the WDG V is the first generation designed to be SIL 2 and part of a safety instrumented system implementation Our design goal was to provide as much sensor and cali bration performance monitoring diagnostic self checks and operational data as possible to the user through graphical display data logging and digital communication What we have been able to do is to provide a complete solution for combustion process control and safety We can offer the end user all of the information required to implement predictive and proactive maintenance programs in addition to a highly reliable combustion analyzer M For more information contact Ametek Process Instruments at 412 828 9040 or www ametekpi com CONTROL EXCLUSIVE Power Un with a New Kind of Redundancy Pepperl Fuchs has introduced the 55500 new diagnostics module for its PS32500 power supplies bringing a new level of reliability by continuously monitoring the conditions and health of the PS3500 power supplies and primary side power conditions The diagnostic module hasfourlayers of monitoring mains out put power supplies and diagnostics to maintain system integrity The PS3500 DM is easily integrated into plant asset management systems through RS485 HART EDDL or FDT DTM technologies and provides intelligent power and real time diagno
96. the most impor tant thing he believes There is a huge beneht Predictive notification can save 7000 to 100 000 or more by avoiding unplanned outages At our facility our most important product is diesel One day s diesel production is worth 300 000 In 2011 we avoided a one day outage You can see why this is important To make it work Bereznai adds his team involved everyone Everybody needs asset management he says and it s very important to involve ev erybody There were many skeptics at first but now they re believers How did Bereznai and his team get started First we got high level buy in he says Then we standardized on HART and later Foundation fieldbus devices Then we put together a mainte nance strategy plan and an action plan We have a living contract with our three DCS vendors to maintain the systems and keep them current And finally we did training Maintenance involves all the staff and everybody does it Extracting diagnostic signals is one of the key use cases for wireless mesh networks in process plants It would seem to be a no brainer to jump in and start enabling wireless systems but like MOL most users are still doing pilot projects One of the reasons for this is the multiplicity still of wireless sensor network standards WirelessHART now IEC62591 Wire lessHART was the first IEC international standard but it won t be the last 5 100 will eventually be approved a
97. ting can be terminated In model identification decisions must be made as to which data and variables to use then which models are going into the controller For example should you include a weak model Obviously this requires process knowledge and MPC expertise A sharp person mentored by a gray hair can lead projects after several years of applications experience Greg Getting back to the data what is most important p CONTROL TALK Mark You want good rich data meaning significant movement in the manipulated variables at varying steps and durations to get accurate models But it does not end there You need to look for consistency in the resulting models Use engineering knowledge and available models or simulators to confirm or modify gains Don t short change this step Gain ratios are very important especially for larger control lers Empirical identification does not enforce relationships such as material balances so there can be a fictional de gree of freedom DOF that the MPC steady state optimizer either a linear program LP or a quadratic program OP may exploit As discussed previ ously techniques are available now to assist with this analysis and adjust gains to improve the model conditioning which frees up the engineer to take a higher level supervisory role Stan How do you get the MPC ready to go online Mark Offline tuning relies on the built in simulator Most important is get
98. ting the steady state behavior of the controller right Simulation can also serve to identify errors on the model gains for example observing a ma nipulated variable MV moving in the wrong direction at steady state You want initial tuning for the dynamic pa rameters to be in the ball park Regard ing steady state you determine how you want the MPC to push manipu lated and constraint variables based on cost factors and priorities making sure you are enforcing the right constraints Unlike override control which is se quential by picking one constraint the optimization is simultaneous mul tivariable and predictive taking into account future violations Some MPCs use move suppression and some refer ence trajectory to affect MV aggres siveness Penalty on error is used for both constraint or quality variables OV and controlled variables CV We have evolved to not distinguish be tween OV and CV except as presented to the operator Greg What kind of expertise do com panies have and need Mark Some on site expertise with re mote access or revisits by external ex pertise is generally the approach for most plants Large companies with a good history of MPC have gotten good at it In general basic and advanced process control groups got hurt in the 1990s It used to be that management were practitioners who underststood and appreciated the technology and the expertise Now it is a mixed bag and you may ne
