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ON THE WEBMonitoring Emissions with Virtual Instrumentation

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More routine process control applications are adopting wireless. Here’s how veteran users do it every day.

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CONTROL (ISSN 1049-5541) is published monthly by PUTMAN Media COMPANY (also publishers of CONTROL DESIGN, CHEMICAL PROCESSING, FOOD PROCESSING, INDUSTRIAL NETWORKING,

PHARMACEUTICAL MANUFACTURING, and PLANT SERVICES ), 555 W. Pierce Rd., Ste. 301, Itasca, IL 60143. (Phone 630/467-1300; Fax 630/467-1124.) Address all correspondence to Editorial and Executive Of�ces, same ad-

dress. Periodicals Postage Paid at Itasca, IL, and at additional mailing of�ces. 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: Quali�ed-reader subscriptions are accepted from Operating Management in the control

industry at no charge. To apply for quali�ed-reader subscription, �ll in subscription form. To non-quali�ed subscribers in the Unites States and its possessions, subscriptions are $96.00 per year. Single copies are $15. International subscriptions are

accepted at $200 (Airmail only.) CONTROL assumes no responsibility for validity of claims in items reported. Canada Post International Publications Mail Product Sales Agreement No. 40028661. Canadian Mail Distributor Information:

Frontier/BWI,PO Box 1051,Fort Erie,Ontario, Canada, L2A 5N8.

A U G U S T / 2 0 1 3 www.controlglobal.com 5

August 2013 • Volume XXVI • Number 8

F E AT U R E S

W E B E X C L U S I V E S

Monitoring Emissions with Virtual Instrumentationwww.controlglobal.com/OntheWeb1308.html

C O V E R S T O R Y

30 / Workingman’s WirelessMore routine process control applications are adopting wireless to save cable, secure added signals and transfer data from spots where wire can’t go. Here’s how veteran users do it every day. by Jim Montague

L E V E L

43 / Back to Basics: Ultrasonic Continuous Level Measurement

How to do ultrasonic level measurement right. by Walt Boyes

E N G I N E E R I N G E D U C A T I O N

47 / Talk to Each Other

A dialog across the generations of engineers. by Danaca Jordan, Greg McMillan, Soundar Ramchandran and Hunter Vegas

S O F T W A R E A N D I N F O R M A T I O N S Y S T E M S

50 / Rationalizing and Refocusing on Alarms

Projects to renovate alerts and alarms in large applications can bene�t by using improved HMI tools. by Jim Montague

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CIRCULATION AUDITED AUGUST 2012

August 2013 • Volume XXVI • Number 8

9 / Editor’s PageHow to Future-Proof Ourselves We solve the problems with the educational system �rst.

11 / On the WebOnline Treasure HuntDon’t miss out by overlooking some of the “secret passages” at ControlGlobal.com.

13 / FeedbackMore on the Beltway Bandits.

14 / Other VoicesAre Industry Analysts Relevant Anymore?Or will a good Google search get you all the data and recommendations you need?

19 / On the BusA Minute to Measure ItWhen time is of the essence, wireless may be the way to go.

20 / Without WiresOutsourcing SCADAUsing cellular radios for SCADA success-fully may depend on where your operation is located.

22 / In ProcessSchneider Electric puts in a bid for Inven-sys, Triconex turns 30 and other process in-dustry news.

28 / ResourcesProcess Safety Online. Videos, ebooks, whitepapers and more.

54 / Ask the ExpertHow to deal with a plugged furnace pres-sure connection.

56/ RoundupLooking for I/O? Check out the latest prod-ucts here.

59 / Products Flowmeters, transducers, fanless PCs and more, plus a sneak peak at the latest itera-tion of Invensys’ I/A System DCS.

63 / Control TalkCommunications for the AgesHow to talk Twitter to the veterans and common sense to the newbies. It’s all in the way you approach it.

65 / Ad IndexCheck these pages.

66 / Control ReportManage a BMA Upgrade LifecycleA 16-hour blender cutover? Chevron did it. Here’s how.

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WALT BOYES EDITOR IN [email protected] t

E D I T O R ’ S P A G E

We have to stop

expecting teachers

to be edutainers.

We can’t do

edutainment and

expect kids to

actually learn

something.

The available jobs aren’t the problem. It’s the quali�cations to do those jobs. There is also, depending on how you count it and �-nagle the numbers, somewhere between 10% and 15% unemployment. Why can’t we match those unemployed folks with the open jobs, and voilà, no open jobs, no unemployment? That’s not going to happen any time soon. The vast majority of unemployed individuals in North America simply don’t have the skills we need to work in the process automation �eld.

Because you’re reading this, you probably aren’t one of those unskilled unemployed. That’s good, provided you recognize that 30 years ago, there were many more jobs open in manufacturing for lesser-skilled people than there are now. Thirty years hence, or even 10 years from now, the skills required to do the job you have will change, and become greater than the skills that you have right now.

That, too, is why the STEM education crisis looks new. It really isn’t. This has been going on for almost three generations now—children don’t want to do science, technology, engineer-ing or math for reasons ranging from “it’s too hard” to “manufacturing is dirty.” But there were always menial jobs to absorb the children who couldn’t cut it in the education system.

Missa Dixon (www.missadixon.com), a writer and STEM educator, says that it took us 60 years to get into this mess, and it will probably take that long to get out of it. At least, she says, that’s about how long it took Finland to develop the very high- quality education system it has now. “In Finland,” she says, “they proved that year-round school, with very small class sizes and physical activity during the school day actually works, and they’ve produced one of the technically highest perform-ing workforces in the world.

“We are going to have to recognize that we may have lost a lot of the last two generations

of our population and pay the karma for it. We decided to economize on education, and we put the money into social programs and pris-ons. But if we want to �x the education system so that we have all the STEM workers we need, and we will need, we have to do some things that will cost money, and some that will be so-cially dif�cult.”

First and foremost, national standards of be-havior in the classroom must be developed and adhered to. Support and encouragement must be given to parents and the community at large, as well as teachers. Teachers can’t babysit, do social engineering and teach too.

“Follow the Finnish model of education,” Dixon says, “and do what the research says works. Small schools, small classes, direct and varied instruction, using a standardized na-tional pre-K through 12th grade curriculum. Once you have the culture back to backing up educational institutions, you train the teachers. Use a national standardized teacher training, with at least one year of in-class shadowing of an experienced teacher.

“This can’t happen overnight, and a lot of these changes will hurt. But they are necessary,” Dixon says. “And we have to stop expecting teachers to be edutainers. We can’t do edutainment and ex-pect kids to actually learn something.”

Companies may have to shell out big money both for retraining workers and contributing to the cost of implementing the Finnish model. And, just in case you think we can skate with-out doing this, China and India are graduating an order of magnitude more STEM workers than we are.

We know that there are many more automation jobs available than there are people to

�ll them. There are, by more than one report, 80,000 more jobs than applicants just in

the United States right now. That’s nice, but you have to ask yourself why they are go-

ing begging for workers.

How to Future-Proof Ourselves

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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.

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Don’t you love that feeling when you put your hands in your pockets, and to your surprise you � nd dollar bills tucked away that you didn’t know you had? Well, this month’s column aims to give you that feeling about www.ControlGlobal.com.

As your senior digital editor, I know this website inside and out. I know the secret passages to getting our premium content and the hidden corners of the process au-tomation web where lots of hidden automation � les await you.

If you’re looking for day-to-day industry news, then you need to stop by our Industry News library (www.controlglobal.com/industrynews/), where you won’t miss a beat about the latest press releases and other important informa-tion we put at your � ngertips.

If you don’t have time to browse through our library, you can always subscribe to our industry news RSS feed. Here is a direct link to it: www.controlglobal.com/in-dustrynews/index.html?mode=rss. At the end of each day, you’ll get an email from us, letting you know about the latest news posted on our site.

For our site visitors who love to listen to industry ex-pert interviews, we have the Process Automation Pod-cast Series library (http://www.controlglobal.com/extras/ARC_Control_Podcasts.html). Every month, our edi-tors get together with an ARC Advisory Group analyst and go over the current cover story. Their conversations and expert analysis gets recorded, and presented to you in a format that’s easy to listen to.

If you have an iTunes account or own an iPod, iPhone or iPad, you can ac-cess these same podcasts via your mobile device or desktop. You can visit our Process Automation Podcast Series library on iTunes (http://ax.itunes.apple.com/podcast/process-automation-media-network/id251132818) and download our podcasts free of charge.

If you enjoy reading the Sunday newspaper because of its extensive cartoons sec-tion, know that www.ControlGlobal.com offers you a comics section of our own. We call it “Out of Control Cartoons.” Visit www.controlglobal.com/extras/Outof-ControlCartoons.html, and get access the light side of the trials and tribulations of life as a process engineer as sketched by Control’s resident cartoonist Ted Williams.

When it comes to blogs, our site not only has � ve blogs—SoundOff!, Unfettered, Control Talk Blog, Manufacturing 2020 and The Great Kandusky—but we also list other blogs that we love to follow.

Visit any of our in-house blogs and see our Blog Roll list on the right-hand col-umn. There we give you links to other blogs such as ABB’s Process Automation In-sights blog, Charlie Fialkowski’s Burner Management blog, Jim Cahill’s blog, Mod-eling and Control blog and S88 Builder Construction blog among others.

I hope you enjoy discovering these not-so-hidden treasures on our site, and browse some more to uncover many more.

KATHERINE BONFANTESENIOR MANAGING EDITOR, DIGITAL MEDIA

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Cybersecurity and the Beltway BanditsFirst, a disclaimer: I’m not speaking for my employer. What follows are my own opin-ion and my own questions.

Your “Beltway Bandits” editorial in July (www.controlglobal.com/articles/2013/boyes-beltway-cybersecurity.html) seems to criticize the Obama Administration’s executive order (XO) for bad advice they’ll get from the Beltway Bandits.

Am I reading this right? What, speci� -cally, in the XO evinces or promotes a lack of understanding of the different cyber se-curity requirements for business IT and industrial process control systems? Ab-sent such speci� cs, I’d think the admin-istration’s emphasis on ICS cybersecurity would be helpful. Doesn’t that in itself show an awareness of the difference be-tween business IT and ICS cybersecurity?

CHARLES TIMMONSSR. PROCESS CONTROL ENGINEER

[Walt Boyes replies]Thanks for writing, Charlie.I think you either misunderstood the

point of the editorial or (as is more likely) I wasn’t completely clear.

First, I not only have no quarrel with the executive order, I welcome it, just as I welcomed other signs from the adminis-tration that, for the � rst time, an adminis-tration is doing something besides making motherhood-and-apple-pie statements.

The problem is not the executive order. It is the sweetheart relationships between the U.S. Dept. of Energy (DOE) and the U.S. Dept. of Homeland Security (DHS) and the Beltway Bandits. These consul-tants have demonstrated over and over that they have no grasp of ICS security, but they’re now rallying around the exec-utive order, claiming expertise they don’t have, and in several cases pointing out that their point of view is that they should be al-lowed to hijack the money into the types of IT security they do understand.

One such bandit actually said that he felt that ICS security was unimportant because people could survive without power, water and fuel, but that nobody could survive if the New York banks were hacked out of business!

I strongly disagree with him, and the fact that he went on to call me, among others, purveyors of fear, uncertainlty and doubt (FUD), made me write the editorial.

I have been a strong supporter of ICS security for at least a decade now, and have put my money where my mouth is, serving on ISA 99 among other things.

Does this help?

And Another Thing[For another take on the Obama Admin-istration’s cybersecu-rity executive order, here is an excerpt from Joe Weiss’ Un-fettered blog post of July 15 (http://community.control-global.com/content/will-nist-approach-executive-order-actually-support-industrial-control-systems-icss)]

I’ve been involved with NIST to one de-gree or other on ICS cybersecurity since 2000 and on other technical issues long before that. I � rmly believed NIST was the best independent organization to be able to develop ICS cybersecurity standards. Unfortunately, I can no longer say that in good faith.

NIST’s technical approach dealing with ICS cybersecurity changed with the smart grid cybersecurity efforts because Congress mandated it to oversee, not actually de-velop, smart grid cybersecurity and interop-erability standards. From an ICS cyberse-curity perspective, it was not a success.

Fast forward to the current executive or-der. I met with a number of NIST senior staff in February. Suf� ce it to say, there was not a clear understanding by them of what makes ICSs different. I watched the � rst NIST industry session from NIST’s Gaithersburg facilities via video and was appalled by the lack of ICS knowledge or formal participation.

Are the politics so thick that NIST can’t do a better job of providing appropriate ICS cybersecurity guidance than it did with the smart grid?

will-nist-approach-executive-order-actually-

The Bene� ts of Modular Batch

Flexibility

Swimming in Device Management’s

Alphabet Soup

Before You Buy Your Next IPC, Read This

ON THE WEBBest Practices in

Batch Management

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Advances in functionality coupled with dramatic price cuts are fueling the use of collaboration tools for process automation projects.

PullingTogether

CT1307_01_CVR.indd 1 7/2/13 4:07 PM

CT1308_13_Feedback.indd 13 7/29/13 12:30 PM

O T H E R V O I C E S

14 www.controlglobal.com A U G U S T / 2 0 1 3

Are Industry Analysts Relevant Anymore?

Forrester showing steady, albeit incremental, revenue growth.

In the process control arena, it’s harder to tell, in that most of the analyst �rms are pri-vately held and do not publish audited num-bers, or are part of a much larger entity that does not report speci�c research unit revenues separately. So the debate on the value of ana-lysts versus the Internet is looming large.

With modern social networking tools, par-ticularly LinkedIn with its groups, but also Google with its basic search tools and Google+ and even Facebook, the ability to connect with peers and do research on products, vendors and technology in general is unprecedented. Post an inquiry on any one of the forums related to a topic, and you generally will get anywhere from several to hundreds of responses. For the most part, these responses come from end users who have real-world experience with the speci�c products and/or vendors. It is hard to beat �rst-hand information.

On the other hand, the objectiveness and, in some cases, the actual identity of the posters can be questioned. There are numerous cases of suppliers promoting their own products and bashing competitors, as well as disgruntled us-ers trashing suppliers over problems that, in some cases, are of their own making. So while there is plenty of free information out on the Web, the objectivity and value of that informa-tion can vary widely.

Analyst �rms make the claim that the tested research methodologies they use ensure the in-formation they provide is validated and objec-tive; therefore, it has real value and is worth the tens of thousands they charge for access. They all have some sort of methodology for ranking and evaluating the vendors, products and tech-nologies they cover. On the plus side, most ana-lysts have signi�cant industry experience and

have held decision-making positions in either end-user or vendor �rms. On the down side, some analysts haven’t actually used a speci�c product or technology recently or, in some cases, ever.

The objectivity claim also needs to be un-derstood in context of the �rm versus the an-alyst. Most analyst �rms have strict policies regarding con�ict of interest and prohibit analysts from taking positions in or with the �rms they cover (as investors or board mem-bers) or receiving direct compensation. Many �rms, however, will produce research-for-hire pieces that are solely funded by a single vendor, and that leads to an objectivity issue, at least regarding that speci�c research. But, in general, the analyst �rms do not grossly fa-vor companies that subscribe to their services over those that do not. Also analysts them-selves may not be overtly biased, but as hu-man beings, they likely fail at being purely objective. If a vendor is constantly incorpo-rating an analyst’s research into its product strategy and marketing, building the analyst up to the analyst �rm management and mak-ing the analyst seem like a “rock star,” then human nature says that analyst will favor that vendor over one that promotes a competing analyst’s point of view.

So, given the questions about analysts’ ab-solute objectivity versus the uncertainty of the quality of input from social networking sources, why consider analysts? There is one signi�cant reason, and that is access to ven-dor strategy. Since analysts still are consid-ered signi�cant market in�uencers, vendors do share strategy and performance informa-tion with analysts that they may not share with the general public or even prospective customers. As a buyer, getting a detailed product roadmap may be dif�cult, since the

Does it make sense

to subscribe to

industry research?

For most, the

answer is the

classic analyst

response: it

depends.

The question that frequently arises is: with Google, LinkedIn and Facebook and other

online resources at their �ngertips, do process control practitioners get any value from

subscribing, often at tens of thousands of dollars, to industry analyst services anymore?

Clearly, in the IT �eld, industry analysts seem to still be in demand, with Gartner and

DAN MIKLOVICMANUFACTURING 2020 BLOGGER

dan.miklov [email protected]

CT1308_14_16_Voices.indd 14 7/29/13 12:26 PM


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O T H E R V O I C E S

vendor is concerned about potential contractual issues. Since the analyst �rm is not buying speci�c product, the only risk a vendor has in sharing the roadmap is it may get “dinged about execution” if it fails to deliver against that roadmap. This is not to say vendors won’t share the infor-mation with prospective buyers. However, the cost of ob-taining it may be as much as an analyst subscription, when you consider the cost of labor, legal to negotiate the non-disclosure agreement and, most likely, travel to visit the vendor’s headquarters.

