Control Engineering April 12

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com
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Think big but pay small!

USB local I/O expansion port supports up to four additional local I/O bases Ethernet remote I/O expansion port supports 32 remote I/O racks and up to 64 GS series AC drives High-speed Ethernet port for network of HMI (up to 32 C-more panels), other controllers, and enterprise system communications Two serial ports for peripheral device interface or simple controller networking USB port for data logging to removable drive, and project transfer
The Productivity3000 programmable controller can get your big job done easier and cheaper. The $599 CPU with 50Mb memory supports large programs, complete with tagname database and program documentation stored onboard. The huge (100,000+) I/O capacity gives you plenty of room to plan and expand. And the CPUs seven communication ports make integrating a large system easier than you can imagine. Download the free programming software and check it out!
input #1 at www.controleng.com/information
PLC, HMIs & Relays for Automation
PLC + HMI with Data Logging

PLC + Operator Interface OCS XL Series Free Programming Software Starts at Removable Mass Data Storage $ 445 TM) (MicroSD MADE IN --- Supports Data Logging Two Serial Ports Ethernet and Telephone Modem USA Option Cards
Visit omega.com/ocsxl_series
Marco Scisetti/Dreamstime.com
Programmable Relays
ZEN Series Starts at $160
High Performance Programmable Logic Controllers (PLCs)

CP1H Series Starts at $1060
5.7Web-Enabled Touchscreen Operator Interface with Data Logging

G3 HMI306 Series Starts at $800
MADE IN
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USA
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COPYRIGHT 2012 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED
Vol. 59 Number 1
JANUARY 2012
C OV E R S TO RY
COVERING CONTROL, INSTRUMENTATION, AND AUTOMATION SYSTEMS WORLDWIDE

FEATU R E
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FEATU R E
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Energy consumption with standards
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65%
Additional 3 30%
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features
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Control system software programming

Strategies and design tools make control system software programming more intuitive, faster, with greater ability to upgrade and reuse code, more easily adapting programming for a variety of controllers.
Using HART with asset management systems

Since its the most broadly deployed smart device platform, is HART the right choice for your plant? Here are some considerations for end users.
Device testing and pre-configuration makes for a flawless startup

The 2011 HART Plant of the Year is Shell Canadas Scotford Upgrader, after programming and commissioning 1,500 devices.
Energy efficiency for machines

Purchase price of a machine accounts for just 2%-3% of its overall cost. Making intelligent choices when choosing motors can save up to 30% of energy consumption over the life of a machine.
2012 projections for PLCs, IPCs, operator terminals

Controllers, operator terminals, and process controls contribute to a more productive manufacturing future, say IMS Research, ARC Advisory Group, and Frost & Sullivan.
CONTROL ENGINEERING (ISSN 0010-8049, Vol. 59, No. 1, GST #123397457) is published 12x per year, Monthly by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. CONTROL ENGINEERING copyright 2012 by CFE Media, LLC. All rights reserved. CONTROL ENGINEERING is a registered trademark of CFE Media, LLC used under license. Periodicals postage paid at Oak Brook, IL 60523 and additional mailing offices. Circulation records are maintained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Telephone: 630/571-4070 x2217. E-mail: customerservice@cfemedia.com. Postmaster: send address changes to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: customerservice@cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA, $ 145/yr; Canada, $ 180/yr (includes 7% GST, GST#123397457); Mexico, $ 172/yr; International air delivery $318/yr. Except for special issues where price changes are indicated, single copies are available for $20.00 US and $25.00 foreign. Please address all subscription mail to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.
JANUARY 2012 CONTROL ENGINEERING www.controleng.com
Industrial Ethernet
Industrial Wireless
Serial Connectivity and Networking
Embedded Computing
Use your Smart Phone to scan for more information.
Moxa Americas, Inc.

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Moore Industries helps run your operations safely, reliably and at peak performance.
Signal Conditioners, Transmitters, Isolators and Converters Temperature Sensors, Transmitters and Assemblies Limit Alarms, Trips and Switches Fieldbus Device Couplers and Power Supplies Process Controllers, Monitors and Backup Stations Smart HART Loop Interfaces and Monitors Process Control and Distributed I/O Networks I/P and P/I Converters, Indicators and Displays and Instrument Enclosures
We dont horse around when it comes to your signal interface instruments.
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CONTENTS
Inside Process
Starts after p. 50. If not, see www.controleng.com/archive for January.
P1
Measuring level in highly dynamic petroleum processes

Getting an accurate level reading where there is fluid boiling and off-gassing makes for quite a challenge. Here are two examples plus advice on bridle configurations
P6
Monitoring critical vessel temperature

Radiometric imaging can help detect and measure uneven temperature gradients quickly and reliably
PRODUCT EXCLUSIVE
departments
8
THINK AGAIN Tax less, export more, educate technically
news
24 26 28 30
How safe are your electrical system work practices? Design system integration projects for success Soapbox: PCs vs. PLCs; more from the IT security students Functional safety just makes things work as they should
10
PRODUCT EXCLUSIVE User interface, integrated software advance machine tool productivity TIPS & TRICKS Building control system integration IT & ENGINEERING INSIGHT What are your manufacturing IT project principles? TECH UPDATE PLC-based Bode loop analysis for industrial controls INTERNATIONAL Exploring robotics for the factory of the future MACHINE SAFETY Planning, execution, safety, and integration BACK TO BASICS Thermowell protection
PRODUCTS
12
14
products
59
Motion controller module; surge protector; PLC motion programmer; wireless bridge Wireless access point; enclosures; photo-electric sensors; motor soft starters Inspection system; control platform upgrades; valve positioner Modeling platform; CAN data logger
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CONTROL ENGINEERING JANUARY 2012 5
JANUARY
online
EXCLUSIVES
www.controleng.com
EXCLUSIVE ONLINE CONTENT

Go to www.controleng.com and find: The Automation & Control Engineering group on Linkedin has passed 20,000 members and counting (link below). Check out the discussions As industrial networks use more IT-based hardware and techniques, the world of IT hacking gets closer. Engineers explain why our networks are soft targets Have you looked in our Webcast section lately? New selections are now available on demand, including advice for fieldbus deployments, understanding integrated safety systems, tips for optimizing Ethernet net works, and methods for integrating safety functions into machine designs
EDUCATION
Now redesigned for easier access All current and earlier tutorials Industrial wireless guidebook Focus on safety when launching a lean manufacturing initiative Advances in flowmeter technology Hybrid fuzzy algorithms for manipulators
DAILY NEWS
Will high oil prices drive upgrades in refineries and pipelines? How to develop a control system design checklist Choosing a programming language Fieldbus Foundation announces new integration platform strategy New bio-diesel production in Europe
Meet the 2012 System Integrator of the Year award winners in a video interview and panel discussion. Executives of the winning companies talk about the steps of a successful project, and what makes for an effective relationship over the long term.
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MORE LEARNING, LESS SURFING

Exclusive blogs at www.controleng.com/blogs
Ask Control EngineeringWhere does all that mercury come from? Machine SafetyNew standards come into force: are you ready? Pillar to PostWhy do we ignore IT security practices?
Join the discussions at www.linkedin.com/ groups?gid=1967039

Chat with 20,000 of your peers and get real-world control questions answered: Whats more important to a career, experience or education? Are enough resources available to secure industrial networks? Looking for good reference works for commissioning process instrumentation. Is proportional control alone enough to run a loop?
TOPIC-SPECIFIC NEWSLETTERS
System Integration, including networks, safety, I/O and system integrators Information Control, including controllers, DAQ, HMIs, MES, programming software and PLM/design software Process Control, including advanced control and instrumentation Machine Control, including motors and drives, motion control, embedded control and machine vision
Point. Click. Watch.

Video: Revisiting the IT security engineers
Meet some new cyber security students, and cover additional topics with the group from last summer. They have some interesting recommendations.
Name Dr. Dennis Hong Job Title Associate Professor of Mechanical Engineering, Virginia Tech Area of Expertise Robotics LabVIEW Helped Me Convey and respond to vast amounts of data in real time Latest Project Design and prototype a car that can be driven by the blind in just 4 months
NI LabVIEW
LabVIEW makes me better because
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2010 National Instruments. All rights reserved. LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. 2784
editorial
THINK AGAIN
Tax less, export more, educate technically
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Council on competitive recommendations also suggests leveraging R&D, and promoting energy and efficiency initiatives.
should drive the private sector to develop and utilize all sources of energy on a market basis while enforcing efficiency standards to ensure a sustainable supply of energy to manufacturers. The report and recommendations, about 60 pages in total, have more details, created under guidance of Council Chairman and Deere & Company Chairman and CEO Samuel Allen and a steering committee of 60 CEOs, university presidents, labor leaders, and laboratory directors. In part, the report says, Smart manufacturing is a growth engine for jobs and a sustainable economy. A $50 billion investment in retooling factories would generate up to $120 billion in revenue resulting from increased demand for products, according to a study by the Apollo Alliance, a business-labor coalition. Manufacturers would achieve higher levels of business performance, turn resources into assets, and discover unique opportunities for competitiveness. The potential for manufacturing process innovation is enormous.... Smart manufacturing enables a coordinated and performance-oriented enterprise that responds quickly to the customer, minimizes energy and material use, maximizes health and safety and generates innovation....smart tools and systems that generate and analyze greater amounts of data are being used to plan, design, build, operate and manage industrial facilities and networks. Hardly have to think again about that. Seems like a no-brainer to me. Read more at www.compete.org.
Contributing Content Specialists Contributing Content Specialists

Frank J. Bartos, P.E., Frank J. Bartos, P.E., braunbart@sbcglobal.net braunbart@sbcglobal.net Jeanine Katzel jkatzel@sbcglobal.net Jeanine Katzel jkatzel@sbcglobal.net Vance VanDoren Ph.D., P.E., Vance VanDoren Ph.D., P.E., controleng@msn.com controleng@msn.com Suzanne Gill, European Editor Suzanne Gill, European Editor suzanne.gill@imlgroup.co.uk suzanne.gill@imlgroup.co.uk Michael Majchrzak, Control Engineering Russia Michael Majchrzak, Control Engineering Russia mike_majchrzak@trademedia.us mike_majchrzak@trademedia.us Tomek Kurzac, Poland Editor-in-Chief Tomek Kurzac, Poland Editor-in-Chief tk@utrzymanieruchu.pl tk@utrzymanieruchu.pl Milan Katrusak, Czech Editor-in-Chief Milan Katrusak, Czech Editor-in-Chief mk@controlengcesko.com mk@controlengcesko.com Andy Zhu, Control Engineering China Andy Zhu, Control Engineering China andyzhu@cechina.cn andyzhu@cechina.cn
he U.S. can lead the world in 21st century advanced manufacturing, at the heart of long-term U.S. productivity and prosperity. How? The U.S. Council on Competitiveness last month released a report and series of recommendations called Make: An American Manufacturing Movement, a strategy map, to Congress, the White House, and 50 governors. Advice, was collected from hundreds of Deloitte interviews over nearly three years and dozens of dialogues where Council members and national thought leaders discussed manufacturing topics. The priority recommendations from the five challenges are: 1. Congress should permanently replace the current world-wide double taxation system with a territorial tax system to facilitate the repatriation of earnings and restructure the corporate tax code to increase investment, stimulate production at scale, and neutralize sovereign tax incentive investment packages. 2. Congress, the administration, and industry should intensify efforts to support the presidents goal to double exports from $1.8 to $3.6 trillion and reduce the trade deficit by more than 50%. 3. Federal, state, and local governments, along with high-schools, universities, community colleges, national laboratories and industry, should prioritize Career and Technical Education (CTE) programs and push for greater integration of community colleges in the innovation pipeline. 4. Congress and the administration should leverage R&D investments across the federal research enterprise to solve challenges in sustainable smart manufacturing systems and to ensure a dynamic discovery and innovation pipeline. 5. Congress and the administration
8
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The Age -Old Debate: Brick vs. Rack?
Now the perfect solution for those who want both in one.
Like a brick style PLC, the L series base unit is compact, efficient and affordable. Like a rack, it offers expandability with a myriad of I/O options and powerful capabilities via snap-on modules for logic, high speed positioning and temperature control. Built-in features like Ethernet, USB and SD memory card slot, along with a single piece of software for all programming, configuring and diagnostics, and you now have a completely different animal. Brick? Rack? No need for harsh words. The debate is over. Get the best of both with L Series PLC.
Lseries
Highly Integrated, High Performance, Expandable PLC with Snap-On I/O
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EXCLUSIVES
Unified CNC user interface

Siemens Sinumerik Operate user interface adds convenience, new features.
iemens Sinumerik Operate user interface improves machine tool performance and convenience by integrating three interfaces. Sinumerik Operate combines the HMI-Advanced, ShopMill, and ShopTurn operator and programming interfaces to create one consistent user interface for machine tools. Animated elements help facilitate intuitive operation and programming. The most complex workpieces easily can be set up and produced in one clamping operation. Sinumerik process measurement cycles are available for automatic workpiece and tool measurement processes with the familiar look-and-feel of Sinumerik Operate. Input masks with animated elements use the Sinumerik high-level language programGuide and, with ShopMill and ShopTurn, include a simulation capability. Measured values can be automatically updated and used for tool correction and zero offset. Animated elements are designed to support machine opera-
tors with predictive graphic animation of operating and programming steps. ShopMills programming functionality also offers graphical support for display of the rotary axis in position patterns, new pocket calculator functions with fit indication, and ability to hide selected positions in position patterns. Cylinder surface transformation and multiple workpiece clamping are included along with new grinding tool types, new measurement probe types, and new depiction modes for tools using graphics and detailed picture views. New shortcuts, such as the Ctrl-F function, allow simplified search operations in most operating areas such as files, tools, or in the editor. Program management is more efficient, allowing PDF files or picture documents in .jpg, .png, and .bmp formats to be saved in directories on local drives for paper-free production.
www.usa.siemens.com/cnc Siemens CNC
Integrated software
adds machine tool productivity
Sinumerik MDynamics CNC milling and turning technology package from Siemens increases user productivity and tool speed, and improves part finish.
any jerks that occur during the acceleration phase along adjacent milling paths, which improves surface finish quality, despite increased machining speeds. The orientation path smoothing (ORISON) function for 5-axis machining helps eliminate the orientation fluctuations that occur over a number of blocks. For various applications, the ORISON function smooths progression of changes to the orientation vector over several NC blocks, for fewer compensation movements that place less stress on the machine dynamics, leaving more dynamic capacity available for path tracking. In the end, not only are circular axes less likely to be slowed down by stringent tolerance specifications, but there is also improved machining speed, surface quality, and contour precision. The new Quick Viewer function for mold-making applications offers a quick overview of the workpiece and the relevant sub-program, enhancing security.
www.usa.siemens.com/cnc Siemens CNC
inumerik MDynamics, a technology package for milling applications, is aimed at users of 3- and 5-axis milling machines. It combines CNC hardware, smart CNC functions, and the integral CAD/CAM/CNC process chain into one usable package for industries that are required to comply with the highest standards of surface quality, precision, and machining speed. Sinumerik MDynamics is geared to applications in industries such as automotive and aerospace, power generation, medical part production, shop floor manufacturing, and tool- and mold-making. Accurate surface machining and precise contouring are provided within the shortest possible machining times, for higher workpiece quality and manufacturing productivity. The Advanced Surface path control system has been upgraded to further improve quality and evenness of milling path velocity profiles and reduce overall machining times. Optimized lookahead function improves part quality and increases productivity for high-speed cutting (HSC) of freeform surfaces. Special emphasis was placed on the optimization and smoothing of
10 JANUARY 2012 CONTROL ENGINEERING www.controleng.com
For decades, ABB variable speed drives and Baldor motors have set the standard for quality, reliability and energy savings. Now, industrial customers in the U.S. can buy these products and receive expert support from a single source. Call 479-646-4711 to locate the district office nearest you. Two trusted names. One local source for sales and support. Only from ABB and Baldor. baldor.com
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Scan with your smartphone to watch a motor and drive energy efficiency video or go to http://bit.ly/mSM0JV. input #7 at www.controleng.com/information
Building control system integration

When integrating building control systems, be specific about what you mean.
Jeff Carpenter
he term integrated systems is commonplace in our industry. It seems easy to define; however,
a deeper look at the concept leads to a realization that systems integration in a modern construction project is a complex topic. It is a topic that can have many different meanings depending on
Unknown high voltage transients cause grief and lost money