99. trator System is ready for your real world Give us a call at one of our Interface Solution Centers e P WORLDWIDE WWW miinet com United States info miinet com Belgium info mooreind be China sales mooreind sh cn M 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 IND 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 RESOURCES Si Contents Under Pressure 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 wboyesQputman net and we ll add them to the website SELECTING A PRESSURE TRANSDUCER This free downloadable white paper discusses the top five selection consid erations and the top three design con siderations for selecting the correct pressure transducer for your industrial applications To get the white paper go to http tinyurl com al96eyu covered include what pressure is pressure sensors pressure measure ment and signal conditioning used to measure pressure The tutorial in cludes basic equations drawings and re
100. ts of four spurs These solutions may provide the optimal solu tion for those who want to minimize junction box size I used to think the original Relcom Mega block had a comforting ruggedness due to its physical mass but Relcom s Cyrus Kelly ex plains the heft came from potting en casing the entire electronics assembly in a substance that sealed the circuitry from its en vironment Cyrus s research revealed that pot ting was no better than the significantly more cost effective technique of conformal coating sealing the circuit with what amounts to a coating of a similar non conductive substance such as acrylic lacquer In other enhancements to the second generation of bricks Relcom en gineers reduced the component count by 35 which can be broadly tied to a proportional in crease in mean time between failures MTBF So perhaps heft isn t an infallible indicator of reliability or ruggedness MooreHawke s www miinet com couplers are extremely rugged The case of the 200 series is metal and an eight or 12 block spur block might break a toe if you dropped it on your foot MooreHawke also has unique auto terminator circuitry that adds the required im pedance matching terminator at the furthest end of the trunk automatically While other couplers may add a short circuit load of 50 mA to 60 mA when a spur is shorted MooreHawke couplers add only a few once a short circuit is detected R
101. ually many customers are using it for automation applications YAIR MARYANKA yair Qyamar com When Will There Be an App for That I enjoy reading Control magazine The only question I have is when will you guys have an app for iPad which delivers Con trol magazine directly to the iPad like many other magazines calvin robertson riotinto com Editor s Note Unfortunately building a workable user friendly and attrac tive magazine app is a lot harder than it looks Our staff is still in the process of exploring our best options for providing just such an app for Control Correction In the Readers Choice Awards story in January p 56 www controlglobal com articles 2013 nice ice readers choice awards html VEGA Americas was misin dentified It took first in the Nuclear Level Gauge category We regret the error MARCH 2013 15 B LA LIPT K he ex core level measurement will in core level only so long as the fuel LESSONS LEARNED EN liptakbela aol com level detectors had operated correctly and if the operators had flooded the reactors as soon as the earthquake was detected and would have started the venting of the hydrogen as soon as the fuel rods were uncovered the hydrogen ex plosions would have been prevented approximate the The Traditional Reactor Level Measurement Figure shows the traditional method used in the majority of nuclear reactors Here the cooling wa ter enters a jac
102. ution of other issues difficult to re solve within the standard itself However to really affect change end users need to express their opinion in one form or an other Though some companies are doing large installations I believe many are in fact voting by effectively saying We are going to wait un til the standards issues are settled before invest ing in a significant way Voting with your wallet is certainly one way to vote However to make effective change and directly influence the outcome of this dispute end users should vote with their time by participating in the appropriate standards committees In the case of WirelessHART and similar trade consortia driven standards this is not directly possible at the standard writ ing level However it certainly is true with ISA based committees which are mandated to have a balanced representation of partici pants A third way to participate is to become involved in your country s IEC National Com mittee In the case of IEC practically all the automation related standards are developed by IEC TC65 www iec ch tc65 and its vari ous subcommittees Using wireless here and there is one thing But using it across 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 operati