So, does it make sense to subscribe to industry research? For most the answer is the classic analyst response: it depends. If you’re part of a very large organization and have enough lever-age over vendors to get the product strategy information you need and vendor viability due diligence for small suppliers, then the incremental value of an analyst �rm might not war-rant an ongoing subscription. If you’re a small company, the value you’d get from the $20,000+ annual fees analyst �rms charge might be spent better elsewhere. Do your due dili-gence using the social networking tools available today.

For the rest in the middle, the use of an analyst �rm as a sanity check, a second opinion, and as a third party with

minimal biases to help break ties or in�uence key decision-makers may well be a good investment. Just remember you get what you pay for and, as with every other purchase, you need to continually reevaluate whether you’re deriving the expected bene�ts from your investment. If nothing else, consider an analyst �rm as a form of insurance. It is al-ways nice to be able to say to upper management when you seem to struggle with a project, “Well, AnalystFirm said that vendor XYZ was a leader and had the ability to ex-ecute above their competitors.” That will probably �y bet-ter than, “Well, I Googled them, and nobody said anything bad about them.”

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One significant reason to consider using an analyst

firm is access to vendor strategy. Vendors do share

strategy and performance information with analysts

that they may not share with the general public or

even prospective customers.

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See more, do more and be more profitable with the most trusted partner in wireless — Emerson. Emerson is your proven partner with Smart Wireless in more customer sites and with more operating hours than anyone else in the process industry. Smart Wireless has the widest range of technologies to expand your vision into more places across your operations. And its self-organizing mesh network delivers the highest reliability available. It is simply the most intelligent, secure and cost-effective operation-wide wireless option available. See how Smart Wireless can empower your bottom line at EmersonProcess.com/SmartWireless

Using wireless here and there is one thing.But using it across my entire operation? There’s no one I could trust to do that.

SURVIVAL OF THE FITTEST

Pepperl+Fuchs, Inc.Twinsburg, Ohio330.486.0002www.pepperl-fuchs.us

Endurance To Withstand The EnvironmentPepperl+Fuchs is the clear choice for industrial-grade flat panel monitors and workstations. Our visualization systems range from general-purpose and Div. 2 monitors to fully integrated Class I, Div. 1 systems. Manufactured with industrial-rated equipment, a full family of high-performance visualization solutions include 10 to 22 inch displays, scanners, keyboards, and other peripherals.

Our expert knowledge of hazardous area protection, and our global support are unsurpassed. When you need safe, reliable, and timely visualization solutions, choose Pepperl+Fuchs. Find high-quality operator workstations and monitors at: www.pepperl-fuchs.us/industrial


O N T H E B U S

JOHN REZABEK CONTRIBUT ING [email protected]


Hey, you’re already

dealing with

Modbus, right?

Could fieldbus be

that much harder?

A Minute to Measure It

into equipment viability, which could be de-grading more quickly—or not. So what’s the quickest way to get a handful of new measure-ments brought into the system?

In the conventional world of 20 years ago, we’d hope we had some spares in a nearby junc-tion box, in suf�cient numbers and of the cor-rect signal level and type. Lacking that, we’d be hustling to route a “multipair” cable perhaps hundreds of feet to the vicinity of the process we had to monitor. If there wasn’t space in an existing tray or some largely empty conduit (some of which might be underground), we’d erect raceways as well. This scenario assumes the host system in the control house has ad-equate spare I/O of the types required—not a given. Even with the sensors and transmitters in hand, the time and effort for installing and interconnecting copper could delay the inte-gration of useful measurements for weeks.

In the last 20 years, hazardous-area-capable multiplexers have become commonplace. If your plant has them deployed, it’s not inconceivable that a nearby “mux” could have some spares ca-pacity. If not, it’s equally viable that I/O bus ex-tenders and modules of the desired type could be purchased and installed for the new points. Since you’re in a hurry, maybe you’d have what you need in the storehouse, or you could rob some cards from a lower priority application. Modern offerings like Emerson’s Charms and Honeywell’s Universal I/O module might further simplify the effort, assuming you had the compatible Honey-well or Emerson host back in the rack room. Even with wireless, speed of deployment also hinges on measurement device availability.

If you have a more generic mux network deployed, there’s a reasonable chance you’re using an open standard such as Pro�bus DP, Modbus or Ethernet. Open standards increase your options, and afford you the opportunity

to integrate more diverse solutions. If your so-lution demands sub-second, closed-loop con-trol, you could deploy Foundation �eldbus us-ing Softing’s FG-110 FF (http://tinyurl.com/llgxvda), and implement control in the �eld. If your host is modern enough to offer a �eldbus H1 interface card, you can use a single, spare, twisted pair of conventional cable—provided it passes some minimal quali�cations and isn’t too long—to install a �eldbus segment. Such a �eldbus segment could support as many as 16 devices of all �avors on a single pair. Pro�bus DP users might have some “purple hose” in the vicinity to which they might add a PA coupler.

If you’re unfamiliar with �eldbus, the pres-sure to get your solution installed and running fast might drive you to a solution you �nd less intimidating. But, hey, you’re already dealing with Modbus, right? Could �eldbus be that much harder?

If you’re comfortable enough with Modbus, you may have a quick path to integrate a wireless solution such as WirelessHART or ISA 100.11a. Both protocols offer Modbus-capable gateways, with the majority available in the “WiHart” �a-vor. It’s common for such gateways to include a web server, providing a fairly straightforward programming interface for setting Modbus com-munication parameters, and many of the vari-ables necessary for individual devices. Once the gateway is con�gured, mounted, powered up and connected to the host system, you can start getting measurements within minutes of con-necting �eld devices to the process.

So does wireless win the race? Depending on your existing spare capacity, storehouse stock and supplier availability, wireless may be the most expedient path to add dozens of new monitor-only indications, with the speed and savings increasing in proportion to the number of measurements you add.

A heat exchanger is fouling, and economic conditions are such that even a brief shut-

down to clean it is especially onerous. Portable measurements are reliable enough to

indicate the problem isn’t getting better by itself, but the boss would rather not rely on

them. Running with crude measurements isn’t going to provide the necessary insight

CT1308_19_OTB.indd 19 7/29/13 4:50 PM

W I T H O U T W I R E S


IAN VERHAPPENDIRECTOR,

INDUS TRIAL AUTOMATION NE T [email protected]

Outsourcing SCADA–A Good Idea?

I recently returned from working in Nunavut in northern Canada for 10 days. While there,

I found myself without cellular coverage; my iPhone 4S does not have a radio compat-

ible with the systems in use. 3G support is supposed to be coming this year. This expe-

rience and the fact of the not irregular ‘lost calls’ while either going over a small rise or

or rounding a bend in the road in rural Alberta has biased me against the use of cellular radio for SCADA, despite the fact that many if not the majority of industrial wireless manufactur-ers offer GSM/GPRS modems.

Proper design and signal boosters will over-come the weak and lost signal challenge. How-ever, many of the locations where SCADA needs to be installed, such as in the oil and gas sector, tend to be remote and may not have cel-lular coverage, thus removing this option from the list of alternatives. In other applications, that tend to be closer to areas of population or where coverage is good, it is certainly a viable option to be considered.

SCADA systems are designed to be able to manage a loss of communications between the remote terminal unit and the master terminal unit, and then resynchronize the databases at either end upon reestablishment of the connec-tion. SCADA systems also differ from directly connected control systems in that they’re de-signed to report by exception or change of state, rather than every value every scan cycle, which reduces the traf�c load, thus making the resyn-chronizing easier and the bandwidth require-ments lower.

One other important consideration with SCADA systems is support for the protocol used between the various nodes. In the power industry, protocols such as DNP 3.0 and IEC 61580 and 60870 are important. Other indus-tries may need support for Modbus RTU, Mod-bus/TCP or one of the ODVA protocols (De-viceNet, ControlNet or EtherNet/IP), while building automation often uses BACNet or LONworks, so users need to be sure their back-haul solution supports the languages used.

With all this in mind, you’re ready to look at the pros and cons associated with choosing to effectively outsource your network backbone.

One obvious bene�t of having your cellular phone provider responsible for your network is that it’s then also responsible for maintaining it and ensuring its availability. With society’s reli-ance on cellular networks, if we lose all cover-age there are likely to be larger problems than loss of communication. RTUs include watch-dog timers and other tools, so that if commu-nications are lost both ends become aware of it. If you use good design practices, you should know when something has gone awry. There is a potential risk that, even though your modem is technically only using its assigned phone number, the tower may have all channels in use when you want to establish the connection.

One disadvantage of outsourcing the net-work is it’s now outside your control, and the provider can make changes that may also re-quire investment on your end, though proper contract management should help manage this potential problem. There’s also the �nger-pointing between the provider, IT and the end user when something happens, with the result that the end user often ends up suffering.

The key question that needs to form the ba-sis for your decisions about a real-time control system is how real is real? In other words, what is acceptable availability and, in the case of SCADA systems, how long can you operate re-motely without viewing/accessing your central control facility?

Engineering is in a large part about risk man-agement. It is therefore your role to evaluate the alternatives, and then design an appropri-ate system to overcome the risks at the lowest lifecycle cost. Many systems today rely on out-side networks and the Internet for connectivity between nodes, and your cellular provider is, therefore, another option for one component of your SCADA system—just be aware of the risks and rewards before making your decision.

The key question

that needs to form

the basis for your

decisions about a

real-time control

system is how real

is real?

CT1308_20_Wireless.indd 20 7/29/13 4:51 PM

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TeamM. Iacobucci, D. McCradden, G. Matusek, J. Loibl, R. Guagliardo, M. Wheeler, K. Siegal, S. Koller, S. Roseberry

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See more, do more and be more profitable with the most trusted partner in wireless — Emerson. Emerson is your proven partner with Smart Wireless in more customer sites and with more operating hours than anyone else in the process industry. Smart Wireless has the widest range of technologies to expand your vision into more places across your operations. And its self-organizing mesh network delivers the highest reliability available. It is simply the most intelligent, secure and cost-effective operation-wide wireless option available. See how Smart Wireless can empower your bottom line at EmersonProcess.com/SmartWireless

Using wireless here and there is one thing.But using it across my entire operation? There’s no one I could trust to do that.

SURVIVAL OF THE FITTEST

Pepperl+Fuchs, Inc.Twinsburg, Ohio330.486.0002www.pepperl-fuchs.us

Endurance To Withstand The EnvironmentPepperl+Fuchs is the clear choice for industrial-grade flat panel monitors and workstations. Our visualization systems range from general-purpose and Div. 2 monitors to fully integrated Class I, Div. 1 systems. Manufactured with industrial-rated equipment, a full family of high-performance visualization solutions include 10 to 22 inch displays, scanners, keyboards, and other peripherals.

Our expert knowledge of hazardous area protection, and our global support are unsurpassed. When you need safe, reliable, and timely visualization solutions, choose Pepperl+Fuchs. Find high-quality operator workstations and monitors at: www.pepperl-fuchs.us/industrial



I N P R O C E S S

Schneider Electric Makes Bid for InvensysFive-billion dollar offer on the table.

Power-One’s Stockholders Approve ABB Acquisition Power-One Inc. (www.power-one.com), a provider of renewable energy and energy-ef�cient power conversion and power management solutions, announced at its recent, special meeting of stockhold-ers that they’d approved the adoption of a merger agreement, pursuant to which ABB (www.abb.com) will acquire Power-One for $6.35 per share of Power-One common stock.

According to the �nal tally of shares voted, approximately 98% of the shares voting at today’s meeting voted in favor of the proposal to adopt the merger agree-ment. These shares represented approx-imately 73.3% of the total outstanding shares of Power-One’s common stock as of the June 18, 2013, record date for the meeting. All of the issued and out-standing shares of the company’s Series C Junior Participating Convertible Pre-ferred Stock voted in favor of the pro-posal to adopt the merger agreement. In addition, the stockholders also approved the nonbinding advisory compensa-tion proposal included in the proxy

statement �led on June 20, 2013.As previously announced on April

21, 2013, ABB agreed to acquire Power-One in an all-cash transaction valued at approximately $1.0 billion. The transaction has already received the re-quired antitrust approvals, and Power-One and ABB expect to complete the transaction by the end of July.

MESA Offers Online Courses MESA International is now offering a variety of instructor-led online courses. Upon successful completion, these courses provide CEUs, and can also be applied towards a MES/MOM Method-ologies Online Certi�cate of Awareness.

Individual courses in MESA’s MES/MOM Methodologies curriculum can now be taken online, or the en-tire nine-course curriculum can be bundled, allowing people to earn the MESA Certi�cate of Awareness (CoA) completely online.

GEP courses are available for mem-bers and non-members. For premium members, MESA credits 100% of mem-bership fees towards the cost of any GEP course. This can yield upwards of

$10,000 in savings for large, premium manufacturing members.

“Neither the speed of business nor the acceleration of technology advance-ment is slowing down,” says Mike Yost, MESA’s president. “The MESA Global Education Program (GEP) helps com-panies establish a reliable approach to aligning technologies and solutions with business needs. There is signi�-cant �nancial and operational bene�t for companies that �gure out how to leverage modern information technolo-gies in their production operations. Tak-ing MESA GEP training online will ex-pand the accessibility of this valuable knowledge to many more companies looking for a competitive advantage.”

To learn more about online course offerings, upcoming dates, and how to register, go to http://tinyurl.com/m3tzeqw. Space is limited.

Saudi Aramco Sponsors ISA EMEA Automation Conference ISA EMEA Automation Conference and Exhibition 2013 is a �ve-day event to be held in Saudi Arabia on Dec. 7-11 at the

Schneider Electric (www.schneider-electric.com) has made a preliminary offer of approximately $5 billion for In-vensys (www.invensys.com). Invensys has indicated that it would be willing to entertain the offer. One of the in-triguing bits about this story is that it is Invensys that revealed the offer with-out consulting with Schneider �rst. Some analysts are speculating that the reason is to possibly start a bidding war.

A number of major players might be tempted. For example, Emerson would certainly be interested, one might think, having already done some pre-liminary courting of Invensys last year. And Invensys’ sell-off of its railroad di-vision last year to Siemens relieved it of a lot of pension debt, which was limit-ing its attractiveness to buyers.

On the other hand, Jeff Immelt, CEO of GE, one company mentioned

as a possible alternative contender, has already said his company isn’t in-terested. He said, “it really doesn’t �t our screen as to the kinds of places that we’re going to put capital.” No other companies have jumped into the bid-ding either.

Breaking: On July 31, Invensys ac-cepted a tender offer of £3.4 billion from Schneider.

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I N P R O C E S S

Sheraton Dammam Hotel and Towers. Saudi Aramco is the main sponsor.

This event will be the �rst full-scale conference and tradeshow dedicated to process automation in the Gulf re-gion. The event will focus on the latest measurement and control technologies through a �ve-day technical confer-ence, product exhibition and training courses.

Saudi Aramco’s sponsorship will pro-vide added value opportunities and �-nancial integrity to the event, and is a critical enabler for holding such events, which will provide a forum for technical exchange and professional networking.

This event features a line-up of edu-cational sessions led by industry leaders from around the globe. The event prom-ises to attract hundreds of delegates from various end-user companies and vendors across the Middle East and beyond.

CC-Link Receives Three Key Manufacturing Certi�cationsThe CC-Link Partner Association (CLPA, www.cclinkamerica.org) has received three major, new certi�ca-tions, which will stimulate growth for the CC-Link open, automation net-work in China, Japan and in the inter-national manufacturing of semicon-ductors, photovoltaics and �at-panel displays.

The three new certi�cations include: CC-Link Safety from the Chinese Na-tional Standard GB/Z 29496.1.2.3-2013; CC-Link from the Japanese Industrial Standard TR B0031; and CC-Link IE Field from Semiconduc-tor Equipment and Materials Interna-tional (SEMI) E54.23-0513.

According to John Wozniak, net-working specialist, CC-Link Partner Association, these certi�cations have a potential pull-through sales effect for North American manufacturers that offer components and systems compli-ant with the CC-Link open network.

