Through The: Looking Glass

THROUGH THE
LOOKING
GLASS
A pragmatist's view
of how emerging
technologies
will revolutionize
tomorrow's controls.
MARCH 2015
ASSET MANAGEMENT
MOVES BEYOND CMMS
CT1503_01_cvr.indd 1
HOW TO CALIBRATE
PRESSURE INSTRUMENTS
BETTER WAYS TO DIAGNOSE
THE PHYSICAL LAYER
3/3/15 9:46 AM
Process
Sensing
from top to bottom
PRESSURE
LEVEL
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FLOW
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Research, price, and buy at: www.automationdirect.com/process-controllers
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* See our Web site for details and restrictions. Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved.
CT1503_full page ads.indd 2
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March 2015 Volume XXVIII Number 3
f e at u r e s
30 / control Systems
of the Future
Through the looking glass of emerging
technologies. by William L. Mostia
W E B
E X C L U S I V E S
Making the Industrial Internet

Real Highlights of the 2014 GE
Intelligent Systems User Conference
by the editors of Control.
www.controlglobal.com/whitepapers/
2015/industrial-internet-ge-2014-usersummit/
39 / asset Management Magnifies Scope

and awareness
More capable software, networks and mobile devices enable asset management
in many new applications and environments. by Jim Montague
c
a t
45 / how to calibrate Pressure instruments

Basics, crucial issues and best practices for successful pressure calibration.
by Jim Montague
CONTROL (ISSN 1049-5541) is published monthly by PUTMAN Media COMPANY (also publishers of CONTROL DESIGN, CHEMICAL PROCESSING, FOOD PROCESSING, INDUSTRIAL NETwORkING,
PHARMACEUTICAL MANUFACTURING, and PLANT SERVICES ), 1501 E. woodfield Rd., Ste. 400N, Schaumburg, IL 60173. (Phone 630/467-1300; Fax 630/467-1124.) Address all correspondence to Editorial and Executive Offices,
same address. Periodicals Postage Paid at Schaumburg, IL, and at additional mailing offices. Printed in the United States. Putman Media 2015. All rights reserved. The contents of this publication may not be reproduced in whole or part
without consent of the copyright owner. POSTMASTER: Send address changes to CONTROL, P.O. Box 3428, Northbrook, IL 60065-3428. SUBSCRIPTIONS: Qualified-reader subscriptions are accepted from Operating Management in the
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M a r c h / 2 0 1 5 www.controlglobal.com
CT1503_05_07_TOC.indd 5
3/3/15 9:47 AM
Competence is knowing how it all fits together
Why choose Endress+Hauser?

More than 100,000 customers in every industry around the globe trust
Endress+Hauser to make their processes safe, efficient and repeatable. Just
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3/3/15 10:13 AM
March 2015 Volume XXVIII Number 3
D E PA RT M E N T S
9 / Editors Page
Cozy up to DHS
Homeland Security wants to help prevent,
respond to and recover from cyber attacks.
On-site
On-line
Hands-on
or in the
Classroom
28 / resources
Books, tutorials, videos, all you need for

loop control online.
49 / Technically Speaking
11 / control Online
Check here for some of our readers favorite

recent links to ControlGlobal.com.
Wireless Level Monitoring

When, where and how to cut the wires.
50 / ask the Experts
13 / Feedback
Our readers speak out on Big Data, Internet protocols and NERC CIP.
You choose.
When to Use Equal Percentage Valves

Get advice from our experts
52 / roundup
14 / Lessons Learned
50 Years of Progress
Bla Liptk looks back at how far weve
come and how far we have to go.
The latest in pressure transmitters and components to meet new challenges.
54 / Products
Get the best in automation technology here.
19 / On the Bus
Better Diagnostics for the Physical Layer

Its keeping the nuts and bolts of the hardware in trim that keeps the system running.
20/ Without Wires
55 / control Talk
Practical Installation Best Practices

Twelve tips for getting the best out of your
new control system and instrumentation.
A blended training
approach to help you keep
up with todays challenges
Customize your training
experience through the
unique offerings provided
to you through our Process
Training University. Whether
it be on-site, on-line or
in the classroom, choose
a training package that is
tailored to meet your needs.
57 / ad Index
ISA Takes on Asset Management

A brief look at the ISA 108 committees
work on asset management best practices.
Check these pages.
22 / In Process
Editor Education
Pressure calibration webinars clear up some
persistent mysteries.
Prepping for Industry 4.0; Hannover Fair

preview; making cybersecurity a team
sport; Nanoline contest winners.
58 / control report
Find out more about

Endress+Hausers unique training:
www.us.endress.com/training
CIRCuLATION AuDITED juNE 2014

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

Pharmaceuticals
Rubber & Miscellaneous Plastic Products
Stone, Clay, Glass & Concrete Products
Textile Mill Products
Tobacco Products
Total Circulation
3,522
3,496
2,855
1,733
1,047
100
60,020
CT1503_05_07_TOC.indd 7
3/3/15 9:47 AM
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EDITORS PAGE
cozy Up to dhS
s we go to press, the U.S. Congress is threatening to suspend funding for the Department of Homeland Security (DHS). Some
members are even calling for its dissolution.
But assuming its still around when you read
this, you might consider enlisting DHS in your
efforts to improve cybersecurity.
Many of you folks think cybersecurity is all
about technology, said Gregory Touhill, retired brigadier general and now deputy assistant secretary of cybersecurity operations and
programs at DHS, speaking to attendees of the
recent ARC Forum. Im here to tell you cybersecurity is not a technology issue; its a riskmanagement issue.
Start by recognizing the full value of your assets. Do you know how much your information is worth? Touhill asked. Businesses too
often fail to account for intellectual property
when determining the value of at-risk assets.
Recognize that cybersecurity is a 24/7 responsibility, and that no single piece of software or other technology offers fail-safe proection against cyber threats. Threats will hunt
you down at home to get access to your work,
Touhill said. Theyll hack your home network
to get a vector.
Its not just nation-state bad actors or individuals who are looking to sell stolen protected information. Hacktivistsfolks who dont necessarily agree with your companys mission or
core values, may look to damage a company,
Touhill said. Then there are those in your own
organization who are simply stupid, he said.
Many industrial control systems were not
designed for security. Companies are adding
potentially vulnerable capabilities like remote
access, wireless and mobile, with no dedicated
on-site cybersecurity expertise. They may need
help fitting these into a security strategy.
With that in mind, on Feb. 12, DHS announced a new Critical Infrastructure Cyber Community C Voluntary Program. Pronounced c-cubed, C is a public-private
Paul Studebaker
partnership designed to help industry adopt

the National Institute of Standards and Technology (NIST) Cybersecurity Framework. The
framework consists of standards, guidelines
and best practices to protect critical infrastructure through cyber risk management.
Touhill was at ARC to announce the C program and advised attendees to adopt NISTs
five-pronged, defense-in-depth core:
1. Identify and inventory your valuables. Put
an asset valuation on your intellectual property,
and put that value on your balance sheet.
2. Protect them appropriately, according to
their value.
3. Detect aberrant behavior. Get the tools
and training to know when youre under attack.
4. Respond according to a plan you develop
before youre attacked. Practice the plan.
5. Recover, again with a practiced plan.
The goals of the C Voluntary Program are
to help industry increase cyber resilience, to increase awareness and use of the Cybersecurity
Framework, and encourage organizations to
manage cybersecurity as part of an all-hazards
approach to enterprise risk management.
Think of it as a DHS community outreach
program for NIST. First, help yourself,
Touhill said. The government cant keep you
free and give you absolute protection. Put risk
management on your corporate agenda.
Then take advantage of your tax dollars at
work. Touhill said DHS offers help through the
Cyber Information Sharing and Protection Act
(CISPA), where companies can anonymously
share information about cyber attacks. It provides cybersecurity evaluations, and consults
and sends emergency teams into the field to
respond to attacks. DHS also issues bulletins
about emerging cyber threats.
Its a cyberhood neighborhood community, Touhill said. We need to watch it.
Editor in chiEf
pstudebaker@putman.net
Businesses too
often fail to account
for intellectual
property when
determining the
value of at-risk
assets.
CT1503_09_Editorial.indd 9
3/3/15 9:46 AM
800 453 6202
3/3/15 10:13 AM
CONTROL ONLINE
Essentials of Network & Security Services
And the Winners Are. . .
very year, our readers weigh in on who they think

provide the best technology. This time, nearly
1,000 respondents cast their votes for the suppliers
that provide the best process automation products and
services in the main disciplines and primary process
industries in nine overall product categories and in 78
subcategories. Check out their choices at www.controlglobal.com/articles/2015/control-readers-namethe-best-process-automation-suppliers-of-2015/.
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IN NUMBERS
End Users Come Together to
Pick Winners of 23rd Annual
Readers Choice Awards
Winning Hearts and Minds for System Upgrades

Looking forward to your next system upgrade with the
same excitement as your next root canal? Who can
blame you? There are more pitfalls in a system upgrade than potholes on Rust Belt highways in March.
One of the biggest is getting the folks who use the
system to support the changes. In How to Get Engineers and Operators on Board for Your Next System
Upgrade, veterans Greg McMillan and Stan Weiner
share their advice on this challenge. www.controlglobal.com/articles/2014/how-to-get-engineers-andoperators-on-board-for-your-next-system-upgrade/.
Free Fieldbus Advice

Field Instrumentation Technical Handbook is a useful compendium of physical
constants, tables and information no engineer responsible for field instrumentation should be without. Its been required reading in many companies for many
years. Dont start your next field instrumentation project without it. Download
your free copy now. www.controlglobal.com/whitepapers/2005/52/.
Valve Positioners? Flow Measurement?

A lot of time and money can be spent deciding
which valves need positioners and which flows
need measurement. We tend to look at short-term
costs such as hardware and not the cost of troubleshooting and the implications on plant performance. In this Control Talk blog, we look at common misconceptions as to whether flow and valve
position control should be used. www.controlglobal.com/blogs/controltalkblog/secondary-flowvs-valve-position-control-tips/.
A top-level view of critical network

security issues including how to implement proper infrastructure, securing
remote access and how the IIoT affects network security. www.controlglobal.com/whitepapers/2015/essentials-of-network-and-security-services/
Proof Testing level Instruments

Part of validating the safety function in
a level instrument is the requirement
for regular proof testing. But full testing
can lead to increased risk and process
downtime. Find out how partial proof
testing can save millions of dollars and
maintain required safety ratings. www.
controlglobal.com/whitepapers/2015/
proof-testing-level-instruments/
Flow and Level Technology Report

Dont miss this free 70-page PDF covering the latest trends in flow and level
instrumentation, including adaptive
level control, fiberoptic flowmeters and
advances in flow instrumentation. It
also contains a collection of back-tobasics tutorials, featuring our most popular tutorial everA Beginners Guide
to Differential Pressure Transmitters
plus tutorials on magnetic flowmeters,
bidirectional flow measurement, ultrasonic continuous level measurement
and radar level measurement, as well
as a collection of case studies and application stories. Go to www.controlglobal.com/assets/wp_downloads/
pdf/141027-Contol-ebook.pdf for the
complete ebook.
ControlGlobal E-News
Multimedia Alerts
White Paper Alerts
Go to www.controlglobal.com and
follow instructions to register for our
free weekly e-newsletters.
Updated every business day, the Control Global online magazine is available at no charge.
Go to www.controlglobal.com and follow instructions to register for our free weekly e-newsletters.
M A R C H / 2 0 1 5 www.controlglobal.com
CT1503_11_web.indd 11
11
3/3/15 9:48 AM
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Emer
G N I K A E P S YL L A C I N H C E T
FEEDBACK
IN MEMORY OF JULIE CAPPELLETTI-LANGE,

VICE PRESIDENT 1984-2012
1501 E. WOODFIELD ROAD, SUITE 400N
SCHAUMBURG, ILLINOIS 60173
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Managing Editor: NANCY BARTELS
nbar tels@putman.net
Senior Technical Editor: DAN HEBERT
dheber t@putman.net
Contributing Editor: JOHN REZABEK
Columnists: BLA LIPTK, GREG MCMILLAN,
IAN VERHAPPEN, STAN WEINER

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Three Reasons Big Data Is a Big Deal

I read with interest your Control Report
column on page 78 of the January issue
(www.controlglobal.com/articles/2015/
big-data-is-no-big-deal/), and Id like to offer a couple of add-on points.
While it is true that big data is just
data, the big deal, which Id translate
into improved profitability for customers,
comes when you aggregate and analyze
all that data in new ways and derive new
outcomes from them. The combination of
computing power, connectivity and cloud
infrastructure with high-fidelity data from
fleets of like devices and advances in analytic algorithms are driving new levels of
equipment upside and performance.
The Internet of Things (IoT) becomes really useful when people place
enough emphasis on the T, meaning
that acquiring, aggregating, analyzing and
presenting data is the starting point for
new value equations, and the opportunity
to automatically drive enhanced behaviors
back into the Thing under control presents a new dimension of value.
The third opportunity comes from
optimizing the fleet based on real-time
connectivity between assets, plus fleetlevel algorithms. A good example of this
is the wind farm optimization technology
from GE that analyzes multiple sources
of data from sensors and each turbine in
real time, then selectively powers/de-powers individual turbine blades to maximize
performance for the complete field.
I think the IoT can be a huge deal for
customers that stretch its capabilities in
new ways.
BERNIE ANGER
Bernie.anger@ge.com
NERC CIP Does Make the Grid Safer

