Control Magazine - March 2015

ASSET MANAGEMENT MOVES BEYOND CMMS

HOW TO CALIBRATE PRESSURE INSTRUMENTS

BETTER WAYS TO DIAGNOSE THE PHYSICAL LAYER

MA

RC

H

20

15

THROUGH THE LOOKING GLASS A pragmatist's view

of how emerging technologies will revolutionize tomorrow's controls.

CT1503_01_cvr.indd 1 3/3/15 9:46 AM

the #1 value in automationOrder Today, Ships Today!

* See our Web site for details and restrictions. © Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405

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from top to bottomProcess Sensing

• Ranges available up 26.4 GPM

• Fast 10ms response time

• Easy-to-turn dial to choose setpoint

• Integrated check valve prevents back fl ow in horizontal or vertical mounting

• LED output status indicator

• IP65 / IP67

FLOWThe ProSense FSD Series � ow switchesmonitor liquid media and provide reliable � ow detection for industrial applications.

Starting at:$125.00

Integrated check valve prevents back fl ow

monitor liquid media and provide reliable � ow detection for industrial applications.

• Mechanical or electronic pressure switches for low-cost indication and switching

• Gauge and vacuum pressure transmitters with ceramic or stainless steel sensing elements

• Digital pressure switches/transmitters with integral LCD display

• Air diff erential sensors also available

PRESSUREProSense pressure switches and sensors monitorhydraulic, pneumatic and other process applicationsreliably and accurately. A wide selection of modelsare available:

stainless steel sensing

Air diff erential sensors

Starting at:$69.00

• Thermocouple and RTD probes and sensors

• Transmitters with integral sensors, or thermocouple or RTD input

• Thermowells and fi ttings

• Thermocouple and RTD extension wire

TEMPERATUREProSense family of temperaturesensing components includes:ProSense family of temperaturesensing components includes:

Thermocouple and RTD probes and sensors

sensing components includes:ProSense family of temperaturesensing components includes:

Starting at:$15.25

• ProSense fl oat level switches provide a low-cost general purpose solution for single point monitoring of liquid level in a variety of applications.

• Continuous level measurement, switching and level control

• Automatic temperature compensation for accurate measurement

• Output options include current, voltage, frequency and relay

• Pushbutton confi gured models, or PC confi gured models using free software

LEVELFlowline non-contact ultrasonic liquid levelsensors use proven technology that won’tfail because of dirty, sticky orscaling liquids.

Output options include current, voltage, frequency

Pushbutton confi gured models, or PC confi gured

Flowline non-contact ultrasonic liquid levelsensors use proven technology that won’t

level measurement, switching and level

Automatic temperature compensation for accurate

sensors use proven technology that won’tfail because of dirty, sticky orsensors use proven technology that won’t

Starting at:$260.00

Starting at:$299.00

Starting at:$9.50

• NEW! ProSense SLT series submersible level sensors provide continuous liquid level measurement using the hydrostatic pressure exerted by the liquid above the sensor

• 4-20 mA output signal compatible with PLCs, panel meters, data loggers, and other electronic equipment

• Intrinsically safe with a +/-0.25% accuracy standard

1503-Control-Sensors(Process)-MAG.indd 1 2/11/2015 7:23:20 AM

Globally Trusted.

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American Made.

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CT1503_full page ads.indd 2 3/3/15 10:12 AM

the #1 value in automationOrder Today, Ships Today!

* See our Web site for details and restrictions. © Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405

Research, price, and buy at: www.automationdirect.com/process-controllers

from top to bottomProcess Sensing

• Ranges available up 26.4 GPM

• Fast 10ms response time

• Easy-to-turn dial to choose setpoint

• Integrated check valve prevents back fl ow in horizontal or vertical mounting

• LED output status indicator

• IP65 / IP67

FLOWThe ProSense FSD Series � ow switchesmonitor liquid media and provide reliable � ow detection for industrial applications.

Starting at:$125.00

Integrated check valve prevents back fl ow

monitor liquid media and provide reliable � ow detection for industrial applications.

• Mechanical or electronic pressure switches for low-cost indication and switching

• Gauge and vacuum pressure transmitters with ceramic or stainless steel sensing elements

• Digital pressure switches/transmitters with integral LCD display

• Air diff erential sensors also available

PRESSUREProSense pressure switches and sensors monitorhydraulic, pneumatic and other process applicationsreliably and accurately. A wide selection of modelsare available:

stainless steel sensing

Air diff erential sensors

Starting at:$69.00

• Thermocouple and RTD probes and sensors

• Transmitters with integral sensors, or thermocouple or RTD input

• Thermowells and fi ttings

• Thermocouple and RTD extension wire

TEMPERATUREProSense family of temperaturesensing components includes:ProSense family of temperaturesensing components includes:

Thermocouple and RTD probes and sensors

sensing components includes:ProSense family of temperaturesensing components includes:

Starting at:$15.25

• ProSense fl oat level switches provide a low-cost general purpose solution for single point monitoring of liquid level in a variety of applications.

• Continuous level measurement, switching and level control

• Automatic temperature compensation for accurate measurement

• Output options include current, voltage, frequency and relay

• Pushbutton confi gured models, or PC confi gured models using free software

LEVELFlowline non-contact ultrasonic liquid levelsensors use proven technology that won’tfail because of dirty, sticky orscaling liquids.

Output options include current, voltage, frequency

Pushbutton confi gured models, or PC confi gured

Flowline non-contact ultrasonic liquid levelsensors use proven technology that won’t

level measurement, switching and level

Automatic temperature compensation for accurate

sensors use proven technology that won’tfail because of dirty, sticky orsensors use proven technology that won’t

Starting at:$260.00

Starting at:$299.00

Starting at:$9.50

• NEW! ProSense SLT series submersible level sensors provide continuous liquid level measurement using the hydrostatic pressure exerted by the liquid above the sensor

• 4-20 mA output signal compatible with PLCs, panel meters, data loggers, and other electronic equipment

• Intrinsically safe with a +/-0.25% accuracy standard

1503-Control-Sensors(Process)-MAG.indd 1 2/11/2015 7:23:20 AM

Globally Trusted.

LEVEL MEASUREMENT

American Made.

These are characteristics that personify American know-

how and craftsmanship. Orion Instruments, born on the

legendary Gulf Coast, embodies the spirit which has

made American products synonymous with quality and

performance. Like you, at the end of the day, we don’t

mind washing a hard day’s work off our hands. Let us

show you what Orion quality is all about.

TENACIOUS. RUGGED. DURABLE.

www.orioninstruments.com

Get Tough.


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

PHARMACEUTICAL MANUFACTURING, and PLANT SERVICES ), 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,

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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.

M a r c h / 2 0 1 5 www.controlglobal.com 5

f e at u r e s

March 2015 • Volume XXVIII • Number 3

c o v e r S t o r y

30 / control Systems of the FutureThrough the looking glass of emerging technologies. by William L. Mostia

a S S e t M a n a g e M e n t

39 / asset Management Magnifies Scope and awareness

More capable software, networks and mobile devices enable asset management in many new applications and environments. by Jim Montague

c a l i b r a t i o n

45 / how to calibrate Pressure instrumentsBasics, crucial issues and best practices for successful pressure calibration. by Jim Montague

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

Making the Industrial Internet Real Highlights of the 2014 GE Intelligent Systems User Conference by the editors of Control.www.controlglobal.com/whitepapers/ 2015/industrial-internet-ge-2014-user-summit/

CT1503_05_07_TOC.indd 5 3/3/15 9:47 AM

More than 100,000 customers in every industry around the globe trust Endress+Hauser to make their processes safe, efficient and repeatable. Just like a puzzle, many pieces must come together at the right time and place to manufacture a product profitably. Endress+Hauser understands there is a world of difference between a good fit and a perfect fit for your critical process measurement needs. This is proven by the sustainable value we generate for our customers through the instruments, services and solutions we deliver.

When you need support, Endress+Hauser is the partner you can depend on for:

• Instrumentation and application expertise

• Life-cycle management

• Traceable and accredited calibration

• Real-time plant information

Discover what we can do for you in our library of case studies, application notes and white papers: www.us.endress.com/success-stories

Why choose Endress+Hauser?

Competence is knowing how it all fits together

Endress+Hauser, Inc2350 Endress PlaceGreenwood, IN [email protected]

Anwendung in Magazinen

Anwendung inBroschüren

Anwendung insw-Publikationen


D E P A R T M E N T S


9 / Editor’s PageCozy up to DHS Homeland Security wants to help prevent, respond to and recover from cyber attacks.

11 / control OnlineCheck here for some of our readers’ favorite recent links to ControlGlobal.com.

13 / FeedbackOur readers speak out on Big Data, Inter-net protocols and NERC CIP.

14 / Lessons Learned50 Years of ProgressBéla Lipták looks back at how far we’ve come and how far we have to go.

19 / On the BusBetter Diagnostics for the Physical Layer It’s keeping the nuts and bolts of the hard-ware in trim that keeps the system running.

20/ Without WiresISA Takes on Asset Management

A brief look at the ISA 108 committee’s work on asset management best practices.

22 / In ProcessPrepping for Industry 4.0; Hannover Fair preview; making cybersecurity a team sport; Nanoline contest winners.

28 / resourcesBooks, tutorials, videos, all you need for loop control online.

49 / Technically SpeakingWireless Level MonitoringWhen, where and how to cut the wires.

50 / ask the ExpertsWhen to Use Equal Percentage ValvesGet advice from our experts

52 / roundupThe latest in pressure transmitters and com-ponents to meet new challenges.

54 / ProductsGet the best in automation technology here.

55 / control TalkPractical Installation Best PracticesTwelve tips for getting the best out of your new control system and instrumentation.

57 / ad IndexCheck these pages.

58 / control reportEditor EducationPressure calibration webinars clear up some persistent mysteries.

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

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

CIRCuLATION AuDITED juNE 2014

Find out more about Endress+Hauser’s unique training:

www.us.endress.com/training

On-siteOn-line

or in theClassroomHands-on

A blended training approach to help you keep up with today’s challenges

Customize your training experience through the unique offerings provided to you through our Process Training University. Whether it be on-site, on-line or in the classroom, choose a training package that is tailored to meet your needs.

You choose.

March 2015 • Volume XXVIII • Number 3

CT1503_05_07_TOC.indd 7 3/3/15 9:47 AM

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Paul Studebaker Editor in chiEfps [email protected] t

E D I T O R ’ S P A G E

cozy Up to dhS

Businesses too

often fail to account

for intellectual

property when

determining the

value of at-risk

assets.

As we go to press, the U.S. Congress is threat-ening to suspend funding for the Depart-ment of Homeland Security (DHS). Some

members are even calling for its dissolution. But assuming it’s still around when you read this, you might consider enlisting DHS in your efforts to improve cybersecurity.

“Many of you folks think cybersecurity is all about technology,” said Gregory Touhill, re-tired brigadier general and now deputy assis-tant secretary of cybersecurity operations and programs at DHS, speaking to attendees of the recent ARC Forum. “I’m here to tell you cy-bersecurity is not a technology issue; it’s a risk-management issue.”

Start by recognizing the full value of your as-sets. “Do you know how much your informa-tion is worth?” Touhill asked. Businesses too often fail to account for intellectual property when determining the value of at-risk assets.

Recognize that cybersecurity is a 24/7 re-sponsibility, and that no single piece of soft-ware or other technology offers fail-safe proec-tion against cyber threats. “Threats will hunt you down at home to get access to your work,” Touhill said. “They’ll hack your home network to get a vector.”

It’s not just nation-state bad actors or individ-uals who are looking to sell stolen protected in-formation. “Hacktivists—folks who don’t nec-essarily agree with your company’s mission or core values,” may look to damage a company, Touhill said. Then there are those in your own organization who are simply “stupid,” he said.

Many industrial control systems were not designed for security. Companies are adding potentially vulnerable capabilities like remote access, wireless and mobile, with no dedicated on-site cybersecurity expertise. They may need help fitting these into a security strategy.

With that in mind, on Feb. 12, DHS an-nounced a new Critical Infrastructure Cy-ber Community C³ Voluntary Program. Pro-nounced “c-cubed,” C³ is a public-private

partnership designed to help industry adopt the National Institute of Standards and Tech-nology (NIST) Cybersecurity Framework. The framework consists of standards, guidelines and best practices to protect critical infrastruc-ture through cyber risk management.

Touhill was at ARC to announce the C³ pro-gram and advised attendees to adopt NIST’s five-pronged, “defense-in-depth” core:

1. Identify and inventory your valuables. Put an asset valuation on your intellectual property, and put that value on your balance sheet.

2. Protect them appropriately, according to their value.

3. Detect aberrant behavior. Get the tools and training to know when you’re under attack.

4. Respond according to a plan you develop before you’re attacked. Practice the plan.

5. Recover, again with a practiced plan.The goals of the C³ Voluntary Program are

to help industry increase cyber resilience, to in-crease awareness and use of the Cybersecurity Framework, and encourage organizations to manage cybersecurity as part of an all-hazards approach to enterprise risk management.

Think of it as a DHS community outreach program for NIST. “First, help yourself,” Touhill said. “The government can’t keep you free and give you absolute protection. Put risk management on your corporate agenda.”

Then take advantage of your tax dollars at work. Touhill said DHS offers help through the Cyber Information Sharing and Protection Act (CISPA), where companies can anonymously share information about cyber attacks. It pro-vides cybersecurity evaluations, and consults and sends emergency teams into the field to respond to attacks. DHS also issues bulletins about emerging cyber threats.

“It’s a cyberhood neighborhood commu-nity,” Touhill said. “We need to watch it.”

CT1503_09_Editorial.indd 9 3/3/15 9:46 AM

800 453 6202


M A R C H / 2 0 1 5 www.controlglobal.com 11

C O N T R O L O N L I N E

And the Winners Are. . .

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.

ControlGlobal E-News

Multimedia Alerts

White Paper Alerts

Go to www.controlglobal.com and

follow instructions to register for our

free weekly e-newsletters.

Essentials of Network & Security ServicesA top-level view of critical network

security issues including how to imple-

ment proper infrastructure, securing

remote access and how the IIoT af-

fects network security. www.control-

global.com/whitepapers/2015/essen-

tials-of-network-and-security-services/

Proof Testing level InstrumentsPart of validating the safety function in

a level instrument is the requirement

for regular proof testing. But full testing

can lead to increased risk and process

downtime. Find out how partial proof

testing can save millions of dollars and

maintain required safety ratings. www.

controlglobal.com/whitepapers/2015/

proof-testing-level-instruments/

Flow and Level Technology ReportDon’t miss this free 70-page PDF cov-

ering the latest trends in � ow and level

instrumentation, including adaptive

level control, � beroptic � owmeters and

advances in � ow instrumentation. It

also contains a collection of back-to-

basics tutorials, featuring our most pop-

ular tutorial ever—A Beginner’s Guide

to Differential Pressure Transmitters—

plus tutorials on magnetic � owmeters,

bidirectional � ow measurement, ultra-

sonic continuous level measurement

and radar level measurement, as well

as a collection of case studies and ap-

plication stories. Go to www.control-

global.com/assets/wp_downloads/

pdf/141027-Contol-ebook.pdf for the

complete ebook.