...but there is a solution
Poof!
Up to 3500V Isolation Barrier
Control FPGA
the audience. A project that does not tackle this reality will likely suffer from unintended consequences. As is true in every aspect of engineering, a complete understanding of a concept is a prerequisite to developing its contract documents. The documents, however, are not enough. A successful project involving integrated systems requires the project team to deliberately determine the intended delivery method of the contract documents within the construction process. Variances in delivery methods can include design-bidbuild, design-build, or various methods of collaborative team structures. But even within a design-bid-build model, an understanding of the relationship of the contractors delivering the integrated systems to the construction manager, the general construction team, the MEP (mechanical, electrical, plumbing) contractors, and other trades is very important and should be structured in an intentional way. Contract documents for something as complex as integrated systems cannot accommodate all of these construction methods at once. Doing so risks the documents being so generic as to be ineffective as a construction delivery tool.
What are integrated systems?
MEASURpoint provides isolation up to 3500V continuously or 5000V for transients, protecting your analog sensor signals. Ethernet and application so ware included.
Measurement of sensor signals in industrial settings can provide big surprises. High common mode voltage from transients caused by nearby generators or motors can wipe-out instrumentation. We have seen this! Using galvanic isolation to eliminate this high voltage makes sensor measurement straightforward. Harsh environments need protection.
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An accepted dictionary definition of integration is to unite with something else. While this definition is generic, it lacks the specificity to accurately reflect the myriad of technical possibilities a system integration project faces. Uniting building systems can be approached in multiple ways: Physical wiring of contact closures from one system to another Low-level, direct communication between disparate systems using serial communication protocols High-level, direct communication between disparate systems from multiple manufacturers, using purposebuilt, proprietary drivers developed through a corporate partnership between manufacturers High-level, direct communication between systems using industry accepted communication protocols Direct communication between dis12
JANUARY 2012
parate systems from a single manufacturer, using proprietary protocols, delivered to the marketplace as a single solution A unified system from a single manufacturer, designed as a single system to address multiple, disparate functions A network of disparate systems, communicating using standard information technology (IT) protocols. It should be evident that attempting to write generic contract documents that accommodate any and all of these possibilities is impossible and pointless. A successful system integration specification is one that is targeted to the specific needs of the project after competent consulting with the project stakeholders. As a starting place in this process, I suggest abolishing the term system integration from our industrial vocabulary. The phrase has become so generic as to be wholly ineffective. Consider the following terms as replacements: Point-level interconnection Low-level protocol interconnection Driver-based integration Standards-based integration Unified system Converged system. Each of the six terms requires a different approach to design, specification creation, and construction delivery to ensure a successful project. For more details on each of these six approaches and a table of relevant codes, standards, and listing agency requirements, click the link in the online box below. ce - Jeff Carpenter PE, RCDD, is with KJWW Engineering Consultants, Des Moines, Iowa. This was excerpted from a CFE Media article in December 2011 Consulting-Specifying Engineer magazine. www.csemag.com www.kjww.com
ONLINE
Read more, including a table of standards: Design approaches for integrated systems http://bit.ly/tYj89M Automation Integrator Guide http://controleng.com/integrators Control Engineering Tips and Tricks page has been updated with recently posted tips at http://controleng.com/events-and-awards/ce-tipsand-tricks.html http://bit.ly/9G71nh More tips: Also see this issues Engineering and IT Insights for 10 tips to establish manufacturing IT project principles.
JANUARY 2012 13
A concept drawing visualizes how the convergence of the physical infrastructure can enable the integration of disparate building systems without some of the common integration roadblocks. Courtesy: KJWW Engineering Consultants
Rock Solid
When accuracy and reliability are your top priorities

Dataforths fully isolated 8B isoLynx SLX300 data acquisition system Powerful: 7 advanced special functions and 4 alarm states
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IT & engineering
INSIGHT
What are your manufacturing IT project principles?
D
Dennis Brandl
Do many projects seem to repeat basic arguments on project direction and options? Does the team often rehash issues? If so, then perhaps you need to specify project principles; 10 tips, and alternatives, follow.
standards, such as OPC-UA and MTConnect or give preference to the vendors recommended communication standard. 5. Pick solutions that follow industry naming and modeling standards, such as ISA88, ISA95, and ISA99 or select vendor solutions that have been optimized for their environment. 6. Give preference to commercially available industrial network hardware, such as hardened Ethernet or give preference to hardened and proven propriety vendor network hardware. 7. Do not modify the equipment vendors code or HMI interface or replace equipment vendor code with custom code that follows the companys interface and HMI standards. 8. Deliver no system or software before the documentation is complete or deliver systems and software as soon as they are available so they can be used by the end user. 9. Never put software developed outside of the company into any company software unless approved by the VP of development or never build software when you can buy it instead. 10. Never change anything on a production system with written approval or fix the problem first, then document the changes and get written approval for a permanent change. If your principles are technology focused, then they should be reassessed every several years. Technologies change, and what made sense five years ago may no longer be appropriate. For example, a build-versus-buy decision may change because the market now offers solutions (so buy), or the market no longer offers solutions (so build). Basically, project principles restrict choices, so must be well thought out and the consequences understood. Following principles may not always lead to the cheapest or fastest solution, but it will lead to best solutions for your environment. ce - Dennis Brandl is president of BR&L Consulting in Cary, N.C., www.brlconsulting.com. His firm focuses on manufacturing IT. Contact him at dbrandl@brlconsulting.com.
Following principles may not always lead to the cheapest or fastest solution but will lead to best solutions for a particular environment.
ONLINE
Design, documentation, support, and system snapshot can preserve software investments. http://bit.ly/pCDJ0n www.acm.org www.iso.org/iso/qmp
14
oes your project team always seem to want to go back to the starting point and rehash old issues? If so, then perhaps you need to specify project principles. Principles are a vital aspect of any successful organization because they provide consistent help and direction in making basic decisions. Principles provide general rules and guidelines that are intended to be persistent and rarely changed. There many principles, ranging from personal, such as I will not lie or I will not steal, to engineering principles such as the U.S. Navys principles of engineering, manufacturing principles, such as the ISA 9004 Quality Management Principles, and professional principles from ACM (Association of Computing Machinery) for ethical activities of software engineers. The value of having well-defined and accepted principles is that they remove many undesirable alternatives that you might use on a project. This is important in IT projects because there are usually many possible strategies, custom and commercial solutions, and vendors. There is no one list of project principles that applies to all companies, but the following examples can help in selecting project principles. For principles, there are often two opposing alternatives. The correct alternative can depend on the size of your company, if you are a vendor or an end user, if you have a good IT organization or rely on external consultants, or if you have preexisting specific company-wide principles. 1. Integrate Best of Breed solutions over a less-capable one-vendor solution or pick an integrated solution from one vendor of a set of Best of Breed solutions. 2. Give preference to buying solutions instead of building them or give a preference to building a focused custom solution instead of compromising on a non-optimal commercial solution. 3. Plan and design for expected future enhancements or plan and design to exactly meet the end users requirements. 4. Give preference to industry communication
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UPDATE
PLC-based Bode loop analysis for industrial controls

Todays PLC can do Bode loop analysis, bringing benefits to industrial controls long enjoyed in the electronics world. The Bode analyzer function block described improved the control loop used on a gas turbine engine, including certification of the turbine control systems.
Gary L. Pratt
Figure 1
Figure 2
ode loop analysis has long been a staple in the electronics world, but due to expense and complexity of the specialized equipment involved, Bode loop analysis has not been as common in the industrial controls field. Todays higher-performance PLCs can do Bode analysis in the PLC logic with none of the traditional expense or complexity. Although it may sound trivial, to maintain the stability of a negative feedback loop, the feedback must remain negative. If at any frequency the total phase shift of the loop becomes 360 degrees, the negative feedback becomes positive feedback and the loop becomes unstable. Since the subtraction in the feedback loop represents 180 degrees itself, the other loop components must contribute less than the remaining 180 degrees. Figure 1 shows how the loop becomes unstable when the total loop shift is 360 degrees and the loop gain is 2.0. Unlike the simplified Figure 1 diagram, the gain and phase of each block of a control loop can vary with frequency and operating point. Figure 2 shows the control blocks of a typical control loop with frequency-dependent components. Ideally, the plant we are attempting to
control would have infinite bandwidth (in other words, the plant would exhibit no frequencydependent behavior throughout the frequency range of interest). Unfortunately, this is rarely the case. At some frequency, the plant begins to exhibit non-ideal behavior, typically consisting of multiple high- and low-pass filters at various filter frequencies. For the purposes of this example, the plant will be modeled with a fixed gain of 1.0 (Gain2=1.0) and a low-pass filter effect at frequency 10 Hz (F2=10 Hz). A single-element low-pass filter such as this plant filter will exhibit zero degrees of phase shift well below its filter frequency (F2), 45 degrees at its filter frequency, and 90 degrees well above its filter frequency. Likewise, its gain will be Gain2 at low frequency, Gain2/2 at its filter frequency, and Gain2/frequency at high frequencies. If the plant consists of two or more low-pass filters, each can contribute 90 degrees and their sum can reach 180 degrees and drive the control loop unstable. A common method to avoid this is to incorporate a Dominant Pole into the Loop Compensation block. The Dominant Pole consists of a single-element low-pass filter at a frequency which is much lower than any filter in the plant. The object is for the effects of this filter (over which we have control) to dominate the filters in the plant (over which we typically have no control). For the purposes of this example, we will place the dominant pole at 1 Hz (F1) with a gain of 10 (Gain1). Figure 3 shows the phase and gain contribution of dominant pole and the plant, and shows how the total gain drops below 1.0 (0.0 dB) well before the total phase reaches 180 degrees (360 when the subtraction is included). Figure 3 shows gain and phase of loop components, and phase at unity gain. Generally, the higher the gain, the better the
16
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Figure 3
control loop will be able to maintain the process variable (output) to the desired the setpoint (input). But this is a bit of a balancing act. If we change the gain of the loop compensation from 10 to 20, as shown in Figure 4, the phase shift around the loop rises from 120 degrees to 137 degrees. As described further in the next section, the trade-off for this improved accuracy will come at the price of ringing on step changes. Its the control engineers job to manage this balance, as well as to employ other techniques to provide the necessary accuracy while maintaining the necessary stability. Figure 4 Shows gain and phase with higher loop gain.
Bode loop analysis
Figure 5 shows typical Bode plot with gain and phase margin.
Bode analysis of nonlinear systems
Bode analysis is the process of measuring the total gain and phase shift around the loop at various frequencies and then determining margins available before the system goes unstable. These margin numbers provide a good summary of the stability of the loop. Phase margin is defined as 360 degrees minus the phase of the loop where the magnitude of the loop reaches unity, and gain margin is the gain where the total loop phase reaches 360. A loop with phase margin greater than zero (phase shift of less than 360 degrees) will be stable, but the closer the phase margin is to zero, the more the loop will ring during a step change. As a rule of thumb, a phase margin of 45 degrees typically provides good stability with some ringing on step changes. A phase margin of 60 degrees usually provides very good stability with little or no ringing on step changes. Figure 3 shows the Phase margin measurement for the control system example. Beware that in some cases the effective loop gain will decrease when a component reaches the limits of its range (saturates). For instance, notice the phase margin of the loop shown in Figure 5 will drop to near zero (at 0.1 Hz) if the gain decreases by 25 dB. If a step change drives any of the components in this loop near saturation, the loop may ring at 0.1 Hz until the ringing settles to the point where the loop components are all operating in their linear range. For this reason, the automated phase margin measurement built into the Bode analyzer block described below defines phase margin as 360 minus the greatest phase shift encountered while the loop gain is greater than unity. Under this definition, the phase margin of the loop in Figure 5 will be roughly 5 degrees.
Very few physical devices are perfectly linear throughout their operating range. A Figure 4 transfer function of a linear device would be a straight diagonal line. Figure 6 (online) shows the transfer function of a nonlinear device. Notice that the gain of the transfer function is less than 1.0 on the ends of the operating range, and up to 2.0 in the center. Bode analysis is a purely linear measurement. If the system is nonlinear, the loop could be stable in some operating ranges but Figure 5 not in others. For that reason, it is important to run the loop analysis in all the operating ranges of the loop components. The Bode analysis of a nonlinear system is performed by executing a series of Bode analyses while the dc setpoint of the system is sequentially increased; see Figure 7 (online). While simple linear Bode analysis can be thought of as analyzing the characteristics of a vector, nonlinear Bode analysis can be thought of as analyzing the characteristics of a surface. This can be illustrated by first calculating the gain of the transfer function as a function of the input (in other words, taking the derivative of the transfer function). ce - Gary L. Pratt, PE, is applications manager, for GE Intelligent Platforms. www.ge-ip.com
www.controleng.com
Figures courtesy: GE Intelligent Platforms
ONLINE
Figures 6-26 appear online, along with continued discussion of logic configuration, correlating signal analysis, and PLC function block details. Go to http:// controleng.com/tutorials.
INTERNATIONAL
Exploring robotics for the factory of the future

Control Engineering Europes Suzanne Gill reports on a European Commission co-funded project that is testing the idea that industrial robot technology could provide a good base for machining, being both flexible and cost-efficient.
Suzanne Gill
are very agile, this agility results in a reduced stiffness compared to conventional machine tools.
While robots
he European Commission is co-funding an 8 million project as part of the European Economic Recovery Plan (EERP) adopted in 2008, which targets the use of industrial robots for high-end machining for cost-effective, flexible, and reliable manufacturing solutions for the Factory of the Future. The inaugural meeting of the European project was hosted in Spain in September 2010 by the coordinating partner of the project, Delcam. The COMET project sees 14 companies from industry, research institutes, and universities sharing and combining their manufacturing expertise with the aim of developing plug-andproduce COmponents and METhods for adaptive control of industrial robots for high-end machining to enable cost-effective, flexible and reliable manufacturing solutions. Mark Gadsden, product marketing manager at Delcam, explained more about the aims of the project: The 30-month COMET project aims to overcome the challenges facing European manufacturing industries by developing innovative machining systems that are flexible, reliable, and predictable with an average of 30% cost-efficien-
cy savings in comparison to machine tools. Because it is both flexible and cost-efficient, industrial robot technology could, from a conceptual point of view, provide a good base for machining. However, in real-life situations industrial robots have three critical limitations: a lack of absolute positioning accuracy, an inability to reject disturbances in terms of process forces, and a lack of reliable programming and simulation tools to ensure right-firsttime machining when production commences. At the present time these limitations are preventing the use of robots in typical machining applications.
Four elements to overcome limits
COMET project YouTube videos include these and several more, showing how robotics and machining combine. www.youtube.com/user/COMETproject Courtesy: COMET, YouTube
18
The COMET project consists of four elements that, together, aim to overcome these limitations. These include: 1. A methodology for describing kinematic and dynamic models of industrial robots (KDMIR) to define accurately the static and dynamic behavior of any industrial robot, which then is represented by its unique signature. 2. An integrated programming and simulation environment for adaptive robot path generation for machining with industrial robots (PSIR), based upon the unique signatures. 3. An adaptive tracking system for industrial robots (ATIR) to detect deviations from the programmed robot path and to adaptively initiate real-time corrections via the robot controller to ensure the necessary machining accuracy. 4. A high dynamics compensation mechanism (HDCM) to accomplish an absolute accuracy better than 50 m; significantly beyond the structural capability of the robot system on its own. Noble aims indeed, but the project has some interesting challenges to overcome, as COMET partner, TEKS, points out. Robots are a compromise between a comparatively low dynamic accuracy, and unrivalled handling flexibility. This means that, while robots are very agile,
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that all developments take into consideration the acceptability to end users in terms of time, cost, and reliability. Commenting on the COMET project to date, Dr. Ir. Jan Ramboer, research programme officer from the European Commission, said: The COMET project is an ambitious and innovative project. I am pleased to see robots being used early on to perform physical tests which are relevant to applications in the European manufacturing industry. Everything is very clear...[with] excellent synergy between partners. Dissemination is good across all levels, in particular the use of social media for communicating the project objectives and developments. Over the next six months almost all the technical tasks in the project will be active. To enable partners to plan and conduct robot machining experiments, a prototype of the high dynamics compensation mechanism (HDCM) will be available. The HDCM will help to accomplish an absolute accuracy better than 50m, significantly beyond the structural capability of the robot system on its own. The integration of models together with the PSIR, adaptive tracking system for industrial robots (ATIR) and HDCM will ensure that tests are performed in realistic enduser environments. Jan Willem Gunnink from Delcam, coordinator of the project, said: I have complete confidence that European manufacturing organizations will benefit from the combined knowledge of the COMET partners which comes from industry, research institutes, and universities. Since the inaugural meeting in September 2010, partners have demonstrated their ability to work as a team, providing a good foundation for the COMET project to move forward and develop new and exciting robot technologies in 2011. Klas Nilsson, associate professor from COMET partner, the University of Lund in Sweden, also believes that the project will have major benefits. He said: This type of project, where you bring together competencies from across Europe, will find new problems too! Together we are able to complement each other to find the best solutions to these problems. John Pandremenos from the University of Patras in Greece and dissemination manager of the project, said: If the project achieves its objectives it will bring big innovations to the manufacturing sector in European industry. It will significantly reduce the cost of machining operations. ce A video about the project can be viewed at www.youtube.com/user/COMETproject, or visit the project website at www.comet-project.eu.
this agility results in a reduced stiffness compared to conventional machine tools. The TEKS robot cell is based at the Advanced Manufacturing Park (AMP) in Rotherham. The company, which has already co-hosted one of the regular general assembly meetings of the COMET project test project, was the first with an operational cell to execution: machining of begin undertaking trials for COMET. the aluminum workpiece TEKS is in the process of developing its for a different robot robotic cell and with consortium partner, Artis configuration (DOE of Germany, it has conducted force measurement Factorial Plan, 6 factests while machining aluminium. The forces tors, 2 levels). Courtesy: generated by the cutting operation have been COMET recorded in detail with an Artis prototype data acquisition solution, at a high sampling rate of 500 kHz. Roland Krain, research and development manager at TEKS, explained the potential benefits of this approach: Traditionally robots are used as handling solutions for assembly. If machining is required in a robotic line or cell, the robot COMET seeks to bring typically would place the part in a big innovations to the conventional machine tool. Such tools range from the high tens of manufacturing sector in thousands pounds to several hundred European industry. It thousand pounds. A robotic machining cell could provide a cost-effective will significantly reduce machining solution. A second-hand the cost of machining robot can, typically, be purchased for 15k, along with a good quality operations. high-speed spindle for 20k, giving the end user multi-axis machining capability for a fraction of the cost of a comparable conventional machine tool. Obviously, the second-hand robot has to be in as new condition, be well maintained, and have a compatible controller; otherwise, the accuracy required might not be achieved. Today, customers generally opt for either a 5-axis machine or a handling robot. If we could bring the two things together, we would be able t o make customers more productive and more competitive, concluded Krain.
ONLINE
www.controlengeurope.com www.comet-project.eu www.youtube.com/user/ COMETproject
20
Setting up cells
Robot cells have now also been set up at a variety of partner facilities using robots from manufacturers such as Kuka, ABB, Motoman, and Comau. The cells will enable industrial tests to be performed on a range of parts, ensuring
- Suzanne Gill is editor of Control Engineering Europe.
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SAFETY
Planning, execution, safety, and integration

