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Contents A4 Using diagnostic functions to improve system safety Some diagnostic capabilities are built into smart instruments, while others are designed into a process.
A10 Specifying industrial enclosures Ask these 10 questions before specifying or modifying industrial enclosures to optimize your operation.
A4
A14 Ensuring effective decision support in a crisis Machines can support humans when facing a stressful situation. Using a standards-based approach can reduce the likelihood of a problem escalating.
A20 Automation products A10
C OMMENT Of safety, protection, and crisis management
I
Jack Smith Editor
f you think about it, safety is implied throughout this entire issue of AppliedAutomation— safety for processes, equipment, and from disasters. In the cover story, the author addresses safety issues by advocating diagnostics. He writes: “Among the best practices and technologies available today are diagnostic functions built into smart field instruments that are capable of identifying covert failures as they happen.” Using diagnostic functions to improve system safety, the author explains how to make temperature sensors smarter and safer, and spot tricky thermocouple failures and leaking rupture disks. In addition, he discusses adding diagnostics to the physical protection layer. In manufacturing, so much emphasis is placed on sophisticated equipment that it’s easy to overlook the enclosures in which this equipment is mounted. The second article asks 10 questions that should be considered before specifying or modifying industrial enclosures.
“Industrial enclosures are essential for housing and protecting wiring and cables, electrical equipment, and machinery controls. They’re also effective protection against radio and electromagnetic interference and other uncontrollable environmental elements such as direct sunlight,” the author writes. The third article presents a topic that isn’t often discussed, but should be: crisis management. And it begs the question: What role should humans play in avoiding disasters? The author advocates a standards-based approach. He writes: “Arguably, the most advanced decision support systems may be found in the aircraft industry. But even these can go wrong sometimes, and it comes back to the skills and training of humans to avoid potential disasters, aided by a standards-based approach.” And as the author concludes: “So, maybe there is a balance between humans and machines that can ultimately make all of us safer. Let’s try to find it.”
ON THE COVER Online, non-intrusive corrosion/erosion monitors provide a continuous measurement of wall thickness. Watching the rate of metal loss over time can help predict time to failure. Courtesy: Emerson Automation Solutions
Applied Automation June 2017
•
A3
C o v e r s t o ry
Using diagnostic functions to improve system safety some diagnostic capabilities are built into smart instruments, while others are designed into a process. Making temperature sensors smarter and safer
By Mark Menezes Emerson Automation Solutions
E
ffective process automation systems depend on many types of field devices, controllers, and networks to provide basic control functions along with safety-instrumented functions. Unfortunately, all these systems can fail in a variety of ways, allowing problems to develop or escalate if not countered quickly and effectively. Users cannot assume failures simply don’t happen, so they must make appropriate plans for how to deal with these possibilities. Among the best practices and technologies available today are diagnostic functions built into smart field instruments that are capable of identifying covert failures as they happen. This improves safety, and also can predict failures before they happen, improving availability. In other cases, a plant may design its own diagnostic, adding devices such as pressure relief valves, rupture disks, and corrosion/erosion monitors in critical places to watch for larger things going wrong. Let’s consider all three approaches.
Many temperature measurement applications suffer from electrical noise, spiking, and signal dropouts. Noise can come from radios, motors, and lightning. Other problems can be caused by wiring problems, mechanical shock, or vibration. Temperature measurements are more susceptible than most other field instruments because the sensors—resistance temperature detectors (RTDs) and thermocouples (TCs)—provide very low-amplitude signals that must then be processed and amplified by the transmitter before being sent to the logic solver. For example, the signal strength of a TC is about 1/400th the strength of the 4-20 mA signal provided by the transmitter. For this reason, best practices suggest locating the transmitter as close to the sensor as possible, minimizing the length of the lead wire (see Figure 1). Even with close coupling between sensor and transmitter, noise or dropouts still can be problematic in some installations, so most users apply damping to suppress spikes and dropouts. While damping improves stability, it slows down the response of the transmitter to rapid changes in process temperature. Because redundant sensors typically are exposed to the same
Figure 1: Temperature transmitters provide critical signal processing functions for temperature sensors along with diagnostics, and come in many shapes and sizes to satisfy any application. As shown here, the Rosemount 248 temperature transmitter is available in a variety of form factors, both wired and wireless. All graphics courtesy: Emerson Automation Solutions
A4 • June 2017
Applied Automation
electrical and physical conditions, most users will set the same damping for all, so this slow response is a common cause. A better approach is to use a signal validation capability built into a transmitter as part of its signal processing and diagnostic functions. The thermal inertia of a temperature sensor inside a thermowell makes extremely fast temperature changes, such as from 200°C (392°F) to 400°C (752°F) in half a second, physically impossible. Even if the transmitter sees such an instantaneous and unrealistic shift between successive readings, it can reasonably assume the change is a spike (or dropout if the change is moving lower), and simply repeat the last good measurement. This approach provides stability without damping or slow response, but it should not be applied where the measurement can legitimately see fast full-scale excursions. Although a sensor can be damaged by a single extreme mechanical shock, most failures are caused by ongoing vibration, loose or corroding connections, or chemical attack. These weaken the sensor and wiring, causing the frequency of spikes and dropouts to increase over time. The transmitter can detect and trend this increasing frequency and predict impending failure, alerting maintenance early enough to take action and prevent total signal loss. Signal validation digs more deeply into the condition of the sensor itself, which can improve both safety and availability of temperature measurements.