Every year, our readers weigh in on who they think provide the best technology. This time, nearly 1,000 respondents cast their votes for the suppliers

that provide the best process automation products and services in the main disciplines and primary process industries in nine overall product categories and in 78 subcategories. Check out their choices at www.con-trolglobal.com/articles/2015/control-readers-name-the-best-process-automation-suppliers-of-2015/.

Winning Hearts and Minds for System UpgradesLooking forward to your next system upgrade with the same excitement as your next root canal? Who can blame you? There are more pitfalls in a system up-grade than potholes on Rust Belt highways in March. One of the biggest is getting the folks who use the system to support the changes. In “How to Get Engi-neers and Operators on Board for Your Next System Upgrade,” veterans Greg McMillan and Stan Weiner share their advice on this challenge. www.control-global.com/articles/2014/how-to-get-engineers-and-operators-on-board-for-your-next-system-upgrade/.

Free Fieldbus AdviceField Instrumentation Technical Handbook is a useful compendium of physical constants, tables and information no engineer responsible for � eld instrumenta-tion should be without. It’s been required reading in many companies for many years. Don’t start your next � eld instrumentation project without it. Download your free copy now. www.controlglobal.com/whitepapers/2005/52/.

Valve Positioners? Flow Measurement? A lot of time and money can be spent deciding which valves need positioners and which � ows need measurement. We tend to look at short-term costs such as hardware and not the cost of trou-bleshooting and the implications on plant perfor-mance. In this Control Talk blog, we look at com-mon misconceptions as to whether � ow and valve position control should be used. www.control-global.com/blogs/controltalkblog/secondary-� ow-vs-valve-position-control-tips/.

SHORTERSHOP-FLOOR TOTOP-FLOOR TRIPS

CUT ENERGYCONSUMPTION

LOW-INFOVOTERS INYOUR SIS

End Users Come Together toPick Winners of 23rd Annual

Readers’ Choice Awards

INTELLIGENCEIN NUMBERS

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The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2012 Emerson Electric Co.

Tank overfill. In the best case, you have to clean up.In the worst case, you end up in court. Want to sleep well at night?

YOU CAN DO THAT

Driving overfill prevention technology forward. Emerson’s Rosemount Tank Gauging System lets you comply with the reworked overfill

protection standard API 2350 (4th edition) for every type of storage tank. The system includes safety features like SIL certification and a unique radar with two independent gauges (level and overfill) in one housing. Learn more and get the latest API 2350 overfill prevention guidance at www.rosemount-tg.com/safety

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The chemicals you provide are critical to consumers’ lives. Level and fl ow control is critical to effi ciently and safely processing those chemicals. For control solutions that work, trust Magnetrol®. We have been providing level and fl ow instrumentation to the chemical industry for decades. And we offer the most advanced measurement and control technology available today.

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TECHNICALLY SPEAKING F E E D B A C KIN MEMORY OF JULIE CAPPELLETTI-LANGE,

VICE PRESIDENT 1984-2012

1501 E. WOODFIELD ROAD, SUITE 400NSCHAUMBURG, ILLINOIS 60173

editorial teamEditor in Chief: PAUL STUDEBAKER

[email protected] t

Executive Editor: JIM [email protected] t

Senior Managing Editor, Digital Media: KATHERINE [email protected] t

Managing Editor: NANCY BARTELSnbar [email protected] t

Senior Technical Editor: DAN HEBERTdheber [email protected] t

Contributing Editor: JOHN REZABEKColumnists: BÉLA LIPTÁK, GREG MCMILLAN, IAN VERHAPPEN, STAN WEINER Editorial Assistant: LORI GOLDBERG

design & production teamVP, Creative Services: STEVE HERNER

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Midwest/Southeast Regional Sales Manager: GREG [email protected] t630/551-2500, Fax : 630/551-2600

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Classi� eds Manager: LORI [email protected] t

Subscriptions/Circulation: JERRY CLARK, JACK JONES888/64 4-1803

executive teamPresident & CEO: JOHN M. CAPPELLETTIVP, Circulation: JERRY CLARKVP, CFO: RICK KASPER

foster reprintsCorporate Account Executive: JILL KALETHA

866-879-914 4 x 168, Fax 219-561-2033ji l lk@ fos terpr in t ing.com

FINALIST JESSE H. NEAL AWARD, 2013 JESSE H. NEAL AWARD WINNER ELEVEN ASBPE EDITORIAL EXCELLENCE AWARDSTWENTY-FIVE ASBPE EXCELLENCE IN GRAPHICS AWARDSASBPE 2009 MAGAZINE OF THE YEAR FINALISTFOUR OZZIE AWARDS FOR GRAPHICS EXCELLENCE

Three Reasons Big Data Is a Big DealI read with interest your “Control Report” column on page 78 of the January issue (www.controlglobal.com/articles/2015/big-data-is-no-big-deal/), and I’d like to of-fer a couple of add-on points.

• While it is true that big data is just data, the “big deal,” which I’d translate into improved pro� tability for customers, comes when you aggregate and analyze all that data in new ways and derive new outcomes from them. The combination of computing power, connectivity and cloud infrastructure with high-� delity data from � eets of like devices and advances in ana-lytic algorithms are driving new levels of equipment upside and performance.

• The Internet of Things (IoT) be-comes really useful when people place enough emphasis on the “T,” meaning that acquiring, aggregating, analyzing and presenting data is the starting point for new value equations, and the opportunity to automatically drive enhanced behaviors back into the “Thing” under control pres-ents a new dimension of value.

• The third opportunity comes from optimizing the � eet based on real-time connectivity between assets, plus � eet-level algorithms. A good example of this is the wind farm optimization technology from GE that analyzes multiple sources of data from sensors and each turbine in real time, then selectively powers/de-pow-ers individual turbine blades to maximize performance for the complete � eld.

I think the IoT can be a huge deal for customers that stretch its capabilities in new ways.

BERNIE [email protected]

NERC CIP Does Make the Grid Safer In response to Joe Weiss’ blog post of Jan. 19 (www.controlglobal.com/blogs/unfettered/ the-nerc-cips-are-not-making-the-grid-more-secure-or-reliable/):

I totally disagree about NERC CIP not making the grid more secure or reliable. Just a few reasons. I have seen where con-trol systems were operated without mal-ware and ultimately became infected. At

least NERC CIP forces utilities to adopt best operating practices for cybersecu-rity. Some of the rules don’t seem to make sense, but they’re many times a compro-mise on what is practical. Control systems are not always patched as recommended. NERC CIP pushes the utility to patch as regularly as practical. Even the vendors of control systems have had to learn their systems better as they’re pressed by their customers to document the used ports and services and pare down the unused. Changing passwords and dis-abling default accounts are but a few of the many best practices that are being pushed by NERC CIP. It’s truly my belief that if not pushed by NERC CIP, many utility companies would not adopt best practices and would be very vulnerable and inse-cure. The only way I see that NERC CIP doesn’t make the grid more secure and re-liable is if the rules are not followed or [if they’re] circumvented.

GREGORY BRYANTgregor y.br [email protected]

No One Protocol for the Internet of ThingsRegarding, John Rezabek’s February col-umn (www.controlglobal.com/articles/2015/the-internet-of-things-paradise-may-be-far-ther-away-than-it-appears/): I think we’re destined to have a multiplicity of protocols in our facilities. Actuators and sensors will be at the level of the not-Internet of Things; Eth-ernet makes no sense there. But connecting AS-interface, IO-Link, FF, HART and Pro-� busPA to the Industrial Internet of Things (IIoT) through intermediaries to Ethernet will allow integration with IIoT. I see Pro� -net as the backbone, with Pro� net-speci� ed proxies mapping data from the sensor level. Pro� net connects devices to the controller, then OPC UA makes sense as the protocol upwards from the controller to the cloud/big data/analytics.

CARL HENNINGcar l .henning@prof ine t .com

abling default accounts are but a few of the

SHORTERSHOP-FLOOR TOTOP-FLOOR TRIPS

CUT ENERGYCONSUMPTION

LOW-INFOVOTERS INYOUR SIS

End Users Come Together toPick Winners of 23rd Annual

Readers’ Choice Awards

INTELLIGENCEIN NUMBERS

CT1503_13_Feedback.indd 13 3/3/15 10:09 AM

14 www.controlglobal.com M A R C H / 2 0 1 5

BÉLA LIPTÁKl ip takbela@aol .com

L E S S O N S L E A R N E D

I taught process

control in the

chemical

engineering

department at Yale,

not because Yale

didn’t like

automation, but

because the faculty

didn’t know

what it was.

Control and Automation–50 Years of Progress

When I started to work as a process con-trol engineer in the late 1950s, the toilet � oat and the thermostat were considered

to be automation. At that time, the main job of the instrument department in a plant was to clean plugged pressure taps and stuck control valves, while our control panels were full of pushbuttons, blinking lights and manual load-ing stations.

My PastIn 1956, we Hungarians fought for freedom and independence, and tried to get rid of So-viet occupation. We used the Molotov cocktail and small arms against their 2,400 tanks. Obvi-ously, we were crushed, and 250,000 young and educated Hungarians (2.5% of the population) escaped. I was one of them.

Later, I received a scholarship at the Stevens Institute of Technology and graduated there. At this point, I got lucky because a former com-missioner of President Roosevelt, Sam Russell, had just started an engineering � rm, and he hired me. During World War II, Sam’s job was to replace the natural rubber supplies that were blocked by the Japanese with synthetic rubber. He did—he knew how to get things done.

His engineering design � rm, Crawford and Russell, which focused on plastics, was a suc-cess, and I, as his chief instrument engineer, had to hire more and more people because jobs were coming in left and right. I remember it was an ABS plant for GE in 1959 where I � rst used a computer. It was little different from John von Neumann s IAS (Figure 1). At that time, vacuum tubes had just been replaced by silicon transistors, and nobody had yet heard of MOS semiconductors or microprocessors.

So I had to hire people. With my thick Hun-garian accent and only 25 years of age, I did not feel comfortable hiring experienced engi-neers, so I asked Sam to let me hire smart, fresh graduates from the best schools, and to let me use every Friday to teach them our profession.

He agreed, and in a couple of years I had the best instrument engineering department of 26 “kids.” I also had a foot-high pile of my “Friday notes” accumulated on the corner of my desk.

At this point I got lucky again, because an old- fashioned publisher named Nick Gronevelt visited me. He reminded me of my grandfather, as his hair was parted in the middle and his watch was held by a gold chain hanging from his vest-pocket.

Nick asked why I didn’t teach from an instru-ment handbook and I told him, “Because we have none.”

“So let us turn your Friday Notes into one,” he said. And so, in 1963 the � rst edition of my Instrument Engineers Handbook (IEH) was published. The co-authors included such names as Page Buckley, Hans Baumann, Greg Shinskey, Paul Murrill, Les Driscoll and Cecil Smith, and the preface was written by Edward Teller, who understood the future of automa-tion. I dedicated the book to the Hungarian Freedom Fighters.

Today, 50-plus years later, I am working on the � fth edition.

Where Are We Today?In the 1950s, our profession was called instru-mentation. Now it is called automation. Today we have robots on Mars that can vaporize the rocks by laser to determine their composition. Soon, while sitting in our hydrogen-fueled, driverless cars, we will be able to order pizza to be delivered hot by the time we get home and our smart car is parking itself.

At the time of the � rst edition, I was teach-ing process control in the chemical engineer-ing department of Yale University, and my handbook was published by the electrical en-gineering division of Chilton. Why? It was not because Yale or Chilton had something against our profession. No, it was because they did not even know that the profession of process con-trol existed. So how much change occurred

CT1503_14_16_Lessons.indd 14 3/3/15 10:11 AM

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16 www.controlglobal.com M a r c h / 2 0 1 5

L e s s o n s L e a r n e d

over the past 50 years? Not that much.To my knowledge, one still can’t receive a doctorate in

automation, and only a few universities offer a bachelor of science or even associate degrees in automation and control engineering. There are a number of certification programs, and ISA currently offers two—Certified Automation Pro-fessional (CAP) and Certified Control Systems Technician (CCST). Online certificates also are offered at the Univer-sity of Kansas and at Dalhouse University.

Man vs. MachineWhile much has been done to advance automation, even more remains to be achieved. We live at a time when cul-tural attitudes are changing as we debate the proper role of machines in our lives. Our culture now accepts that there is no harm in machines substituting for the routine functions of the human brain.

While in everyday life we accept the spread of automa-tion, in most of our industries, the operator is still the boss. Automation is seldom used to protect against operator errors.

Safety statistics show that the number-one cause of indus-trial accidents is human error. One could refer to Three-Mile Island, where the operators injected water into the in-strument air supply; to the BP accident, where there was no automation to keep the drilling pipe straight; to the ferry

accident in Korea, where safety overrides were not provided to prevent the captain from turning sharply into a fast ocean current; or to airplane accidents, where the pilots were not prevented from landing at the wrong speeds or gaining alti-tude too fast. The list goes on.

In other words, the culture of trusting man more than machine has to change. It has to be recognized that safety provided by automation is also manmade, but it is made by different men than the panicked rooky operators running around in the dark at 2 a.m., as occurred at Chernobyl. No, safety automation should be designed by professional con-trol engineers, who have spent months to identify all poten-tial “what if” sources of possible accidents, and have eval-uated their potential consequences before deciding on the emergency actions that are to be triggered automatically when the potentials for such accidents arise.

It is this hazard and operability study (HAZOP) during

the design phase of the plant that is the key to safety, not de-pendence on the action of panicked operators. The choice is not between depending on humans or machines. The choice is between trusting the judgment of two kinds of peo-ple—the operator or the HAZOP team.

For absolute safety, what is needed is override safety con-trol (OSC), which can’t be turned off or overruled by any-thing or anybody. When the plant conditions enter a highly accident-prone, life-safety region, the uninterruptible, safe shutdown of the plant must be automatically triggered. The functioning of OSC must be so designed that it can’t be stopped by cyber attacks because it is not connected to the Internet at all. It can’t be overruled by the operators and can’t be modified or turned off by them. In short, once the OCS is activated, the plant must be shutting down under the preplanned, totally automatic HAZOP control, and nothing and nobody can prevent that.

The status QuoDuring the past 50 years, some progress has been made, but not enough. Ours is the profession that can simultaneously maximize production and safety while minimizing operat-ing and energy costs. Optimization through automation can simultaneously increase GDP and profitability, and can do it while also reducing both pollution and energy consump-tion. We can increase productivity without using a single pound of additional raw material and without spending a single additional BTU of energy, plus we can protect our industries from human errors, sabotage or cyber terrorism.

My hope is that in the next 50 years this finally will be understood.

