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THE DCS: FROM DISTRIBUTED TO CENTRALIZED TO NETWORK-CENTRIC USE INFERENTIAL MEASUREMENTS TO FILL IN THE BLANKS IN PROCESS ANALYSIS NO FIELDBUS LOVE CHILD FOR HART AND FOUNDATION

Top Dogs DECEMBER 2014

ARC and Control Name the Top 50 Suppliers in Process Automation.

W O R K F O R C E

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Collect. Analyze. Act. Avantis Condition Manager. Turning events into improvement opportunities. Why be satisfied with status quo? With Condition Manager, you can collect raw data in real-time, analyze pending equipment failures on the spot and act with informed contextual information. Condition Manager collects information from any asset and drives maintenance workflow in any asset management system. To learn more, download our whitepaper at software.invensys.com/funnel.

ÂŠ 2014 Schneider Electric. All rights reserved. Schneider Electric, Invensys, Avantis, Condition Manager and Workforce Enablement Solutions are trademarks of Schneider Electric, its subsidiaries or affiliates. All other brands and product names may be trademarks of their respective owners.

Process and power automation Better together It just makes sense. Every industrial process is dependent on power to operate. In order to provide visibility, it's long been the status quo for information from various electrical components to be brought into the automation system through hardwired I/O signals. Using System 800xAâ&#x20AC;&#x2122;s digital fieldbus technologies (IEC 61850, MODBUS TCP, PROFINET, FOUNDATION Fieldbus, Ethernet IP), users can not only import status information without adding to a project's I/O count, but they are afforded better diagnostic and load information, enabling predictive maintenance and opportunities to save energy. System 800xA. Itâ&#x20AC;&#x2122;s all about control. www.abb.com/800xA

ABB Process Automation Division Visit us at our blog or on YouTube: www.ProcessAutomationInsights.com www.youtube.com/user/ProcessAutomation

December 2014 • Volume XXVII • Number 12

Top Dogs 30 / The ARC/Control Top 50

Size matters in enabling the Top 50 biggest process control and automation suppliers worldwide and in North America to develop new innovations, fill gaps in their capabilities, and thrive despite volatile economic and accelerating technical changes. by Allen Avery, Larry O’Brien and Jim Montague

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39 / D istributed to Centralized to Network-Centric For 25 Years, We’ve Watched in Wonder at the Progress of Our Most Powerful Systems. by Paul Studebaker P

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44 / F ill in the Blanks with Inferential Measurements of Composition Improve control by eliminating the delays, limitations, failures and expense of analyzers. by Greg McMillan and Pierce Wu W E B

E X C L U S I V E S

Every Man’s Guide to OPC w w w.cont rolglobal.com /whitepaper s/ 09 0910 matrikon-opc/

CONTROL (ISSN 1049-5541) is published monthly by PUTMAN Media COMPANY (also publishers of CONTROL DESIGN, CHEMICAL PROCESSING, FOOD PROCESSING, Industrial Networking, Pharmaceutical Manufacturing, and PLANT SERVICES ), 1501 E. Woodfield Rd., Ste. 400N, Schaumburg, IL 60173. (Phone 630/467-1300; Fax 630/467-1124.) Address all correspondence to Editorial and Executive Offices, same address. Periodicals Postage Paid at Schaumburg, IL, and at additional mailing offices. Printed in the United States. © Putman Media 2014. All rights reserved. The contents of this publication may not be reproduced in whole or part without consent of the copyright owner. POSTMASTER: Send address changes to CONTROL, P.O. Box 3428, Northbrook, IL 60065-3428. SUBSCRIPTIONS: Qualified-reader subscriptions are accepted from Operating Management in the control industry at no charge. To apply for qualified-reader subscription, fill in subscription form. To non-qualified subscribers in the Unites States and its possessions, subscriptions are $96.00 per year. Single copies are $15. International subscriptions are accepted at $200 (Airmail only.) CONTROL assumes no responsibility for validity of claims in items reported. Canada Post International Publications Mail Product Sales Agreement No. 40028661. Canadian Mail Distributor Information: Frontier/BWI,PO Box 1051,Fort Erie,Ontario, Canada, L2A 5N8.

D e c e m b e r / 2 0 1 4 www.controlglobal.com

Simply reliable: Process safety from Endress+Hauser.

Eliminate the risk of storage tank overfill Do you need to revamp your safety instrumented system? Do you want to comply to the latest safety guidelines and standards such as API2350 Edition 4 and IEC 61511/61508? Eliminate your risk of storage tank overfi ll without compromising availability and e�ciency. Together with our partners, such as Rockwell Automation, we can provide a complete solution for field-proven, standardized overfi ll prevention systems which include: • “Safety by design” - systems with built-in mechanical integrity • State-of-the-art vibronic fork technology with failsafe design - a second line of defense and active warning system with detailed information • Simple and remote built-in proof testing function helps reduce downtime and prevents staff from working in hazardous areas • SIL3 - 1oo1 using point level tuning fork with up to 12 year proof-test interval www.us.endress.com/overfi ll-prevention-news

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December 2014 • Volume XXVII • Number 12

D E PA RT M E N T S 9 / Editor’s Page

Baby, It’s Cold Outside Whatever else you might think about Keystone pipelines, you have to love the engineering.

11 / Control Online

The best-read and most popular of our online content.

13 / Feedback

APC in 25 years; what process control really is; and what we should put in the magazine.

14 / Other Voices

The Dawn of a New Era in Control Demand is increasing for automation skills to bring business processes under control.

19 / On the Bus

Foundations Blend, not Technologies Disparate origins mean the HART and Foundation marriage won’t beget a common heir.

20 / Without Wires

Making Sense of Your Diagnostic Data NAMUR NE107 tells how to communicate diagnostics as actionable information.

22 / In Process

Rockwell Automation envisions the Connected Enterprise; CSIA’s new online search tool; and more process news.

28 / Resources

Control software resources online include tutorials, videos, whitepapers and more.

47 / Ask the Experts

Is model-less predictive control any good, and other questions for our experts.

49 / Roundup

Hot and heavy: the latest in temperature and pressure technology.

Rockwell Automation CEO Keith Nosbusch addresses the faithful at the 2014 Automation Fair in Anaheim, California.

52 / Products

See the latest automation technology here.

54 / Control Talk

Process Control Psychology 101 How to get everyone on board for your next system upgrade.

57 / Ad Index

These folks would like a word with you.

58 / Control Report

Brain Power for Power Supplies Simple power supplies can now do a whole lot more.

Circulation aUdited june 2014 Food & Kindred Products.....................................................................................15,398 Chemicals & Allied Products..................................................................................9,095 Systems Integrators & Engineering Design Firms...................................................7,458 Primary Metal Industries.........................................................................................4,272 Electric, Gas & Sanitary Services............................................................................3,847 Petroleum Refining & Related Industries.................................................................3,600 Miscellaneous Manufacturers.................................................................................3,597

Paper & Allied Products..........................................................................................3,522 Pharmaceuticals......................................................................................................3,496 Rubber & Miscellaneous Plastic Products..............................................................2,855 Stone, Clay, Glass & Concrete Products.................................................................1,733 Textile Mill Products...............................................................................................1,047 Tobacco Products.......................................................................................................100 Total Circulation....................................................................................................60,020

D e c e m b e r / 2 0 1 4 www.controlglobal.com

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Insightful monitoring, trending and troubleshooting tools Use these tools for real-time tuning and testing: • Debug View window can suspend each task and program separately. • PID View window allows precise tuning of your PID loops • Data View window monitors your chosen program elements - discrete or analog I/O, and system parameters • View Trend Data in its own view as well as within speciﬁc ladder instructions like PID, RAMPSOAK, and High/Low Alarm.

The built-in simulator creates a virtual PLC so you can test your logic without the hardware present. The Windows application runs on your PC and uses the same code as the CPU firmware for the most accurate simulation. Test part of your logic or whole programs quickly and conveniently. • Simulates discrete and analog I/O with access to timers, counters, control bits, etc. • Simulate PID - use the Simulator coupled with the Trend View for outstanding visibility into your PID processes. Each Do-more CPU comes with a coupon for a 30-day free trial of online video training. So visit www.do-moreplcs.com for the details, watch overview videos, and download the free software to take it for a spin.

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EDITOR’S PAGE

Baby, It’s Cold Outside

hen our little company hires a new employee, we follow the usual application, resume, references and interview process, as well doing a psychological profile. But the top-level decision-makers have one more criterion they call the “train test.” They ask themselves, would I want to sit next to this person on an all-day train ride? I recently found myself on a long bus ride northwest from Omaha, Nebraska, with the president of Keystone Pipeline, Corey Goulet. The occasion was a press event presented by Siemens. The destination was TransCanada’s Keystone Pipeline pump station near Stanton, Nebraska. The purpose was to give us a guided tour of the pump, drive and control technology of the pumping station and the pipeline, and the event included a detailed on-bus presentation of the existing Keystone and proposed Keystone XL pipelines. As an aside, I’m aware that man-made greenhouse gases contribute to global warming, and that whatever makes carbon emissions cheaper and more plentiful increases the risk and problems of the X and following generations. The tour group included representatives of TransCanada and Siemens, as well as half a dozen journalists. The mid-November trip coincided with an early cold snap and snowfall. Temperatures had dropped from the 50s to single digits in a day. Slick roads led to low speeds and numerous accidents. Goulet told us the oil moves at a “fast walking pace” through the 30-in. diameter pipeline. Turbulent flow prevents components from stratifying, and keeps the interfaces sharp between batches of different grades of oil. The pipeline capacity is about 550,000 barrels per day (the current U.S. oil production rate is about 9 million barrels per day). The 36-in. Keystone XL offers a capacity of 700,000 barrels per day with similar pumping and controls. Unmanned pumping stations, roughly every 50 miles, each have two to five 5,000- or 6,000-

Paul Studebaker

hp pumps, depending on the terrain. A single variable-frequency drive (VFD) is typically used to start each pump and to trim pumping capacity to match the oil grade. The entire system is supervised and controlled from an operations center in Calgary. Local personnel can be on-site in less than an hour. Isolation valves every mile or so can be closed to limit the amount of any leak or spill. “There’s a phone number posted prominently every place a road crosses the pipeline, and we take any calls from farmers very seriously,” Goulet said. Closing the valves takes a little time—even though it’s moving relatively slowly, that’s a lot of oil to bring to a halt. Siemens supplied Keystone’s 35 pump stations with 133 pumps, 35 control systems, 35 mediumvoltage VFDs, 33 soft starters, VFD and electrical distribution shelters, and 19 substations. About 100 miles up U.S. 275 and a mix of state and county roads brought us to the pumping station, which occupies a couple of acres fenced out of a farmer’s field. Beautiful whiteenameled pipes rising out of the ground are plumbed to a row of five huge pumps, three and a half of which were humming as we donned toecaps and hard hats, and climbed out of the bus into clear, cold, biting wind. We toured the shipping-container-sized electrical enclosure, where a PC-based HMI displays current operating status of the station, then walked over to the piping (which although unheated, was pleasantly warm due to friction). The 6,000-hp VFD occupies its own enclosure, which we observed from afar. On the bus ride back to Omaha, I thought, while I’m not enthusiastic about Keystone XL, it’s good to know it would be built with integrity and safeguards, and the pumping stations would be works of engineering art. I think it would be better than putting all that oil on long train rides.

Editor in chief pstudebaker@putman.net

Beautiful whiteenameled pipes rising out of the ground are plumbed to a row of five huge pumps, three and a half of which were humming.

D e c e m b e r / 2 0 1 4 www.controlglobal.com

800 453 6202

C o n t r o l o n l i ne

Moving Forward with Flow

An Introduction to ISA TR84.00.07

SIL Ratings for Fire and Gas System Hardware. www.controlglobal.com/ whitepapers/2014/an-introduction-toisa-tr84-00-07/ McCrometer

ne of the most popular articles on our web site right now is Senior Technical Editor Leslie Gordon’s “Advances in Flow Measurement and Control” (www.controlglobal.com/ articles/2014/advances-in-flowmeasurement-and-control). Gordon reports that more capable digital signal processing algorithms have resulted in a move toward electronic instrumentation such as mass, ultrasonic and magnetic flowmeters, while the stalwart mechanical differential pressure, turbine and positive-displacement devices remain the most appropriate technology for certain tasks. So see what’s happening in vortex, ultrasonic, electromagnetic, thermal mass and Coriolis meters.

A collection of the latest trends, articles, tutorials, applications and more. www. controlglobal.com/whitepapers/2014/ flow-and-level-instrumentation/

Lambda Tuning for PID Controllers Will Lambda tuning work in your process control loop? Seven examples show its relevance and simplicity. www. controlglobal.com/whitepapers/2013/ lambda-tuning-the-universal-methodfor-pid-controllers-in-process-control/

Procedures for Loop Checking and Field Instrument Testing Senior Digital Editor Katherine Bonfante throws out some basic questions about loop checking and field testing in the Controlling Interests blog. See her questions and the readers’ answers at www.controlglobal.com/blogs/controlling-interests/ loop-checking-and-field-instrument-testing-procedure/.

Control Talk: PID Form Tips The PID form that you learned in school is not the most common one in use today. Check out this blog post for the differences and the consequences of not understanding them. www.controlglobal.com/blogs/controltalkblog/pidform-trick-or-treat-tips/.

Natural Language for Automation Process Automation Hall of Famer William Hawkins builds the case for a single programming language as the solution to the problem of what he calls “opaque automation,” a situation where the automation that’s supposed to help a plant run safely is so well hidden from the operators behind a flood of alarms and messages that when something goes wrong, they can’t figure out what it is. Click www.controlglobal.com/articles/2014/process-automation-programming-language-one-forall/ to read this “Other Voices” column and check out the responses from readers.

Unfettered: ICS Cybersecurity Doesn’t Need Digital There is a prevailing misconception that you need to have a digital system in order to be cyber vulnerable. Read why this is not necessarily so. www. controlglobal.com/blogs/unfettered/ what-is-ics-cybersecurity/

Jim Montague

Feeding the Engineering Pipeline There’s lots of hand-wringing in the press, in the HR department and even in the boardrooms about where the next generation of good engineers and operators is going to come from, but the solutions seem to be few and far between. Not so fast. Executive Editor Jim Montague has scoped out how some companies are feeding their pipelines with creative programs and alliances between themselves and schools, community organizations and other businesses. Click www.controlglobal. com/articles/2014/automation-companies-prepare-younger-generations-toreplace-retiring-employees/ for the complete story.

Flow and Level Instrumentation

ControlGlobal E-News Multimedia Alerts White Paper Alerts Go to www.controlglobal.com and follow instructions to register for our free weekly e-newsletters.