In response to Joe Weiss blog post of Jan. 19
(www.controlglobal.com/blogs/unfettered/
the-nerc-cips-are-not-making-the-gridmore-secure-or-reliable/):
I totally disagree about NERC CIP not
making the grid more secure or reliable.
Just a few reasons. I have seen where control systems were operated without malware and ultimately became infected. At
least NERC CIP forces utilities to adopt

best operating practices for cybersecurity. Some of the rules dont seem to make
sense, but theyre many times a compromise on what is practical. Control systems
are not always patched as recommended.
NERC CIP pushes the utility to patch as
regularly as practical. Even the vendors
of control systems
have had to learn
their systems better
as theyre pressed by
their customers to
document the used
ports and services
and pare down the
unused. Changing
passwords and disabling default accounts are but a few of the
many best practices that are being pushed
by NERC CIP. Its truly my belief that if
not pushed by NERC CIP, many utility
companies would not adopt best practices
and would be very vulnerable and insecure. The only way I see that NERC CIP
doesnt make the grid more secure and reliable is if the rules are not followed or [if
theyre] circumvented.
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GREGORY BRYANT
gregor y.br yant@duke-energy.com
No One Protocol for the Internet of Things

Regarding, John Rezabeks February column (www.controlglobal.com/articles/2015/
the-internet-of-things-paradise-may-be-farther-away-than-it-appears/): I think were
destined to have a multiplicity of protocols in
our facilities. Actuators and sensors will be at
the level of the not-Internet of Things; Ethernet makes no sense there. But connecting
AS-interface, IO-Link, FF, HART and ProfibusPA to the Industrial Internet of Things
(IIoT) through intermediaries to Ethernet
will allow integration with IIoT. I see Profinet as the backbone, with Profinet-specified
proxies mapping data from the sensor level.
Profinet connects devices to the controller,
then OPC UA makes sense as the protocol
upwards from the controller to the cloud/big
data/analytics.
CARL HENNING
carl.henning@profinet.com
CT1503_13_Feedback.indd 13
13
3/3/15 10:09 AM
LESSONS LEARNED
Control and Automation50 Years of Progress

BL A LIPTK
liptakbela@aol.com
hen I started to work as a process control engineer in the late 1950s, the toilet
float and the thermostat were considered
to be automation. At that time, the main job
of the instrument department in a plant was to
clean plugged pressure taps and stuck control
valves, while our control panels were full of
pushbuttons, blinking lights and manual loading stations.
My Past
I taught process
control in the
chemical
engineering
department at Yale,
not because Yale
didnt like
automation, but
because the faculty
didnt know
what it was.
14
In 1956, we Hungarians fought for freedom

and independence, and tried to get rid of Soviet occupation. We used the Molotov cocktail
and small arms against their 2,400 tanks. Obviously, we were crushed, and 250,000 young and
educated Hungarians (2.5% of the population)
escaped. I was one of them.
Later, I received a scholarship at the Stevens
Institute of Technology and graduated there. At
this point, I got lucky because a former commissioner of President Roosevelt, Sam Russell,
had just started an engineering firm, and he
hired me. During World War II, Sams job was
to replace the natural rubber supplies that were
blocked by the Japanese with synthetic rubber.
He didhe knew how to get things done.
His engineering design firm, Crawford and
Russell, which focused on plastics, was a success, and I, as his chief instrument engineer,
had to hire more and more people because jobs
were coming in left and right. I remember it
was an ABS plant for GE in 1959 where I first
used a computer. It was little different from
John von Neumanns IAS (Figure 1). At that
time, vacuum tubes had just been replaced by
silicon transistors, and nobody had yet heard of
MOS semiconductors or microprocessors.
So I had to hire people. With my thick Hungarian accent and only 25 years of age, I did
not feel comfortable hiring experienced engineers, so I asked Sam to let me hire smart, fresh
graduates from the best schools, and to let me
use every Friday to teach them our profession.
He agreed, and in a couple of years I had the

best instrument engineering department of 26
kids. I also had a foot-high pile of my Friday
notes accumulated on the corner of my desk.
At this point I got lucky again, because an
old- fashioned publisher named Nick Gronevelt
visited me. He reminded me of my grandfather,
as his hair was parted in the middle and his
watch was held by a gold chain hanging from
his vest-pocket.
Nick asked why I didnt teach from an instrument handbook and I told him, Because we
have none.
So let us turn your Friday Notes into one,
he said. And so, in 1963 the first edition of
my Instrument Engineers Handbook (IEH)
was published. The co-authors included such
names as Page Buckley, Hans Baumann, Greg
Shinskey, Paul Murrill, Les Driscoll and Cecil
Smith, and the preface was written by Edward
Teller, who understood the future of automation. I dedicated the book to the Hungarian
Freedom Fighters.
Today, 50-plus years later, I am working on
the fifth edition.
Where Are We Today?

In the 1950s, our profession was called instrumentation. Now it is called automation. Today
we have robots on Mars that can vaporize the
rocks by laser to determine their composition.
Soon, while sitting in our hydrogen-fueled,
driverless cars, we will be able to order pizza to
be delivered hot by the time we get home and
our smart car is parking itself.
At the time of the first edition, I was teaching process control in the chemical engineering department of Yale University, and my
handbook was published by the electrical engineering division of Chilton. Why? It was not
because Yale or Chilton had something against
our profession. No, it was because they did not
even know that the profession of process control existed. So how much change occurred
www.controlglobal.com M A R C H / 2 0 1 5
CT1503_14_16_Lessons.indd 14
3/3/15 10:11 AM
Tank overfill.
In the best case, you have to clean up.
In the worst case, you end up in court.
Want to sleep well at night?
YOU CAN DO THAT

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Emerson_RTG_API2350_Choice_awards_ControlM_7x10_2015.indd 1
3/3/15 10:14 AM
2015-02-19 09:49
Lessons Learned
over the past 50 years? Not that much.

To my knowledge, one still cant receive a doctorate in
automation, and only a few universities offer a bachelor of
science or even associate degrees in automation and control
engineering. There are a number of certification programs,
and ISA currently offers twoCertified Automation Professional (CAP) and Certified Control Systems Technician
(CCST). Online certificates also are offered at the University of Kansas and at Dalhouse University.
Man vs. Machine

While much has been done to advance automation, even
more remains to be achieved. We live at a time when cultural attitudes are changing as we debate the proper role of
machines in our lives. Our culture now accepts that there is
no harm in machines substituting for the routine functions
of the human brain.
While in everyday life we accept the spread of automation, in most of our industries, the operator is still the boss.
Automation is seldom used to protect against operator errors.
Safety statistics show that the number-one cause of industrial accidents is human error. One could refer to ThreeMile Island, where the operators injected water into the instrument air supply; to the BP accident, where there was no
automation to keep the drilling pipe straight; to the ferry
Ours is the profession that can simultaneously

maximize production and safety while
minimizing operating and energy costs.
accident in Korea, where safety overrides were not provided
to prevent the captain from turning sharply into a fast ocean
current; or to airplane accidents, where the pilots were not
prevented from landing at the wrong speeds or gaining altitude too fast. The list goes on.
In other words, the culture of trusting man more than
machine has to change. It has to be recognized that safety
provided by automation is also manmade, but it is made by
different men than the panicked rooky operators running
around in the dark at 2 a.m., as occurred at Chernobyl. No,
safety automation should be designed by professional control engineers, who have spent months to identify all potential what if sources of possible accidents, and have evaluated their potential consequences before deciding on the
emergency actions that are to be triggered automatically
when the potentials for such accidents arise.
It is this hazard and operability study (HAZOP) during
16
mr. von neumanns marvelous machine

Figure 1. The IAS was the first electronic computer built at the
Institute for Advanced Study (IAS), in Princeton, New Jersey,
between 1945 and 1951 by John von Neumann and his team.
the design phase of the plant that is the key to safety, not dependence on the action of panicked operators. The choice
is not between depending on humans or machines. The
choice is between trusting the judgment of two kinds of peoplethe operator or the HAZOP team.
For absolute safety, what is needed is override safety control (OSC), which cant be turned off or overruled by anything or anybody. When the plant conditions enter a highly
accident-prone, life-safety region, the uninterruptible, safe
shutdown of the plant must be automatically triggered.
The functioning of OSC must be so designed that it cant
be stopped by cyber attacks because it is not connected to
the Internet at all. It cant be overruled by the operators and
cant be modified or turned off by them. In short, once the
OCS is activated, the plant must be shutting down under
the preplanned, totally automatic HAZOP control, and
nothing and nobody can prevent that.
The status Quo

During the past 50 years, some progress has been made, but
not enough. Ours is the profession that can simultaneously
maximize production and safety while minimizing operating and energy costs. Optimization through automation can
simultaneously increase GDP and profitability, and can do
it while also reducing both pollution and energy consumption. We can increase productivity without using a single
pound of additional raw material and without spending a
single additional BTU of energy, plus we can protect our
industries from human errors, sabotage or cyber terrorism.
My hope is that in the next 50 years this finally will be
understood.
Bla liptk, Pe, automation and safety consultant, is also editor of the instrument
and automation engineers handbook. he can be reached at liptakbela@aol.com.
www.controlglobal.com M a r c h / 2 0 1 5
CT1503_14_16_Lessons.indd 16
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ON THE BUS
better diagnostics for the Physical Layer
hy is it, after weeks of seemingly troublefree plant operation, the phone rings on
the holiday weekend when the goose is
in the oven and the table is set for dinner? Fortunately for me, the crew on shift was prepared
to muddle through until normal business hours
after the weekend. They just wanted to know
whether the problem they were seeing was
likely to cause a spurious trip of some production-critical pumps. Dinner was saved thanks
to the fact that we had proven years ago that a
bad indication from a suction pressure transmitter would hold last value, and the associated interlock wouldnt trip. While a persistent
bad indication would defeat a necessary protection that prevented significant mechanical
damage, the disruptions were fleeting enough
to remain a mere annoyance.
When the issue was investigated on the next
normal business day, it was immediately apparent that the segment was failing due to waterlogged and corroded terminals in an intermediate terminal box. The little enclosure was
designed to be weather-tight, but weve all seen
how simple it can be to defeat a systems accommodations for preventing moisture entry.
When a limit switch cover is removed to
make an adjustment, a frail-looking O-ring
flops out. Its easily misaligned or omitted when
the cover is reassembled. How many covers
have you found loose, missing gaskets or simply open to the environment? Just condensation of moist air from the warmer seasons can
be enough to begin corruption of circuit boards
and terminations. In all but the most arid climates, anyone who has spent any time servicing instruments knows the experience of removing the cover of a troubled instrument and
having a cup of water drain out.
The most experienced troubleshooters,
such as Emerson Process Management Distinguished Technologist Marcos Peluso, agree
that defects and oversights in the physical
layertwisted-pair copper, power supplies, ter-
john Rez abek
minals, conduit systems and enclosuresaccount for over 90% of the problems encountered in field device networks, even 4-20 mA.
Pelusos colleagues have devised a solution,
at least for 4-20 mA loops that connect to the
top-end 3051 HART pressure transmitter:
Power Advisory diagnostics for advanced loop
integrity. The diagnostic is communicated to
any HART-capable asset management software
and alerts the end user to impending issues
with moisture, cable integrity, terminal corrosion and power supplies. Since these physical
layer disorders usually take some time before
they affect the signal, a weekly report should allow the end user to detect and avert a problem.
But what about the rest of the devices?
Profibus PA and Foundation fieldbus have
had a repertoire of physical layer diagnostics
for nearly a decade, ranging from simple handheld devices such as the Relcom FBT-6 to thefeature-laden Pepperl+Fuchs field diagnostics
handheld and advanced diagnostics module
(ADM). All these tools can alert the user to defects in the physical layer. The Pepperl+Fuchs
units use an embedded expert system to suggest likely causes for the detected symptoms
and recommend remedial actions. But while
they can identify an ailing network, you might
still have challenges determining the precise
location of the defect.
Couplers providing simple short-circuit protection for each fieldbus spur substantially improved the fault tolerance of fieldbus segments.
But Pepperl+Fuchs has designed a new generation of intelligent couplers that can detect and
mitigate degradation or progressive failures owing to water ingress, sloppy terminations, high
vibration, corrosion, cable abuse and device
faults on each individual spur.
If such couplers can perform as promised,
measurement and control professionals using
them can count on more peaceful holidays in
the future. Perhaps the goose of physical layer
defects is finally cooked.
contributing Editor
Jrezabek@ashland.com
Anyone who
has spent any
time servicing
instruments knows
the experience of
removing a cover
and having a cup of
water drain out.
M a R c h / 2 0 1 5 www.controlglobal.com
CT1503_19_OTB.indd 19
19
3/3/15 10:21 AM
Without Wires
isa takes on asset management

ian verhappen
Director,
inDustrial automation ne t works
iverhappen@industrialautomationnetworks.com
The documents will

describe a set of
coordinated
activities for an
organization to
optimize the value
from intelligent
devices.
20
sset management is a critical, but underused capability of modern control systems.