Chinese industries, such as automo-tive, semiconductor and liquid crys-tal displays, have been demanding improvements in safety. CC-Link IE Field Network with integrated safety can deliver safety shutdown of pro-cesses in response to an emergency signal from light curtains, safety gates, E-stops, etc. The SEMI certi�cation assures manufacturers of semiconduc-tors, photovoltaics, �at-panel displays and related micro- and nano-electron-ics that CC-Link IE Field is compat-ible with standards-based manufac-turing architectures, and its many

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I N P R O C E S S

features have the capabilities to deliver improved operational performance.

CC-Link has been a de facto standard network in Japan for some time. The certification in Japan as-sures suppliers and manufacturers in both Japanese domestic and export markets that CC-Link meets the important IEC 61158 international fieldbus standard.

Gas Rig Explodes in Gulf of MexicoOn July 23, the Hercules 265 gas rig, leased by Walter Oil & Gas Corp. of Houston, exploded in the Gulf of Mexico as workers were preparing it for production. The 44-member crew was evacuated and no injuries were reported.

According to a spokesman for the Bureau of Safety and Environmental Enforcement, natural gas was leaking at the site, but no oil had been released.

The platform, about 60 miles south-west of Grand Isle, La, exploded around 11:45 p.m, the Coast Guard reported. It said a Coast Guard vessel witnessed the blast.

The crew of Hercules 265 evacu-ated the rig when natural gas began spewing from the well some 150 feet underwater. The explosion and �re oc-curred after the crew left in lifeboats. No cause has been given for the ex-plosion, and investigators are speaking with crew members about the cause of the initial blowout. The �re was extin-guished by mid-day on July 25, but the rig has partially collapsed.

Invensys Celebrates Triconex AnniversaryInvensys (www.iom.invensys.com) has announced a yearlong celebration to mark the 30th anniversary of its Tri-conex (http://iom.invensys.com/EN/Pages/triconex.aspx) safety and critical control products. Invensys says it leads

the market when it comes to overall safety instrumented systems. More than 13,000 Triconex controllers are in use today in safety and critical control applications worldwide, and they have collectively amassed more than 600 million hours of safe operation.

“Triconex has always been identi�ed as a premier system for industrial safety and critical control,” says Harry Forbes, senior analyst, ARC Advisory Group. “The merits of various system architec-tures are always debated, but Triconex safety systems have always provided high levels of safety, availability and re-liability. ARC believes these are the rea-sons Triconex safety and critical control systems, solutions and turbo machinery applications are globally respected and recognized by end users in a wide range of industries and applications.”

The Triconex brand was born in 1983 when Jon Wimer gathered a team of engineers, developers and profes-sionals to build the world’s premier industrial safety system. In 1994, Tri-conex was acquired by Siebe plc of the United Kingdom. In 1999, Siebe and British Tire and Rubber, another Brit-ish engineering �rm, merged to form Invensys plc.

Other groundbreaking Triconex solutions include the Tricon control-ler, a fault-tolerant controller based on triple modular redundancy ar-chitecture. In the past year, Inven-sys also released its Triconex Safety View solution, the world’s first soft-ware alarm and bypass management solution certified by TÜV Rhein-land for use in SIL3 applications, as well as its Trident and Triconex Gen-eral Purpose system version 3.0.

Invensys has planned several special events in the coming year to mark the anniversary of its Triconex brand, in-cluding a celebration at the company’s Triconex and Foxboro Client Confer-ence, scheduled for Sept. 10-13 in San Antonio, Texas, as well as regional cel-ebrations across the globe at various In-vensys locations.

U. S. Industrial Outlook BrightensThe industrial automation picture in the U.S. is mixed with factory automa-tion leading and process automation lag-ging, reported Mark Douglass, analyst at Longbow Research (www.longbowre-search.com), in the �rm’s second quarter economic newsletter published in July, .

Demand in the U.S. has strength-ened since 2013’s �rst quarter, primar-ily on increased strength from discrete markets, in which many respondents are now exceeding expectations.

U.S. demand is up in mid-single-digit numbers year over year versus low single-digit increases year over year in the �rst quarter, driven by strength from discrete markets, though process markets are showing some small im-provement as well. The strength ap-pears to be due to a pickup in end-user spending, notably in food and bever-age, automotive, packaging and con-sumer durables, rather than in ma-chine OEMs. International demand remains mixed with strong growth in Brazil, but softer, though stabilizing, demand in Germany and a weak sec-ond quarter in Mexico.

Pricing is �at versus �at to slightly up in the �rst quarter, and invento-ries appear largely �at as well, with no problems reported with lead times.

The domestic outlook is still for year-over-year growth in the mid-single dig-its, with respondents generally more optimistic in regard to discrete markets compared to process. International re-spondents were largely positive, with Brazil and Mexico fairly optimistic and the German outlook neutral.

Based on Longbow’s survey, de-mand in the U.S. has strengthened since the �rst quarter, primarily on increased strength from discrete mar-kets as process markets increased only very slightly, and many respondents are now exceeding expectations compared to only meeting them or slightly miss-ing them in the previous quarter.

CT1308_22_26_InPro.indd 25 7/30/13 1:03 PM

I N P R O C E S S

U.S. Demand up Modestly Aggregate responses indicate a mid-single-digit, year-over-year increase ver-sus low single-digit increases in the �rst quarter. Process markets picked up very slightly, and are now higher by approx-imately low- to mid-single digits year over year versus higher by low-single digits in the �rst quarter with most indi-cating business was about what they had expected coming into the year. Oil and gas markets remain strong, although mining was mixed on recent weakness in copper and gold markets.

International Demand Remains MixedGerman demand is down about high single digits, but appears to have stabi-lized. Though electronics markets are currently weak, automotive and chem-ical markets appear strong, and con-sumer markets are resilient. In Brazil,

those Longbow spoke with reported be-ing up by approximately mid teens ver-sus down high single to low double dig-its in the �rst quarter of this year. There appears to be more spending for MRO and a corresponding increase in volume of smaller orders, rather than higher-margin, new-capacity projects.

Demand in Mexico has softened since Longbow’s last channel check, and the majority reported declines year over year versus mid- to high single-digit increases in the �rst quarter. Some of the softness is likely a result of a slower state-owned oil and gas sector due to political transition-ing in the latter part of last year.

Global Pricing Flat, Global InventoryLevels Remain StableGlobal prices are �at compared to slight increases in the �rst quarter, with many expecting the traditional increases of a

few percentage points from major man-ufacturers next quarter, such as Rock-well Automation’s annual increase in August. Global inventory levels have remained �at for most, though a few respondents reported inventory had in-creased to better serve customers’ needs.

Outlook Still OptimisticThe domestic outlook is still for year-over-year growth of mid-single digits, with respondents generally more opti-mistic when it came to discrete mar-kets compared to process.

International respondents were largely positive, though optimism levels de-creased slightly and varied by region. German respondents were neutral in their expectations, moderating somewhat from the �rst quarter, though Brazil and Mexico each expressed fairly strong levels of optimism.

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R E S O U R C E S


Links to Process SafetyControl’s Monthly Resource Guide

Every month, Control’s editors take a speci�c product area, collect all the latest, signi�cant tools we can �nd,

and present them here to make your job easier. If you know of any tools and resources we didn’t include, send

them to [email protected], and we’ll add them to the website.

GUIDE TO FUNCTIONAL SAFETYThis free tool from Rockwell Auto-mation provides a guide to functional safety in the process industry. Intro-ducing principles and standards relat-ing to safety in process applications, the guide discusses how to implement effective solutions, and delivers an overview of functional safety guidance in the application of IEC 61511, the process industry-speci�c implementa-tion of IEC 61508 that covers the safety management of electrical, electronic and programmable electronic systems throughout their lives. Process Safe-book 1 provides insight to many facets of process safety, including safety life-cycle, hazards and hazard identi�ca-tion, risk and risk reduction, determin-ing SIL targets, reliability techniques, SIL veri�cation and functional safety, assessment and auditing. To download the free tool, visit: www.emea.rock-wellautomation.com/process/en/free-safety-guide.aspx.

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MIND THE SAFETY GAPPlant safety is at or very near the top of almost every manufacturer’s oper-ating priority list, often with a stated goal of zero incidents or accidents. Functional safety focuses on the safe-guards required to manage and miti-gate hazards. It seeks to answer the following types of questions: What can go wrong? How severe might it be? How likely is it to happen? Does it matter? Do we have enough pro-tection? Safeguards typically include safety instrumented systems, such as emergency shutdown systems, alarm

functionality of the distributed control system, burner management systems and pretty much any other automa-tion and control technology that pro-vides a layer of protection that enables safe operation. While functional safety has proven successful in reducing the probability of catastrophic events and does recognize the role of human fac-tors, it does not explicitly address the key roles of management and busi-ness processes in maintaining the op-erational integrity and pro�table per-formance of process plants. Process safety moves beyond functional safety, seeking to assure that the safeguards and safety equipment are available and operating at peak performance. It includes enforcing routine mainte-nance procedures, keeping mainte-nance backlogs or records of the safety critical devices that manage those risks and enforcing practices such as stan-dard operating procedures. This white paper demonstrates how modern pro-cess safety management goes beyond functional safety to keep plants con-tinuously safe and pro�table. The free, downloadable PDF is found at http://tinyurl.com/ktwj4tb.

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INTRINSIC SAFETY DEMYSTIFIEDOver the past several decades, intrin-sic safety has established itself as the preferred method of explosion protec-tion for global energy and petrochemi-cal projects. This latest installment in Control’s “Essentials” series explains the ins and outs of intrinsic safety tech-nology, how it compares with other methods of explosion protection, and

new technology developments poised to increase the scope of its application to higher energy systems. This free, downloadable white paper is found at http://tinyurl.com/ndc7r77.

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SAFETY INSTRUMENTED SYSTEMS“Essentials of Safety Instrumented Systems” is another unit in Control’s “Essentials” series. It provides process industry professionals with an up-to-date, top-level understanding of the most important SIS issues. From fun-damental concepts and terminology to the ongoing debate over integrated ver-sus stand-alone safety systems, readers can get up to speed quickly on the key technology and marketplace drivers. The direct link to the free, download-able PDF is located at www.control-global.com/13WPpdf/130128-Essen-tials-eBook.pdf.

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PROCESS SAFETY PODCASTSFor your listening pleasure, and full of important safety information, Con-trolGlobal.com has a wide selection of podcasts on process safety free for downloading. Hear Control’s editors talk with experts such as Asish Ghosh, Bill Goble, Charlie Fialkowski and Ed-die Habbi, a team of ARC analysts and others regarding process safety issues, alarm management, safety standards and more. For a complete list of avail-able podcasts, go to http://tinyurl.com/k9ntfpn.

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W I R E L E S S F I E L D N E T W O R K S

Communication is what’s important. Whether it happens over a cable or through the air is irrelevant, so long as the link is secure and the data transfer is successful. Luckily, there are now plenty of avenues to make that happen, so wireless devices and methods are becoming as routine in process monitoring, data acquisition, automation and even control as sensors, I/O points, hardwiring, PLCs and DCSs—just like the toothbrushes, clean socks, car keys, sack lunches and other items that engineers, operators and other working people use daily.

However, wireless transmitters, antennas, site surveys and wire-less protocols remain unfamiliar to many potential users. So it helps to know how those further along the learning curve use wireless to solve mundane, but persistent operational headaches.

Curing Common ComplaintsFor instance, Thames Power Services’ 1,000-MW Barking Power Sta-tion (www.barkingx.info) near London recently installed 35 Rosemount 708 acoustic transmitters from Emerson Process Management (www.emersonprocess.com) to �nd more failed steam traps, leaking or mis-behaving valves and costly boiler tube leaks, and reduce steam losses, feedwater costs and downtime (Figure 1). If a steam trap fails or a leak develops, an acoustic device in the transmitters reports sound and temperature changes, which are con�gured to alert operators of a po-tential problem. Ian MacDonald, Barking’s senior control systems en-gineer, reports the transmitters immediately helped by identifying a leak from a high-pressure, super-heater steam trap, which would have cost £1400 for every day of downtime.

“Improving process performance is all about understanding what’s happening around the plant and being able to respond quickly to any problems,” explains MacDonald. “Wireless tech-nology enables us to introduce additional measurement points quickly and cost-effectively at any location so we can gather more information to identify potential faults.”

Later, Barking installed 15 more acoustic transmitters to monitor other problematic areas, including vent valves that can stick during

More routine process control applications are

adopting wireless to save cable, secure added

signals, and transfer data from spots where wire

can’t go. Here’s how veteran users do it every day.

by JIM MONTAGUE

Workingman’s Wireless

CT1308_30_41_CoverStory.indd 30 7/30/13 9:47 AM



start-up and pressure relief valves that don’t seat correctly. Previous manual monitoring was time-con-suming and also failed to indicate when or why a release occurred, increasing the chances of a safety, regulatory or environmental incident. The new wireless devices enable precise monitoring and alert operators when valves have opened for as little as 1 second.

Next, data is fed into Barking’s existing Emerson Ovation control system, where noise levels can be trended to identify gradual changes. Repairs can then be scheduled during normal off-times to main-tain maximum plant availability and avoid forced downtime. Using its existing wireless networks, more

devices can be added at much lower cost than if they had to be individually wired-in. This gives the plant more opportunities for monitoring where it was previously cost-prohibitive,

such as identifying blockages in Venturi eductors, which typically use inlet/outlet pressure differences to create suction and rapidly mix injected substances.

“Having already installed Emerson’s Smart Wireless THUM adaptors for access to stranded HART diagnostic data in �eld devices, we were familiar with Smart Wire-

less,” adds MacDonald. “The mobility and �exibility of the battery-powered wireless devices also allow us to run trials and move devices to different areas without temporary

cables. As a result, we can spot early problems and improve response to malfunction-ing equipment, enabling better planning and use of maintenance resources.”

Finding the Right FitProbably the most important virtues on the road to wireless are patience and �exibility in researching, designing and implementing the most useful solution. For instance, engineers at Valero Energy Corp.’s (www.valero.com) re�nery in Wilmington, Calif., were introduced to wireless several years ago when a third-party, point-to-point wireless system was installed to extend process monitoring. However, it was cumbersome and took too much time to deliver data, according

to Rick Felix, Valero’s associate process control systems coordinator. So the plant’s engineers sought improved wireless tools; implemented Honeywell Process Solu-

tions’ (www.honeywellprocess.com) OneWireless site-wide in 2009; and have been tai-loring it to suit their applications and enhancing performance ever since.

“Re�nery assets are typically spread over a large geographical area. Plants are of-ten required to monitor multiple points in applications involving level, �ow, pres-

sure and gas detection., and, up to 90% of the installed cost of measurements in these applications can be for cable conduit and related construction,” says Felix. “Wireless networks make it possible to easily obtain point measurements in the most remote and hard-to-access locations without interrupting normal operations. Wireless systems can work consistently and reliably in areas previously considered impractical, and lower cost per I/O with wireless may justify projects that wouldn’t have been feasible with wired transmitters.”

Back on the wired side, Wilmington originally employed a Honeywell TDC 2000 DCS, and subsequent upgrades added TDC 3000 equipment, while legacy US sta-tions were migrated to Experion PKS with new HMIs, Icon stations and Experion servers. The re�nery is presently moving to C300 controllers, which will be used for blender control. The plant was commissioned in 1969 and expanded with alkyla-

tion and �uid catalytic cracking (FCC) units in 1982. It produces 15% of south-ern California’s asphalt supply. Meanwhile, Wilmington’s OneWireless R200

installation includes Honeywell’s Wireless Device Manager (WDM), Field Device Access Points (FDAPs) and XYR6000 wireless transmitters.

“Our wireless network provides more reliability and ease of use than earlier systems,” adds Felix. “Also, OneWireless supports multiple proto-cols and is simple to manage and operate. Our wireless system provides a cost-effective, manageable solution for non-critical process monitoring applications, including pipeline movement, �are monitoring, LPG purge



gas pressure, heat exchanger tempera-ture and tank high-level alarms.”

Because Valero and the Wilming-ton plant were early wireless adopt-ers, they’ve learned many valuable lessons. For instance, the plant’s ini-tial wireless transmitters and multi-nodes were installed by Honeywell and then handed over to Valero for day-do-day maintenance and expan-sion. “However, our staff encoun-tered some problems, such as signal strength issues due to antennas that weren’t wrapped well enough to han-dle the weather, and some other ca-bles that corroded,” explains Felix. “There were also some challenges in programming the multi-nodes.”

So in August of 2012, Wilming-ton conducted a new wireless site sur-vey, and migrated its OneWireless R120 systems to OneWireless R200. The multi-nodes were replaced with FDAPs, while R200 and WDM pro-vided improved system reliability and connectivity and an intuitive, web-based user interface. They allowed in-tegration of the wireless network with the plant’s control system using indus-try-standard protocols.