Updated every business day, the Control Global online magazine is available at no charge. Go to www.controlglobal.com and follow instructions to register for our free weekly e-newsletters. D e c e m b e r / 2 0 1 4 www.controlglobal.com

ACE IN THE HOLE

And the Knock Out Drum. And the Separator. And the Feedwater Heater. And the Sump. When process applications require best-in-class level control technology, you’ve got to play your cards right. The Eclipse® Model 706 guided wave radar transmitter can deal with nearly any process condition – even the most challenging. • Superior signal-to-noise ratio provides the most accurate and reliable level measurement available • Extensive line of probes, including overfill safe probes, handle a variety of level challenges • Advanced diagnostics take the user interface to new levels of convenience and functionality • HART® and FOUNDATION fieldbus™ protocols provide full digital communications capabilities • Convenient pre-configuration reduces installation time – apply 24 VDC and walk away • Quick-disconnect probe coupling makes servicing easier

Don’t gamble with reliability. Contact Magnetrol® – the guided wave radar innovator – to learn more about the ECLIPSE Model 706 transmitter.

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G N I K A E P S YL L A C I N H C E T

FEEDBACK

IN MEMORY OF JULIE CAPPELLETTI-LANGE, VICE PRESIDENT 1984-2012 1501 E. WOODFIELD ROAD, SUITE 400N SCHAUMBURG, ILLINOIS 60173 Editor in Chief: PAUL STUDEBAKER pstudebaker@putman.net Executive Editor: JIM MONTAGUE jmontague@putman.net Senior Managing Editor, Digital Media: KATHERINE BONFANTE kbonfante@putman.net Managing Editor: NANCY BARTELS nbar tels@putman.net Senior Technical Editor: DAN HEBERT dheber t@putman.net Senior Technical Editor: LESLIE GORDON lgordon@putman.net Contributing Editor: JOHN REZABEK Columnists: BÉLA LIPTÁK, GREG MCMILLAN,

IAN VERHAPPEN, STAN WEINER Editorial Assistant: LORI GOLDBERG

design & production team VP, Creative Services: STEVE HERNER sherner@putman.net Art Director: BRIAN HERTEL bher tel@putman.net Senior Production Manager: ANETTA GAUTHIER agauthier@putman.net

publishing team Group Publisher/VP Content: KEITH LARSON

Where Will APC Be 25 Years from Now? I read your article “Process Optimization Gains Industrial Strength,” (October 2014, www.controlglobal.com/articles/2014/ process-optimization-gains-industrialstrength/). I found it interesting how the idea of process optimization began with a multiple-loop control for continuous problem identification and correction. This idea is the basis for many important topics today. Chemical engineers, for example, use control systems that regulate pressure regardless of the input value. The system keeps the pressure at the desired value, while adjusting variable values that will deter the output value being desired. Advanced process control (APC) implementations were stated to “remain incredibly hard.” However, oil refineries among other companies, have made APC applications more common. Businesses today use knowledge and understanding to contribute to corporate objectives. As technology continues to thrive, it will be interesting to see APC over the next 25 years.

klarson@putman.net Midwest/Southeast Regional Sales Manager: GREG ZAMIN gzamin@putman.net 630/551-2500, Fax: 630/551-2600 Western Regional Sales Manager: LAURA MARTINEZ 310/607-0125, Fax: 310/607-0168 lmar tinez@putman.net Northeast/Mid-Atlantic Regional Sales Manager: DAVE FISHER 508/543-5172, Fax 508/543-3061 dfisher@putman.net Classifieds Manager: LORI GOLDBERG lgoldberg@putman.net Subscriptions/Circulation: JERRY CLARK, JACK JONES 888/64 4-1803

executive team President & CEO: JOHN M. CAPPELLETTI VP, Circulation: JERRY CLARK VP, CFO: RICK KASPER

foster reprints Corporate Account Executive: JILL KALETHA 866-879-914 4 x 168, Fax 219-561-2033 jillk@fosterprinting.com FINALIST JESSE H. NEAL AWARD, 2013 JESSE H. NEAL AWARD WINNER ELEVEN ASBPE EDITORIAL EXCELLENCE AWARDS TWENTY-FIVE ASBPE EXCELLENCE IN GRAPHICS AWARDS ASBPE 2009 MAGAZINE OF THE YEAR FINALIST FOUR OZZIE AWARDS FOR GRAPHICS EXCELLENCE

VALERIE SCHWEIN NEW YORK UNIVERSIT Y vrs240@nyu.edu

What Does “Process Control” Mean Anyway? In providing solutions to realize the potentials for improvements in production and manufacturing, I found that the phrase “process control” does not have a sufficiently universal meaning Many people by default take it for what is known as “regulatory control,” that is, the compensation for disturbances, so that process parameters are close to desired target values—the setpoints. Regulatory control as a function can be optimized, including criteria such as close to target, costs, and constraint requirements, etc. This is, of course, only one aspect of process control. Another aspect of process control is the adjustment of setpoint values, i.e., giving operating directions to the regulatory control to implement. This engineering job is an aspect of operations management, often implemented through supervisory control. Supervisory control, as a function, can

also be optimized, addressing the balance of multitude of objectives, such as product quality, costs, throughput, environmental protection and satisfying constraint requirements, including safety, commitments, availability, capacity, regulations, etc. There are several optimization solutions on the market to achieve these objectives at various levels of thoroughness, which include advanced and intelligent supervisory control. One way to help resolve the problem mentioned by Paul Studebaker—“Few companies have been able to fully optimize a process, and there remains a great deal of unrealized potential”—I wish www.controlglobal. com would help professionals be well aware of these two areas of control and control optimization. With that aim in mind, it would be also useful to have an unbiased resource to provide, for each regulatory and supervisory control solution in the market today, a map of what internal and external resources are required to plan, install and maintain each solution. This would include, as conditions and business needs change, the costs of implementation in addition to manpower and fees, the capability scope of each solution, and how quickly improvements are obtained. It’s a scary new world in process control, but you can defend your plant against cyber attack.

IT TOOLS ELEVATE DCS CAPABILITIES

OCTOBER 2014

editorial team

PROCESS OPTIMIZATION GAINS INDUSTRIAL STRENGTH

ADVANCES IN FLOW MEASUREMENT AND CONTROL

CT1410_01_CVR.indd 1

CARLOS MORENO

ULTR AMA X CORPOR ATION carlos.moreno@ultramax.com

[Paul Studebaker responds: Carlos, we start with a broad definition of process control: An engineering discipline that deals with architectures, mechanisms and algorithms for maintaining the output of a specific process within a desired range. Over the years, Control has published and ControlGlobal. com has amassed much of the information you seek, but alas, not in the format you describe. Perhaps others can direct you to an existing organized body of knowledge. Meanwhile, we’ll keep working on it.] D E C E M B E R / 2 0 1 4 www.controlglobal.com

10/8/14 12:19 PM

Other Voices

The Dawn of a New Era in Control Dr. Pe ter G. Martin

Process Automation Hall of Fame (2013) peter.g.mar tin@invensys.com

Industry does not typically position profitability, safety, environmental integrity and security as realtime control challenges, but they are. 14

ost process engineers I talk to look back on the 1970s and 1980s as the heyday of control engineering, and in many ways it was. More engineers were focused on the applications of real-time control theory then than now. When you look at how far they have brought control strategies and technologies, it would be easy to conclude that the science of control engineering had been saturated. But as I see the good work control engineers are still doing and the value they are creating for industrial companies, I cannot help but believe that there is still considerable potential for advancement and expansion. In fact, I believe that industry has just scratched the surface of control engineering, and that perhaps the day of the control engineer is just dawning. The growth potential of any technology or technological approach should be analyzed from two perspectives: the capability of the technology and scope of application. For example, in the field of process control, the introduction of multivariable predictive control provided a major leap forward in capability, but its scope of application was actually a bit narrower than traditional feedback control, primarily due to the cost and time required to apply it. In fact, over the years many advances in control technology have been based on capability, moreso than scope or enhancements. Process control technologies were developed to enable efficiency improvements in complex industrial production processes. Efficiency refers to process control applied to meet the production requirements of industrial operations safely, while simultaneously working to reduce energy and material consumptions. The word â&#x20AC;&#x153;controlâ&#x20AC;? as used in industrial organizations is generally assumed to mean process control for improved efficiency. Control strategies are still largely focused on improving efficiency. To date, there has really been very little effort to formally apply real-time control to other industrial challenges

www.controlglobal.com D e c e m b e r / 2 0 1 4

beyond the scope of efficiency improvement. There is considerable evidence that this is about to change in a very big way. A number of market-driving forces are causing industrial companies to consider the application of real-time controls in new domains. Perhaps the most influential driving force has been the transition of some critical business variables of industry toward real-time variability. Two decades ago, most of the critical business variables of industry changed very minimally or not at all for months on end. For example, the price industrial companies paid for electricity was contractually a constant value for months at a time. When this was the case, there was no need to control the price of electricity because it seldom changed. All industrial companies had to do was apply realtime controls to reduce the consumption of electricity without any concern for its price, and the cost they paid would be correspondingly reduced. Not anymore! With the deregulation of electric power grids, the price of electricity started to fluctuate in much shorter time frames, and those fluctuations have become larger over time. Today in the U. S., the price of electricity can change on the open grid every 15 minutes. This means that consumers such as industrial plants need to control more than just the overall consumption of electricity. They need to control the consumption within very short pricing periods. If they donâ&#x20AC;&#x2122;t do this, they may reduce the overall consumption of electricity over a day, while the price they pay for the consumed electricity over that day actually increases because they consumed during highprice periods. The real-time variability of electricity prices has triggered a domino effect across other energy sources and raw materials used throughout industry. Production processes consuming a significant amount of electricity have transitioned to a similar level of real-time variability.

It feels like we’re running in circles trying to meet regulations and process demands. I wish we could operate at a higher level.

YOU CAN DO THAT You can move forward and run at a higher level with Fisher® control valves and instruments. We understand that you need to keep employees safe and equipment in compliance with regulations. And that’s getting more difficult as the process industry changes. Fisher products can help you maintain a safer operation and meet growing regulatory demands. You can experience our commitment to innovation in process control firsthand with a visit to the Emerson Innovation Center for Fisher Technology. There, Fisher products are rigorously tested and verified beyond industry standards by a staff of dedicated technologists. Watch a video of Fisher product testing at www.Fisher.com/HigherLevel, then schedule a visit.

Other Voices

Today in the U.S., the price of natural gas on the open market also changes every 15 minutes, and the price of some raw materials, such as base minerals used in industrial production, may change as fast as multiple times each minute. Some of the critical business variables associated with industrial production have transitioned to real-time or near real-time variability. The traditional approach taken by industrial companies has been to manage business variables on a monthly, transactional basis, while controlling operational variables such as flow, pressure, level and temperature in real-time frames. This worked fine as long as all business variables changed only on a monthly or greater time frame. As some of the business variables have shifted to real-time variability, traditional business management approaches and time frames proved insufficient. In fact, a number of industry executives I interviewed suggested that their production processes were in control, but their business processes were out of control. This presents a daunting challenge to industrial companies. What is required to meet this challenge effectively is the application of real-time control on real-time business variables. This application is directly targeted to bring the realtime components of business profitability under control again. Therefore, the scope increase required to meet this challenge is the application of real-time control strategies to business profitabilityâ&#x20AC;&#x201D;real-time profit control. This requires the development of real-time business measures for the real-time components of profitability because such measures are a prerequisite for real-time control. When all the critical business variables directly associated with the profitability of business operations were stable for months at a time, industrial engineers applied linear and nonlinear optimization software to optimize to a selected business objective. The optimization software is designed to maximize or minimize to a particular objective, such as maximizing production value or minimizing energy cost, while not exceeding critical constraints, such as safety and environmental requirements. As key business variables have transitioned to real-time variability, control strategies are required to bring the business under control, but the objectives of these control strategies, the setpoints, must be set to not exceed the critical constraintsâ&#x20AC;&#x201D; much in the same way as traditional optimization software. Unfortunately, some constraint functions, such as the function associated with safety and environmental risk, also tend to vary with the maintained state of the production equipment, quality of raw materials and phase of production. This has led to real-time variability in these constraint functions, also requiring the application of real-time control. Therefore two additional potential scope increases for real-time control are safety and environmental risk control. Both of these require real-time measurement approaches to measure the risks associated with production processes. Industrial operations are comprised of assets from physical 16

www.controlglobal.com D e c e m b e r / 2 0 1 4

process equipment right through to critical business assets. In industrial operations, the phrase asset management has been co-opted to mean equipment maintenance. Maintenance departments are measured on the availability of the equipment assets, and operations is measured on the production throughput realized from the operation of the assets. The challenge is that the production assets must continually operate at peak performance to drive optimal results for the business and operation. Neither asset availability nor production throughput directly measure asset performance. For optimal performance, the asset performance of every equipment asset in industrial companies must be measured and controlled in real time. Applying real-time control to asset performance of equipment assets provides a strong foundation for safety, environmental, efficiency and profitability control. This domain is referred to as real-time asset performance control. One final, increasingly significant area in which real-time control theory needs to be applied going forward is security control. Security in industrial companies has many facets. Perhaps the one in most urgently in need of attention is cybersecurity. As industry pushed for more openness, standards and commercial off-the-shelf technologies (COTS) in automation systems, these systems were opened to cybersecurity risks. Openness is a desired characteristic of automation systems, but a high level of security is absolutely essential. Implementing an effective cybersecurity strategy involves bringing the security risks to industrial companies under control. Once again, this involves real-time measurement of cybersecurity risks and the application of real-time control. Industry does not typically position profitability, safety, environmental integrity and security as real-time control challenges, but they are. I believe industry is at the dawn of a new era in the field of controls in which real-time measurement and control continue to be applied to process efficiency, but also to safety risk, environmental risk, security risk, asset performance and profitability. The knowledge and skills of control engineers are going to be the exact knowledge and skills industry requires moving forward. The topological scope of the control problem is also increasing in multiple dimensions. Traditionally, process control was directed toward the control of process units or plant areas. Today, that control model must extend down the plant architecture to individual industrial assets and up the industrial hierarchy to include plants, enterprises and entire value chains. Extending both the functional and topological scope of control will result in huge improvements in efficiency, profitability, safety and environmentally friendliness of industrial businesses. The talent required to lead the way is control engineering, but control engineering redefined for the future. Is control engineering an obsolete discipline? No way. Control engineering will define the path for successful industrial companies that rise to meet the challenges of today and tomorrow.