Spotting tricky TC failures Here’s a typical application where validation can predict sensor failure. In hydrocarbon processing applications, TCs are often preferred over RTDs when fast response or high temperatures (greater than 600°C or 1,112°F) are involved. TCs are typically more physically robust than RTDs, but they can fail in a way not readily apparent. The junction at the tip where the dissimilar wires are joined is the measuring point, but if physical shock or vibration breaks down the insulation and the two wires form a contact (short circuit) somewhere else, the new contact point becomes the measuring point, wherever it might be. Because this new junction is invariably farther from the hot process, in most hydrocarbon applications, a damaged TC will read low, although the opposite is true in cryogenic applications. Most processes are dangerous when they run too hot, so a low reading can create a safety risk. Because one physical shock could damage multiple TCs designed to be redundant, especially when they are installed close to each other or the lead wires are routed in the same bundle, this problem can manifest itself as a common cause. Modern smart temperature transmitters are configurable to accept either RTD or TC inputs. When configured for a TC, they use their voltage circuitry to determine tem-
Figure 2: Users need to monitor the space between the PRV and the rupture disc to ensure no build-up of back-pressure. Use of a wireless pressure gauge minimizes lifecycle cost.
perature. But transmitters also can use their resistance measuring circuitry, which would be used with an RTD, to monitor the resistance of the TC. While resistance of the TC cannot be used to determine temperature, it does help to detect and predict failures. Changes in TC circuit resistance can suggest several things. If resistance goes to infinity, the circuit is open. If resistance decreases from its normal level, there is probably a short circuit. If resistance increases, the wire or termination is probably corroding. These changes may be immediate, but more often they’re gradual, so measuring and trending resistance changes can be used to predict failure and improve availability.
Adding diagnostics to the physical protection layer If both the basic process control system (BPCS) and safety instrumented system (SIS) fail, a plant relies on physical protection to reduce the consequences of an incident to employees and the community. As with the BPCS and SIS, for each hazard the user must identify and quantify the risk of a physical protection failure, and must apply best practices and technology to minimize the possibility of it happening. For example, in the case of an over-pressure event, most hydrocarbon and chemical processing plants rely on pressure relief devices for physical protection, such
Applied Automation June 2017 • A5
C o v e r s t o ry New instruments combining acousas pressure relief valves (PRVs) and Users in hydrocarbon tic and temperature sensors capable rupture discs. of capturing telltale sounds from malThe PRV is set to open when the and chemical plants often functioning valves can identify direct process pressure approaches the releases as well as ongoing leaks safe limits of the process equipfrom incomplete valve seating. Such ment or piping, with the excess install a rupture disc just devices can be wired, or can compressure typically vented to the municate via WirelessHART, in either flare. It has the highest pressure case, sending data to the BPCS. setting and should only work if all upstream of the PRV. PRVs often “simmer,” releasing small the other safety instrumented funcamounts of product, before pressure tions fail. Excess flaring causes reaches the full release point. An acoustic instrument can environmental impacts, usually resulting in penalties. detect simmering, providing operators with another indicaAlthough the PRV will close itself after the pressure tion of a possible developing incident, and giving them returns to a safe condition, it is common for dirt in the time to call for maintenance, or to make a process adjustprocess fluid to prevent it from fully re-seating, leading ment and avoid the release entirely. to small, ongoing leaks. These leaks are often difficult to detect, yet over time can cause significant process loss Spotting leaking rupture disks and environmental impact. Because PRVs are mechanical devices, there are no electronic elements capable of Users in hydrocarbon and chemical plants often install providing diagnostic functions. But as smart transmitters a rupture disc just upstream of the PRV. In the case of a can improve performance of temperature sensors, new toxic or hazardous fluid, the rupture disc provides a more devices can add diagnostic capabilities to these simple positive barrier and layer of protection to minimize the risk but critical physical protection devices. of PRV leakage. Where the process contains a corrosive fluid, only the rupture disc is normally wetted. This means the plant often can avoid having to install an expensive PRV made from a corrosion-resistant material. Only the rupture disc has to be made from an exotic alloy. Unfortunately, this approach creates another risk (see Figure 2). If a small pinhole leak appears in the rupture disc, any leaked fluid will be trapped between the rupture disc and the PRV. This creates a backpressure on the outside of the disk, so instead of bursting at the design pressure, the disc will not burst until the rising process pressure can overcome the disk and the pressure between the disk and valve. Under these conditions, the burst pressure may exceed the safe design limit of the process, risking an uncontrolled and potentially catastrophic release into the environment. To prevent this, the American Society of Mechanical Engineers (ASME) recommends installing a pressure gauge or instrument between the rupture disc and the PRV to monitor the pressure in the space between the devices. This can be a wired device, but given that these are typically located in physically inaccessible, hazardous, or toxic environments, such locations are particularly well suited to wireless devices.
Online corrosion/erosion monitoring
Figure 3: Online, non-intrusive corrosion/erosion monitors provide a continuous measurement of wall thickness. Watching the rate of metal loss over time can help predict time to failure.