The ISA108 Intelligent Device Management (www.isa.org/isa108) committee is tacking the subject, and is now close to completing
its first document, ISA-dTR108.1-2015, Part 1:
Concepts and Terminology.
The purpose of ISA108 is to define standard
templates of best practices and work processes
for the implementation and use of diagnostic
and other information provided by intelligent
field devices in the process industries. The
three-part document set will be based on the
equipment lifecycle phase or by other means
necessary to provide work processes with appropriate role definitions. The various parts of the
standard series identified to date address the
following aspects of Intelligent Device Management (IDM):
Part 1: Concepts and Terminology describes IDM concepts and terminology necessary. It gives an overview of the basic concepts
of how intelligent devices can be managed and
how this device management plays a larger role
in the overall objectives of a facility throughout
its lifecycle.
Part 2.1: Configuration and Revision Management specifies work processes related to
configuration and revision of intelligent devices, including establishing an IDM program,
engineering and setting of parameters, replacement and tracking, storing and updating related
data in configuration databases, and auditing
by documenting work processes for management of intelligent device configuration integrity, configuration adequacy and configuration
congruency for a full facility lifecycle.
Configuration integrity refers to the application-oriented processes for establishing and
maintaining design integrity, including processes for managing change. Configuration adequacy refers to device-oriented processes that
provide assurance that necessary functions are
properly and fully configured, and that unde-
sired functions in the device are disabled. Configuration congruency processes assure that
the multiple databases where intelligent device
configuration data are stored all have the same
data, and that configuration changes propagate
accurately and in adequate time.
Part 2.2: Diagnostics Utilization specifies
multiple work processes related to diagnostics
done by intelligent devices, including establishing an IDM program, training, maintenance of
intelligent devices, scheduling of maintenance,
audit and continuous improvement.
Part 2.3: Procedure Management specifies
multiple work processes not covered in other
parts, including inspection and function testing of intelligent devices to assure that correct
and appropriate manual and automated procedures are used for support of intelligent devices.
Part 2.4: Calibration Management addresses the program activities and work processes for managing calibration procedures,
including inferential (analytical) and physical measurements, such as cover calibration
checks, statistical analysis of calibration checks,
decisions about calibration versus replacement,
and actual calibration requirements.
The last of the Part 2 documents is Part 2.5:
Intelligent Valve Management, covering activities and work processes, including on-line
diagnostics and repair, as well as off-line turnaround, diagnostics and repair processes, including in-line procedures and shop repair related to final control elements.
Part 3: Implementation Guide(s) provides
guidance on implementation of intelligent device management and will be developed upon
completion of the Part 2 documents.
Working groups have been identified for
each of the Part 2 documents, and the first document has been submitted to the IEC as a new
work item under SC65E. For more information
or to participate, contact Charley Robinson
(crobinson@isa.org) at ISA or your countrys
national standards body.
CT1503_20_Wireless.indd 20
3/3/15 10:22 AM
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In Process
Get ready for Industry 4.0

Hannover Fair preview shows how smart devices and the Internet promise to streamline
manufacturing for future productivity.
ike any earthshaking event, Hannover Messe (www.hannovermesse.

de) is so huge that its pre-shocks
start to arrive way before the event itself.
This years version of the worlds
largest manufacturing exhibition
will be held April 13-17 in its usual
26 halls in Hannover, Germany, but
organizers and more than 40 exhibitors provided a comprehensive sneak
peek of the fairs Industry 4.0 and related solutions on Feb. 3 at the ewerk
hall (www.ewerk.net). Organizers expect the fair to top the 6,400 exhibitors it hosted two years ago. Theyll
be joined by India as the events 2015
partner country, which will feature
its new Make in India program to
make it easier for manufacturers to do
business there.
Dr. Jochen Koeckler, member
of Deutsche Messe AGs managing
board, reports his organization asked
manufacturers if theyre ready for Industry 4.0 or the 4th Industrial Revolution, and the answer is almost always
no. Research shows 50% of those in
manufacturing never heard of Industry
4.0, and 25% have heard of it, but dont
know what its about, said Koeckler.
So the message is that we need to be
prepared because another recent study
found that an 18% increase in efficiency and a 15% increase in savings
will be possible over the next five years
thanks to the productivity enabled by
Industry 4.0.
To achieve these gains, Koeckler reports that Industry 4.0 will also bring
profound changes to industrial production models and energy systems. In factories, there will be a move away from
mass production as more customers demand customized products at the same
low prices as for mass-produced goods.
22
Industry 4.0 InsIders

Johann Hofmann, senior vice president of ValueFacturing at Maschinenfabrik Reinhausen GmbH, Vijay Gokhale, ambassador of India to Gemany, and Dr. Jochen Koeckler,
member of Duetsche Messe AGs managing board, answer questions from the audience at the Hannover Fair Preview last month in Berlin.
Likewise, energy grids will need to become more intelligent, so they can balance and deploy available power, gas
and heat from many sources.
Koeckler adds the answer to these
challenges is Integrated Industry,
which is the smart, digital networking and integration of manufacturing systems and processes. Integrated
Industry is about allowing machines
and workpieces to communicate with
each another, which will allow entire
production lines to autonomously and
dynamically reconfigure themselves,
and make small-batch and one-off
production commercially viable in
large plants.
Manufacturing in Europe, North
America and Asia will all depend on
Industry 4.0, but most companies still
dont know what they need to do to
be ready for it, adds Koeckler. What
they need to do is form close networks
with all stakeholders involved in their
production processes, and Hannover

Messe 2015 with its theme of Integrated IndustryJoin the Network!
will show them how. After Hannover
Messe, visitors will be able to say, yes,
were ready for Industry 4.0, because
theyll be able to take home ideas, and
achieve more competitive production.
showcase of solutions
As usual, the heart of Hannover Fair
will be its thousands of exhibits and
their solutions to help make manufacturers more efficient. Here are some
highlights of the technologies and
products that will be exhibited:
ABB (www.abb.com) will demonstrate its new range of swirl and vortex
flowmeters that can measure volume
mass energy and flow in one device.
The SwirlMaster comes in standard
(FSS430) or extended (FSS450) versions with ABBs swirl technology that
enables very short upstream and down-
CT1503_22_26_InPro.indd 22
3/3/15 10:22 AM
Keep Your Process

and Plant Safe
Moore
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oore IIndustries:
ndustries: L
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off P
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rotection T
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hat C
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Cracked
ra c ke d
Protect your valuable processes by turning to Moore
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Add layers of protection to existing safety systems
Isolate an SIS from a basic process control system
Share, split and pass valuable HART data
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Watch videos, download white p
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3/4/15 9:04 AM
IN PROCESS
stream piping requirements. FSS430

provides an analog output with HART
communication, and FSS450 has functions usually found in flow computers,
such as steam-power calculations, with
and without condensation return, and
the ability to receive signals from other
transmitters for density, temperature
and pressure via an analog 4-20 mA
signal. Both flowmeters have ABBs
universal graphic display, digital outputs configurable as pulse, contact
and frequency output, and an optional
integrated temperature sensor. Also,
ABBs new VortexMaster has a lowercost, entry level version (FSV430) and
an extended version (FSV450) with the
same enhancements as FSS450. Both
VortexMaster versions are available in
a remote design with up to 30-meter
cable lengths.
Beckhoff (www.beckhoff.de) will

show many-core control with its
C6670 industrial server, which features 12, 24 or 36 processor cores and
64 to 2,048 GB of RAM. Each core
also employs Beckhoffs TwinCAT 3.1
automation platform. This means not
only are PLC, motion control, robotics and CNC functions integrated into
one software system and executed on
one CPU, but condition monitoring
and energy management functions of a
smart factory are included, too.
Phoenix Contact (www.phoenixcontact.com) will launch its new PSR
Mini safety relays, which it reports are
the worlds slimmest at just 6 mm wide,
but have positively driven contacts that
maintain the power and safety of larger
relays. Requiring up to 70% less space
and needing only one enabling con-
tact, PSR Minis design is based on a

thin, powerful basic relay characterized by minimal space requirements,
low energy consumption and high system availability. They can switch up to
6 A, are compatible with many signal
transducers, and are approved for use
in many different mechanical and process applications, including distributed
systems in potentially explosive areas.
Cybersecurity Needs
to Be a Team Sport
One of the biggest mistakes a company

can make in thinking about cybersecurity is thinking of it strictly as a technology concern, a Department of Homeland Security (DHS) official told ARC
Forum attendees at the annual ARC
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Available in five different body sizes, the

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The Ranger QCT features Quick Change Trim that

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24CAS-226A.indd
www.controlglobal.com
1
M A RC H / 2 015
1/12/15 11:08 AM
3/3/15 10:23 AM
In Process
Industry Forum event in February in

Orlando, Florida.
Many of you folks previously thought
cybersecurity was all about technology,
said Gregory Touhill, deputy assistant
secretary of cybersecurity operations and
programs at the DHS and a retired brigadier general. Im here to tell you cybersecurity is not a technology issue; its a
risk-management issue.
As such, companies need to ensure
cybersecurity isnt relegated to ITspecific discussions, but is a staple of
meeting agendas and a factor in all decisions that address business risks.
Do you know how much your information is worth? Touhill asked. Businesses too often fail to account for the
value of their intellectual property when
they do asset valuations, he said. And
the financial threat and reputation risks
posed by the theft of intellectual property or the exposure of client or personnel information can destroy a business.
Currently in the commercial sector, the average length of time between
when a security breach occurs and
when the affected business detects that
breach is more than 240 days, Touhill
said. Thats unacceptable. Id like
to know [as a business owner] when
theyre coming through the gate, not
when theyre going out the gate.
Getting all employees to understand
that cybersecurity is a 24/7 responsibility and that no single piece of software
or other technology is a fail-safe protection against cyber threats is essential,
according to Touhill.
Are you training your workforce to
take the same cybersecurity precautions
at home as they do at work? Touhill
challenged. Sophisticated hackers have

begun targeting companies high-ranking employees at home, he said, trying
to get access to sensitive business information made vulnerable when employees work away from the office on
less-well-protected devices or using lesssecure networks.
And its not just nation-state actors or
individuals looking to sell stolen protected information who pose a cyberthreat, Touhill added. Hacktivists
folks who dont necessarily agree with
your companys mission or core valuesmay look to damage a company
by exposing sensitive business information. Hacktivism is something that
wise companies keep in mind as part of
their risk calculus, he stated.
Mitigation of cyber risks is multifaceted, Touhill noted. Technology alone
Sharing passion.
Cooperating as partners.
Finding solutions.
You are the expert in your field and
Pepperl+Fuchs will treat you as one.
Working as partners, we share our
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The result is an innovative solution that
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www.pepperl-fuchs.com
25
3/3/15 10:23 AM
Got HART Devices?
IN PROCESS
GET
CONNECTED!
MACTeks family of
HART modems...
HEARD ON THE STREET

Asahi/America Inc. (www.asahi/america.com), has named Daniel Anderson to
the office of president and CEO. Former president and CEO Hidetoshi Hashimoto
will remain with the company as chairman of the board of directors. Anderson assumed his new position on Jan. 1, 2015.
F.W. Webb Company (http://fwwebb.com/) is the new authorized distributor for Opto
22 industrial automation hardware and software in the Northeast. The Process Controls Division of F.W. Webb is expanding its distribution territory for the Opto 22 product line into each New England state and New York, New Jersey and Pennsylvania.
USB
Belden Inc. (www.belden.com) has formed a partnership with Shanghai Hi-tech

Control System Co. (www.hite.com.cn/en/channel/433.html) to jointly develop,
market and sell new industrial networking solutions.
M&M Software GmbH (www.mm-software.com) of St. Georgen, Germany, has become a sponsoring member of the FDT Group (www.fdtgroup.org). M&M Software will
take a seat on the board of directors and the executive committee of the FDT Group.
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Iconics (www.iconics.com) has achieved OPC UA Client Lab Certification from

the OPC Foundation (https://opcfoundation.org/) for its Genesis64 V10.85 Platform Services.
is not going to solve all of your problems,

he said. Cybersecurity requires a vigilant
mindseta company-wide awareness
of and respect for the multitude of very
real business risks posed by malware,
phishing scams and more. If any salesman comes to you and says, I have the
solution thats going to make you bulletproof, then alarm bells should be going
off in your mind, he said.
Touhill advised attendees to take a fivepronged, defense-in-depth approach to
cybersecurity: identify, protect, detect, respond and recover.
The first step, identification, involves
taking stock of the business information
assets and determining which of these
are of highest value and most critical to
the business. Protection and detection
require a commitment on the part of
all employeespermanent and contract
workers in all functions of the business.
And its vital for companies to have
and, of equal importance, to rehearsea
response and recovery plan they will employ in the event of a security breach.
You have to have a plan and you
have to practice it, he said. How many
26
times does your company practice [dealing with] a major disaster with your IT
infrastructure?
The time to generate a response
plan to a hack is not the morning of an
attack, Touhill noted.
Nanoline Contest
Winners Announced
A team from Benton Central Jr./Sr. High
School in Oxford, Indiana, has won Phoenix Contacts (www.phoenixcontact.com)
2015 Nanoline Contest. The grand prize
is a trip to Louisville, Kentucky, in April.
Team members include Blake Stawsma,
Justin Shultz, Wil Barce, Kyle Laramore,
Bryce Nehrig and Nate Post. The team
designed and built the Fully Automated
Nanoline T-Shirt Cannon, which runs
on Phoenix Contacts Nanoline Controller and uses the intuitive, flowchart-based
nanoNavigator software to control the application. The group will travel to Louisville in April, where they will observe the
final rounds of the VEX Robotics World
Championship.
3/3/15 10:23 AM
3/3/15 1:23 PM
RESOURCES
In the Loop
Controls Monthly Resource Guide
THIS SYSTEM IS CLOSED
This is a basic tutorial on closed-loop
control systems. It covers the basic definitions and descriptions of how closedloop systems work, a discussion of
closed-loop summing points and how
to use them, transfer functions, multiloop closed-loop systems and closedloop motor control. The direct link is
www.electronics-tutorials.ws/systems/
closed-loop-system.html.
ELEctronIcs tutorIaLs
www.electronics-tutorials.ws
WHAT IS PID CONTROL?