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ON THE BUS

Foundations Blend, not Technologies

ow do you tell a HART device from a Foundation fieldbus (FF) device? There have been times when we’ve puzzled over it. With the merging of the HART Communication Foundation and the Fieldbus Foundation, some have wondered if there will be some new offspring, or if devices from one protocol will become conversant in the other. Foundation fieldbus and HART technologies have a lot of things in common. Why wouldn’t they play nicely together some day? The Fieldbus/HART foundation merger has no goal of making one protocol out of the two. The two technologies are intended to progress on their individual paths, and neither has “convergence” on the roadmap. That doesn’t mean that there won’t be some common territories along those paths, as there have been already. The two have covered a lot of common ground with enhanced electronic device description language (EDDL) and NE 107 (NAMUR role-based diagnostics), and will be progressing through the specifications for field device integration (FDI) concurrently. But while moving along similar paths, the two technologies aren’t likely to mate or bring forth an heir. To understand why this duo won’t be doing a rumba, one has to revisit the origins of these two similar, yet different technologies. HART came about as an answer to the first proprietary protocol to feature complete digital integration of mainstream field devices with a leading process-industry host: Honeywell DE. Such devices communicated digitally with the Honeywell LCN-based controllers of the late 1980s. Honeywell was winning projects by bundling the DE transmitters with its DCS, and its competitors needed a response. In those days, a 300-baud modem for a dial-up connection was considered pretty geeky, so when HART adopted a 1,200-baud communication rate, no one thought it terribly slow. Superimposing this relatively high-frequency signal on the

john Rez abek

low-frequency (e.g., 10-Hz) signal of analog 4-20 mA transmitters enabled HART to preserve the backward compatibility and interoperability that makes it so popular today. HART communicates ones and zeroes by “frequency shift keying,” that is, modulating the frequency of the signal. Those little HART devices are humming their signal back to the host or handheld communicator. So why don’t Foundation fieldbus devices have an ear for the HART music? FF grew out of the ISA SP50 committee, the same one that created the 4-20 mA standard for analog communications. The committee had high participation from end users, who desired a single, interoperable, vendor-independent bus for control and digital integration of field devices. FF sought to create a complete digital infrastructure, where devices could communicate with each other, executing a repertoire of function blocks that included closed-loop control, i.e., “control in the field.” The physical layer for FF is twisted-pair copper—the same as HART—but instead of humming discretely on top of 4-20 mA, the devices blast a square wave of ±10 mA into an impedance of about 100 ohms at a fixed frequency more than 25 times the characteristic frequency of HART devices, which is 31.25 kHz. They aren’t listening for a tune. Ones and zeroes are determined by “zero crossings.” That’s the “direction” of crossing high-to-low (a 1) or low-to-high (a 0) of the square wave in a window of about a millisecond. The frequency was chosen for backward compatibility to existing, analog, twisted-pair wiring, noise immunity and a network maximum length of almost two kilometers with no switches or repeaters. The chipware and boards needed to transmit and receive these two protocol cousins are therefore very different, and the effort to adapt a device to contain both probably exceeds the cost of just stocking one of each. There are some skunkworks where new chips are being brewed that may reduce the cost, so while HART and FF may never interoperate, maybe someday they’ll just be a board-swap apart.

contributing Editor JRezabek@ashland.com

To understand why this duo won’t be doing a rumba, one has to revisit the origins of these two similar, yet different technologies.

D e c e m b e r / 2 0 1 4 www.controlglobal.com

Without wires

Making Sense of Your Diagnostic Data ian verhappen

Director, Industrial Automation Ne t works iverhappen@industrialautomationnetworks.com

NAMUR NE107 tells how to communicate diagnostics as actionable information. Maintenance

The process value is still valid, but internal diagnostics predict that the device can fail soon. There can be more than one alarm limit for this function to provide extensive notice to allow for scheduling of device maintenance. This alarm is normally sent to the asset management or preventative maintenance planning tools.

Out of specification

The process value is not valid, but other than that, the device is functioning. One typical reason for this notification is that the device is operating outside the calibrated range. This notification should be sent to the operator HMI, as well as maintenance and possibly engineering.

istributed control systems are now approximately 50 years old. During that time they’ve continued to evolve with not only increased control capabilities as a result of new algorithms and processing capacity, but also new forms of I/O, including wireless, which is an enabler to improving how we operate and control our facilities. Wireless technology means it’s now possible to gather data from more places and in higher concentrations than we’ve ever been able to do before. Having more data available doesn’t always translate into more information since,

Check function

The process value is not valid because someone is working on the device. This alarm should be displayed on the operator HMI, though they should already be aware of this because they issued a work permit to the technician.

Failure

The process value is not valid due to a device malfunction. This alarm should be reported to the control system logic and operator HMI, as well as the maintenance system(s), so it can be repaired. The control system logic should be designed so that, in the event the device is not working properly, the associated control algorithms that rely on the field device also go to a safe condition. Foundation fieldbus accomplishes this when using control in the field with the status bit transmitted with every function block communication.

Diagnostic active

The diagnostic features of the device are on and working.

Diagnostic passive

The diagnostic features of the device have been disabled.

www.controlglobal.com D e c e m b e r / 2 0 1 4

as mentioned in the October 2014 column (www.controlglobal.com/articles/2014/standardized-messaging-for-process-optimization-), in order to know if data can or should be used for closed-loop control, we need to know if it’s valid. However, intelligent devices often contain hundreds of parameters, so the challenge is now becoming how to select which parameters are valid, when, and more importantly, which ones should be used under what conditions. Fortunately many control systems are adopting the NAMUR (www.namur.de) NE107 recommendations that, in addition to indicating if the diagnostic functions are working, also filter the messages themselves into three useful categories (see chart). Any of the symbols can be used to represent the states, with the colors in the first column on the left being used with the HMI status near a tag, the center column for black-and-white displays or printed reports, and the final column as the full representation whenever possible. On the right hand side of the chart are defnitions of the meaning of the categories of symbols. Additional work also is being done by the ISA108 Intelligent Device Management committee (www.isa.org/isa108) to “define standard templates of best practices and work processes for implementation and use of diagnostic and other information provided by intelligent field devices in the process industries.” The work of ISA108 and other standards such as ISA18 Alarm Management and ISA101 HMI are providing the impetus and evolution of best practices to the control systems of the future. As we continue to implement these systems and then incorporate the lessons learned while doing so, proces control systems will evolve to support safer and more reliable manufacturing as well as production facilities.

In Process

Visualizing the Connected Enterprise Future to Offer Faster Time to Market, Lower Total Cost of Ownership, Improved Asset Utilization and Better Enterprise Risk Management

utomation Fair, the granddaddy of the user-group meeting, a mash-up of training sessions, technical presentations, tradeshow and pep rally, took place this year on Nov. 19-20 in Anaheim, California. Rockwell Automation CEO Keith Nosbusch, in an address to the assembled media outlined the company’s vision of what the industrial landscape will soon look like—and a heady vision it is. Nosbusch describes the automation giant’s Connected Enterprise vision as a game-changer. “These are exciting times,” he explains. “The value at stake is enormous.” He adds, in Rockwell Automation’s view, there are four “value drivers” customers are seeking: “Faster time to market, lower total cost of ownership, improved asset utilization and better enterprise risk management. The Connected Enterprise is focused on rapid value creation across all four drivers.” He went on to flesh out what the Connected Enterprise will look like. Secure networks and contextualization of the data will help create information that can be shared. This results in an enterprise that can be quantified, says Nosbusch. “We’re at an inflection

High Stakes “The value at stake is enormous,” said Keith Nosbusch, chairman and CEO of Rockwell Automation, while describing the company’s Connected Enterprise vision before the opening of Automation Fair 2014 in Anaheim, California.

point for the Connected Enterprise,” he explains. “It’s enabled by integrated control and information. To realize it, there must be a convergence of IT and OT. Operations technology (OT) is the world of industrial equipment, such as machines, controllers, sensors and actuators. Information technology (IT)

includes ERP, finance, HR, logistics, quality and CRM. Critical to the OT side is real-time data that drives control and safety. It’s typically acted upon in milliseconds or microseconds.” Both IT and OT are critical for the success of an industrial enterprise. And in the past, most approaches to convergence have been expensive and unscalable, adds Nosbusch. “We’ve made tremendous progress in bringing forward an IT-OT solution through our partnership with Cisco,” he explains. “This flatter, more open approach delivers a level that wasn’t possible with the previous generation of technology, and it enables IT and OT convergence.” Nosbusch noted several major industry trends that help to identify a great opportunity. According to a Rockwell Automation survey conducted with Industry Week, nearly three-fourths of U.S. plants are more than 20 years old, and less than 14% of these manufacturers have tied their machines to the enterprise network, he reports. Further, manufacturing has generated 2 exabytes of big data, according to a McKinsey report. Plants are experiencing losses of $20 billion annually due to

Heard on the Street GE’s Intelligent Platforms (www.ge-ip.com) has announced that its exida-certified Mark VIeS safety management system recently received the exida 2014 Safety Award in the logic solver category. Exida presented awards in three categories: sensors, logic solvers and interface modules. ODVA (www.odva.org) has authorized two test service providers (TSP) to conduct ODVA conformance testing services for CIP Safety in Germany. The Institute of Ergonomics, Manufacturing Systems and Automation (IAF) at the Otto von Guericke University of Magdeburg has been authorized as a TSP for CIP 22

www.controlglobal.com D e c e m b e r / 2 0 1 4

Safety on EtherNet/IP, and FISW Steuerungstechnik has been authorized as a TSP for CIP Safety on Sercos III. ZigBee Alliance (www.ZigBee.org) has announced the unification of its wireless standards into a single standard named ZigBee 3.0. This standard will provide interoperability among the widest range of smart devices, and give consumers and businesses access to innovative products and services that will work together seamlessly. All device types, commands and functionality defined in current ZigBee Pro-based standards are available to developers in the new standard.

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In Process

unscheduled downtime, and updating obsolescent automation systems will cost industry $65 billion, according to studies from ARC Advisory Group. These opportunities are perfect scenarios for optimization of production

through the Connected Enterprise via the convergence of IT and OT, and they’re enhanced by modern trends such as the Internet of Things (IoT). “Rockwell Automation and our partners are applying our industrial expertise

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to realize the Connected Enterprise through processes and business models,” explains Nosbusch. At the Process Systems User Group (PSUG) conference leading up to Automation Fair, John Genovesi, vice president and general manager, Information Software and Process Business, Rockwell Automation, zeroed in on the process control piece of the Connected Enterprise. Rockwell Automation’s interpretation of the modern distributed control system (DCS) not only runs processes, it drives efficiency, reduces total cost of ownership and helps users prepare for the future by enabling the Connected Enterprise, Genovesi says. Experts expect the IoT to drive $19 trillion into global economies, he explained, and “leveraging the industrial IoT in manufacturing represents a full one-third of that.” Much like the smartphone’s computing power, he adds, applications and Internet connectivity have empowered people in business, so the modern DCS can connect and empower individuals in industrial facilities. “Any DCS supplier provides the base level of functionality—control, I/O, HMI,” says Genovesi, adding that the company’s PlantPAx differentiates itself by giving its users faster time to

In Process

market, lower total cost of ownership, improved asset utilization and reduced risk. These capabilities depend on solutions in four critical areas: design, operations, maintenance and security. Engineering and design are speeded by an integrated development and design environment that uses an expanding library of process objects as well as reference architectures. By building with proven components, Genovesi adds, “You know it’s just going to work.” The company has also made rapid progress in virtualization with open templates, preconfigured systems and images that can “run on any server,” Genovesi says. Templates significantly reduce the time required to integrate, for example, skids, which for conventional systems, “can add as much as 50-70% to the cost of the skid. In some cases, you’re nearly doubling the price

of a skid just to integrate it.” Having one unified architecture “from power through process control to packaging” not only speeds design and build, it reduces spare parts and maintenance training requirements, Genovesi adds, pointing out that integrated control and information systems offer high visibility, for example, of energy consumption. And for process optimization, “We’ve spent a lot of time bringing APC [advanced process control] solutions closer to control,” Genovesi says. “Our industry experts drive applications that bring 4-8% improvements in productivity, and pay for themselves in less than a year—sometimes in as few as four months.” To address security issues, risk management technologies implemented with and through Cisco networks offer layered security, “defense in depth

that meets government standards,” Genovesi added. Safety and critical control systems can be viewed on the PlantPAx operating station, and offer “unique packages that generate causeand-effect logic.”

CSIA Offers Online Search Tool A new online search tool established by the Control System Integrators Association (CSIA, www.controlsys.org) will improve the way plant managers, directors of operations and other industry clients find control system integration companies. to meet their automation needs. The Industrial Automation Exchange (http://csiaexchange.com/) is a comprehensive directory for locating

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system integrators and suppliers. CSIA executive director Bob Lowe says the online search tool will allow project managers, directors of quality assurance and other decision-makers at companies to learn about system

integration, as well as be connected with the right people and products. Lowe notes the Industrial Automation Exchange was created as a convenient way for all system integrators and industry suppliers to be more accessible

to industry clients. Membership in CSIA is not required to be listed on the exchange. The site offers detailed profiles outlining an integrator’s expertise and allows for potential clients to compare up to three companies in a particular industry at a time, and even ask questions of exchange members.

Mynah Donates $1.5 M to Missouri School Mynah Technologies has made a $1.5-million Mimic simulation software donation to the Missouri University of Science & Technology’s (www.mst.edu.com) Doshi Teaching Laboratory in Rolla, Missouri. The Mimic software was donated in conjunction with Emerson Process Management’s donation of its DeltaV control system, and creates a virtual lab within the Doshi Teaching Laboratory. Together, the donation consists of a virtual lab system that hosts the simulation and software products, as well as the process control hardware and software. The virtual lab will be used for hands-on, experiential learning in the chemical and biochemical engineering departments at the university.

ODVA Forms SIG for EtherNet/IP in the Process Industries ODVA reports that it will form a new special interest group (SIG) for EtherNet/IP in the process industries. The SIG will leverage the inherent strengths of EtherNet/IP to develop enhancements to the EtherNet/IP specification to address three key use cases for automation applications in the process industries: field deviceto-industrial control system (ICS) integration; field device-to-plant asset management (PAM) integration; and a holistic field-to-enterprise

In Process

Road Trips ARC Advisory Group (www.arcweb. com) has announced the keynote speakers for its 2015 Industry Forum to be held Feb. 9-12 in Orlando, Florida. The speakers are Peter Holicki, corporate vice president, Manufacturing, Engineering and Environment, Health & Safety Operations, Dow Chemical; Gregory Touhill, deputy assistant secretary, Cybersecurity Operations and Programs, Office of Cybersecurity and Communications, National Protections and Programs Directorate, U.S. Dept. of Homeland Security; and Stephan Biller, chief manufacturing scientist, General Electric.

chemical industry. SOCMA joins five other chemical industry associations that support the event. They are: the American Institute of Chemical Engineers (AIChE), Association of Consulting Chemists and Chemical Engineers (ACC&CE), Fluid Controls Institute (FCI), Fluid Sealing Association (FSA) and the Measurement, Control and Automation Association (MCAA).