A6 • June 2017
Applied Automation
Users in hydrocarbon processing industries understand where their processes are corrosive or erosive. Engineers carefully design piping and other mechanical systems to last at least until the next scheduled outage. In the meantime, expected corrosion/erosion “hotspots”—for example, on the outside elbows of pipes—are manually inspected, annually or more often. Unfortunately, the rate of corrosion or erosion on a
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HART diagnostics from safety systems
T
he control and monitoring systems in many control system (DCS). The hardwired link is usually plants only use the 4-20 mA analog signal from Modbus or Ethernet. their HART devices, missing out on the value The wireless adapter shown in Figure 4 has been provided by the HART information. This is particularly evaluated by Exida as a component and has an true for smart instruments and valve actuators used FMEDA report available online. It does not affect the with safety systems, which send analog loop, and therefore has their analog signal to a dedia minimal effect on SIS loop calcated logic solver, meaning valuculations. able process variables and conA limitation for using wireless dition diagnostics never make it adapters in SIS loops has been back to the control system. the availability of different types But there is a solution, as of certifications for the device, many users can access the which in the past was only Figure 4: Wireless adapters, such as the HART information in their safety intrinsically safe (IS). The wireTHUM from Emerson, can send HART data devices by outfitting their existless adapter in Figure 4 now via a wireless network, and the options ing sensors and actuators with is rated for use in hazardous for users to deploy them in hazardous wireless adapters. These adaptareas in North America where locations grow as the availability of hazers connect to HART devices the explosion-proof method of ardous ratings increases. and communicate variables and protection is used. The adapter diagnostics via a WirelessHART connects directly onto HART network. The adapter converts a wired HART input devices via a threaded conduit, creating a rated to a WirelessHART output, and this wireless signal is assembly. This new explosion-proof certification is sent to a gateway through a WirelessHART network. especially useful in SIS applications where it can be The gateway is hardwired to the target system, such used to access stranded variables and diagnostic as an asset management system or a distributed data from safety systems.
given asset is not easy to predict and can vary widely day-to-day due to changes in flowrate, fluid composition, temperature, pressure, use of corrosion inhibitors, and other conditions. The risk to a user is that a faster-thanexpected rate of metal loss can lead to a catastrophic loss of containment over a relatively short period of time, even days or weeks. A better approach than periodic manual inspection is continuous online monitoring. Available in either wired or wireless versions, online sensors attached to the outside of the pipe or vessel use ultrasonic technology to measure metal thickness continuously. Historical data determines the rate of metal loss and expected time to failure. While a small number of corrosion/erosion sensors provide immediate safety and labor benefits from reduced need for manual inspection of hot spots, the real payback comes when a user combines a network of wall thickness sensors with other sensors to measure and predict fluid corrosion/erosion, including intrusive coupon-based sensors, temperature (intrusive or clampon), pH, flow, pressure, and others (see Figure 3). Comprehensive, plant-wide visibility and corrosion/erosion prediction allows users to operate more aggressively without increased risk:
A8 • June 2017
Applied Automation
Extends time between shutdown intervals Reduces use of corrosion-inhibiting chemicals Increases capability to use “opportunity crudes,� lowercost but more highly corrosive/erosive feedstocks. Diagnostic functions, whether they are built into a smart device, or something designed within a given plant, help detect problems early while they are still easy to manage. Discovering that a TC is quietly corroding before there is a loss of operation, a PRV is headed toward failure before a more catastrophic incident, or a pipe is about to start leaking, can prevent downtime, avoid environmental damage, and prevent fatalities. There are many ways to put these measures into place, provided a plant is willing to make the critical first steps. Mark Menezes manages the Emerson Automation Solutions measurement business in Canada, including pressure, temperature, level, flow, and corrosion. He has a chemical engineering degree from the University of Toronto, with an MBA from York-Schulich. Menezes has 20 years of experience with Emerson, and 27 years of experience in process automation.
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I n d u s t r Ia l e n c l o s u r e s
Specifying industrial enclosures ask these 10 questions before specifying or modifying industrial enclosures to optimize your operation. By Steve Sullivan Rittal Corporation
M
achinery and equipment are the life-blood of any industrial or manufacturing operation. But these assets run because of the industrial enclosures deployed throughout the facility to house and protect the operational controls that make them function. Industrial enclosures are essential for housing and protecting wiring and cables, electrical equipment, machinery controls, and more. They’re also effective protection against radio and electromagnetic interference and other
uncontrollable environmental elements such as direct sunlight and heavy rain. For these reasons, plant managers in oil and gas, material handling and packaging, and food and beverage industries rely on the controlled environment of enclosures to protect their equipment from the elements and keep their operations running smoothly.
10 things to know before specifying or modifying enclosures Because of the critical role that industrial enclosures play across so many industries and in so many environments, it’s important to specify and modify enclosures for specific environments and controls. A one-size-fits-all approach will not work and could jeopardize important equipment. Sometimes, knowing what questions to ask before specifying and/or modifying industrial enclosures will save time and money, but more importantly, will improve protection and ensure uptime. Following are 10 critical questions for your specifying team to consider, as well as your suppliers for industrial enclosures or enclosure systems.
1.
What is the application? It’s crucial to map out the function the enclosure or enclosure system will serve in your facility. For example, if the enclosure serves as an electrical drive house, it will be important to know if it should be modified with multiple doors, a power disconnect, or multiple panels. You also may want to know whether the enclosure needs to be populated with busbar power or other accessories (see Figure 1)
2.
Into what type of environment will the enclosure be going? Using NEMA and UL ratings ensures that the enclosure will stand up to the contaminants, moisture, and particulates of indoor and outdoor environments. For example, food and beverage environments will require frequent wash downs with harsh chemicals, while oil and gas operations may require protection from salt water (see Figure 2). Another consideration is the extremes of hot, cold, and humidity to which enclosures and systems will be exposed. Figure 1: The use of busbar for power management can improve internal layout design to maximize space and reduce costs. All graphics courtesy: Rittal Corporation
A10 • June 2017
Applied Automation
Figure 2: Stainless steel enclosures are optimal for harsh environments such as food and beverage that use harsh chemicals for frequent wash downs.
3. What are the space restrictions outside the
enclosure? Facility managers want to fit the maximum amount of equipment in the smallest amount of space. Space factors to consider include where the machinery will be located, aisle width, ease of access for maintenance, distance to ceilings and walls, and line of sight. Modular enclosures, for example, can be bayed in a variety of configurations to meet space challenges (see Figure 3).