Figure 1. The IAS was the first electronic computer built at the

Institute for Advanced Study (IAS), in Princeton, New Jersey,

between 1945 and 1951 by John von Neumann and his team.

mr. von neumann’s marvelous machine

Ours is the profession that can simultaneously

maximize production and safety while

minimizing operating and energy costs.

Béla lip ták , Pe, automat ion and safe t y consul tant , is also edi tor of the ins trument and au tomat ion engineers’ handbook . he can be reached a t l ip takbela@aol .com.

CT1503_14_16_Lessons.indd 16 3/3/15 10:11 AM

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O N T H E B U S

john Rezabek contribut ing [email protected]

M a R c h / 2 0 1 5 www.controlglobal.com 19

Anyone who

has spent any

time servicing

instruments knows

the experience of

removing a cover

and having a cup of

water drain out.

Why is it, after weeks of seemingly trouble-free plant operation, the phone rings on the holiday weekend when the goose is

in the oven and the table is set for dinner? For-tunately for me, the crew on shift was prepared to muddle through until normal business hours after the weekend. They just wanted to know whether the problem they were seeing was likely to cause a spurious trip of some produc-tion-critical pumps. Dinner was saved thanks to the fact that we had proven years ago that a “bad” indication from a suction pressure trans-mitter would “hold last value,” and the associ-ated interlock wouldn’t trip. While a persistent “bad” indication would defeat a necessary pro-tection that prevented significant mechanical damage, the disruptions were fleeting enough to remain a mere annoyance.

When the issue was investigated on the next normal business day, it was immediately appar-ent that the segment was failing due to water-logged and corroded terminals in an interme-diate terminal box. The little enclosure was designed to be weather-tight, but we’ve all seen how simple it can be to defeat a system’s accom-modations for preventing moisture entry.

When a limit switch cover is removed to make an adjustment, a frail-looking O-ring flops out. It’s easily misaligned or omitted when the cover is reassembled. How many covers have you found loose, missing gaskets or sim-ply open to the environment? Just condensa-tion of moist air from the warmer seasons can be enough to begin corruption of circuit boards and terminations. In all but the most arid cli-mates, anyone who has spent any time servic-ing instruments knows the experience of re-moving the cover of a troubled instrument and having a cup of water drain out.

The most experienced troubleshooters, such as Emerson Process Management Dis-tinguished Technologist Marcos Peluso, agree that defects and oversights in the physical layer—twisted-pair copper, power supplies, ter-

minals, conduit systems and enclosures—ac-count for over 90% of the problems encoun-tered in field device networks, even 4-20 mA.

Peluso’s colleagues have devised a solution, at least for 4-20 mA loops that connect to the top-end 3051 HART pressure transmitter: Power Advisory diagnostics for advanced loop integrity. The diagnostic is communicated to any HART-capable asset management software and alerts the end user to impending issues with moisture, cable integrity, terminal corro-sion and power supplies. Since these physical layer disorders usually take some time before they affect the signal, a weekly report should al-low the end user to detect and avert a problem. But what about the rest of the devices?

Profibus PA and Foundation fieldbus have had a repertoire of physical layer diagnostics for nearly a decade, ranging from simple hand-held devices such as the Relcom FBT-6 to the-feature-laden Pepperl+Fuchs field diagnostics handheld and advanced diagnostics module (ADM). All these tools can alert the user to de-fects in the physical layer. The Pepperl+Fuchs units use an embedded expert system to sug-gest likely causes for the detected symptoms and recommend remedial actions. But while they can identify an ailing network, you might still have challenges determining the precise location of the defect.

Couplers providing simple short-circuit pro-tection for each fieldbus spur substantially im-proved the fault tolerance of fieldbus segments. But Pepperl+Fuchs has designed a new genera-tion of intelligent couplers that can detect and mitigate degradation or progressive failures ow-ing to water ingress, sloppy terminations, high vibration, corrosion, cable abuse and device faults on each individual spur.

If such couplers can perform as promised, measurement and control professionals using them can count on more peaceful holidays in the future. Perhaps the goose of physical layer defects is finally cooked.

better diagnostics for the Physical Layer

CT1503_19_OTB.indd 19 3/3/15 10:21 AM

W i t h o u t W i r e s


ian verhappenDirector,

inDus trial automation ne t [email protected]

The documents will

describe a set of

coordinated

activities for an

organization to

optimize the value

from intelligent

devices.

asset management is a critical, but under-used capability of modern control systems. The ISA108 Intelligent Device Manage-

ment (www.isa.org/isa108) committee is tack-ing the subject, and is now close to completing its first document, ISA-dTR108.1-2015, “Part 1: Concepts and Terminology.”

The purpose of ISA108 is to define standard templates of best practices and work processes for the implementation and use of diagnostic and other information provided by intelligent field devices in the process industries. The three-part document set will be based on the equipment lifecycle phase or by other means necessary to provide work processes with appro-priate role definitions. The various parts of the standard series identified to date address the following aspects of Intelligent Device Man-agement (IDM):

Part 1: Concepts and Terminology de-scribes IDM concepts and terminology neces-sary. It gives an overview of the basic concepts of how intelligent devices can be managed and how this device management plays a larger role in the overall objectives of a facility throughout its lifecycle.

Part 2.1: Configuration and Revision Man-agement specifies work processes related to configuration and revision of intelligent de-vices, including establishing an IDM program, engineering and setting of parameters, replace-ment and tracking, storing and updating related data in configuration databases, and auditing by documenting work processes for manage-ment of intelligent device configuration integ-rity, configuration adequacy and configuration congruency for a full facility lifecycle.

Configuration integrity refers to the appli-cation-oriented processes for establishing and maintaining design integrity, including pro-cesses for managing change. Configuration ad-equacy refers to device-oriented processes that provide assurance that necessary functions are properly and fully configured, and that unde-

sired functions in the device are disabled. Con-figuration congruency processes assure that the multiple databases where intelligent device configuration data are stored all have the same data, and that configuration changes propagate accurately and in adequate time.

Part 2.2: Diagnostics Utilization specifies multiple work processes related to diagnostics done by intelligent devices, including establish-ing an IDM program, training, maintenance of intelligent devices, scheduling of maintenance, audit and continuous improvement.

Part 2.3: Procedure Management specifies multiple work processes not covered in other parts, including inspection and function test-ing of intelligent devices to assure that correct and appropriate manual and automated proce-dures are used for support of intelligent devices.

Part 2.4: Calibration Management ad-dresses the program activities and work pro-cesses for managing calibration procedures, including inferential (analytical) and physi-cal measurements, such as cover calibration checks, statistical analysis of calibration checks, decisions about calibration versus replacement, and actual calibration requirements.

The last of the Part 2 documents is Part 2.5: Intelligent Valve Management, covering ac-tivities and work processes, including on-line diagnostics and repair, as well as off-line turn-around, diagnostics and repair processes, in-cluding in-line procedures and shop repair re-lated to final control elements.

Part 3: Implementation Guide(s) provides guidance on implementation of intelligent de-vice management and will be developed upon completion of the Part 2 documents.

Working groups have been identified for each of the Part 2 documents, and the first doc-ument has been submitted to the IEC as a new work item under SC65E. For more information or to participate, contact Charley Robinson ([email protected]) at ISA or your country’s national standards body.

isa takes on asset management

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Like any earthshaking event, Han-nover Messe (www.hannovermesse.de) is so huge that its pre-shocks

start to arrive way before the event itself. This year’s version of the world’s

largest manufacturing exhibition will be held April 13-17 in its usual 26 halls in Hannover, Germany, but organizers and more than 40 exhibi-tors provided a comprehensive sneak peek of the fair’s Industry 4.0 and re-lated solutions on Feb. 3 at the ewerk hall (www.ewerk.net). Organizers ex-pect the fair to top the 6,400 exhibi-tors it hosted two years ago. They’ll be joined by India as the event’s 2015 partner country, which will feature its new “Make in India” program to make it easier for manufacturers to do business there.

Dr. Jochen Koeckler, member of Deutsche Messe AG’s managing board, reports his organization asked manufacturers if they’re ready for In-dustry 4.0 or the 4th Industrial Revo-lution, and the answer is almost always no. “Research shows 50% of those in manufacturing never heard of Industry 4.0, and 25% have heard of it, but don’t know what it’s about,” said Koeckler. “So the message is that we need to be prepared because another recent study found that an 18% increase in effi-ciency and a 15% increase in savings will be possible over the next five years thanks to the productivity enabled by Industry 4.0.”

To achieve these gains, Koeckler re-ports that Industry 4.0 will also bring profound changes to industrial produc-tion models and energy systems. In fac-tories, there will be a move away from mass production as more customers de-mand customized products at the same low prices as for mass-produced goods.

Likewise, energy grids will need to be-come more intelligent, so they can bal-ance and deploy available power, gas and heat from many sources.

Koeckler adds the answer to these challenges is “Integrated Industry,” which is the smart, digital network-ing and integration of manufactur-ing systems and processes. Integrated Industry is about allowing machines and workpieces to communicate with each another, which will allow entire production lines to autonomously and dynamically reconfigure themselves, and make small-batch and one-off production commercially viable in large plants.

“Manufacturing in Europe, North America and Asia will all depend on Industry 4.0, but most companies still don’t know what they need to do to be ready for it,” adds Koeckler. “What they need to do is form close networks with all stakeholders involved in their

production processes, and Hannover Messe 2015 with its theme of ‘Inte-grated Industry—Join the Network!’ will show them how. After Hannover Messe, visitors will be able to say, ‘yes, we’re ready for Industry 4.0,’ because they’ll be able to take home ideas, and achieve more competitive production.”

showcase of solutionsAs usual, the heart of Hannover Fair will be its thousands of exhibits and their solutions to help make manufac-turers more efficient. Here are some highlights of the technologies and products that will be exhibited:

ABB (www.abb.com) will demon-strate its new range of swirl and vortex flowmeters that can measure volume mass energy and flow in one device. The SwirlMaster comes in standard (FSS430) or extended (FSS450) ver-sions with ABB’s swirl technology that enables very short upstream and down-

Johann Hofmann, senior vice president of ValueFacturing at Maschinenfabrik Reinhau-

sen GmbH, Vijay Gokhale, ambassador of India to Gemany, and Dr. Jochen Koeckler,

member of Duetsche Messe AG’s managing board, answer questions from the audi-

ence at the Hannover Fair Preview last month in Berlin.

Industry 4.0 InsIders

Get ready for Industry 4.0Hannover Fair preview shows how smart devices and the Internet promise to streamline

manufacturing for future productivity.

CT1503_22_26_InPro.indd 22 3/3/15 10:22 AM

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I N P R O C E S S

stream piping requirements. FSS430 provides an analog output with HART communication, and FSS450 has func-tions usually found in � ow computers, such as steam-power calculations, with and without condensation return, and the ability to receive signals from other transmitters for density, temperature and pressure via an analog 4-20 mA signal. Both � owmeters have ABB’s universal graphic display, digital out-puts con� gurable as pulse, contact and frequency output, and an optional integrated temperature sensor. Also, ABB’s new VortexMaster has a lower-cost, entry level version (FSV430) and an extended version (FSV450) with the same enhancements as FSS450. Both VortexMaster versions are available in a remote design with up to 30-meter cable lengths.

Beckhoff (www.beckhoff.de) will show “many-core control” with its C6670 industrial server, which fea-tures 12, 24 or 36 processor cores and 64 to 2,048 GB of RAM. Each core also employs Beckhoff ’s TwinCAT 3.1 automation platform. This means not only are PLC, motion control, robot-ics and CNC functions integrated into one software system and executed on one CPU, but condition monitoring and energy management functions of a smart factory are included, too.

Phoenix Contact (www.phoenix-contact.com) will launch its new PSR Mini safety relays, which it reports are the world’s slimmest at just 6 mm wide, but have positively driven contacts that maintain the power and safety of larger relays. Requiring up to 70% less space and needing only one enabling con-

tact, PSR Mini’s design is based on a thin, powerful basic relay character-ized by minimal space requirements, low energy consumption and high sys-tem availability. They can switch up to 6 A, are compatible with many signal transducers, and are approved for use in many different mechanical and pro-cess applications, including distributed systems in potentially explosive areas.

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CT1503_22_26_InPro.indd 24 3/3/15 10:23 AM


I n P r o c e s s

Industry Forum event in February in Orlando, Florida.

“Many of you folks previously thought cybersecurity was all about technology,” said Gregory Touhill, deputy assistant secretary of cybersecurity operations and programs at the DHS and a retired briga-dier general. “I’m here to tell you cyber-security is not a technology issue; it’s a risk-management issue.”

As such, companies need to ensure cybersecurity isn’t relegated to IT-specific discussions, but is a staple of meeting agendas and a factor in all de-cisions that address business risks.

“Do you know how much your infor-mation is worth?” Touhill asked. Busi-nesses too often fail to account for the value of their intellectual property when they do asset valuations, he said. And the financial threat and reputation risks

posed by the theft of intellectual prop-erty or the exposure of client or person-nel information can destroy a business.

Currently in the commercial sec-tor, the average length of time between when a security breach occurs and when the affected business detects that breach is more than 240 days, Touhill said. “That’s unacceptable. I’d like to know [as a business owner] when they’re coming through the gate, not when they’re going out the gate.”

Getting all employees to understand that cybersecurity is a 24/7 responsibil-ity and that no single piece of software or other technology is a fail-safe protec-tion against cyber threats is essential, according to Touhill.

“Are you training your workforce to take the same cybersecurity precautions at home as they do at work?” Touhill

challenged. Sophisticated hackers have begun targeting companies’ high-rank-ing employees at home, he said, trying to get access to sensitive business in-formation made vulnerable when em-ployees work away from the office on less-well-protected devices or using less-secure networks.

And it’s not just nation-state actors or individuals looking to sell stolen pro-tected information who pose a cyber-threat, Touhill added. Hacktivists—”folks who don’t necessarily agree with your company’s mission or core val-ues”—may look to damage a company by exposing sensitive business infor-mation. Hacktivism is “something that wise companies keep in mind as part of their risk calculus,” he stated.

Mitigation of cyber risks is multifac-eted, Touhill noted. “Technology alone

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CT1503_22_26_InPro.indd 25 3/3/15 10:23 AM


I N P R O C E S S

is not going to solve all of your problems,” he said. Cybersecurity requires a vigilant mindset—a company-wide awareness of and respect for the multitude of very real business risks posed by malware, phishing scams and more. “If any sales-man comes to you and says, ‘I have the solution that’s going to make you bullet-proof,’ then alarm bells should be going off in your mind,” he said.

Touhill advised attendees to take a � ve-pronged, “defense-in-depth” approach to cybersecurity: identify, protect, detect, re-spond and recover.

The � rst step, identi� cation, involves taking stock of the business’ information assets and determining which of these are of highest value and most critical to the business. Protection and detection require a commitment on the part of all employees—permanent and contract workers in all functions of the business. And it’s vital for companies to have—and, of equal importance, to rehearse—a response and recovery plan they will em-ploy in the event of a security breach.

