Professional Documents
Culture Documents
Compressor control
Discrete wireless
High performance HMI
Defense in Depth
Temperature special section
www.isa.org/intech
The Emerson logo is a trademark and a service mark of Emerson Electric Co. 2012 Emerson Electric Co.
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12
COVER STORY
By Peter G. Martin
PROCESS AUTOMATION
SYSTEM INTEGRATION
20 A guide to effectively
30 The high
executing compressor
performance
control retrots
HMI
By Rick McLin
By avoiding fundamental mistakes
during the design phase, engineers can
consider any retrot an opportunity
to improve compressor operation and
efciency. Major areas to make compressor control improvements include
compressor control algorithms and
control system interactions.
By Bill Hollield
Human-machine interface (HMI) software to create sophisticated graphics
has advanced rapidly over the years,
but process graphics design concepts
have not kept pace with human
interface design. There are better ways
to design process control graphics that
improve operator effectiveness.
FACTORY AUTOMATION
AUTOMATION IT
26 Discrete wireless
38 Defense in Depth
By Bill Lydon
Wireless standards to date have focused on analog sensors, but standards
are emerging for discrete wireless.
Standards groups are starting to view
general factory automation as the next
big application area for wireless.
www.isa.org
By Eric J. Byres
The cyber-attacks on industrial automation systems are increasing and can
create downtime and damage. Understanding the basic concepts of defense
in depth help in defending automation
systems.
Talk to Me
Application engineering and
product innovations
Your Letters
Security issues, career changes,
and more.
10 Automation Update
Virtual reality training, By the
Numbers, and more.
47 Executive Corner
Whats on YOUR mind?
49 Association News
In Memoriam, Certication Review
52 Automation Basics
Selecting temperature
measurement and control systems
56 Young Innovators
Innovation, education, and
experience
57 Workforce Development
Findingor developingthe
right person for the job?
58 Channel Chat
When is safe safe? The value
of a risk assessment
60 Standards
Standards update: Alarm
management
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RESOURCES
64
64
64
65
65
Datales
Classied Advertising
Statement of Ownership
Index of Advertisers
ISA Jobs
InTech Online
www.isa.org/intech
WEB EXCLUSIVE
Events calendar
Find out about upcoming
events in the industry.
www.isa.org/intech/calendar
Story Idea
Automation Industry Connection
See what company is doing what at ISA Jobs.
Find out about people and positions.
www.isa.org/intech1/jobs
Products 4 U
Companies are releasing new products all the time;
nd out the latest automation products hitting the
plant oor.
www.isa.org/intech/products
2012 InTech
ISSN 0192-303X
People in Automation
Technology is great, but when it all comes down
to it, the industry thrives because of the people
working day in and day out. From movers and
shakers, to the real people behind the scenes,
nd out about the heroes in automation.
www.isa.org/intech/people
eclipse.magnetrol.com
Application engineering
and product innovations
Bill Lydon
blydon@isa.org
PUBLISHER
Susan Colwell
scolwell@isa.org
PRODUCTION EDITOR
if we do our job industry will thrive. Martins comments punctuated the importance
of automation professionals, and the panel
discussed the need to interest new people to
join the profession. Also discussed was the
expanding role of automation professionals
to go beyond machine and process to include integration with business systems.
It is valuable for automation professionals to keep expanding their knowledge of
new automation technology, methods, and
the expanding range of products that are
building blocks to create application solutions. Certainly there are many ways to
learn about new solutions. The Internet and
industry magazines deliver information, but
I suggest that conferences also provide a
truly interactive way to improve knowledge
and skills.
A number of industry and vendor conferences took place this past year, and a
great example of a valuable non-vendor
conference was ISA Automation Week
2012, where automation professionals
from around the world beneted from a
smorgasbord of application engineering
ideas exchanged in more than 60 technical
conference sessions, networking events,
and among the 88 vendors displaying
unique new technological solutions. In
addition to the formal presentations and
sessions, the opportunity to talk with automation people from other companies
and industries provided a cross-pollination
of ideas that can stimulate new thinking
and innovations. Attending and participating in local ISA section meetings, industry
symposia (examples: water/wastewater;
safety and security), and events is another
way to gain knowledge and interact with
other automation professionals.
It is important for your career and your
company to stay ahead of industry competitors by applying technology. Ideas are
powerful and transformational and best
found by putting yourself in the right environments.
Ashley Atkins
aatkins@isa.org
ART DIRECTOR
Colleen Casper
ccasper@isa.org
GRAPHIC DESIGN SPECIALIST
Pam King
pking@isa.org
ISA PRESIDENT
Eoin Riain
EDITORIAL ADVISORY BOARD
CHAIRMAN
Steve Valdez
GE Sensing
Joseph S. Alford Ph.D., P.E., CAP
Eli Lilly (retired)
Joao Miguel Bassa
Independent Consultant
Vitor S. Finkel, CAP
Finkel Engineers & Consultants
Guilherme Rocha Lovisi
BAYER MaterialScience
David W. Spitzer, P.E.
Spitzer and Boyes, LLC
James F. Tatera
Tatera & Associates Inc.
Michael Fedenyszen
R.G. Vanderweil Engineers, LLP
Dean Ford, CAP
Glenmount Global Solutions
David Hobart
Hobart Automation Engineering
Allan Kern, P.E.
Tesoro Corporation
Security issues
I appreciate the article, Uninterruptible power supplies and
cybersecurity by Michael A. Stout (January/February 2012 InTech). The authors expertise and product offering are from the
UPS world, which is great. The same security issues apply to any
device located in the facilityfor example, HMIs, PCs, SCADA
system, or any operating/control device. Security by obscurity no
longer ies. Unless a serious security event occurs at a facility in
questionwater/wastewater, power generation/distributionit
is tough to get the attention of those with budget control to
implement the proper security policies and defenses.
Jeff
tiple drives, etc. that do not require modication by a system integrator. This will reduce the investment by system users in terms of
producing their software standards.