Are you using planning and execution tools? Are you integrating safety and controls? If not, you should be.
M
JB Titus, CFSE
ONLINE
Safety and security channel http://controleng.com/safety Siemens - Safety Evaluation Tool http://bit.ly/vATnsB Pilz - PAScal safety calculator http://bit.ly/uEZc3S Rockwell Automation -SISTEMA http://bit.ly/t2mzUi -Safety ROI tool http://bit.ly/vRSI7y Engineering interaction: What are your opinions of these safety tools, and what additional tools have you found useful? Leave a comment; on the Machine Safety blog at http://controleng.com/blogs.
22
achine guarding has performance level (PL), safety clearly entered the integrity level (SIL), probability technology world of a dangerous failure per hour with integrated safe(PFHD), and several more. ty systems. Are you still using Integrated safety systems are proven to improve productivity, 1970s approaches for planning and executing? Scotty didnt safety, and the bottom line. Why beam colleagues to the Starship arent more integrated safety Enterprise via Hertz Rent-a-Car! systems used in manufacturing? Weve entered the 21st century In the U.S., many still havent with state-of-the-art technolcompleted their first risk assessogy approved for use in machine ment nor are they aware of the safety applications. Along with changes in safety standards new technologies comes new Siemens safety evaluation allowing machine guarding tools designed to assist indus- tool is among automation thats not hardwired. try in the evaluation, design, vendor offerings. Courtesy: Weve also evaluated the and validation stages of your Siemens Industry Rogers Innovation Adoption machine guarding responsibility. Curve theory to find that the One such software (announced in Novem- market has moved from the early adopter ber at Rockwell Automations Safety Automa- stage to the early majority stage. With 85% tion Forum and Automation Fair in Chicago) is of the market still ahead, is the rest of the maran ROI (return on investment) calculation tool ket still caught up in 40 years of this is the way for machine safety. Its primary application is weve been implementing machine safety and it in the project development stage for securing works? Is it reluctance to change to something investment funding. This comprehensive tool is new or lack of trust? Some talk about the slightly unique because it combines financial-, injury-, higher cost of new components, but when they and productivity-related data to calculate a pro- see how dozens of engineering hours, wiring, jected investment ROI. A basic understanding is and checkout are eliminated, they quickly realthat the new integrated safety systems can pro- ize the savings potential. I believe integrated vide improved business performance for manu- safety systems have a unique message that the facturers compared with conventional hardwired trusted channels arent used to delivering. Ten machine guarding solutions. years of early adopters say that integrated safeSiemens, Pilz, and Rockwell Automation ty systems (1) improve organizational behavior each have tools for users to design safety circuits and (2) serve as a bridge to improve practices, compliant to IEC 62061 and EN ISO 13849-1. help boost productivity, increase efficiency, and Projects can be archived and retrieved as needed improve overall safety, sustainability, and busifor timely updates, and the tools will also gen- ness performance. erate a safety standard compliant report that In my opinion, automation suppliers of can be incorporated into your required machine integrated safety systems also can positively documentation. They generally include a com- influence adoption if they started delivering complete library of safety products for planning pelling messages to manufacturing executives a complete safety circuit. All of these project who can influence the adoption rate. ce - J.B. Titus, a Certified Functional Safety planning and execution tools provide automatic calculations of requirements such as common- Expert, does the Machine Safety Blog for CFE cause failures (CCF), diagnostic coverage (DC), Media. www.jbtitus.com
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NEWS
How safe are your electrical system work practices?

Survey shows many dont always follow the rules when working on industrial control equipment. Clamor for regulatory reform among survey respondents tells the story.
Jeanine Katzel
Although it probably wont come as a surprise to some, a lot of plant and controls engineers are taking what appear to be risks in the workplace today. Many simply arent following workplace standards and regulations in particular NFPA 70E (Standard for Electrical Safety in the Workplace; www.nfpa.org)when it comes to working on energized electrical equipment. Everyone agrees the ramifications of ignoring safety practices when handling electricity can be lethal, but are the risks being taken really what they seem? In a recent Control Engineering article (see Codes and Regulations: Electrical Controls Dirty Little Secret: We Dont Follow NFPA Rules at http:// bit.ly/ovLLWF), an experienced controls engineer took a different kind of risk by suggesting that hes not the only one out there who has opened a live panel and changed a speed setting on a VFD using no electrical personal protective equipment (PPE). Yes, hes putting himself in harms waybut, he asks, how much so? How much risk is too much? How much PPE really needs to be worn? Are requirements unreasonable, too cumbersome or complex, or in need of reform? The printed and posted version of the article invited Control Engineering readers to share their thoughts about these matters in an informal poll linked to the article above. The anonymous survey generated lively discussion with more than 300 responding to the dozen questions posed. Following are high24
lights of findings, along with a selection of candid observations about this controversial issue. (Survey was available on the Control Engineering website, www.controleng.com, for readers of the PPE safety article cited above. It was available from Oct. 17 to Dec. 16, 2011. Total responses=302.)
Near-unanimous agreement
Those responding to the survey knew of what they spoke: Nearly all (96%) said they worked on applications requiring the electrical PPE specified in NFPA 70E. However, more
Do you regularly violate NFPA 70e rules when working on control panels?
Always Mostly Sometimes Rarely Never No response 4% 3% 1% 19%
(Always + Mostly = 72%)
34% 38%
than half (59%) also said they rarely or never wore the required protective equipment. Another quarter (27%) said they donned required PPE only sometimes. Nevertheless, companies apparently provided the needed PPE. Nearly 40% of survey participants indicated electrical PPE was always available for them to use and another 37% said it was available sometimes or mostly. Only 12% said needed PPE was rarely or never available. Further, nearly two-thirds (66%) said their companies required electrical PPE, including
fire-retardant clothing, to be worn when working on energized panels greater than 50 V. Then why wasnt it used? The comments of a number of respondents were enlightening: PPE gear restricts me from being able to constructively do what needs to be done, said one. Protective equipment presently available causes more safety issues than it solves. When using a full suit, your vision and feel are very limited, said another. Gloves I cant feel with and a shield I cant see out of are more of a hazard than the electricity itself, offered a third. Additional questions further probed respondents safety habits when working on industrial control panels. A whopping 84% said they rarely or never used electrical PPE when performing non-high-voltage tasks such as programming an ac VFD. Nearly two-thirds (66%) said they rarely or never used electrical PPE when using an electrical meter. More than half (56%) admitted they worked on (actually touched) energized circuits greater than 120 V, and nearly threequarters (74%) said they worked on (actually touched) energized circuits above 50 V. Almost all respondents rejected extremes such as wearing electrical PPE to plug in a floor lamp at home. If we applied safety rules at home like they are in industry, doors would need to be removed or protected to remove pinch points, bathtubs would be a drowning hazard, and we would be required to lock out a lamp before replacing the bulb, added one respondent.
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ONLINE
Is the NFPA 70E standard too complex to follow and too restrictive for everyday use?
Yes 94% n Read an expanded version of this article, including more comments from survey participants, on the Control Engineering website. n See the original article that sparked the survey. http://bit.ly/ovLLWF n Safety and Security Channel www.controleng.com/channels/plant-safety-and-security.html n Machine Safety blog www.controleng.com/blogs/machine-safety.html
N No 6%
ADD YOUR ENERGY
Should industrial control panels have their own arc flash standard?
Yes 89% 9% 9% No No response 2%
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A cry for clarification, reform
Finally, the survey asked respondents some pointed questions about todays standards and regulations. Surprisinglyor perhaps notalmost everyone (92%) revealed they sometimes violated NFPA 70E rules when working on industrial control panels. Some 72% of these admitted to these practices always or mostly. Why might so many who should, and do, know better engage in such risky practices? For one, nearly all (94%) believe that NFPA 70E is too complex to follow and too restrictive for everyday use. And nearly 90% of respondents said that industrial control panels should have their own arc flash standard. Comments largely attacked the complexity of NFPA 70E regulations. Said one respondent, They are so complex and restrictive that they have had the opposite effect than intended. Most controls guys have elected to completely ignore themeven the regulations they should be paying attention to. Another pleaded simply: Please make the standards easier to read and understand. Disapproval, however, was not universal. NFPA Continued on page 28
JANUARY 2012 25
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Design system integration projects for success

See tips and tricks on automation and control system integration project management for advice from the 2012 System Integrator of the Year winners. See related video.
How an automation system integration project is designed and managed determines if it meets deadlines, budget, goals, expectations, and overall project success. Representatives for the 2012 System Integrator of the Year Award winners provide advice. Vance VanDoren, Control Engineering and Plant Engineering contributing content specialist and editor of the Automation Integrator Guide, spoke with (left to right in the video frame) Dave Bishop, president and CEO, Matrix Technologies; Rick Pierro, president, Superior Controls; and Lee Juckett, co-managing director, Mangan Inc. (Click on the photos to hear video snippets from each telling more about their companies.) Tips and tricks in the video discussion include the following. Break down a control system integration project into manageable steps. Appraise the project with the client, looking at all the pros and cons of doing the project. Select automation hardware and software that might be involved to get a rough estimate of cost, plus or minus 50%. Define scope and specifications, getting within plus or minus 30%. Execute the project. At this point, some integrators will estimate cost within 10%; others may provide a firm amount, discussing if small changes are included or the cost of larger changes. This includes consulting and programming, and extends to factory acceptance test (FAT) and commissioning. ONLINE
Watch the video at http://controleng.com/videos See the System Integration Hall of Fame with more about these three companies and other winners of the annual System Integrator of the Year Award project. http://controleng.com/SIY
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Vance VanDoren, Control Engineering contributing content specialist and editor of the Automation Integrator Guide
At http://controleng.com/videos watch the video for more automation and controls system integration advice from the leaders of the three 2012 System Integrator of the Year award winners. From left, Dave Bishop, president and CEO, Matrix Technologies; Rick Pierro, president, Superior Controls; and Lee Juckett, co-managing director, Mangan Inc.
Closeout (sometime finish, rather than tossWeigh the rolled into execution) ing things over the fence benefits of any includes training, manufrom one department or als, training, and clean- proposed change project stage to another. ing up; this last 10% of Project managers need in a system the time can take considto have great organizaerably more than 10% of integration project tional, communications, the budget. and collaboration skills, with costs in In approaching the to get clear understandschedule and project, get team meming and sign-offs at each bers from all areas step along the way. money. involved, including operWhen a change ations; look at methodology and scope is identified, see if its a clarificaand definitions; and ensure theres tion within project scopeand if not, appropriate industry expertise. weigh the benefits of the change with Stick to the process, ensuring the costs in schedule and money. project scope gets affirmed and solidiWork as team to ensure success of fied, which can ruffle feathers early but the project. ensures satisfaction later. - Compiled from video by Mark Involve operators and business lead- T. Hoske; video production by Peter ers from the beginning and ensure a set Welander, CFE Media, for Control of engineers is engaged from start to Engineering and Plant Engineering.
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Soapbox: PCs versus PLCs for process control

Dont settle for faults inherent in Recently PLCs have been benefitting PLCs and PCs. Take the best of each from special process control modules for a more effective hybrid system for that may be added. One thing that PLCs process control. PLCs have been an do very well is discrete control like opening and closold-time favoring valves. PLCs ite for automation have been effiand control. The cient in positiontop-down proing for robotics. grams and inputIn a hybrid output type of ladsystem, the PC der logic offered as can serve as reliable control of the supervisory process. With the device with delgrowing need for egated controls to production infor- Turbomation engineers software and the PLC and other mation and quality hardware integrated systems; hybrid field devices. All control, the inad- PC and PLC control systems are more calibration, data equacies of PLCs popular than ever, the company says. analysis, and data were exposed. Courtesy: TurboMation history are hanThe PC, with its user friendly operating systems, dled by the PC. The PC provides the looked more like a candidate to dis- human machine interface. Actual proplace the PLCs. It is not an acceptable cess control is carried out by the PLC solution when a PC-controlled machine and the field devices best suited for the is reaching dangerous operating con- application. Interdevice communication ditions. The PLC is inadequate when capabilities add functionality. This way complex mathematics is required. PLCs the best capabilities of all the devices do not handle image analysis well or are safely leveraged for the best results. temperature and pressure, where high This also lends itself to cloud-based levels of accuracy are needed. Temper- remote control or data acquisition. ature and pressure control is better left - Jacob George is application engito intelligent field devices like dedicat- neering manager at TurboMation. ed temperature or pressure controllers. www.turbomation.com
From left: Will Newby, Alex Pierson, Andrew Fox are among students who took an industrial control networks and hardware course at DePaul University in Chicago. Watch the video; heed their warnings. http://controleng.com/videos
Video: IT security students examine industrial networks

As industrial networks move into the conventional IT space, security engineers think were missing some obvious safeguards. With growing adoption of Ethernet as the backbone of industrial systems, more industrial devices outfitted with Ethernet connectivity, and more networks accessible from the Internet, plant-level networking is getting harder to tell from conventional IT. In fact, many enterprise-side IT engineers have little if any trouble getting around the areas we industrial folks always considered our stuff. If youre not sure you buy that idea, take a look at the video above. Its a talk with six IT students from DePaul University in Chicago who have just taken a course on industrial control networks and hardware. Four of the students completed the class last June, and two others finished in November. None of them had any industrial background, but had little trouble understanding what a PLC does and how its programmed. We met some of these students last summer in an earlier video giving a taste of what the class was about and heard what interested them about working with industrial networks. This new discussion is more about what they were able to do, and even some recommendations on what industrial users can do to harden networks. It may be an eye-opener, and certainly something to think about if you thought the obscure nature of control systems was going to protect you. - Peter Welander, content manager, Control Engineering, pwelander@ cfemedia.com
How safe are your electrical system work practices?

Continued from page 25 70E is aggravating, but it is the law of the land, observed another. Getting caught with an injured or dead employee not following the electrical safety rules can get you a one way trip to prison. The poll does unequivocally suggest a strong need for further investigation into the viability of safety standards such as NFPA 70E. What happened to common sense safety measures? queried one respondent. Working on energized equipment is inherently dangerous. It always will be, but it is often the only way to fix or even find a problem. Training is the key!
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We all know electricity can be dangerous. We also know that life by its very nature holds risks. Balancing hazards against the safety measures that offset them is often a fence walk. Despite what regulations require, it is obvious that many disagree with them. They have chosenfor various reasonsto disregard them and take risks they believe are reasonable and educated. What is also obvious is that the controversyand the discussioninvolving these issues are far from over. - Jeanine Katzel is contributing content specialist, CFE Media, Control Engineering, www.controleng.com. Reach her at jkatzel@sbcglobal.net.
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Functional safety just makes things work as they should

It is very easy to get caught up in the If we take a machine on a plant complexity of a safety system, after all, floor that is stopped, that is one of the the consequences can be unthinkable. most dangerous things that can hapHowever, functional safety is all about pen, Jones said. People with good making thinks work just as they should. intentions may try to do things they Some functional systems are more are not capable of doing to get it runcomplicated than others, but the same ning and then things happen. principal applies to That is often where whatever system you task analysis comes are designing, said into play. Just how do Derek Jones, a TUV workers on the plant functional safety engifloor going to do the of all failures come neer with Rockwell task at hand safely from design. Ensuring Automation during his to make the sure the presentation at Rock- people and technology machine runs safely well Automation Fair and productively, Jones are all on the same 2011s Safety Automasaid. page adds productivity tion Forum in ChicaAccidents hapand profitability to go on safe design, safe pen because somebody assessments. Its about does not know the manufacturing. things like sustainabilimplications of what ity, performance, productivity, time is going on around them, Jones said. to market, compliance, development We have the technology, but we still costs, information, and operations and need what is going on here upstairs (in maintenance costs. your brain). The whole process needs to The thing is about safety is hav- be homogeneous. ing plan; making sure everyone knows Functional safety is also about makwhat the plan is and then when some- ing sure everything is in order like all thing happens sticking to the plan. the paperwork or you followed the standards correctly. Just because you have followed standards and you do have the proper technology in place, sometimes things just happen. It is about doing due diligence. Can we prove what we did was right. And, if not, is it something we can learn from for the next time, Jones said. Making sure everything and everybody is on the same page is difficult enough, but making sure the process is correct from the start is a difficult task. Sixty percent of all failures come from design, said Michael Miller, TUV functional safety trainer at Rockwell Automation. Ironing out all design errors and making sure people and technology are all on the same page all adds up to a more productive and profitable manufacturing environment. Safety is as much about productivity than anything else, Jones said, and productivity is all about safety. - Greg Hale is editor and founder of Industrial Safety and Security Source (ISSSource.com). Reach him at ghale@isssource.com. Edited by Amanda McLeman, managing editor, Control Engineering.
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Dealing with mercury from coal-fired power plants