The 2015 Chem Show (www.chemshow.com) will be held Nov. 17-19 at the Javits Center in New York. In the run-up to the show, the Society of Chemical Manufacturers and Affiliates (www.socma.com) has become an endorsing association. With a global membership of more than 220 companies, SOCMA is the only U.S.-based trade association that’s dedicated solely to the specialty

The Smart H2O Summit (www.smarth20summit.com), will be held on Aug. 17-19, 2015, at the Marriott Marquis hotel in San Francisco, and the Water Innovation Project (www.waterinnovationproject.com), an idea lab and leadership hub that is currently developing a road map for the connected utility, has partnered with the summit. Smart H2O Summit director Jane McDermott says that the partnership will facilitate the development of thought-leading conference content, and provide a platform for innovative information technology companies to exhibit at the event.

communication architecture. The formation of this SIG is one outgrowth of ODVA’s process initiative, which is aimed at optimization of process integration (OPI). The SIG’s scope of work is founded on the goal of proliferating adoption of EtherNet/IP in the process industries, and will focus initially on integration of field devices with industrial control systems and related diagnostic services. The work of the SIG will result in a unified communication approach to process applications, enhancing the ability of users to exchange information to and from the field. The work of the SIG is expected to be completed in phases generally aligned with key use cases. ”ODVA’s SIG for EtherNet/IP in the process industries will provide ODVA’s members with a venue to

concentrate on technical requirements often unique to process applications,” explains Katherine Voss, president and executive director of ODVA. “The result will provide users in all production domains of industrial automation, inclusing discrete, hybrid and process, with a featurerich and future-proof solution using EtherNet/IP.” ODVA is issuing its call for SIG participants in December 2014 with an organizational meeting of the SIG to be held in the first quarter of 2015. Participants will include individuals from ODVA’s principal members— Cisco Systems, Endress+Hauser, Rockwell Automation and Schneider Electric—in addition to other participants from ODVA’s 300-plus member companies.

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When You Need to Know More about Control Software Control’s Monthly Resource Guide VIDEOS! TUTORIALS! WEBINARS! MathWorks’ website contains dozens of multimedia tutorials on Matlab and Simulink software for process and discrete applications. Some of the topics include “PID Controller Design,” “Gain Scheduling of PID Controllers,” “Early Verification of Control Systems,” “Interactive Control Systems Tutorial” and “Simulink Overview.” The link to these controller topics is www.mathworks.com/control-systems. MathWorks w w w.mathworks.com

INSTRUMENT CONTROL FUNDAMENTALS This National Instruments whitepaper covers the writing of instrument control applications using a number of different programming languages and technologies. Some of these technologies include NI LabView, NI LabWindows/CVI, NI LabView SignalExpress, C++, Visual Basic, C#, instrument drivers and VISA. The set of tutorials and concept documents provide information on how to use these programming languages for instrument control. Topics covered include general instrument control software technologies, programming languages used for instrument control, and non-Windows operating systems (Linux and Macintosh). The direct link is at www. ni.com/white-paper/4357/en/. National Instruments www.ni.com

ALL OPC, ALL THE TIME OPC Programmers’ Connection has pointers to organizations supplying source code and developers’ toolkits, as well as companies providing training and consulting services. There are also pages of useful links, tools and techniques for

OPC developers and a “free stuff” page with a summary of freely downloadable OPC software. Both OPC Classic and OPC UA subjects are covered, as are a basic “Introduction to OPC,” security issues, the latest news about OPC developments, and links to free OPC clients, servers and utilities. OPC Progr ammers’ Connection w w w.opcconnect.com

GAMP GUIDELINES This whitepaper discusses good automated manufacting process (GAMP) guidelines for the use of process simulation software, including the guidelines themselves, the impact of system testing and qualification on using process simulation software, its impact on project risk mitigation, and GAMP4 requirements for suppliers. The direct link is at www.controlglobal. com/assets/Media/MediaManager/ wp_06_048_mynah_gamp4.pdf. Mynah w w w.mynah.com

AVOID WORM ATTACKS The whitepaper, “How Stuxnet Spreads—A Study in Infection Paths in Best Practice Systems,” addresses the question of securing control systems from attacks by Stuxnet-like worms and other malware. Understanding how the Stuxnet worm might have migrated from the outside world to a supposedly isolated and secure industrial control system matters very much to the owners and operators of such systems. Only by understanding the full array of threats and pathways into a SCADA or control network can critical processes be made truly secure. This paper by analysts from Tofino Security,

Abterra Technologies and SCADAhacker.com covers a range of potential “infection pathways” in a typical ICS system. Read it at www.controlglobal.com/assets/11WPpdf/110228_ Tofino_Stuxnet.pdf. ControlGlobal w w w.controlglobal.com

IN CASE YOU CUT THE LECTURE IEEE Control Systems Society’s website has a collection of taped lectures on a variety of control system software and design subjects. They are highly technical, and many are deep dives into control system theory. Most run 45 minutes to an hour. Lecture titles include “From DCSs to Game Theory,” “Controlling Wind Energy for Utility Grid Reliability,” “Controlling for Energy Efficiency,” “Large-Scale Distributed Control for Tomorrow’s Electricity Grid” and “Taming the Data Deluge—A Systems and Control Perspective.” All lectures are free. The direct link is at www.ieeecss.org/publications/online-lecture-library. Control Systems Socie t y w w w.ieeecss.org

HOW TO PROGRAM A PLC This brief, introductory tutorial covers PLC basics and offers simple explanations of ladder logic, function block diagrams, structured text programming language, instruction lists and sequential function charts. The page also includes a list of items to consider when choosing a PLC and a list of common PLC-related acronyms. The direct link is located at www.amci.com/tutorials/ tutorials-what-is-programmable-logiccontroller.asp. Advanced Micro Controls Inc. w w w.amci.com

If you know of any tools and resources we didn’t include, send them to ControlMagazine@Putman.net with “Resource” in the subject line, and we’ll add them to the website. 28

www.controlglobal.com D e c e m b e r / 2 0 1 4

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tâ&#x20AC;&#x2122;s good to be big because there are some huge bones that need chewing, long roads to run and problems to be solved. Just as the largest oil tankers, container ships and offshore platforms are better at smoothing out the ride on stormy seas, the Top 50 global and North American process control and automation suppliers are better at weathering economic upheavals and increasingly volatile markets, and responding to accelerating and multiplying technological innovations. Though thereâ&#x20AC;&#x2122;s always some minor jockeying based on year-to-year sales, most of the Top 50 suppliers ranked by ARC Advisory Group confirm their preeminent status by maintaining their overall positions each year, while still achieving successful and steady sales and revenue growth both in North America and worldwide.

www.controlglobal.com D E C E M B E R / 2 0 1 4

C o n t r o l / A R C A u to m at i o n To p 5 0 Top 50 Global Automation Vendors

2013 Worldwide Revenue (US$ millions)

Siemens

12,749.05

ABB

11,120.12

Emerson

8,919.02

Rockwell Automation

6,155.00

Schneider Electric

5,748.00

3,723.83

Mitsubishi Electric

3,610.97

Danaher

3,433.00

Yokogawa Electric

3,430.74

Honeywell

3,297.26

Endress+Hauser

2,418.67

Omron

2,390.08

IMI

2,251.01

Phoenix Contact

2,186.67

Cameron

2,085.70

Ametek EIG

2,034.60

Invensys

2,014.08

Fanuc

1,897.90

Spectris

1,873.70

Flowserve

1,615.70

Festo

1,496.00

Yaskawa

1,220.47

National Instruments

1,172.56

FMC

1,163.25

Mettler-Toledo

1,065.60

Teledyne Instruments

1,029.16

Advantech

1,025.00

Wika

1,000.00

azbil Group (Yamatake)

915.91

Wago

914.67

Weidmuller

853.73

IFM

840.00

Fuji Electric

810.37

Hitachi

806.43

Bosch Rexroth

794.64

Roper Industries

779.60

Samson

761.33

Metso

733.53

Eaton

713.11

MKS Instruments

669.40

Pepperl+Fuchs

666.67

Harting

645.33

Krohne

616.40

Turck

600.00

Beckhoff

580.00

B&R

573.33

Burkert

548.00

Toshiba

547.86

Horiba

457.46

Vega

400.00

Total

107,354.91

D e c e m b e r / 2 0 1 4 www.controlglobal.com

C o n t r o l / A R C A u to m at i o n To p 5 0 Top 50 NORTH American Automation Vendors 1

Emerson

3,916.52

Rockwell Automation

3,225.00

ABB

2,293.25

Danaher

1,465.89

Schneider Electric

1,437.00

Siemens

1,380.76

1,366.60

Ametek EIG

1,123.41

Honeywell

935.38

Teledyne Instruments

822.30

Cameron

806.07

Invensys

630.94

Spectris

593.96

Roper Industries

550.40

Flowserve

549.34

IMI

495.44

Endresss+Hauser

493.41

National Instruments

483.60 361.48

The difficulty of these epic projects is compounded by the fact that refineries, process plants, transportation networks and other infrastructures take years to build, while market conditions and requirements seem to emerge or dry up in months if not weeks. In fact, based on their sales revenues in 2013, Vega emerged as the only new member of the Global Top 50 for this year, and Krohne, Pentair and Harting were the three new members of the North American Top 50. In total, the collective sales of the Global Top 50 increased by more than 4.8% from almost $102.4 billion in 2011 to more than $107.3 billion in 2013, while sales by the North American Top 50 swelled by more than 15.6% from almost $24.4 billion in 2011 to close to $28.2 billion in 2013. As you’d expect, these kinds of results are easier said than done.

MKS Instruments

Mettler-Toledo

351.65

Advantech

307.50

Badger Meter

298.53

FMC

290.81

Yokogawa Electric

290.04

Omron

286.81

Yaskawa

255.58

Toshiba

237.97

Festo

224.40

Turck

216.60

Thermo Fisher Scientific

200.61

Mitsubishi Electric

188.12

Eaton

172.57

Weidmuller

167.33

Good Stress

OSIsoft

140.93

Metso

139.37

Belden

138.59

Wago

137.20

IFM

126.00

Vega

120.00

Phoenix Contact

109.33

Parker

109.06

Bosch Rexroth

105.50

Wika

100.00

SPX

94.39

B&R

86.00

Pepperl+Fuchs

78.67

Horiba

68.62

Krohne

67.80

Pentair

61.38

Harting

61.33

Even when the news is positive—exemplified by ongoing U.S. and global economic recoveries or hydraulic fracturing aiding energy independence— major economic and technological shifts can create challenges and stress levels that it seems only the largest, multi-skilled organizations can handle. Shifting liquid natural gas (LNG) facilities from import to export is a hugely complex job, right? Well, so is ramping up tracking and tracing for pharmaceutical, food and beverage products from raw materials to consumers to meet new regulations and demands, or using big data in mines to direct autonomous drilling and transport vehicles, or fracking without damaging groundwater aquifers,

Total

2013 North America Revenue (US$ millions)

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or shifting from trucks to railroads to pipelines to transport oil and gas from new sources. The difficulty of these epic projects is compounded by the fact that refineries, process plants, transportation networks and other infrastructures take years to build, while market conditions and requirements seem to emerge or dry up in months if not weeks. For example, during recent debates on the Keystone XL pipeline, U.S. gas prices dropped back to averages of $3 per gallon from the $4 per gallon that made scrubbing Canada’s oil sands profitable. So how long will the pipeline extension and all those plays and supporting controls in Alberta remain economically viable? How can necessarily slow-to-deploy process applications hope to keep up with fast-changing opportunities and global markets? Size in the form of tens of thousands of employees and partners in dozens if not a hundred countries can help, of course, but only if they’re all well-connected and nimble enough to use their early intelligence effectively. Today, this knowledge is all under the cloudenabled, Big Data, Internet of Things (IoT) and smart-industry umbrella, and is another skill at which many of the Top 50 excel. However, even when they find a capability they can’t develop organically, they usually have the resources to acquire the know-how and people they need to plug the holes in any niches they require.

Views from the Top How do you get nimble? Hire a good leader. The ability to bring resources and people together to solve users’ problems and partner with them to complete big projects is what the Top 50’s presidents and CEOs do best with help from North America’s recent performance and IoT. There’s strife around the world, but the North American market has been a stabilizing force, according to Steve

When they find a capability they can’t develop organically, the Top 50 usually have the resources to acquire the know-how and people they need to plug the holes in any niches they require. Sonnenberg, executive vice president, Emerson, and president of Emerson Process Management. “In fact, it’s become the new emerging market,” said Sonnenberg at Emerson Global User Exchange 2014 in October. “Our orders for the first three quarters were up 6%, and North America was more than double that.” These results were fueled by oil and gas projects in North America, with international activity recovering in Asia, Latin America, the Middle East and Africa. In the past year, Emerson has added more than 3,500 staff, and acquired four companies, including Management Resources Group (MRG) for reliability solutions, Virgo for on/off valves, Enardo for safety and environmental equipment for tanks and terminals, and APM for level instrumentation for bulk solids. Vimal Kapur, new president of Honeywell Process Solutions (HPS), also emphasized the emergence of natural gas in North America. “China and the Americas continue to lead in capital spending, but Europe, Middle East and Asia (EMEA) and Asia Pacific are recovering as well,” said Kapur at Honeywell Users Group Americas 2014 this past June. “The oil and gas industries in the Americas continue to dominate capital spending in the region, especially as they migrate to new natural gas sources. These changes have been having a profound impact for the past two or three years, and this trend is going to continue for several more years.

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C O N T R O L / A R C A U TO M AT I O N TO P 5 0

HOW THE TOP 50 ARE COMPILED To develop the Top 50 lists of automation suppliers based on revenue, the analysts at ARC Advisory Group use publicly available financial data wherever possible from the leading firms supplying process control and automation technologies. Although firms with increased renenues are added and those with decreased sales relative to the others and those that have been acquired are subtracted, the basic analysis methodology hasn’t changed. When these big companies have businesses unrelated to automation, or if they don’t provide details of the extent of their process control activity, ARC uses other publicly available information and its own database to calculate a meaningful determination of the scope of their automation business. This scope is based on Control’s and ARC’s definition (below) of which technologies constitute control and automation and which do not. Over time, the scope and focus has tightened on revenue generated by process control and automation activities. Technologies included in the Top 50 definition: • Process automation systems and related hardware software and services; • PLC and related hardware, software, services, I/O and bundled HMI; • Other control hardware components, such as third-party I/O, signal conditioners, intrinsic safety barriers, networking hardware, unit controllers, and singleand multi-loop controllers; • Process safety systems; • SCADA systems for oil and gas, water and wastewater, and power distribution; • AC drives; • Motion control systems;

• Computer numerical control (CNC) systems; • Process ﬁeld instrumentation, such as temperature and pressure transmitters, flowmeters, level transmitters and associated switches; • Analytical equipment, including process electrochemical, all types of infrared technology, gas chromatographs for industrial manufacturing and related products; • Control valves, actuators and positioners; • Discrete sensors and actuators; • All kinds of automation-related software from advanced process control, simulation and optimization to third-party HMI, plant asset management, production management (MES), ERP integration packages from the major automation suppliers and similar software Other automation-related services provided by automation suppliers; • Condition-monitoring equipment and systems; and • Ancillary systems, such as burner management systems, quality control systems for pulp and paper, etc. Technologies not included in the Top 50 definition: • Pumps and motors; • Robotics; • Material-handling systems; • Supply chain management software; • Building automation systems; • Fire and security systems; • Processing equipment such as mixers, vessels, heaters, as well as process design licenses from suppliers that have engineering divisions; and • Electrical equipment, such as low-voltage switchgear, etc.