Selvan Murugan
WWW.ISA.ORG
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Integration and commissioning of this complete analytical system is easier than ever
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process gas chromatograph offers high-reliability and precision while minimizing the
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nvensys Operations Management implemented an operator-training simulator for the U.S. Department of Energy
using SimSci-Esscor EYESIM virtual reality
training solution.
Designed for use within integrated
gasication combined cycle power plants
with carbon capture, and implemented at
the National Energy Technology Laboratorys Advanced Virtual Energy Simulation
Training and Research Center in Morgantown, W.Va., the EYESIM solution uses
3-D virtual reality simulation to help train
power plant control room and eld operators. Wearing a stereoscopic headset,
IGCC eld operators are immersed in a
virtual environment with the ability to
move throughout the plant, coordinating
their activities with control room operators and interacting as if they were in the
actual facility.
The EYESIM solution is also fully integrated with plant operating models, built
on Invensys operations managements
SimSci-Esscor DYNSIM dynamic simulation software, so actions taken by a eld
operator affect the plants process, and
actions performed in the control room
change the information visible to the eld
operator. Fully interactive animations respond and react to the actions of plant
personnel, illustrating how various pieces
of equipment will operate under almost
any scenario and condition. As a result,
eld and control room operators learn to
collaborate and perform as a team.
Multiphase
owmeter market
growing fast
Multiphase owmeters are an evolving
technology and the fastest growing owmeter type, outpacing ultrasonic and other new-technology owmeters, according
to a new study from Flow Research, The
World Market for Multiphase Flowmeters. The study found that the multiphase
owmeter market totaled $240.0 million in 2011. The market is projected to
increase at a compound annual growth
rate of 14.5 percent through 2016 until
it reaches $472.2 million. While the bulk
of these revenues are from multiphase
meters, some also come from dual phase
meters manufactured by multiphase meter
suppliers.
Multiphase owmeters determine the
percent of gas, water, and oil that makes
up the uid as it comes out of an oil or
gas well. They then use other values to
determine the owrate of each uid.
This information is very valuable because
it tells the operator how much of each
type of uid is coming out of the well
before the uids are separated. Multiphase owmeters also yield valuable information about the condition of the oil
or gas well where the drilling occurs.
WWW.ISA.ORG
78%
11
enterprise control
Automation engineers improve business performance
By Peter G. Martin
12
WWW.ISA.ORG
COVER STORY
13
COVER STORY
14
WWW.ISA.ORG
universally better
www.honeywellprocess.com/pks
COVER STORY
trial automation system from the database comprised of the vast number
of process sensors already installed in
the plant along with some key business
variables, such as current energy cost,
raw material cost, and product value.
16
It is important to realize that realtime protability control does not replace the traditional process control.
Rather, effective real-time process
control must be in place for the profitability control to work. The relationship between process control and
protability control can be thought of
as a cascade control strategy with profitability control as the primary loop
and process control as the secondary loop (Figure 3). Protability control must rst be applied across each
plant and then across the entire eet
of plants in the enterprise to realize
maximum business benet. Clearly,
protability control has broader implications and scope than process control
and a broader perspective of real-time
automation environments is required
to make enterprise control a reality.
WWW.ISA.ORG
Learn: uke.com/320Series
COVER STORY
WWW.ISA.ORG
20
WWW.ISA.ORG
ompressors are major pieces of capital equipment with long, effective lifespans. Unfortunately, control system obsolescence, plant
recongurations, and changes in process requirements can all
drive the need for a control system retrot over the lifetime of the compressor, and the multivariable, nonlinear system architectures required
for compressor control can cause fear and uncertainty for the engineers
responsible for executing the project.
However, by avoiding fundamental mistakes during the design phase,
engineers can instead consider any retrot as an opportunity to improve
compressor operation and efciency. This article will explore major areas
to make compressor control improvements, including:
l Compressor control algorithms
l Control system interactions, including capacity control
PROCESS AUTOMATION
FAST FORWARD
l
21
PROCESS AUTOMATION
22
WWW.ISA.ORG
sure ratio across the compressor closely followed the measured differential
pressure across a ow measurement
device. Delta P vs. h is still widely in use
today, due to its relative operational
simplicity and low cost. In fact, this
control method requires only a ow
and a differential pressure measurement across the compressor to function successfully.
Unfortunately, while Delta P vs. h is a
major improvement on minimum ow
recycle, it still has signicant problems. The method does not account for
changes in gas properties and requires
a suction pressure that does not signicantly change during operation.
As control systems have become more
advanced, it has become possible to implement more elaborate thermodynamic models for compressor control. As a
result, some form of a compressor head
model has largely replaced Delta P vs. h.
Compressor head vs. ow
The compressor head vs. ow algorithm
calculates the head generated by the
compressor and plots it versus the temperature- and pressure-compensated
ow produced. Regardless of whether
the algorithm is based on polytropic or
adiabatic head, this approach can accurately predict the compressor operating
point at various temperatures and pressures. In addition, it is not affected by
changes in the molecular weight of the
gas. The basic equations for this algorithm are shown below.
The basic equation for polytropic
head is dened as:
Where
Hp =
Pd =
Ps =
Td =
Ts =
n
=
Polytropic head
Discharge pressure
Suction pressure
Discharge temperature
Suction temperature
Number of moles of gas in a
given pressure/volume
PROCESS AUTOMATION
Z
= Gas compressibility
R
= Universal gas law constant
MW = Molecular weight of the gas
The difculty with using this equation
for surge control is that not all the variables can be measured directly. Gas compressibility and molecular weight cannot
be determined except by ofine analysis.
To eliminate these variables from
the equation, it is necessary to utilize
the ow relationships of differential
pressure-ow measurement devices.
Orice, venturi, annubar, and other
head-type measurement devices have
ow equations that include terms for
molecular weight and compressibility.