4.
What are the temperature conditions inside and outside of the enclosure? High temperatures can cause costly equipment failures. As the use of electronics in controls grows, enclosure cooling becomes increasingly critical. When more than 35% of enclosure applications require cooling, traditional cooling methods such as heat sinks and fans often are not sufficient. More robust solutions such as chillers coupled with air-to-water heat exchangers should then be considered.
5.
What ergonomic requirements must be met for users to interface with the enclosure? The swing of the door, location of the mounting panel, sidewalls, LED lighting, and a variety of modifications must be considered based on the space and use of the enclosure (see Figure 4).
6.
What material is the enclosure made of? The choice of stainless steel or carbon steel affects both the rating and cost of an enclosure. Depending on regula-
Figure 3: Wall-mount enclosures protect smaller control units and HDMI interfaces to ensure longer life.
tions and environment, stainless steel might be required or may not provide the necessary ROI to justify it against the lower cost of carbon steel enclosures.
7.
How critical are enclosure aesthetics to the facility? No longer an after-thought, the appearance and layout of your facility (especially on the production floor) can affect the critical work being performed for your customers. By baying enclosures in neat, uniform rows, with branded badges, facilities showcase a level of cleanliness and safety that improves customer and employee perception.
Facility managers want to fit the maximum amount of equipment in the smallest amount of space.
8.
How will cable be brought into and managed in the enclosure? It’s helpful to know in advance whether a modular or uni-body enclosure system works best for your operation. Knowing this will let you know whether cutouts for cable entry will be done while the enclosure is standing or on its back, or whether they can be done on an individual enclosure panel or part at a workbench. In the latter
Applied Automation June 2017 • A11
I n d u s t r Ia l e n c l o s u r e s
Figure 4: Proper lighting makes for a safer and more efficient working environment.
case, the user will need to know whether the enclosure should be modified for cable entry from the roof, sides, or base—or even all sides.
9.
How difficult will it be to service the enclosure and the equipment inside? You’ll need to know if the enclosure’s design allows the user to easily and safely service and conduct repairs. For example, consider the enclosure’s construction for things like removing and replacing doors and panels, ease of access and movement in the shop or plant, inside access for wiring or other necessary work, and ease of installing accessories.
10.
What are the internal design requirements for the enclosure? Knowing these requirements in advance will help you modify enclosures for the kind of equipment to be installed. Pre-installation modifications can account for electrical equipment, electromagnetic compatibility or shock and vibration considerations, busbar power management, and cutouts for fans or other climate control systems (see Figure 5).
A12 • June 2017
Applied Automation
Figure 5: Busbar power management delivers a “plug and play” solution for power accessories, routing, and design.
To be well-informed is to be well-armed Enclosures are not just metal boxes. They are carefully controlled environments that ensure your operations run day and night. The more thought that designers, specifiers, and managers put into choosing the right enclosure for their needs, the quicker the ROI will be in the uptime of their equipment. When it comes to the role of industrial enclosures in planning facility layout or augmentation, sometimes the best answer starts with a few simple questions.
Steve Sullivan is the training supervisor at Rittal Corporation, where he oversees instructor-led, computer and web-based learning. He co-founded Rittal University Online and has been with Rittal for more than 20 years.
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CRISIS MANAGEMENT
Ensuring effective decision support in a crisis Machines can support humans when facing a stressful situation. Using a standardsbased approach can reduce the likelihood of a problem escalating. Dr. Maurice J. Wilkins,
build operator displays that look artistically great, but can confuse the operator in an emergency. But when configured correctly, these alarms and displays can perator error help rather than confuse. during periUnfortunately, we often ods of abnordon’t use this system intelmal operaligence to benefit the protions has cess operator. been put forOn March 23, 2005, ward as one of the causes there was an explosion in of many major recent incithe isomerization unit of dents. But before we give the BP Texas City Refinery, humans a bad rap, incident which at the time was BP’s reports suggest the problargest facility. The explolem often stems from poor sion killed 15 people and procedures, inadequate injured 170. The incident training, and the lack of centered around the rafsufficient resources. In finate splitter. many cases, with the right BP’s incident investigaskills and tools, a good tion, led by J. Mogford, operator can help avoid issued a report showing these situations. several basic procedureArguably, the most related errors, such as a advanced decision support level alarm acknowledged systems may be found in but not acted upon, a heatthe aircraft industry. But up ramp-rate that was too even these can go wrong fast, and operators trying sometimes, and it comes Figure 1: The Boeing B-17 procedure checklist became a protostart up the unit in manual back to the skills and traintype for many more to come in aviation. All graphics courtesy: when procedures indicated ing of humans to avoid Yokogawa Electric Corporation it should be in automatic. potential disasters, aided Moreover, operators turned by a standards-based on the burners before veriapproach. fying liquid was circulating. Later, we will examine how a Putting humans under stress standards-based approach may have averted this incident. Another clear example of operator overload happened Process control systems have evolved over the years on Sunday, July 24, 1994, when a lightning strike started to the point where we can measure, display, and alarm a fire on the crude distillation unit at the Texaco Milford almost anything in almost any color. We can provide many Haven refinery, which eventually led to an explosion on different alarms on the same measurement, including varithe fluid catalytic cracking unit (FCCU). Although the ous high and low values, as well as rate of change. We Yo k o g a w a E l e c t r i c Corporation
O
A14 • June 2017
Applied Automation
Figure 2: Capturing bestpractice procedures using appropriate management of change can result in significant improvements.