Dear Control Engineering: When I read about new EPA regulations on mercury emissions from coal-fired power plants, I want to know where the mercury comes from, and how to get rid of it. Power plants do not create mercury, lead, arsenic, or other heavy metals any more than they would be able to create gold. Those pollutants are elemental metals and present in coal. The problem is that when you burn coal, you vaporize those metals and send them out the stack. There is some controversy as to exactly what happens in the atmosphere, but eventually those metals condense, either in their elemental form or after reacting with something else in the process (e.g., chlorine), and fall to earth in rain drops. Rain goes into rivers and lakes, and fish accumulate the metals. (There are other types of pollutants, such as dioxin, that can be formed in a combustion process, but thats a different issue.) Mercury emissions have gone down, at least as a function of total electricity produced, but many plants still have little in the way of abatement equipment. Conventional FGD scrubbers can help with mercury to some extent, but if you really want to cut it down, activated charcoal injection is usually best. If the fluegas is at the right temperature, mercury will condense and stick to finelyground activated carbon particles blown into the stream. The particles are then removed in a baghouse. This process works, but the result is contaminated charcoal. The usual disposal method is landfilling or burial. If you put it in an old coal mine, youre returning it whence it came. - Peter Welander, pwelander@cfemedia.com, Control Engineering
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Control System Software Programming

Strategies and design tools make control system software programming more intuitive, faster, with greater ability to upgrade and reuse code, more easily adapting programming for a variety of controllers: PLCs, PACs, IPCs, and embedded controls.
Krzysztof Pietrusewicz and ukasz Urbaski
hat are the options when preparing industrial control system applications? Does the user have to choose between robustness and functionality of the control solution? Are there solutions for rapid prototyping of industrial control systems? Most of the off-the-shelf programmable logic controllers (PLCs) can be programmed in at least one of the languages described in IEC 61131-3: IL Instruction List low-level programming language similar to Assembler LD Ladder Diagram graphical language based on rules of the electrical circuits with wires, relays, etc. FBD Function Block Diagram graphical language with the possibilities to implement complex control and numerical functions in a simple way. User can use provided function blocks grouped in libraries and create custom blocks (written in any of the IEC 61131-3 com-
Simple PID control in ST language Courtesy: Control Engineering Poland

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pliant languages) to build a control algorithm. ST Structured Text text language similar in its syntax to Pascal and Basic; effective solution for every complex control algorithm SFC Sequential Function Chart graphical language describing operation of the process and machine. This is the only language in the IEC 61131-3 standard that depends on usage of at least one other language from the list. SFC is used to create a state machine of the process; each state is created with another language, such as ST or IL. Whats most commonly used now? In a poll of Control Engineering U.S. and Control Engineering Poland readers, the most popular programming language is Ladder Diagram. Function block diagram language, similar to circuit with logic elements, is in second place among PLC programming languages. In third place is Instruction List language. Advanced accumulator management engines help with the most complex numerical dependencies within a control system algorithm. Structured Text language can be used to implement any control algorithms. Advanced users can easily create their own regulator function blocks controlling both Single-Input Single-Output (SISO) and Multiple-Input Multiple-Output (MIMO) processes. This language takes fourth place on the most popular PLC programming languages list. Its becoming more popular with the increasing computing power of the newest PLCs. Structured Text language is the perfect tool to create user libraries, which add value to every PLC. Function block usage is the first step in creating object-oriented tasks for PLC. The number of people declaring knowledge of ST is increasing each year. Many young engineers prefer ST to LD, so it will be gaining popularity in the industry in coming years. With SFC language, known as language of
the technologist, users can create flowcharts of the whole machine or process. Certain PLCs now accept programming using ANSI C language, compliant with the Kernighan and Ritchie standard. Some advanced models can be even programmed with C++. Industrial control systems manufacturers often offer additional, platform-dependent, dedicated programming languages. They are prepared by manufacturers to easily integrate with hardware-specific functions, such as access to BIOS, unique serial numbers, etc. Industrial PCs (IPC) are equipped with traditional operating systems, usually Microsoft Windows, and real-time systems running on the same PC. The advantage of such a connection is the use of real-time languages from the IEC 61131-3 list and Microsoft Windows-based highlevel languages like C++ or C#. During recent years many traditional PLCs have evolved, and sometimes its hard to distinguish PLCs from IPCs. When the device has much more functionality than PLC, computing power similar to IPC, but the robust enclosure of a PLC, it is a programmable automation controller (PAC). PACs have gained distributed control system (DCS) manufacturers attention; some are using PACs in their DCS offerings. PACs allow the use of a larger number of textual high-level programming languages (C, C++, C#) as well as graphical ones (see below). To program complex control systems, a new programming language has been introduced, Continuous Function Chart (CFC). CFC is high-level graphical language similar to FBD, but it has the additional functionality of being able to create multi-thread algorithms that can be computed in parallel from a programmers point of view. Graphical programming (such as Mathworks Matlab/Simulink, National Instruments LabVIEW, and others) is gaining more attention since these tools usually integrate programming and simulation functionality. Users can check or even look for correct regulator gains and prototype control algorithm of the machine/process in the software-in-the-loop mode. Graphical integrated development environment (IDE) interfaces, if properly designed, can be very helpful during system setup and debugging. Many new IDEs let users specify system configuration with drag-and-drop methods instead of hard-coding every parameter. Most control equipment IDEswhere control, visualization, and motion are designedcan simulate the final project before it is compiled
Control programming images courtesy of Control Engineering Poland (left), (and from top) National Instruments, Rockwell Automation and Beckhoff Automation; cover image collage by Michael Smith, creative director, CFE Media.
and uploaded to the hardware. The newest advanced IDEs are complex IT systems supporting pure OPC technology and OPC Data Access protocol. (For instance, Mathworks Matlab/Simulink can be an OPC DA client and get data from an industrial control system supporting OPC.) Online, read three steps for mechatronic parallel programming design. http://bit.ly/rqnuBS - Krzysztof Pietrusewicz and ukasz Urbaski teach at West Pomeranian University of Technology, Szczecin, and contribute to Control Engineering Poland. For more on each section that follows, click on or enter the URLs provided. Edited by Mark T. Hoske, Control Engineering, www.controleng.com.
www.controleng.com
Much more on control system programming and design
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How to choose the best programming language
Rockwell Automation RSLogix 5000 v20 programming software, in combination with scalable, right-sized control system components, allows users to scale from 200 to 10,000 I/O points in one control platform and common user experience.
Fred Habenschuss, commercial engineering manager, Rockwell Automation, offers more guidance on how to use IEC 61131-3 programming languages. Choosing a control programming language most suitable for the task at hand reduces program complexity and troubleshooting/maintenance costs, it will also make the code more readable, improve the development process, and enhance controller performance. The first step in solving discrete, process, batch, drive, safety and motion control challenges is to ensure the language editors for relay ladder logic (RLL), function block diagram (FBD), sequential function chart (SFC) and structured text (ST) programming are native to your programming software and controller. Then match the task to the language. Select this language when a section of the code represents: Relay Ladder Logic (RLL) for: Continuous or parallel execution of multiple operations (not sequenced) Boolean or bit-based operations Complex logical operations Message and communication processing Machine interlocking Operations that service or maintenance personnel may have to interpret to troubleshoot the machine or process Servo motion control Function Block Diagram (FBD) for: Continuous process and drive control Loop control
Calculations in circuit flow Sequential Function Chart (SFC) for: High-level management of multiple operations Repetitive sequences of operations Batch process Motion control sequencing (via sequential function chart with embedded structure text) State machine operations Structured Text (ST) for: Complex mathematical operations structured text (ST) Specialized array or table loop processing ASCII string handling or protocol processing For example, its possible to use relay ladder logic for complex data handling, such as sorting algorithms. This process would work, but take weeks (and perhaps hundreds of rungs of code) to program. It would be time-consuming to write and maintain, less readable, and require extra time in the controller to scan and execute. Using structured text is more suitable, making programming simpler, straightforward and more efficient, approximately 10 lines of code with less impact on controller performance. http://bit.ly/tSSTCr
Software transforms control
Simulation software objects from Matlab can be processed in real time by Beckhoff Automation TwinCAT 3 programming software. Courtesy: Beckhoff Automation
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Bob Trask, PE, is senior electrical engineer, Beckhoff Automation, explains that IEC 61131-3 programming, plus C++, C#, and object-oriented extensions and third-party software modules can operate on IPCs, serving as multipurpose PLCs and/or numerical control (NC) targets. An IPC can extend beyond a human-machine interface. There are more development options, building on the tried-and-tested IEC 61131-3 programming standard, promoted by PLCopen and supported worldwide by most major control software vendors. The next step is to introduce more tools for programmers including C++, C#, and object-oriented extensions to IEC 61131, and use more third-party software modules to enhance development of modern machines. Note that open platform does not mean open source. Having an open platform means being able to integrate already developed code and programs from widely varied sources including IEC 61131-3 environments, Matlab, .NET, Java, Web services, ASP, Microsoft Silverlight, HTML5, as well as any common language runtime (CLR) functionality that currently drives the worlds technology as we know it. This leads to practical strategies (not having to reinvent the wheel, so to speak) by using popular concepts that have a proven track record, such as objectoriented programming (OOP). An open platform should also include the ability to integrate physi-
Connecting the Global Engineering Community

Control Engineering is the leader in connecting the global industrial engineering audience through coverage of and education about automation, control, and instrumentation technologies in a regionally focused, actionable manner through online and print media and in-person events.
ControlEng.com: Visit www.controleng.com for the information you
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Engineers Choice Awards: Each year the editors of Control Engineering rely on the insight of engineers in the eld to help determine the most noteworthy products introduced in the past year. Automation Integrator Guide: The annual Automation Integrator Guide is a unique and comprehensive service directory listing more than 1,800 automation system integrators and contract engineers. Manufacturing/Automation Summit: This three-day event will bring together some of the top industry experts to tackle key issues facing manufacturing in the U.S., and will explore how manufacturers can take advantage of the rapidly-expanding global manufacturing market. Learn more about how you can connect with the global engineering community at www.ControlEng.com
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cal devices (drives, I/O, etc.) without penalties in time and cost. http://bit.ly/txSs3b
Add value, depart from traditional control code
Diagram shows B&R Automation Studio architecture, illustrating the trend of integrating more types of control into programming software. Courtesy: B&R Industrial Automation
Daniel Ghizoni, senior solutions engineer, B&R Industrial Automation Corp., said controls development in automation applications has advanced beyond producing code to integrating mechanical, electrical, and control domains of the machine to create a mechatronic entity. A multidisciplinary development approach helps create controls designs that are easy to repeat, maintain, and enhance. Embracing this understanding introduces a multidisciplinary development approach to controls design. The design cycle of the mechatronic system follows a more collaborative structure, with constant reviews and iterations throughout the design process. A good place to start development of the software architecture and tasks is right after creating the product idea, and before even beginning the product specification. During this transition, designers can begin exploring the feasibility of ideas and concepts, and start defining key value-adding processes. Consider development languages based on industry standards, such as specified by IEC 61131-3. Standards untie intellectual property from the automation provider. In addition, users also should have ANSI C and C++ also avail-
able? Next-generation programming software advantages include: n Flexible implementation n Preservation of legacy assets n Better use of available expertise and enduser specifications n Sustainable design during development and service lifecycle stages n Optimized productivity n Faster modifications and enhancements n Reuse of intellectual property across platforms and projects n Separation of software from target hardware n Fewer errors n Faster time to market http://bit.ly/tC2EKY
PLC makeover: Open, control
Richard Chung, product manager at Eaton, said, for discrete control and manufacturing, the trend toward using programmable logic controllers (PLCs) controls is increasing as specialized control systems are abandoning proprietary based controllers in favor of more open, readily available, and sustainable hardware platforms. PLCs, still used for most discrete control and manufacturing, are increasing in use, as even specialized control systems are abandoning their proprietary based controllers in favor of more open, readily available, and sustainable hardware platforms. Five standard programming languages per IEC 61131-3 has led to the development of a common programming standard and execution code for PLC systems independent of PLC brand or manufacturer. It is promoting interoperability and saving engineers time when working with solutions from multiple vendors. The emergence and growing adoption of the Controller Development System (CoDeSys) helps users minimize programming time and maximize available skill sets. Investing in this programming environment yields a knowledge base and competency level that is portable to different projects and different manufacturers hardware. http://bit.ly/vwhayw
Control system design checklist
CoDeSys Application Composer and Professional Developer Edition by 3S-Smart Software Solutions helps IEC 61131-3 language programmers who are familiar with and appreciate the many advantages of working with high level language development tools. Courtesy: Smart Software Solutions
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Jonah Paul, product manager for industrial software at National Instruments, involve the entire development team in control system architecture and technology decisions. This threepart checklist helps engineers get from concept to application development, reduce development headaches, and accelerate the design cycle. Intense global competition is putting pressure on engineers to deliver systems with higher throughput, reduced operating cost, and more features that improve productivity, increase efficiency, and differentiate their systems from the
stem techno What control logy and plat loop rates are form needed? How reliable does this ap pli ca tio n need to be How will users ? interact with this system? Can a modu lar hardware platform be used to make use of future technologies? 2. La munication What control architecture loop rates are needed? How reliable does this ap plication need How will users to be? interact with this system? Can a modu lar hardware pla tfo rm be Is there a ne used to make ed to connec use of future t to existing technologies? hardware or enterprise sys tems? ftware de y out system com
Control s ystem de sign chec klist 1.

Choose cont rol sy
By coupling NI LabVIEW system design software with modular NI RIO hardware, an engineer can use one tool to program a variety of board-level controllers and programmable automation controllers, including those that use field-programmable gate arrays (FPGAs) capable of multi-threaded processing. Courtesy: National Instruments
velopment to What control ols loop rates are needed? How reliable does this ap pli cation need How will users to be? interact with this system? Can a modu lar hardware platform be Is there a ne used to make ed to connec use of future t to existing technologies? Based on the hardware or hardware tar enterprise sys gets, what de tems? Does it make velopment too sense to use l(s ) are necessa to an operatin a ry? g system an system design tool to ma d/or hardware ke the code What is the ov agnostic target? erall cost ve rsu development tool(s) to im s bene t of using the pro plement the control system posed software ? - Informatio
n courtesy of National Ins truments; gra phic by Contro l Engineering
3. Select so
competition. These systems cannot be restricted to the programming of one device or even one type of device, but rather these systems have multiple hardware target types, communication methods, and development tool options that impact the effectiveness of the programmer. Because of this complexity the entire development team needs to be involved in the up-front system level architecture and technology decisions. This may seem like a daunting task, but three stages can help engineers get from concept proposal to application development, reduce development headaches, and accelerate the design cycle. See control system design checklist (top right) and more at http://bit.ly/rAtpia.
Control programming: Write once, run anywhere with open systems
op programs that can be used more broadly. While this may work in the IT world, but in the world of industrial controls, it creates a development nightmare for the programmer. Its extremely difficult to design sophisticated programs for process (and even discrete) control that run on multiple devices. Often the program will have to be dumbed down and reduce the functionality of the entire application. Programming example: New Enterprise Stone & Lime Co. Inc. (NES&L) at http://bit.ly/rven32.
Efficient boiler control programming
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Related links and more about Pietrusewicz and Urbaski. http://bit.ly/rqnuBS Hybrid PC and PLC designs http://bit.ly/uYG8wB http://controleng.com/PACs http://controleng.com/process Online article, Efficient boiler control programming, has more details, photos, video link at http://bit.ly/ujCVXX www.3s-software.com CoDeSys by Smart Software Solutions www.beckhoffautomation.com/ twincat www.br-automation.com www.controlengpolska.com www.eaton.com www.engineering-redefined.com www.hurstboiler.com www.nesl.com www.ni.com/LabVIEW www.opcfoundation.org www.opto22.com www.plcopen.org www.rockwellautomation.com www.usa.siemens.com www.zut.edu.pl
Tom Edwards, senior technical advisor for Opto 22, said with industrial controls, it is extremely difficult to design sophisticated programs for process and even discrete control that run on multiple devices, often requiring simplification. Open systems help. If people write control programs, it would be useful to run them on multiple types of control devices: Write once and run anywhere. One of the major hurdles in developing control programs for multiple controllers is that despite the promises of various vendors, closed and proprietary architectures and programming difficulties resulting from attempts to develop for more than one hardware platform or tier create serious stumbling blocks in achieving this portability. The dream has always been that the individual automation vendors would move on from nonportable machine-level code and programming designed to run on only one particular brand or type of their hardware, and offer a way to devel-
Colm Gavin, product marketing manager, engineering software, Siemens Industry Inc., said engineering software opened the way for an original equipment manufacturer (OEM), Hurst Boiler and Welding, to program boiler controls more efficiently and expand business. Jimmy Bruner, control systems manager at Hurst Boiler & Welding, said programming software upgrade improved boiler controls, decreased engineering time and complexity on all the companys product lines, primarily because of three capabilities: integration, reusability, and scalability. Bruner said, With the old way, it was not unheard of for us to spend two or three days on a project, he explained. Now, we can do it in 4 or 5 hours. We can do so much more with our existing staff. In terms of engineering time, were saving some 30% to 40%, he continued. We werent able to get to some projects before. With new software, we can develop parts and pieces and share them across product lines. They are available to mix and match in more places. It will allow us to expand our product line, apply more automation, and do more with less. ce
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process instrumentation
Using HART with Asset Management Systems