For example, the classic orice equation:
Where
Q = Flow, in appropriate units
H = Differential pressure across
ow measurement device
(head)
K
= Orice coefcient, dependent
on ow units and geometry
The
term is present in both
the head and ow equations. These
equations are used to generate the plotting coordinates used on the polytropic
head versus ow compressor control
map. Changes in molecular weight,
suction temperature, and compressibility affect the X and Y coordinates by
the same amount, allowing the generation of compressor maps that are valid
for variable composition gas streams.
This approach generates a compressor control map often referred to as a
Universal Surge Curve. This approach is
valid for all temperatures and pressures
as dened by the manufacturers compressor map and accounts for changes
in molecular weight. Accommodate
changes in gas properties, such as the
heat capacity ratio, by incorporating
the thermodynamic relationships derived from Charles and Boyles law.
Pressure ratio
Surge line
Surge line
Pd/Ps
Speed 2
Pd/Ps
Speed 1
5 deg
0 deg
-5 deg
-15 deg
-30 deg
Q2
Flow
Figure 5. Variable speed control
Q2
Q1
Q1
Flow
23
PROCESS AUTOMATION
Surge line
Speed lines
Pressure ratio
Pd/Ps 2
Speed 1
Pd/Ps 1
Q2
Flow
Speed 2
Min speed
Q1
WWW.ISA.ORG
Rick McLin, development manager, Turbomachinery ControlsRockwell Automation, has more than 25 years of experience
in turbomachinery controls (TMC) as an end
user and leader of development teams in
the U.S. and abroad. Rick spent 16 years
at one of the largest oil companies in the
world, developing surge control algorithms
and implementing distributed control systems in oil and gas production facilities.
Rick also led the development of the subsea compressor control and safety systems
developed for Statoil in the North Sea.
View the online version at www.isa.org/intech/20121202.
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Discrete wireless
Wireless discrete monitoring and controls standards emerging
By Bill Lydon
26
ndustrial wireless is proving valuable for automation professionals in many areas of industrial automation with products and standards
emerging. People are comfortable with wireless
since they use it in their daily lives with cell phones,
personal computers, security monitoring, and other devices. Wireless standards to date have focused
on analog sensors, but there is growing interest and
adoption of wireless for discrete monitoring and
for controlling digital output points. Discrete monitoring and control points signicantly outnumber
analog input and outputs in automation systems
and are the largest installation cost on most projects. Discrete points monitor contact closures from
a wide range of sensors and use contact outputs to
control a wide range of devices, including motors,
two position valves, and solenoids. If wireless cost
and reliability improve to compete with hardwiring, this would be a real improvement in automation systems. Today, wireless sensors are being applied to select applications that have a high return
on investment as a low-cost means for monitoring
hard-to-reach locations and deploying new innovative applications. Examples include connecting
far distant sensors that are too expensive to wire,
such as tank monitoring/control, and as an alternate to electromechanical slip rings on rotating
machines connecting electrical signals from a stationary to rotating structure.
WWW.ISA.ORG
Discrete considerations
One of the challenges for wireless is the majority of discrete points (contacts in/out; digital in/
out) in factory automation require high-speed
response since they are typically part of interlocking control logic that synchronizes machine
and assembly line operations. In addition, the
point density is much higher than analog points
in process applications. There are a wide range
of devices, including limit switches, proximity
sensors, relays, push buttons, stack lights, machine stops, and motor starters. Applications
that do not require high response speed are
the rst candidates for wireless. Interestingly,
there are approved safety applications in operation using wireless 802.11, but it is important
to remember that wireless becomes part of the
safety loop. If there is a communications breakdown, this causes a safety fault.
Proprietary wireless
Early adopter users have been ahead of wireless standards using various proprietary wireless
devices primarily to monitor and control hardto-reach discrete points. There are a number of
proprietary industrial wireless offerings in the
U.S. and Canada and other countries, and many
operate in the 900-MHz band or lower frequency,
providing a strong signal that allows communi-
FACTORY AUTOMATION
WirelessHART
activity
FAST FORWARD
l
ISA 100.11a
The ISA 100.11a Working Group 16 has been considering discrete factory automation and published a technical report, ISA-TR100.00.03-2011
INTECH NOVEMBER/DECEMBER 2012
27
FACTORY AUTOMATION
Track-mounted equipment
Track-mounted equipment includes
overhead cranes, hoists, gantries, and
rail cars that are used to move material
and personnel.
Rotary equipment
Rotary equipment (e.g., packaging llers) typically spins around a single xed
axis.
Torque and gauge tools
Torque tools are used on automated
assembly lines to tighten fasteners
(e.g., bolts) to a prescribed tightness.
Gauge tools are used in manufacturing
operations to measure specic attributes
of a unit of work against a prescribed
tolerance.
Mobile material containers
Mobile material containers (also called
intermediate bulk containers or IBCs) are
used to transport raw materials, workin-process (WIP), and nished goods to
various locations within a manufacturing operation. Examples include totes,
super sacks, barrels, and similar vessels.
Mobile high-value assets
Mobile high-value assets include removable or replaceable tooling (e.g., molds,
dies), storage (e.g., movable racks), maintenance tools (e.g., powered hand tools),
and other transportable assets that are
used in the manufacture of product or
maintenance of machines.
Mobile test and calibration xtures
Mobile test and calibration xtures
refer to combinations of sensors and
recorders that capture data related to
units under test.
WWW.ISA.ORG
dition to controllers, there are many devices using industrial Ethernet, including
sensors, motor drives, and robots that
can easily be connected to an 802.11
wireless Ethernet network. Key considerations in these applications include total
number of 802.11 access points required
to adequately cover desired area, existing
wireless Ethernet networks operating in
the same area, wireless range, installation environment (indoor or outdoor),
and security. Since these applications are
running over standard wireless Ethernet,
there can be a lot of other communications trafc with the potential to create
problems. Some companies are communicating with safety devices over 802.11,
and these are approved safety applications. These safety applications are interesting but if there is a communications
fault, the machine process must go to the
specied safe state stopping production.
PI activity
The PI organization responsible for
PROFIBUS and PROFINET has a wireless working group focused on wireless.