This tutorial is a basic discussion, with
illustrations, of the principles of proportional integral derivative (PID) control and how its used with controllers.
It also covers tuning rules and starting settings for common control loops.
The direct link is at www.expertune.
com/tutor.aspx.
ME tso E xpErtunE
www.exper tune.com
CASCADING CONTROL
A brief blog post by Jacques Smuts, author of Process Control for Practitioners
(http://amzn.to/16sFjEM), covers cascade control basics: what it is, how to
manage it, its advantages and disadvantages, when you should use it, and
when you shouldnt. The direct link
is at http://blog.opticontrols.com/archives/105.
optIcontroLs
www.opticontrols.com
BIG BOOK OF CONTROL LOOPS

Control Loop Foundation for Batch &
Continuous Processes, by Terry Blevins
and Mark Nixon, is a guide for engineers, managers, technicians and others who are new to process control, or
experienced control engineers who

are unfamiliar with multi-loop control techniques. After the traditional
single-loop and multi-loop techniques
that are most often used in industry
are covered, a brief introduction to advanced control techniques is provided.
A free 163-page PDF provides a Power
Point outline of the same material
at www.controlloopfoundation.com/
downloads/about-the-book/ControlLoop-Foundation-Overview.pdf. The
book itself is available from the ISA
website in both hardcopy and ebook
form in both English and Chinese.
Isa
www.isa.org
ZEN AND THE ART OF LOOP CONTROL

Process Control Hall of Famer F. Greg
Shinskey meditates on disturbance dynamics and the three classes of disturbances: setpoint changes, load variations and noise. Other meditation
subjects include internal model control, feedback, load response, identifying load components, dynamic difference, effects on controller tuning,
accommodating setpoint changes,
and more. Read Meditating on Disturbance Dynamics at www.controlglobal.com/articles/2011/meditatingon-disturbance-dynamics/?start=1.
controLGLobaL
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A SEVEN-STEP PROGRAM
The performance of industrial control
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It affects the stability, robustness and
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This white paper outlines a systematic,

seven-step approach for improving control system performance, and describes
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The paper is free, but registration is required. The direct link is at www.controlglobal.com/whitepapers/080502pas-7performancesteps/.
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PROCESS CONTROL FOR THE REAL WORLD

Practical Process Control is a free online ebook with contributions by multiple authors. Subject covered include
fundamentals, the components of control loops, graphical modeling, PID
controller design and modeling, tuning concepts, tuning using closedloop data, evaluating controller performance, the control of integrating
processes, advanced classical control
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direct link is at www.controlguru.com/.
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TUNE-UP TIME
This free guide offers a best-practices
approach to PID controller tuning. It
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Included are basic terminology, steps
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and other valuable insights. The direct
link is at www.yokogawa.com/us/technical-library/white-papers/pid-tuningin-distributed-control-systems.htm.
Yokogawa corporation of america
www.yokogawa.com
If you know of any tools and resources we didnt include, send them to ControlMagazine@Putman.net with
Resource in the subject line, and well add them to the website.
28
CT1503_28_Resources.indd 28
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3/3/15 10:19 AM
CONTROL SYSTEMS
OF THE FUTURE
Through the looking glass

of emerging technologies
by William L. Mostia
CT1503_30_38_CoverStory.indd 30
3/3/15 10:51 AM
CONTROL IN THE FUTURE
ow might we expect emerging technologies to play out

in the world of process control? Successfully predicting
the future is difficult at best, so we sought out and consulted with industry visionaries and long-term planners to
see where there is consensus about how rapidly developing
operator interfaces, computing, data analytics and virtual reality will change our craft. Their informed speculation indicates these emerging technologies and others will be impacting our industries at an increasing, even amazing, rate.
Our list is by no means exhaustive, as many technologies
are just now emerging out of their cocoons, and theres no
telling what else might be lurking out there in companies
big and small, and in the garages of the DIYers.
Of course, the process industries are notoriously
conservative, with a large installed base of equipment that ranges from pneumatic to sophisticated digital control systems, all of which are currently making money. So while we will see rapid
changes in commercial technology, adaptation by
the process industries will be on a value-added basis and always dependent on the cultural acceptance of
the involved personnel.
Current Trends Are Safe Bets

First, we can expect continued incremental improvements
in our currently available control systems technology. Many
of our DCS systems are underutilized, and their future may
already be lurking within them or with the DCS vendors
current offerings.
Moores Law, the number of transistors in a dense integrated circuit doubles approximately every two years, is
expected to continue into the next decade or so, but may
slow from doubling every two years to doubling every three
years. Coming developments in carbon nanotube fieldeffect transistors, junctionless transistors, single-electron
transistors and memistors may well extend Moores Laws
life. So we will continue to see improvements in computing and memory, which will support the emerging technologies. Well get larger operator screens with higher resolutions, and control hardware platforms will run faster,
smarter and with more memory.
Network capacity will have to expand to meet demand,
placing pressure on the existing infrastructure. Process control algorithms will advance in sophistication, but the next
generation of systems will see self-aware controllers and sensors incorporating artificial intelligence (defined as capable
of cognitive and memory functions, resilience, awareness of
its environment and its place in the process context, etc.)
to develop advanced control strategies to achieve the
controller goals. Cloud computing will play
a part in the next generation of
DCS/SCADA, but the
extent and balance between the virtual and the hardware/

software world is unknown and controversial.
Control Rooms Center on the Operator

The trend of centralization of the control room remote from
the process area is likely to continue, says Pierre Skonnegard
of CGM (www.cgm.se) in Sweden, a partner with ABB
(www.abb.com) in designing the control rooms of the future. Skonnegard also felt that operator attentiveness, awareness and health would be given greater consideration.
The video arcade environment, with the operators sitting
during a substantial portion of their shifts looking at video
screens, can lead to operator health concerns. Chairs are being developed that will adjust automatically to the operators
physique using biometric sensing, and in the future, will
be able to monitor the operators health and attention level.
DCS consoles are already available that have two positions
to accommodate the operator sitting down or standing up,
with an easy transition between the configurations. Biometric sensing will be used to support security, and to allow the
control room to adapt to the people currently in it. Ambient
intelligence, where electronic systems and environments are
sensitive and responsive to the presence of people, will be
given greater attention.
Displays to Expand and Collaborate

Our displays will become even larger and in some cases
curved, with higher definition allowing us to display larger
amounts of data with higher resolution, which well be able
to see from farther away. We can display more than P&IDbased and physical process graphics to help operators deal
with Big Data and abnormal situations by providing rapid
access to information without having to navigate screens for
improved situation awareness. Its reasonable to assume that
operators will interact with the control system by talking (using natural language processing and Bluetooth technology),
as well as hand gestures, touch and the traditional pointing
device and keyboard.
Using large, edgeless displays, we can now build movie
theater- or wall-sized panels. For example, Saudi Aramco
has installed a wall of video 67 meters (220 ft) long by 3 meters (10 ft) tall with 150 screens by Barco in its Operation Coordination Center. It serves as a nerve center for all Saudi Aramco operations, and can display all their operational data.
Shades of full graphic panels!
Currently available displays embedded in tables, such
as the ABB 3D KPI dashboard, have horizontal or vertical
modes of operation, and can be used as collaborative workstations. Microsoft is introducing an 84-in., 4K Surface Hub
with state-of-the-art digital whiteboarding that could be
used as a collaborative workstation in the control room and
conference rooms.
31
3/3/15 10:51 AM
Control in the future
Clouds Work Better with fog

Cloud computing refers to remote, public Internet- or private intranet-based
virtual servers where application software and data may reside rather than
in local computers. These applications
may share resources and provide redundancy (dedicated and just-in-time).
Some of this represents virtualization of

local hardware, i.e., control functions in
the cloud while I/O is local. Cloud computing for process control would have
process control applications, other virtualized control functionality and data
residing in the cloud.
Issues of privacy, security and reli-
ability will delay the adoption of this

technology, even in local clouds. Still,
some cloud-based DCS products are
appearing, such as the Schneider Electric/Invensys Industrial Cloud Historian designed to deal with big data.
The cloud, in any case, will probably
hold the key to the next generation of
DCS/SCADA. Of interest in this area
is the Architecture for Service-Oriented Process (www.IMC-AESOP.eu)
project, whose goal is developing the
next generation of SCADA/DCS systems. The plant and corporate IT side
will likely adopt this long before the
control people.
Our ability to store information also
has risen exponentially, and the cost of
memory has come down tremendously.
In 2004, the cost of a megabyte of storage
was about $0.175; in 2014 it was $0.0085,
a reduction of 95%. Moores Law predicts
that memory costs will continue to fall.
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control systems and instrumentation to ensure
speed, support mobility and enable local control.
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On the other hand, one of the corollaries to Parkinsons Law is, Data
expands to fill the space available for
storage. Sensors are becoming more
pervasive and cheaper as well smarter,
offering more data. Digital bus communication will become the norm even
within legacy systems. Wireless is ex-
panding, allowing instruments to be

placed in many heretofore unavailable
locations, powered by batteries or by
power harvested from the environment.
We cant leave out the final elements,
where increased diagnostic data has
become available. Video cameras and
other sources only compound the prob-
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lem of overflowing data. For example,

a plant with just 300 tags, each transmitting just one measurement per second, generates more than 9 billion data
points per year. For the operator, engineer, manager or control system, having
all the necessary data to make decisions
is great and desired, but theres no such
thing as a free lunch. With this big flood
of data, we have become data-rich, but
information-poor, and can be easily overwhelmed by the quantity, velocity, noise
and uncertainty in the data.
This is where the cloud and data analytics come in. The common definition
of cloud computingusing a network
of remote servers hosted on the Internetis too simple for the process industries. Were averse to using the Internet
to store proprietary company information, and concerns about cybersecurity,
reliability, safety and liability are big issues. Our more likely configuration resembles a cloudy day, where multiple
external clouds use the public Internet,
private corporate clouds use the company intranets, and local plant clouds,
each providing cloud computing functions at their level, share applications,
computing and memory resources as
needed to provide data analytics on demand and dynamically.
In addition, as has been proposed by
Flavio Bonomi, et al., Cisco Systems,
in their paper, Fog Computing and Its
Role in the Internet of Things, we need
a fog layer with low latency, location
awareness, widespread geographical
distribution, mobility, a very large number of nodes, predominant wireless access, a strong presence of streaming and
real-time applications, and heterogeneity (Figure 1).
Data Analytics Poised to explode

Data analytics is the science of examining or analyzing large, small and sparse
quantities of raw data with the purpose
of drawing conclusions, finding relationships and converting the data into useful
information. Data mining is an example
of this. Data predictive analytics extract
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PrePare to See Your realitY augmented

Microsofts HoloLens augmented-reality goggles merge the physical world
with virtual reality by projecting
holograms into the users view
of physical space. The holograms may be of three-dimensional objects, a virtual physical
space or operator displays.
A built-in camera, computer, lenses and microphone enable the goggles to place the holograms appropriately in the operators view of
real space, and allow the operator to manipulate them via gesture, voice and gaze. Holograms also may be pinned in place so operators can move around them or through a virtual
landscape.
According to Wired magazine, HoloLens will be introduced this year to developers and commercial partners,
who will create applications and help Microsoft refine its
design and performance. When its performance and value

are proven, you might expect to start seeing it in control
rooms and on the plant floor as a tool for engineering and
operator interface, equipment maintenance and more.
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3/3/15 10:52 AM
AnAlytics turn DAtA into informAtion

Figure 2: Once analytics have massaged, manipulated and
crunched the data, and analyzed, collated and organized the
information, they must present it to the operator. Here, Honeywells Maxpro VMS analyzes and prioritizes video to support safety and security.
information from existing large data sets to determine patterns

and predict future outcomes and trends.
Data analytics will be used to take the Big Data in the fog
and/or cloud, and extract useful information for plant operators, engineers, supervisors and managers, as well as people
at the enterprise level. Data analytics also will be used to analyze video for security and safety in collaborative operations
and in support of artificial intelligence (AI) applications and
operator online and personal advisors.
Data analytics are already availableone example is
Honeywells Maxpro VMS for safety and security (Figure
2)but wider use is expected when the flood of data begins to overwhelm the existing systems. Once the data analytics have massaged, manipulated and crunched the data,
and analyzed, collated and organized the information, they
must present it to the operator or other plant personnel using
graphics and visualization tools. Processing speed will be of
the essence where real-time information is required.
Ai Beyond Siri
Weve become familiar with AI in the form of smart, virtual personal assistants (SVPAs), which entered the market
in 2011. Examples include Apples Siri and Microsofts Cortanasoftware agents that can perform tasks or services for
an individual. In process control, operator SVPAs will be
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The next new technology is Google

Glass, a form of augmented reality
where a view of a physical, real-world
environment is enhanced by computer-generated input such as text,
sound, video or graphics to provide additional information. It has the poten-
bl
e N 3.6
ow
world). There may be short-term activities where VR will excel, such as

in collaborative efforts in engineering
or with people who are in remote locations, during data visualization or
interacting with virtual objects within
the control system.
M
Av im
ai ic
la
v
more sophisticated, with an inherent

understanding of the process, the operating context, the operating environment (using plant historical database),
operator preferences and practices,
data analysis, case-based reasoning
and the ability to learn and remember.
Its reasonable to expect that an operator can have such a mobile personal
assistant, as well as more sophisticated
plant digital advisors with more capability and a larger knowledge base, all
connected through the local cloud or
fog. IPSofts (www.ipsoft.com) Amelia
software might serve as a prototype for
a personal assistant or plant advisor.
Artificial intelligence will be increasingly embedded in the process
control world. The future should bring
self-aware sensors and control systems
that automatically determine their relationship to variables and control
loops, understand the effects of disturbances, be goal-orientated, spot and
analyze patterns, do case-based reasoning, know the past and project the future as well as a human being.
Dynamic Modeling
More help for operators