“You have to have a plan and you have to practice it,” he said. “How many

times does your company practice [deal-ing with] a major disaster with your IT infrastructure?”

“The time to generate a response plan to a hack is not the morning of an attack,” Touhill noted.

Nanoline Contest Winners AnnouncedA team from Benton Central Jr./Sr. High School in Oxford, Indiana, has won Phoe-nix Contact’s (www.phoenixcontact.com) 2015 Nanoline Contest. The grand prize is a trip to Louisville, Kentucky, in April. Team members include Blake Stawsma, Justin Shultz, Wil Barce, Kyle Laramore, Bryce Nehrig and Nate Post. The team designed and built the “Fully Automated Nanoline T-Shirt Cannon,” which runs on Phoenix Contact’s Nanoline Control-ler and uses the intuitive, � owchart-based nanoNavigator software to control the ap-plication. The group will travel to Louis-ville in April, where they will observe the � nal rounds of the VEX Robotics World Championship.

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Measurement and Control Technologies

Asahi/America Inc. (www.asahi/america.com), has named Daniel Anderson to

the office of president and CEO. Former president and CEO Hidetoshi Hashimoto

will remain with the company as chairman of the board of directors. Anderson as-

sumed his new position on Jan. 1, 2015.

F.W. Webb Company (http://fwwebb.com/) is the new authorized distributor for Opto

22 industrial automation hardware and software in the Northeast. The Process Con-

trols Division of F.W. Webb is expanding its distribution territory for the Opto 22 prod-

uct line into each New England state and New York, New Jersey and Pennsylvania.

Belden Inc. (www.belden.com) has formed a partnership with Shanghai Hi-tech

Control System Co. (www.hite.com.cn/en/channel/433.html) to jointly develop,

market and sell new industrial networking solutions.

M&M Software GmbH (www.mm-software.com) of St. Georgen, Germany, has be-

come a sponsoring member of the FDT Group (www.fdtgroup.org). M&M Software will

take a seat on the board of directors and the executive committee of the FDT Group.

Iconics (www.iconics.com) has achieved OPC UA Client Lab Certi� cation from

the OPC Foundation (https://opcfoundation.org/) for its Genesis64 V10.85 Plat-

form Services.

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Control’s Monthly Resource Guide

R E S O U R C E S


If you know of any tools and resources we didn’t include, send them to [email protected] with “Resource” in the subject line, and we’ll add them to the website.

In the Loop

THIS SYSTEM IS CLOSEDThis is a basic tutorial on closed-loop control systems. It covers the basic defi-nitions and descriptions of how closed-loop systems work, a discussion of closed-loop summing points and how to use them, transfer functions, multi-loop closed-loop systems and closed-loop motor control. The direct link is www.electronics-tutorials.ws/systems/closed-loop-system.html.

ELEctronIcs tutorIaLs w w w.elec tronics-tu tor ials .ws

WHAT IS PID CONTROL?This tutorial is a basic discussion, with illustrations, of the principles of pro-portional integral derivative (PID) con-trol and how it’s used with controllers. It also covers tuning rules and start-ing settings for common control loops. The direct link is at www.expertune.com/tutor.aspx.

ME tso E xpErtunEw w w.exper tune.com

CASCADING CONTROL A brief blog post by Jacques Smuts, au-thor of Process Control for Practitioners (http://amzn.to/16sFjEM), covers cas-cade control basics: what it is, how to manage it, its advantages and disad-vantages, when you should use it, and when you shouldn’t. The direct link is at http://blog.opticontrols.com/ar-chives/105.

op t IcontroLsw w w.opt icon trols .com

BIG BOOK OF CONTROL LOOPSControl Loop Foundation for Batch & Continuous Processes, by Terry Blevins and Mark Nixon, is a guide for engi-neers, managers, technicians and oth-ers who are new to process control, or

experienced control engineers who are unfamiliar with multi-loop con-trol techniques. After the traditional single-loop and multi-loop techniques that are most often used in industry are covered, a brief introduction to ad-vanced control techniques is provided. A free 163-page PDF provides a Power Point outline of the same material at www.controlloopfoundation.com/downloads/about-the-book/Control-Loop-Foundation-Overview.pdf. The book itself is available from the ISA website in both hardcopy and ebook form in both English and Chinese.

Isaw w w.isa.org

ZEN AND THE ART OF LOOP CONTROLProcess Control Hall of Famer F. Greg Shinskey meditates on disturbance dy-namics and the three classes of distur-bances: setpoint changes, load varia-tions and noise. Other meditation subjects include internal model con-trol, feedback, load response, identi-fying load components, dynamic dif-ference, effects on controller tuning, accommodating setpoint changes, and more. Read “Meditating on Dis-turbance Dynamics” at www.control-global.com/articles/2011/meditating-on-disturbance-dynamics/?start=1.

controLGLobaLw w w.controlglobal .com

A SEVEN-STEP PROGRAMThe performance of industrial control loops directly affects company profit-ability and operability in several ways. It affects the stability, robustness and safety of the process. In addition, it plays a role in the cost, efficiency and maximum rate of production, and in-fluences the quality of the product.

This white paper outlines a systematic, seven-step approach for improving con-trol system performance, and describes the key points to follow for ensuring each step is implemented successfully. The paper is free, but registration is re-quired. The direct link is at www.con-trolglobal.com/whitepapers/080502-pas-7performancesteps/.

pasw w w.pas.com

PROCESS CONTROL FOR THE REAL WORLDPractical Process Control is a free on-line ebook with contributions by mul-tiple authors. Subject covered include fundamentals, the components of con-trol loops, graphical modeling, PID controller design and modeling, tun-ing concepts, tuning using closed-loop data, evaluating controller per-formance, the control of integrating processes, advanced classical control architectures, cascade control, feedfor-ward and three-element control. The direct link is at www.controlguru.com/.

thE controL Guruw w w.controlguru.com

TUNE-UP TIMEThis free guide offers a best-practices approach to PID controller tuning. It shares a simplified and repeatable pro-cedure for analyzing the dynamics of a process and for determining appro-priate model and tuning parameters. Included are basic terminology, steps for analyzing process dynamics, meth-ods for determining model parameters, and other valuable insights. The direct link is at www.yokogawa.com/us/tech-nical-library/white-papers/pid-tuning-in-distributed-control-systems.htm.

Yokogawa corpora t ion of amer icaw w w.yokogawa.com

CT1503_28_Resources.indd 28 3/3/15 10:31 AM

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CONTROL SYSTEMS OF THE FUTURE Through the looking glass

of emerging technologiesby Wil l iam L. Mostia

CT1503_30_38_CoverStory.indd 30 3/3/15 10:51 AM


How might we expect emerging technologies to play out in the world of process control? Successfully predicting the future is dif� cult at best, so we sought out and con-

sulted with industry visionaries and long-term planners to see where there is consensus about how rapidly developing operator interfaces, computing, data analytics and virtual re-ality will change our craft. Their informed speculation in-dicates these emerging technologies and others will be im-pacting our industries at an increasing, even amazing, rate.

Our list is by no means exhaustive, as many technologies are just now emerging out of their cocoons, and there’s no telling what else might be lurking out there in companies big and small, and in the garages of the DIYers.

Of course, the process industries are notoriously conservative, with a large installed base of equip-ment that ranges from pneumatic to sophisti-cated digital control systems, all of which are cur-rently making money. So while we will see rapid changes in commercial technology, adaptation by

the process industries will be on a value-added ba-sis and always dependent on the cultural acceptance of

the involved personnel.

Current Trends Are Safe BetsFirst, we can expect continued incremental improvements in our currently available control systems technology. Many of our DCS systems are underutilized, and their future may already be lurking within them or with the DCS vendors’ current offerings.

Moore’s Law, “the number of transistors in a dense in-tegrated circuit doubles approximately every two years,” is expected to continue into the next decade or so, but may slow from doubling every two years to doubling every three years. Coming developments in carbon nanotube � eld-effect transistors, junctionless transistors, single-electron transistors and memistors may well extend Moore’s Law’s life. So we will continue to see improvements in comput-ing and memory, which will support the emerging tech-nologies. We’ll get larger operator screens with higher res-olutions, and control hardware platforms will run faster, smarter and with more memory.

Network capacity will have to expand to meet demand, placing pressure on the existing infrastructure. Process con-trol algorithms will advance in sophistication, but the next generation of systems will see self-aware controllers and sen-sors incorporating arti� cial intelligence (de� ned as capable of cognitive and memory functions, resilience, awareness of its environment and its place in the process context, etc.)

to develop advanced control strategies to achieve the controller goals. Cloud computing will play

a part in the next generation of DCS/SCADA, but the

extent and balance between the virtual and the hardware/software world is unknown and controversial.

Control Rooms Center on the OperatorThe trend of centralization of the control room remote from the process area is likely to continue, says Pierre Skonnegard of CGM (www.cgm.se) in Sweden, a partner with ABB (www.abb.com) in designing the control rooms of the fu-ture. Skonnegard also felt that operator attentiveness, aware-ness and health would be given greater consideration.

The video arcade environment, with the operators sitting during a substantial portion of their shifts looking at video screens, can lead to operator health concerns. Chairs are be-ing developed that will adjust automatically to the operator’s physique using biometric sensing, and in the future, will be able to monitor the operator’s health and attention level. DCS consoles are already available that have two positions to accommodate the operator sitting down or standing up, with an easy transition between the con� gurations. Biomet-ric sensing will be used to support security, and to allow the control room to adapt to the people currently in it. Ambient intelligence, where electronic systems and environments are sensitive and responsive to the presence of people, will be given greater attention.

Displays to Expand and CollaborateOur displays will become even larger and in some cases curved, with higher de� nition allowing us to display larger amounts of data with higher resolution, which we’ll be able to see from farther away. We can display more than P&ID-based and physical process graphics to help operators deal with Big Data and abnormal situations by providing rapid access to information without having to navigate screens for improved situation awareness. It’s reasonable to assume that operators will interact with the control system by talking (us-ing natural language processing and Bluetooth technology), as well as hand gestures, touch and the traditional pointing device and keyboard.

Using large, edgeless displays, we can now build movie theater- or wall-sized panels. For example, Saudi Aramco has installed a wall of video 67 meters (220 ft) long by 3 me-ters (10 ft) tall with 150 screens by Barco in its Operation Co-ordination Center. It serves as a nerve center for all Saudi Ar-amco operations, and can display all their operational data. Shades of full graphic panels!

Currently available displays embedded in tables, such as the ABB 3D KPI dashboard, have horizontal or vertical modes of operation, and can be used as collaborative work-stations. Microsoft is introducing an 84-in., 4K Surface Hub with state-of-the-art digital whiteboarding that could be used as a collaborative workstation in the control room and conference rooms.

C O N T R O L I N T H E F U T U R E

CONTROL SYSTEMS OF THE FUTURE


C o n t r o l i n t h e f u t u r e

Clouds Work Better with fogCloud computing refers to remote, pub-lic Internet- or private intranet-based virtual servers where application soft-ware and data may reside rather than in local computers. These applications may share resources and provide re-dundancy (dedicated and just-in-time).

Some of this represents virtualization of local hardware, i.e., control functions in the cloud while I/O is local. Cloud com-puting for process control would have process control applications, other vir-tualized control functionality and data residing in the cloud.

Issues of privacy, security and reli-

ability will delay the adoption of this technology, even in local clouds. Still, some cloud-based DCS products are appearing, such as the Schneider Elec-tric/Invensys Industrial Cloud Histo-rian designed to deal with big data.

The cloud, in any case, will probably hold the key to the next generation of DCS/SCADA. Of interest in this area is the Architecture for Service-Ori-ented Process (www.IMC-AESOP.eu) project, whose goal is developing the next generation of SCADA/DCS sys-tems. The plant and corporate IT side will likely adopt this long before the control people.

Our ability to store information also has risen exponentially, and the cost of memory has come down tremendously. In 2004, the cost of a megabyte of storage was about $0.175; in 2014 it was $0.0085, a reduction of 95%. Moore’s Law predicts that memory costs will continue to fall.

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Figure 1: Rather than the cloud of commercial

computing, industry will prefer a set of private

corporate clouds, with a “fog” level near the local

control systems and instrumentation to ensure

speed, support mobility and enable local control.

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Corporate Cloud

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On the other hand, one of the cor-ollaries to Parkinson’s Law is, “Data expands to fill the space available for storage.” Sensors are becoming more pervasive and cheaper as well smarter, offering more data. Digital bus com-munication will become the norm even within legacy systems. Wireless is ex-

panding, allowing instruments to be placed in many heretofore unavailable locations, powered by batteries or by power harvested from the environment.

We can’t leave out the final elements, where increased diagnostic data has become available. Video cameras and other sources only compound the prob-

lem of overflowing data. For example, a plant with just 300 tags, each trans-mitting just one measurement per sec-ond, generates more than 9 billion data points per year. For the operator, engi-neer, manager or control system, having all the necessary data to make decisions is great and desired, but there’s no such thing as a free lunch. With this big flood of data, we have become data-rich, but information-poor, and can be easily over-whelmed by the quantity, velocity, noise and uncertainty in the data.

This is where the cloud and data ana-lytics come in. The common definition of cloud computing—using a network of remote servers hosted on the Inter-net—is too simple for the process indus-tries. We’re averse to using the Internet to store proprietary company informa-tion, and concerns about cybersecurity, reliability, safety and liability are big is-sues. Our more likely configuration re-sembles a cloudy day, where multiple external clouds use the public Internet, private corporate clouds use the com-pany intranets, and local plant clouds, each providing cloud computing func-tions at their level, share applications, computing and memory resources as needed to provide data analytics on de-mand and dynamically.

In addition, as has been proposed by Flavio Bonomi, et al., Cisco Systems, in their paper, “Fog Computing and Its Role in the Internet of Things,” we need a “fog” layer with low latency, location awareness, widespread geographical distribution, mobility, a very large num-ber of nodes, predominant wireless ac-cess, a strong presence of streaming and real-time applications, and heterogene-ity (Figure 1).

Data Analytics Poised to explodeData analytics is the science of examin-ing or analyzing large, small and sparse quantities of raw data with the purpose of drawing conclusions, finding relation-ships and converting the data into useful information. Data mining is an example of this. Data predictive analytics extract

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Microsoft’s HoloLens augmented-reality gog-

gles merge the physical world

with virtual reality by projecting

holograms into the user’s view

of physical space. The holo-

grams may be of three-dimen-

sional objects, a virtual physical

space or operator displays.

A built-in camera, computer, lenses and mi-

crophone enable the goggles to place the ho-

lograms appropriately in the operator’s view of

real space, and allow the operator to manipu-

late them via gesture, voice and gaze. Holo-

grams also may be pinned in place so opera-

tors can move around them or through a virtual

landscape.