Since its the most broadly deployed smart device platform, is HART the right choice for your plant? Here are some considerations for end users.
John Yingst
mplementing an asset management system that covers field instrumentation in a process plant environment requires some type of smart device platform. Since most modern field devices provide HART communication capability in addition to the analog process variable, plants may have to weigh approaches employing either traditional or integrated HART I/O as part of the decision to move to an instrument asset management system. This article examines some key questions for end users seeking to optimize the lifecycle performance of their instrumentation assets. Is HART information sufficient for a comprehensive asset management program? Is native HART-enabled I/O a necessity, or are there practical ways to use it in a legacy I/O environment? Should users expect to make substantial hardware changes to have something that works well?
nicator can be used for temporary on-site interaction with smart field instrumentation devices. Whats needed is a means to interface with field instruments on a continuous plant-wide basis to capture preventative maintenance information and conduct appropriate remote servicing activities. Thats the basic function of an IAMS.
Understanding the technology
Background assumptions
Increasingly, manufacturers are turning to instrument asset management systems (IAMS) to improve their process efficiency, reduce maintenance requirements, and enhance overall productivity. Plants can achieve significant reductions in operating costs and production downtime as a result of implementing an effective asset management strategy. Since a large percentage of manufacturing revenues are budgeted for maintenance, these savings contribute significantly to a companys bottom line. As soon as plant equipment is commissioned, it is subject to degradation. The process, human interaction, and time all conspire to corrupt the function of process equipment and associated field devices. To control and slow the decline, plant maintenance groups are responsible for the operational oversight and timely repair of equipment. Their challenge is to keep installed assets performing while also reducing the resources and personnel required for the maintenance function. A local operator interface or handheld commu38
In recent years, field devices and equipment supporting digital technologies have proven to provide benefits to the typical process plant operation. Digital devices offer a great deal of data about the operating environment. This data can be utilized by applications that prevent losses or disruptions, enhance quality and reliability, and reduce maintenance costs. One of the reasons for the growth and popularity of digital device technology has been the broad adoption of the HART Communications protocol, which provides an open standard for digitally enhanced 4-20 mA communication with smart field instruments. Most modern distributed control system (DCS) solutions include integrated HART I/O modules that connect to smart devices. This I/O is essentially hybrid, because part of it handles the conventional 4-20 mA signaland looks very much like the old nonHART I/Owhile the other part handles the digitally encoded HART signal. In any DCS, integrating an asset management system basically requires a means of connecting the asset management software to the HART I/O and on to the devices. While the basic protocol is pretty much the same in all control systems, the mechanism for this integration is normally proprietary, with each vendor choosing an implementation approach that works best for them. Theres a lot of room for some secret sauce to make better use of the limited bandwidth available with the HART protocol. Despite the lack of an open standard for integrating HART I/O, there are certain features
HART Communicator can be connected anywhere along the 4-20 mA loop (HART Secondary Master)
Control System (DCS or PLC)
4-20mA Representing the Primary Variable (Mass Flow) HART Digital Signal Carrying Primary, Second, Third or Fourth Variable Process Data, and Instrument Diagnostic Information
4-20 mA Proportional to 2nd Variable 4-20 mA Proportional to 3rd Variable 4-20 mA Proportional to 4th Variable Alarm in Response to Selected Variable HART Transmitter Fault Alarm HART Interface Module "Breaks Out" Data from Smart HART Instruments (HART Primary Master) Smart HART Multivariable Mass Flow Transmitter
Flow
automation end users expect in all DCS platforms. For example, the I/O should be able to use the instrument range information from the smart HART side to tell the analog side automatically how to range the 4-20 mA output. In addition, standard HART information such as engineering units, digital process variables, and alarm information should be available to the DCS for control purposes and accessible from every field instrument without any knowledge of the specifics of the device. The HART protocol has universal commands for obtaining this information. The rest of the unique information in a smart instrument used for configuration, calibration, troubleshooting, maintenance, and diagnostics is described in its Device Description (DD) files. DD technology has been refined to include useful graphical and organizational constructs, and this refinement is referred to as EDDL, or Electronic Device Description Language. DDs are
binary files containing an electronic description of parameters and functions needed by a host application to communicate with the device. Instrumentation vendors use specific programming tools and a tokenizer to create the encoded DD files. The software or tools that make use of the DD information are generally considered to be the asset management system, which is primarily of interest to instrument maintenance technicians. Many automation equipment suppliers now use FDT/DTM (Field Device Tool/Device Type Manager) technology so they can present more meaningful device information. DTMs are software components that contain device-specific data, functions, and logic elements. They can range from a simple graphical user interface for setting device parameters to highly sophisticated applications that perform complex calculations for diagnostics and maintenance purposes,
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If native HART I/O is not available, interfaces for individual or groups of instuments can strip off the digital data and send it to the control host. Courtesy: Moore Indistries International
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For more information, visit: www.hartcomm.org www.honeywellprocess.com www.fdtgroup.org www.miinet.com
The IAMS is simply a container enabling communications to the devices, a way to organize information, as well as a path to the technician or operator.
For simplicity of operation, native HART-enabled I/O is the best. Most current DCS platforms offer some version of it.
or implement complex business logic for device calibration. The DTM also contains interfaces to enable communication with the connected system or tool. Device suppliers are able to embed intelligence in a DTM in a way that is very difficult to accomplish with DD files, such as a number of graphical constructs that cannot be expressed within DD technology. Moreover, the DTM is device and revision specific so that it has knowledge about the particular version of each device on the control network. It is interesting that the automation industry attaches so much importance to the IAMS, when it is the contents of the DTM that really have value for the end-user. The IAMS is simply a container enabling communications to the devices, a way to organize information, as well as a path to the technician or operator.
Issues to consider
While FDT/DTM technology offers some very attractive benefits, there are practical caveats and cautions that end users should be aware of. First, and of greatest concern, is the fact that a DTM must be installed in every client (frame) where it is needed. So, an end user with 10 clients spread around the plant and DTM packages
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from 10 different vendors must perform at least 100 installationsmaybe more if a given vendor has several DTM packages. Combine that with multiple revisions available for given DTM packages, and the result can be a significant maintenance problem. A future revision of the FDM specification (Rev 2.0) promises to allow DTMs to be loaded to a server and deployed to the clients, but for now, this is how DTMs must be managed. By contrast, its read-it-and-forgetit for most systems using DDs. Since DTMs are Microsoft Windows programs, they are dependent upon Windows versions, supporting infrastructure such as DOT NET, programming tools, and the specific frame revisions level. A DTM that works in one environment may not have been tested in another. As such, the end user must be careful and check all of the specifications provided by the DTM vendor. When in doubt, test it first. Additionally, DTMs sometimes behave differently in monolithic or stand-alone frames like PactWare, from the way they act in a DCS environment. With a stand-alone frame, the path to the device can be relatively short and simple with no bandwidth restriction. A DCS must carefully manage the limited available bandwidth, especially for HART devices. A DTM doesnt know what environment it is in, and so it has no way of knowing how to wait in line. The result can be poor apparent performance in a DCS environment. Device vendors are becoming savvier about this issue, but the end user must still watch out for the occasional offender. Lastly, some DTMs are fragile and can crash, even bringing the client down with them. This is generally not catastrophic, but it can be quite annoying. DD technology may not be perfect, but at this stage of the game, it has proven more mature and easier to manage. For the last several years, work has been going on to unify DD and FDT/DTM technologies and produce a single solution for Field Device Integration (FDI). FDI Cooperation, LLC, was formed in response to end-user demands for easier integration of automation and control devices across industrial networks. While it is apparent this effort will mean a lot of work on all sides of the smart device technology supply chain, it is yet to be seen how transparent the coming changes will be to end users. DD files and DTMs dont go away, and backwards compatibility is being promised, which is quite reassuring.
Choices facing end users
Process manufacturers seeking to implement a comprehensive instrument asset manage-
ment solution based on HART technology are faced with a number of important choices. For example, can plants utilize a solution with smart field devices connected to a control system that doesnt fully support HART I/O? In most cases, operations with legacy DCS platforms that want to make use of an IAMS must rely on external HART multiplexers, or muxs, to bring digital HART messages into the IAMS. The multiplexer is used to strip off the digital HART message and provide it to the IAMS software package. The multiplexer hardware module routes the HART analog and digital signals to two separate communication pathways. The standard analog 4-20 mA signal is routed to a standard, non-HART enabled, analog input module while the digital signal passes through the multiplexer hardware and is transported over an RS-485 network to the instrument management system. Experience has shown that HART multiplexers can offer extremely flexible and reliable systems for handling anything from a handful to thousands of HART devices on a single network. Frequently, the mux approach is the only way to bring older control systems forward unless the plant wants to use handhelds or upgrade the DCS, which often is not an option. For some operations, however, its not worth the investment. The preferred integration solution, as implemented by current generation DCS technology, employs HART-enabled I/O modules supporting HART digital device data along with analog 4-20 mA data. With this technology, digital device data from HART-enabled I/O is treated alongside the analog process variable data, which is tightly integrated into the control system environment. This enables the use of additional process variables (e.g., PV, SV, TV and FV), range information, device identification information, and the device status (general and device-specific) as part of the control strategy. With HART-enabled I/O, device diagnostics can be tightly integrated into the DCS alarm/ event subsystem and asset management applications. There is no need for separate instrument monitoring systems or software packages. Instrument alarming is either handled in the software package used for configuration, troubleshooting, and diagnostics, or, preferably, in the control system itself, where alarms can be sequestered for maintenance technicians. Some automation suppliers have developed robust device management solutions designed to communicate with HART devices connected to HART-enabled I/O as well as HART devices connected to hardware multiplexers, remote
I/O systems, and HART modems. These solutions provide plant instrument engineers, technicians, and maintenance personnel with an optimized environment that simplifies tasks and enables remote device management, whereby instruments that have faults or need diagnosis are automatically identified and classified. Integrated with the safety system HART I/O, for example, these solutions use live data from connected devices to establish database records and assign templates so maintenance personnel can compare configuration of one device with another device, or historical configuration of the same device or another device. Device management solutions can employ a technique known as mux monitoring to bring non-integrated HART data to the control room. Mux monitorFrequently, the ing allows plant personnel to monitor mux approach is the HART devices on hardware multiplexer/remote I/O networks and provide only way to bring alerts from these devices to the DCS older control systems alarm and event system. This approach simplifies migration from legacy conforward unless the trol systems to newer DCS platforms plant wants to use while retaining installed field devices and the value of smart instrumentation. handhelds or upgrade Simplified export-import capabilities the DCS, which often make migration of existing databases is not an option. much easier and less intensive.
Future outlook
Companies around the world have begun formal programs to make use of the diagnostic data in their HART smart instruments. HART field device responses contain valuable information regarding the devices health, and having this data sent with every message provides plant personnel with confidence in the integrity of the process measurement along with immediate notification of any problem. Despite ongoing advancements in intelligent instrumentation, such as those delivered by DDs and DTMs, the value of smart devices cannot be realized without a capable instrument asset management system. From a maintenance perspective, a HART-enabled asset management solution allows an entire plant to be monitored from a single location, with fault diagnosis often performed remotely. Many HART instruments provide additional status information that can be used for predictive maintenance and replacement of equipment on an as-needed basis. This results in reduced maintenance trips, fewer process disruptions, and high system availability. ce John Yingst is a senior principal product manager for Honeywell Process Solutions.
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Proves Valuable on a Major Project and Contributes to a Successful Startup

The 2011 HART Plant of the Year is Shells Scotford Upgrader, recognized after using HART-enabled devices to facilitate loop testing, startup, valve tuning, safety systems and remote device diagnostics.
By Andy Bahniuk
HART Communication
ditors note: As Canadian oil production from oil sands has been growing, many energy companies have been building new or adding to existing facilities to help fill demand for product from these sources. In 2011, Shell commissioned a 100,000 bpd (barrel per day) expansion to its existing 155,000 bpd capacity Scotford Upgrader facility near Fort Saskatchewan, Alberta. Shell Scotford is also home to a refinery and chemical plant. Supporting a safe and successful start-up of the upgrader expansion meant the Scotford instrumentation team had to work quickly and efficiently with a minimum of mistakes. The team found that HART technology provided a way to streamline testing and pre-configuration of devices so when they were installed, everything was ready to run for a smooth start-up. Shell instrumentation technologist Andy Bahniuk worked handson through the process. Here is his account of the experience, which has earned the Scotford Upgrader the 2011 HART Plant of the Year Award, presented by the HART Communication Foundation to recognize innovative use of HART technology in real-time industrial process plant applications.
A major challenge
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For more information, visit: www.hartcomm.org www.shell.com See also these links: www.eddl.org www.fdtgroup.org
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In late 2010, the team at Shells Scotford Upgrader Expansion faced a dilemma. How do we safely program and commission over 1,500 HART devices from 26 vendors (including HART Communication Foundation member companies Rosemount, E+H, Fisher, Krohne, K-Tek, Magnetrol, Metso, and Ohmart Vega), in a timely fashion? How do we gain the trust of operations and
upper management during loop checks and control narrative testing to guarantee a safe and successful start-up and continued smooth plant operation? How can we continue to provide daily instrument trouble-shooting, and not only preventable but predictable ongoing maintenance? The answer was easy with the capabilities of HART Communication and a flexible asset management system. All the HART information was readily available in a centralized control room gathered either by a network of MTL multiplexers or our distributed control system (DCS) with HART I/O. A majority of the HART instruments are connected to the SIS (safety instrumented system), or to third-party vendor provided skids. Other, more critical instruments are used for regulatory control with more conventional HART-enabled 4-20 mA control. The existing Shell Scotford facilities had experienced success using HART technology but were using only some of the capability of the technology. With an interest in leveraging the full intelligence of their HARTenabled devices, the upgrader expansion project team got approval to broaden the application of HART on this project beyond the use of handheld device configuration. This decision made valuable device information available to staff in operations, maintenance and instrumentation. Measurement and control devices were to be shipped pre-configured, but when the devices arrived not configured, the challenge for the instrumentation and control team became downloading 1,500 instruments with ranges, engineering units, NAMUR values, and transmitter body temperature alarms. They began by creating a database to provide these values in tabular form and establishing a systematic process of 24/7
transmitter downloading, allowing these critical values to be loaded in a timely fashion. This process saved time and enabled us to proceed with the next steps of commissioning: loop function and control narrative testing.
Critical testing
Loop function testing and process variable simulations were done using HART communication and standard HART methods on the devices. All testing was centralized from one location and witnessed by both the operations and engineering teams. In some cases, where a device could not be tested without process present, such as a vortex or ultrasonic flowmeter, testing with device methods provided a perfect substitute. This ensured total confidence for both the operator and engineer that all field devices functioned properly. This procedure confirmed that all critical parameters were loaded successfully and saved 30% of the time normally required. It also eliminated the potential for human error associated with this work. During control narrative and safety cause-andeffect testing, loop test methods were also used to simulate various process values and to walk through different process scenarios. This testing saved considerable time before the final phase of commissioning and start-up. Some of the critical and complex safety narratives involved more than 15 inputs as well as multiple outputs. Using HART communication and simulating all these inputs from the control room enabled us to test and complete with confidence. The overall time saving was over 50% during this phase. The value and versatility of HART technology during commissioning and start-up activities proved even more critical while trying to achieve a steady-state process condition. HART communication was used for tuning the smart Fisher DVC positioners for optimal process control and valve response time. It also allowed us to use the DVC6000 methods to fine tune the positioner to match the controller as well as perform valve calibrations in half the time. Smart valve positioners also provide the ability to read the digital feedback of the valve position value without any additional hardware. With the information we receive from the positioner on the control valve, we are able to pass the digital feedback value using the HART fourth variable (QV) through the FDM gateway. This value is used on graphics to show the actual valve position feedback. This has eliminated the need for any external hardware in addition to the valve positioner, saving approximately $2,000 per valve.
During the upgrade, technicians discovered that the new devices they wanted to install had not been pre-configured as they had expected. Having to do all that in-house added many more steps to the process. Courtesy: Shell
About Shell Scotford

Shell Scotford is home to three distinct operating facilities: ChemicalsManufactures 530,000 tpy of styrene monomer and 604 tpy of ethylene glycol RefineryCapacity 100,000 bpd Scotford UpgraderTotal capacity 255,000 bpd (including 100,000 bpd expansion, commissioned in 2011) Total staff on site is more than 1,300 (plus contractors). Host systems: RefineryFoxboro DCS UpgraderHoneywell DCS and Field Device Manager
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The Shell Scotford facility has three main operating units with an upgrader, refinery, and chemical plant all using oil sands production as the main feedstock. Courtesy: Shell
It gets cold up there
Having a central location for device configuration and historian data collection is valuable during the life cycle of a HART device.
During our long, cold Canadian winters the temperature can go as low as -45 C. To protect the instruments from freezing, our transmitters have been mounted in insulated enclosures with heaters. During these winter months, monitoring the status of this heater is a critical task to ensure safe operation in our facility. With HART technology we have the ability to monitor transmitter temperature variables and pass this parameter through our asset management system to alert maintenance if it starts freezing. We pass the temperature to operator graphics for live monitoring and surveillance. This has helped us improve our efficiency in executing annual preventive maintenance on heater boxes, saving us more than $200,000 per year. Most importantly, it ensures trouble free operation throughout the winter. Having a central location for device configuration and historian data collection is valuable during the life cycle of a HART device. Simple re-calibration, parameter checks, and device diagnostics can be performed right from the central control room. In the case of device replacement all parameters are stored in a central location and can be readily downloaded to a new device. When considering the expense of permits and gas testing as well as having to carry a handheld device to each individual transmitter, the cost saving is in the magnitude of $100,000 annually.
Safety and reliability
During the initial project phase, Shell decided to use the NAMUR settings to prevent spurious trips or unsafe operations caused by faulty transmitters. HART devices compliant with NAMUR standard values provided that infrastructure. Risk of instrument failure tends to be higher during start-up and by setting our device compliance to NAMUR standard values we could ensure that our start-up went smoothly and without any major instrument issues. Another challenge was to have a higher SIL rating on some critical furnace gas valves to ensure safety and reliability. The partial stroke test (PST) function supports testing valves without the need to isolate them from the process. With the PST process, the respective valve is moved by approximately 5% to 15% during normal process operation. This testing supports online diagnosis of the actuators and reduces the probability of failure on demand (PFD). Our HART asset management system with Metso positioners using an FDT/DTM driver can execute the PST to provide a sophisticated and quick solution. All the functionalities, beginning with precommissioning to normal operation, were the same for HART and Foundation fieldbus devices. Shell uses both and has taken full advantage of both technologies; the biggest benefit being that we did not have to subject our HART devices to any separate interoperability testing. All our HART devices were plug-and-play, connected through an asset management system. This provided full advantage of EDDL and FDT/DTM technology without any additional testing. We are using the ability to open a virtual window and unlock all the power of HART Communication for any type of measurement device as well as all manufacturers.
Ongoing maintenance
Shell uses HART status byte information (sent with each communication request) to represent the device health status on maintenance graphics. HART device status gives important information such as device malfunction, device in simulation, device variable saturated, and most importantly, the device has more status information available. These graphics create an easy visual of the device status at a glance. Monitoring realtime device diagnostics with more status available will direct maintenance to troubleshoot the device in detail and has reduced trouble-shooting time tremendously. Finding bad actors has never been easier. ce Andy Bahniuk, R.E.T., is a lead instrumentation technologist for Shell Canada at the Scotford Upgrader facility.
At Shell, safe and reliable operation is a core value. From the beginning, Shell took important steps to ensure the focus on a safe and steady start-up were the priority throughout the process.
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Integrated Safety
Exactly what does this mean?