Many people feel that the operator is
the weak link in the control system,
which is another way of saying the
human factor is the weak link in the
whole system. Its doubtful that the role
of the operator will be diminished in
the near to intermediate future, as they
are the primary element that provides
resilience (flexibility) in the system, but
a long-term trend is there.
Meanwhile, inexpensive computing power and memory, and advances
in computing technology have made
virtual reality (VR) more technically
feasible. The Oculus Rift, a headmounted VR display, so interested
Facebook that it shelled out $2 billion
for Oculus VR (www.oculus.com). It
seems unlikely that operators will be
wearing a one-pound set of goggles all
day long and living in a virtual world
(though the goggles have cameras that
allow you to see through to the real
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CONTROL IN THE FUTURE
tial to provide operators with a continuously available headsup display of important data and additional information.
Microsoft recently announced its answer to Google Glass,
called HoloLens, which will be bundled with Windows 10
for release to developers this year (sidebar, page 35). This device has the potential to revolutionize the operator interface
by providing data visualization and a collaborative operating
environment for operators, engineers and corporate experts,
as well as trusted third parties and vendors.
Cybersecurity: The Killer App

New control system growth will be constrained by cybersecurity concerns. Users will expect cybersecurity to be built
in, not just added on. While it will retain its reactive nature,
cybersecurity will also become predictive, based on artificial
intelligence, and will use data analytics, case-based reasoning, cognitive functionalities and other AI methodologies
to prevent access, detect and block or eliminate intruders,
learn from its mistakes and the mistakes of others, find system vulnerabilities, and eliminate or place roadblocks in the
way of intruders.
Its hard to predict the future, but its clear that emerging
ACKNOWLEDGEMENTS
Valuable insights were conttributed for this article by:
Bernie Anger, general manager, GE Intelligent Platforms
Jonathan Crane, chief commercial officer, IPsoft
Dave Cronberger, customer solutions architect, Cisco
Adrian Fielding, Andrew Stuart, Paul Hodge and Paul
McLaughlin, Honeywell Process Systems
Brent Leimer, market manager, Winsted Control Room
Consoles
Pierre Skonnegard, control room designer, CGM
Susanne Timsjo, manager, software architecture and
user experience, ABB
Bob Voss, director, applications research, Panduit
technologiesaugmented and virtual reality, artificial intelligence, cloud and fog computing, and data and predictive
analyticsare poised to change the industry.
William L. Mostia, PE, fellow, SIS-TECH Solutions,
is a frequent contributor to Control.
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Asset MAnAgeMent
More capable software,

networks and mobile devices
are enabling asset
management in many
new applications and
environments.
by Jim Montague
provide early warning of deterioration of critical equipment

and perform basic analysis based on the mathematical models in its diagnostics, but it also would provide predictive
capabilities. Designed around its central controls and plugging into modular adaptors, the utilitys PAM uses several
Honeywell solutions, including:
Alarm Management software to provide real-time alarm
and event visualization and analysis, which replaces multiple alarm printers, monitors operations and operator workloads, and helps eliminate nuisance alarms;
Asset Management software that consists of an advanced
data analysis and online computing platform for troubleshooting process problem and faults, and an interface for implementing mathematical models used in diagnostics;
Meridian Energy and Honeywell
ook at anything up close, and a lot more details appear.

Asset management in process control is no exception, so
when engineers and technicians reexamine the performance and lifecycles of their equipment, many new questions, maintenance issues and requirements show up.
Originally, asset management began as a way to go beyond maintaining operations and uptime, and determine
how to get the most value out of equipment and production
systems over their lives. More recently, this quest has drawn
asset management into settings where its basic principles are
being joined by new software, communications and mobility tools to generate more long-term value.
For instance, Meridian Energy (www.meridianenergy.
co.nz) is New Zealands largest state-owned power utility,
providing about 30% of the nations electricity from renewable sources, primarily hydro and wind (Figure 1), to about
180,000 customers. Its New Zealands only supplier of carbon-zero-certified electricity.
However, though its renewable profile appears modern and hip, Meridian faced an aging plant infrastructure,
mainly because many of its hydro sites were commissioned
in the 1960s. As a result, Meridian recently completed a fiveyear upgrade of its plant-wide monitoring and control networks, and centralized its control room operation in Twizel,
located in the middle of New Zealands South Island.
the Road to Prediction

To shore up their monitoring and secure more useful intelligence from their raw sensor and alarm data, Meridians
Generation Improvement Team sought to integrate their
IBM- and Maximo-based computerized maintenance management system (CMMS) and plant historian with a plant
asset management (PAM) system from Honeywell Process
Solutions (www.honeywellproces.com). It would not only
Optimizing Air pOwer

Figure 1. Meridian Energy integrated its CMMS with Honeywells
PAM system to better monitor and analyze data coming into its
centralized control room from its hydro and wind power plants
in New Zealand.
CT1503_39_44_Feature2.indd 39
39
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Control Performance Monitor for

continuous, real-time asset monitoring
and prioritizing poor performers;
Operational Insight that provides
PAMs flexible data visualization and
key performance indicator (KPI) dashboards, enabling better operational decisions by providing web-based access
to PAMs control center.
Working in concert with their existing CMMS, Meridians plants and
equipment give PAM condition data
and results of many on- and offline
automated and semi-automated tests.
Plant data is classified and collated
with business logic, and plant dashboards are updated showing condition
and predicted days to failure. When a
non-normal condition is detected or
predicted, an email recommending
specific action is automatically sent to
the right personnel.
The biggest success thats come out
of PAM is increased visibility of transformer conditions, says Mark Williams, an engineer at Meridian. Prior
to the PAM implementation, transformer condition monitoring data relied on individuals to enter the test results into Maximo, and then others to
analyze that data and publicize the
results in sufficient detail to flag any
health issues in a timely fashion. Also,
in developing the PAM models, specialist expertise was used to improve our
transformer condition monitoring program, and job plans were upgraded.
Neil Gregory, Meridians technology
and process strategist, explains, We
didnt and still dont expect PAM to pick
up catastrophic conditions on a daily basis, but we do expect and get very early
warning of changes in condition that we
wouldnt get without the system. PAM
is a cost-effective means of maintaining
visibility of the health of assets that are
critical to our business.
Bart Winters, asset management solutions product manager at Honeywell,
says, We focus on asset health, real-time
performance and monitoring, but now
were also protecting users and their ap-
plications against the precursors of failure. So were still monitoring vibration,

current changes, oil analysis and infrared thermography, but we also compare
each performance to an ideal parameter,
which helps define what it means in the
context of its particular operating unit.
This means we can look at a whole process system and all its components parts
in one place, and this saves a lot of time
on troubleshooting, finding problems
and getting back to production.
streamlined by software
While asset management is historically
costly, time-consuming and labor-intensive, improvements in software and
hardware are making it more approachable for a wider circle of users applying
it to more varied projects that go beyond maintenance to each new level of
optimization and sustainability.
For example, Mohawk Fine Papers
(www.mohawkconnects.com) in Cohoes, New York, recently saw its energy
costs balloon by 30% over a few years,
and redoubled its efforts to reduce its
energy consumption with better asset
management. Energy makes up 60% of
Mohawks operating and maintenance
costs, and our motor and pump assets
consume 75% of that energy, says Paul
Stamas, Mohawks vice president of IT.
So management needed visibility into
data on the factory floor for better decision making, and we needed an EAM
system that integrated energy into our
asset management strategy.
As a result, Mohawk selected InforEAM condition-monitoring software
from Infor (www.infor.com), which has
a web-based architecture, integrates
seamlessly with the companys enterprise resource planning (ERP) system,
and works with its Microsoft SQL Server
2005 database software. Stamas reports
that InforEAM allowed Mohawk to
improve preventive maintenance with
more proactive inspections, calibrations
and repairs, and even worked with SQL
Server to add video files to its work instructions. Because better maintenance
3/3/15 1:10 PM
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Asset MAnAgeMent
reduced its total energy consumption,

Mohawk also implemented InforEAM
Enterprise Asset Sustainability software.
This solution enables us to compare our assets designed energy use
versus actual energy consumption. We
can now incorporate energy efficiency
into our asset management program,
explains Stamas.
Mohawk also integrated its asset sustainability system with thousands of its
plant-floor sensors to collect more realtime energy data. This data helps us
identify assets that are degrading in
performance and consume excess energy, which triggers alerts and allows
In-chassis
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us to proactively identify and resolve

cases of wasted energy. We also collect
real-time energy use with the sensors,
compare that against our utility bills,
report that information in the EAM
system, and break down our assets to
identify real opportunities. With EAM
Enterprise, we expect an additional 15
to 20% drop in energy consumption
on top of the nearly 15% weve already
realized with InforEAM best-practice
maintenance.
Kevin Price, EAM product director at Infor, reports InforEAM, version 11.1, expands the jurisdiction of
asset management beyond reporting
and maintenance to include more advanced condition monitoring, inspections, reliability and other functions.
People used to have multiple SCADA
systems, and it was a challenge to get
alerts or trends, says Price. We develop a combined roadmap that understands a users system and requirements, and enhances their return on
asset, reliability-centered maintenance
and asset performance management.
Similarly, New Belgium Brewing
Co. (www.newbelgium.com) in Fort
Collins, Colorado, recently discovered
that scheduled and unscheduled downtime on its bottling lines were causing
it to produce only 150,000 cases of beer
per week on lines that were capable
of producing 294,000 cases per week
(Figure 2). After ramping up our bottling line to meet growing customer
demand, we were disappointed to find
the brewery was producing only about
half of what it was capable of producing, says Joe Herrick, packaging systems manager at New Belgium. Our
brewerys manual systems generated a
huge amount of data, but we had no
way of presenting it in context.
Consequently, New Belgium sought
help from system integrator Apex Manufacturing Solutions (http://apexmfgsolutions.com) in Boise, Idaho, and
they decided to implement Wonderware MES Performance software from
Schneider Electric (www.schnedier-
A S I A PAC I F I C | A F R I C A | E U R O P E | M I D D L E E A S T | L AT I N A M E R I C A | N O R T H A M E R I C A
3/3/15 1:10 PM
electric.com). The software not only tracks and records the

bottling process, but it also turns raw data into user-friendly
presentations that help improve performance. For example,
Wonderware MES facilitates shift changes by providing new
workers with data on the performance of the previous shift,
and integrates with the brewerys existing Wonderware System Platform and Wonderware HMI software. These combine to improve operators ability to maintain precise production schedules and manage the materials supply chain
during the brewing process.
With Wonderware MES coupled with our continuous improvement strategy, we increased the efficiency of our packaging line by 30%, which allowed us to extend our packaging
capacity to about 1.3 million barrels each year, adds Herrick.
Improved manufacturing efficiencies plus increased line
production means we saved more than $400,000 in planned
labor costs and decreased downtime by 50%.
Simpler Setups
Besides aiding routine operations, some asset management
software can even help out during setup and configuration.
Schneider Electric and New Belgium Brewery
ASSET MANAGEMENT
FULL SUDS POTENTIAL

Figure 2: New Belgium Brewings bottling and packaging line
recently adopted Wonderware MES Performance software to
decrease downtime by 50%, save $400,000 in planned labor
costs and increase capacity to 1.3 million barrels per year.
For instance, Royal Dutch Shell (www.shell.com) recently

worked with Emerson Process Management (www.emersonprocess.com) to develop a more efficient configuration so-
The Connected Factory

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+1 (717) 767-6511 I info@redlion.net I www.redlion.net

2015 Red Lion Controls, Inc. All Rights Reserved.
43
3/3/15 1:11 PM
ASSET MANAGEMENT
lution for Shells Prelude floating natural gas (FLNG) production vessel project, which will operate off the coast of
Australia. With more than 5,000 Foundation fieldbus devices at the Prelude site, many with more than 100 configurable parameters, Shell was concerned about the time it
would take to complete commissioning tasks. Configuring
the devices one at a time is error-prone and laboriousconfiguring one device can take up to an hour, and then configuration for each must be verified.
Consequently, Shell adopted Emersons Asset Management Software (AMS) Suite: Intelligent Device Manager
v. 12.5, which can commission Foundation fieldbus devices
faster. Users can bring devices online with features, options
and alerts they select in a fraction of the time normally required. Emerson expects AMS Suite to reduce commissioning time on smart devices by almost 80%, and allow users to
make online changes to many devices simultaneously. Also,
the softwares Device Manager User Configurations tool lets
users standardize asset configuration and eliminate configuration errors. Users can apply configuration templates to
device placeholders or live devices, so they can be commis-
sioned one by one as field engineers are wiring the segments

or automatically in groups.
We expect to reduce commissioning time and loop testing for Foundation fieldbus devices by 10,000 to 20,000 manhours for mid-size to large projects with this new functionality, says Rong Gul, Shells corporate subject matter expert
on smart instrumentation and instrument asset management.
Management Goes Mobile

No doubt empowered by their spiffy software capabilities,
many asset management systems also appear to be freeing
themselves from fixed applications and individual locations
with help from wireless networking, Internet protocol (IP)
communications and cloud computing services. Price reports that Infors software is also migrating onto tablet PCs,
smart phones and its Cloud Suite service to help users generate performance models faster. Mobility gets information
and models out into the field so users can make sense of
vertical and micro-vertical situations, and make better decisions on the spot, says Price.
Jim Montague is Controls executive editor.
3 - in - 1
MEASUREMENT
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Product Level
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interface level and multipoint temperature in a tank from a single level
instrument.
The Measureable Difference