Since PROFINET is Ethernet-based, it
is already being applied running over
802.11 and Bluetooth. In addition, the
PROFISAFE safety protocol is being applied over 802.11 wireless using PROFINET as the transport mechanism. The
wireless working group is also developing the FA WSAN (factory automation
wireless sensor actuator network) specication. The technology is based on the
ABB WISA technology and uses the IOLink standard as the protocol. The IOLink standard denes a point-to-point
connection for discrete I/O that provides information from smart discrete
devices. In a hardwired application, this
is accomplished with a three-conductor
sensor/actuator cable and an IO-Link
Master. Only one IO-Link device can
be connected to a single port. A unique
characteristic of the WISA/WSAN technology is that the radio and sensors can
be powered from the radio waves.
User concerns
Users are learning that industrial plant
wireless requires a systems approach. For
example, wireless has been growing at a
fast rate, which has the potential to create
FACTORY AUTOMATION
of total points on a project will be wireless in the near future is anyones guess.
The number of wireless points deployed today is a small fraction relative
to the number of hardwired points. In the
future, the number of points that will be
connected wirelessly is likely to increase,
assuming wireless for discrete applications becomes more responsive, reliable,
and cost-effective. It is hard to compete
with the reliability and availability of hardwiring to an I/O card for discrete points.
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29
Unit 2
Overview
05-31-10
13:22:07
Total
Alarms
1
PULV
5000
5000
15
7500
1250
5
1200
1200
3000
Steam
KLBH
4750
Air
KLBH
7400
Steam
F
990
Fd Wtr
KLBH
4580
Coal
KLBH
1000
Reheat
F
1005
Drum
Lvl in.
-0.5
Furn
Pres
-0.5
1 Hr
0
0
-15
1 Hr
0
0
-5
Steam
psig
2400
Status
A-ON E -ON A
B -ON F -ON
C-ON G-OFF E
D-ON H-ON
Turbine Generator
Gross MW Net MW
Alarms
C
MVAR
HZ
PUMPS
AND
FANS
LPT -A
in.hg
LPT -B
in.hg
A2 HWP
ON
B2 HWP
OFF
A2 CWP
ON
B2 CWP
ON
Hydrogen
psig
1 Hr
600
600
0
Hydrogen
F
Turb Oil
F
Stator
GPM
A2 ECW
ON
B2 ECW
ON
A2 FD
ON
A2 ID
ON
C-SBAC
ON
D-SBAC
ON
Drum Lvl
in.H2O
HW Lvl
in.H2O
DA Lvl
in.H2O
DA Wide
FT.H2O
Cond Hdr
psig
-0.5
20.1
0.0
AUTO
9.0
SO2
#/MMBTU
Stack CO
ppm
Inst Air
psig
200
90
702.1
Boiler
A/F Ratio
640.1
BBD
pH
- 5.2
Econ
pH
60.00
Econ Gas
Out F
0.2
Aux Stm
psig
0.2
Fans
Furn in.H2O
49.1
104
AUTO
115
AUTO
351
3.1
3.1
A2 ID
Stall
A2 FD
Stall
B2 ID
Stall
B2 FD
Stall
Econ
% O2
Sec Air
in.H2O
CEMS/MISC
NOX
% Opac
#/MMBTU
400
AUTO
7.1
9.4
9.4
775
300
- 0.5
25
25
25
25
6.0
7.0
21.0
0.45
0.9
30
lmost three decades ago, we control engineers were given a new task for which
we were ill-prepared. We installed control systems with the capability to display realtime process control graphics for the operator.
But the screens were blank, and we were responsible to ll them up.
We had no available guidelines as to what
constituted a good graphic. So, we did the best
we could with what we knewwhich wasnt
much! As a result, we set in place a low-performance paradigm of what a control system
human-machine interface (HMI) should look
like, and inertia has done the rest. Mostly for
convenience, we chose to depict the process as
a P&ID view covered in live numbers. We stuck
with that paradigm even as graphic capabili-
WWW.ISA.ORG
SYSTEM INTEGRATION
FAST FORWARD
l
High performance displays depict information. Information is data, in context, made useful. HPHMI graphics show not only the process
value, but where it is relative to whats good.
Abnormal conditions are designed to stand out
clearly. Color is used consistently, effectively,
and sparingly. Graphics are designed with a
proper hierarchy.
Displaying information
In Figure 1, much money has been spent on the
instrumentation. But can you answer the simple
question, Is this process running at peak efciency, or very poorly? To know that, one must have
specic training and months of experience in normal and abnormal situations. The operator must
compare each number to a memorized mental
map acquired through experience and upsets. This
is a difcult cognitive process. Most operators have
well over a thousand such numbers and status indications spread out over dozens of graphics. Detecting abnormal conditions is difcult.
In the Figure 2 depiction, a compressors instruments are displayed in a different fashion. The
normal or desired range of each value is clearly
depicted using the light blue range. The values
proximity to alarm ranges and automated interlock thresholds is shown. (We normally expect operators to also memorize which sensors are interlock initiators). Values in alarm are depicted with a
redundantly-coded alarm priority indicator.
With a single two-second glance at this bank
of properly designed analog indicators, the operators can tell if any values are outside of the
normal range, by how much, and the proximity of the measurement to both alarms and interlock activation. Humans intuitively understand analog depictions. The abnormally high
discharge temperature shown is easy to detect
even though it is not yet in alarm. Alarm condi-
31
SYSTEM INTEGRATION
Suct
psig
Inter
psig
Dsch
psig
Suct
degF
Dsch
degF
Inter
degF
E. Vib
mil
N. Vib
mil
W. Vib Motor
mil
Amps
Oil
psig
Oil
degF
Alarm
Indicator
Interlock
Threshold
Alarm
Range
Desirable
Operating
Range
42.7
38.7
93.1
185
95
120
170
12
170
80
290
Alarm
Range
Wrong
Graphic hierarchy
Better
Pump Not
Running
STOPPED
(Shape is Filled
Darker)
Pump
Running
Better
Wrong
RUNNING
(Shape is Filled
Brighter)
480.1 psi
480.1 psi
Priority 2
Priority 3
480.1 psi
Diagnostic
Priority
480.1 psi
Priority 1
480.1 psi
Priority 2
4
480.1 psi
480.1 psi
Priority 3
Diagnostic Priority
Figure 3: Depicting status and alarms with redundant coding and proper color usage
32
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Performs Well
Under Pressure.