Now Available to View On Demand at www.controleng.com/webcast
A lot has been written about integration of safety and process control; the topic has been debated extensively since the majority of todays automation systems started to incorporate (Safety Integrity Level) SIL certied Safety Instrumented Systems (SIS) as an inherent part of their system. The industry had used words such as interfaced and integration to illustrate different degrees of connectivity and functionality, sometimes using phrases such as integrated but separate to illustrate the undiminished safety integrity of these automation systems. This Webcast will start with denitions of interfaced and integrated systems and expand the concept of integration to include the sensors and nal elements part of the SIS, as well as the positive impact on the operators and their ability to better respond and resolve abnormal conditions in the plant, while maintaining core industry requirements on SIS with regards to independence and integration, while taking the automation investment to its full potential.
Speakers:
Safety Systems Business Development Manager, ABB
Luis M. Duran
Peter Welander
Content Manager & Moderator, Control Engineering
Sponsored by:
View this Webcast today at:
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OEM sustainability
Energy Efficiency for Machines

Purchase price of a machine accounts for just 2%-3% of its overall cost. Making intelligent choices when choosing motors can save up to 30% of energy consumption over the life of a machine.
Ian Hitchins
ndustry and infrastructures consume more than 31% of available energy globally, with electrical motors alone representing more than 60% of this amount. With the increasing cost of electricity, intelligent consumption is a major concern for users and manufacturers. When a decision is made to acquire a new machine, a manufacturer should consider the amount of energy that will be consumed by this machine during its lifecycle. Among expenses from the acquisition to dismantling of a machine, the purchase price accounts for 2% to 3% of the overall costs; the remainder is mainly its energy consumption. Smart solutions exist today to make the most of the available energy.
Machine engineering can be a key source of improvement in the energy consumption of machines. A machine is designed according to performance criteria and productivity. The engineers goal is to find the most efficient, economic, and competitive solutionsand motor selection is the result of these choices. Generally, the selection is finalized when the mechanical part is defined and the power consumption is typically not taken into account; however, the growing cost of energy imposes new strategies. The choice of the motor should be the starting point of any reflection to reduce the power demand. Considering the mechanical requests, the motors that will equip the machine must answer several criteria.
Better design, controls make OEM greener

Original equipment manufacturer promotes green initiatives. Automation and smarter machine design help bottle packing equipment use less plastic, less heat, and produce less scrap.
Mario Mazzotta
he effort to be green, reducing environmental impact, has gained popularity as more consumers examine companies environmental records before doing business. There is tremendous pressure on bottling companies to be environmentally friendly, especially in the bottled water industry. Staying ahead of what green means is particularly challenging. All the water bottles that our machinery works with started out at 18 grams of plastic; now theyre down to the 12-gram area, said Mike Weaver, president and Co-CEO at Standard-Knapp, a manufacturer of automatic pack-
aging machinery. This major modification of decreasing the average weight of a bottle by onethird produces a ripple effect on downstream operations. In packaging machinestray packers and loaders, case packers, shrink wrappers, and bottle packersbottles are moved on a highspeed conveyor belt. As machine speed decreases to collect and organize bottles for packaging, it creates a condition called line pressure. With lighter bottles, this pressure can damage the shape of the bottle, for the bottler and the end user. Distorted bottles cause processing problems as bottles are harder to divide into lanes, handle, and meter.
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First, motors allow machine continuous operation and provide the needed torque at the rated speed. This first consideration determines the motor size. The designer must also consider the motor torque requested to start the machine. Eventually, the motor may have to be oversized. Duty cycle is also a key pointany time the machine is started, there is a motor heating and it is essential not to exceed a limit which, at last, will end with the failure of the motor. The ultimate decision is based on the environmental conditions and will take into account the temperature and the altitude at which the machine is due to operate. When all these evaluations are made, the selected motor is usually larger than necessary for continuous operation. As the motor is not running at its rated power, its efficiency is reduced. That inevitably leads to increased energy consumption. Due to motor and machine efficiency, part of this energy is simply wasted. A closer examination of the machine, its modes of operation, and dynamic performances is the best way to choose the most suitable motor technology. Making intelligent choices when choosing motors can save up to 30% of energy consumption over the life of the machine. ce - Ian Hitchins is vice president of OEM solutions, Schneider Electric. www.schneider-electric.com
Energy consumption with standard motors

10%
Energy consumption with standards
1
50%
65%
Additional 3 30%
2 3
(1) Using a motor with higher efficiency saves up to 10% energy. (2) A variable speed drive to control a motor saves up to 50%. (3) A servo drive and synchronous motor brings 30% more savings, compared to standard drives in positioning applications. Courtesy: Schneider Electric
Global cost during motor life
A motors energy bill is approximately motor cost x 100. Beyond the investment, the key is to secure an efficient motor control. During a motors average 15-year life, 1% of the cost is capital investment, 2% is installation and maintenance, and 97% is energy cost. Courtesy: Schneider Electric
A high-speed servo motor pulls products into the packing area, creating continuous, low-pressure conveying for smooth bottle laning, ensuring balanced lines and jam-resistant operation. Better motion control with the servo motor eliminates line pressure at the beginning of a packing machine and allows the packaging machinery to do a better job of handling thinner bottles. The machine design handles recyclable and reusable boards for the shrink-wrapped trays that hold the bottled product and eliminate tray end walls (moving away from corrugated material). This uses less material and offers more support than a pad. Limiting heat in the process is another opportunity for savings. Shrink wrapping traditionally has proven to be one of the greatest drains on energy usage. The metal chain pulling the cases goes into the tunnel at about 200 degrees and comes out of the tunnel at 260 degrees, Weaver explained. Every inch of chain that goes through the tunnel increases in temperature by about 60 degrees, which means that on the return path, its heating
up the room. That turns out to be the single biggest energy user in a heat train tunnel because its taking the heat out of the tunnel. Replacing the metal chain with a plastic conveyor belt lowers energy consumption and can reduce customer cooling costs. ce - Mario Mazzotta is customer relations-marketing manager, Southern California, StandardKnapp Inc. www.standard-knapp.com www.controleng.com/channels/sustainableengineering.html
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Standard-Knapps Versatron Active Product Transport (APT) case packer is designed for high-speed packing of nonround containers, especially reverse tapered, locking shape, trigger, and unstable bottles, flasks, and other difficult-to-handle containers. Industries include beverage, spirits and wine, food, household chemical, personal care, and automotive. Courtesy: Standard-Knapp
automation future
2012: Another Strong Year for PLCs, IPCs, Operator Terminals, says IMS Research
Controllers, operator terminals, and process controls contribute to a more productive manufacturing future, say IMS Research, ARC Advisory Group, and Frost & Sullivan.
y the end of 2010, the world market size for programmable logic controllers (PLCs) is estimated to have surpassed its 2008 level, almost as if the recession never happened, according to Alex Hong, IMS Research analyst, control and automation. This represents a much faster recovery than most other automation equipment markets, where 2008 levels are not expected to be beaten until the end of 2011, Hong noted. Growth varies by region, of course. Asia will continue to be the main contributor to PLC market development. China is now the most significant global machinery producer, largely because of its position as the worlds primary manufacturing base. The recent recovery of EMEA and the Americas has driven strong export demand and, in spite of the recovery seemingly faltering amid a flurry of recent negative news, this will continue in the longer
Combined IPC and operator terminal market revenues and growth by quarter (Americas)
20%
15%
5%
0%
1Q10
2Q10
3Q10
4Q10
1Q11
2Q11
3Q11
-5%
Courtesy of IMS Research
48
% Growth
Revenues
10%
term. This export demand, coupled with blooming domestic needs, will inspire new automation plant investment and construction. Further, while automation demand in India is relatively lower, there are end-user projects performing quite well in the region, such as automotive. Overall, the potential market for India is huge, suggesting much room for growth developments. Based on these factors, China and India will lead the developments for PLCs in Asia Pacific with a relatively high growth in 2011, projected to be nearly 20%; future annual growth is anticipated to be in the double digits over the next four years. Historically the U.S. has represented the main driving force in the Americas region, and it enjoyed a strong recovery in 2010. However, it is no longer the only country in the Americas that will contribute significantly to this regions future development. Brazil, as the one of the most important countries in Latin America, is a rapidly emerging market for automation equipment. Its strength in end users, notably within the oil and gas industry, coupled with the upcoming Olympic Games in 2016, will stimulate further automation developments and infrastructure investments. Having said this, the U.S. will remain the core contributor for future PLC developments in the Americas. The overall market is projected to enjoy a growth rate of 11.5% in 2011; afterwards it is projected to return to more stable growth at the single-digit level. Western Europe is the most important market for EMEA, as Germany led the way and was the first country coming out of the recession. Germany will continue to be the market leader in the PLC market and be the main driving force for future demand. Greece and Spain, as mentioned in previous graph, are still struggling with their sovereign debt. However, because these two countries are not major markets for PLCs, they arent expected to signif-
icantly affect the entire EMEA development. The emerging markets in Eastern Europe, where automation level is relatively low but growth is rapid, will make up for some of the negative growth regions. As the EMEA market is mature, the PLC growth in EMEA will be relatively slow at 10.4% growth in 2011. Similar to the Americas, this region is expected to retain a single-digit growth rate over the next few years. Summarizing these points, growth at the world level in 2011 is projected to be 12.5%, Hong concluded.
IPCs and OITs
The world market for PLC hardware, software & services Relative market sizes ($M) - 2008 and 2012
EMEA
Americas
2008 2012
Asia Pacific
As for industrial PCs and operator interface terminals (OITs), Mark Watson, research manager, control and visualization for IMS Research, said, the general sentiment of suppliers is that 2012 will be another strong year. They continue to have full order books at least for the first 6-9 months.... This is somewhat surprising, when we see endless doom-and-gloom articles in the media about the increasing likelihood of a global double-dip recession. Recent data also shows that both the IPC and operator terminal markets fared well in third quarter this year. World IPC figures for the first three quarters of 2011 were up over 24% on the same period in 2010. Comparably, regional growth figures of 18%, 29%, and 23% were estimated for Americas, Asia Pacific, and EMEA respectively; although Asia Pacific revenues did drop slightly in the third quarter this year following a very strong result in the second quarter.
Japan
0.0
500.0
1000.0
1500.0
2000.0
2500.0
3000.0
3500.0
4000.0
Revenues ($M)
Courtesy of IMS Research
The operator-terminal quarterly market tracker of IMS Research recorded similar results. Operator terminal revenues from the Americas, Asia Pacific, and EMEA all had estimated strong growth in the first three quarters of 2011. Each region was up by 32%, 19%, and 12% respectively compared with the same period in 2010, Watson said. Read more from both analysts and others from IMS Research at http://imsresearch.com. http://controleng.com/PACs See also p.32 control programming software.
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Continued process automation growth predicted in 2012: ARC Advisory Group

expects a rebound to healthy growth for automation shipments to many of the hot developing countries for 2011. ARC also expects many of developed regions to rebound to moderate health in 2011 as many suppliers have seen their aftermarket business come back online. Consequently, ARC feels the global automation markets are on track to return to pre-recession shipment levels in 2011, as noted in the ARC research report, Automation Expenditures for Process Industries Worldwide Outlook. The growth from Q1 2010 to Q1 2011 is nearly 20% in the global and U.S. indices, 21 percent in the Asian index, and 14% in the European index. Even though these numbers are encouraging, the double-digit year-over-year growth rates are more heavily influenced by the weak 2010 results than the strong showing in Q1 2011. - David Clayton, senior analyst, ARC Research, covers process automation. More research g www.arcweb.com
he year 2010 was an important year for the overall automation market as it saw a return to growth for many automation products and suppliers. ARC Advisory Group predicts continued annual growth in process automation in 2011 through the forecast period of 2015. The timing of the 2010 recovery, however, was not felt evenly across the various suppliers and product segments. Orders increased almost unilaterally for all of the major automation suppliers over the course of 2010, but the ability to turn these increased orders into recognized revenues varied significantly across the major suppliers depending on a number of factors including preferred sales channel, vertical market focus, and each suppliers mix between aftermarket sales and greenfield projects. Most automation markets saw a rebound in new orders over the course of 2010, with a corresponding increase in order backlogs. Based on the growth in incoming orders for new project business seen throughout the year, ARC
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automation future
Automation Crossroads: Hows Your Future Factory?

Emerging megatrends are cyber security, mobile and wireless technology, enterprise ecosystem, cloud computing, and sustainability, according to a Frost & Sullivan report.
ndustrial automation is at a crossroads, according to a new report released by Frost & Sullivan. Automation & Control Systems Market examines the current market and factories of the future. Senior research analyst Karthik Sundaram said, Frost & Sullivans vision of the factory of the future is catalyzed by five megatrends cyber security, mobile and wireless technology, enterprise ecosystem, cloud computing and sustainability. These megatrends will influence all aspects of an industrial enterprise. For instance, operating personnel in future factories will not be confined to workstations
Do you have a factory of the future today?

Future factories will have secure wireless networks supporting a highly automated production process, seamlessly interlinked with enterprise software working through the clouds. A high-end factory will involve collaborative manufacturing promoting operational excellence and aiding sustainability. Operating personnel in future factories will track production lines, perform maintenance operations, and monitor process issues from their tabletsall while on the move.
Courtesy: Frost & Sullivan and Control Engineering
inside control rooms. The advent of tablets and mobile platforms will enable them to track production lines, perform maintenance operations, and monitor process issues from their tablets all while on the move. The adoption of secure cloud computing technology will give factories access to relevant strategic data from the Internet to execute real-time decisions and enhance operational efficiency.
50
In essence, future factories will have secure wireless networks supporting a highly automated production process, seamlessly interlinked with enterprise software working through the clouds, said Sundaram. A high-end factory will also involve collaborative manufacturing promoting operational excellence and aiding sustainability. The report also said the automation and control solutions product portfolio is nearing saturation, either directly or indirectly. A major trend underlining this development is the narrowing product definition between individual products, in particular the programmable logic controllers and distributed control system product lines. Vendors have currently emerged with hybrid products that combine PLC and DCS functionality as a means to counter high competition and gain end-user recognition, said Sundaram. Despite economic advantages, the emergence of such products has clouded end-user perception to a large extent, and it remains to be seen if this technical strategy yields expected results. Clearly noticeable is a significant shift from the traditional parameters determining the automation and control systems (ACS) market. Currently, it is a companys product portfolio that yields the maximum influence in the automations and controls market space, followed closely by service support and cost considerations. This, however, is set to change. In the coming years, the emphasis on the IA product portfolio is likely to diminish, said Sundaram. In contrast, the need for globalized service support, coupled with cost factors, is expected to gain significant momentum. As the ACS market steadily graduates towards the next level, it will offer automation vendors challenging opportunities for growth and excellence. Vendors will need to be in tune with ongoing developments and enhance their ability to compete and succeed in future factories. ce - Edited by Mark T. Hoske, CFE Media, Control Engineering, www.controleng.com. www.industrialautomation.frost.com See sustainability: http://controleng.com/channels
inside process
Measuring Level in Highly Dynamic Petroleum Processes