According to Wired magazine, HoloLens will be intro-

duced this year to developers and commercial partners,

who will create applications and help Microsoft refine its

design and performance. When its performance and value

are proven, you might expect to start seeing it in control

rooms and on the plant floor as a tool for engineering and

operator interface, equipment maintenance and more.

PrePare to See Your realitY augmented




information from existing large data sets to determine patterns and predict future outcomes and trends.

Data analytics will be used to take the Big Data in the fog

and/or cloud, and extract useful information for plant opera-tors, engineers, supervisors and managers, as well as people at the enterprise level. Data analytics also will be used to an-alyze video for security and safety in collaborative operations and in support of artificial intelligence (AI) applications and operator online and personal advisors.

Data analytics are already available—one example is Honeywell’s Maxpro VMS for safety and security (Figure 2)—but wider use is expected when the flood of data be-gins to overwhelm the existing systems. Once the data ana-lytics have massaged, manipulated and crunched the data, and analyzed, collated and organized the information, they must present it to the operator or other plant personnel using graphics and visualization tools. Processing speed will be of the essence where real-time information is required.

Ai Beyond SiriWe’ve become familiar with AI in the form of smart, vir-tual personal assistants (SVPAs), which entered the market in 2011. Examples include Apple’s Siri and Microsoft’s Cor-tana—software agents that can perform tasks or services for an individual. In process control, operator SVPAs will be

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Figure 2: Once analytics have massaged, manipulated and

crunched the data, and analyzed, collated and organized the

information, they must present it to the operator. Here, Hon-

eywell’s Maxpro VMS analyzes and prioritizes video to sup-

port safety and security.

AnAlytics turn DAtA into informAtion



more sophisticated, with an inherent understanding of the process, the op-erating context, the operating environ-ment (using plant historical database), operator preferences and practices, data analysis, case-based reasoning and the ability to learn and remember. It’s reasonable to expect that an oper-ator can have such a mobile personal assistant, as well as more sophisticated plant digital advisors with more capa-bility and a larger knowledge base, all connected through the local cloud or fog. IPSoft’s (www.ipsoft.com) Amelia software might serve as a prototype for a personal assistant or plant advisor.

Artificial intelligence will be in-creasingly embedded in the process control world. The future should bring self-aware sensors and control systems that automatically determine their re-lationship to variables and control loops, understand the effects of distur-bances, be goal-orientated, spot and analyze patterns, do case-based reason-ing, know the past and project the fu-ture as well as a human being.

More help for operatorsMany people feel that the operator is the weak link in the control system, which is another way of saying the human factor is the weak link in the whole system. It’s doubtful that the role of the operator will be diminished in the near to intermediate future, as they are the primary element that provides resilience (flexibility) in the system, but a long-term trend is there.

Meanwhile, inexpensive comput-ing power and memory, and advances in computing technology have made virtual reality (VR) more technically feasible. The Oculus Rift, a head-mounted VR display, so interested Facebook that it shelled out $2 billion for Oculus VR (www.oculus.com). It seems unlikely that operators will be wearing a one-pound set of goggles all day long and living in a virtual world (though the goggles have cameras that allow you to “see through” to the real

world). There may be short-term ac-tivities where VR will excel, such as in collaborative efforts in engineering or with people who are in remote lo-cations, during data visualization or interacting with virtual objects within the control system.

The next new technology is Google Glass, a form of augmented reality where a view of a physical, real-world environment is enhanced by com-puter-generated input such as text, sound, video or graphics to provide ad-ditional information. It has the poten-

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tial to provide operators with a continuously available heads-up display of important data and additional information.

Microsoft recently announced its answer to Google Glass, called HoloLens, which will be bundled with Windows 10 for release to developers this year (sidebar, page 35). This de-vice has the potential to revolutionize the operator interface by providing data visualization and a collaborative operating environment for operators, engineers and corporate experts, as well as trusted third parties and vendors.

Cybersecurity: The Killer AppNew control system growth will be constrained by cyberse-curity concerns. Users will expect cybersecurity to be built in, not just added on. While it will retain its reactive nature, cybersecurity will also become predictive, based on arti� cial intelligence, and will use data analytics, case-based reason-ing, cognitive functionalities and other AI methodologies to prevent access, detect and block or eliminate intruders, learn from its mistakes and the mistakes of others, � nd sys-tem vulnerabilities, and eliminate or place roadblocks in the way of intruders.

It’s hard to predict the future, but it’s clear that emerging

technologies—augmented and virtual reality, arti� cial intel-ligence, cloud and fog computing, and data and predictive analytics—are poised to change the industry.

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Valuable insights were conttributed for this article by:

• Bernie Anger, general manager, GE Intelligent Plat-

forms

• Jonathan Crane, chief commercial officer, IPsoft

• Dave Cronberger, customer solutions architect, Cisco

• Adrian Fielding, Andrew Stuart, Paul Hodge and Paul

McLaughlin, Honeywell Process Systems

• Brent Leimer, market manager, Winsted Control Room

Consoles

• Pierre Skonnegard, control room designer, CGM

• Susanne Timsjo, manager, software architecture and

user experience, ABB

• Bob Voss, director, applications research, Panduit

ACKNOWLEDGEMENTS


A s s e t M A n A g e M e n t


Look at anything up close, and a lot more details appear. Asset management in process control is no exception, so when engineers and technicians reexamine the perfor-

mance and lifecycles of their equipment, many new ques-tions, maintenance issues and requirements show up.

Originally, asset management began as a way to go be-yond maintaining operations and uptime, and determine how to get the most value out of equipment and production systems over their lives. More recently, this quest has drawn asset management into settings where its basic principles are being joined by new software, communications and mobil-ity tools to generate more long-term value.

For instance, Meridian Energy (www.meridianenergy.co.nz) is New Zealand’s largest state-owned power utility, providing about 30% of the nation’s electricity from renew-able sources, primarily hydro and wind (Figure 1), to about 180,000 customers. It’s New Zealand’s only supplier of car-bon-zero-certified electricity.

However, though its renewable profile appears mod-ern and hip, Meridian faced an aging plant infrastructure, mainly because many of its hydro sites were commissioned in the 1960s. As a result, Meridian recently completed a five-year upgrade of its plant-wide monitoring and control net-works, and centralized its control room operation in Twizel, located in the middle of New Zealand’s South Island.

the Road to PredictionTo shore up their monitoring and secure more useful intel-ligence from their raw sensor and alarm data, Meridian’s Generation Improvement Team sought to integrate their IBM- and Maximo-based computerized maintenance man-agement system (CMMS) and plant historian with a plant asset management (PAM) system from Honeywell Process Solutions (www.honeywellproces.com). It would not only

provide early warning of deterioration of critical equipment and perform basic analysis based on the mathematical mod-els in its diagnostics, but it also would provide predictive capabilities. Designed around its central controls and plug-ging into modular adaptors, the utility’s PAM uses several Honeywell solutions, including:

• Alarm Management software to provide real-time alarm and event visualization and analysis, which replaces multi-ple alarm printers, monitors operations and operator work-loads, and helps eliminate nuisance alarms;

• Asset Management software that consists of an advanced data analysis and online computing platform for troubleshoot-ing process problem and faults, and an interface for implement-ing mathematical models used in diagnostics;

More capable software,

networks and mobile devices

are enabling asset

management in many

new applications and

environments.

Figure 1. Meridian Energy integrated its CMMS with Honeywell’s

PAM system to better monitor and analyze data coming into its

centralized control room from its hydro and wind power plants

in New Zealand.

Optimizing Air pOwer

Me

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erg

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by Jim Montague

CT1503_39_44_Feature2.indd 39 3/3/15 1:09 PM



• Control Performance Monitor for continuous, real-time asset monitoring and prioritizing poor performers;

• Operational Insight that provides PAM’s flexible data visualization and key performance indicator (KPI) dash-boards, enabling better operational de-cisions by providing web-based access to PAM’s control center.

Working in concert with their ex-isting CMMS, Meridian’s plants and equipment give PAM condition data and results of many on- and offline automated and semi-automated tests. Plant data is classified and collated with business logic, and plant dash-boards are updated showing condition and predicted days to failure. When a non-normal condition is detected or predicted, an email recommending specific action is automatically sent to the right personnel.

“The biggest success that’s come out of PAM is increased visibility of trans-former conditions,” says Mark Wil-liams, an engineer at Meridian. “Prior to the PAM implementation, trans-former condition monitoring data re-lied on individuals to enter the test re-sults into Maximo, and then others to analyze that data and publicize the results in sufficient detail to flag any health issues in a timely fashion. Also, in developing the PAM models, special-ist expertise was used to improve our transformer condition monitoring pro-gram, and job plans were upgraded.”

Neil Gregory, Meridian’s technology and process strategist, explains, “We didn’t and still don’t expect PAM to pick up catastrophic conditions on a daily ba-sis, but we do expect and get very early warning of changes in condition that we wouldn’t get without the system. PAM is a cost-effective means of maintaining visibility of the health of assets that are critical to our business.”

Bart Winters, asset management so-lutions product manager at Honeywell, says, “We focus on asset health, real-time performance and monitoring, but now we’re also protecting users and their ap-

plications against the precursors of fail-ure. So we’re still monitoring vibration, current changes, oil analysis and infra-red thermography, but we also compare each performance to an ideal parameter, which helps define what it means in the context of its particular operating unit. This means we can look at a whole pro-cess system and all its components parts in one place, and this saves a lot of time on troubleshooting, finding problems and getting back to production.”

streamlined by softwareWhile asset management is historically costly, time-consuming and labor-in-tensive, improvements in software and hardware are making it more approach-able for a wider circle of users applying it to more varied projects that go be-yond maintenance to each new level of optimization and sustainability.

For example, Mohawk Fine Papers (www.mohawkconnects.com) in Co-hoes, New York, recently saw its energy costs balloon by 30% over a few years, and redoubled its efforts to reduce its energy consumption with better asset management. “Energy makes up 60% of Mohawk’s operating and maintenance costs, and our motor and pump assets consume 75% of that energy,” says Paul Stamas, Mohawk’s vice president of IT. “So management needed visibility into data on the factory floor for better deci-sion making, and we needed an EAM system that integrated energy into our asset management strategy.”

As a result, Mohawk selected In-forEAM condition-monitoring software from Infor (www.infor.com), which has a web-based architecture, integrates seamlessly with the company’s enter-prise resource planning (ERP) system, and works with its Microsoft SQL Server 2005 database software. Stamas reports that InforEAM allowed Mohawk to improve preventive maintenance with more proactive inspections, calibrations and repairs, and even worked with SQL Server to add video files to its work in-structions. Because better maintenance

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reduced its total energy consumption, Mohawk also implemented InforEAM Enterprise Asset Sustainability software.

“This solution enables us to com-pare our assets’ designed energy use versus actual energy consumption. We can now incorporate energy efficiency into our asset management program,”

explains Stamas. Mohawk also integrated its asset sus-

tainability system with thousands of its plant-floor sensors to collect more real-time energy data. “This data helps us identify assets that are degrading in performance and consume excess en-ergy, which triggers alerts and allows

us to proactively identify and resolve cases of wasted energy. We also collect real-time energy use with the sensors, compare that against our utility bills, report that information in the EAM system, and break down our assets to identify real opportunities. With EAM Enterprise, we expect an additional 15 to 20% drop in energy consumption on top of the nearly 15% we’ve already realized with InforEAM best-practice maintenance.”

Kevin Price, EAM product direc-tor at Infor, reports InforEAM, ver-sion 11.1, expands the jurisdiction of asset management beyond reporting and maintenance to include more ad-vanced condition monitoring, inspec-tions, reliability and other functions. “People used to have multiple SCADA systems, and it was a challenge to get alerts or trends,” says Price. “We de-velop a combined roadmap that un-derstands a user’s system and require-ments, and enhances their return on asset, reliability-centered maintenance and asset performance management.”

Similarly, New Belgium Brewing Co. (www.newbelgium.com) in Fort Collins, Colorado, recently discovered that scheduled and unscheduled down-time on its bottling lines were causing it to produce only 150,000 cases of beer per week on lines that were capable of producing 294,000 cases per week (Figure 2). “After ramping up our bot-tling line to meet growing customer demand, we were disappointed to find the brewery was producing only about half of what it was capable of produc-ing,” says Joe Herrick, packaging sys-tems manager at New Belgium. “Our brewery’s manual systems generated a huge amount of data, but we had no way of presenting it in context.”

Consequently, New Belgium sought help from system integrator Apex Man-ufacturing Solutions (http://apexm-fgsolutions.com) in Boise, Idaho, and they decided to implement Wonder-ware MES Performance software from Schneider Electric (www.schnedier-

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electric.com). The software not only tracks and records the bottling process, but it also turns raw data into user-friendly presentations that help improve performance. For example, Wonderware MES facilitates shift changes by providing new workers with data on the performance of the previous shift, and integrates with the brewery’s existing Wonderware Sys-tem Platform and Wonderware HMI software. These com-bine to improve operators’ ability to maintain precise pro-duction schedules and manage the materials supply chain during the brewing process.

“With Wonderware MES coupled with our continuous im-provement strategy, we increased the ef� ciency of our packag-ing line by 30%, which allowed us to extend our packaging capacity to about 1.3 million barrels each year,” adds Herrick. “Improved manufacturing ef� ciencies plus increased line production means we saved more than $400,000 in planned labor costs and decreased downtime by 50%.”

Simpler SetupsBesides aiding routine operations, some asset management software can even help out during setup and con� guration.

For instance, Royal Dutch Shell (www.shell.com) recently worked with Emerson Process Management (www.emerson-process.com) to develop a more ef� cient con� guration so-

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Figure 2: New Belgium Brewing’s bottling and packaging line

recently adopted Wonderware MES Performance software to

decrease downtime by 50%, save $400,000 in planned labor

costs and increase capacity to 1.3 million barrels per year.

FULL SUDS POTENTIAL

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A S S E T M A N A G E M E N T

lution for Shell’s Prelude � oating natural gas (FLNG) pro-duction vessel project, which will operate off the coast of Australia. With more than 5,000 Foundation � eldbus de-vices at the Prelude site, many with more than 100 con� g-urable parameters, Shell was concerned about the time it would take to complete commissioning tasks. Con� guring the devices one at a time is error-prone and laborious—con-� guring one device can take up to an hour, and then con-� guration for each must be veri� ed.

Consequently, Shell adopted Emerson’s Asset Manage-ment Software (AMS) Suite: Intelligent Device Manager v. 12.5, which can commission Foundation � eldbus devices faster. Users can bring devices online with features, options and alerts they select in a fraction of the time normally re-quired. Emerson expects AMS Suite to reduce commission-ing time on smart devices by almost 80%, and allow users to make online changes to many devices simultaneously. Also, the software’s Device Manager User Con� gurations tool lets users standardize asset con� guration and eliminate con� g-uration errors. Users can apply con� guration templates to device placeholders or live devices, so they can be commis-

sioned one by one as � eld engineers are wiring the segments or automatically in groups.