MTS Systems Corporation, Sensors Division 3001 Sheldon Drive Cary, NC Tel. 800-633-7609 www.mtssensors.com info.us@mtssensors.com
44
3/3/15 1:12 PM
C A L I B R AT I O N
Exper ts from Wunderlich-Malec and Beamex present

a two-par t ISA webinar on the basics, crucial issues and best
practices for successful pressure calibration. by Jim Montague
s natural forces go, pressure is pretty straightforward, but

there are some important aspects that must be remembered to calibrate pressure-based devices.
To reacquaint users with pressures crucial details, two
90-minute webinars were delivered recently by ISA (www.
isa.org) and Beamex (www.beamex.com). The three presenters were Hunter Vegas, project engineering manager
at Wunderlich-Malec (www.wmeng.com.com), Ned Espy,
technical director at Beamex and Roy Tomalino, professional services engineer at Beamex.
Both sides of the pressure equals force divided by unit
area equation need to be taken into account, says Vegas.
With tanks, a common myth is that the shape can affect
pressure at the bottom, but this isnt true because 1 in. x 1 in.
x 23 ft of water always weighs 10 lbs regardless of its shape, so
the shape of a tank has no impact on the 10 psi pressure at its
bottom. All that matters is the height of the liquid.
If this tank were filled with mercury, then this initial 10 psi
would be multiplied by mercurys specific gravity (SG) of 13.6
to produce a pressure of 136 psi, and if a 1-psi blanket of nitrogen is added at the top to suppress fumes, it would bring the
bottom pressure up to 137 psi. When calibrating a differential
pressure (dP) transmitter thats reading pressure at the bottom,
three things matterheight of the liquid, SG of the liquid and
any pressure on top, says Vegas. Likewise, a 23-ft storage tank
at 100% will read 276 inches of water column (in.H2O), and a
10-in.H2O nitrogen blanket will bring it up to 286 in.H2O, until
a compensation leg, bubbler or other device is added (Figure 1).
The Three Up-Down Test

Tomalino first connected a Beamex MC6 calibrator to the high
side of a Siemens dP transmitter set up for 0-100 in.H2O and
a 4-20 mA output that provides a linear function of 4 mA at 0
in.H2O, 12 mA at 50 in.H2O and 20 mA at 100 in.H2O, and has
a 0.5% of span error tolerance. These levels correspond to zero,
50% and 100% of the transmitters set operating pressure, and

Tomalino used a connected 300-psi air pressure pump with
venting to move the transmitter up through each level and back
down through each in a three up-down test.
The calibrator just needs to know what to expect, says
Tomalino. We first zero it for the atmospheric pressure, and
have only a 3-second delay while it looks for a stable signal
and automatically grabs the test point.
Tomalino reports his first test failed because its 0.59% of
span was outside the set 0.5% error tolerance. The MC6s
raw data and graph showed that largest error during the test
occurred on its high side, and he adds its important to preserve this as-found data to aid trending. If you can gather
10 years of calibration data, you can see if a transmitter is
drifting, is rock solid or needs adjustment every time, says
Tomalino. Dont erase a test, trim and then test again.
Because the dP transmitter has HART communications, Tomalino adds that screwdrivers and potentiometers cant be used
to adjust its zero and span. Instead, MC6s diagnostic service is
opened, reminds the user to remove the transmitter from automatic control, adjusts its current and sensor trim to 100% at
100 in.H2O, and allows it to stabilize. Next, the zero level is also
typically trimmed, and when the transmitter is tested again, it
passes with a largest error of 0.128% of span, which is documented as its as-left condition. Both as-found and as-left data
sets are combined in the transmitters calibration certificate.
Vegas adds that the placement of a pressure transmitter
can impact measurement performance. Mounting a steam
pressure transmitter below a line protects the transmitter,
but the condensation in the tubing will shift the transmitter
reading. This problem is solved by shifting the transmitter
calibration to account for the water in the tubing. Tomalino
demonstrated this procedure on a Rosemount 3051 PT set
for 0-250 in.H2O that equates to a 4-20 mA output, but needs
to elevate its zero to account for a 10-in. wet leg, so it adjusts
CT1503_45_48_Feature3_1.indd 45
45
3/3/15 1:13 PM
Implementing
a calibration
system?
c a l i b r at i o n
N2 blanket
(10 in. wc)
FI
L
H
nitrogen
LT
Reading @ 100% = height (in) x SG

23 ft x 12 in/ft x 1.0 (SG) = 276 in. wc
ISA, Beamex and Wunderlich Malec
100% = 23 ft
SG = 1
DP Calibration of Storage tankS

Figure 1: A 23-ft storage tank at 100% will read 276 inches of water
column (in.H2O), and a 10-in.H2O nitrogen blanket will push it to 286
in.H2O, until a compensation leg, bubbler or other device is added.
Our calibration and IT expertise helps you face

calibration process improvement projects that are
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new calibration system depends especially on the
implementation of the system and the ability to define
and adopt a new calibration process. Learn more at:
beamex.com/CalibrationProcessImprovements
Beamex, Inc.
Phone: (770) 951-1927
Toll free: (800) 888-9892
www.beamex.com
beamex.inc@beamex.com
the transmitter to read 10-260 in.H2O with 10 in.H2O at the

4 mA output and 260 in.H2O at the 20 mA output. We begin with 10 in.H2O, take it up to 135 in.H2O and 260 in.H2O
at 100%, and go back down the same way, adds Tomalino.
However, if we forget to stop at 10 in.H2O and vent all the
pressure at the end, then the calibrator wont accept this as
zero because it wasnt the correct 4-mA value. But we cant go
back to the 10-in.H2O setpoint, so we must go up past it and
then back down to it again.
This time, the calibration test failed because the 10-in. wet
leg should have equated to 4 mA, but was only reading 3.9
mA. So it needed to be trimmed to zero, and was adjusted to a
0.006% of span error, which allowed it to pass the calibrators
test. All the as-found, adjustment and as-left data need to be
documented and added to the calibration certificate.
Steam Drum level

In the second webinar, Vegas states, Steam drums bedevil
people because they must know more than its tap-to-top
height. You need SG of the water in the drum and the water
in the wet legs to calculate 0% and 100% levels. SG of the water in the drum is determined by the boiler operating pressure,
but SG of the wet legs depends on the type of heat tracing. Its
important to leave the heat trace on year round because if its
turned off, then the level reading will be affected.
For example, a calculation was done on a 36-in., tap-to-tap
steam drum at 600 psig with wet legs that were steam traced
with 45 psig steam. The drum water had a 0.787 SG, and the
wet leg water had a 0.923 SG. Subtracting high-side from low-
3/3/15 1:14 PM
ACCUTUBES
side readings results in a 0% level of -33.23 in.H2O and 100%

level of -4.9 in.H2O (Figure 2).
Espy says steam drum level calibration steps include:
Making sure interlocks are bypassed or boiler is out of service (because many steam drum level transmitters feed lowhigh level trips) before isolating the transmitter;
Calculating the steam drum level calibration, including the zero setting of -33.23 in.H2O and the span setting of
-4.9 in.H2O;
Setting the zero and span;
Returning the transmitter to service;
Once steam trace is at temperature and boiler is at normal pressure, adjusting the zero if necessary to match sight
glass or mechanical gauge.
Tomalino again used the MC6 to calibrate level transmitter steam drum and level transmitter capillary functions
for a Rosemount 3051 transmitter. Its tricky to calibrate
a transmitter with such large zero shifts, and one usually
needs to consult the manual for the exact procedure, he
says. Tomalino pulled a slight vacuum on the transmitter to
set the 4-mA and 20-mA points for this calibration.
Thousands
of Effective
Installations
Worldwide!
Diaphragm Seals
Vegas adds that the three main types of dP seal assemblies
pad type, pad type with single capillary and dual capillary
sealcan all cause problems. Pads and seals directly measure pressure, but the diaphragms in them are easily damaged if installed incorrectly. The fill fluid inside the capillaries that transfer process pressure to transmitters can leak
and cause quality problems in the process. These fluids can
become viscous and have slow response due to low ambient
or process temperature and pressure, or boil in high vacuums and high temperatures and ruin the seals.
Seals are fragile and expensive, so you want to be sure
the gaskets are in place before theyre bolted down, and you
always need to be aware of ambient temperature, explains
Espy. Its also important to address up-front how testing and
calibration will be performed to avoid big headaches. Flush
rings are useful for venting and applying calibration pressure, and this means the seal doesnt have to be unbolted to
perform a calibration.
Espy adds that dP seal calibration steps include:
Isolate both seals from process using flush rings;
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47
1/14/2015 12:11:12 PM
3/3/15 1:14 PM
BetaGauge 330
Pressure Calibrator
with Internal
electric pump
Finally a calibrator that
can handle pressure,
mA, and temperature
with a press of a button.
Calibration calculations:
0% setting = high low pressure @ 0% level = -33.23 in. wc
100% setting = high low pressure @ 100% level = -4.90 in. wc
Steam
36 in.
Steam trace
Conditions:
45 psig, SG = 0.923
LT
Steam drum
Conditions:
600 psig, SG = 0.787
Calibration of a SteaM DruM level

Figure 2: Water in a 36-in. steam drum at 600 psig will have a 0.787 SG, while a steam
trace in its leg will be at 45 psig and 0.923 SG. Subtracting high-side from low-side
readings results in a 0% level of -33.23 in.H2O and 100% level of -4.9 in.H2O.
Be sure both seals are at their normal position and elevation;

Vent both seals to atmosphere using flush rings; record the current 4mA reading as found;
Apply span pressure on the high
seal and record the current 20-mA
reading as found;
Vent both seals and adjust the
transmitter to read 4 mA as left;
Apply span pressure to the high
seal and adjust the 20-mA point as left;
Close the vents and return the
seals to service.
Tomalino adds that a tank with a 0
to 25-in.H2O level range and 4-20 mA
transmitter output may have a -28.46
in.H2O to -3.46 in.H2O pressure based
on its process SG, capillary fill fluid
SG and a long capillary to the low-side
sensor, and these need to be compensated for in its calibration and trim.
Calibrating level transmitters with
capillaries can be mind-bending for
technicians, so you need to break it
into chunks to conquer it, says Tomalino. The big picture has three parts:
as-found, adjustment if necessary and
as-left if you adjust. In our example, we
needed to adjust, and those steps are
trim lower and trim upper.
Using the scaled variable function
White Paper Available Online
48
in the transmitter, we scaled the transmitter, so 0 to 25-in.H2O input equals

-28.46 to -3.46 PV. For this transmitter,
the lower trim should be performed
first, and is related to the PV closest to
zero. That PV is -3.46 in.H2O and is the
actual 100% span value of 25 input and
20-mA output. The upper trim is the
PV furthest from zero, -28.46 in.H2O,
which is 0 input and 4-mA output. So
the lower trim is our 20-mA output,
and the upper trim is the 4-mA target.
This can be confusing.
The pressure calibration shows
pressure coming in and current going
out. Perform the lower trim using 25
in. H2Oin and expecting 20 mA out.
Enter -3.46 and send it. Next, do the
upper, 0 in, 4 mA out, and enter -28.46
to complete the adjustment. Then capture your as-left results, do an up-down
test to check for hysteresis, see that its
passed, and save the results.
[Editors note: This article is based on
two webinars, Oct. 2, 2014, and Feb.
19, 2015, organized and hosted by the
ISA and Beamex. They can be viewed at
http://bit.ly/1BDo8hE and at http://bit.
ly/1C1F8NS].
Jim Montague is Controls executive editor.
3/3/15 1:14 PM
T E C H N I C A L LY S P E A K I N G
Simplify Tank level Monitoring with Wireless
rocess plants and related facilities such as

tank farms are filled with vessels, tanks and
similar storage units, and most of these
units could benefit from a system to measure,
monitor and view inventory on a near real-time
basis. Logistical benefits of tank level monitoring include reduced emergency deliveries, better inventory management and labor productivity improvements, says Michael Robinson,
director of solutions, Endress+Hauser (www.
us.endress.com).
Wireless is a good fit for this application, as
most tank level instruments are installed at the
top of a tank, a tough spot to access. Many tanks
also require long home-run wiring. Wiring in
corrosive environments has a tendency to fail
at connection points, and conduit systems can
rust and deteriorate. Finally, many tanks are installed in hazardous areas, making it expensive
to run and maintain wiring.
Available wireless level measurement technologies include differential pressure and radar, both of which can be made truly wireless
with a battery-powered option. In the case of
tank level monitoring, its feasible to have a very
low update rate and correspondingly long battery lifeup to 10 years in some cases.
But many tanks have existing conventional
wired instruments, and others need to use
level measurement technologies not available
in wireless versions. For these instruments,
a wireless adapter can be used to convert the
wired instrument output to wireless. Although
this isnt a completely wireless solution, it does
solve the problem of wiring back to an inventory management system.
Transforming level measurements into wireless signals is only one part of the equation;
the second is transmitting this information to
a tank inventory monitoring and management
system. Two options for creating this data link
are via the cloud or a local Wi-Fi network.
Our wireless tank inventory monitoring
solution can include an AC-, battery- or solar-
DAN Hebert
powered cellular communications modem,

which transmits tank level information to our
cloud-based service SupplyCare that is hosted
on secure Endress+Hauser servers, explains
Robinson.
One could configure a system similar to SupplyCare by buying a modem, contracting with
a cell provider, contracting with a cloud storage firm and installing appropriate tank inventory management software, such as an HMI
with database storage capability, in the cloud.
Once tank level data is sent to the cloud, it can
be accessed for inventory management by any
device with an Internet connection and proper
login credentials.
Emerson Process Management (www2.emersonprocess.com) installed its Rosemount tank
gauging equipment for inventory measurement
of liquid storage tanks for St1 (www.st1.eu), a
Swedish petroleum refinery in Gothenburg.
The plant has both wired and wireless equipment, all connected to a wireless gateway.
Emersons Smart Wireless Gateway collects
tank data from the instruments and makes it
available through a WirelessHART Wi-Fi network. To improve access to the wireless network, St1 also added a wireless connection
from the control room to the local gateway via
the Wi-Fi based Emerson Pervasive Field Network (PFN).
The PFN link at St1 includes three industrial hotspot units. One is connected to the
local gateway and to a remotely installed directional panel antenna. A second serves as a
repeater to achieve line of sight.
The third unit is installed in the control
room area, and its connected to a remotely installed panel antenna. In addition, its equipped
with an integrated antenna to create a Wi-Fi
zone, enabling operators to access the wireless
network from any place in the control room.
This data is also now available to any tank level
management and inventory system within the
Wi-Fi coverage area.
Senior Technical ediTor