Getting an accurate level reading where there is fluid boiling and off-gassing makes for quite a challenge. Here are two examples plus advice on bridle configurations.
John Yerkovich, Wayne Buhler, Sr.
uestar Pipeline Co. operates a facility that processes 120 million cubic feet of natural gas per day, where it chills the gas to remove some of the heavier hydrocarbons in liquid form. This increases the value of the gas and yields a salable product in the heavier gas liquids. When the plant was built, the levels in the processing vessels were measured using guided wave radar level transmitters installed in bridles on the sides of the tanks. But in some parts of the plant it turned out to be impossible to get true level readings. Questar called on Emerson Process Management, which found a way to measure the level despite fluid boiling and off-gassing, by replacing the guided wave radars with newer models and using the transmitters implied length output to find the true levels. This discussion will explain the process of solving the problem.
Problem 1: The receiver/economizer
A good example of the problem showed up in the receiver economizer (Fig. 1), which is supposed to be kept 50% filled with liquid propane at 55 psig. The process operated in cycles and control was a challenge, because it involved interacting loops for flow, level, and pressure. When the pressure dropped, the fluid would begin to boil, and the radars level reading would increase very rapidlymore rapidly, in fact, than was physically possible. The level would fail high and the plant would trip. Questar consulted with Steve Newton, Emersons local level specialist, on several occasions. He would help tune the process for the operating conditions and would get everything running, but as soon as he left, conditions would change and
the plant would trip again. A close look at the sight glasses on the affected vessel showed that over the course of a cycle the liquid propane would make a sudden drop in level and then begin to boil vigorously, filling the sight glass with bubbles and driving the surfacesuch as it wasout the top. It was obvious why the radar gauges could not get good readings; in fact graphs of the radar signals showed that when this happened the liquid surface seen by the radar would simply vanish, and the level reading with it. This is actually a fairly common problem in gas plants and refrigeration applicationsanywhere a liquid can suddenly begin evolving large amounts of gas in bubble form. The question was what to do about it. Newton suggested replacing the existing guided wave radar (GWR) unit heads with Rosemount 5300 GWR heads. These mounted the
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Fig. 1: When the pressure in the economizer dropped, the fluid would begin to boil, and the radar devices level reading would fail high and trip the plant.
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inside process
same way as the existing units, and even used the same antennas, so the switchover was mechanically simple. The big difference was the additional functionality of the new models, specifically their probe end projection function.
Probe end projection
A guided-wave radar (GWR) level Fig. 2: When the transmitted pulse from the GWR gage consists of a transreaches an interface, it reflects from the resulting mitter/receiver head discontinuity. Measuring the time it takes for the and a probe antenna pulse to reach the interface and return tells the waveguide that extends distance to it. down into the liquid content to be measured. The transmitter sends a pulse down the probe. The liquid has a different dielectric constant from the air or vapor above it, which means that the immersed portion of the probe has different microwave propagation characteristics above and below the surface of the fluid, or at any other interface. As shown in Fig. 2, when the transmitted pulse reaches an interface, it reflects from the resulting discontinuity; meaFig. 3: Hydrocarbons reduce the speed at which suring the time it takes the pulse travels along the probe, making the for the pulse to reach probe appear to be longer. Measuring that apparthe interface and return ent length increase and then back-calculating tells the distance to it. gives a reading of the amount of hydrocarbons The strength of the present. reflected pulse depends on the dielectric constant of the liquid to be measured, so water (dielectric constant = 80.4) gives a strong signal, but propane (dielectric constant = 1.6) gives a much weaker signal. And if there is no good surface there will be no corresponding reflection at all. The situation clearly called for a different method. There is a technique with GWR devices called probe end projection that infers the level of the liquid by measuring other parameters. Since hydrocarbons have a greater dielectric constant
P2
Fig. 4: Using probe end extension, the readings stabilized and the trips were eliminated.
than air, they reduce the speed at which the pulse travels along the probe, delaying the return from the tip and making the probe appear to be longer than it really is (Fig. 3). The more hydrocarbons presentwhether in the form of liquid or bubblesthe longer the probe appears to be. By measuring that apparent length increase and then back-calculatingusing the actual length of the probe and the known dielectric constant of the hydrocarbonsits possible to derive a reading of the amount of hydrocarbons present. Instead of a noisy reflection disturbed by every bubble, the output signal is a steady representation of the actual level. The Rosemount 5300 GWR has probe end projection as a standard feature, as well as a more powerful transmitted pulse and the ability to track rapid changes, but the units originally fitted did not, so implementing the new method involved simply replacing the GWR heads and programming the new units appropriately. The 5300 uses the same antenna as the existing 3300, so the change was simple. With the erratic level reading stabilized, it was possible to tune the level loop properly, removing much of the damping that had been put in to try to cope with the rapidly-changing level signal. As shown in Fig. 4, the process now controls to within about 10% to 15% of setpoint and there are no more plant trips.
Problem 2: The chiller
A problem similar to that in the receiver economizer was also present in the chiller (Fig. 5), which holds liquid propane at 32 F. This unit has a level setpoint of 50% measured by a GWR on a bridle. As the pressure dropped, the fluid would boil and the GWR would lose its level, fail high, and trip the plant. In this case, as with the receiver economizer, the solution was to replace the GWR with a type
inside process
gassing is present in a small-diameter bridle, it can act like an air pump, similar to an aquarium pump, moving liquids from the lower process connection, up the bridle, and out the top process connection.
Fig. 5: The chiller holds liquid propane at 32 F with a level setpoint of 50% measured by a GWR on a bridle. As the pressure dropped, the fluid would boil and the GWR would lose its level, fail high, and trip the plant. Fig. 6: Replacing the GWR with a type 5300 set to use probe end projection and retuning the loop brought the level under control.
If enough off-
5300 set to use probe end projection, then retune the loop. The result is shown in Fig. 6. As a result of the new radar gage installations, nuisance level alarms have been significantly reduced. The plant can be left unattended through weekends and after normal operating hours.
Other considerations
There are a number of other factors that can affect the accuracy of radar level measurement in difficult applications: Bridle diameterSmall-diameter bridles (less than 2-in.) can exhibit gas lift, in which the liquid surface is lifted due to expanding gasses in the bridle, as well as bubbles traveling up the bridle, giving a false surface level, an unstable surface, and rapid apparent level changes. If enough off-gassing is present it can act like an air pump, similar to an aquarium pump, moving liquids from the lower process connection, up the bridle, and out the top process connection. Using a larger-diameter bridle (4-in.) will reduce this effect to mere burping, rather than lifting the entire fluid column. The large diameter also gives the radar a more stable surface from which to reflect signals. Bridle temperatureIts a good idea to keep the temperature of the bridle as close as possible to that of the vessel. Since a bridle has much less mass than a vessel, it heats and cools much faster with changes in ambient temperature, and shows different levels for that reason. If the tank is cold, for example, and the contents not boiling, but the bridle is warm because it is exposed to the environment, the fluid has less density and is likely to boil and give false level readings. The answer is to insulate the bridle. Multiple levelsA single bridle (or sight
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glass) with two process connections should not be used in a vessel containing multiple fluids (perhaps oil above water, with air or vapor on top), because the interfaces between the fluids may not show up in the bridle, or if they do they will be at the wrong heights. It is much better under these conditions to install two bridles, one above the other, to show the top level surface and the interface independently. Three process connectionsAttempting to get an accurate reading on multiple interfaces by using a bridle with three connections to the vessel might seem to be a way around having to use two bridles (each with its own radar), but it requires care in placing the connections. The distance between the connections should not exceed the anticipated thickness of the upper layer. In addition, this arrangement can lead to some uncertainty about the level of the top layer. Four process connectionsThis method tends to work better than three connections, as it gives less chance of trapping fluids. The distance between the connections should, as before, be roughly equal to the anticipated upper product thickness. Direct vessel mountingPutting the radar gauge directly in the vessel eliminates the inaccuracies found with bridle connections. This method will give accurate readings of the level and interface as it is actually occurring in the vessel. The disadvantage of this method is that the fluids may not be separating as well as they would in a still bridle environment. Sometimes installing the radar in the vessel inside a stilling well with multiple holes can solve both issues. ce John Yerkovich is an automation services supervisor for Questar Pipeline Co. Wayne Buhler, Sr., is a sales engineer for Emerson Process Management.
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inside process
Monitoring Critical Vessel Temperature

Radiometric imaging can help detect and measure uneven temperature gradients quickly and reliably.
Lenny Shaver
easuring temperature accurately has always been one of the most important and difficult things to do when monitoring the safety of critical vessels in refineries and other industrial plants. Extreme temperatures and non-uniform temperature gradients make it nearly impossible for traditional measurement methods to monitor every critical point or to obtain complete data.
This gasifier has a system of 14 infrared cameras to monitor the vessel shell. Over the years, it has helped identify hot spots caused by internal deterioration of the refractory lining more quickly than the previous thermocouples.
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Without accurate and early detection of temperature changes, the likelihood of failure-related problems increases, creating safety and reliability issues. The consequences of undetected failures can be very serious and pose extreme safety risks if a vessel isnt properly monitored. A rupture in chemical reactors, storage tanks, and piping systems can all lead to catastrophic loss of life, product, and capacity. These all require sophisticated monitoring techniques to spot irregular temperatures and trends that precede unsafe and costly problems. For many years, thermocouple systems and fiber optic sensors have been viewed as the traditional solution for temperature measurement in vessel monitoring applications. Yet, these types of sensors can be both unreliable and cost prohibitive to install and operate. They typically utilize wired or fiber optic networks and employ point sensors which only monitor the temperature of discrete points on the outside of a vessel. This can result in inaccurate measurements due to skin temperature gradients. In addition, failures of thermocouples leave dangerous holes in overall monitoring schemes until replacement or repair can be made. Of course, missing points in the monitoring scheme put the critical vessel, plant, and staff at risk when unexpected hot spots arise. One primary reason legacy sensors have accuracy and maintenance problems is that they must be attached or adhered to the surface of the shell or skin of the vessel. The harsh and hot environment leads to degradation of connections, failed junctions, delamination, separation from the surface, and ongoing maintenance expense and hassle. Over time, as the heat and weather elements degrade these traditional sensors, plant personnel and management lose confidence in monitoring systems that were supposed to safeguard the equipment. Innovative thermal imaging systems, however, have demonstrated how radiometric thermography has evolved into a mature and
Human Machine Controller

cost-competitive alternative. The noncontact nature of infrared thermal imaging allows it to be more robust, more reliable, and easier to maintain. It is also easy to interface with modern control systems using technological advantages such as graphical visual displays, historical archiving and trending, and easy integration to plant SCADA systems. All these result in providing operators with better insight into the health of their reactors and processes, which has a major impact on safety for personnel and the overall plant.
Seeing is believing
One of the emerging trends making inroads in the chemical, power, and refining sectors is the proliferation of thermal imaging cameras for a variety of applications, including critical vessel monitoring. These devices allow operators of high-temperature and high-pressure vessels to see, in color, real-time thermal behaviors of equipment. This insight is unavailable with fiber optic systems, giving infrared thermal imaging an edge when it comes to early detection of possible failures. Thermal imaging systems go further by providing a more complete look at the temperature profile of the vessel, highlighting where potential dangers lie. With a system of infrared cameras constantly monitoring the environment as a whole, the potential to detect an emerging problem early is much higher.
Vessel monitoring in action
A large system using 14 infrared cameras for a single gasifier has been online for over eight years, monitoring a Chevron-Texaco-designed gas separations system for a major specialty gas producer. According to maintenance personnel, the original thermocouple-grid system started to degrade from the day it was installed because it was in direct contact with the vessel shell. Over time, the internal elements began to react at different temperatures and operators lost confidence in the data. The old system gave only a general idea of where a potential problem might be developing, constraining the ability of operators to respond proactively. Furthermore, it had to be
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removed and reinstalled whenever work had to be done on the vessel internals, which consumed a considerable amount of extra labor and time. After implementing the infrared imaging system, the operators quickly realized several benefits. The most convenient was the ability to connect directly with their plants DCS and data historian system. With the installation of a thermal imaging system, they were no longer forced to react to problems as they occur. Instead, over time they were able to document the temperature personality of the gas separation system and catalog its behaviors to properly assess, predict, and respond to potential problems. Moreover, they could store weekly thermographs of their vessel to benchmark normal patterns and compare changes over time. After rebricking their unit with a new refractory lining, they were able to establish specific locations of hot zones and kept an eye on changes over time. This helped to understand the degradation of the refractory, particularly when zones get progressively hotter, which normally indicated some substrata refractory problem. With the new system, operators receive alarms much further in advance, which gives ample warning to help make informed decisions on how to respond to potential dangers. Having a high level of confidence in knowing where safe limits are, operators know when to ride out an event or when to shut down. During start-up of the unit, for example, the plant operators thought they had a hot spot developing on a nozzle connection, which would not have been detected with a thermocouple-based system. However, the thermal imaging system allowed them to continue monitoring the area and the situation never progressed to an alarm. The infrared imaging system allowed them to make an informed assessment of the risk in plenty of time and determine that it was prudent to go forward while monitoring.
Enhancing safety
HMC = HMI + PLC
Combo HMI/PLC Class I, Division 2 Various Sizes Available Shared Memory and Software Analog or Digital Plug-In I/O Modules Saves Space, Time and Money
Better alarm response time, enhanced predictive abilities, and improved information availability have emerged as
CONTROL ENGINEERING JANUARY 2012 P7
inside process
Infrared imaging monitoring systems can feed data directly to a DCS and historian to support trending and guide maintenance efforts.
three key benefits for radiometric infrared imaging in critical vessel monitoring. Operators are now able to connect their monitoring systems to their DCS and data historians to analyze trends and obtain information necessary to make important maintenance and capital decisions that impact the bottom line of their plants. A continuous, real-time stream of information showing exactly how a vessel is behaving allows operators to identify potential problem areas before they even arise and analyze the occurrence later. This prevents emergencies and mitigates unplanned downtime in plant areas where sufficient insight was difficult, or impossible, to obtain. Plants continue to upgrade their monitoring systems to noncontact, infrared solutions, and greenfield designs increasingly incorporate infrared solutions into the specifications from the inception. As the manufacturing industries continue to evolve, the key to success is ensuring the right technology is in place to help them evolve as safely as possible. ce Lenny Shaver is director of business development for LumaSense Technologies, Inc. www.lumasenseinc.com
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PRODUCTS
DIN-rail mounted surge protection from Weidmuller protects control panels from lightning strikes Reconfigurable camera link frame grabber and a motion module added to controller platform
National Instruments introduced two new additions to its recongurable I/O (RIO) technology including a recongurable camera link frame grabber for embedded vision applications and a motion module for the CompactRIO platform. The NI PCIe-1473R frame grabber is a PC-based embedded vision board that combines FPGA technology with a camera link interface to support high-performance embedded imaging and inspection. The NI 9502 brushless servo drive C Series module makes it possible to drive brushless servo motors, including six new custom NI motor options. The frame grabber is designed for advanced inspection and imaging applications that require image preprocessing and high-speed control such as medical imaging, web and surface inspection, and high-speed sorting. Users can program the new frame grabbers onboard FPGA with the NI LabVIEW FPGA Module for custom image processing and analysis in real time, with little to no CPU intervention.
National Instruments
& software
Weidmullers DIN-rail mounted Varitector VSPC surge protection can protect control panel equipment from damage and breakdowns due to local lightning strikes. The product family includes over 60 models with a robust range of pluggable, replaceable, single- and multi-channel modular surge protection devices (SPDs). Meeting UL 497B requirements, VSPC provides a combination of wire-to-ground and wire-to-wire protection. The separate bases accommodate eld connections and make a ground path from the SPD, via the grounded DIN-rail. Targeted at measurement, control, and eldbus applications, VSPC is rated for discharge currents up to 20 kA (8/20 s). A combination of gas discharge tubes, varistors, and suppression diodes, in single- or multi-stage congurations, are used to protect nominal voltages between 5 Vdc and 230 Vac. VSPCs are suitable for analog current and voltage loops, dc and ac status signals, and a wide variety of serial interface and telephone network installations. To minimize panel rail space, various VPSC models with four conductors (e.g. two analog loops) can be protected by one 17.8mm (0.7inch) wide module.
Weidmuller
www.ni.com
www.weidmuller.com
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Integrated, open PLC and motion programming for packaging uses a common programming language
IndraMotion for Packaging, Bosch Rexroths open system solution, is now available with software version 12 and comes with additional functions to program robotic applications with the PLC in accordance with IEC 61131-3. MultiEthernet interfaces help reduce the costs for OEMs having to adapt their solutions to end user requirements. The latest software version, which incorporates the CoDeSys V3 runtime system and comprehensive PLCopen function libraries, can implement all PLC and motion programming tasks, including individual drives, synchronized movements, and robotics, in the IEC 61131-3 programming languages. This allows for a much more efcient division of work and reduces the amount of engineering involved in made-to-order constructions. The system contains many technology functions that are typical in the packaging industry, such as print mark control, product grouping, magic belt, or intermittent duty cycle.
Bosch Rexroth AG
Industrial wireless bridge with 802.11b/b/n communication from Aaxeon can use Power over Ethernet
Aaxeon Technologies IP67 rated industrial high-power 802.11b/g/n outdoor AP/bridge/client has IEEE 802.11n standard compliance capabilities, the APX-3100 supports higher throughput and features a 600mW radio for faster communication and longer reached distances than a traditional IEEE 802.11g solution. It features IEEE 802.3af PoE compatibility, enabling it to be used in locations where socket availability is limited or nonexistent. A web based utility offers system administrators an easy method to upgrade rmware and manage the device over the Internet. When using SNMP, the APX-3100 can support multiple access point congurations from one location. The outdoor AP/bridge/client uses easy-to-install elements to simplify deployment. Features include waterproof IP67 enclosure, 600 mW output power, WPA/WPA2 encryption, spanning tree and IGMP snooping protocol support, and PoE IEEE 802.3af Compliant.
Aaxeon Technologies LLC
www.boschrexroth-us.com
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software &
PRODUCTS
Wenglor photoelectric sensor line offers configuration variety in M18 housings
Wenglor has created a range of sensors in a plastic M18 housing designed to provide efciency and economy with high-tech features. The mechanical design is available for straight and angled reex sensors, retro-reex sensors, and through beam sensors with a cable or plug. With housing lengths of 35 mm (straight variant) and 50 mm (angled variant), the photo-electronic sensors are very compact and can be integrated into any application. All operation modes are equipped with an antivalent output, a potentiometer for adjusting switching distance, and two diagnostic LEDs that indicate switching status, contamination, and supply voltage. Switching distance can be adjusted precisely to any application with the potentiometer which is protected against destruction due to overtwisting by means of a mechanical limit stop.
Wenglor Sensoric GmbH
Wireless access point provides higher data rates than legacy 802.11a devices and 5 GHz wireless connectivity
Advantech EKI6331AN IEEE 802.11a/n IP55 industrial wireless access point/CPE provides three times higher data rates than legacy 802.11a devices, and provides a reliable 5 GHz wireless connectivity which is a wide, clean band of more nonoverlapping channels than 2.4 GHz to avoid communication interference. With 2x2 MIMO (multiple input multiple output) technology, the unit provides both higher data rates in transmission and greater reliability in received quality. The PoE injector enhances exibility in deployment of the AP/CPE even where the dc power supply is hard to fulll and with the support of WMM and IGMP snooping protocols, the EKI-6331AN effectively improves the reliability of wireless connectivity. To secure wireless connections, it implements the latest encryption technologies including WPA2/WPA/802.1x for powerful security authentication.
Advantech Corporation
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Stellar semiconductor soft starters are designed to control three-phase ac induction motors.
The Stellar SR33 Series basic soft starters are designed for general purpose applications where traditional across-the-line starting or wye-delta starting would typically be appropriate. Units in the family are available in 22 A to 482 A sizes, and are suitable to control three-phase ac induction motors with a wide variety of motor loads. All units feature two-phase control, separately adjustable motor start voltage, start and stop times, and fault indication of up to seven fault types. Ideal for applications such as pumps, blowers, and conveyors, the SR33 series soft starters use thyristors for controlled reduced-voltage motor starting and stopping, and internal contacts for efcient running at rated speed.
AutomationDirect
www.advantech.com
www.automationdirect.com
Customizable mobile enclosure from Concept Systems can house all electrical and electronic components in a work cell.
Concept Systems has announced a new line of control centers named ControlCore. These customizable mobile enclosures can house all the electrical and electronic components that are typically incorporated in a factory work cell. Units in the family accept power directly from the utility source, and include all circuit breakers and power conditioners. Internal motor control centers contain all variable frequency drives (VFDs) and motor starters. Large circuits are provided for driving high current devices such as air compressors. For security-conscious applications, different access control options are available, and different levels of shock and vibration protection and climate controls are available, making the ControlCore a good choice for use in harsh or dirty environments. These enclosures can be outtted for operation inside or outdoors, and for mobile use, they can be provided with trailer mounts.
Concept Systems Inc.,
www.conceptsystemsinc.com
60
Control system platform and workflow software supports real-time optimization