C O N T R O L / A R C A U TO M AT I O N TO P 5 0

“Fortunately, HPS is in a unique position to integrate and serve users all along the oil and gas value chain from upstream to midstream to downstream with new SCADA, RTU, DCS, safety, advanced and field instrumentation solutions. The other challenge is that large capital expenditure projects are growing more complex, expensive and time-consuming. So instead of us coming in and adding automation and control at the end of a project before start-up, it’s becoming increasingly critical for us to execute automation, and get it out of the critical path of these projects.”

Merge Today, Sales Tomorrow While trends like economic recoveries and slowdowns, conversions for fracking and other shifts are ongoing, several recent acquisitions, mergers and divestitures by the Top 50 will help them, but won’t affect their positions on the lists until 2014’s financial results are compiled next year. However, even as these moves give them new capabilities to serve their customers, they can still be drawn into some unfamiliar process control territories. Most notably, Schneider Electric completed its purchase of Invensys earlier this year, and has spent much of 2014 integrating Invensys’ many divisions and solutions, such as Foxboro, Triconex and Wonderware, into its existing portfolio. This acquisition and merger is most likely to reshuff le the Top 50’s traditional order because it combines two of the list’s longtime members. Likewise, Emerson’s acquisition of MRG this past spring is expected to help it reduce downtime, enhance safety and improve compliance, mostly in upstream oil and gas applications. This investment leverages Emerson’s reliability strategy and complements its existing lifecycle services offerings. In addition, Rockwell Automation recently entered the wireless sensor arena by buying vMonitor, which has the world’s largest installed base of wireless wellhead monitoring systems for natural and artificially lifted wells with more than 6,000 well sites at major oil and gas facilities worldwide. Meanwhile, ABB reports it’s selling its huge Full Service business to Nordic Capital. This division provides fully outsourced, industrial maintenance services. It was developed as an adjacent business to ABB’s lifecycle service business, and has become a successful, standalone unit. ABB reports it’s divesting Full Service because of limited synergies with its core portfolio. Also, Siemens agreed in October to buy Dresser-Rand Group for about $7.6 billion in cash, and will close the sale next summer. Siemens reports it will run DresserRand as its oil and gas business, enabling it to become the leading rotating equipment and process system integrator for the oil and gas industry.

To help them and their customers navigate these new waters, most Top 50 members plan to use IoT, cloud-based services, and reliability and predictive maintenance tools and software. Finally, General Electric secured approval in June of its $17-billion takeover of Alstom’s gas and steam turbine business. The deal will reportedly allow GE to develop joint ventures in the steam turbine, renewable energy, and electricity transmission sectors. To help them and their customers navigate these new waters, most Top 50 members plan to use IoT, cloud-based services, and reliability and predictive maintenance tools and software. The major process control suppliers are already one-stop shops for most products, so these latest tools will allow many of their existing solutions to work together more effectively, securely, safely and profitably. Allen Aver y is automation research analyst and Larr y O’Brien is vice president for research at ARC Advisory Group. Jim Montague is Control’s executive editor.

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25 YEARS OF CONTROL

Distributed to Centralized to Network-Centric

For 25 Years, We’ve Watched in Wonder at the Progress of Our Most Powerful Systems by Paul Studebaker

n 2015, the distributed control system (DCS) will mark its 40th anniversary—40 years since the first Honeywell TDC2000 was installed at Exxon’s Sarnia, Ontario, refinery, and Yokogawa 1989 introduced its version, Centum. By 1980, Bailey (now part of ABB) introduced the Network 90 system, Fisher Controls (now part of Emerson) introduced the ProVoX system, and Fischer & Porter (now also part of ABB) introduced DCI-4000. During this period, the DCS swept alternative process control technologies from the field. “In the late 1970s, market analysts projected the decline of analog control, but no one anticipated the speed or completeness of this transformation,” wrote Terry McMahon in April 2005. “At least two generations of process control engineers have matured during the DCS era, which has endured much longer than earlier technologies.” In the 1980s, users began to look at DCSs as more than basic process control. If proprietary systems were opened,

data could be shared and greater things could be achieved. This led to adoption of Unix operating systems and Ethernet-based networks. The full TCP/IP standard was not imple2014 mented, but using Ethernet allowed object management and global data access. PLCs were integrated into the DCS infrastructure, and plant-wide historians emerged to capitalize on the extended reach of automation systems. The first DCS to adopt Unix and Ethernet networking technologies was Foxboro’s I/A Series. The 1990s saw increased adoption of commercial offthe-shelf (COTS) components and IT standards, and the controversial move from Unix to Windows. Even today, the real-time operating system (RTOS) for control generally remains on variants of Unix or proprietary operating systems, but above that, applications tend to be Microsoft-based. Continued on page 41

TIMELINE OCTOBER1988

Microprocessor-Based Control: Current Challenges

In Control’s 284-page inaugural issue, editor Brian Wolske’s DCS wish list included improvements in real-time manipulation of online process data, advanced control, expert systems, ruggedization, business management integration and open system connectivity.

NOVEMBER1989

ARCO Alaska Meets North Slope Challenge

A Bailey Network 90 DCS and Management Command System console and data acquisition platform automate the world’s largest gas processing plant in Prudhoe Bay, Alaska, monitoring 7,500 process and 5,000 safety I/O points.

JANUARY1989

Honeywell’s First TDC2000 Controller Marks 14 Years at Imperial Oil

Part of the world’s first distributed control system, installed in 1974 at Esso Petroleum’s Sarnia, Ontario, refinery marked 14 years of service, and was linked to Honeywell’s latest TDC3000 system without need for hardware or software modification.

D E C E M B E R / 2 0 1 4 www.controlglobal.com

25 YEARS OF CONTROL

OCTOBER1990 DCS Innovations

Senior associate editor Keith Larson identified significant trends including batch control applications and intensifying competition with PCs and PLCs, as well as easier integration with other manufacturers’ systems, embedded advanced control capabilities and incorporation of off-the-shelf operator consoles.

Getting the Most from Your DCS

Using a distributed control system simply to replace analog/pneumatic controls falls short of its potential, said Honeywell’s Mel Beard. Relatively small additional expenditures for advanced control, optimization and information integration can yield substantial returns.

OCTOBER1992

Study Predicts DCS Growth in Software

An Automation Research Corp. (ARC) study said vendors of distributed control systems are realizing that standardization will make DCS hardware a commodity, and are concentrating on software and services. Global growth of 5% annually is predicted for the next five years from the current $1.6 billion.

AUGUST1993

DCSs Become Smaller, Modular, Hybrid

APRIL1991

1990s–The Decade of DCS Partnerships

Lynn Parker at Tennessee Eastman Co. explained the increasing prevalence of end-user partnerships with DCS manufacturers and how these alliances can shorten project time cycles, improve use of higher level functions, improve both parties’ application expertise and reduce training, spare parts and maintenance costs.

AUGUST1991

Avoid Automation Obsolescence

Foxboro’s Mark Davidson described how modular hardware and software, standardized power and voltage requirements, and applications written to common communication services allow seamless migrations and a long-lived automation system architecture.

SEPTEMBER1991 Distributed Control Opens Up at the Seams

The trend of DCS suppliers to incorporate more off-the-shelf computer hardware and software is intensifying, said editor Keith Larson. Examples include PCbased configuration tools, Unix workstations, Windows-based operator consoles and Ethernet-based data highways.

A study by Frost & Sullivan Market Intelligence found traditional DCSs moving down in size and complexity to meet PLCs head-on in a battle for mid-level applications.

SEPTEMBER1994

Client-Server Approach Links Distributed Controls to Desktop PCs

Monsanto’s Arthur Huggard described how the ability to readily access and analyze process data through favorite spreadsheets has paid for itself more than three times over at the company’s glass plant in Springfield, Massachusetts.

MAY1995

The Shifting Sands of DCS, PLC and PC Technology

As the underlying microprocessors and hardware become more alike, the distinctions among the three alternative platforms are increasingly about software and supplier application expertise, said editor in chief Keith Larson. Meanwhile, convergence on open systems may eventually render the decision moot.

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MARCH1994

Foxboro, Honeywell Settle Jurassic Dispute

Foxboro initiated legal action over a Honeywell flyer showing a “Turbosaurus” dinosaur chasing a fleeing fox. The flyer played on a Foxboro ad campaign showing the imminent extinction of proprietary DCS technology. Both companies agreed to discontinue the disputed practices.

MARCH1996 Opening the Black Box

An “open system” used to involve a big, black (proprietary) box with an Ethernet connection, wrote news editor Bob Sperber. Now, “application programming interfaces (APIs), common objects, increasing network standardization and the efforts of consortia at all levels are making users—not developers—the masters of their process control destinies.”

Continued from page 39 As the DCS became increasingly network-centric, many of the suppliers built new “process automation systems” from the ground up to maximize functionality with Ethernet and fieldbuses. These solutions included Rockwell Automation’s PlantPAx, Honeywell’s Experion, ABB’s System 800xA, Emerson’s DeltaV, Siemens’ Simatic PCS 7 and Yokogawa’s Centum VP. Since the inaugural issue of Control magazine in October, 1988, we’ve made the DCS the center of our process control coverage. Over the past 25 years, we’ve described how DCS has evolved from distributed control with centralized microprocessing, to “truly distributed control” with centralized supervision of microprocessors in the field, to today’s rise of virtualization, where critical and non-critical functions coexist in servers (or even the cloud). Control, safety, supervisory, historian and business functions are increasingly distributed as needed in network-based architectures across field devices, controllers, thin clients, central processors and the web.

With increasing use of inexpensive and standard COTS hardware and operating systems, the heart of the DCS is moving from equipment to software and services. Applications now include production management, model-based control, real-time optimization, plant asset management, real-time performance management, alarm management and more. Much of today’s activity is in wireless networks, mobility, remote access, business optimization and decision-making, which largely run outside the DCS. In 2013, we described the latest permutation of the original DCS, Honeywell’s TDC 2000, now typical of the best of today’s systems: “You’d think a DCS as useful and successful as Experion PKS Orion R2 might stop for a well-deserved break, or at least pause to catch its breath,” wrote executive editor Jim Montague. “But that’s just not how its developers operate. Together, they just keep churning out an unrelenting stream of improvements, capabilities and innovations, until it seems like there’s nothing that Experion can’t do—and maybe that’s the point.”

MAY1996

Emerson Introduces DeltaV

Initially taking aim at smaller applications that might traditionally be using PLC and PC combinations, the product of Emerson’s “Hawk” project uses controversial Windows NT and a plug-and-play bus architecture that starts to take full advantage of the promises of remote I/O.

OCTOBER1996 NT Threats, NT Promises

DCS vendors are giving Windows NT an increasing role in distributed control by taking advantage of its strengths and working around its weaknesses. “In the short run, vendors say NT is good enough to rival Unix,” wrote senior editor Paul Studebaker. “Over the long haul, they expect the system to become the best as a result of a huge dedication of resources and attention by Microsoft, developers and users.”

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AUGUST1996

Field-Centric Architecture Displaces the DCS

Fisher-Rosemount’s PlantWeb expands on the DeltaV concept with intelligent field devices, scalable control/computing platforms and integrated modular software fully compatible with Microsoft systems. “The DCS moves from the center of the architecture to being, in effect, a node on a field-centric network,” wrote editor in chief Keith Larson. The network is directly accessible by other departments such as maintenance and engineering.

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25 YEARS OF CONTROL

FEBRUARY1997 JUNE1997

Founding Father of DCS

In 1969, Honeywell embarked on “Project 72” to “explore the state of the art and come up with proposals for developing product lines in the 1970s,” said Renzo Dallimonti, who led the project. “It was not until 1975 that we felt we were ready to release what was then called the TDC2000, which the media, in time, labeled the DCS or distributed control system.”

Will Microsoft Have Unix for Lunch?

Beyond the operator interface, Unix dominates the demanding world of process control, but Windows NT offers popular features at a price that’s hard to resist. Despite Unix’s large following, proven capability, distributed computing and 64-bit architecture, most industry experts expect Windows’ commercial popularity to drive its ultimate success.

OCTOBER1997 JANUARY1998

Open DCS: Be Careful What You Ask For

A world of freedom and a new range of responsibilities await those who specify, create and implement open control systems, wrote editor in chief Paul Studebaker. Open control systems are being sold with broad claims of performance swimming in a sea of acronyms. Decide what you need your system to do, write your specification accordingly, and test any candidate to be sure it will perform as you expect.

JULY1999 DCS: Dead Yet?

“It’s gotten so that control system vendors refuse to use the DCS moniker for fear of being considered closed, proprietary and even archaic,” wrote Rich Merritt, technical editor. But, “the ever-evolving distributed control system has so far survived many reports of its demise.”

New Frontiers for Distributed Control

DCSs are the obvious source of process information for managing assets and making decisions, but users can’t find the software, wrote technical editor Peggy Piper. Users need an accepted fieldbus standard, packages that harvest field information, controlled access and, of course, proven and rapid payback on the investment.

JULY1998

DCS = PLC = PC?

Vendors of DCS-, PLC- and PCbased systems are adopting each others’ functionality, and adding similar features in their efforts to satisfy end-user demands and earn additional market share. The result is systems that work, look and act a lot alike. Users have to look at all the options to find the best, most economical solution.

APRIL2000 JANUARY2001 The System Decision

“Don’t just compare features, benefits and prices,” wrote Kevin Totherow, systems integrator. A better method is to focus on plant issues and needs, and the system vendor’s long-term strategy. “In the long run, the least painful problem is paying too much for the initial purchase.”

JANUARY2003 Framework Wars

An epic battle is under way for ownership of the control system architecture marketplace, this time over the framework: “Despite vendor claims of using standards and ease of integration, many users are concerned that vendors once again may be trying to fence them in with proprietary products.” 42

www.controlglobal.com D E C E M B E R / 2 0 1 4

Windows 2000 Debuts to Mixed Reactions

Experts said, “Don’t be too quick to convert your plant.” Apart from its high cost, Windows 2000 does not have many I/O or device drivers yet. Wait at least until after the next service pack is issued “sometime in June to fix some of the rumored 63,000 bugs.”