media put the blame on the lightning strike, the incident report stated, “These events, though significant in initiating a plant upset, were not the cause of the release and explosion that occurred five hours later. These consequences resulted from subsequent failures to manage the plant upset safely.” Luckily, although there were some serious injuries, no one was killed. Among many other things, the report cited bad alarm management, poor human-machine interface (HMI) display design, and a failure to follow procedures. For example, the report stated, “From the limited amount of alarm information relevant to the event, which was preserved from just one of the journals, it was seen that in the last 10.7 minutes before the explosion, the two operators had to recognize, acknowledge, and take appropriate action on 275 alarms. At times during the morning, operators were doing nothing but acknowledging alarms.” The report went on to say the chances of operators restoring control manually were reduced as the incident progressed due to them being overloaded by a “barrage of alarms.” There were 2,040 alarms configured, 87% of which were high priority. During the incident, the operators had to cope with alarms coming in at a rate of one every 2 to 3 seconds, which resulted in many simply being cancelled. There was no evidence that a vital highlevel alarm on the flare drum that went off 25 minutes before the explosion was ever seen. In addition, the report indicated the FCCU HMI graphics were not designed in a way to help the operators control the process. Process data was limited and color use was confusing, so important data was not highlighted. Much of what was displayed illustrated the structure of plant equipment and had no relevance to operations. Critical procedures had fallen into disuse from lack of practice and documentation.
The role of procedures These incidents show how the effective use of procedures is one of the key items in maintaining safe and reliable operations under all conditions. In fact, if configured correctly, well-planned alarms can trigger procedures in
many abnormal situations, and a well-designed HMI can bring a developing incident to the attention of an operator in a timely manner. For example, the airline industry is among the safest and most automated in the world. In fact, most modern aircraft could not fly without the use of computer guidance, yet procedures play a big part in the way aircraft are operated. Pilots need to go through many procedures before, during, and after a flight. History suggests recorded procedures were introduced by test pilots in 1935 after the crash of a B-17 Flying Fortress in Dayton, Ohio. The B-17 was the most advanced bomber at the time, but the crash almost caused the program to be abandoned due to a gust lock still being engaged at takeoff. It was said that the plane was too complicated to fly. In response, test pilots developed procedures for use during takeoff, in-flight, before landing, and after landing. Boeing eventually delivered more than 12,000 of the aircraft to the U.S. Air Corps, and they flew 1.8 million miles without a serious mishap. An example of the B-17 procedures is shown in Figure 1. Every type of aircraft from small private planes to the largest jumbo jet now use procedures for all aspects of the journey, and not following them could lead to a pilot losing his or her license, or worse. Another example of outstanding use of procedures is the now famous “Miracle on the Hudson.” Captain Chesley (Sully) Sullenberger and his crew saved U.S. Airways flight 1549 on Jan. 15, 2009, when the plane struck a flock of geese just after takeoff from La Guardia airport in New York. They landed the plane safely on the Hudson. It turned out that none of the crew had flown together before, but the procedures drilled into all airline crew enabled them to do all the necessary things by rote. In the process industries, we use standard operating procedures (SOPs) for all aspects of running a pro-
Applied Automation June 2017 • A15
Crisis management cess, under all conditions. However, some of the better operators often tweak procedures to improve them. As experienced operators are retiring with often less experienced operators replacing them, plants try to capture these tweaks to develop best-practice procedures (see Figure 2). These procedures can be run semi-automatically, where the control system runs the steps to a point where the operator must confirm it is safe to continue, or the control system runs the procedure completely automatically. The machine runs the process, but there is always a need for human oversight.
Experience counts Under normal conditions, humans operate very well, but as stress builds, people react in different ways. Some become heroes in wartime situations by giving leadership under fire, but in manufacturing we don’t expect heroism. Having several very skilled “operators” probably saved Qantas flight 32 on Nov. 4, 2010. The flight, using an A380 Airbus—the world’s largest and most technically-advanced passenger aircraft at the time—had left Singapore for Sydney. Over Indonesia, one of the engines blew apart, rendering almost the entire wing controls inoperable and leaving only one engine to power the plane. The pilots were inundated with messages: 54 came in to alert them of system failures or impending failures, but only 10 could fit onto the screen. The pilots watched as screens full of messages came in. Luckily, there were five experienced pilots onboard, including three captains who were on “check” flights. Even with that much experience available, it took 50 minutes to work through and prioritize the messages. The incident report concluded that without those pilots, the flight would probably not have made it. In fact, the “airmanship” of the pilots saved the plane. If the pilots
Figure 3: Standards-based decision support should help operators, not create more confusion.
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had followed all the advice from the flight systems, the plane would have crashed. The most senior pilot told the others to read the messages but “feel” the plane. They managed to land safely with one working engine. There are many times when the quick thinking of an operator has probably saved a process, but of course, these successes don’t get the same publicity as aircraft incidents.