So far, Wilmington’s active One-

Wireless network consists of 30 wire-less transmitters, 11 FDAPs, two FDAPs wired to the DCS, and the WDM connected via serial Modbus to the Honeywell DCS.

“R200 was a lot faster to deploy, and it lets us troubleshoot our transmit-ters much quicker,” adds Felix. “Work on the R200 system has proven to be much less labor-intensive than with the original R120 system.”

Though they need power routed to them, FDAPs do message routing, so users can connect wireless devices to the control network and route data from the � eld. They also allow creation of a secure, ISA100-compliant, wire-less network of � eld instruments which communicate with each other and route messages from neighboring � eld devices to controllers. Likewise, WDM enables gateways and security manag-ers to make sure communications be-tween � eld instruments and the plant are secure. They support a web-based user interface, allowing process and � eld engineers with basic IT knowl-edge to quickly set up wireless systems, and they reduce time required to com-mission, monitor and troubleshoot the wireless device network.

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While each application has its own quirks and requirements, there are still some primary

procedures for implementing wireless in any process or plant:

• Investigate and inventory your process application’s basic operational and perfor-

mance needs and use them to guide you toward the right wireless solution.

• Evaluate your existing wired and any wireless networks together and upgrade your

overall communication integration plan. Combine with functional needs above to help

choose appropriate wireless equipment.

• Complete a thorough wireless site survey and radio frequency (RF) assessment to de-

termine the application and plant’s physical setting and possible interference sources,

such as buildings, steel walls, geographic features, distance issues, etc.

• Test and select best-suited antennas and placement for most stable coverage and op-

timal signal transmission and reception.

• Begin to implement wireless in smaller, non-critical pilot projects to check on unique

site characteristics and issues. Make sure wireless devices can be adjusted and

moved as application’s needs change.

• Install and roll out wireless components and network to meet application’s present re-

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• Instruct fi eld staff in installation, maintenance and troubleshooting skills required to

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“OneWireless helps us optimize our plant processes and reliability, improves safety and security, and ensures regula-tory compliance,” says Felix. “It’s been much more than just avoiding the cost of wire because the key bene�t of wireless lies in the ability to integrate valuable data into control sys-tems and advanced applications, while also sharing that data with other networked applications. Many other projects are now becoming possible for us, such as short-range site-to-site, using inputs in control, etc.”

Water Goes WirelessOne of the best indications that wireless is taking over basic process control is its widespread adoption in municipal ap-plications, especially in water and wastewater processes.

For example, Oslo Municipality’s public works depart-ment recently replaced costly operator panels with connect-Blue’s (www.connectblue.com) Bluetooth wireless main-tenance and operations devices at several hundred pump stations which manage water and wastewater �ows through-out Norway’s largest city (Figure 2). The Bluetooth units give the utility’s ABB ITTM AC 800C control system an Ethernet interface and web-server access to process data on

customized web pages, local dynamic data logging and ac-cess to the city’s wide area network (WAN).

In addition, Oslo’s staff can use Bluetooth handhelds to service machinery, adjust and reprogram each pump station

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Figure 1: Barking Power Station near London uses about 50 Rosemount

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on site, and connect with overall control systems. Connect-ing AC 800C to the WAN also enables personnel at the pump stations to automatically store software changes on the WAN server, so they no longer have to return to the control room to download program adjustments before pro-ceeding to another station.

Likewise, regional water management association Ag-gerverband (www.aggerverband.com) recently automated operations at its 200 x 41-meter Genkel Dam and its 8-mil-lion cubic-meter drinking water reservoir in Gummersbach and Meinerzhagen, Germany, with help from water man-agement contractor HST Hydro-Systemtechnik (www.sys-temtechnik.net) in Meschede, Germany. To monitor water withdrawal, water levels, temperature, evaporation, wind ve-locity, and constantly check physical dam shifts in relation to its substrate, Genkel’s new process control system needed to link 12 stations, including a “measuring raft” located in the middle of the reservoir and Aggerverband’s central con-trol room that monitors and controls several dams.

Consequently, 11 of the 12 stations implemented BC2000 bus terminal controllers with PLC functions from Beck-hoff Automation (www.beckhoff.com/water), which were

STATE OF WIRELESS NETWORKINGA survey of more than 150 readers of sister-publication Industrial

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Nearly 57% of respondents presently have wireless in their ap-

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Wireless HART 31.6%

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WiFi (802.11n) 9.2%

Proprietary protocol 9.2%

802.11a 5.1%

ZigBee (802.15.4) 1%

Meanwhile, 47.5% of respondents have approved projects to

deploy wireless during the next year, but 52.5% have not. Of the

47.5% of respondents who plan to deploy wireless, the most popu-

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Wireless HART 35.8%

802.11b/g 16.1%

WiFI (802.11n) 14.8%

ZigBee (802.15.4) 4.9%

Proprietary protocol 6.2%

802.11a 2.5%

In addition, respondents’ most common uses or intended uses

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Monitoring 59.7%

Control 27.7%

Alerts/alarms 12.6%

Also, respondents needed varying cycle times from their wire-

less devices, including:

1 second or slower 52.8%

500-999 msec 20.8%

100-499 msec 15.2%

Faster than 100 msec 11.2%


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networked via a 1.5-km Lightbus ring and Beckhoff ’s ADS TwinCAT data transport protocol. However, reaching the raft required using Beckhoff ’s KN6551 wireless terminal, a radio link based on IEEE 802.15.2 and a solar power supply.

“These terminals, which can be integrated easily into the bus terminal system, use the 2.5 Ghz band,” says Frank Huetger, HST’s IT systems product manager. “A directional antenna ensures a stable radio link.”

Revising When Needed Because wireless is still a relatively new technology in many places, those reluctant to use it in the �rst place are quick to blame and dismiss it again when it has growing pains. So what wireless really needs most of all is a willingness to sometimes rethink, readjust and renovate wireless components, designs and layouts to achieve stable communications.

For instance, St1 Energy’s (www.st1.se) petroleum re�n-ery in the harbor area of Gothenburg, Sweden, uses Emer-son’s Rosemount tank gauging equipment and a mix of wired and wireless components for level and temperature mea-surements, but found it had no direct access from its control room to its Smart Wireless Gateway, which is based on the

WirelessHART (IEC 62591) standard and collects data from the wireless �eld network. Ironically, to monitor their wireless network’s status and con�gure devices, St1’s technicians pre-viously had to go into the �eld and investigate.

So St1 implemented a wireless link from its control room to the gateway via Emerson’s Wi-Fi-based Pervasive Field Network (PFN) solution. PFN at St1 includes three

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Figure 2: Oslo’s water/wastewater staff uses Bluetooth devices and

handheld units to manage several hundred pumping stations by giving

the utility’s ABB ITTM AC 800C control system an Ethernet interface and

web-server access to process data on customized web pages, local

dynamic data logging and the city’s wide area network (WAN).

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of ProSoft Technology Inc.’s (www.prosoft-technology.com) RadioLinx industrial hotspot units indoors connected to three remote, outdoor panel antennas. The � rst hotspot is connected to the gateway; the second serves as a repeater to achieve line-of-sight and relay data; and the third is in St1’s control room, where it creates a Wi-Fi zone (Figure 3).

This layout enables operators to access the re� nery’s wire-less � eld network from anywhere in the control room, via laptop PCs equipped with AMS Wireless Con� gurator, AMS Wireless Snap-On and/or TankMaster software. In fact, Snap-On software gives users a graphical overview of the tank farm, devices on the network and their status.

Likewise, Sunstate Cement Ltd. (www.sunstatecement.com.au) in Queensland, Australia, recently completed an $85-million expansion to increase capacity to 1.5 million tonnes, including installing a wireless local area network (WLAN) between three ship unloaders and four access points. However, the WLAN malfunctioned, and the un-loaders couldn’t communicate back to the main controller.

“At � rst, Sunstate Cement thought the problem was with Siemens’ (www.siemens.com.au) wireless equipment. They had very low signal strength, even from only a few meters

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Figure 3: To connect its control room and � eld-based wireless tank gaug-

ing system, St1 re� nery in Gothenburg, Sweden, implemented Pervasive

Field Network (PFN), which includes three RadioLinx industrial hotspot

units indoors connected to three outdoor panel antennas, and which is

displayed on AMS Wireless Snap-On software’s graphical overview of the

tank farm, devices on the network and their status.

CONFIRMING COVERAGE



away from the WLAN’s access points, and there were com-munication dropouts between the main controller and the three RTU PLCs on the unloaders,” says Falk Holman, Siemens Australia’s networks product manager. “The � rst thing I found was that the initial installer hadn’t conducted any WLAN channel planning, and there were so many col-lisions and interferences because the traf� c wasn’t coordi-nated between the four WLAN access points.”

Holman explains that access collisions can be avoided by conducting space division multiple access (SDMA) or fre-quency division multiple access (FDMA) procedures. He adds that WLAN simulation software like Siemens’ Sinema E can improve communication performance before installation.

“We also discovered that plant staff had installed 5-GHz antennas, but the network was con� gured for a 2.4-GHz frequency range,” explains Holman. “Also, antennas on the access points were installed below structures and were too low and adjacent to solid concrete walls. So, after selecting the 5-GHz range for the network, we reallocated channels to each of the access points and the corresponding load-ers.” Holman adds that channels available for the network ranged between 149 and 165 (5,745 MHz and 5,825 MHz) for Sunstate’s outdoor application. However, because there’s a 2-MHz overlap between channels, Holman arranged the channels in an ad hoc order to prevent interference.

A second round of tests with a Cisco spectrum analyzer showed slightly weaker signal strength (-70 dBm or 48%), but much greater signal quality. “Unfortunately, we still ex-perienced communication dropouts,” says Holman. “So, what else was wrong and why was it only 48%? Well, we found the installer used omni directional antennas, which can have high gain but a very small vertical lobe. So, when the loaders were parked, it was impossible for the antennas to have line-of-sight due to a big difference in the height of the mounting positions. Also, we noticed the antennas were mounted too close together. To use antenna diversity prop-erly in a 5-GHz radio cell, we recommend using 20 times the wavelength as the clearance. And, locating two access-point antennas under a belt conveyor didn’t help either.”

Consequently, Sunstate raised its antennas from 2 me-ters to 5 meters and relocated redundant cable. “We found 5 meters of excess cable stuffed into a 1-meter channel, which can cause cable attenuation,” adds Holman. “Luck-ily, we used this extra cable when the antennas were relo-cated away from the overhead structures and raised higher.

After making these corrections and using Siemens iPCF rapid roaming functionality, Sunstate’s wireless system is operating as originally designed. In fact, Holman reports it’s been running without interruption for more than 12 months without any replacement or added hardware.

Jim Montague is Control ’s execut ive edi tor.

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L E V E L

Back to Basics: Ultrasonic Continuous Level MeasurementUltrasonic level is one of the �ve non-contacting continuous level measurement technologies,

and the one that is most often misused or misapplied. Here’s how to do it right.

by Walt Boyes

The �ve non-contacting level measure-ment technologies are radar, nuclear, laser, weight and ultrasonic. Each of them has both good points and bad. Radar, for example, is relatively expen-sive in the more accurate versions (fre-quency-modulated, continuous-wave, FMCW), while nuclear level is limited to relatively small vessels, and there are licensing and safety considerations. Lasers appear to have developed an application niche, especially in the measurement of bulk solids and pow-ders. Weighing systems can be used in some vessels, but it is, again, a rela-tively niched application solution. Of all of these, ultrasonic level measure-ment is the most widely used non-con-tact technology. Ultrasonic level trans-mitters are used in most industries and are very widely used in open-channel �ow measurement systems, sited atop a �ume or weir.

How Does It Work?Ultrasonic level sensors work by the “time of �ight” principle using the speed of sound. The sensor emits a high-fre-quency pulse, generally in the 20 kHz to 200 kHz range, and then listens for the echo. The pulse is transmitted in a cone, usually about 6° at the apex. The pulse impacts the level surface and is re-�ected back to the sensor, now acting as a receiver (Figure 1), and then to the trans-mitter for signal processing.

Basically, the transmitter divides the time between the pulse and its echo by two, and that is the distance to the surface of the material. The transmitter is designed to listen to the

highest amplitude return pulse (the echo) and mask out all the other ultra-sonic signals in the vessel.

Because of the high amplitude of the pulse, the sensor physically vi-brates or “rings.” Visualize a motion-less bell struck by a hammer. A dis-tance of roughly 12 in. to 18 in. (300 mm to 450 mm), called the “blanking distance” is designed to prevent spu-rious readings from sensor ringing. This is important for installation in ar-eas where the distance above the level surface is minimal.

Physical Installation IssuesThere are some important physical installation considerations with ultra-sonic level sensors.

1. Make sure the materials of con-struction of the sensor housing and the face of the sensor are compatible with the material inside the vessel. Most ultrasonic sensor vendors pro-vide a wide selection of sensor mate-rials of construction in case the stan-dard sensor housing isn’t compatible. Most sensors come with a PVC or CPVC housing. PVDF, PTFE (Tef-lon) and PFA (Tefzel) are usually available. In some cases, a housing of aluminum or stainless steel with a polymer face can be provided.

2. Make sure that the operating tem-perature range of the sensor is not ex-ceeded on either the high or low temper-ature end. The materials of construction may deform or the piezoelectric crystal may change its frequency if the tem-perature range is exceeded. The change in ambient temperature is usually

compensated, either by an embedded temperature sensor, a remotely mounted temperature sensor or a target of known distance that can be used to measure the ambient temperature.

3. Locate the sensor so that the face of the sensor is exactly 90° to the sur-face of the material. This is especially important in liquid and slurry level measurement. In some bulk solids

Figure 1. The sensor sends pulses toward the sur-

face and receives echoes pulses back.

Signal echoesfrom surface

6° cone beam

Cutaway mounting�angeBlanking

distance

ULTRASONIC SENSOR

CT1308_43_46_Feature2.indd 43 7/30/13 1:19 PM

L E V E L

measurements, this can be modi�ed (and this will be discussed in a later section of this article). If you do not do this, your echo will either be missed entirely by the sensor, or it will use an echo that is bouncing off the vessel wall or a vessel internal structure in-stead of the real level.

4. Make sure that the vessel inter-nals do not impinge on the pulse sig-nal cone from the sensor. If they do, you may get a spurious high amplitude echo that will swamp the real return echo from the surface of the material.

5. Make sure you avoid agitators and other rotating devices in the ves-sel. Sometimes you can do this with an additional waveguide. If you can’t, make sure you purchase a transmitter that can compensate for the effects on the echo of the agitator blade moving in and out of the signal cone.

6. Mount your sensor where it can’t be coated by material or condensation inside the vessel. Coatings attenuate the signal, sometimes so much that there is no longer enough power to get through the coating to the surface and back. If it isn’t possible to avoid coat-ings, try to provide some means of cleaning the sensor face. Some trans-mitters provide a signal “�gure of merit” that can be used to detect coat-ings or other signal failures and acti-vate an alarm function.

7. Always use the vendor-supplied mounting hardware for the sensor. Hard-conduit-wiring an ultrasonic sen-sor can increase the acoustic ringing and make the signal unusable.

Application ConsiderationsBecause ultrasonic level sensors and transmitters are inexpensive and usually

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Figure 2. Sometimes the measured value is “what the level would be if the agitator

were turned off.”

Motor drivenagitator

Vortex fromagitator

INSTALLATION ISSUES


L E V E LL E V E L

easy to install, they’re often used at the outer edge of the application envelope, and erratic or erroneous signal and signal failure often result.

1. Try to avoid agitated tanks even when the agitator is below the surface of the material. Agitation can produce whirlpools or cavitation, which may at-tenuate the signal or cause it to bounce off a vessel wall. In some cases, the agitation may be so extreme that the measurement you are trying to make is “what the vessel level would be if the agitator was turned off” (Figure 2). This is not a real measurement, and it may not be possible to make it with any degree of con�dence or accuracy.

2. Sparged tanks, where air or an-other gas is introduced into the vessel by means of diffusers or spargers, can cause bubbles or foam to form on the surface of the material. It is good to avoid this application. A layer of bub-bles or foam can attenuate the signal either entirely or partly. If it attenu-ates the signal entirely, there will be no echo return. It is more insidious if it only attenuates the signal partly. A false echo can occur from somewhere in the foam layer, rather than either the surface of the foam or the surface of the liquid below the foam (Figure 3).

3. Avoid foam. Foam can do three things to the accuracy of the level mea-surement, and all of them are bad. First, it can attenuate the signal so that there is no echo or only an intermittent echo. Intermittent echo can sometimes be dealt with using a sample-and-hold circuit or algorithm in the transmitter so that the level doesn’t change until the next good echo. Sometimes, how-ever, that can be dangerous, as in the case of a vessel where the level is quite near the maximum �ll point.