DECEMBER2001 Good Migrations?

“Is it really possible to retain much of your investment in your old DCS while reaping the benefits of a new control systems platform?” asked Dan Hebert, P.E., technical editor. Experienced end users said, given the choice, it’s often wiser to keep the old system or replace it entirely.

MARCH2004

Running with the Big Dogs

APRIL2003

Centralized vs. Distributed: Is Bigger Better?

As recently as five years ago, field-based distributed control was impractical. In 1998, a 100-I/O PLC with an open communications protocol such as Ethernet cost about $5,000. Today, a 100-I/O PLC with Ethernet can be purchased for less than $500, and fast, reliable networking is easily accomplished.

DECEMBER2006 The DCS Spirit Lives On

Classic DCSs typically remain only in highavailability refining and power applications, but their strategies and capabilities persist in integrated digital automation architectures, which give users improved project execution and timing, higher operational efficiency and uptime, safer facilities and smarter plants with predictive technology.

MARCH2010

Surprise! Field-Based Control Beats DCS

Studies by ARC and ISC both arrived at the same conclusion, wrote John Rezabek, contributing editor. “The SP50 committee set out years ago to define and specify a robust, vendor-independent controls suite, exploiting the intelligence of microprocessor-based field devices that would equal or exceed the ‘bulletproof’ DCSs of the 1990s. They succeeded.”

DECEMBER2013 Let the DCS Fit the Process

One size definitely doesn’t fit all when it comes to process control. DCSs are gaining new capabilities, such as integrating with safety systems, because big process applications are unique environments— even from one to another—so they need the appropriate controls hardware and software deployed in the correct manner to operate safely and efficiently.

Senior technicale editor Rich Merritt observes that the big vendors have been resting on their haunches. It’s time for the dominant dogs of DCS to reassure the market that they still lead the pack, and still offer the best hardware and software in the industry. If not, customers might start the hunt for better process control by turning to second-tier suppliers.

APRIL2005

Three Decades of DCS Technology

At least two generations of process control engineers have matured during the DCS era, which has endured much longer than the pneumatic, electronic analog and computer-based control eras, wrote Terry McMahon, columnist. DCS technology and its pioneers have had a profound effect on our profession and should be recognized.

DECEMBER2008

Does the DCS Have a Future?

What were once simple control systems are now decision-support and decision-automation systems. Rich Merritt, senior technical editor, polled system integrators and vendors, and found that users want systems that will put more people and functions—engineers, managers, maintenance, planning, environmental and the supply chain— in touch with the process. They said, “We want to report problems in a timely manner to the right people and automate complex decisions.”

MAY2011

Distributed Safety Arrives

Executive editor Jim Montague pointed out that process safety systems are following the DCS path: first distributed (or often nonexistent) systems, then centralized via triple-modularredundant safety controllers and local I/O, and now distributed via SIL-rated safety networks connected to safety-rated intelligent I/O and via ever-smarter and often redundant instruments and controllers.

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I N F E R E N T I A L A N A LY S I S

Fill in the Blanks with Inferential Measurements of Composition Improve control by eliminating the delays, limitations, failures and expense of analyzers. by Greg McMill an and Pierce Wu

he most important process variable on the process flow diagram (PFD) is often the process composition. Yet the installed and maintenance costs of analyzers have precluded their widespread use. Analyzers are typically only used in equipment and a stream where the composition has been both problematic and essential for product quality. Often overlooked are the process analysis and optimization opportunities afforded by more extensive use of online composition measurements. Simple and inexpensive inferential measurements of composition can be used to fill in the blanks. The inputs to the inferential measurements use common sensors, probes and meters that can be inserted in a line. The measurements are continuous and require no sample preparation. Except for spectral calculations, the computational time is less than a second, so inferential measurements are essentially as fast as the sensors, probes and meters. Inferential measurements must always be corrected at some point by analyzers and first-principle calculations. Consequently, the use of inferential measurements does not eliminate the need for analysis somewhere at some time. The analyzer could be in the field, a plant lab or a third-party lab. Inferential measurements offer the ability to eliminate the considerable delay of at-line analyzers (e.g., 5-50 min) and excessive and variable delay of offline analyzers (e.g., 2 h to 2 wk), and reduce the vulnerability to analyzer resolution limits and failures. Inferential measurements also can eliminate process dead time and process time constants, providing an essentially instantaneous response with future values. The opportunities for expanding the scope and effectiveness of online data analytics and closed-loop control can be extraordinary. 44

www.controlglobal.com D E C E M B E R / 2 0 1 4

Cue in on Step Response Here we focus on the use of step-response models to provide a linear dynamic estimator. While the inputs are typically accurate mass flows, densities and temperatures, other online measurements of physical properties such as conductivity, dielectric spectroscopy, pH, turbidity and viscosity may be used. The ISA Interchange post â&#x20AC;&#x153;Inferential Measurements of Process Compositionsâ&#x20AC;? (http://automation.isa.org/ author/gregmcmillan/) discusses practical considerations in the use of these physical property measurements. Step response models can take advantage of the software used to identify the dynamics for tuning and for model predictive control (MPC). The process inputs that affect the inferential measurement are stepped in both directions, possibly with a pseudo-random binary sequence similar to what is done to identify the MPC dynamics of disturbance variables. The process outputs being predicted are analyzer measurements with the same cycle time and analysis time as during normal operation. So that the MPC inputs are independent variables, controllers that manipulate process inputs to the model and whose controlled variable is affected by the inferential measurement must be in manual. For example, a distillation column temperature controller that manipulates a reflux-to-feed ratio would need to be in manual during the identification of the dynamics of an inferential measurement of overhead or bottoms composition. The dynamics identified are used to synchronize inferential measurements with analyzer predictions. By omitting these dynamics, the inferential measurements used for process control provide a new update without any delay or lag. MPC matrix condition number and analysis can be

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SCLR %DV

used to help eliminate correlations between inputs to ensure the MPC inputs are independent variables. Step response models use an openloop gain, total loop dead time, primary time constant and possibly a secondary time constant. The step response models described here all work in percent signals since the PID algorithm works in percent signals. The conversion to the signals in engineering units seen in the control room is done by scaler blocks that use the input and output scale ranges. An open-loop, steady-state process gain is used for processes that decelerate to a steady state as a result of negative feedback within the process. An openloop integrating process gain is used for processes that ramp as a result of no feedback within the process. An open-loop runaway process gain is used for processes that accelerate as a result of positive feedback within the process. The models identified by tuner and MPC identification software take into account the controller scale ranges of the manipulated variables and process variables and include the effect of valve or variable-frequency drive (VFD) and measurement dynamics. As a result, the process gain identified is really an open-loop gain that is the product of the valve or VFD gain, process gain and measurement gain. Correspondingly, the process dead time is actually a total loop dead time, including the dynamics of the automation system. While the primary (largest) and secondary (second largest) time constants are normally in the process for liquid composition and temperature control, they can be in the automation system.

Do the Math Figure 1 shows the time domain block diagram for a step response model. The normal operating value of the percent composition estimator input variable (%AVo ) is subtracted from the new value of the percent composition estimator input variable (value of the percent composition estimator input variable (%AVn) to

ADD 1 %AVn

Process feedback

Second Order plus Dead Time Step Response Model 2

%XV %AV

MUL

FIL o

%PV

ADD

1/ p Ki = Ko/ p

MUL

%AVo

INT

4 s

SUB

%PV n

%PVo %PV f

ADD

tf PV m

SUB

Signal Processing Blocks: ADD (add), DT (dead time), FIL (filter), MUL (multiply), SCLR (scaler), SUB (subtract) and INT (integrator)

%PV f

PV n

Variables and parameters:

9 ADD PV x

MUL Kx

10 PV fx

SCLR

6 PVf

PV f 7

Analyzer Dead Time DT

PVn = process variable new value

Ki = open loop integrating process

(engineering units)

gain (%/sec/%) (1/sec)

PVf = process variable future value

Ko = open loop gain (%/%) (dimensionless)

(engineering units) PVfx = process variable corrected

Kx = fraction of error used as correction (dimensionless) %AVn = composition estimator input variable new value (%) %AVo = composition estimator input

future value (engineering units) %PVo = process variable operating point (%) ∆%PV = process variable change (%)

variable operating point (%) ∆%AV = composition estimator input

(engineering units)

variable change (%) ∆%DV = disturbance variable change (%)

∆tf = timer interval for prediction of future value

∆%XV = disturbance corrected

%PVn = process variable new value (%)

composition estimator input variable change (%)

%PVf = process variable future value (%) PVm = process variable measured

∆PVx = process variable correction

τs = secondary time constant (sec)

value (analyzer result)

τp = primary time constant (sec)

(engineering units)

θo = total loop dead time (sec)

Step Response Depends on Internal Process feedback Figure 1. The sign of the feedback signal added at point 4 in the estimator determines the type of open-loop process response. A negative value indicates negative feedback and hence a self-regulating process. A positive value indicates positive feedback, a runaway process.

create a percent analysis deviation variable (∆%AV) at point 1 that is added to the change in the disturbance value (∆%DV) to get the percent change in the estimator input with the disturbance correction as a process input (∆%XV) at point 2. The step response output is the normal operating value of the percent process variable (%PVo) added to a deviation variable (∆%PV ) that is the output of the series of dynamics blocks. The result is passed through a scaler block to

provide a new value of the process variable (PVn) in engineering units at point 5. The dynamics inserted after the openloop, steady-state process gain are a dead time block for the total loop dead time (θo) and a filter block for the secondary time constant (τs ) to provide all of the parameters for a second-order plus dead time step-response model. For integrating and runaway process models, the normal operating point of the manipulated variable that is the D e c e m b e r / 2 0 1 4 www.controlglobal.com

I N F E R E N T I A L A N A LY S I S

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Integrating Runaway Dead time self-regulating Lag self regulating Process Variable

negative bias must be sufficiently greater than zero (e.g., 50%) to provide negative as well as positive changes in the process variable. This bias represents a process load. To achieve a new target or setpoint, the manipulated variable must be temporarily changed to be different from the load. The open-loop gain must also be large enough to provide a full range of process variable response. When the process variable settles out at the new operating point, the manipulated variable returns to be equal to the load plus any compensation for the change in disturbance variable. The future value for an integrating process is the disturbance corrected composition estimator input value (∆%XV) multiplied by the open loop gain and a time interval for prediction (∆tf ) to give a change in the percent future value (∆%PVf) at point 6. This change is added to the normal operating point and passed through a scaler block to provide a future value of the process variable (PVf) in engineering units. For synchronization with an atline or off-line analyzer, the new value must be passed through a dead time block that is the analyzer dead time (e.g., sample transportation delay plus cycle time plus ½ analysis time). This new value of the process variable in engineering units that include the dynamics of the step response model and analyzer is compared to the actual measurement (e.g., at-line analyzer result). The new value for the step response model output subtracted from the actual measurement is the error in the prediction. The error is multiplied by a factor less than one (e.g., K x = 0.4). The resulting fraction of the error is added to the future value in engineering units (PVf x) to provide a corrected future value (PVf) that is not slowed down by the process or analyzer dynamics. A PID loop or MPC can use the corrected future value as the controlled variable to provide incredibly fast control.

Time

DEAD TIME DOMINANT PROCESSES ARE DIFFERENT Figure 2. The open-loop response of a dead-time-dominant process (a self-regulating process with a time constant much less than the dead time) is much different from self-regulating, integrating and runaway processes, and as a result the tuning rules are quite different.

Rein in Runaways The block diagram (Figure 1) provides insight as to how the model changes depending upon the sign of process feedback within the process. The sign of the feedback signal added at point 4 in the estimator determines the type of openloop process response (response with the PID in manual). A negative value indicates negative feedback and hence a self-regulating process. The openloop response will settle out at a steady state for a given disturbance or PID output change. A zero value indicates zero feedback corresponding to an integrating process. The open-loop response will ramp until a physical or signal limit is reached. A positive value indicates positive feedback, indicative of a runaway process (open-loop unstable process). The open-loop response will eventually accelerate, possibly to a point of no return. Open-loop tests on runaway processes are not done at all or long enough to show significant acceleration. These processes are designed to have large positive feedback time constants to slow down the acceleration. The process gain and

positive feedback time constant of runaway is not identified by software but can be estimated based on ordinary differential equations (ODE). The online document “First Principle Process Relationships” (www.controlglobal.com/whitepapers/2014/firstprinciple-process-relationships) shows how the process gains, time constants and dead times can be derived from ODE for all types of process feedback. Figure 2 shows the open-loop response of self-regulating, integrating and runaway processes with an additional process classified as dead-time-dominant, which is a self-regulating process with a time constant much less than the dead time. While dead-time-dominant processes are not often seen due to thermal lags, the tuning rules are quite different. The online white paper “So Many Tuning Rules, So Little Time” (www.controlglobal.com/whitepapers/2014/so-manytuning-rules-so-little-time/) details how tuning rules change with the type of process response. Greg McMillan is a member of the Control Process Automation Hall of Fame (2001), Pierce Wu is a simulation project engineer at Mynah Technologies.

ask the expertS

Model-less Predictive Control; Mass Flow of Steam; Rotary Valve Torque

I receive InTech/ISA Review, and recently I read an article on multivariable predictive control using models by Allan Kern, and I do not agree with his analysis on model-less strategies. I have implemented many multivariable predictive controllers on complex plants (SMOC2/Shell license) where both the ROI and the performance was excellent in the long run. Obviously competent process control engineers had to review and adjust, if necessary, the model’s parameters, but the control algorithm is very robust, and the needs for adjustment are not so frequent even with non-linear processes. Typically the control algorithm is robust using state-variable theory (state estimators, Kalman filters, observers) to arrive at black and gray models. This means that for good performance more (not fewer) models are needed, and the model-less views, as told by Kern, are incorrect. What do you think of model-less use in predictive control? Michel Chande vau mchandevau@yahoo.fr

You are right. In order to control/optimize a process, one must understand it.A

BÉl a LiptÁk

liptakbela@aol.com

I agree with your assessment. In our book, Advanced Control Foundation, we provide many examples where MPC has produced amazing results. These results would not be possible without an explicit knowledge of the process, i.e., control being based on the process model. Terry Ble vins

Terr y.Blevins@Emerson.com

Referring to Equation 8.6 (2) in your handbook, “Process Control and Optimization,” page 1,575, my application involves a DP-type flow element and the following operating conditions: Measured flow (F)..............................100 kg/s Measured pressure (P).......................100 barg Absolute pressure (Po)...................1.01325 bar

Reference pressure (PR).................. 101.01325 Actual temperature (T)......500 °C (773.15 ºK) Ref. temperature (TR)......................813.15 ºK Density (ρ)...................................30.13869861 [P = 98.98675 bara (100 barg), T = 500 °C] Specific gravity (SG).................... 25.01136814 [The density of air at NTP = 1.205 kg/m3 and SG equals density/1.205] Reference density (ρ R)...............28.18237295 [P = 98.98675 bara (100 barg) T = 540 °C] Ref. spec. gravity (SGR).............. 23.38786137 [The density of air at NTP = 1.205 kg/m3 and SGR equals reference density/1.205] Compressibility (X).................... 0.920440391 [P = 98.98675 bara (100 barg), T=500 °C] Ref. compressibility (XR)............ 0.935913474 [P = 98.98675 bara (100 barg), T = 540 °C] Actual steam quality (Q)........................... 100 [steam temperature is above saturation, quality is 100%] Ref. steam quality (QR).............................100 [steam temperature is above saturation, quality is 100%] I’m interested in calculating the compensated flow (FC) in kg/s, but depending on which equation I use, the results are different. If I use specific gravity (calculated from measured steam pressure and temperature) for flow compensation, then: (1) FC = F*ρ/ρ R = 100*1.069417 = 106.9417 kg/s. If I use steam pressure and temperature for flow compensation, then: (2) FC = F*(P+P0)/PR*TR/(T+T0) = 100*1.051736 = 105.1736 kg/s. If I use steam pressure, temperature, compressibility (calculated from measured steam pressure and temperature) and quality (100%) for flow compensation, then: (3) FC = (P+P0)/RP*RT/(T+T0)*X/ XR*QR/Q = 100*1.034348 = 103.4348 kg/s. When steam pressure or steam temperature decreases, the steam density increases and compressibility drops. Decreasing steam pressure or increasing steam temperature reduces steam density and increases compressibility. In my example, the temperature of 40 °C dropped from design; therefore, density and

This column is moderated by Béla Lipták (http://belaliptakpe.com/), automation and safety consultant and editor of the Instrument and Automation Engineers’ Handbook (IAEH). If you have an automationrelated question for this column, write to liptakbela@aol.com.