dheber t@putman.net
Transforming level
measurements into
wireless signals is
only one part of the
equation.
M A r c H / 2 0 1 5 www.controlglobal.com
CT1503_49_TechSpeak_2.indd 49
49
3/3/15 1:15 PM
ask the experts
When to Use Equal Percentage Valves
m1
(Gv)
tripkovicn@yahoo.com
(Gp) CW
Process
gain
GP = F
GPM
C
GP = 3
m /s
Set pt.
(r)
TIC
(Gc)
TT
(Gs)
e
+
c
Sensor
gain
% %
100%
Gs =
=
span F C
The selection goal is control loop stability. This we obtain by making the loop response to load changes as linear as possible
(keeping the loop gain more or less constant).
The gain of any device is the ratio of its output
divided by its input. The loop gain (LG) is the
product of the gains of the loop components:
the process (Gp), sensor (Gs), controller (Gc)
and valve (Gv). Tuning the loop means that if
our goal is quarter-amplitude damping, we adjust the controller gain (Figure 1), so that the
loop gain (LG) will be about 0.5.
Process
fluid (u)
Controller
gain
Gc = %m
%e
Dimensionless
m
+
NeNad Tripkovich
Load
(u)
Valve gain
3
Gv = GPM m /s
% %
Is there some general rule on when we

should use equal percentage (=%) and
when linear control valves? I know that
the determining factor is the inherent flow characteristic, the flow vs. lift at constant pressure
drop, or something like that. I do not know what
this means, because constant valve pressure
drop rarely exists except in the ideal conditions
of the manufacturers test lab.
Set
point (r)
Loop gain =(Gc)(Gv)(Gp)(Gs) =
% GPM F %
=
% % GPM F
= Dimensionless
CONSTANT GAIN
Figure 1: If the process is non-linear (Gp varies with
load), the gain product of the loop (LG) should be
held more or less constant by compensating for
the variation in Gp by using a non-linear valve with
This column is moderated

by Bla Liptk (http://
LG = (Gp)(Gs)(Gc)(Gv) = CPG(Gc) ~ 0.5
inverse Gv non-linearity.
Linear valves: If the total process gain (TPG

= (Gp)(Gs)(Gv)) is more or less constant (does
not change much with load), linear valves
should be used. In a linear (constant gain) valve,
a 1% change in lift results in a 1% change in
flow (Gv = 1.0). TPG is acceptable if it stays between 0.5 to 2.0 as the load varies between its
minimum and maximum limits. Linear valves
are used in most applications except heat transfer (temperature control).
characteristic (Gv = 1/Gp) so the installed characteristics of the total process will be more or
less linear (TGP = 0.5 to 2.0). Naturally, Gv can
never be the exact inverse of Gp, but as long as
the selected valve characteristic keeps the TPG
within 0.5 and 2.0, instability and limit cycling
can usually be avoided by good controller tuning (assuming TGP = 1.0 when adjusting Gc).
belaliptakpe.com),
automation and safety
TPG = (Gp)(Gs)(Gv) ~ 0.5 to 2.0
consultant, who is
also the editor of
the Instrument and
Automation Engineers
Handbook (IAEH). If you
have automation-related
questions send them to
liptakbela@aol.com.
50
Non-Linear Valves: If the valve gain rises

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

(=%) valves are used on heat-transfer processes
because in heat transfer (temperature control),
when the heat load is low, the heat transfer surface area available to transfer that heat (load) is
large. As a consequence, at low loads the heat
transfer is efficient; the process gain (Gp) is
high. As the load rises, the same heat transfer
area has to transfer more and more heat, and
therefore its efficiency (the process gain) drops.
To compensate for this, we need a valve whose
gain rises with load (=%). For example, if the se-
CT1503_50_51_ATE.indd 50
3/3/15 1:16 PM
ask the expertS
lected =% is, say, 3%, flow will increase

3% for each 1% increase in lift. Therefore, the higher the load (flow), the
higher this 3% quantity becomes and,
therefore, the valve gain (Gv) rises with
load.
Some will also use =% valves when using constant-speed centrifugal pumps to
transfer fluid through long pipes. They
do that because at low flows, when the
pressure drop in the pipe (Ppipe) is small,
most of the inlet pressure is burned up
in the valve (Pvalve), so a small change
in lift results in a large change in flow
(Gp is high). As the load rises, the pipe
drop (Ppipe) also rises, and therefore less
pressure drop is left for the valve, so Gp
drops. This method of compensation is
wrong because its at low flows that one
should not burn up all that energy in the
form of valve pressure drop (Pvalve)! Instead, variable-speed pumps providing
constant valve pressure drop and linear
valves should be used.
As you can see, you asked a complex
question, which I could answer only
briefly here. So if you need an in-depth
explanation, see Chapter 6.7, starting on
page 1,154 of Volume 2 of the Instrument Engineers Handbook, where Table
6.1g lists the selection of valve characteristics for many applications.
Bl a Liptk
Liptakbela@aol.com
Use a linear valve when controlling flow, liquid level, pressure

and composition, and then use an
equal-percentage valve when controlling temperature.
In more than 60 years working with
control loops, almost all the cases where
I had to change valve characteristics, I
have been replacing equal-percentage
with linear.
F. Greg Shinske y
shinskey@metrocast.net
In order to make the control as stable as possible, you want the loop
response to be as linear as possible.
If you put the loop in manual and move
the output 10%, you want to see the same
10% change in the measurement regardless of whether you moved the output
from 10% to 20% or from 70% to 80%. If
the response is nonlinear, it is difficult to
tune the loop because a gain that works
great at low valve opening will not work
as well as the valve opens further.
Lets say youre controlling flow with a
valve on a long pipe fed by a centrifugal
pump. When the valve first cracks open,
the flow is very low, the pump discharge
pressure is high, and the line loss is very
small. In this case, the control valve is
taking nearly all of the pressure drop,
and a small change in valve position will
result in a big flow change.
Now consider the same when the
valve is 80% open. In this case, the
flow is high, the pump discharge pressure will have fallen, and the line loss
will be much larger. Now the pressure
drop across the valve is much lower, and
a small change in valve position will not
change the flow very much at all.
In this case, an equal percentage
valve is the appropriate choice because
the characteristic of the valve offsets the
effect of the piping. When the valve first
opens, a 5% change will not move the
valve much. However when the valve is
more than 50% open, a 5% change will
move the valve a great deal more. This
inverts the effect of the piping and creates a more linear response for the loop.
Now consider a case where you are
controlling flow, but the pipe is short
and the pump has a fairly flat flow
curve. The valve is now taking the full
line drop regardless of its position. In
this scenario, a linear valve trim would
be a better choice because a 5% valve
position change will affect the flow consistently regardless if the valve is barely
open or nearly fully open.

P. Hunter Vegas, PE
phvegas50@gmail.com
Linear or =% valves have very practical applications, not just theoretical ones. The exact conditions can
be found in many references, for example, Emersons Control Valve Handbook.
(www.documentation.emersonprocess.
com/groups/public/documents/book/
cvh99.pdf).
I came across an application on startup where the =% valve gave poor control because the piping pressure drop
was low. I had to do an inverse characterization in the DCS (which amounted
to gain scheduling). In other words, the
process piping was larger than it needed
to be.
Two classic examples of linear valve
applications are a bypass valve around a
heat exchanger for temperature control
and a trim valve in parallel with a larger
main valve.
Simon Lucchini
Simon.Lucchini@Fluor.com
In general, control valves with an

equal percentage inherent characteristic are used to produce a linear installed characteristic in process
control. Such an installed characteristic
in flow vs. lift for control valves can be
mathematically derived, and has been
published in books on process control.
Some control valves are provided
with custom-made trims so that the
pump curve is built-in. This provides
high loss coefficients at low flows and
low loss coefficients at high flows, and
eliminates the need for parallel valve
operation, and therefore reduces maintenance while increasing reliability and
controlability in process control. Boiler
feed water valves are an example.
Ger ald Liu, P. Eng.
gerald.liu@shaw.ca
CT1503_50_51_ATE.indd 51
51
3/3/15 1:16 PM
ROUNDUP
Grace Under Pressure

Pressure transmitters and their related components are rising to meet new challenges.
52
DP WITHOUT LINES AND TUBES
LOW-PRESSURE AIR, NON-CORROSIVE GASES
Deltabar FMD71 level transmitter uses two pressure sensor moduleshydrostatic and
head pressureconnected
electronically to one transmitter. Using a Ceraphire ceramic sensor, the transmitter
calculates differential pressure (DP) from both sensors, and transmits level, volume
or mass via 4-20 mA with HART, eliminating DP measurement problems caused by impulse lines or capillaries.
Endress+Hauser
888-ENDRESS (363-7377); www.us.endress.com
Kobolds PMP differential

pressure sensor is used for
controlling and measuring
the DP of low-pressure air or
non-corrosive gases, and is
ideal for monitoring filters.
The sensing range is 0 to 500
mm H2O (50 mbar), and the
maximum pressure is 750 mbar. It offers a four-digit display
and a 4-20 mA output signal. Relay, hysteresis, time delay of
the relays and the analog output are programmable.
Kobold Instruments Inc.
412-788-2830; www.koboldusa.com
CALIBRATOR COMBINES FEATURES
DISPLAY IMPROVES EFFICIENCY
HPC40 Series handheld

pressure calibrator is compact and offers deadweight
tester accuracy, active temperature compensation and a
non-menu interface. It delivers laboratory accuracy onsite
and calibrates pressures from
vacuum to 15,000 psi with an accuracy of 0.035% of reading
for all ranges. HPC40 is the first mA loop calibrator thats
fully temperature compensated from -20-50 C.
Crystal Engineering
805-595-5477; www.crystalengineering.net
SmartLine pressure transmitters feature a graphic display that supports graphical

process data in easy-to-read
trend lines and bar graphs.
Part of the Smart Connection Suite, it allows control
room operators to send messages to the display to make it easier for field operators to
determine required maintenance. When integrated with Experion PKS, SmartLine can display its maintenance mode.
Honeywell Process Solutions
800-822-7673; www.honeywellprocess.com
SUBMERSIBLE LEVEL VIA HYDROSTATICS
PRESSURE MEASUREMENT IN CORROSIVES
ProSense level sensors include two styles of SLT submersible level transmitters,
which measure liquid levels
by sensing hydrostatic pressure and providing a 4-20 mA
signal. SLT1 has a 1-in. diameter housing and a 0-5 psig to
0-50 psig sensing range. SLT2 has a 2.75-in. diameter PTFE
diaphragm surrounded by a stainless steel, non-fouling cage,
and 0-5-psig to 0-30-psig sensing range.
Automation Direct
800-633-0405; www.automationdirect.com
A Kynar process connection

is an alternative, cost-effective solution to remote seals
for some corrosive process
fluids and gases. This option
is available for select models in ABBs 2600T pressure
transmitter series. The process wetted parts consist of highly corrosion-resistant Kynar
and diaphragm materials, such as tantalum. Its maximum
working pressure is 145 psig.
ABB
800-435-7365; www.abb.com/measurement
CT1503_52_53_Roundup.indd 52
3/3/15 1:17 PM
ROUNDUP
MORE COMPATIBLE, GREATER RANGE
HIGH-ACCURACY WET/WET DP
PT-503 submersible pressure

transducers have PVC housings for operating in environments with regular, prolonged exposure to harsh,
corrosive chemicals, even at
-30-130 F and depths to 450
ft. Other features include
4-20 mA, Modbus, 0-5 Vdc and mV/V outputs; Hytrel, PVC
and urethane cable options; Teflon-coated or ceramic transducer face; and breathable, hydrophobic vent tube cap.
Automation Products Group Inc.
888-525-7300; www.apgsensors.com
PX509HL Series DP transducers are shock- and vibration-rated and provide long
life in containment pressures
up to 10,000 psi. Features include welded, stainless-steel
construction and user-accessible potentiometers for zero
and span, a micro-machined silicon sensor at the core to
provide stable readings with high accuracy of 0.08%, and a
broad compensated range of -20-85 C on most ranges.
Omega Engineering Inc.
888-TC-OMEGA (826-6342); www.omega.com
SPEED OF RESPONSE, STABILITY
PRESSURE RANGES TO 5,000 PSIG
Sitrans P500 pressure transmitters are designed for custody transfer and compressor applications They are
available in several ranges
to cover all applications and
have a SIL2/SIL 3 safety rating. Their 88-ms speed of
response, 0.14% total performance and five-year 0.05% stability make them suitable for compressor anti-surge and
throughput applications.
Siemens
800-365-8766; www.usa.siemens.com/pressure
MGF16BN digital pressure gauges come in pressure ranges to 5,000 psig at

standard accuracy of 0.25%
of full scale and with optional accuracy of 0.1% of
full scale. The display is a
4.5-digit LCD with 0.5-in.
numerals and a lower alphanumeric display for engineering
units and to aid setup. Each gauge includes up to 15 field-selectable engineering units, depending on the sensor range.
Meriam Process Technologies
800-817-7849; www.meriam.com
TWO-WIRE, 0.1% ACCURACY
SMART DP IN TIGHT SPOTS
Type 5000 rugged, two-wire