Second, foam can provide a false reading of the true level. You can get a reading from inside the foam layer, in-stead of the actual level.

Third, foam clumps can cause the echo to be de�ected away from the vertical, and the sensor may receive an

echo that has made one or two hops against the side of the vessel, yet still be a high enough signal to fool the transmitter.

4. Avoid volatile liquids. Back when I was in sales, I sold an ultrasonic trans-mitter to a major northeastern United States utility for the measurement of level in huge bunker oil tanks. The

sensor was installed in early November, and it worked acceptably well until mid-May of the following year, when the customer reported that the sensor was insisting that the level in the tank was several feet higher than it actually was.

This “ghost level” phenomenon is a function of the volatile liquid in the tank. As the ambient temperature rose,

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L E V E L

the vapor blanket on top of the bunker oil began to become more dense and increased in height. The ultrasonic sensor picked up the top of the vapor layer, instead of the actual oil level in the tank.

By late June, the sensor was regularly reading 80% to 100% because the early summer heat had caused the vapor blanket to �ll the tank. We replaced the ultrasonic sensor with a FMCW radar sensor, which worked correctly, and I learned something.

5. In solids and powders, you may have to aim the sensor at a point that is not 90 degrees to the level surface (perpen-dicular to the vertical axis of the vessel). You may want to aim the sensor because of rat-holing and angle-of-repose is-sues at the top, midpoint or bottom of the angle of repose. Try to have the transmitter calculate what the actual level might be. At least one vendor has developed a multiple sen-sor array that can scan the angle of repose and determine what the actual �lled volume of the vessel is.

6. Avoid pressurized tanks. The speed of sound changes with temperature and density, and pressurizing the vapor space above the level can affect the density of the vapor space and, therefore, the speed of sound.

Ultrasonic Open-Channel FlowmetersOne of the most important applications for ultrasonic level sensors and transmitters is measuring open-channel �ow (Figure 4).

Most of the same caveats apply to ultrasonic level sensors used as �owmeters as apply to ultrasonic level sensors used as tank level measurement devices. There are a few more:

1. Avoid wind and sun. Wind can blow through the vapor

space and attenuate the signal or blow it off course. Sun can raise the temperature of the sensor housing itself beyond the operating temperature range of the device—and higher than the ambient temperature.

2. Make sure that there isn’t foam on the surface. This can happen often in nitrifying wastewater discharges.

3. Make sure that there is not too much turbulence or ripples (or if the �ume or weir is large enough, wave action) on the surface.

4. Above all, make sure that the �ume or weir is installed correctly. Many problems blamed on the ultrasonic trans-mitter are actually problems that are caused by the �ume not being installed level both horizontally and vertically, as well as front to back through the measurement zone.

5. Make provisions to keep ice from forming on the sen-sor in the winter or dripping condensation in the summer.

The One-Trick Pony—Not!Ultrasonic sensors are simple to understand, easy to install and inexpensive. It’s easy to go to them as the unthinking sen-sor of choice for level applications, just as many people go to differential pressure level sensors. Yet, as many users have found, ultrasonic sensors and transmitters are tricky beasts. As with any other �eld instrument, applying an ultrasonic level sensor too far outside the manufacturer’s recommended ap-plication envelope is destined to fail, and sometimes fail spec-tacularly. But, if you follow these basic guidelines, you will have successful ultrasonic level installations.

Wal t Boyes is Control ’s edi tor in chief.

Figure 3. Bubbles, foam, vapor and internal structures make

ultrasonic measurement very dif�cult.

Motor drivenagitator

Vapor layer

Internalstructures

Foam layer

SpargerBubbles from

sparger

CHALLENGES AT THE OUTER EDGE OF THE ENVELOPEFigure 4. The level sensor works exactly the same way—mea-

sures level. The primary device (�ume or weir) measures �ow.

The �ow transmitter takes the level signal and produces a �ow

value based on the primary device.

6° beamParshall �ume (typ.)

Channel

Flowtransmitter

134.56

OPEN-CHANNEL FLOW




Greg: The process control knowledge gained over four de-cades of experience is largely gone thanks to retirements. For example, I am the only person from Monsanto’s Engineer-ing Technology still practicing dynamic modeling and con-trol, and some may ask “practicing what?” since I am largely retired from active duty. The problem really hit home when I asked the biggest names in process control technology— Charlie Cutler, Béla Lipták, Bill Luyben and Greg Shins-key—to be keynote speakers at ISA Automation Week 2011 and found out they are or will soon be octogenarians.

This is good news in terms of longevity, but a red �ag in terms of losing access to incredible knowledge. To add insult to injury, many of the books I consider my core knowledge are now out of print. To avoid a relegation of innovation in the automation profession to moving and manipulating data, we need to �nd out how to nurture and expand control expertise by better com-munication between generations. More speci�cally, how do we help the new generation of automation engineers bene�t from the legacy and move the profession forward?

While some may say control technology is mature, I take the view that the �exibility and power of modern day soft-ware opens up vast opportunities for creativity. We can take process control to the next level if we can address many questions. How can we take full advantage of what has been learned? Will people be given the time to explore new pos-sibilities and the freedom to publish the knowledge gained? Will a supplier or a user ever again support a person like me? Will there ever be another Shinskey?

To get a view from each generation, I posed key questions to Danaca Jordan, manufacturing staff engineer for a specialty chemical company, Hunter Vegas, senior project manager at

Avid Solutions Inc., and Soundar Ramchandran, senior direc-tor of technology for Ascend Performance Materials. Each of these participants in the ISA Mentor Program has extraordi-nary technical and communication skills.

(1) What can each generation learn from the other generations in terms of communication and solving problems on the job?Danaca: My generation (Generation Y) needs to focus, real-ize communication has consequences, and do more effec-tive networking. Here are some things we need to learn and should try to share.

Multi-tasking is a part of our generation’s culture; it can have positive effects, such as the ability to recover from inter-ruptions quickly and extreme adaptability, but sometimes I lack the focus I see in other generations. I am guilty of check-ing email during meetings, browsing during teleconferences and having multiple IM sessions (internal company messages, of course!) active while trying to work on something that re-ally deserved my full attention. We have more ways than ever to procrastinate and distract ourselves, and if we are not mind-ful, it will affect our productivity.

Through the examples of others, I have learned that writ-ten and verbal messages can and will be saved or forwarded to people you did not intend to include. The angry email you sent yesterday could end up hurting your credibility with a customer or your employer. In tense situations I have made a habit of saving emails for the next day, and often end up deleting or completely rewriting them. A point here for all generations is that anything posted online is no longer under your control, including comments that could re�ect badly on you or your company.

Talk toEach Other

A dialog across the generations.

by Danaca Jordan, Greg McMillan,

Soundar Ramchandran and Hunter Vegas




Finally, online networking is for more than just job-hunting. We have global virtual communities set up for almost everything that we do, like or support. People all over the globe share stories in these forums about how speci�c products worked, what prob-lems they encountered, and how they overcame them—all with-out giving speci�c details of their plants’ operations. Someone somewhere in the world is having the same issue you are, and we now have tools in place to discuss solutions without spending time or money on conferences and meetings. Newer engineers can ask questions with some anonymity, and veteran practitio-ners have a way to quickly share their experience and thoughts outside of formal journals and company reports.

Hunter: Let me start by saying that I am not a big fan of creating generational “labels” and trying to force-�t a large group of people into a simplistic box. Every engineer is dif-ferent, each is motivated by his own particular set of per-sonal experiences, and many take some offence when they are lumped into a generic group which may not have any relevance or similarity to them at all.

To that end, I will tend to frame my answers by referring to “younger/less experienced” engineers and “older/more seasoned” engineers. Of course, “younger” and “older” are relative terms, but I have found this reference to be much more useful than grouping engineers by their year of birth.

Communication is critical to the success of any project, regardless of the age group involved. So many intergenera-tional problems balloon out of control when one group stops talking/listening to the other. I have watched older engi-neers dismiss great ideas from younger engineers because they had not thought of it themselves, or they were unfamil-iar with the technology. I have watched younger engineers stumble and fail because they thought they knew it all, and were too proud to ask for help.

Personally I have found that the most effective commu-nication is a face-to-face conversation. I derive as much (or more) information from visual cues, body language and voice in�ection than from the words themselves. Tweets, texts, emails and memos are �ne, but if you truly want to communicate with another person, then there is nothing better than doing it in person.

Soundar: While realizing generalization is subject to individual experience and uniqueness, free will and adaptation in the hu-man response, the recognition of generational differences can

help one understand some of the behavior at play in communi-cation. Statistical methods can con�rm these tendencies.

Baby Boomers (1946 to 1964) are characterized by hard work, positive attitude and a general sense that the world will get better with time. The key question the Boomer wants answered is, “What does it mean?”

Generation X (1960 to 1984) was a period of awakening for many—Vietnam war, Nixon, Iran hostage crisis, Ronald Reagan, Berlin Wall, Chernobyl, AIDS, MTV, etc.

The key question Generation X asks is, “Does it work?”Generation Y (1977 to 1994) is incredibly sophisticated,

tech-wise and immune to most traditional forms of market-ing and sales pitches. The key answer that the Millennials are curious to know is, “How do we build it?”

Recognizing the core strengths of every generation, we can bene�t from each other by recognizing and learning the following:

• From the Boomers, we can learn a positive and upbeat attitude, and ask “why” and “how” enough times to get to the root cause of something;

• From Gen X, we can learn to become self-aware, focus on individual strengths and weaknesses, and �gure out how we can work as a team to deliver great results;.

• From the Millennials (Gen Y), we can learn the speed of adaptation, opening our minds to new ideas and new ways of looking at things, and using the new tools being developed to take advantage of the power of electronic means of communication.

(2) What are the biggest challenges faced and potential im-provements in terms of getting the right information that is timely and useful?Danaca: There are several key issues involved in sorting through and �nding helpful information quickly. The foremost con-cern is information overload. When �rst looking into a subject, the sheer volume of information that has been written is over-whelming. Journals, books, blogs and papers are scattered across the Web and mixed with biased marketing literature. Much of the educational literature is not online or searchable, so it can only be accessed through hard copies. Finally, from a normal Google search, it’s dif�cult to determine if a paper or book is still viable. Is this instrument still the best for liquid service? Is this rule of thumb good for newer column trays?

The surest way to combat the overload is with a mentor. A knowledgeable mentor will help narrow down the mass

Gen Y We have more ways than ever to procrastinate and distract ourselves, and if we are not mindful, it will affect our productivity.”




volume of information by suggesting an author or article for various topics.

In a solid entry or blog, authors will give overviews of a topic with links and citations to peer-reviewed articles and books. Open editing and commenting reveals or prevents biases. I of-ten think that this kind of system would be wonderful for an internal company knowledge base. We could add our technical reports, discuss comments and questions, and share ideas be-tween isolated sites and corporate engineering without formal meetings, conference call-in codes or cost center charges.

Hunter: There are some key concepts that, if understood and applied, would have an enormous positive impact in the engineering workplace of today, for example,

• Many “new” technologies are rebranded/repackaged “old” technologies;

• Some technologies are truly new and can be transfor-mational;

• Change is not always good;• Change is not always bad.It is an odd mix, but each concept has very different

meanings to different age groups. Many “new” technologies are rebranded/repackaged

“old” technologies; despite what one reads in the latest mar-keting brochures, most “new” technologies are not new at all. On the other hand, occasionally a new technology hits the market that is new and works an order of magnitude bet-ter than any competing offering.

This is where younger engineers tend to shine, as they generally follow the latest trends and are more knowledge-able on the most recent offerings. However, just because a new product looks good does not mean that it will actually work. A more experienced engineer will tend to be more cautious when implementing such a technology to be cer-tain it delivers all that it promises. That caution is usually the result of several past instances where the “best thing since sliced bread” was not all it was purported to be.

Change is not always good; younger engineers are used to a constantly changing world and tend to be more com-fortable with an atmosphere of continuous change. Unfortu-nately, change for change’s sake is not always a good thing. There may be a sound reason why the plant has “always done it that way,” and just because the current technology is old does not mean that it isn’t the best solution available.

Change is not always bad; older engineers tend to stick

with the tried and true. If it works, why mess with it? How-ever, that reluctance to try new things will often make them miss out on transformational technologies that can generate dramatic improvements in productivity and reliability. Even harder for an older engineer is the decision to give a particu-lar technology another try after it has failed before.

The point of my answer is that both young and older engi-neers have much to offer each other if they open their minds and hear what the other group has to say. Older engineers should listen to younger engineers and try out their ideas when they present them. Younger engineers should listen to the older engineers and understand the history of why cer-tain equipment and/or procedures are being used. Each has information the other desperately needs.

Soundar: The questions that need to be answered in terms of doing a better job in process control for improving exist-ing systems, as well as executing new projects in a timely and useful manner, are these:

• What is it that we’re trying to accomplish?• How will it impact the bottom line?• When and how will the impact be realized?• Why is it important to do this?The biggest challenge I see is that most of the time we

start the dialog with the “why is it important to do some-thing” question. While it is important to know the answer to this question in a deep and fundamental sense, it becomes a distraction, as the conclusion and recommendation is not obvious in the “why.” Working the details of any problem should lead to a conclusion or a recommendation. It is the conclusion or recommendation, the ultimate result from the scienti�c analysis, which is more important than the me-chanics of analysis itself. Most of us miss this and get mired in “teaching the science” to the decision-makers. This is the fundamental reason for failure of many communications; they fail to achieve the desired outcome and leave both par-ties disappointed.

Greg McMil l an is a Control columnis t . Danaca Jordan is a manufac tur ing s taf f engineer for a special t y chemical company. Hunter Vegas is senior projec t man-ager a t Av id Solu t ions Inc. , and Soundar Ramchandran is senior direc tor of tech-nology for Ascend Per forance Mater ials .

[Editor’s note: Continue this conversation online at www.con-trolglobal.com/gentalk0813.html. More generational talk will also appear in the September issue.]

Gen X“Many intergenerational problems balloon out of control when one group stops talking/listening to the other.”



S O F T W A R E & I N F O R M A T I O N S Y S T E M S

Rationalizing and Refocusing on AlarmsProjects to logically renovate alerts and alarms in large applications can bene�t from seeing

more clearly into their processes with improved HMI tools.

by JIm Montague

Knowing what you’re looking at is the most important thing, but a sharp focus can help you get there. De�ning, organiz-ing, prioritizing and understanding alerts and alarms is one of the most critical jobs in process control. However, perhaps be-cause so many applications are isolated, inadequate and dan-gerous alarm practices can persist for years. Sometimes it’s too few useful alarms, but more often it’s �oods of duplicate and unnecessary alerts that were thrown in for compliance and convenience’s sake rather than ensuring safe operations.

The solution begins with an inventory of processes and alerts, but it continues with assessing and prioritizing alarms, incorporating more helpful database software and HMIs, and training staff to follow these improved procedures.

For instance, Vale’s (www.vale.com) Copper Cliff nickel smelter in Sundbury, Ontario, runs two �ash furnaces, which take in 4200 tonnes of dry solid charge (DSC) ore powder per day, and �ash-smelt it into nickel matte product, sulphur gas for fuel and iron slag. However, several years ago, engineers in Vale’s Ontario division started an alarm rationalization project because the two furnaces were generating more than 17,000 alarms per day on average, most of which weren’t understand-

able to the operators, and which didn’t lead to useful action. “Previous rationalization projects tried to reduce alarms,

but always ended up adding more,” says Gerry Seguin, Vale Ontario’s senior automation specialist. “Then a consultant from the Engineering Equipment Materials Users Association (EEMUA, www.eemua.co.uk) came in for a seminar; gave a report on consequences that really hit home; and showed the alarms weren’t the operators’ faults because they hadn’t been given the tools for their job. After that, we were able to get �-nancing, resources and people, including bringing back two pensioned operators full-time to go over all alarm interactions.”

So Vale Ontario implemented EEMUA’s Publication 191, “Alarm Systems—A Guide to Design, Management and Procurement,” and ISA’s (www.isa.org) ISA 18 alarm man-agement standard; evaluated and reduced alarm system loading on the two �ash furnaces, and redesigned its alarm systems to assist operators. Vale also partnered with Invensys (http://iom.invensys.com), and adopted its PAS Alarm Man-agement Software database, which works with its existing Foxboro I/A Series process control software to download ap-proved alarms to the application’s �eld controllers.