“We expect to reduce commissioning time and loop test-ing for Foundation � eldbus devices by 10,000 to 20,000 man-hours for mid-size to large projects with this new functional-ity,” says Rong Gul, Shell’s corporate subject matter expert on smart instrumentation and instrument asset management.

Management Goes MobileNo doubt empowered by their spiffy software capabilities, many asset management systems also appear to be freeing themselves from � xed applications and individual locations with help from wireless networking, Internet protocol (IP) communications and cloud computing services. Price re-ports that Infor’s software is also migrating onto tablet PCs, smart phones and its Cloud Suite service to help users gen-erate performance models faster. “Mobility gets information and models out into the � eld so users can make sense of vertical and micro-vertical situations, and make better deci-sions on the spot,” says Price.

Jim Montague is Control ’s execut ive edi tor.

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As natural forces go, pressure is pretty straightforward, but there are some important aspects that must be remem-bered to calibrate pressure-based devices.

To reacquaint users with pressure’s crucial details, two 90-minute webinars were delivered recently by ISA (www.isa.org) and Beamex (www.beamex.com). The three pre-senters were Hunter Vegas, project engineering manager at Wunderlich-Malec (www.wmeng.com.com), Ned Espy, technical director at Beamex and Roy Tomalino, profes-sional services engineer at Beamex.

“Both sides of the ‘pressure equals force divided by unit area’ equation need to be taken into account,” says Vegas. “With tanks, a common myth is that the shape can affect pressure at the bottom, but this isn’t true because 1 in. x 1 in. x 23 ft of water always weighs 10 lbs regardless of its shape, so the shape of a tank has no impact on the 10 psi pressure at its bottom. All that matters is the height of the liquid.”

If this tank were � lled with mercury, then this initial 10 psi would be multiplied by mercury’s speci� c gravity (SG) of 13.6 to produce a pressure of 136 psi, and if a 1-psi blanket of nitro-gen is added at the top to suppress fumes, it would bring the bottom pressure up to 137 psi. “When calibrating a differential pressure (dP) transmitter that’s reading pressure at the bottom, three things matter—height of the liquid, SG of the liquid and any pressure on top,” says Vegas. Likewise, a 23-ft storage tank at 100% will read 276 inches of water column (in.H2O), and a 10-in.H2O nitrogen blanket will bring it up to 286 in.H2O, until a compensation leg, bubbler or other device is added (Figure 1).

The Three Up-Down TestTomalino � rst connected a Beamex MC6 calibrator to the high side of a Siemens dP transmitter set up for 0-100 in.H2O and a 4-20 mA output that provides a linear function of 4 mA at 0 in.H2O, 12 mA at 50 in.H2O and 20 mA at 100 in.H2O, and has a 0.5% of span error tolerance. These levels correspond to zero,

50% and 100% of the transmitter’s set operating pressure, and Tomalino used a connected 300-psi air pressure pump with venting to move the transmitter up through each level and back down through each in a three up-down test.

“The calibrator just needs to know what to expect,” says Tomalino. “We � rst zero it for the atmospheric pressure, and have only a 3-second delay while it looks for a stable signal and automatically grabs the test point.”

Tomalino reports his � rst test failed because its 0.59% of span was outside the set 0.5% error tolerance. The MC6’s raw data and graph showed that largest error during the test occurred on its high side, and he adds it’s important to pre-serve this as-found data to aid trending. “If you can gather 10 years of calibration data, you can see if a transmitter is drifting, is rock solid or needs adjustment every time,” says Tomalino. “Don’t erase a test, trim and then test again.”

Because the dP transmitter has HART communications, To-malino adds that screwdrivers and potentiometers can’t be used to adjust its zero and span. Instead, MC6’s diagnostic service is opened, reminds the user to remove the transmitter from au-tomatic control, adjusts its current and sensor trim to 100% at 100 in.H2O, and allows it to stabilize. Next, the zero level is also typically trimmed, and when the transmitter is tested again, it passes with a largest error of 0.128% of span, which is docu-mented as its as-left condition. Both as-found and as-left data sets are combined in the transmitter’s calibration certi� cate.

Vegas adds that the placement of a pressure transmitter can impact measurement performance. Mounting a steam pressure transmitter below a line protects the transmitter, but the condensation in the tubing will shift the transmitter reading. This problem is solved by shifting the transmitter calibration to account for the water in the tubing. Tomalino demonstrated this procedure on a Rosemount 3051 PT set for 0-250 in.H2O that equates to a 4-20 mA output, but needs to elevate its zero to account for a 10-in. wet leg, so it adjusts

Experts from Wunderlich-Malec and Beamex present a two-part ISA webinar on the basics, crucial issues and best practices for successful pressure calibration. by Jim Montague

C A L I B R A T I O N

CT1503_45_48_Feature3_1.indd 45 3/3/15 1:13 PM


the transmitter to read 10-260 in.H2O with 10 in.H2O at the 4 mA output and 260 in.H2O at the 20 mA output. “We be-gin with 10 in.H2O, take it up to 135 in.H2O and 260 in.H2O at 100%, and go back down the same way,” adds Tomalino. “However, if we forget to stop at 10 in.H2O and vent all the pressure at the end, then the calibrator won’t accept this as zero because it wasn’t the correct 4-mA value. But we can’t go back to the 10-in.H2O setpoint, so we must go up past it and then back down to it again.”

This time, the calibration test failed because the 10-in. wet leg should have equated to 4 mA, but was only reading 3.9 mA. So it needed to be trimmed to zero, and was adjusted to a 0.006% of span error, which allowed it to pass the calibrator’s test. All the as-found, adjustment and as-left data need to be documented and added to the calibration certificate.

Steam Drum levelIn the second webinar, Vegas states, “Steam drums bedevil people because they must know more than its tap-to-top height. You need SG of the water in the drum and the water in the wet legs to calculate 0% and 100% levels.” SG of the wa-ter in the drum is determined by the boiler operating pressure, but SG of the wet legs depends on the type of heat tracing. It’s important to leave the heat trace on year round because if it’s turned off, then the level reading will be affected.

For example, a calculation was done on a 36-in., tap-to-tap steam drum at 600 psig with wet legs that were steam traced with 45 psig steam. The drum water had a 0.787 SG, and the wet leg water had a 0.923 SG. Subtracting high-side from low-

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Figure 1: A 23-ft storage tank at 100% will read 276 inches of water

column (in.H2O), and a 10-in.H2O nitrogen blanket will push it to 286

in.H2O, until a compensation leg, bubbler or other device is added.

100% = 23 ft

LT

Reading @ 100% = height (in) x SG23 ft x 12 in/ft x 1.0 (SG) = 276 in. wc

FI nitrogen

N2 blanket(10 in. wc)

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SG = 1

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side readings results in a 0% level of -33.23 in.H2O and 100% level of -4.9 in.H2O (Figure 2).

Espy says steam drum level calibration steps include: • Making sure interlocks are bypassed or boiler is out of ser-

vice (because many steam drum level transmitters feed low-high level trips) before isolating the transmitter;

• Calculating the steam drum level calibration, includ-ing the zero setting of -33.23 in.H2O and the span setting of -4.9 in.H2O;

• Setting the zero and span;• Returning the transmitter to service; • Once steam trace is at temperature and boiler is at nor-

mal pressure, adjusting the zero if necessary to match sight glass or mechanical gauge.

Tomalino again used the MC6 to calibrate level trans-mitter steam drum and level transmitter capillary functions for a Rosemount 3051 transmitter. “It’s tricky to calibrate a transmitter with such large zero shifts, and one usually needs to consult the manual for the exact procedure,” he says. Tomalino pulled a slight vacuum on the transmitter to set the 4-mA and 20-mA points for this calibration.

Diaphragm SealsVegas adds that the three main types of dP seal assemblies—pad type, pad type with single capillary and dual capillary seal—can all cause problems. Pads and seals directly mea-sure pressure, but the diaphragms in them are easily dam-aged if installed incorrectly. The fill fluid inside the capil-laries that transfer process pressure to transmitters can leak and cause quality problems in the process. These fluids can become viscous and have slow response due to low ambient or process temperature and pressure, or boil in high vacu-ums and high temperatures and ruin the seals.

“Seals are fragile and expensive, so you want to be sure the gaskets are in place before they’re bolted down, and you always need to be aware of ambient temperature,” explains Espy. “It’s also important to address up-front how testing and calibration will be performed to avoid big headaches. Flush rings are useful for venting and applying calibration pres-sure, and this means the seal doesn’t have to be unbolted to perform a calibration.”

Espy adds that dP seal calibration steps include:• Isolate both seals from process using flush rings;

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• Be sure both seals are at their nor-mal position and elevation;

• Vent both seals to atmosphere us-ing flush rings; record the current 4- mA reading as found;

• Apply span pressure on the high seal and record the current 20-mA reading as found;

• Vent both seals and adjust the transmitter to read 4 mA as left;

• Apply span pressure to the high seal and adjust the 20-mA point as left;

• Close the vents and return the seals to service.

Tomalino adds that a tank with a 0 to 25-in.H2O level range and 4-20 mA transmitter output may have a -28.46 in.H2O to -3.46 in.H2O pressure based on its process’ SG, capillary fill fluid SG and a long capillary to the low-side sensor, and these need to be compen-sated for in its calibration and trim.

“Calibrating level transmitters with capillaries can be mind-bending for technicians, so you need to break it into chunks to conquer it,” says Toma-lino. “The big picture has three parts: as-found, adjustment if necessary and as-left if you adjust. In our example, we needed to adjust, and those steps are trim lower and trim upper.

“Using the scaled variable function

in the transmitter, we scaled the trans-mitter, so 0 to 25-in.H2O input equals -28.46 to -3.46 PV. For this transmitter, the lower trim should be performed first, and is related to the PV closest to zero. That PV is -3.46 in.H2O and is the actual 100% span value of 25 input and 20-mA output. The upper trim is the PV furthest from zero, -28.46 in.H2O, which is 0 input and 4-mA output. So the lower trim is our 20-mA output, and the upper trim is the 4-mA target. This can be confusing.

“The pressure calibration shows pressure coming in and current going out. Perform the lower trim using 25 in. H2Oin and expecting 20 mA out. Enter -3.46 and send it. Next, do the upper, 0 in, 4 mA out, and enter -28.46 to complete the adjustment. Then cap-ture your as-left results, do an up-down test to check for hysteresis, see that it’s passed, and save the results.”

[Editor’s note: This article is based on two webinars, Oct. 2, 2014, and Feb. 19, 2015, organized and hosted by the ISA and Beamex. They can be viewed at http://bit.ly/1BDo8hE and at http://bit.ly/1C1F8NS].

Jim Montague is Control ’s execut ive edi tor.

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Figure 2: Water in a 36-in. steam drum at 600 psig will have a 0.787 SG, while a steam

trace in its leg will be at 45 psig and 0.923 SG. Subtracting high-side from low-side

readings results in a 0% level of -33.23 in.H2O and 100% level of -4.9 in.H2O.

LT

Steam

HL

36 in.

Steam drumConditions: 600 psig, SG = 0.787

Calibration calculations:0% setting = high – low pressure @ 0% level = -33.23 in. wc100% setting = high – low pressure @ 100% level = -4.90 in. wc

Steam traceConditions:

45 psig, SG = 0.923

Calibration of a SteaM DruM level


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

DAN HebertSenior Technical ediTordheber [email protected] t

M A r c H / 2 0 1 5 www.controlglobal.com 49

Transforming level

measurements into

wireless signals is

only one part of the

equation.

Process plants and related facilities such as tank farms are filled with vessels, tanks and similar storage units, and most of these

units could benefit from a system to measure, monitor and view inventory on a near real-time basis. “Logistical benefits of tank level monitor-ing include reduced emergency deliveries, bet-ter inventory management and labor produc-tivity improvements,” says Michael Robinson, director of solutions, Endress+Hauser (www.us.endress.com).

Wireless is a good fit for this application, as most tank level instruments are installed at the top of a tank, a tough spot to access. Many tanks also require long home-run wiring. Wiring in corrosive environments has a tendency to fail at connection points, and conduit systems can rust and deteriorate. Finally, many tanks are in-stalled in hazardous areas, making it expensive to run and maintain wiring.

Available wireless level measurement tech-nologies include differential pressure and ra-dar, both of which can be made truly wireless with a battery-powered option. In the case of tank level monitoring, it’s feasible to have a very low update rate and correspondingly long bat-tery life—up to 10 years in some cases.

But many tanks have existing conventional wired instruments, and others need to use level measurement technologies not available in wireless versions. For these instruments, a wireless adapter can be used to convert the wired instrument output to wireless. Although this isn’t a completely wireless solution, it does solve the problem of wiring back to an inven-tory management system.

Transforming level measurements into wire-less signals is only one part of the equation; the second is transmitting this information to a tank inventory monitoring and management system. Two options for creating this data link are via the cloud or a local Wi-Fi network.

“Our wireless tank inventory monitoring solution can include an AC-, battery- or solar-

powered cellular communications modem, which transmits tank level information to our cloud-based service SupplyCare that is hosted on secure Endress+Hauser servers,” explains Robinson.

One could configure a system similar to Sup-plyCare by buying a modem, contracting with a cell provider, contracting with a cloud stor-age firm and installing appropriate tank inven-tory management software, such as an HMI with database storage capability, in the cloud. Once tank level data is sent to the cloud, it can be accessed for inventory management by any device with an Internet connection and proper login credentials.

Emerson Process Management (www2.em-ersonprocess.com) installed its Rosemount tank gauging equipment for inventory measurement of liquid storage tanks for St1 (www.st1.eu), a Swedish petroleum refinery in Gothenburg. The plant has both wired and wireless equip-ment, all connected to a wireless gateway.

Emerson’s Smart Wireless Gateway collects tank data from the instruments and makes it available through a WirelessHART Wi-Fi net-work. To improve access to the wireless net-work, St1 also added a wireless connection from the control room to the local gateway via the Wi-Fi based Emerson Pervasive Field Net-work (PFN).

The PFN link at St1 includes three indus-trial hotspot units. One is connected to the local gateway and to a remotely installed di-rectional panel antenna. A second serves as a repeater to achieve line of sight.

The third unit is installed in the control room area, and it’s connected to a remotely in-stalled panel antenna. In addition, it’s equipped with an integrated antenna to create a Wi-Fi zone, enabling operators to access the wireless network from any place in the control room. This data is also now available to any tank level management and inventory system within the Wi-Fi coverage area.

Simplify Tank level Monitoring with Wireless

CT1503_49_TechSpeak_2.indd 49 3/3/15 1:15 PM


a s k t h e e x p e r t s

This column is moderated

by Béla Lipták (http://

belaliptakpe.com),

automation and safety

consultant, who is

also the editor of

the Instrument and

Automation Engineers’

Handbook (IAEH). If you

have automation-related

questions send them to

[email protected].