Millise
con
d-le
vel
Re
du
nd
an
rity
ecu
NS
/WA
LAN
Easy-to-Use P
Integrated Industrial
Ethernet Solutions
Tel: 1-888-669-2872
Connectivity
Fax: 1-714-528-6778
Industrial Ethernet
Switches
usa@moxa.com
www.moxa.com
Platform
Gig
ab
idth
ndw
Ba
it
www.moxa.com/MXview_download
SYSTEM INTEGRATION
Feed Composition
%A %B %C
Coolant:
GPM C
Feed
MPH
ADTV-1 ADTV-2
MPH
MPH
Temp
C
Pres
psig
Product: Thionite
State: Mid-Run
RTAM: ON-OK
Reserved
Faceplate Zone
36
WWW.ISA.ORG
Feed
ADTV-1
ADTV-2
Temp
Pres
Level
SYSTEM INTEGRATION
Conclusion
Our sophisticated control systems are
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37
Defense
in Depth
38
he past two years have been a real wakeup call for the industrial automation industry. For the rst time ever, it has been
the target of sophisticated cyber-attacks like
Stuxnet, Night Dragon, and Duqu.
The most destructive post-Stuxnet threat is
the malicious malware known as Shamoon. As
with Stuxnet, Duqu, and Flame, it targeted organizations in the Middle East, in this case Saudi
Aramco, Qatars RasGas, and likely other oil and
gas concerns in the region. It is a new species,
however, because it did not disrupt an industrial process as Stuxnet did, nor did it stealthily
steal information as Flame and Duqu did.
Instead it removed and overwrote the information on the hard drives of 30,000 to 55,000
(yes, those numbers are correct!) workstations
of Saudi Aramco (and who knows how many
more at other rms). It is believed to have been
launched by a single disgruntled employee
working inside the corporate rewall.
What Shamoon and the others teach us is
that relying on a single defensive solution (like
a single Internet rewall) exposes a system to
a single point of failure. No matter how well-
WWW.ISA.ORG
AUTOMATION IT
not have the magic key for getting past all the
subsequent defenses.
n Context- and threat-specic layers of defense.
Each of the defenses should be designed to be
context- and threat-specic.
This last point is the most subtle and perhaps
the most important. Going back to the bank example, note that banks do not simply have additional security guards at every level. Banks understand that threats come in different avors,
ranging from the desperate drug addict with a
gun to the sophisticated fraud artist. Thus for the
banks, each defensive layer is optimized to deal
with a specic class of threats.
39
AUTOMATION IT
Process Measurement
like you've
never seen it
before
Scan.Learn
RESOURCES
40
WWW.ISA.ORG
Remote Access
Evolved
Thermal imaging
detects equipment issues
BC09 basement-living-room
FAST FORWARD
l
42
WWW.ISA.ORG
43
Inspecting tanks
In automated process environments,
thermal imaging can also be used to
inspect tanks. Scan the outside surface
for variances in temperature at different points. Inspect gaskets, seals, and
valves at their openings. Monitor tank
levels; locate uid, solid, oater levels, and sludge. While large process
tanks typically have built-in visual or
electronic indicators for tracking prod-
44
WWW.ISA.ORG
Tank inspection
to the other.
A trap that is failed open can go undetected for long stretches of time
weeks or even monthsand be very
costly once it is detected. A thermal imager will display these traps as warm on
both sides. If you nd a trap that looks
like that, make sure it has not just cycled. If it has, and remains hot on both
sides after more than a few minutes, it
likely is not working properly.
Verify that electro-mechanical equipment targets are operating at a minimum of 40% of load. Lighter loads do
not produce as much heat, making it
harder to detect problems.
Within the safe zone, get as close to
the target as you can. (While thermal
imaging is non-contact, if you measure
live electricity with enclosure doors removed, NFAP 70E safety standards still
apply. Wear appropriate PPE, try to
Specialized process
stay four feet away from the target, equipment inspection
and minimize time spent in the arcash zone.)
Do not try to shoot through doors; thermal gradients within an electrical cabinet make it impossible to understand the thermal impact inside the cabinet.
Infrared does not penetrate glass or plastic safety shields, so you will need to
work around those.
If inspecting outside, take wind and air currents into considerationas they
could cool any abnormal hot spotsaccount for ambient temperatures, and
watch out for thermal loading (heat from the sun).
Remember that not all problems are indicated by excessive heat. Restricted ow
in a cooling system could be indicated by a cooler-than-normal reading.
When working with low-emissivity assets, consider sources of reective infrared
radiation.
When trending assets, it is important to have consistent loads for capturing accurate temperature data over time.
45
Conclusion
By its very nature, troubleshooting is
scenario-specic. Personal experience
goes a long way in determining just
how useful thermal imagers can be.
The more time you spend using a thermal imager, the better you will become
Infrared theory
Thermal imagers create pictures by measuring infrared energy or heat. The thermal imager reads the surface temperature of objects and then assigns different
colors to the different temperatures, resulting in a picture of sorts. But not all materials emit thermal energy equally. Emissivity is the property that describes how
efciently an object radiates or emits heat. It is expressed as a value from 0 to 1.0.
Shiny materials have low emissivity; painted or heavily oxidized metals, and nonmetals, have higher emissivity.
at identifying anomalies. As your thermal knowledge and skill build up, they
can be combined with existing knowledge of line and equipment functionality, adding up to formidable troubleshooting power and, thus, improved
long-term maintenance.