103. vel Transmitters Depth Transmitters e Precision Micromachined Silicon Sensor PX709LGW Series with Lightning Surge Protector e 5 Point NIST Traceable Calibration 700 ux e 316L SS Case and Diaphragm 665 e High Pressure Molded Cable Seal e Premium Temperature Performance e Broad Compensated Temperature Range Visit omega com px709gw Conduit Fitting PUE Series TA S now 7 gooth 1 Compact Rugged Solid State General Purpose Digital Pressure Explosion Proof Flame Pressure Transmitter Gauge with Protective Rubber Boot Proof and IS Rated Pressure Transmitter for DPG8001 Series P PX170 Series St a n s at Hazardous Locations Starts at 5250 PX835 Series Readings Starts at 5560 Spattered Design x k m LI Visit 170 series OMEGA COPYRIGHT 2013 ENGINEERING INC ALL RIGHTS RESERVED LB IL E E T a er Luka EC K E n d a l FH masqa s RACER _ ONE T m maid WIE mm 2 8 6 mom D 1 Freelance A DCS that stands the test of time Rely on tt You spoke we listened You said Easy to use Reliable Scalable and Value for your Money in a DCS Our answer Freelance an easy to use DCS that you can rely on Whether you re a
104. water and steam AWL HP SP RWL I AL gt CL Emergency HP I I Normal operation A Height of reference leg AWL Actual wet leg weight hydrostatic head CL Corrected level signal to control room d p Differential pressure HP Pressure on the high pressure side of the d p cell LP Pressure on the low pressure side of the d p cell LT Level Transmitter NL Normal level level measurement signal during normal operation AWL RWL RA Reverse acting the output signal drops as the detected differential pressure rises RWL Reference wet leg weight hydrostatic head SpG x A SP Steam pressure A Difference subtraction AL The amount of wet leg loss RWL AWL APT Transmitter detecting the actual height of the reference leg gt Summation HOW TO CALCULATE THE CONDENSATE LEVEL Figure 2 This control system continuously calculates the correct lev el CL if during an emergency some or all of the condensate has boiled off from the wet leg Converting a traditional system Figure 1 to this one is easy and does not require a plant shutdown Dr David Nyce designed such a thermal conductivity based in core level sensor for the Knolls Atomic Power Lab oratory In that design a number of metal probes of differ ent lengths are inserted each equipped with two vertically separated thermocouples TC The one located at the tip is heated while the second unheated reference t
105. wide tair stands ready to solve a full range of residential commercial municipal and industrial needs INSPIRED SOLUTIONS FOR A CHANGING WORLD PENTAIR COM lt PutmanMedia IN MEMORY OF JULIE CAPPELLETTI LANGE VICE PRESIDENT 1984 2012 555 W PIERCE RD SUITE 301 ITASCA ILLINOIS 60143 executive team 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 Imartinez 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 Technical Editor DAN HEBERT dhebert putman net Contributing Editor JOHN REZABEK Columnists BELA L
106. wmeters at the Ceuta facility pres ent other challenges All the flow meters could not be removed at the same time because each genset has to be stopped when the flowmeter is removed and Ceuta had only one backup flowmeter Calibrating all of them at once would virtually shut down the facility But doing them one ata time also presented problems The process would drag out over nearly a year and incur extra costs Canosa says The original plan was to remove a flowmeter replace it with a backup and send the flow meter back to the manufacturer for calibration But Ceuta has special tax and customs procedures and the equipment must pass both proce dures when being sent and when it is returned This fact coupled with the transporting and the calibration time could take as long as a month for each one With 11 flowmeters the total calibration time could be up to 11 months Atthat point in 2010 Endesa began conversations with Endress Hauser in Spain to find a better way The so lution was to use Endresst Hauser s on site calibration service one which the company says is unique in the industry The service works this way Once Endress Hauser consults with a company to find out the scope of its needs and its plant availability a time for the calibration is sched uled The entire kit of necessary calibration equipment is packed in three flight cases and a calibration specialist accompanies it to the facil ity where th

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