A standards-based approach As stated earlier, modern control systems can have the versatility and intelligence to help an operator, but without guidance, these features can confuse as much as aid the operator, hence the need for standards (see Figure 3). With an effective HMI display, an operator can easily see what state the process is in, and if an alarm is activated, it can be seen easily and acted upon quickly. But process alarms also can be used to trigger an automated action if configured correctly. The action can be a combination of informing the operator, taking corrective action, or even halting the process if needed. The International Society for Automation (ISA), a globally-recognized standards development organization, has two standards and one in development addressing operator decision support: n ANSI/ISA-18.2-2009: Management of Alarm Systems for the Process Industries n ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems n ISA106: Procedure Automation for Continuous Process Operations. ANSI/ISA-18.2 provides requirements and recommendations for the alarm management lifecycle. The lifecycle
stages include philosophy, identification, rationalization, detail design, implementation, operation, maintenance, monitoring and assessment, management of change, and audit. Using this standard should prevent incidents like the one at Texaco Milford Haven. Alarms are rationalized and prioritized so high-priority alarms either trigger an action automatically or ensure an immediate operator response. ANSI/ISA101.01 is directed at those responsible for designing, implementing, using, or managing Figure 4: A hypothetical BP Texas City raffinate splitter control room HMI with standardsHMIs in manufacturing applicabased decision support. tions. The standard itself has internal standards aimed at producing an HMI philosophy, graphic style Draw on historical data for memory of what has guide, and design toolkit—all of which should lead to an happened in the past interface helpful to the operator. The ISA106 committee has produced one technical Incorporate both data and models to analyze and report defining models and terminology, and is close to present the best options releasing a second report on work processes, before starting the steps of developing a standard. The standard will Assist operators in semi-structured or unstructured help define which procedures should be automated and decision-making processes under what circumstances. When combined, these three standards offer powerful Support, rather than replace, operator judgment tools to provide decision support in times of normal and abnormal operations. Aim at improving the effectiveness, rather than BP Texas City done right efficiency, of decisions. Returning to the BP Texas City incident discussed earIn process industries, decision support of this nature lier, Figure 4 shows how the integration of alarm, HMI, and is not yet widely available. But with the advent of less procedure management might have prevented the incident. expensive and more powerful computers, enhanced deciImagine what one of the operators could and should have sion support will be more widely used to predict impendseen on the control-room screens prior to the incident: ing events as they are developing, allowing operators to take corrective action. The high-level alarm is tripped Mary L. Cummings, former director of the Humans and Automation Laboratory at the Massachusetts Institute The procedure is paused of Technology and a Navy F-18 pilot, has conducted research into human-automated path planning optimiza There is a mismatch in the material balance tion and decision support. She observed: “Humans are because no liquid is leaving the column doing a pretty good job, but they do it even better with the assistance of algorithms. This research is really The column temperature is significantly above showing the power of how, when algorithms work with the desired value. humans, the whole system performs better.” So, maybe there is a balance between humans and All this information could have been used by the operamachines that can ultimately make all of us safer. Let’s tor or an automated system to alleviate the abnormal try to find it. situation, preventing the disaster that followed. An effective standards-based decision support sysMaurice J. Wilkins, PhD, C.Eng, FIChemE, FInstMC, tem can help improve process safety and provide ISA Fellow, is executive advisor to Global Marketing HQ at critical aid to operators in times of stress, but more is Yokogawa Electric Corporation. He has vast experience in needed. An effective decision support system should process operations and human factors. be able to:
Applied Automation June 2017 • A17
A DV E R T I S E M E N T
SEW-EURODRIVE … Power Transmission Innovation MOVIGEAR® The MOVIGEAR® Mechatronic Drive System for horizontalmaterials handling from SEW-EURODRIVE sets new standards in terms of efficiency and functionality. MOVIGEAR® not only combines the gear unit, motor and drive electronics within one highly reliable, efficient, and hygienically designed unit, it also reduces total start-up cost and annual operating costs in your material handling system…by as much as 50%!
IE3 Compliant DRN.. Motor Our new DRN.. induction motors meet the stringent IE3 super-premium energy efficiency standard. They also fit existing gear units – allowing for easy upgrades and retrofits of existing DRE (IE2) gearmotors. The weight and dimensions of the new DRN motors have only marginal changes as compared to the DRE series. Due to its outstanding system stability, tight control, and high-cycling capacity, the DRN.. electric motor can replace a servo motor in many cases. Plus, its multiple brake sizes allow a higher torque for a stopping brake or a lower torque for a VFD holding brake. And finally, its wide HP range and various connector options enable the DRN motor to be used in a wide variety of new and retro-fit applications.
DRC Electronic Motor The DRC electronic motor provides an ultra-efficient motor and electronics package for those gear units already installed in your system. Like MOVIGEAR, the DRC electronic motor consists of a permanent-field synchronous motor with integrated drive electronics in a completely enclosed housing. The DRC electronic motor offers greater flexibility allowing it to mount to any gear unit plus, offers an optional mechanical brake.
About SEW-EURODRIVE Engineering excellence and customer responsiveness distinguish SEW-EURODRIVE, a leading manufacturer of integrated power transmission and motion control systems. SEW-EURODRIVE solutions set the global standard for high performance and rugged reliability in the toughest operating conditions. With its global headquarters in Germany, the privately held company currently employs over 16,000 employees with a presence in 48 countries worldwide. U.S. operations include a state-of-the-art manufacturing center, five regional assembly plants, more than 63 technical sales offices and hundreds of distributors and support specialists. This enables SEW-EURODRIVE to provide local manufacturing, service and support, coast-tocoast and around the world.
SEW-EURODRIVE, Inc. | Tel: 864-439-7537 | www.seweurodrive.com
A DV E R T I S E M E N T
Tadiran batteries are proven to last up to 40 years High energy lithium batteries
Tadiran is the leading manufacturer of bobbin-type lithium thionyl chloride (LiSOCl2 ) batteries that power remote wireless devices. These industrial grade batteries feature extraordinarily high energy density and high capacity along with the widest possible temperature range, making them ideal for use in the Industrial Internet of Things (IIoT). With an annual self-discharge rate of just 0.7% per year, Tadiran batteries deliver proven 40-year operating life, up to 4X longer than competing batteries that have annual self-discharge rates of up to 3% per year. For applications that require periodic high pulses to power advanced two-way wireless communications, Tadiran offers PulsesPlus ÂŽ batteries that combine a standard bobbin-type LiSOCl2 cell for low background current with a patented hybrid layer capacitor (HLC) that delivers periodic high pulses. As PulsesPlus batteries become depleted, they feature a unique endof-life voltage curve that can be interpreted to deliver low battery status alerts.