ABOUT THE AUTHOR
46
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hrough a series of special events and forums over the past month, I have had
a chance to engage in some in-depth,
highly insightful conversations with process engineering, control engineering, and IT executives
across a range of industries. From oil and gas to
ne chemical to water/wastewater to food and
beverage, these professionals shared some common priorities and goals as they look forward to
2013. It might be interesting to see if they align
with your own.
Information security as
a strategic imperative
There is no doubt that safety and security of people and processes have long been top-of-mind,
but in todays information-enabled enterprise, the
stakes have gotten higher. While nobody will go
on the record (and why would they?), it is fair
to say that the great majority of companies we
talk to are under constant threatboth malicious
and accidentalfrom hackers, viruses, uneducated employees, and well-meaning contractors,
among others. The wrong breach at the wrong
time could have drastic consequences, and nobody wants it to happen on their watch.
Devices playing on open networks, such as
EtherNet/IP, is pervasive, and we have moved, as
Cisco describes it, from an Internet of People
to an Internet of Things. We also have new opportunities for remote access for monitoring, diagnostics, and maintenance, but companies are
struggling with how to do it safely, securely, and
consistently.
This means that we need to stop thinking of
security as something to implement after the
system is installed. We need to design security
in from the beginning, and we need to manage
it at all layersdevice, controller, process, and
enterprise. And since it is highly likely that the
devices in the future will be walking around the
plant in someones pocket or clipped to their
belt, we need to move to a model where we secure the data and not the device. The data HAS
to go somewhere or it is not particularly valuable, so validating the data and managing who
has access to it is much more productive than
only worrying about which devices it sits on and
who has access to those devices.
47
ators are more open to modern technology, and executives are recognizing the
treasure trove of information from production. All of this is happening while we
48
real business improvement. They are embracing newer, more contemporary process control platforms. They are adopting open, standards-based architectures.
They are installing wireless. They are integrating mobile devices. They are using
multi-channel
communicationsdata,
voice, videoand they are creating collaborative ecosystems with their equipment OEMs, their integrators, and their
automation suppliers.
One last observation on the conversations of the past monthand that is the
high degree of optimism that people have
for what the future holds. Despite all the
competitive, economic, and regulatory
pressures we face, it is an exciting time
to be in this industry, and better security,
more collaboration, and re-thinking roles
and technologies will help the forwardthinking companies in this eld achieve
success.
WWW.ISA.ORG
In memoriam
Leslie R. Driskell
Leslie
R.
(Les)
Driskell of Mt.
Lebanon, Penn.,
died on 5 November. Born in 1916
to a family of very
modest means in
Louisville, Ky., he
achieved international prominence as an instrument engineer, consultant, author, and teacher specializing in control valves and industrial
process control systems.
Dropping out of the University of Louisville after one year for nancial reasons,
Driskell worked at various clerical jobs
during the Depression and eventually
became a technician at Seagram-Calvert
Distilleries while also taking correspondence courses in what was then a new
eld, industrial process control.
During the war, Driskell worked for
DuPont and was deferred from military service because he was supervising
all instrumentation at the corporations
$45-million plant manufacturing synthetic rubber, which was vital for the war
effort. He also taught night courses in
industrial instrumentation for Purdue University, sponsored by the U.S. War Training Program.
After the war, Driskell moved his family
to Pittsburgh. After answering a blind ad in
the ISA Journal, he began working for BlawKnox Construction. This eventually became
the Chem Plants division of Dravo Corporation. While at Dravo, he began writing
articles for engineering magazines. These
led to offers to teach and consult, as well
as work on standards and practices committees of what was then the Instrument
Society of America (ISA). Driskell served
as chair, ISA Standards & Practices Committee, from 1967-88; chair, Final Control Elements Committee, from 1957-66;
president, ISA Pittsburgh Section, from
1954-55; and director, ISA Louisville Section, in 1947. In 1968, he received the
Instrumentation Technology Award and
was named ISA Fellow. Driskell received
E. Ross Forman
Edgar Ross Forman of Erdenheim, Penn.,
died on 29 October. Born in Camden in
1923, he was a mechanical professional
engineer and a pioneer in automated systems and control engineering.
Forman was active for many years in
MathCounts, an outreach program of
the National Society of Professional Engineers. He was also a former president of
the NSPE Valley Forge Chapter. He authored numerous papers,
trade journal articles, and chapters in major books for the industry on Chemical Engineering Control Systems.
Forman was the only president of the ISA Philadelphia Section
49
CAP answer
The correct answer is B, Cancel out the
interaction between two process variables and their outputs. In MIMO (multiple input, multiple output) systems, often
the process variables and outputs interact
with one another, which makes control of
the independent variables difcult. A forward decoupling algorithm can be used
to cancel out these interactions, making
more traditional control methods applicable to these complex systems.
Answer A is not correct; accumulation
of the interactions would be counterproductive to the loop performance, and
would simply magnify the coupling between inputs and outputs.
50
CCST answer
The correct answer is A, A resistor is
placed across the input terminals of the
controller. A 250 resistor in a 420mA
DC current loop will produce a 15VDC
signal, as indicated in Ohms law: E = I
R, where E is voltage, in volts; I is current,
in amps; and R is resistance, in ohms. At
4mA (0.004A), E = 250 x 0.004A = 1V.
At 20mA (0.020A), E = 250 x 0.020A
= 5V.
Answer B is a true statement for a current loop, but is not the way that a current signal is converted to a voltage signal
that is required by the controller. This answer indicates the driving force for direction of current ow.
WWW.ISA.ORG
Answers C and D would electrically modify the behavior of the circuit, but would
not convert current signals to voltage signals. A diode across the controller could be
used to prevent current ow in the reverse
direction, or could be used with an LED in
an optical isolation circuit. A capacitor in
a current loop could be used to suppress
surges at the transmitter terminals.
Reference: Goettsche, L.D. (Editor),
Maintenance of Instruments Systems, 2nd
Edition (2005), ISA Publishing
Selecting temperature
measurement and
control systems
52
easuring and controlling temperature is undoubtedly the most common measured parameter because it
is critical to so many operations and tasks. Accurate temperature measurement and control is
vital to the quality of manufactured goods, such
as nished metal components, and to the efcient and safe operation of a process or system.