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ask the expertS

specific gravity increased, whereas compressibility decreased. For testing purposes, I’ve modified Equation 8.6(2) of page 1,575. If I modify the equation and use the one below, then: (4) FC = (P+P0)/RP*RT/(T+T0)*XR/X*QR/Q = 100*1.069417 = 106.9417 kg/s. In this case, the result of equation with specific gravity compensation (1) and the modified equation (4) with pressure, temperature and compressibility are exactly matching. Please advise if equation 8.6 (2) in your handbook needs to be corrected or if my modified equation is wrong. Kumar Chennai,

kumaralstom@hotmail.com

Usually, the problem is that the compressibility and/or quality (X & Q) terms are not accurately known. I believe that Equation 8.6 (2) is correct, but I’m asking Drs. Cheng, Meeker and Liu (or any other expert) to double-check and let you know.

might undersize or oversize the actuator. Ian H.Gibson

gibs0108@optusnet.com.au

A section in the Fisher Control Valve Handbook (www. pacontrol.com/download/Emerson-Control-ValveHandBook.pdf), “Rotary Actuator Sizing” (page 132), has a discussion, including “Torque Equations” and two practical tables for easy parameters’ selection. Rotary Actuator Applications Guide (www.parker.com/literature/Literature%20Files/euro_cylinder/v4/htr-app_1230-uk. pdf) has a special section dealing with “Calculating Torque Requirements” (page 5) as well as some examples. “Rotary Actuator Sizing, Valdisk and Valdisk 150,” (www.f lowserveperformance.com/performhelp/sizing _ selection:valtek:rotary_actuator_sizing), Steps 3-6, deal with some forms of torque calculations. If these are not enough, feel free to contact me directly.

Bél a Lipták

Avihu Hir am

liptakbela@aol.com

You’re making the assumption that steam follows the ideal gas law. Since it doesn’t, this might explain the discrepancies you’ve noted. (I haven’t tried to check your calculations, but it would not surprise me.) In the old days, we had to use multipliers/dividers to do P/T compensation like you have. Modern control systems have significantly superior capabilities. You can use steam look-up tables, and directly use density and compressibility in the compensation equation. I haven’t looked under the hood of the recent DCS, but I strongly suspect that they already have standard, built-in compensation blocks for steam. Simon Lucchini

Simon.Lucchini@fluor.com

How can I calculate the torque of a rotary valve without using manufacturer data? Is there any general rule for the torque calculation of rotary valves? I need this for actuator sizing. Can you provide me with a good reference on this subject? A. R ahimi

a.rahimi@ tam.co.ir

Don’t try to do this without using the valve manufacturer’s data because the torque values are critically dependent on valve design, seal material, friction factor of the ball to seal, process pressure, frequency of operation, dryness or lubricity of process f luid, etc. And the maximum allowable stem torque depends on stem material and design. The calculation is hard enough if you use the manufacturer’s data, so the risk is high that without it, you 48

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Avihu@HiramEng.com

What symbols are used for pulse inputs to PLC/DCSs in flowsheets or other schematic? Hiten A. Dal al, P.E.

hiten_dalal@kindermorgan.com

There is no standard symbol for PLC/DCS schematics. Each vendor provides a generic function block to treat the signals. By the way, you haven’t mentioned what physical parameter is being measured with the pulses. R a j Binne y

binney4family@internode.on.net

There is no specific symbol used for pulse input or, for that matter, for any analog or digital input. ISA standard 5.1 is the document where these things are defined. I have looked at the most recent edition, which I think is 2009, and there is no provision to show the technology used to make a measurement. For example, there are many ways that a flow can be measured: differential pressure, turbine, Coriolis, magnetic, ultrasonic, vortex shedding, target, etc. The flow diagram only shows these as an FT or flow transmitter. Your pulse input must represent something with a pulse count, pulse duration or pulse frequency. Whatever it is, it’s only the technology used to measure something like flow, level, temperature, whatever. The symbol is xT where x is the property being measured by the transmitter. You are permitted to supply additional notation (words or illustration) on a P&I Diagram if you want to identify the type of transmitter. Dick Caro RCaro@CMC.us

ROUNDUP

Hot and Heavy Keep pressure and temperature under control with these technologies. TEMPERATURE TRANSMITTER SPORTS SMARTS

ZERO-SPAN ADJUSTMENT

SmartLine temperature transmitter can display messages from the control room as well as process data. It features intuitive diagnostics for both the transmitter and sensor, displaying a real-time view of sensor health. A built-in dual-input and digital-output option minimizes the number of instruments needed for both monitoring and switching needs. Honeywell Process Solutions 800-343-0228; www.honeywellprocess.com

LE1 pressure transmitter comes with a zero-span adjustment for device calibration in the field. It’s designed for industrial applications, including pump and compressor monitoring, refrigeration and HVAC. It has compact, stainless-steel construction with ceramic sensor and an accuracy level of 0.5%. It’s available with Micro, Packard or Cable Leads electrical connections for installation flexibility. Winters Instruments 800-946-8377; www.winters.com

DP/PRESSURE TRANSMITTERS

ZONE 2 TRANSMITTERS

A low-power version of the company’s DPharp EJA-E series differential pressure/ pressure transmitter outputs both 1-5 Vdc and HART signals. The transmitter consumes just 27 mW. The unit has a reference accuracy of ±0.055%. Basic settings for this new DPharp transmitter can be done easily using a setting switch and an external adjustment screw on the transmitter. Yokogawa Corp. of America 281-340-3800; http://yokogawa.com/us

ST130 series head-mount transmitters with thermocouple or RTD inputs are ATEX Zone 2-approved for use in potentially explosive atmospheres with flammable gases present. They’re USB-configured, loop-powered and provide a proportional 4-20 mA output. ST130s also carry UL Class I, Div. 2 approvals. These transmitters also mount in compact DIN Form B connection/sensor heads. Acromag 248-624-1541; www.acromag.com

GOES UNDERWATER

MODULAR DESIGN

PT-503 submersible pressure transducers have a PVC housing that withstands prolonged exposure to harsh and potentially corrosive chemicals, even at temperatures from -30 °F to 130 °F and depths to 450 ft. The units are available with 4-20 mA, Modbus, 0-5 Vdc and mV/V outputs. Cable options include Hytrel, PVC and urethane. They also have a Teflon-coated or ceramic transducer face. Automation Products Group 888-525-7300; www.apgsensors.com

Sitrans TS500 resistance thermometers and thermocouples have a modular design, and come in a large range of sizes, materials, sensors and transmitters. A wide range of process connections, connection heads, sensor types, transmitters and displays are available to configure individual solutions. They support HART, Profibus PA and Foundation fieldbus communication standards. Siemens Industry 800-743-6367; www.industry.usa.siemens.com

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ROUNDUP

EXPLOSION-PROOF SCANNER

PRESSURE SWITCH WORKS MECHANICALLY

PD6830X is a rugged, explosion-proof, NEMA 4X/ IP68 Modbus master, slave or snooper (sniffer). It’s designed for accurate display and quick access to temperature and pressure information, locally or remotely, in hazardous areas or in the harshest safe area applications. PD6830X can accept up to 16 individually programmed process variables from multiple Modbus temperature and pressure devices. Precision Digital 800-343-1001; www.predig.com

ProSense MPS25 mechanical pressure switches are designed for tough applications. They feature an all-welded 316 stainless-steel, sealeddiaphragm actuator design (for up to 100 psi), or a directacting, 316 stainless-steel piston design with a Buna-N O-ring (for 200 to 7,500 psi). The stainless-steel housing provides resistance to vibration. Pressure ranges from vacuum to 7,500 psig are available. AutomationDirect 800-633-0405; www.automationdirect.com

EASY TO CONFIGURE

BLUETOOTH SMART

Mini Pro analog signal conditioners include two spacesaving temperature transducers—one module for resistance thermometers (RTDs) and the other for thermocouples. Both have options for creating custom linearization tables. Output can be freely defined, allowing loop calibration via the simple configuration software. The temperature transducers are only 6.2 mm wide. Phoenix Contact 800-322-3225, www.phoenixcontact.com

Hobo MX1101 is a data logger that measures and transmits temperature and humidity data wirelessly to mobile devices via Bluetooth Smart technology. The self-contained wireless data logger, works with the company’s free HoboMobile app for logger setup and data management. User can access data over a 100-foot range from an iOS mobile device. Onset Computer Corp. 800-564-4377; www.onsetcomp.com

MULTIVARIABLE TRANSMITTERS

TWO TRANSDUCERS ON ONE TRANSMITTER

266C Series multivariable transmitters provide temperature, pressure-compensated flow and level measurement. They can make temperature and pressure corrections for density. For boiler drum applications, they calculate corrections for the liquid and steam density on the basis of the measured absolute pressure, and correct for temperature variations of the reference impulse piping. ABB 800-435-7365; www.abb.com

Deltabar FMD71 level transmitters use two pressure sensor modules connected to one transmitter. One sensor measures hydrostatic pressure, the other measures head pressure. Each sends a digital signal corresponding to temperature-compensated measured pressure to the transmitter, which calculates the differential pressure and transmits level, volume or mass via 4-20 mA with HART as a standard two-wire, loop-powered device. Endress+Hauser 888-363-7377; www.us.endress.com

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ROUNDUP

HOUSED BY STAINLESS STEEL

MEDIA-ISOLATED PRESSURE SENSOR

PX51-USBH pressure sensor has an all stainless-steel body and imperial or metric pressure ports. The transducer is temperature-compensated from 60-160 °F, and can be operated between -50-185 °F. The unit is available in pressure ranges from 750-30,000 psi. It is CE-approved to industrial specification EN16326-1:2006. Free software allows displaying data from multiple sensors. Omega 888-826-6342; www.omega.com

154 Series of media-isolated, piezoresistive silicon pressure sensors comes housed in a 316L stainless-steel package as standard. The compact, 19-mm sensor is also available in an ASTM Grade 2 CP titanium housing for very harsh environments. Standard ranges for pressure are from 0-15 psi to 0-300 psi in gauge reference format, as well as from 0-7 bar to 0-28 bar in absolute reference. Measurement Specialties 800-745-8008; www.meas-spec.com

MANY FROM ONE

UNIVERSAL ISOLATED DUAL-INPUT TRANSMITTERS

Rosemount 4088 multi-variable transmitter provides differential, static and temperature measurement from one transmitter. It sends a reliable and stable signal via Modbus, BSAP or MVS. It’s integrated into an oil and gas production network by transmitting data to flow computers and RTUs. An extended range option captures flow rate spikes above the upper range limit of the transmitter. Emerson Process Management 949-757-8500; www.emersonprocess.com

OptiTemp TT51 series temperature transmitters feature accuracy of 0.05% of span and a five-year stability of 0.05%. The TT51 series is also IEC61508-2 SIL 2-approved for safety-related applications. They work in an ambient temperature range of -40-85 °C, and have a galvanic isolation of 1,500 Vac. They feature a two-, three- and four-wire connection technology. Krohne 800-356-9464; www.krohne

FUSED GLASS GIVES SOLID SENSE ABILITY

TEMPERATURE MONITOR DOES WIRELESSHART

SolidSense II pressure transducers and transmitters with glass-fused strain gauge technology reduce drift or zero instability. A 316L stainlesssteel, chromium-rich, wetted flow path offers superior corrosion resistance. Active temperature compensation improves process pressure measurement in plants exposed to wide temperature variations. FM- and ATEX-compliance meets demanding applications. Brooks Instrument 1-888-554-FLOW; www.BrooksInstrument.com

THZ WirelessHART temperature solution combines a battery-powered HART temperature transmitter with a WirelessHART adapter. The device transmits temperature measurements and critical HART diagnostic information to a WirelessHART gateway, even if power is not readily available. The device has 20-bit input resolution and a weatherproof, IP66, NEMA Type 4X, dual-compartment housing. Moore Industries 818-894-7111; www.miinet.com

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Product introductions

CAN’T INTERRUPT THIS

MONITORS PARTICULATES

Modular uninterruptible power supplies (UPS) include control units and buffer and battery modules for protection against incoming power faults for 24-Vdc applications. The control units feature status relays for status monitoring, direct switchover to the battery modules when a supply outage is detected, and automatic reconnection to the load when power recovers. The buffer module bridges short-term power supply failures for dips up to 100 ms. Weidmüller 800-849-9343; www.weidmuller.com

Tribo.dsp U3400H is a twowire, loop-powered, wide dynamic range particulate monitor for both high- and low-temperature applications using the HART protocol. The unit is CSA-certified for hazardous locations. Simple to install and requiring no operator sensitivity adjustment, the unit suits emission monitoring and process flow applications where a continuous 4-20 mA signal is needed. It can be wired directly to a PLC, DCS, data logger or control device. Auburn Systems 978-777-2460; www.auburnsys.com