For applications requiring extended storage life followed by high current drain, Tadiran offers TLM Series lithium metal oxide batteries that pack powerful amounts of energy into small spaces. TLM Series batteries are ideally suited for medical applications such as portable defibrillators and allow batteryoperated surgical drills to be small and ergonomic while delivering the high torque needed for efficient drilling cycles.
TLM Series batteries also power mil/aero applications, such as providing back-up power that glides UAVs to safe landings. TLM Series batteries also allow miniaturized guided munitions to be periodically tested for system readiness whereas legacy reserve/ thermal batteries are bulkier and do not permit system readiness testing without exhausting the battery.
Industrial grade Li-ion rechargeable batteries For remote energy harvesting applications, Tadiran manufactures TLI Series industrial grade Lithium-ion (Li-ion) batteries. Whereas consumer grade Li-ion rechargeable batteries have a limited lifespan of approximately 5 years and 500 full recharge cycles, TLI Series batteries can operate for up to 20 years and 5,000 full recharge cycles and feature an extended temperature range. TLI Series batteries can also deliver periodic high pulses to power advanced wireless communications.
Toll-free: 800-537-1368 | Tel: 516-621-4980 | sales@tadiranbat.com | www.tadiranbat.com
A u t o mAt i o n P r o d u c t s Managed Ethernet switches Stride managed industrial Ethernet switches from AutomationDirect offer more connectivity choices for Ethernet applications. Stride SE2 series switches provide Modbus TCP and EtherNet/IP management capability. The Stride Web-based configuration tool is used for monitoring, setup (quick setup, network, and redundancy settings), and advanced operations. SE2 series managed Ethernet switches include 8-port (two versions with fiber optic ports) and 16-port fast Ethernet switches, and an 18-port Gigabit switch. The 8-port switch and 18-port Gigabit switch models have SFP fiber optic port options. These optional SFP transceivers add fiber connectivity at fast Ethernet or Gigabit Ethernet speed. Stride managed Ethernet switches provide reliable network connections in harsh industrial environments. With metal housings, these Stride switches are specifically built to withstand extreme conditions, including drastic temperature changes, electrical interference, and corrosion. AutomationDirect, www.automationdirect.com
Servo amplifier, single-axis controller The Sigma-7Siec from Yaskawa combines a SERVOPACK servo amplifier with a one-axis motion controller in a single compact package. It was created for automation applications that require the control of only one servo motor, while requiring exceptionally quick, precise, and reliable servo system performance. The new Sigma-7Siec builds on the legacy of the MP2600iec, an existing Yaskawa product that offers an amplifier/controller combination. The new unit accomplishes both tasks while using the smaller footprint of an individual amplifier, conserving space in tight control cabinets. Sigma-7Siec also delivers the advantages common to all Sigma-7 SERVOPACK amplifiers, including EtherNet/IP and Modbus/ TCP for connectivity, and a built-in web server. Yaskawa America Inc. www.yaskawa.com
LED enclosure light is UL approved The LED System Light from Rittal Corporation is the first UL-approved lighting system designed for industrial enclosures. The LED technology, with UL E76083 certification, shines into every corner of an industrial enclosure. The new light delivers up to three times the luminous flux of the closest competitor. Intelligent lighting is tailored to the geometry of the enclosure. Light is dispersed through a special optical cover with Fresnel structure in two designs for precise lighting. The Fresnel lens uses a prism-like pattern to provide magnified light coverage. The cover rotates easily, for adaptive light distribution. With enormous intensity, from 900 to 1,200 lumens, the light provides brilliant illumination. Rittal Corporation, www.rittalenclosures.com
Control panels for hazardous areas The CPX series control panels from Beckhoff are designed for use in hazardous areas. The company’s new CPX control panel and Panel PC series enable applications in hazardous areas and classified Zone 2/22. The CPX portfolio offers a wide selection of screen formats, sizes, installation options, and features.This means that process industry applications can now also benefit from advanced capacitive multi-touch technology, enabling the realization of intuitive and feature-filled operating concepts. Beckhoff offers system-integrated solutions for explosion protection with a new and extensive portfolio of explosion-proof components. Beckhoff, www.beckhoff.com
Motor combines gearbox, electronics Lenze Americas has introduced the Lenze Smart Gear g350, a compact mechatronic drive unit combining a gearbox, motor, electronics, and software. It is available with torques of 25, 50, and 75 Nm in basic or advanced levels (including brake). The g350 unit blends the motor and gearbox elements, so the gear ratio slips far into the motor housing. The integrated electronics and software make it possible for a fixed motor speed to be easily adapted via a user-friendly app for any NFC-enabled smartphone. At the same torque, speeds ranging from 42 to 216 rpm can be freely selected at the g350 gearbox output, resulting in a drastically reduced number of variations. This reduction then affords cost savings because fewer in-stock components and less engineering efforts are needed. Additionally, the g350 features integrated ramp functions and brake control options to ensure that conveyed goods are transported smoothly and safely without jerking motions that can damage materials and increase wear and tear on machine components. Lenze Americas, www.Lenze.com
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A u t o mAt i o n P r o d u c t s Weight processing module The HI 1734-WS weight processing module from Hardy Process Solutions is a plug-in for Rockwell’s POINT input/output (I/O) chassis. The module is easy to mount, set up, calibrate, and maintain. The HI 1734-WS is a true weight processing module designed for the POINT I/O systems, as opposed to passing raw analog-to-digital (A/D) counts through to the programmable logic controller (PLC) for interpretation as in competitive models. HI 1734-WS highlights include fast installation and commissioning with no programming required; connectivity to EtherNet/IP, DeviceNet, and ControlNet in linear, star, and ring topologies; and energy efficient—consumes just 1 W when powering Hardy IT junction boxes and up to four load cells. Hardy Process Solutions, www.hardysolutions.com