When to Use Equal Percentage Valves

Q Is there some general rule on when we should use equal percentage (=%) and when linear control valves? I know that

the determining factor is the inherent flow char-acteristic, the flow vs. lift at constant pressure drop, or something like that. I do not know what this means, because constant valve pressure drop rarely exists except in the ideal conditions of the manufacturer’s test lab.

NeNad Tripkovicht r ipkov icn@ yahoo.com

A The selection goal is control loop stabil-ity. This we obtain by making the loop re-sponse to load changes as linear as possible

(keeping the loop gain more or less constant). The gain of any device is the ratio of its output divided by its input. The loop gain (LG) is the product of the gains of the loop components: the process (Gp), sensor (Gs), controller (Gc) and valve (Gv). Tuning the loop means that if our goal is quarter-amplitude damping, we ad-just the controller gain (Figure 1), so that the loop gain (LG) will be about 0.5.

LG = (Gp)(Gs)(Gc)(Gv) = CPG(Gc) ~ 0.5

Linear valves: If the total process gain (TPG = (Gp)(Gs)(Gv)) is more or less constant (does not change much with load), linear valves should be used. In a linear (constant gain) valve, a 1% change in lift results in a 1% change in flow (Gv = 1.0). TPG is acceptable if it stays be-tween 0.5 to 2.0 as the load varies between its minimum and maximum limits. Linear valves are used in most applications except heat trans-fer (temperature control).

TPG = (Gp)(Gs)(Gv) ~ 0.5 to 2.0

Non-Linear Valves: If the valve gain rises as the valve opens, its characteristic is called equal percentage (=%), and if its gain drops as it opens, it is called quick-opening (QO). Special, custom-made valves can provide other non-lin-earities, for example, having gains that are the inverse of the pump curves. Therefore, com-pensation is provided by using an inverse valve

characteristic (Gv = 1/Gp) so the installed char-acteristics of the total process will be more or less linear (TGP = 0.5 to 2.0). Naturally, Gv can never be the exact inverse of Gp, but as long as the selected valve characteristic keeps the TPG within 0.5 and 2.0, instability and limit cycling can usually be avoided by good controller tun-ing (assuming TGP = 1.0 when adjusting Gc).

Equal Percentage Valves: Equal percentage (=%) valves are used on heat-transfer processes because in heat transfer (temperature control), when the heat load is low, the heat transfer sur-face area available to transfer that heat (load) is large. As a consequence, at low loads the heat transfer is efficient; the process gain (Gp) is high. As the load rises, the same heat transfer area has to transfer more and more heat, and therefore its efficiency (the process gain) drops. To compensate for this, we need a valve whose gain rises with load (=%). For example, if the se-

Figure 1: If the process is non-linear (Gp varies with

load), the gain product of the loop (LG) should be

held more or less constant by compensating for

the variation in Gp by using a non-linear valve with

inverse Gv non-linearity.

m1

(Gv) (Gp) CW

Set pt. (r)

°F°F

c

% %

Load(u)

m + +

Process�uid (u)

%m %e

Controllergain

Dimension-less

Gc =

Setpoint (r)

e

b +

TIC (Gc)

TT (Gs)

% %

GPM GPM

Loop gain =(Gc)(Gv)(Gp)(Gs) = = = Dimensionless

°F

Processgain

GPM

m3/s °CGP =

GP =

% % °C°F

100% span Gs = =

Sensorgain

⎝

⎠

⎝

⎠

⎝

⎠

Valve gain

Gv = GPM %

m3/s % ⎝

⎠

⎝

⎠

⎝

⎠

CONSTANT GAIN

CT1503_50_51_ATE.indd 50 3/3/15 1:16 PM

a s k t h e e x p e r t s


lected =% is, say, 3%, flow will increase 3% for each 1% increase in lift. There-fore, the higher the load (flow), the higher this 3% quantity becomes and, therefore, the valve gain (Gv) rises with load.

Some will also use =% valves when us-ing constant-speed centrifugal pumps to transfer fluid through long pipes. They do that because at low flows, when the pressure drop in the pipe (ΔPpipe) is small, most of the inlet pressure is burned up in the valve (ΔPvalve), so a small change in lift results in a large change in flow (Gp is high). As the load rises, the pipe drop (ΔPpipe) also rises, and therefore less pressure drop is left for the valve, so Gp drops. This method of compensation is wrong because it’s at low flows that one should not burn up all that energy in the form of valve pressure drop (ΔPvalve)! In-stead, variable-speed pumps providing constant valve pressure drop and linear valves should be used.

As you can see, you asked a complex question, which I could answer only briefly here. So if you need an in-depth explanation, see Chapter 6.7, starting on page 1,154 of Volume 2 of the Instru-ment Engineers Handbook, where Table 6.1g lists the selection of valve character-istics for many applications.

Béla liptákLip takbela@aol .com

A Use a linear valve when control-ling flow, liquid level, pressure and composition, and then use an

equal-percentage valve when control-ling temperature.

In more than 60 years working with control loops, almost all the cases where I had to change valve characteristics, I have been replacing equal-percentage with linear.

F. GreG ShinSkeyshinskey@metrocas t .ne t

A In order to make the control as sta-ble as possible, you want the loop response to be as linear as possible.

If you put the loop in manual and move the output 10%, you want to see the same 10% change in the measurement regard-less of whether you moved the output from 10% to 20% or from 70% to 80%. If the response is nonlinear, it is difficult to tune the loop because a gain that works great at low valve opening will not work as well as the valve opens further.

Let’s say you’re controlling flow with a valve on a long pipe fed by a centrifugal pump. When the valve first cracks open, the flow is very low, the pump discharge pressure is high, and the line loss is very small. In this case, the control valve is taking nearly all of the pressure drop, and a small change in valve position will result in a big flow change.

Now consider the same when the valve is 80% open. In this case, the flow is high, the pump discharge pres-sure will have fallen, and the line loss will be much larger. Now the pressure drop across the valve is much lower, and a small change in valve position will not change the flow very much at all.

In this case, an equal percentage valve is the appropriate choice because the characteristic of the valve offsets the effect of the piping. When the valve first opens, a 5% change will not move the valve much. However when the valve is more than 50% open, a 5% change will move the valve a great deal more. This inverts the effect of the piping and cre-ates a more linear response for the loop.

Now consider a case where you are controlling flow, but the pipe is short and the pump has a fairly flat flow curve. The valve is now taking the full line drop regardless of its position. In this scenario, a linear valve trim would be a better choice because a 5% valve position change will affect the flow con-sistently regardless if the valve is barely

open or nearly fully open.

p. hunter VeGaS, pephvegas50@gmail .com

A Linear or =% valves have very prac-tical applications, not just theoreti-cal ones. The exact conditions can

be found in many references, for exam-ple, Emerson’s Control Valve Handbook. (www.documentation.emersonprocess.com/groups/public/documents/book/cvh99.pdf).

I came across an application on start-up where the =% valve gave poor con-trol because the piping pressure drop was low. I had to do an inverse charac-terization in the DCS (which amounted to gain scheduling). In other words, the process piping was larger than it needed to be.

Two classic examples of linear valve applications are a bypass valve around a heat exchanger for temperature control and a trim valve in parallel with a larger main valve.

SiMon [email protected]

A In general, control valves with an equal percentage inherent charac-teristic are used to produce a lin-

ear installed characteristic in process control. Such an installed characteristic in flow vs. lift for control valves can be mathematically derived, and has been published in books on process control.

Some control valves are provided with custom-made trims so that the pump curve is built-in. This provides high loss coefficients at low flows and low loss coefficients at high flows, and eliminates the need for parallel valve operation, and therefore reduces main-tenance while increasing reliability and controlability in process control. Boiler feed water valves are an example.

Gerald liu, p. enG.gerald. l [email protected]

CT1503_50_51_ATE.indd 51 3/3/15 1:16 PM

Grace Under PressurePressure transmitters and their related components are rising to meet new challenges.

R O U N D U P

DP WITHOUT LINES AND TUBESDeltabar FMD71 level trans-mitter uses two pressure sen-sor modules—hydrostatic and head pressure—connected electronically to one trans-mitter. Using a Ceraphire ce-ramic sensor, the transmitter calculates differential pres-sure (DP) from both sensors, and transmits level, volume or mass via 4-20 mA with HART, eliminating DP measure-ment problems caused by impulse lines or capillaries. Endress+Hauser 888-ENDRESS (363-7377); www.us.endress.com


LOW-PRESSURE AIR, NON-CORROSIVE GASESKobold’s PMP differential pressure sensor is used for controlling and measuring the DP of low-pressure air or non-corrosive gases, and is ideal for monitoring filters. The sensing range is 0 to 500 mm H2O (50 mbar), and the maximum pressure is 750 mbar. It offers a four-digit display and a 4-20 mA output signal. Relay, hysteresis, time delay of the relays and the analog output are programmable.Kobold Instruments Inc. 412-788-2830; www.koboldusa.com

CALIBRATOR COMBINES FEATURESHPC40 Series handheld pressure calibrator is com-pact and offers deadweight tester accuracy, active tem-perature compensation and a non-menu interface. It deliv-ers laboratory accuracy onsite and calibrates pressures from vacuum to 15,000 psi with an accuracy of 0.035% of reading for all ranges. HPC40 is the first mA loop calibrator that’s fully temperature compensated from -20-50 °C.Crystal Engineering 805-595-5477; www.crystalengineering.net

DISPLAY IMPROVES EFFICIENCYSmartLine pressure trans-mitters feature a graphic dis-play that supports graphical process data in easy-to-read trend lines and bar graphs. Part of the Smart Connec-tion Suite, it allows control room operators to send mes-sages to the display to make it easier for field operators to determine required maintenance. When integrated with Ex-perion PKS, SmartLine can display its maintenance mode. Honeywell Process Solutions 800-822-7673; www.honeywellprocess.com

SUBMERSIBLE LEVEL VIA HYDROSTATICSProSense level sensors in-clude two styles of SLT sub-mersible level transmitters, which measure liquid levels by sensing hydrostatic pres-sure and providing a 4-20 mA signal. SLT1 has a 1-in. diam-eter housing and a 0-5 psig to 0-50 psig sensing range. SLT2 has a 2.75-in. diameter PTFE diaphragm surrounded by a stainless steel, non-fouling cage, and 0-5-psig to 0-30-psig sensing range. Automation Direct 800-633-0405; www.automationdirect.com

PRESSURE MEASUREMENT IN CORROSIVES A Kynar process connection is an alternative, cost-effec-tive solution to remote seals for some corrosive process fluids and gases. This option is available for select mod-els in ABB’s 2600T pressure transmitter series. The pro-cess wetted parts consist of highly corrosion-resistant Kynar and diaphragm materials, such as tantalum. Its maximum working pressure is 145 psig.ABB 800-435-7365; www.abb.com/measurement

CT1503_52_53_Roundup.indd 52 3/3/15 1:17 PM

R O U N D U P


MORE COMPATIBLE, GREATER RANGEPT-503 submersible pressure transducers have PVC hous-ings for operating in envi-ronments with regular, pro-longed exposure to harsh, corrosive chemicals, even at -30-130 °F and depths to 450 ft. Other features include 4-20 mA, Modbus, 0-5 Vdc and mV/V outputs; Hytrel, PVC and urethane cable options; Te� on-coated or ceramic trans-ducer face; and breathable, hydrophobic vent tube cap. Automation Products Group Inc. 888-525-7300; www.apgsensors.com

HIGH-ACCURACY WET/WET DP PX509HL Series DP trans-ducers are shock- and vibra-tion-rated and provide long life in containment pressures up to 10,000 psi. Features in-clude welded, stainless-steel construction and user-acces-sible potentiometers for zero and span, a micro-machined silicon sensor at the core to provide stable readings with high accuracy of 0.08%, and a broad compensated range of -20-85 °C on most ranges.Omega Engineering Inc. 888-TC-OMEGA (826-6342); www.omega.com

SPEED OF RESPONSE, STABILITY Sitrans P500 pressure trans-mitters are designed for cus-tody transfer and compres-sor applications They are available in several ranges to cover all applications and have a SIL2/SIL 3 safety rat-ing. Their 88-ms speed of response, 0.14% total performance and � ve-year 0.05% sta-bility make them suitable for compressor anti-surge and throughput applications. Siemens 800-365-8766; www.usa.siemens.com/pressure

PRESSURE RANGES TO 5,000 PSIGMGF16BN digital pres-sure gauges come in pres-sure ranges to 5,000 psig at standard accuracy of ±0.25% of full scale and with op-tional accuracy of ±0.1% of full scale. The display is a 4.5-digit LCD with 0.5-in. numerals and a lower alphanumeric display for engineering units and to aid setup. Each gauge includes up to 15 � eld-se-lectable engineering units, depending on the sensor range. Meriam Process Technologies 800-817-7849; www.meriam.com

TWO-WIRE, 0.1% ACCURACYType 5000 rugged, two-wire I/P pressure transmitter con-verts one pressure input into a 4-20 mA or 10-50 mA output with 0.1% accuracy. Its de-sign includes a temperature-compensated piezoresistive transducer for accurate mea-surements of non-corrosives. Type 5000’s lightweight hous-ing includes a 0.25-in. NPT pressure port and 0.5-in. NPT conduit port.Marsh Bellofram Corp. 800-727-5646; www.marshbellofram.com

SMART DP IN TIGHT SPOTS 815DT is a loop-powered, mi-croprocessor-based DP trans-mitter with a con� gurable, single-pole, single-throw, normally open solid-state re-lay. Its discrete output signal can be used for signaling, control and emergency shut-downs, and it communicates via HART7 and Modbus RTU. Available ranges include 0-138 in H2O; 0-415 in H2O, 0-50 psid, 0-100 psid, 0-300 psid and 0-500 psid. SOR Controls Group Ltd. 800-676-6794; www.sorinc.com

CT1503_52_53_Roundup.indd 53 3/3/15 1:17 PM


P r o d u c t i n t r o d u c t i o n s

HiGHEr WirE EXPErtisEWireXpert 4500 Cable Cer-tifier’s dual control system enables one technician to run tests from either end of a cable. Proven accuracy and a 2.5-GHz range allow certifying to TIA standards as well as the emerging 2.0-GHz Category 8 standard. Optional test adapters handle all categories of copper patch cords; multi-mode MPO cables; simplex-encircled, flux-compliant, multi-mode and single-mode links; industrial Ethernet cabling systems; and more.Softing Inc. www.softing.us

duAL-tEMP trAnsMittErs LEVErAGE sMArt HArtTHZ3 and TDZ3 two-wire (loop-powered) transmitters accept direct inputs from 14 RTD types, nine thermocou-ple types, resistance and po-tentiometer devices, and di-rect millivolt sources. Dual inputs allow backup and fail-over protection, or 15 transmitters on one digital HART loop can monitor 30 points. Signal processing, HART and device-intelligence support capabilities include average and differential measurement, high- and low-select, and more.Moore Industries www.miinet.com

suPPLiEs dELiVEr MAXiMuM PoWErPROmax power supplies sport start-up temperatures as low as -40 °C, hazardous area approvals (UL, Class I Div. 2) and a 300% power boost. All-metal housings and DIN-rail mounting provide shock and vibration resistance. Sixteen models offer 5-, 12-, 24- or 48-Vdc outputs for loads up to 40 A. Features include front-panel voltage adjustment, LED lo-cal status and remote status monitoring through integrated relay contacts. Weidmuller 800-849-9343; www.weidmuller.com

suitE sPot For oPErAtor trAininGUniSim Competency Suite improves console and field operator competency. Uni-Sim Operations offers a pro-cess training curriculum. UniSim Curriculum tracks progress. Tutor stores domain knowledge and experiences, and teaches and evaluates “what if” reflexes and diagnos-tic abilities. Field View supports an interactive, navigable, panoramic view for realistic field operator training, and 3D Connect integrates simulations in a 3D virtual environment.Honeywell Process Solutions http://hwll.co/UltimateOperator.