In todays market, there are myriad devices for
monitoring and controlling temperature, ranging from simple temperature controllers to complex distributed control systems. Most temperature measurement and data acquisition products
are well-suited for the job for which they are intended, but care must be taken when applying
them in harsh industrial environments.
Many low-cost monitoring and control devices and systems perform well in applications
where they are not exposed to environmental stress. While these lower-cost devices and
WWW.ISA.ORG
AUTOMATION BASICS
DAS or PLC?
PLCs, with their inherent and almost limitless
exibility and wide-ranging application capabilities, are the clear choice for complex control applications. PLCs have similar temperature measurement performance to most DAS
equipment, but they may not support certain
types of thermocouple or RTD sensors. In addition, PLCs sometimes deliver inferior measurement of electrically noisy sensor inputs.
Furthermore, most PLCs do not have local data
INTECH NOVEMBER/DECEMBER 2012
53
AUTOMATION BASICS
recording capability.
If PLC limitations are a hindrance
for the particular application, a modern data acquisition/data logging
system is a logical choice. Oftentimes
a DAS can work with a PLC, by doing what the PLC may not be able to
dosuch as measuring unusual input sensors, providing more accurate
measurements, and providing backup
data recording along with quick access
to historical data.
Since there is a lot of overlap in the
measurement capability of a PLC versus DAS, choosing one over the other
will be based on many other factors.
This may include the presence of
and preference in usingan existing
vendors PLC system. If the plant can
cost-effectively plan a new system that
meets all objectives using their preferred PLC vendor, that can be the best
choice.
A DAS, however, can be the best
choice when control is not the main
requirement, and when the plant does
not have established PLC expertise and
support. The combination of excellent
measurement performance, easy to use
and inexpensive software, web browser
access and readily available connectivity to other plant systems via common
protocols makes a DAS an attractive solution for many applications.
In general, DASs are used for two distinct purposes: testing/laboratory applications and industrial applications.
A lower-end, less robust DAS will often
work well in a clean lab environment,
but that same DAS will not be able to
perform in a harsh industrial environment, such as a petrochemical plant.
DASs for test laboratory and industrial process environments both have
their own performance challenges.
Some test applications require temperature measurements of energized
components or circuits where the
thermocouple sensor is in direct contact with high AC voltage. Successful
measurement under these conditions
requires differential inputs with high
common mode voltage and noise rejection specications, as well as robust
channel-to-channel and channel-to-
Data acquisition systems can combine monitoring, control, display, and data handling in
a single unit.
Considerations when
choosing a DAS solution
WWW.ISA.ORG
Considerations for
choosing the right DAS
n
n
n
n
AUTOMATION BASICS
tervals, the les in the memory can be automatically copied to another ash memory, and these les can be copied
and archived to an FTP server. These features enable three
copies of the same data le to be stored at the same time in
different locations, providing redundant and highly secure
data storage.
A DAS should also be highly scalable to expand as needed.
This can be done by adding input modules or by connecting
to expansion hardware via a serial or Ethernet connection
using a protocol such as Modbus, which can enable users to
add hundreds of input channels to the base unit.
REFERENCES:
http://www.isa.org/InTechTemplate.cfm?Section=Communities&tem
plate=Ecommerce/FileDisplay.cfm&ProductID=7926&le=ACFE8EB.
pdf
High Winds Tester
http://www.isa.org/InTechTemplate.
cfm?Section=Archives4&template=/ContentManagement/ContentDisplay.cfm&ContentID=71521
Protection or Degradation
http://www.isa.org/InTechTemplate.
cfm?Section=Archives4&template=/ContentManagement/ContentDisplay.cfm&ContentID=63839
OPC
www.opcfoundation.org
55
n this rapidly changing world, it is very important to think different in order to stay ahead
of global competition. I would like to share my
life experiences with automation professionals
who aspire to grow and make a difference in this
world.
I have worked hard since my early years. I grew
up in India in a humble, middle-class family and
was motivated by science and math. I fell in love
with chemistry during my undergraduate years and
56
WWW.ISA.ORG
Prabhu Soundarrajan is the director of ISAs chemical and petroleum division. He is also the global
director at RAE systems, a leading innovator of
wireless safety sensors for industrial markets, and
has held executive positions as vice president of
sales and business development, global business
unit manager, and has served on the board of directors of international organizations. Prabhu has
authored several papers and patents and also has
won the best paper award at ISA. He is a young
innovator and is willing to mentor aspiring young
ISA members.
n the same way that the factory environment is much different today than
it was ve, ten, or twenty years ago
especially in terms of automationthe
workforce environment has also changed.
That should not surprise us, but we seem
to be taking a long time to adapt to the
new situation.
What has not changed is that all
companies, sooner or later, need people to fill positions. With increased reliance on automation, we may need less
unskilled labor, but in truth we often
need highly skilled people for critical
positions. Companies need fewer op-
pany. This may be driven by strict emphasis on the bottom-line and the quarterly
dividend. After all, it is hard to show training as a prot center.
To some degree I can understand
this, since a companys mission is to
make a product or deliver a service,
not specifically to train people. They
may minimize in-house training if they
see little value added from it, and in
hard times they may decide training is
an easy thing to cut. But often the specialized offerings that outside agencies developed go under-utilized, since
jobseekers may not pursue training if
57
and
components.
Both OSHA and ANSI
are important agencies in North America. They provide
guidelines on how
machinery can operate safely in order to
prevent a dangerous
situation. However,
neither organization
creates standards on
how or when a safety component is con- Lakeview of levee in New Orleans
Source: fotolia.com
sidered safe. Both
OSHA and ANSI rely
on standards, such as ISO/EN 13849 and
the harm or damage could be. It is usually
IEC 62061, to dene what makes safety
a combination of the likelihood of occurdevices safe, as well as how the safety derence and the consequences: How likely is
vices should be used on machinery in order
this to happen? How serious could it be?
to achieve a safe state of operation.