As a result, alarms on Copper Cliff’s two �ash furnaces dropped to a daily average of just 66, which exceeded EEMUA’s average alarm rate benchmark for steady operation. “We also researched to ensure that operators had enough time between alarms and trips to respond effectively,” adds Seguin. “Since the initial project in 2007-08, all new alarms go through an alarm manager to make sure they meet the criteria we’ve laid out, which is like a risk assessment chart that evaluates likelihood, criticality and potential damage, and sets priority levels.”

Seguin reports that Copper Cliff is continuing to improve its alarm and HMI philosophy and rationalization process and is applying it to other areas of the smelter, including a new replace-ment nickel converting unit it will commission this September.

Pull Pointer Out of PanelSimilarly, DTE Energy’s (www.dteenergy.com) Greenwood Energy Center (GWEC) in Avoca, Mich., has been upgrad-ing its DCS from a 1990s-era Westinghouse Distributed Processing Facility (WDPF) system and lightbox displays to ABB’s (www.abb.us) Process Portal A (PPA) 800xA DCS, but �rst decided rationalize and reorganize several thousand alarms and related devices and software.

Figure 1: The vertical, analog-style indicator and sliders in Opto 22’s groov

platform allow uses to create interfaces that can be more quickly under-

stand and responded to by their operators.

EASILY UNDERSTOOD INTERFACE

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“Previously, many of our DCS alarms weren’t rationalized. They were just characterized as high or high worse, and so we had a lot of noise and chattering alarms that were only �xed occasionally,” says Kip Dobel, senior engineer in GWEC’s Engineering Support Organization. “In fact, operators deter-mined unit status by the different volumes of alarms and not actual alarms. Some also found interesting ways to silence nui-sance alarms, such as jamming a pointer in their board. Pages of alarms would scroll by on a unit trip, making it very easy for an important alarm to get lost in all the noise.”

Located 60 miles north of Detroit, GWEC is an 800-megawatt “peaker” oil and gas plant, which helps power the grid when demand is high. This means it ramps its elec-trical production up and down more than other plants.

To focus on important alarms and eliminate chatter, Do-bel reports that GWEC began migrating from WDPF to PPA 800xA in 2010, and installed Matrikon’s (www.matrikonopc.com) Process Guard software to help with post-event unit trip analyses. PPA 800xA included customer libraries, seven opera-tor consoles, three engineering work packages (EWPs), domain and 800xA controllers, and AlarmInsight operator assistance software for 800xA, which grew out of collaboration by ABB and Matrikon. GWEC also runs OSIsoft’s PI historian software to document high-priority alarms and check on operating devices.

Document and Bring in Veterans“We had about 6000 analog I/O points, and this meant dealing with about 10,000 decisions just to rationalize alarms and alerts from our analog sig-nals,” explains Dobel. “We wanted to give our operators an alarm system that would provide timely, accurate in-formation to assist in op-erating the powerhouse in a controlled manner; employ Matrikon’s Alarm Manager management of change (MOC) software to handle the rationalization; set up and execute an alarm rationalization scheme follow-ing EEMUA 191’s principles; and provide rationalization data to the operators’ consoles.”

Dage adds, “Previously, we were putting Band-Aids on the bleeders in our alarm system, but we weren’t com-pleting the documentation needed. This was the �rst time we did full documentation.”

Dobel added that GWEC also hired a senior software en-gineer from Matrikon to help get its three-month, $250,000

alarm rationalization project started; hired some retired op-erators to help; and set up a dedicated Alarm Rationalization Room to present component data, trace alarm pro�les and facilitate hashing out the most logical and ef�cient ways to reorganize and reassign them.

“If you haven’t done a rationalization project before, we recommend you hire an external expert to help, but make sure you check their credentials and bring them in for a trial week to see if they can do what you need to get done,” adds Dobel. “Also, using retired operators was help-ful because they walked down the system and traced many devices and alarms, but it was also a mistake because we needed to get more of our current operators involved too. A good rationalization team should have a panel board op-erator, a DCS expert that knows all the logic blocks in the systems and how they relate to the alarms, instrument technicians, and a scribe to keep everyone on track.

“The rationalization room got everyone on the same page. A lot of tribal knowledge had built up in our processes, and we needed to eliminate it by standardizing on common best practices. So, it helped to talk about what was bringing us to certain alarm situations.”

The rationalization team started with GWEC’s I/O tag list and the plant’s piping and instrumentation diagrams (P&IDs). “We found we


could sort the tag database however we wanted, but we learned it was better to take the P&IDs and rationalize the whole system,” says Dobel. “You have to ask questions like, ‘What �ow do I need here?’ or ‘What level do I need here?’ The aim is to avoid unnecessary double alarms, but it can take a long time do them—sometimes three or

four hours to reach consensus on one alarm. You have to get your subject matter experts (SMEs) for the process on speed dial.”

Help Operators Do Their Jobs GWEC also used AlarmInsight soft-ware to present alarm pro�les and op-erating data to its operators in a more

concise and less text-heavy format. “Be-sides delivering important alarms, we tried to give our operators assistance beyond the routine and obvious tasks, and help them with things they might not think about at 3 a.m. So we focused more rationalizing some of these un-usual events.” says Dage. “For instance, we found we rarely used Level 2 and Level 3 alarms, so we began to discuss the reasons why, and document our alarm philosophy.”

Likewise, to optimize its own alarm system, Compañía Mega (www.cia-mega.com.ar) recently held joint work-shops with Honeywell Process Solu-tions (www.honeywellprocess.com), and implemented its Alarm Con�guration Manager (ACM) software. ACM was integrated with the plant’s existing pro-cess control system, Honeywell’s Total-Plant Solution (TPS), and implemented recommendations from EEMUA 191. Mega is a joint venture between the Dow Chemical Co. and Brasoil Alli-ance Co., which provides hydrocarbon feedstocks to Dow’s Bahia Blanca site in Argentina and has two gas plants linked by a 600-km pipeline.

In short, Compañía Mega and Honeywell used ACM and EEMUA’s guidelines to:

• Standardize the alarm process by de�ning a plant alarm policy, so all staff operates with the same quality of alarms.

• Dramatically reduce the number of alarm activations requiring op-erator intervention.

• Provide peace of mind to operators by not overwhelming them with unnecessary alarms.

• Improve the response time of opera-tors to verify incoming alarms and make decisions when an alarm is activated.

• Reduce human error in the man-agement of alarms, avoiding un-necessary production stops, equip-ment failure, vents, etc.

This concern about alarm ratio-nalization is gathering steam. Jason


MiMiC v3.5Available Now!



Wright, market manager for PlantPAx software at Rockwell Automation (www.rockwellautomation.com) says, “We’re seeing a mind shift, especially in the process industries, about alarms and HMIs. Historically, alarms were driven just by knowing the process and following the critical ele-ments. HMIs layouts followed PIDs. Today, HMIs are driven by a greater appreciation for human-factors engineering and the best ways to convey information to the operators, so they can respond appropriately.

“Using ISA 18.2 as a guide, we’ve expanded the Alarm State Model in our PlantPAx 3.0 software to include three distinct alarm suppression states,” adds Wright. “The previous two were ‘suppression by design’ and ‘disabled or out of service,’ and now we’ve added a third for granularity called ‘shelving,’ which al-lows alarm suppression with an automatic timeout.”

Seeing More ClearlyHMIs also can give operators a better understanding and chance to respond to alarms and performance changes.

For example, system integrator One-Step Automation (www.one-step.com) in Niverville, Manitoba, builds auto-mation systems for grain handling and processing, but these users want HMIs they can use anywhere to get real-time feedback on bin levels, motor failures and alarms, surge hop-per levels, and the ability to control shutdown processes.

“Much of the equipment in seed processing facilities is driven by variable-frequency drives (VFDs),” says Arlin Fri-esen, One-Step’s automation specialist. “Clients want to ad-just motor speeds based on the quality of product they see coming off the processing equipment, and they want to monitor product quality with live camera feeds.”

Consequently, Friesen used Opto 22’s (www.opto22.com) groov platform and its web browser without plug-ins to build One-Step’s own operator interface that can be used on PCs, tablet PCs and smart phones. “This allows our users to con-trol VFD speeds using groov’s adjustable buttons or sliders, while the interface also displays live product �ows via IP cameras on their equipment,” adds Friesen.

While groov doesn’t have direct alarm capabilities yet, us-ers can add whatever alerts or alarms they want when building their interfaces. Also, groov and its optimized displays (Figure 1) are based on HMI best practices for building screens with prioritized data, minimal graphics and muted colors.

On the HMI hardware side, Red Lion Controls (www.redlion.net) reports its new Graphite operator interface panels include cast-aluminum construction and full-color touchscreens, and combine a range of plug-in modules with protocol conversion, data logging and web-based monitoring and control. The plug-ins reduce development and commissioning time compared to traditional systems, which typically use an HMI paired with separate I/O, PLCs and other controllers, and require more pro-gramming and con�guration (Figure 2).

Management and More DocumentationBack at Greenwood Energy Center, Dobel explains that management buy-in and commitment were crucial to GWEC’s alarm rationalization project, not just for funding and resources, but to give the team the authority to make ra-tionalization decisions and require operators stick to them—even though there are some exceptions. “For example, if your facility had a historical event, has to meet an EPA re-quirement or must carry out a particular management re-quirement, then these just have to be done,” adds Dobel.

In all, Dobel, Dage and their colleagues spent about eight hours a day for three months hashing out alarms. “That was too much, so we’d recommend a schedule of doing ratio-nalization in the morning and then gathering information in the afternoon,” says Dobel. “So far, we’re done with ra-tionalizing alarms for 80% to 85% of our I/O components, and we’re also still working on the logic for our smart alarms and maintaining the existing alarm system. And we’re still meeting once a week to do more rationalization. In fact, on his own, John triaged that last 20% of our alarms and made them Priority 4, so operators can assign priority levels later.

“Alarm rationalization includes many different devices, but the basic questions for each are always the same: ‘Do the operators need to know about this alarm?’ and ‘What are the consequences?’ adds Dage.

Dobel adds, “After documenting your alarm rationaliza-tions, it’s also important to be consistent with the rationaliza-tion rules you come up with, and as you build those rules, you need to document them too. And get started doing alarm ratio-nalization now. Don’t wait for an incident or accident.”

Besides continuing its rationalization efforts, GWEC and the team are doing more continuous improvement, and have set up another whiteboard to aid communications be-tween operators, IT and other players on items to work on. For example, it lists the Top 20 alarms each week and ad-dresses the bad actors behind them, which has already re-duced the number and severity of these alarms.

Jim Montague is Control ’s execut ive edi tor.


Figure 2: Graphite operator interface panels have cast-aluminum construction

and full-color touchscreens, and combine a range of plug-in modules with

protocol conversion, data logging and web-based monitoring and control.

ALUMINUM TABLET HMIS

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A S K T H E E X P E R T S

Plugged Furnace Pressure Connection

[Author’s note: Every month I select the questions and answers to print from among the many received. This month, for exam-ple, I received an interesting question concerning a “soft sen-sor,” which can indirectly obtain �ow from pump power and speed. Another question involved the formation of the FDI Cooperation, which should end the present “Babel of commu-nication protocols” by developing a single common protocol for Field Device Integration (FDI).

So why did I select the simple question below? Because that question represents reality out in the field. IT and al-gorithm wizards can develop the smartest devices or pro-tocols, but if the information they work with is bad, it will do no good. The key law of control design is “Garbage in, garbage out!”]

QWe’re measuring the pressure in a furnace as shown in Figure 1. Should the blast pressure be more than purg-ing pressure? Is this right?

If the �gure is right, why use a purging line? Could we just use blast pressure all the time?

Assuming that we have the same 7kg/cm2 N2 pressure supply for both purging and blast input, and the furnace pressure is 3.5kg/cm2, why could we not just use the blast pressure all the time? If we did that, would the pressure transmitter show 3.5kg/cm2 or not? If not, why?

So if the pressure transmitter is showing 3.5kg/cm2, then why is the purging line required? Is the purging line and blast line difference only related to consumption of N2 ?

ASHISH GARGashishgarg.ecb@gmail .com

A The purge and the blast lines serve two different func-tions. The purpose of the “purge �ow” is to make sure that the line between the furnace and the pressure

transmitter is �lled with clean and cold nitrogen. This can and should be achieved by continuously introducing a small �ow of purge nitrogen into the furnace.

The purpose of the “blast �ow” is different! It’s purpose is to periodically blast a large �ow of nitrogen though the con-necting line to the furnace, and thereby blow out any plug-ging or any material that is beginning to build up between the furnace and the three-way solenoid that isolates the pres-sure transmitter from the nitrogen �ow during blasting.

So what is wrong with your present system? Two things:1) The purge �ow is not controlled at a low �ow rate, and2) The connecting line to the furnace is probably too

small.What is the consequence of this? The consequence is that

the pressure detected by the pressure transmitter is the sum of the furnace pressure plus the pressure drop of the purge �ow in the connecting line (probably 0.25 in. diameter) as it travels through the small diameter tube before it enters the furnace. This results in inaccurate pressure measurement.

How do you �x it? As shown in Figure 2, you need to do two things:

1) In the purge line, you should eliminate the needle valve and the check valve, and replace them with a purge �owmeter, as shown on the right side of the �gure, and

2) Increase the diameter of the pipe, which carries the blast �ow into the furnace to a larger one (0.5 in. or larger), so that the pressure drop will be negligible

This column is moderated by Béla Lipták (http://belaliptakpe.com/), automation and safety consultant, who is also the editor of

the Instrument and Automation Engineers’ Handbook (IAEH). If you would like to become a contributing author of the 5th edi-

tion or if you have an automation related question for this column, write to [email protected]

Figure 1. A reader wants to know why, given the design above,

both a purge and a blast line are needed.

Seal diaphragm

Blast (B)

Purge (A)

Furnace

N2

N2

PIT

S

AB

WHY DO WE NEED A PURGE LINE?

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A S K T H E E X P E R T S


through it during purging. In Figure 2, I have identi�ed the pipe section which should be made larger in diameter with red coloring.

BÉLA LIPTÁKl ip takbela@aol .com

A The �rst thing I used to do when facing an unsolv-able problem was to accept the fact that something you think you know is true is, in fact, not true. The

�rst thing I would do is to remove the purge supply pressure regulator. Or, if it is required for some other reason, install an ordinary pressure regulator set as high as you can, con-sidering the system design. As designed, any occasional up-set in stack pressure will push stack materials back into the pressure connection before the regulator can respond. This gradually will obstruct the end of the pipe.

The purge �ow should be set by the needle valve, and it should have as much pressure drop across it as possible. If you have most of the purge pressure drop across the needle valve, it will behave as a constant �ow device even as the stack pressure changes. This would be like a constant cur-rent electrical source.

You do not show the sizes of the piping between the purge system and the stack. It has to be large enough so that the measured pressure does not change with changes in the purge f low. Even if the purge seems to

f low freely, there is always the chance of a restriction severe enough to show up when you do your “blast.” I would see if it is possible to remove and inspect that pip-ing at the next available opportunity. I suspect the prob-lem is an obstruction in the piping. Perhaps you can work around that. Maybe use new piping and an alterna-tive connection to the stack.

CULLEN LANGFORDCul lenL@aol .com

A If a purge rotameter is indicating �ow, that means purging is working, and differential pressure across the rotameter is positive. Furnace pressure normally is

maintained negative, so that �re does not come back. Purge rotameters come in a standard range, and any standard man-ufacturer should be acceptable.

Furnace pressure is normally maintained a few mm H2O negative. Normally a very low-range transmitter should be used, and if the same transmitter is facing 7 bar, there could be permanent damage to the pressure transmitter.

Also, the SOV exhaust port is connected to the pressure source. This is possible only if the SOV is the universal type. Normal SOVs will not function when exhaust is connected to the pressure point.

DEBASIS GUHA debasis_guha71@ yahoo.com

Figure 2. Eliminate the needle valve and the check valve in the purge line, and replace them with a purge �owmeter (see right-hand

side of diagram), and increase the diameter of the pipe carrying the blast �ow (red lines on the left.)

Seal diaphragm

Tube

Float

Flow controlvalve (v)

Spring #2

Spring #1

P2

Flow @ Pi inlet pressureN2 @ 7.0 bars

Purge �owmeter

Flow @ Po

outlet pressure (3.5 bars)

Diaphragm

Regulatorvalve

Blast (B)

Purge (A)

Furnace

N2

N2

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THE FIX

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I/O and Terminal BlocksOur guide to the good stuff.