MAnAGEd sWitcHEs tArGEt dEMAndinG nEtWorKsN-Tron series NT24k com-pact DIN rail-mountable, Power over Ethernet Plus, IEEE802.3af/at switches pro-vide shock (200 g) resistance, vibration (50 g) tolerance and up to -40-85 °C operating temperature range. Three models span eight to 16 ports, 10- to 49-Vdc power inputs and applications from security cameras, panel displays and wireless access points to general industrial applications. All models feature 30-ms recovery for rings up to 250 nodes.Red Lion www.redlion.net/NT24k

tHErMAL MAss FLoWMEtEr noW on FoundAtionThermatel TA2 thermal dis-persion mass flowmeters add Foundation fieldbus to the ad-vantages of the standard TA2 model, including dual gas calibration with two unique curves, field adjustability for gas type or mix, calibration verification to reduce downtime and unnecessary recalibra-tions, internal resettable and non-resettable totalizers, strong signal at low flows and low pressures with high turndown, and ISO 17025 and NIST-traceable calibrations. Magnetrol International, Inc. www.magnetrol.com

CT1503_54_Products.indd 54 3/3/15 1:18 PM

C O N T R O L T A L K

GreG McMillanStan weiner, pecontrol ta [email protected] t


Practical Installation Best Practices

Greg McMillan and Stan Weiner bring their wits and more than 66 years of process control experience to bear on your questions, comments and problems.

Write to them at [email protected].

Be prepared for shock and awe when you lay out your expectations to your contractors.

Stan: We continue our conversation started last month with Tim Green, operations man-ager, field services at Maverick Technologies (www.mavtechglobal.com), on making sure a control system will meet the performance ca-pability possible with today’s instrumentation.

Greg: What guidance can you offer based on your field experience and that of your key field people?

tim: There are many considerations, but here are the foremost installation best practices. The list is a collaborative effort that involved the Maverick construction managers and commis-sioning managers:

1. Install steam and liquid transmitters be-low the process tap, and air and gas transmit-ters above the process tap. In liquid-filled ap-plications, often the static fill will need to be zeroed out to null the effect of the liquid head pressure.

2. For magnetic flowmeters and other meters requiring ground rings, ensure that the ground ring material is appropriate for the process liq-uid by referencing the instrument data sheet. A standard 316SS ground ring may not last two weeks if Hastelloy C was required.

3. Fill differential pressure (DP) flow trans-mitters from the bottom to avoid the entrap-ment of air in the impulse lines. Conversely, drain impulse lines intended to be dry right be-fore commissioning.

4. Verify orifice plate materials and dimen-sions, and that they’re installed based on the flow direction. The beveled side of an orifice plate must be facing upstream.

5. Sensing elements of flow transmitters nor-mally require a minimum straight run of pipe prior to and after the sensor location. Follow the manufacturer’s recommendation. Note that there is no buffer in this number, and it may not take into account all of the piping de-tails. The straight run must be more than the

minimum. The straight run will need to be in-creased if there are nonplanar elbows, process equipment or valves upstream. Insertion flow meters will require greater analysis to get the sensor at the point in the pipe cross-section that is at the average pipe velocity.

6. Install radar transmitters with the device plumb. Make sure the horn or probe is correct for the service. For coaxial probes, make sure the standoffs are installed correctly to prevent false readings. If standoffs are not used, ensure the probe is not bent to avoid reading contact points with the housing of the bridal or inter-nal structure of the tank. When using transmit-ters with horn-type radar, avoid mounting too close to the sidewall, internal structures, inflow or sparge lines. Make sure the installation does not interfere with tank venting. Be sure to run an echo graph with the tank empty, all of the dip tubes installed, and the agitator running as a baseline reading that includes the effect of in-

CT1503_55_56_CTtalk2.indd 55 3/3/15 1:19 PM

C O N T R O L T A L K


ternals and geometry for future refer-ence. This is especially important for detecting problems from coating of the probe and vortexing of the liquid.

7. Always design wireless systems af-ter a thorough site survey. The number and locations of transmitters for sig-nal hopping must be more than ade-quate to make sure transmission is not blocked when a transmitter is removed from service. Locations of transmitters may need to be adjusted. Sales may not realize how critical this site sur-vey is. Pay attention to future physical changes to the site and possible park-ing of tank trucks and service vehicles that may interfere with the existing wireless system.

8. Temperature transmitters are de-signed for multiple sensors, so make sure the correct sensor is selected and connected to the appropriate termi-nals. If there is a mixture of two-wire, three-wire and four-wire resistance temperature detectors (RTDs), the risk of incorrect terminations greatly increases due to the lack of standard-ization. Ensure that the probe length matches the thermowell depth, the fit is tight, and the tip is bottomed out in the well. Also use high-temp pipe dope to avoid thread damage.

9. Make sure the flowmeter element is installed in the correct orientation because most flowmeters are sensitive to flow direction.

10, Install analytical probes within the limits of the factory cable lengths between the transmitter and sensor. At-tempts to extend the wiring to meet op-erations or maintenance requests will result in erratic readings. The factory cable must be used and junction boxes not introduced. Substituting cables and adding junctions causes shielding, termination, color coding and resis-tance problems.

11. Avoid installing pH and ORP probes before process fluids are flow-ing. Protect the probe from physical damage and keep the wet cap on the probe during storage. This wet cap can

be used to protect the electrodes before start-up, but the caps must be removed before commissioning. If the electrode tip dries out or is knocked against any-thing or hit by debris, the glass surface can be permanently damaged.

12. Check motors for proper starter size. Starter sizes follow the denomi-nation of money: dime, quarter, half dollar and dollar. NEMA 1 through 4 horsepower ratings are 10, 25, 50 and 100. When bump-testing rotation, de-couple the pump from the motor to avoid loosening the impeller. Verify all thermal overload protection matches the motor nameplate. The horsepower should not be assumed.

Greg: Thermowells and electrodes need to see a representative process temperature and composition with a fast response time and negligible noise. Achieving this objective translates to specific sensor location requirements. The tip must be near the centerline of a pipeline or beyond the baffle and away from a sparger or dip tube in a vessel. The tip must see a single phase (e.g., liquid or gas) and maximum uni-formity (e.g., sufficient axial and radial mixing to achieve blend and mini-mize noise). In addition, it must intro-duce a minimum amount of dead time (e.g., transportation delay from equip-ment to sensor must be less than the time constant of a good, clean sensor), and also sustain an adequate velocity to prevent a slow sensor time constant from fouling. Finally, it must prevent exposure of electrodes to high tem-peratures or high acid, base or alcohol concentrations that cause premature aging, chemical attack or dehydration of glass electrodes.

Often there is a compromise needed in the location of the sensor where a larger transportation delay is accepted to achieve a single phase, sufficient uniformity and adequate velocity. The increase in total dead time rarely ex-ceeds a few seconds, and may actually reduce the total dead time in the sys-

tem by reducing the sensor time con-stant or signal filter time needed. For example, a pH electrode located in a recirculation line will introduce less dead time than an electrode in a ves-sel due to an inherently faster time constant and by avoiding coatings. A thermowell or electrode located 25 pipe diameters downstream of a heat exchanger or static mixer will provide a more repeatable measurement with less need for a signal filter. This dis-tance is increased for desuperheaters and static mixers with gaseous reagents (e.g., flashing ammonia) to avoid drop-lets and bubbles, respectively. For more details on thermowell and pH electrode installation requirements, see the books Advanced Temperature Measurement and Control and Ad-vanced pH Measurement and Control.

Stan: We conclude with a Top 10 E&I Start-Up “Believe It or Don’t” List.

E&I Start-Up “Believe It or Don’t” List 10. Inadequately sized actuators were found and replaced before start-up.9. All of the control valves had better than 0.25% resolution.8. Minimum straight run for flowme-ters was based on piping system de-tailed drawings.7. Thermowells measured the average pipe temperature.6. Electrodes measured the average pipe composition.5. Insertion flowmeters measured the average pipeline velocity.4. pH electrodes were not installed un-til the process fluid was near normal velocity.3. Sensors location was optimum in terms of minimizing dead time and maximizing single-phase consistency and measurement repeatability.2. All of the control loops had initial tuning settings identified automati-cally during high-fidelity simulation testing and operator training. 1. Innovation and advanced process control was used everywhere.

CT1503_55_56_CTtalk2.indd 56 3/3/15 1:20 PM

ADVERTISER . . . . . . . . . . . . . . . . . . . . . . . . PAGE NO.

ABB Automation . . . . . . . . . . . . . . . . . . . . . . . .4

Advantech . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Allied Electronics . . . . . . . . . . . . . . . . . . . . . . 17

AutomationDirect . . . . . . . . . . . . . . . . . . . . . . .2

AVG Automation . . . . . . . . . . . . . . . . . . . . . .59

Badger Meter . . . . . . . . . . . . . . . . . . . . . . . . . 18

Beamex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Cashco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Daisy Data Displays . . . . . . . . . . . . . . . . . . . .38

Emerson Process Management/Fisher . . . . .60

Emerson Process Management/Saab . . . . . . 15

Endress+Hauser . . . . . . . . . . . . . . . . . . . . . .6, 7

Festo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Honeywell Process Control . . . . . . . . . . . . . . 33

Load Controls . . . . . . . . . . . . . . . . . . . . . . . . .36

MacTek . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Magnetrol International . . . . . . . . . . . . . . . . . 12

Maple Systems . . . . . . . . . . . . . . . . . . . . . . . .34

Martel Electronics . . . . . . . . . . . . . . . . . . . . .48

Meriam Process Technologies . . . . . . . . . . . . 47

Moore Industries . . . . . . . . . . . . . . . . . . . . . . 23

MTS Systems . . . . . . . . . . . . . . . . . . . . . . . . .44

Mynah Technologies . . . . . . . . . . . . . . . . . . . 37

National Instruments . . . . . . . . . . . . . . . . . . . 10

Omega Engineering . . . . . . . . . . . . . . . . . . . .29

Opto22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Orion Instruments . . . . . . . . . . . . . . . . . . . . . .3

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ProSoft Technology . . . . . . . . . . . . . . . . . . . . 42

Red Lion Controls . . . . . . . . . . . . . . . . . . . . .43

Rotork Controls . . . . . . . . . . . . . . . . . . . . . . . 41

Weidmuller . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Winsted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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

Jim montague e xecut ive editor

[email protected] t

58 www.controlglobal.com m a r c h / 2 0 1 5

Lifting my

head from all the

specialized niches I

cover, I could again

see how process

control fits into

the larger world.

editor education

i’ve covered and written about process control and automation for quite awhile, but it always seems like there remain many basic concepts

that elude my limited ability to understand them. I can describe how they work, of course, but I’m short on knowing why.

Luckily, several of these were cleared up on Feb. 19 when I attended the second of two 90-minute webinars hosted by the ISA (www.isa.org) and presented by Hunter Vegas, proj-ect engineering manager at Wunderlich-Malec (www.wmeng.com.com), Ned Espy, technical director at Beamex (www.beamex.com) and Roy Tomalino, professional services engineer at Beamex. I liked the second webinar so much that I asked ISA for the YouTube link to the first one held on Oct. 2, 2014, and then had the bright idea to write this issue’s “How to Cali-brate Pressure Instruments” feature on page 45.

Anyway, besides learning about detailed best practices for calibrating pressure devices, I was reminded by the presenters of the underpin-nings of not just pressure, but process applica-tions in general. Very refreshing. Lifting my head from all the specialized niches I cover, I could again see how process control fits into the larger world.

“When we’re talking about good measure-ment, we’re really talking about good me-trology practice and data with demonstrable pedigree that can show traceability back to in-ternational standards,” says Espy. “We do cali-bration to bring transmitters that have drifted back to their good-as-new condition.”

At its most basic, pressure is defined as force divided by unit area. However, Vegas explains that this simple equation can occur in some unexpected ways. For instance, if a large force is spread over a relatively large area, then the net local force is small, while a small force over a small area can have a high net local force. For instance, a 14,000-lb elephant that always has at least two 314-sq.in. feet on the ground gener-ates 22.3 lbs./sq.in., but a 120-lb. woman with

one 0.25-sq.in. heel on the ground produces 240 lbs./sq.in.

Likewise, Vegas added it’s important to re-member that, when using a standard orifice plate in an air line, differential pressure (dP) is multiplied by four when the flow is doubled, and dP is multiplied by nine when the flow is tripled. “Flow and dP have a squared relation-ship, so the dP’s square root is needed to con-vert or relate to a given flow,” adds Vegas. “This is usually done in the DCS, so if it’s done in the field, you need to make sure the DCS doesn’t do it again.”

Apart from its counterintuitive behavior, pressure also comes in many units that can be hard to sort out. The primary pressure units are atmospheres, pounds per square inch (psi), Newtons per square meter (kPa), bars that are 0.01 kPa, inches of water column (in.H2O), mil-limeters of mercury (mmHg, Torr) and inches of mercury (in.Hg). “People get confused be-cause there are so many units, and then ambi-ent pressure is also affected by altitude, temper-ature, humidity and even latitude,” adds Vegas. “Depending how your scale is set, at sea level you may see any of these: 0 psig (gauge), 14.7 psia (absolute), 1 atmosphere, 30 in.Hg or 760 mmHg. In.H2O is based on the weight of a 1-in. cube of water, and 27.7 in.H2O equals 1 psi.”

Besides using or converting to the right units, pressure measurements also depend on where on the scale those measurements start. Espy adds, while absolute pressure begins with zero in a vacuum and gauge pressure begins with zero at ambient barometric pressure, dP happens in a closed system that looks at the dif-ference between two pressure signals coming from a high leg and a low leg, and zero differ-ential happens when both legs are connected.

After struggling to understand the second webinar, it was a relief to get some grounding from the first. It probably would have helped to not view them bass-ackwards, but my loss can be your gain. Check them out.

CT1503_58_CTreport2.indd 58 3/3/15 1:22 PM


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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.

YOU CAN DO THATIt feels like we’re running in circles tryingto meet regulations and process demands. I wish we could operate at a higher level.


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Control Magazine - March 2015