Risk is usually expressed as high, moderate, or low (qualitative), or as a number,
Does the equipment meet with current safety standards so
with the higher number indicating the
greater the risk (quantitative).
as to comply with adopted OSHA and/or ANSI standards?
Risk assessment is the process of identifying hazards related to environment, health,
Natural levees serve as barriers by conToo often, many manufacturing faciliand safety that are intrinsic properties of
ning rivers during periods of ordinary
ties believe that they are safe simply bework-related activities, assessing both the
ow. They may even protect low-lying
cause there is already some sort of safety
likelihood that the hazard will lead to a loss
areas from ooding if the level of a river
device or devices in place, and no one
and the severity of that potential loss. The
is not too high. For this reason, articial
has been hurt on the existing equipment.
results of likelihood and severity are comlevees designed to contain a river during
However, the question needs to be asked
bined according to an agreed-upon rule to
ood stages are often built, but these aragain, when is safe safe?
give a single measure of potential risk.
ticial levees can themselves create probHow can you evaluate existing machinSimply put, a risk assessment is a carelems by conning the river to a narrow
ery already in place? Does the machinery
ful examination of what, in your workchannel, or conning sediment, which in
already provide proper functional safety?
place, could cause harm or damage to
turn raises the river bed higher and highAnd does the equipment meet with curpeople, property, or the environment. You
er. These same levees can provide a false
rent safety standards so as to comply with
can then decide if you have taken enough
sense of security as we just witnessed
adopted OSHA and/or ANSI standards?
precautions or should do more to prevent
with Hurricane Isaac.
The wrong approach is to simply ignore
any harm or damage from happening.
these issues and hope nothing will ever
Safety measures do not obviate risk
happen. The correct approach is to conABOUT THE AUTHOR
Functional safety standards exist to ensure
duct a functional safety risk analysis and
Rick Carpenter (rick.carpenter@lomancsi.
the safety of processes and to help prevent
see where any safety issues may be.
com) is functional safety and life sciencaccidents from happening on the induses manager at Loman Control Systems,
trial plant oor. These standards provide
Assess likelihood and severity
Inc., a Control System Integrator Assoa formulized method to determine the
Risk is, by denition, the chance or likeliciation (CSIA) Certied member based in
risk associated with industrial machinery.
hood that someone or something could
Lititz, Penn. To learn more about CSIA,
Functional safety standards also provide
be harmed or damaged by the hazard, tovisit the associations web site at www.
guidelines to prevent unsafe conditions
gether with an indication of how serious
controlsys.org.
58
WWW.ISA.ORG
NEW CHALLENGES
REQUIRE A
NEW APPROACH.
also play a part in overall plant performance metrics and can be used as an input to process improvement efforts. This
is typically in conjunction with process
historian data and control loop effectiveness data. The focus of the assessment
process is to apply engineering judgment
and review to determine whether the
alarm system is performing properly.
Earlier this year, the ISA18 committee
completed two additional ISA technical
reports:
ISA-TR18.2.4-2012, Enhanced and
Advanced Alarm Methods, is intended
to help people evaluate when to use
enhanced and advanced alarming methods, what benets they can achieve, and
what challenges and costs to expect. Per
ISA-18.2-2009, enhanced and advanced
alarm methods typically go beyond the
basic methods and techniques that are
usually, or at least initially, applied. While
signicant improvement in alarm system
function and performance can usually
WWW.ISA.ORG
ISA salutes
our partners.
Through the ISA Corporate Partnerships Program,
leading companies have joined together to invest
in the future and work together to solve the
problems our industries face. Automation
professionals around the world will benefit
from their support of ISA, and were
proud to recognize their contributions.
We accomplish more together than we
ever could alone. So, on behalf of ISA
members, leaders, and customers
everywhere, let us humbly say...
Thank you.
Focus on temperature
This content is courtesy of
62
WWW.ISA.ORG
PID controller
Red Lion Controls released the PAX2C PID controller, which is
designed specically for the process and temperature control
markets. Applications include food and beverage, plastics, packaging, energy, gas, heat treating, and glass processing.
The PAX2Cs features include eld installable plug-in option
cards, which simplify conguration by enabling customers to use
different cards to build their own controllers. This type of exibility eliminates the need to order additional products to meet
changing application requirements. A dual-line tri-color display
provides at-a-glance visual representation of up to 16 changing
alarm conditions with seven programmable color zones; customizable to allow users full access to bar graphs, annunciators, color
zones and display mnemonics.
The PAX2C also features universal input, a universal power
supply, and easy programming, rmware, and software upgradesusing a standard built-in USB connector and Red Lions
Crimson software to support both current
needs and future requirements.
Red Lion Controls
www.redlion.net
63
classieds
datales
Maintenance Management
Software/ CMMS
ADVANCED TEMPERATURE/
PROCESS CONTROLLER
Omegas new CN2300 series DIN
Ramp/Soak Advanced Temperature/Process
Controller with USB interface features a
graphic/text LCD display and datalogging
options. This affordable controller has 64
independent programs, 255 segments per
program, universal inputs, autotune, modular isolated control outputs, alarm functions and has 5 language
options: English, French, German, Italian and Spanish. Ideal for
food, automotive, manufacturing and chemical industries.
FastMaint CMMS
Your FAST TRACK to maintenance management
http://www.omega.com/pptst/CN2300.html
Omega Engineering, Inc.
Phone: 1-800-TC-OMEGA or 203-359-1660
STATEMENT OF OWNERSHIP
MANAGEMENT AND CIRCULATION
(Required by 39 U.S.C. 3685)
Custom REPRINts
Actual # of copies
of single issues published
nearest to ling date
6,737
6,401
-Mail subscriptions:
41,143
34,133
47,880
40,534
1,714
1,422
281
267
1,995
1,689
Total distribution:
49,875
42,223
568
567
none
none
Total:
Percent paid and/or requested circulation:
50,443
96%
42,790
96%
64
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