Software development kit for OPC UA Honeywell Process Solutions has introduced fully-scalable software toolkit that simplifies the interconnection of industrial software systems, enabling them to communicate with each other regardless of platform, operating system, or size. The Matrikon FLEX OPC Unified Architecture (OPC UA) Software Development Kit (SDK) is ideal for applications where minimal memory and processing resources are common. Intended for use by discrete and process industry manufacturers, commercial customers, and automation original equipment manufacturers (OEMs), Matrikon FLEX is the first high-performance developer toolkit that quickly and easily enables any application, regardless of size, with OPC UA. Honeywell Process Solutions, www.honeywellprocess.com
Compact industrial computers The SmartAIO U7-300 series computers from EFCO are based on the latest Intel Atom processors and highly-integrated Qseven CPU modules, and are extremely compact. This series of compact computers is designed for maximum network interoperability, offering gateway connectivity for Industrial Internet of Things (IIoT)ready automation applications. The extended application-specific interface support includes two Gigabit Ethernet ports, four USB ports (two USB 3.0 and two USB 2.0), an HDMI connection, two RS-232 ports, two RS-232/422/485 ports, 8-bit Isolation GPI, 8-bit Isolation GPO, and audio. The latest industrial PCs from EFCO also are equipped with slots for half- and full-size PCI Express mini cards.
Remote tank monitoring hatch sensor SignalFire has introduced the Hatch Watchdog, a wireless thief hatch sensor that monitors the status of tank hatches to mitigate environmental and safety risks associated with accidental emissions. When tank hatches—known as thief hatches—remain ajar, they can release vapors into the atmosphere. Stringent regulations in controlling emissions can result in fines due to leaking tank hatches. Protecting the environment also is a priority for many companies with green initiatives. The sensor tracks the angle of the tank hatch and wirelessly reports status (open/closed/ cracked) and changes to a central gateway that formats and transmits the data to a control center for remote monitoring. Modbus or digital alarming is available at the gateway. The Hatch Watchdog also operates as a standard wireless node in any SignalFire Remote Monitoring and Control Network. SignalFire Wireless Telemetry www.signal-fire.com
EFCO, http://efcotec.com/product/
Thermal data logger The newest generation DATAPAQ EasyTrack3 data logger system from Fluke Process Instruments simplifies thermal profiling. The data logger is equipped with a rugged and light polycarbonate casing that withstands harsh treatment and heat up to 212°F (100°C) without distortion and without harm to the electronics. Versions with four or six thermocouple channels are available. Data is stored in a non-volatile memory— the capacity has been tripled to up to 18,000 readings per channel. The loggers use replaceable 9-V batteries. An intelligent power management feature ensures long battery life for more than 50 profiling runs. Calibration certificates stored aboard the logger can be printed anytime. Fluke Process Instruments, www.flukeprocessinstruments.com
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A u t o mAt i o n P r o d u c t s Rotary tables GTB series servo positioning rotary tables from DESTACO features a roller-gear drive and is a lifetime-lubricated solution that has been designed and engineered to deliver high torque, with high speed and motion flexibility to meet demanding payload requirements in a wide variety of general industrial rotary table applications. The units are 34% lower in height and 64% lower in weight when compared to competitive models, while being able to deliver 1.4 times the torque. The unit’s lifetime-lubrication design also eliminates the need for maintenance. The rotary tables produce a very high torque comparable to much larger units, but in a very compact size. They can be mounted in vertical and horizontal orientations. Each model can support a wide range of off- the-shelf servomotors for maximum motion flexibility and performance. DESTACO, www.destaco.com
DIN-rail power supplies The DPC series of highly efficient ultra slim DIN rail ac-dc power supplies from XP Power are designed for industrial applications. Available in 30, 50, and 70 Watt single output models, the power supplies accept the universal input range from 90 to 264 Vac without the need for input selector switches. Taking up significantly less space on the rail by being up to 44% slimmer than current generation DIN rail power supplies, the 30 Watt DPC30 measures just 3.6 by 3.94 by 0.89 inches. In addition, the 50 Watt DPC50 measures 3.6 by 3.94 by 1.18 inches, and the 70 Watt DPC70 measures only 3.6 by 3.95 by 1.59 inches. Offering all the popular nominal output voltages from 5 to 48 Vdc, the single output can be adjusted up to +30% of stated nominal. XP Power, www.xppower.com
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Control Freak? If you like being in control, then SEW-EURODRIVE is your perfect partner! We put you in charge of every move with our gearmotors and electronics. No headaches, no whining, and virtually no maintenance. You build it and we move it…simple!
Don’t you wish all partners were this easy…?
seweurodrive.com | 864-439-7537
Big ideas open up completely new perspectives. We have taken another step towards mechatronic integration with the combination of the new g500 gearbox range and the Lenze Smart Motor. By using this single drive solution you will be able to cover a broad spectrum of applications and reduce the number of variants you need by up to 70%. Thanks to the excellent levels of energy efficiency and the long life expectancy, your machines will achieve more productivity with a maximum degree of reliability. Find out more about our intelligent approach to solutions at www.Lenze.com.
As easy as that.