MULTI-PROTOCOL ETHERNET I/OThe new BusWorks XT Se-ries Ethernet I/O modules interface discrete I/O sig-nals directly to an EtherNet/IP, Modbus/TCP or Pro�net measurement and control system network. They fea-ture dual Ethernet ports, re-movable, front-facing terminal blocks and support for a rail power bus. Two models offer 16 digital I/O channels, sup-porting any combination of inputs and outputs. Acromag 248-295-0880; www.acromag.com

DOUBLE-DECKER TERMINAL BLOCKSJust 5.2-mm to 6.2-mm wide, TopJob double-deck fuse and disconnect terminal blocks are up to 24% more com-pact than existing designs. They support process mea-surement applications re-quiring a common pro�le for feedthrough, disconnect/test and fusing of analog signals. They have four jumper slots per block and a 6.2-mm wide double-deck, fuse-disconnect model. Wago 800-346-7245; www.wago.us

EXTREME I/OSiplus Extreme ET200SP distributed I/O system com-bines easy-to-use features with high ef�ciency even in harsh environments. The I/O requires approximately 50% less space than conventional I/O modules, and operates from -40 °C to +70 °C. It’s resistant to harmful gases, is pro-tected against condensation, and operates at elevations from -1000 m to +5000 m.Siemens Industry Inc. www.siemens.com/siplus

SIMPLIFIED CONNECTIVITYThree G11 Series AS-inter-face I/O modules simplify connectivity, and deliver the fastest analog-to-digital con-version available. Two mod-ules offer two analog outputs each; one for 0-20 mA opera-tion for �at-cable connectiv-ity, and one for 0-20 mA operation with an M12 round con-nector. The third module offers four analog outputs of either 0-20 mA or 0-10 V for �at-cable connectivity. Pepperl+Fuchs 330-486-0001; www.pepperl-fuchs.us

POWER BOXThe new EP9214 power dis-tributor box enables the local distribution and switching off of the power supply, and can supply up to four NEC Class-2 circuits via typical M8 plug connectors. It has complete diagnostics and control functionality for up to eight 24 VDC branches per power box. Equipped with 7/8-in. plug connectors, it main-tains a total current of 16 A for each control. Beckhoff Automation 952-890-0000; www.beckhoffautomation.com

LOW-COST TERMINAL BLOCKSKonnect-It single-level termi-nal blocks handle currents up to 175 A, accept a wide range of wiring sizes from 26 AWG to 2/0 AWG, and have a 100kA SCCR rating. Double-level terminal blocks come in 20 A and 30 A versions and a variety of colors. Konnect-It triple-level terminal blocks han-dle up to 24A, and accept a wide range of wiring sizes from 24 AWG to 12 AWG. Automation Direct 770-889-2858; www.automationdirect.com

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16-CHANNELS, NO PROGRAMMINGMX-Series multiplexers have 4-20mA, 0-10Vdc, contact closures and RS-232/485 I/O module selections. The base unit connects directly to the �beroptic cable. Power is sup-plied through an external 24-VDC power supply. Each base unit has a duplex optical port con�gured for use with 1300 nm wavelength and single- or multi-mode optical �ber. No programming is required.Ultra Electronics, NSPI 512-434-2800; www.ultra-nspi.com

DAQ AND CONTROLMAQ20 features 32 PID loops for each system com-munications module, soft-ware options, and a built-in Modbus and FTP server. The system consist of a family of DIN-rail-mounted, program-mable, multi-channel signal conditioning I/O and communication modules that mount on a 35 x 7.5-mm, gull-wing DIN rail. A backbone mounts within the rail to provide power and communications. Dataforth 800-444-7644; www.dataforth.com

ETHERCAT MODULAR I/O NX-Series modular I/O uses distributed clock functions of the EtherCAT machine net-work to achieve high-speed deterministic control and real-time performance with microsecond accuracy and with nanosecond resolution. Digital I/O units range from two to 16 input or output points in just 12-mm width. A full range of analog I/O is available, with two to eight signals per unit. Omron Automation and Safety 866-88-OMRON; www.omron247.com

PROCESS TERMINAL BLOCKSThe Allen-Bradley 1492-JP process terminal blocks pro-vide a 45% space savings per signal loop, as compared to traditional solutions, while maintaining similar voltage and current ratings. The mul-tifunctional design provides an integrated shielding connection in feed-through and fuse terminal blocks, removing the need for an additional grounding terminal block.Rockwell Automation www.rockwellautomation.com

SMALL-FOOTPRINT PUSH-IN TERMINAL BLOCKS STIO 2.5 series of push-in technology (PT) terminal blocks now includes a small-footprint version. The PTIO 1.5/S series is only 3.5-mm wide with a new top-level lo-cation for the power wiring. They’re available in three- and four-wire versions, and allow easy and fast termination of ferruled wire by simply pushing the wire for a complete termination. Phoenix Contact 800-322-3225; www.phoenixcontact.com

PROFINET FOR I/OPACSystems RX3i I/O Pro-�net scanner enables GE’s most advanced I/O to be used as a distributed intelligent node. Combined with the PACSystems RX3i controller, it makes a high-performance-form factor for the most de-manding applications. PAC8000 I/O Pro�net scanner allows rugged I/O to be used in extreme temperature and corrosive environments. GE Intelligent Platforms www.ge-ip.com


R O U N D U P


STAINLESS STEEL I/OBL Compact I/O solution is available in a stainless-steel model to provide greater re-sistance to corrosion and other contaminants. It col-lects a variety of signals in a single, rugged node on a net-work. It makes it possible to obtain analog, digital, thermocouple, RTD, serial, RFID or a mixture of signal types in an on-the-machine device over EtherNet/IP, DeviceNet, CANopen and Pro� bus-DP.Turck 800-544-7769; www.turck.us

FIVE FOR REMOTE I/OAdam-6117PN eight-chan-nel isolated analog input, Adam-6150PN 15-channel isolated digital I/O, Adam-6151PN 16-channel isolated digital input, Adam-6156PN 16-channel isolated digital output Pro� net modules, and Adam-6160PN six-channel isolated relay Pro� net modules are designed with 2500 VDC isolated protection, making them very resistant to � eld interference. Advantech Industrial Automation800-205-7940; www.advantech.com/ea

NO MORE MARSHALLINGThe Foxboro Intelligent Mar-shalling solution features the Universal Fieldbus Module, a per-channel, con� gurable I/O module that supports a variety of analog and digital signal types. Each channel is software-con� gurable on a per-point basis with no extra hardware required. All con� gu-rations can be done at the workstation, which all but elimi-nates traditional marshalling panels. Invensys www.ion.invensys.com

WIRELESS FOR REMOTE SITESWNM wireless network mod-ule is an accurate and reliable solution for sending process signals between remote � eld sites. Operating at standard frequencies of 902-928MHz or 2.4-2.4835GHz, it doesn’t require a regulatory license, and can be installed without performing costly RF site sur-veys. Models are available for Ethernet and serial (RS-485) communication networks. Moore Industries-International 818-894-7111; www.miinet.com

UPGRADE LEGACY DIGITAL I/O The G4D32EB2-UPG and G4EB2 I/O processors up-grade a legacy mistic or Pamux G4 digital I/O system on a serial network to operate as part of an Ethernet/TCP-based control system without needing to replace or modify existing I/O or � eld wiring. When upgraded, digital I/O can be accessed over a standard Ethernet network, and included as part of a control program or custom software application.Opto 22 800-321-6786; www.Opto22.com

SMART SERIAL I/OR1200 series of smart serial RS-485 remote I/O offers the bene� t of simple wiring, as they only use two wires to communicate with the con-troller or other RS-485 de-vices. It uses the EIA RS-485 communication protocol and 3 kV DC I/O isolation between I/O channels, RS-485 port and power circuits and is ESD- and EFT-compliant CE/FCC, UL 508 certi� cation. Moxa 888-MOXA-USA; www.moxa.com


P R O D U C T I N T R O D U C T I O N S


TWO-WIRE FLOWMETERThe Proline Promag 200 electromagnetic �owme-ter is a two-wire magmeter that offers the same measur-ing performance as four-wire magmeters. It’s available in line sizes of 1/12 in. to 1 in. It operates in process temper-atures from -40 ºF to 304 ºF. Connections include welded, threaded, hygienic and �anged versions that meet EN/DIN PN 16-40, ASME B16.5 Cl 150, Cl 300 and JIS 10K and 20K process connection pressure ratings.Endress+Hauser 888-363-7377; www.us.endress.com

SMART ANALYTICAL SENSORSSmartSens is a family of two-wire, loop-powered analytical sensors with integrated trans-mitter technology. They offer direct connection of sensors to process control systems, and can be installed in ex-plosive and hygienic areas. They’re ideal for chemical, pharmaceutical, food and bev-erage, power, water and wastewater applications. Offered for pH, oxidation-reduction potential (ORP) and conductivity, they can be connected directly to the process control system. Krohne 800-FLOWING; www.us.krohne.com

MULTIVARIABLE TRANSMITTERSThe 266 series multivariable transmitters directly calculate the mass or standard volume �ow for gases, vapors and liq-uids with dynamic �ow com-pensation from three process variables: differential and ab-solute pressure and temper-ature. They can replace a DP or guage transmitter, RTD and associated wiring, and measure the level of liquid-�lled tanks and boiler drum levels with temperature- and/or pres-sure-dependent density changes of the process medium. ABB Measurement Products 800-829-6001; www.abb.com/measurement

TINY TRANSDUCERSFeaturing 1% accuracy, the Model S Series of submin-iature pressure transducers �t into tight spaces and ac-curately measure pressure ranges from 100 psi to 15000 psi. These rugged transduc-ers are designed to handle high pressure and temperatures with a high natural fre-quency and �ush diaphragm for applications such as engine and transmission test stands, pressure brake testing and hy-draulic sensor testing. Honeywell Sensing & Controlhttps://measurementsensors.honeywell.com

EXPLOSION-PROOF, CORROSION-RESISTANTHalp-48-3L-LED hazardous area LED light �xtures are designed to provide high-quality light output in an ex-tremely rugged design that can be used in wet and cor-rosive environments, while also maintaining compliance with hazardous location regulations. They come with three, 4-ft long LED tube lamps, each with a 50,000 hour opera-tional life and producing 2160 lumens, for a total of 6480 lumens of light output. Larson Electronics 800-369-6671; www.magnalight.com

1/8 DIN GRAPHIC DISPLAY PANEL METERDpi1701 1/8 DIN mono-chrome, high-resolution graphic display panel meter and data logger for tempera-ture and process measure-ment features optional alarm relays, isolated analog out-put, isolated 24-VDC excita-tion voltage and a wireless receiver. The logging starts/stops based on time and date, alarm 1 or 2 status, or a key press. The process input is displayed in horizontal bar graph, line graph charting or standard digital format. Omega 888-826-6342; www.omega.com

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P R O D U C T I N T R O D U C T I O N S

WET/WET DP TRANSMITTERAST5300 wet/wet differen-tial pressure transmitter with 5-PSID measurement range is an additional, lower-pres-sure option. It offers low dif-ferential pressure ranges in high line pressures (1500 psi) with excellent burst pres-sure capabilities. With no oil-�lled cavities and no internal o-rings to fail, AST5300 is ideal for food and beverage, oil and gas, �uid power, pharmaceuticals and semiconductor industries.American Sensor Technologies 973-448-1901; www.astsensors.com

UNIVERSAL VALVE ACTUATORUniversal valve actuator uses one motor and control soft-ware to operate virtually any Valco or Cheminert rotary valve, both two-position and multiposition. Actuators in-clude a universal 24-VDC power supply and manual in-terface. An OEM version that excludes these items is also available. Universal Actuator is CE/RoHS-compliant and has a variety of interface options including RS232/485, USB and BCD.Valco Instruments Co. 800-367-8424; www.vici.com

IPC FANLESS PROCESSORThe Fanless iPC-Series of industrial computers from Nematron have Intel Dual Core Atom N2800 proces-sors. Solid-state storage me-dia and optional 24-VDC fur-ther add to the strength and reliability of these rugged, industrial, fanless PCs offerings. Four sizes of LED-back-lit versions are available. All sizes and models have UL and cUL 508, as well as Class I Division 2, RoHS and European CE approvals.Nematron 734-214-2000; www.nematron.com

PORTABLE PRESSURE CALIBRATORCA700 portable pressure calibrator is equipped with a silicon-resonant sensor that uses Yokogawa propri-etary DPHARP technology. CA700 can measure pres-sures with an accuracy to within ±0.01% of rdg, and can output and measure current and voltage to within ±0.015% of rdg. It features a variety of functions, including a wide selection of measuring ranges, as found/as left data storage, and memory capacity to store calibration procedures. Yokogawa Test & Measurement 800-888-6400; http://tmi.yokogawa.com/us

MODULAR SAFETY RELAYSSirius 3SK1 safety relays for monitoring and control sys-tems are available with relay or semiconductor outputs. Both mechanical and elec-tronic sensors can be con-nected to the safety relay by means of screw-type or spring-loaded terminals. The advanced units feature all the product characteristics of the standard version, and not only allow the addition of modules with output expansions, but also of modules with input expansions for additional sensors. Siemens Industry Inc. http://siemens.com/safety-relays

EXPANDABLE FANLESS MINI PCFanless Mini PC model LPC-700F features built-in PCI or PCIe expansion slot capability. It ships stan-dard with an Intel i7 Pro-cessor 3610QE CPU and a multitude of I/O connectiv-ity built-in directly, such as 4x USB 3.0, 6x RS232/Serial, 2x Gigabit LAN ports, VGA, DVI-D and HDMI video connectors and audio in/out. LPC-700F fanless computer comes standard with a 128-GB solid state drive (SSD).Stealth.com888-783-2584; www.stealth.com

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C O N T R O L E X C L U S I V E


Future-Proo�ng the DCS

“It will have a new name that re�ects this new technology and new capabil-ities,” says Mary Beth Connolly, vice president of marketing for Invensys’ systems business. “But we want to bal-ance the ‘newness’ with the sense that this is really the next step in the evolu-tion of the I/A Series DCS. We prefer to call it a modern control system, one that extends the life of our customers’ investments, essentially future -proof-ing their technology.”

Grant LeSueur, director of product management, and one of the fathers of the Invensys enterprise control system, InFusion, adds, “This concept is an extension of our ‘con-tinuously current’ philosophy. The modern control system does not require customers to replace everything they have on a regular cycle, but lets them continue to wring as much value as possible from existing technology while leveraging the emergence of our modern control and safety systems.”

One of the system’s beta testers, Michael McKenzie of BP in Brisbane, Australia, agrees. “The decision to upgrade with Invensys was made for a few reasons. The initial driver was that we were facing a substantial obsolescence issue and we had ranked this issue as a signi�cant risk to on-going op-erations,” he says. “After initial review, we realized that we needed to upgrade the vast majority of our DCS, but like most sites, we didn’t have the luxury of a site-wide shutdown to make a full change possible. We needed a solution that would allow us to upgrade components we needed to, with-out sacri�cing functionality or usability for our operators. That was the main reason for moving ahead with Invensys.”

ModernLe Sueur says, “In a nutshell, we use a combination of new in-novation and existing technology to deliver a modern system that’s �exible and easy to use, while at the same time eliminat-ing constraints that would prevent the system from being im-proved, updated or built upon. This control offering features object-oriented architecture, a completely new visualization offering, new, larger and more capable controllers, a strong

virtualization offering and new virtual controllers, device integration, our In-telligent Marshalling universal I/O, and �eld device management.”

McKenzie points to this last as a key feature that BP has already used heavily: “We use the Invensys con-trol-room side software as an of�ine con�guration tool for DCS, Founda-tion �eldbus and HART. This gives us integrated support for Foundation �eldbus. In our recent maintenance,

we moved all temperature inputs from thermocouple input cards in the �eld to Foundation �eldbus, and set up monitor-ing of the health of the instruments without the need for an instrument tech to do anything more than plug in the ther-mocouples to the �eldbus devices.”

Le Sueur explains, “BP used our control-room side software for of�ine con�guration because it provided a centralized con-�guration repository, even though in some cases the control con�gurations were being loaded into much older systems. However, our control-room side software can be used online too. Because BP was operating an older system in some areas, the software was used to centrally manage the entire system, but exported to the older portions of the system until they could be upgraded. With the new system, these older portions of the control system can be managed online as well.”

The system is based on a focused, simple, easy-to-understand design that ensures no single piece of hardware or software can negatively affect the operator’s ability to control the plant. “In effect,” Le Sueur said, “we’ve designed a zero single point of failure. The design goes beyond a pure redundant backup phi-losophy. We’ve instituted 1-n failure mode, which allows the system to tolerate multiple concurrent failures before the per-formance of the plant even begins to degrade.”