ULTRA-FAST DATA LOGGER

HMI+PLC

HiTemp140-FR is a hightemperature data logger with an ultra-fast response time. It features a 2.0 x 0.0625-in. diameter probe and is capable of recording up to 4 Hz. Also, HiTemp140-FR’s body is made of food-grade stainless steel, suitable for use in environments up to 140 °C. The probe can measure temperatures from -200-260 °C. The unit comes in two models which feature 36- and 72-in. flexible probes. CAS DataLoggers 800-956-4437; www.dataloggerinc.com

FT1A Touch 14 I/O combines a 3.8-in. touchscreen HMI and control in one package, all programmable with the company’s PC-based software. The device has 14 I/O: eight discrete inputs, two of which can be configured as analog, four outputs and two analog outputs. PID control functions include auto-tuning, anti-reset windup and bumpless transfer. It also has communications ports for serial networking, remote Ethernet and Modbus TCP. IDEC 800-262-4332; www.idec.com/usa

FIRE-SAFE GLOBE VALVES

MIXES GASES ON-SITE

Clampseal fire-safe globe valves are for refining and chemical plants where fire safety is a major concern. These fire-safe valves are available in Y, angle and Tpattern configurations in 1/2 in. to 4-in. sizes, up to ASME 2500 pressure ratings, and with NPT, butt-weld or socketweld ends. Other end connections are available. The firesafe valve meets API fire-safe standards, and contains a simple mechanism that compensates for thermal expansion. Conval 860-749-0761; www.Conval.com

GasMix is set up onsite to mix and/or dilute two to 12 gas standards, and can be used for applications such as synthetic gas mixture generation and more. With dedicated software, the device operates on its own from one injection to a fully automated and pre-programmed sequence, and can remotely control an external injection valve and the start of an analyzer. A built-in audit trail function ensures total traceability. UP Analytical 210-508-3655; www.upanalytical.com

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Product introductions

SOFTWARE STREAMLINES HAZARD ANALYSIS

COMMUNICATE VIA MODBUS

Phast 7.11 software for process industry hazard analysis lets users view flame shapes in radiation contour graphs; insert a side-view image; view the bund and release direction in the context of predicted hazard range; and apply new default models with options for using the multienergy explosion model. Phast also has an optional 3D Explosions module that allows users to conduct an even more realistic and detailed evaluation of explosion hazards. DNV GL +47 4153 9750; www.dnvgl.com

UA Modbus Gateway can connect to any device that uses the standard Modbus protocol over serial or Ethernet connections on one side, and makes it securely available to OPC UA clients on the other via OPC UA over Ethernet. The device is suited for applications that have limited power availability in remote conditions, are remote or unmanned stations that need data collection, or must operate in extreme temperatures and/or dusty environments. MatrikonOPC 877-628-7456; www.matrikonopc.com

ANALYZES FREE CHLORINE

SHUT IT DOWN REMOTELY

FC80 panel-mount freechlorine analyzer is a plugand-play device that monitors free chlorine in drinking water, rinse water, cooling water or other fresh water samples from 0.05-20 ppm chlorine as the standard range or 0.015.00 ppm with the low-range sensor. FC80 is compliant with EPA method 334.0. An advanced panel-mount design includes built-in flow control, which eliminates the need for complicated pressure regulators and rotometers. Electro-Chemical Devices 800-729-1333; www.ecdi.com

Remote shutdown system (RSDS) shuts down assets remotely with fail-safe logic necessary for wireless operation of critical systems. This long-range wireless telemetry system can be configured with either a PLC monitoring system or the company’s gateway-controlled standalone system that can monitor inputs and generate control commands autonomously. The device interfaces with any type of sensor and transmits the data wirelessly to a gateway. SignalFire Wireless Telemetry 978-212-2868; www.signal-fire.com

MODULAR CORDSETS

STREAM SELECTOR

Powerfast for process automation provides a robust and reliable modular wiring solution that includes a line of cordsets, receptacles, reducers, reducer tees and others that provide users with a way to configure a complete power distribution system. The connectivity products are UL-approved, available in A-size (7/8 in.) and D-size (1-3/8 in.) connectors, and rated for up to 30 A of power for a wide range of operations. Turck 800-544-7769; www.turck.us

Cheminert C65 Series liquid handling stream selector is an integrated motor/valve assembly. Using a proven valve design and the 24 V motor from the company’s microelectric actuators, C65 only needs to be connected to the instrument’s power supply. An optional serial interface board permits RS-232 communications for position input control and confirmation of valve position. The compact package comes in four-, six-, eight- and 10-position configurations. Vici Valco Instruments 800-367-8424; www.vici.com

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C O N T R O L TA L K

Process Control Psychology 101

S Greg Mcmill an Stan weiner, pe controltalk@putman.net

Greg McMillan and Stan Weiner bring their wits and more than 66 years of process control experience to bear on your questions, comments and problems. Write to them at controltalk@putman.net.

tan: As engineers, we forget sometimes that

Leah: As a chemical engineering student at the

we are people with egos and mindsets that can make or break a project. The best solution is not always perceived as such. We alluded to the understanding of psychology needed in the June 2012 column, “The Human Factor” (www.controlglobal.com/articles/2012/mcmillanweiner-human-factor/). Here, we take a closer look. We are fortunate to have the insight and perspective of Leah Ruder, process automation systems group manager at the Midwest Engineering Center of Emerson Process Management.

Missouri University of Science and Technology, I didn’t hear about this career opportunity until John Hedrick, the president of Automation and Control Technologies (A&CT), gave a guest lecture to my advanced control class. I went to work for A&CT. I knew I was amidst a fantastic group of people, such as Bob Otto (see February 2007 column “The Best of the Best, Part 2,” www.controlglobal.com/articles/2007/039/) and Alex Muravyev (see September 2011 column “The Key to Process Knowledge and Sustainable Manufacturing,” www.controlglobal.com/articles/2011/ key-process-knowledge-sustainable-mfg/), but did not realize until many years later what a special environment it was. I thought it was like this everywhere. I was really lucky to be mentored there. My next gig was with Automation and Control Concepts (A&CC). I spent six years as contractor to a large food company, upgrading every batch control system at its dry pet food plants in North America. It was a pretty cool learning experience principally involving the flowability of solids. The consistency could range from being granular almost like sand to being very tacky like powdered eggs. The moisture content could vary considerably, so packing and clumping was a common problem with the screw auger. You could have a 14-in. diameter screw trying to accurately add just 200 pounds to a batch. As the batch addition neared completion, the rate of change of weight increased due to the height of the fill. The corporate engineering department developed some specialized control strategies to provide a much more accurate batch addition. While the objective of an accurate addition sounded simple, the real solution was complex and critical due to material variability, fast addition rates and batch cycle times of less than five minutes. Besides achieving the desired quality, you don’t want to over-add costly ingredients, and you mustn’t violate the order of ingredients on the product label to maintain compliance with U.S. Food and Drug Administration (FDA) requirements.

Greg: My whole career was an accident. Jokes come to mind about causalities but the real deal was a series of extraordinarily fulfilling roles in a field I had never even heard about until the interview with Monsanto in 1968. I chose being an instrument and electrical (E&I) design and construction engineer over other job offers in aerospace and communications system design. Leah, how did you get into process automation?

www.controlglobal.com D e c e m b e r / 2 0 1 4

C O N T R O L TA L K

Stan: What was the existing system? Leah: To be kind, you could say the system was primitive. The batch management system (BMS) was programmed in a digital operating system (DOS) to adjust the cutoff point based on the last batch. The plants dug in their heels, basically saying, “We don’t want the new system.” The experience was a big education on the psychology of the rollout of projects.

Greg: How did the corporate staff convince the plants to change?

Leah: The mechanical, process and control specialists in corporate engineering showed the plants that material characteristics were introducing variability, and that the variability was actually worse when their auto-tuning algorithm was turned on. After they reluctantly agreed to the new system, the typical comment after seeing the results was, “I can’t believe how great it is!” After about half of the plants had seen the benefits of the new system, the other plants could see the metrics and were clamoring to be next in line for the upgrade.

Stan:

What other good approaches were used in upgrade projects?

Leah: The headquarters recognized how important the total solution was and would pay for any field device improvements at no cost to the plant. Often the plants didn’t know what was not working. When pressed as to why they did not report upfront a problem subsequently found in commissioning and startup, the plant often said, “Oh, we just go out and kick it.” This sort of thing happened in every project. I don’t know the reasons, but maybe it was a lack of communication and lack of understanding that the control system can only be as good as the measurements and final control elements.

Greg: In the ISA Mentor program, I see

that plant automation engineers are overloaded. There seems to be no limit as to what will be piled on. I don’t think engineers are particularly apt to turn down an opportunity to do more of what they love and tell their boss this is too much. Do you see this as an increasing problem?

Leah: Plant people often don’t have the

arms crossed, always monitoring who is happy and who is upset. You don’t know the dynamics of why. It works best to go one-on-one privately. People often open up and want to discuss what they know with an individual. It is incredibly important to develop a mutual understanding and respect. One person could make or break the actual and perceived success of a project. This process is not straightforward. People may remain puzzles. I find this situation interesting, besides challenging. I seem to have a knack for reading people’s dispositions and developing productive relationships.

opportunity to make the most out of the opportunity in a migration project. They may not even have time for a review. We have been asked to write the customer requirements. We have been told to port over, and just duplicate and reverse-engineer as necessary, despite the fact that there could be 15 years of miscellaneous stuff, most of which is not helpful and even detrimental.

Greg: We conclude with the “Top 10

Stan: How do you deal with customer

Signs a Customer Is Not On-Board with an Upgrade Project.”

staffing?

Leah: Bigger players do have staff in process control to have engagement. We make the most out of this opportunity. Smaller customers do not even know what they are missing. I instruct engineers to ask if the proposed work plan is the best solution. You need to maintain humility and seek openings and situations to create mutual understanding through discussions. Egos crush opportunities. You don’t want to go into a room and say, “This is the way it is.”

Greg: How do you achieve the communication needed?

Leah: You don’t want to make disparaging remarks. You don’t know who is in the room. If the boss is in the meeting, you may not get the truth. People will not admit to that they don’t understand. You need to talk in non-supplier-specific terms. You need to translate what you want to say into generic industry terms. You get a sense of who is not involved in the conversation based on body language, such as sitting back with

Top 10 Signs a Plant Is Not On-Board with an Upgrade Project 10. Project definition is an existing configuration. 9. Project team is nameless. 8. No donuts in the meeting room. 7. Attendees are accountants. 6. Project cost and completion date are the only topics of interest. 5. When innovations are proposed, the question is always, “Does this change anything?” 4. When asked about checkout and commissioning coordination, the reply is, “Huh?” 3. Arms are crossed, hands are crossed or eyes are crossed. 2. Operators are marching outside the meeting room with signs saying, “No Way No How!” 1. Your plant badge no longer works.

Want to Talk Control with Greg and Stan? This is your chance have your voice heard and share what you have learned for the benefit of the profession. The process is simple. You talk by phone with Greg McMillan for an hour or two. The conversation is free to go wherever is of most interest to you. To join the conversation, please contact Nancy Bartels (nbartels@putman.net). D e c e m b e r / 2 0 1 4 www.controlglobal.com

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CONTROL REPORT

Brain Power for Power Supplies Jim Montague

e xecutive Editor jmontague@putman.net

Users already have diagnostics for predictive maintenance and asset management in their controllers and field devices, and now they want them in their power supplies too. 58

verything is getting “smart,” and this trend appears to be holding true for power supplies as well. Devices that used to only deliver power, convert it and maybe offer surge protection are now monitoring and measuring current and voltage profiles, implementing alerts and alarms for predefined operating ranges, and sending data on power supply performance up to higher-level systems and users for analysis and optimization efforts. For instance, Richard Anderson, senior automation specialist at Solid State Automation and Controls (http://solidstateautomation.com) in Houston, Texas, reports in a whitepaper, “How to Develop Cost-Effective, Ruggedized, SkidBased Applications for Remote Deployments,” that SSAC recently designed and built a viscosity-reducing, skid-based, oil-mixing system for an unmanned production platform in the Gulf of Mexico, and employed Siemens Industry’s Siplus S7-1200 PLCs, ET200M I/O modules, MP377 HMIs and two power supplies in an explosion-proof, NEMA 7 enclosure and intrinsically safe track pad. The two power supplies consist of two Sitop units, both capable of 24 Vdc and 120 Vac with a redundancy module between them. They support and maintain high availability on the skid’s equally redundant PLCs, which pull data from a flow sensor, and use 4-40 mA analog wiring, HART, Profibus and Profinet communications protocols and Siemens’ Scalance wireless modules to transmit it to the user’s onshore DCS. Likewise, S7-1200 PLCs can also use Modbus RTU and Modbus TCP for communicating between legacy RS-232 and RS-485 systems and industrial Ethernet, while Sitop 1600 DC uninterruptible power supplies have two Ethernet ports for integrating with Profinet and reporting to users’ higher-level networks. The whitepaper is available at www.industry. usa.siemens.com/automation/us/en/power-supplies/power-supply-sitop/Documents/AMWPSSSBA-0714-Lo-res.pdf.

www.controlglobal.com D e c e m b e r / 2 0 1 4

I’d add not to take my word that power supplies are getting smarter, but I can’t because when I researched this topic, I ran across two articles I wrote on it last year and the year before. In the earlier article, “Power Supplies Take Sophisticated Paths” (www.controlglobal.com/ articles/2012/montague-power-supplies-paths), Roolf Wessels, business unit manager for monitoring and protection at Pepperl+Fuchs, said, “Power supplies have always been a bit of a stepchild compared to other process control devices, but users are recognizing that power is the most critical element in their applications. You can lose a few I/O points and networking nodes and still run an application, but losing power means losing your whole application, so it’s worthwhile investing in high-reliability, high-efficiency power. As a result, users want more diagnostics in their power supplies. They already have diagnostics for predictive maintenance and asset management in their controllers and field devices, and now they want it them their power supplies, too.” In the more recent article, “Power Supplies Get in on the Reliability Act” (www.controlglobal.com/articles/2013/power-supplies-getin-on-the-reliability-act), Mike Garrick, power supply manager at Phoenix Contact, added, “Applications become more robust when a power supply can report when its connected field devices are drawing too much current, while the integrity of the DC bus is intact. For example, if the system is designed for 10 amps, it’s become a reasonable expectation for the power supply to provide a signal to the process controller when the load starts to draw more than 10 amps. This signal is an early warning that the load is drawing too much current, and maintenance should be scheduled. When this early warning is received, the controller knows the process is running at the proper voltage at a current beyond the nominal rating of the supply. The reason for this could be a field device that’s getting old and requires service.”

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