Invensys Operations Management has released its ArchestrA System Platform 2012 and ArchestrA Workflow 2012 software offerings. ArchestrA System Platform and ArchestrA Workflow provide the core integration and collaboration platform inside of the companys InFusion Enterprise Control System and, when used in combination, offer a broad range of automation and information functionality that allows users to empower their people, processes and systems for real-time business optimization. ArchestrA System Platform 2012 provides a single, scalable and open platform for the entire spectrum of automation and information applications, addressing the business and functional needs of industrial automation, operations and information personnel. ArchestrA Workflow 2012 business process management software enables industrial users to model, execute, analyze and improve work processes inside and outside of their facilities, driving higher levels of collaboration, productivity and innovation. It allows critical operational workflows to be created, deployed, tracked and assessed to drive greater process consistency and accountability.
Invensys Operations Management
Inspection software added to smart camera, creating an industrial vision solution with broad applicability
Teledyne Dalsa has launched its BOA Pro smart camera, which has the companys Sherlock inspection software, resulting in a compact industrial vision solution for a wide variety of manufacturing applications. BOA Pro applications are configured through a Web browser. During development, images from the camera are fed directly to the Sherlock GUI, and commands from the program are executed directly on the camera. This approach optimizes the user design experience while providing an accurate representation of runtime performance. A secondary interface is available through a standard web browser for device setup, runtime monitoring, and firmware updating. At runtime, BOA Pro runs autonomously and can be disconnected from the PC. Teledyne Dalsas Sherlock inspection software provides a comprehensive set of vision tools and capabilities that can be applied to applications across all industries. Design flexibility is provided to allow users to customize algorithms, construct scripts and develop operator interfaces.
Teledyne Dalsa Inc.
http://iom.invensys.com
www.teledynedalsa.com
Beckhoff Automation releases major upgrade of its PC-based control platform

Beckhoff Automation has released TwinCAT 3, with delivery of this new generation of software to customers expected to start in early 2012. When combined with its eXtended Automation Technology (XAT) the company says dynamic PC-based control software is available that expands the standard automation world. In addition to the object-oriented IEC 61131-3 extensions, the programming languages of the IT world are available in TwinCAT 3 via C and C++. Additionally, the integration of Matlab/Simulink facilitates a connection to scientific fields. All of this is possible in one flexible engineering environment. The software modules can run in different languages within a common runtime. The advantage of this modularity is improved reuse of modules once they have been written and tested. The runtime operates under demanding realtime conditions with the use of multi-core technology and the support of 32-bit or, in the near future, 64-bit operating systems.
Beckhoff Automation GmbH
New electro-pneumatic valve positioner offers high accuracy and speed for linear and part-turn actuators
ABBs new EDP300 series digital positioner is designed for regulating air-driven linear and rotary actuators, including control valves. The new design incorporates an advanced algorithm to position the valve actuator with what it characterizes as unsurpassed accuracy and speed. It also offers ABBs HMI with menu-driven programming and control selection of options, saving time and cost. EDP300s diagnostics include optional pressure sensors to determine valve and actuator performance, allowing engineers to monitor actuator conditions in real-time and improving process reliability. The unit also incorporates a partial stroke test (PST) function for in-process verification of valve integrity. With an integrated valve signature function, testing and verification of actuator and positioner assembly baseline performance can be completed without the need for additional hardware. Designed with a high degree of mounting flexibility, the EDP300 has application options for linear or rotary actuators with the same footprint as the ABB TZIDC positioner. An optional stainless steel housing permits the EDP300 to operate in corrosive environments typically found in chemical, pulp and paper, and offshore applications.
ABB
www.beckhoff.com
www.abb.com
www.controleng.com
software &
PRODUCTS
Modeling and testing platform enables users to incorporate electrical power systems models
MathWorks has announced a new version of SimPowerSystems that offers a stronger connection to Simscape and other physical modeling products in the Simulink family. With new capabilities such as support for the Simscape editing mode, SimPowerSystems 5.5 now offers engineers the ability to share models of electrical power systems with all other Simscape users. SimPowerSystems lets engineers model and simulate electrical power systems in Simulink for automotive, aerospace, defense, and industrial applications. Models can connect to other models built using Simscape and other domain-specic add-on products, such as SimMechanics and SimHydraulics. This helps engineers detect integration issues between systems before any physical hardware is built. MathWorks, www.mathworks.com
CAN data logger with scripting functionality lets users run custom-developed scripts and features
Kvaser AB has introduced a new high-speed Controller Area Network (CAN) to USB data logger that boasts the ability to run user-developed scripts to suit a wide variety of CAN applications. Kvaser Eagle, a exible enhanced evolution of the Memorator Professional, has been designed with engineers in mind who need customized features such as CAN protocol converters, CAN gateways, advanced CAN logging functionality, CAN node simulation, and standalone ECU programming. The company is aiming this device at a broad range of industries, including automotive development, industrial diagnostics, and oil and gas monitoring. Its script functionality allows users to develop customized applications written in the Kvaser t programming language. The programming language, which is event driven and C-like, is compiled into efcient byte code for execution on Eagle with the developers PC. Kvaser also has a network of technical associates with different domain expertise who will become a source of application-specic Kvaser t software for Eagle. Kvaser AB, www.kvaser.com/eagle
PRODUCT & LITERATURE SHOWCASE

2011 Dataforth Full-Line Product Catalog
Instrument Class Industrial Electronics from Dataforth Corporation are your assurance of rugged signal and data integrity along with wide spectrum accuracy and unrivaled reliability. The new 300-page Product Catalog includes up-to-date information and specifications for all Dataforth signal conditioning, data acquisition, and data communication products. The publication also introduces the new 6.2mm slim-line DSCP family of signal converters and ReDAQ Shape software for the 8B isoLynx SLX300 data acquisition system. Call 800-444-7644 or visit www.dataforth.com.
All Dataforth products are manufactured in the USA.
Acromag Signal Conditioners & Ethernet I/O With more than 50 years of industrial I/O experience, Acromag can help you solve your process monitoring and control challenges. Get our new product guide today. NEW! Low-Cost Transmitters 4-20mA Isolators and Splitters Ethernet, Modbus Remote I/O
877-295-7057 www.acromag.com
Acromag_CE_ProdLitShowcase2.indd 1 Webcasts
See the latest Control Engineering on-demand: 5/31/2011
5:25:27 PM
Safety Integration Wireless Technology Arc Flash University Ethernet Technology
Place your Classified, Literature Showcase or Product Mart ads today! Contact: Iris Seibert at 858-270-3753 or ISeibert@CFEMedia.com
62
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Control Engineering
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Request more information about products and advertisers in this issue by using the http://controlengineering.hotims.com link and reader service number located near each. If youre reading the digital edition, the link will be live. When you contact a company directly, please let them know you read about them in Control Engineering.
Company Page# RSN Web
Barbara Hoffman (248) 538-8804 BHoffman@CFEMedia.com

AR, IL, IN, IA, KS, KY, LA, MN, MO, MS, NE, ND, OK, OH, SD, TX, WI, Central Canada
ABB Inc . . . . . . . . . . . . . . . . . . . . 21. . . . . . . . 12 . . www.processautomationinfo.com/25 Allied Electronics . . . . . . . . . . . . 19 . . . . . . . . 11 . . www.alliedelec.com AutomationDirect . . . . . . . . . . . . C2 . . . . . . . .1 . . . www.automationdirect.com B & R Industrial Automation . . . 15. . . . . . . . 10 . . www.br-automation.com Baldor Electric Company . . . . . . 11 . . . . . . . . .7 . . . www.baldor.com Beckhoff Automation LLC. . . . . . 27. . . . . . . . 15 . . www.beckhoff.com Data Translation Inc. . . . . . . . . . . 12. . . . . . . . .8 . . . www.DATATRANSLATION.COM Dataforth Corp . . . . . . . . . . . . . . 13. . . . . . . . .9 . . . www.dataforth.com Integrated Safety On-Demand Webcast . . . . . . . . . 45. . . . . . . . . . . . . www.Controleng.com/webcast MathWorks . . . . . . . . . . . . . . . . . C4 . . . . . . . 22 . . www.mathworks.com/ltc Mitsubishi Electric Automation Inc . . . . . . . . . . . . . . 9. . . . . . . . . .6 . . . www.meau.com Moore Industries - Intl. Inc . . . . . 4. . . . . . . . . .4 . . . www.miinet.com Moxa Technologies . . . . . . . . . . . 3. . . . . . . . . .3 . . . www.moxa.com National Instruments . . . . . . . . . 7. . . . . . . . . .5 . . . www.ni.com NuScale Power . . . . . . . . . . . . . . 25. . . . . . . . 14 . . www.nuscalepower.com Omega Engineering Inc . . . . . . . 1. . . . . . . . . .2 . . . www.omega.com Rittal Corporation . . . . . . . . . . . . 29. . . . . . . . 16 . . www.rittal-corp.com Schneider Electric . . . . . . . . . . . . 23. . . . . . . . 13 . . www.SEreply.com Siemens Industry Inc . . . . . . . . . C1, 31 . . . . 17 . . www.sea.siemens.com Solutions for Engineers . . . . . . . 35. . . . . . . . . . . . . www.ControlEng.com Yaskawa America Inc . . . . . . . . . C3 . . . . . . . 21 . . www.yaskawa.com
Bailey Rice
(630) 571-4070 x2206 BRice@CFEMedia.com

AK, AZ, CA, CO, HI, ID, MT, NV, NM, OR, UT, WA, WY, Western Canada
Iris Seibert (858) 270-3753 ISeibert@CFEMedia.com

CT, DE, MD, ME, MA, NC, NH, NY, NJ, PA, RI, SC, VA, VT, WV, DC, Eastern Canada
Julie Timbol (978) 929-9495 JTimbol@CFEMedia.com
CFE Media Contributor Guidelines Overview

Content For Engineers. Thats what CFE Media stands for, and what CFE Media is all about engineers sharing with their peers. We welcome content submissions for all interested parties in engineering. We will use those materials online, on our website, in print and in newsletters to keep engineers informed about the products, solutions and industry trends. www.controleng.com/contribute explains how to submit press releases, products, images and graphics, bylined feature articles, case studies, white papers, and other media. * Content should focus on helping engineers solve problems. Articles that are commercial in nature or that are critical of other products or organizations will be rejected. (Technology discussions and comparative tables may be accepted if non-promotional and if contributor corroborates information with sources cited.) * If the content meets criteria noted in guidelines, expect to see it first on our Websites. Content for our e-newsletters comes from content already available on our Websites. All content for print also will be online. All content that appears in our print magazines will appear as space permits, and we will indicate in print if more content from that article is available online. * Deadlines for feature articles intended for the print magazines are at least two months in advance of the publication date. Again, it is best to discuss all feature articles with the appropriate content manager prior to submission. Learn more at: www.controleng.com/contribute
Inside Process CFE Media LLC . . . . . . . . . . . . . . P5 . . . . . . . . . . . . www.cfemedia.com Galil Motion Control . . . . . . . . . P3 . . . . . . . 18 . . www.galilmc.com Load Controls Inc.. . . . . . . . . . . . P8 . . . . . . . 20 . . WWW.LOADCONTROLS.COM Maple Systems Inc . . . . . . . . . . . P7 . . . . . . . 19 . . www.maplesystems.com
www.controleng.com
back to
BASICS
Thermowell protection
Thermowells, while protecting temperature sensors from a process fluid, can undergo tremendous stresses. A new standard is designed to lower risk of failures.
hermowells protect temperature sensors from direct contact with a process fluid. But once inserted into the process, the thermowell can obstruct flow around it, leading to a drop in pressure. This phenomenon creates low-pressure vortices downstream of the thermowell (the same principle underlying vortex flowmeters). Vortices can occur at one side of the thermowell and then the other, which is known as alternating vortex shedding. This effect can be seen in the example of a flagpole rippling a flag in the wind. The result is that thermowells experience a ONLINE combination of stresses: the flow pushing on the thermowell (drag forces) and the vortex shedAt www.controleng.com, ding (lift forces). Instrument engineers should search on thermowells for: -More on the author evaluate the thermowell to see if it can withstand -2 more graphics these stresses as they can cause mechanical fail-4 Quantitative criteria ure. The industry standard for this evaluation -Design improvements is ASME PTC 19.3 TW-2010, which, in 2010, superseded ASME PTC 19.3 1974. Motivation for the new standard followed some catastrophic failures of thermowells in nonsteam service. These thermowells had passed the criteria laid out in 1974. The 2010 standard includes significant Figure 1: Flow around a thermowell advances in the knowledge of therCourtesy: ABB mowell behavior, increasing from
Jennifer Wilson
Is the in-line resonance supressed?

The in-line vibrations due to the vortex shedding created by low density gas are small enough to be sufficiently suppressed by the thermowell. This is assessed by calculating the Scrunton number and the Reynolds number
Y YES
NO Does the thermowell pass the cyclic stress condition?

The cyclic drag stress is evaluated at the in-line resonance giving a value for combined stress. The cyclic lift stresses should be neglected. If the fatigue stress limit is less than the combined stress calculated, the thermowell fails the cyclic stress condition
Y YES
NO Frequency limit = 0.4 Frequency limit = 0.8
Figure 4: Frequency limit decision chart (simplified) Courtesy: ABB

64
four pages in 1974 to over 40 pages in 2010. The recent standard evaluates thermowell suitability with new and improved calculations including: Various thermowell designs including stepped thermowells Thermowell material properties Detailed process information Review of the acceptable limit for frequency ratio More accurate evaluation of stresses that affect thermowells. Flow passing the thermowell creates alternating vortices downstream known as shedding vortices. These shedding vortices cause the thermowell to vibrate. If this vortex shedding rate (fs) matches the natural frequency (fnc) of the thermowell, resonance occurs, and dynamic bending stress on the thermowell greatly increases. Forces created by the fluid in the Y plane (inline with flow) are called drag, and forces created in the X plane (transverse to flow) are called lift, as shown in Figure 2 (online). The vortex shedding rate for the drag and lift must be calculated. The in-line forces (parallel to flow) are approximately 2x the transverse forces. If the fluid is flowing at a very low velocity, the forces exerted on the thermowell are small, which greatly reduces the risk of thermowell failure. The new standard states that the natural frequency, frequency limit, steady-state stress, and dynamic stress do not need to be calculated if all the following conditions are met: The process velocity, V, is less than 0.64 m/s [2.1 ft/s]; Root diameter minus bore diameter (A d) 9.5 mm [0.376 in.]; Unsupported length, L 0.61 m [24 in.]; Root diameter, A 12.7 mm [0.5 in.]; Tip diameter, B 12.7 mm [0.5 in.]; Maximum allowable working stress, S 69 MPa [10 ksi]; Fatigue endurance limit, Sf 21 MPa [3 ksi]; The thermowell material is not subject to corrosion or embrittlement. Although the risk of thermowell failure is small if these conditions are met, in-line resonance can still be excited at low velocities, which may lead to sensor failure. ce - Jennifer Wilson has worked for ABB for more than 5 years.
www.abb.com/instrumentation
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Modeling electric potential in a quantum dot. Contributed by Kim Young-Sang at HYU. This example available at mathworks.com/ltc
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