Future-Proof “Having a set of clear layers within the system that are built on standard interfaces allows our customers to mix and match technology and software versions, and gives them the ability to adopt new innovation and technologies, while

Over the past six months, Invensys executives have given the editors of Control some advance looks into the

as-yet-unreleased new iteration of the I/A Series DCS. We have had a chance to look under the hood, kick the

tires and talk to the beta testers. We have seen a redesign that is an evolution of the I/A Series system, one

that includes several new features and is built on other existing technology that has new capabilities.

Invensys used a combination of new

innovation and existing technology

to deliver a modern system, while

eliminating constraints that would

prevent the system from being

updated or built upon.

CT1308_61_62_Exclusive.indd 61 7/30/13 12:44 PM

C O N T R O L E X C L U S I V E


keeping the plant running,” Connolly says. “This also gives them the ability to adapt to changing compliance, regula-tory and other operating or production standards, and allows them to increase or change the power of the system with-out major distruptions of production.”

As result, Invensys can update the control room side of the system based on “Internet time,” the rapidly chang-ing cycle of hardware and software updates in the IT world, while continuing to update the process-connected compo-nents based on “plant time.”

“Here’s the thing,” Le Sueur says, “The value of a control system is diminished if the cost of implementing it is pro-hibitive. Users and customers don’t see the point of a new system if it can’t be easily installed, and if it can’t make life easier for operators, systems engineers and technicians.”

Does McKenzie agree? “In short, yes. The new evolution of I/A allows for much easier upgrade of all components and will ensure that we can keep our system well away from ob-solescence, so that we’re not required to perform large scale upgrades as we’re doing now. The movement of the new sys-tem to Windows 7 and Server 2008 R2 will also ensure that the operating systems remain supported by Microsoft, and security patches remain available.”

Beyond Cybersecurity to Business ContinuityLe Sueur says, “Our clients are moving beyond cybersecu-rity to focus on business continuity. As we deliver new capa-bilities in these areas, it’s vital that our customers are able to apply them! BP perfectly demonstrates the system’s unique ability to provide new cybersecurity hardening and plant de-sign for engineers, management and operators, a new virtu-alization offering for control engineers, new mesh network capabilities, wired and wireless, for management and engi-neers, and integrated control and safety for the plant.”

Le Sueur adds, “We’ve created an Instrument Manage-ment Suite including Field Device Manager for operators, engineers and maintenance people, and a situational aware-ness library and a new visualization offering for operators, and we’ve provided a new tool, based on the SAMA docu-mentation standard, we call ‘Dynamic SAMA’ for risk re-duction and troubleshooting for operators and engineers.”

Evolution, Not Revolution“Our customers don’t want a revolution when it comes to their control and safety systems,” says Gary Freburger, president of Invensys control systems group. “What they’re focused on is re-liability, performance, safety and security. They want their sys-tems to work and be dependable for years to come. The I/A Series system is future-proof. What makes our system unique is

that it won’t ever be outdated.”He adds, “Our vision for the future

of industrial automation begins with a modern control system, one that ele-vates plant personnel with greater situ-ational awareness; one that simpli�es effort and predictive guidance as they ful�ll their roles; one that can be easily and cost-effectively implemented, con-�gured and maintained throughout a

plant’s lifecycle; one that is secure and that can evolve and ex-pand. The evolution of the I/A Series system achieves this vision by modernizing the control room, and delivering more robust safety and security systems and next-gen simulation and visual-ization tools that enable new predictive capabilities and higher levels of real-time performance improvement.”

He went on, “As companies confront new problems and issues like the talent crisis, globalization and the emergence of a real-time value chain, they realize they must modern-ize, manage and control their plants with new urgency. They need all of their components to work as one system, especially as they’re faced with a newer, differently skilled workforce. They also want to extend the life of the process-connected components, while being able to change out the control-room elements. Business continuity is a growing is-sue at every level of our clients’ organizations. All companies need to be equipped to handle cybersecurity vulnerabilities, unpredictable natural disasters and unplanned emergencies. That’s exactly what our modern control system does.”

Freburger thinks there is more in this evolution than just upgrades for Invensys’ existing customer base. “We believe at least three elements of the system, and probably more, will be attractive to prospective customers, who today use com-peting systems,” he says.

“First, this is a truly modern system built on a mix of new technologies and existing technologies with new capabili-ties. It will enable plant personnel on many levels of the organization to contribute to the business success of the company. Because it remains modern, it future-proofs their control and safety investment.

“Second, the system leverages a unique capability that our competitors can’t offer: the strength of our software portfolio which provides the best of truly integrated capabilities for vi-sualization, HMI, simulation, asset management and more.

“Third, our reputation for client commitment and service is unique and unmatched and it will remain so, across the system’s lifecycle,” he concludes.

Invensys expects to release the new I/A Series DCS at its global Foxboro and Triconex client conference in San An-tonio, Texas, the week of September 10. For more informa-tion, please visit http://ourevents.invensys.com/FoxboroTri-conexClientConf/pages/home.aspx.

Users and customers don’t see the

point of a new system if it can’t be

easily installed, and if it can’t make

life easier for operators, systems

engineers and technicians.

CT1308_61_62_Exclusive.indd 62 7/30/13 12:46 PM

C O N T R O L T A L K

GREG MCMILLANSTAN WEINER, PEcontrol ta [email protected] t


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 [email protected].

Communication for the Ages

Stan: Communication is increasingly the bot-tleneck for better performance by the individ-ual, project and plant. The days of the engineer being able to hole up in a cubicle with vendor catalogs and spec sheets are long gone. For the �rst time we have four generations in the work place at the same time, each with different cul-tures, skills and expectations.

Greg: Jim Cahill, Emerson’s social media manager, introduced me to Steve Elwart, di-rector of Systems Engineering at Ergon Refin-ing Inc. Steve has an extraordinary combina-tion of practical technical and communication knowledge.

Stan: What is the generational history at Ergon Refining?

Steve: We are five to 10 years behind in the generational turnover seen in the refining in-dustry, but we’ve seen explosive growth in the company with a corresponding increase in staffing requirements. We don’t hire mid-ca-reer. We hire co-ops and graduates. They are the Millennial Generation (18 to 30 years old). Some of their mothers are younger than I am. There are big differences in lifestyles and ver-naculars. This was the big motivation for me getting an advanced degree in communication.

Stan: What are some of the distinguishing characteristics of the co-ops and new hires?

Steve: Multi-tasking is a natural behavior. They are not seeing the value of relationships. They are not as likely to initiate extensive one-on-one conversations, leaving the more experi-enced wondering why they don’t come to seek help. Communication is concise. They tend not to have sense of reasonableness of scale. For ex-ample, when they see a digital temperature they

get hung up on a hundredth of a degree, not re-alizing the sensor was only good to two degrees.

Kids raised by helicopter parents may think they are always winners, expecting praise for everything they do. Quick positive feedback is expected. In one Duke University study (http://tinyurl.com/cqjy5qm), work received was im-mediately filed without comment, acknowl-edged or shredded. The reaction for the work being filed was about as negative as for the work being shredded.

The “here and now” is most important. When Millennials or the Next Generation asks what time it is, they don’t want to know how to build a watch. The expectation is achievement and zero risk.

Creativity is less due to the need for immedi-acy and zero risk, and the attitude, “If you can’t Google it, it is not real.” Decisions are “three bids and buy,” foregoing the development of re-lationships and a more in-depth understanding.

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C O N T R O L T A L K


Everything is viewed as free and open source. You don’t need to give credit or reference. These things can all be read as rudeness, but what is rude to one generation is not to another.

Greg: How do you make email more effective?

Steve: I start the email with the moti-vating lead followed by the request. For more complex issues, especially where there is a misunderstanding, disagree-ment or mistake, verbal one-on-one in-person conversations, but if necessary by phone, accomplish much more.

Stan: How do you see the grade level progression of the various generations?

Steve: Now 38- to 42-year-olds may have a younger boss. Gen Y is passing up Gen X in promotions. The Harvard Business Review blog, “Don’t Dismiss Your Gen X Talent,” indicates that while Gen X talent is the key to the success of most companies, it is being leapfrogged by Gen Y and blocked by Boomers delaying retirement.

Greg: Maybe Gen Y’s greater interest in quick results, sustained effort, flexibil-ity, mobility and the desire to move up is leading to more promotions. What are some of the key characteristics of Gen X that companies need to recognize?

Steve: Xers are more interested in craft and have less loyalty to the com-pany than Boomers. When a web guy was asked to do databases, he said no because it was not his thing. Gen X saw Boomers get RIFed (reduction in force) and feel a sense of betrayal. Gen X will work like a dog if the work is interest-ing, but at the same time, it is more concerned about a balance between work and life. Xers may turn down a new position offering 10% more in pay if there is significantly less free time. Gen X may not be willing to move to a new location. Xers value relationships

more and take a longer view than Mil-lennials.

Greg: What are the characteristics of Boomers like you and me?

Steve: Boomers have more loyalty to the company and are willing to assume many different roles. For example, one boom-er’s career progression was from chemist to shift foreman to plant manager to vice president of HR to safety program leader. Boomers and older Xers are “change agents.” They are not risk-adverse. They understand there is risk with anything, and your job is to mitigate risk rather than think you can achieve zero risk. They re-alize that being right eight out of 10 times is better than three out of three.

Stan: How do we help the Millennials get the skills and knowledge they need, given that they’re best positioned for a leadership role and to take advantage of new technology?

Steve: Boomers and Xers need to take the initiative. They need to start the conversations and communicate effectively. They need to provide the knowledge and encourage the behav-ior needed to go beyond the immediate and below the surface. They must cre-ate and foster relationships with suppli-ers of hardware, software and services. Expertise captured in software is not as much the total solution as envisioned. The potential in the software can go largely untapped. Boomers and Xers must show that relationships inside and outside the plant are key.

Greg: Software has advanced consid-erably as a tool to help get the most out of an application, and prevent potential problems as discussed in June’s “Control Talk” column, “MPC Route to Success (http://tinyurl.com/kemt4j4). The impor-tant realization here is that there is still great value in the expertise of the people employing the tool. So, what can IT do to help?

Steve: Unfortunately the first reaction by IT to new technology is “no.” As a result, CD, DVD, Internet access, cell phones, smart phones, tablets and the cloud were all initially banned. Even-tually, technology wins, but progress is delayed. There is more technology at home than in the work place, and this can frustrate younger workers. Millen-nials will buy the latest and make an end run around IT. This was one rea-son BYOD (bring your own device) has made such inroads into the workplace.

People want to carry their stuff with them and stay connected. People get upset if a text or email is not answered within an hour no matter what the time. People can be working on fun stuff 24/7. The line between work and pleasure is getting blurred. The only way to catch up with some of the younger workers is by LinkedIn and Facebook. IT should man-age and leverage rather than ban new technologies.

Stan: What are the best ways to com-municate knowledge?

Steve: Boomers are accustomed to in-struction manuals. Millennials prefer short five- to 10- minute videos. Each video should be limited to three con-cepts. The videos can snap together like Legos. For presentations, you pull in the pieces. The videos don’t need to be professionally done. A video can be shot in a kitchen with a dog wander-ing in and out. They can be as raw as Gonzo Journalism.

Pictures provide an analogy and generate interest, but can be too capti-vating, not releasing the viewer to the subsequent content. If the presentation is too cool, the audience may be more interested in the presentation technol-ogy than the message. It is better to go simple. [For a longer version of this conversa-tion and a list of the “Top 10 Emails You Do Not Want from Your Boss,” please go to www.controlglobal.com/0813ControlTalk.html.]

CT1308_63_64_ControlTalk.indd 64 7/29/13 4:56 PM

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Procomsol . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

ProSoft Technologies . . . . . . . . . . . . . . . . . . 45

RC Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Red Lion Controls . . . . . . . . . . . . . . . . . . . . . 38

Rockwell Automation . . . . . . . . . . . . . . . . . . 33

Siemens Energy & Automation . . . . . . . . . . . 3

Siemens PA . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Vega Americas . . . . . . . . . . . . . . . . . . . . . . . . 42

Wago . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Winsted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Yokogawa . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

C L A S S I F I E D SA D I N D E X

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SCS_1111_Classified.indd 1 11/11/11 9:53 AMDry run protectionThe PMP-25 Pump Load Control guards against dry run-ning, cavitation and overload. It monitors true pump power for maximum sensitivity. The display shows pump load, trip points and delays. Its NEMA 4X enclosure is small enough to � t on Size 1 starters and can be door-, panel- or wall-mounted. Load Controls Inc., (888) 600-3247, www.loadcontrols.com.

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C O N T R O L R E P O R T

JIM MONTAGUE E XECUT IVE EDITOR

[email protected] t


Chevron Manages BMA Upgrade Lifecycle

The journey is often more important than the destination, and this is especially true

for lifecycle management in blending and movement automation (BMA) applications.

“Overall, process control system lifecycle management seeks to provide the greatest

ROI over the life of the system,” says Paul Singh, Ph.D., global blending and oil move-

ment specialist at Chevron Corp. (www.chev-ron.com). Singh presented “Control System Lifecycle Management and BMA Upgrades at Chevron” in June at Honeywell Users Group 2013 (www.honeywellprocess.com).

Singh reports Chevron’s BMA applications at its re�neries strive for standardized, on-line, closed-loop, real-time optimization. This is achieved with multi-blend optimization (MBO) scheduling and planning at the enter-prise level, which downloads objectives and recipes to blend property controls (BPCs) at the operator stations. Planners �gure out optimum processes to perform and then run them on the re�nery’s DCS and its blend ratio controls (BRCs), related instruments and analyzers.

Chevron’s DCS and blending applications process 50,000 bpd to 800,000 bpd and use vin-tage and new equipment, including:

• BRC v44.3 through Experion Blend Con-trol (EBC) and BMA 320.7 for BRC;

• BPC v54.0 through OpenBPC BMA 320.7 for BPC and optimization;

• SDM v44.2 through Inventory Monitor BMA 320.7 for inventory monitoring; and

• Knock engines through Raman spectro-graphic analyzers from Process Systems Inc.

Singh adds that blending optimization at Chevron since 2005 has been a continuous process aided by several programs, including: multi-product, multi-period, non-linear opti-mization implementation and upgrades; and migration from NIR and other online analyz-ers to Raman modeling and online analyzers.

“We gained a lot of bene�ts with the Raman analyzers, which are easier to maintain. We’ve been using them for about 32 months, includ-ing between blends, and had virtually no down-time,” says Singh. “So what’s the motivation for all these upgrades? Well, our �rst priority is safety and the environment. We also want to

use the same systems, and make products that are at least 95% on-spec, which we’ve achieved because we’re usually 98% on-spec.

“We also found that, as we improve safety and environmental performance, pro�t im-proves as well. For example, the difference be-tween the top quarter of performers and the bottom quarter can be more than $1.50 to $2 per barrel, while a performance variation of just 10 cents can add up to about $5 million per year for a typical re�nery. And you can lose $500,000 in one day of doing a process wrong, or gain it if you do what’s right.”

Singh adds that Chevron’s applications must be as nimble as possible. “Large re�neries can’t make blends and analyze them later,” he ex-plains. “We need to be flexible to reduce down-time between blends. We have one re�nery with barely a half hour between blends.

“Gone are the days when we made the same product day in and day out. Now re�neries make 50 to 80 products, and they must meet just as many specs. So, we use predictive prop-erties and account for opt-ins, such as adding ethanol. In the future, we’ll see even more op-erational complexity, as well as increasing regu-lations of conventional fuels and reformulated blendstock for oxygenate blending (RBOB) now; E15, E85 and biofuels on the horizon and tighter rules for data capture and retention.”

Fortunately, Chevron is becoming even more pro�cient in its lifecycle and BMA prac-tices. For example, Singh reports it completed a BMA320 upgrade about three years ago by implementing redundant C300 controllers on multiple blenders and adding EBCs and Open-BPCs. “We completed our mogas blender cutover in just 16 hours,” adds Singh. “This up-grade produced signi�cant economic bene�ts, including increasing uptime and decreasing deviation from maximum profit by 50%.”

We completed our

mogas blender

cutover in just

16 hours. This

increased uptime

and decreased

deviation from

maximum profit

by 50%.

CT1308_66_ControlReport.indd 66 7/29/13 4:52 PM

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can be sure your system will shut down when required, and keep running safely when a componentfails. Electronic marshalling in DeltaV SIS gives you the flexibility to implement safety functions easily,safely, while eliminating time consuming tasks, re-work and re-design headaches associated withtraditional marshalling. That’s modern. That’s peace of mind. Find out more at: www.DeltaVSIS.com

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