I/P pressure transmitter converts one pressure input into a
4-20 mA or 10-50 mA output
with 0.1% accuracy. Its design includes a temperaturecompensated piezoresistive
transducer for accurate measurements of non-corrosives. Type 5000s lightweight housing includes a 0.25-in. NPT pressure port and 0.5-in. NPT
conduit port.
Marsh Bellofram Corp.
800-727-5646; www.marshbellofram.com
815DT is a loop-powered, microprocessor-based DP transmitter with a configurable,

single-pole,
single-throw,
normally open solid-state relay. Its discrete output signal
can be used for signaling,
control and emergency shutdowns, and it communicates via HART7 and Modbus RTU.
Available ranges include 0-138 in H2O; 0-415 in H2O, 0-50
psid, 0-100 psid, 0-300 psid and 0-500 psid.
SOR Controls Group Ltd.
800-676-6794; www.sorinc.com
CT1503_52_53_Roundup.indd 53
53
3/3/15 1:17 PM
Product introductions
54
HiGHEr WirE EXPErtisE
suitE sPot For oPErAtor trAininG
WireXpert 4500 Cable Certifiers dual control system

enables one technician to
run tests from either end
of a cable. Proven accuracy
and a 2.5-GHz range allow
certifying to TIA standards
as well as the emerging 2.0GHz Category 8 standard. Optional test adapters handle all
categories of copper patch cords; multi-mode MPO cables;
simplex-encircled, flux-compliant, multi-mode and singlemode links; industrial Ethernet cabling systems; and more.
Softing Inc.
www.softing.us
UniSim Competency Suite

improves console and field
operator competency. UniSim Operations offers a process training curriculum.
UniSim Curriculum tracks
progress. Tutor stores domain
knowledge and experiences,
and teaches and evaluates what if reflexes and diagnostic abilities. Field View supports an interactive, navigable,
panoramic view for realistic field operator training, and 3D
Connect integrates simulations in a 3D virtual environment.
Honeywell Process Solutions
http://hwll.co/UltimateOperator.
duAL-tEMP trAnsMittErs LEVErAGE sMArt HArt
MAnAGEd sWitcHEs tArGEt dEMAndinG nEtWorKs
THZ3 and TDZ3 two-wire

(loop-powered) transmitters
accept direct inputs from 14
RTD types, nine thermocouple types, resistance and potentiometer devices, and direct millivolt sources. Dual
inputs allow backup and failover protection, or 15 transmitters on one digital HART
loop can monitor 30 points. Signal processing, HART and
device-intelligence support capabilities include average and
differential measurement, high- and low-select, and more.
Moore Industries
www.miinet.com
N-Tron series NT24k compact DIN rail-mountable,

Power over Ethernet Plus,
IEEE802.3af/at switches provide shock (200 g) resistance,
vibration (50 g) tolerance and
up to -40-85 C operating
temperature range. Three
models span eight to 16 ports, 10- to 49-Vdc power inputs
and applications from security cameras, panel displays and
wireless access points to general industrial applications. All
models feature 30-ms recovery for rings up to 250 nodes.
Red Lion
www.redlion.net/NT24k
suPPLiEs dELiVEr MAXiMuM PoWEr
tHErMAL MAss FLoWMEtEr noW on FoundAtion
PROmax power supplies

sport start-up temperatures as
low as -40 C, hazardous area
approvals (UL, Class I Div. 2)
and a 300% power boost. Allmetal housings and DIN-rail
mounting provide shock and
vibration resistance. Sixteen
models offer 5-, 12-, 24- or 48-Vdc outputs for loads up to 40
A. Features include front-panel voltage adjustment, LED local status and remote status monitoring through integrated
relay contacts.
Weidmuller
800-849-9343; www.weidmuller.com
Thermatel TA2 thermal dispersion mass flowmeters add

Foundation fieldbus to the advantages of the standard TA2
model, including dual gas
calibration with two unique
curves, field adjustability for
gas type or mix, calibration
verification to reduce downtime and unnecessary recalibrations, internal resettable and non-resettable totalizers, strong
signal at low flows and low pressures with high turndown,
and ISO 17025 and NIST-traceable calibrations.
Magnetrol International, Inc.
www.magnetrol.com
CT1503_54_Products.indd 54
3/3/15 1:18 PM
C O N T R O L TA L K
Practical Installation Best Practices

Stan: We continue our conversation started
last month with Tim Green, operations manager, field services at Maverick Technologies
(www.mavtechglobal.com), on making sure a
control system will meet the performance capability possible with todays instrumentation.
Greg: What guidance can you offer based on

your field experience and that of your key field
people?
tim: There are many considerations, but here

are the foremost installation best practices. The
list is a collaborative effort that involved the
Maverick construction managers and commissioning managers:
1. Install steam and liquid transmitters below the process tap, and air and gas transmitters above the process tap. In liquid-filled applications, often the static fill will need to be
zeroed out to null the effect of the liquid head
pressure.
2. For magnetic flowmeters and other meters
requiring ground rings, ensure that the ground
ring material is appropriate for the process liquid by referencing the instrument data sheet.
A standard 316SS ground ring may not last two
weeks if Hastelloy C was required.
3. Fill differential pressure (DP) flow transmitters from the bottom to avoid the entrapment of air in the impulse lines. Conversely,
drain impulse lines intended to be dry right before commissioning.
4. Verify orifice plate materials and dimensions, and that theyre installed based on the
flow direction. The beveled side of an orifice
plate must be facing upstream.
5. Sensing elements of flow transmitters normally require a minimum straight run of pipe
prior to and after the sensor location. Follow
the manufacturers recommendation. Note
that there is no buffer in this number, and it
may not take into account all of the piping details. The straight run must be more than the
minimum. The straight run will need to be increased if there are nonplanar elbows, process
equipment or valves upstream. Insertion flow
meters will require greater analysis to get the
sensor at the point in the pipe cross-section that
is at the average pipe velocity.
6. Install radar transmitters with the device
plumb. Make sure the horn or probe is correct
for the service. For coaxial probes, make sure
the standoffs are installed correctly to prevent
false readings. If standoffs are not used, ensure
the probe is not bent to avoid reading contact
points with the housing of the bridal or internal structure of the tank. When using transmitters with horn-type radar, avoid mounting too
close to the sidewall, internal structures, inflow
or sparge lines. Make sure the installation does
not interfere with tank venting. Be sure to run
an echo graph with the tank empty, all of the
dip tubes installed, and the agitator running as
a baseline reading that includes the effect of in-
GreG McMill an
Stan weiner, pe
controltalk@putman.net
Greg McMillan and

Stan Weiner bring their
wits and more than
66 years of process
control experience to
bear on your questions,
comments and
problems.
Write to them at
controltalk@putman.net.
Be prepared for shock and awe when you lay out your expectations to your contractors.
CT1503_55_56_CTtalk2.indd 55
55
3/3/15 1:19 PM
C O N T R O L TA L K
ternals and geometry for future reference. This is especially important for
detecting problems from coating of the
probe and vortexing of the liquid.
7. Always design wireless systems after a thorough site survey. The number
and locations of transmitters for signal hopping must be more than adequate to make sure transmission is not
blocked when a transmitter is removed
from service. Locations of transmitters
may need to be adjusted. Sales may
not realize how critical this site survey is. Pay attention to future physical
changes to the site and possible parking of tank trucks and service vehicles
that may interfere with the existing
wireless system.
8. Temperature transmitters are designed for multiple sensors, so make
sure the correct sensor is selected and
connected to the appropriate terminals. If there is a mixture of two-wire,
three-wire and four-wire resistance
temperature detectors (RTDs), the
risk of incorrect terminations greatly
increases due to the lack of standardization. Ensure that the probe length
matches the thermowell depth, the fit
is tight, and the tip is bottomed out in
the well. Also use high-temp pipe dope
to avoid thread damage.
9. Make sure the flowmeter element
is installed in the correct orientation
because most flowmeters are sensitive
to flow direction.
10, Install analytical probes within
the limits of the factory cable lengths
between the transmitter and sensor. Attempts to extend the wiring to meet operations or maintenance requests will
result in erratic readings. The factory
cable must be used and junction boxes
not introduced. Substituting cables
and adding junctions causes shielding,
termination, color coding and resistance problems.
11. Avoid installing pH and ORP
probes before process fluids are flowing. Protect the probe from physical
damage and keep the wet cap on the
probe during storage. This wet cap can
56
be used to protect the electrodes before

start-up, but the caps must be removed
before commissioning. If the electrode
tip dries out or is knocked against anything or hit by debris, the glass surface
can be permanently damaged.
12. Check motors for proper starter
size. Starter sizes follow the denomination of money: dime, quarter, half
dollar and dollar. NEMA 1 through 4
horsepower ratings are 10, 25, 50 and
100. When bump-testing rotation, decouple the pump from the motor to
avoid loosening the impeller. Verify all
thermal overload protection matches
the motor nameplate. The horsepower
should not be assumed.
Greg: Thermowells and electrodes

need to see a representative process
temperature and composition with a
fast response time and negligible noise.
Achieving this objective translates to
specific sensor location requirements.
The tip must be near the centerline
of a pipeline or beyond the baffle and
away from a sparger or dip tube in a
vessel. The tip must see a single phase
(e.g., liquid or gas) and maximum uniformity (e.g., sufficient axial and radial
mixing to achieve blend and minimize noise). In addition, it must introduce a minimum amount of dead time
(e.g., transportation delay from equipment to sensor must be less than the
time constant of a good, clean sensor),
and also sustain an adequate velocity
to prevent a slow sensor time constant
from fouling. Finally, it must prevent
exposure of electrodes to high temperatures or high acid, base or alcohol
concentrations that cause premature
aging, chemical attack or dehydration
of glass electrodes.
Often there is a compromise needed
in the location of the sensor where a
larger transportation delay is accepted
to achieve a single phase, sufficient
uniformity and adequate velocity. The
increase in total dead time rarely exceeds a few seconds, and may actually
reduce the total dead time in the sys-
tem by reducing the sensor time constant or signal filter time needed. For
example, a pH electrode located in a
recirculation line will introduce less
dead time than an electrode in a vessel due to an inherently faster time
constant and by avoiding coatings. A
thermowell or electrode located 25
pipe diameters downstream of a heat
exchanger or static mixer will provide
a more repeatable measurement with
less need for a signal filter. This distance is increased for desuperheaters
and static mixers with gaseous reagents
(e.g., flashing ammonia) to avoid droplets and bubbles, respectively. For
more details on thermowell and pH
electrode installation requirements,
see the books Advanced Temperature
Measurement and Control and Advanced pH Measurement and Control.
Stan: We conclude with a Top 10 E&I

Start-Up Believe It or Dont List.
E&I Start-Up Believe It or Dont List
10. Inadequately sized actuators were
found and replaced before start-up.
9. All of the control valves had better
than 0.25% resolution.
8. Minimum straight run for flowmeters was based on piping system detailed drawings.
7. Thermowells measured the average
pipe temperature.
6. Electrodes measured the average
pipe composition.
5. Insertion flowmeters measured the
average pipeline velocity.
4. pH electrodes were not installed until the process fluid was near normal
velocity.
3. Sensors location was optimum in
terms of minimizing dead time and
maximizing single-phase consistency
and measurement repeatability.
2. All of the control loops had initial
tuning settings identified automatically during high-fidelity simulation
testing and operator training.
1. Innovation and advanced process
control was used everywhere.
CT1503_55_56_CTtalk2.indd 56
3/3/15 1:20 PM
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CT1503_57_Classifieds.indd 57
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CONTROL REPORT
editor education
Jim montague
e xecutive editor
jmontague@putman.net
Lifting my
head from all the
specialized niches I
cover, I could again
see how process
control fits into
the larger world.
58
ve covered and written about process control

and automation for quite awhile, but it always
seems like there remain many basic concepts
that elude my limited ability to understand
them. I can describe how they work, of course,
but Im short on knowing why.
Luckily, several of these were cleared up
on Feb. 19 when I attended the second of two
90-minute webinars hosted by the ISA (www.
isa.org) and presented by Hunter Vegas, project engineering manager at Wunderlich-Malec
(www.wmeng.com.com), Ned Espy, technical
director at Beamex (www.beamex.com) and
Roy Tomalino, professional services engineer
at Beamex. I liked the second webinar so much
that I asked ISA for the YouTube link to the first
one held on Oct. 2, 2014, and then had the
bright idea to write this issues How to Calibrate Pressure Instruments feature on page 45.
Anyway, besides learning about detailed best
practices for calibrating pressure devices, I was
reminded by the presenters of the underpinnings of not just pressure, but process applications in general. Very refreshing. Lifting my
head from all the specialized niches I cover,
I could again see how process control fits into
the larger world.
When were talking about good measurement, were really talking about good metrology practice and data with demonstrable
pedigree that can show traceability back to international standards, says Espy. We do calibration to bring transmitters that have drifted
back to their good-as-new condition.
At its most basic, pressure is defined as force
divided by unit area. However, Vegas explains
that this simple equation can occur in some
unexpected ways. For instance, if a large force
is spread over a relatively large area, then the
net local force is small, while a small force over
a small area can have a high net local force. For
instance, a 14,000-lb elephant that always has
at least two 314-sq.in. feet on the ground generates 22.3 lbs./sq.in., but a 120-lb. woman with
one 0.25-sq.in. heel on the ground produces

240 lbs./sq.in.
Likewise, Vegas added its important to remember that, when using a standard orifice
plate in an air line, differential pressure (dP) is
multiplied by four when the flow is doubled,
and dP is multiplied by nine when the flow is
tripled. Flow and dP have a squared relationship, so the dPs square root is needed to convert or relate to a given flow, adds Vegas. This
is usually done in the DCS, so if its done in the
field, you need to make sure the DCS doesnt
do it again.
Apart from its counterintuitive behavior,
pressure also comes in many units that can be
hard to sort out. The primary pressure units
are atmospheres, pounds per square inch (psi),
Newtons per square meter (kPa), bars that are
0.01 kPa, inches of water column (in.H2O), millimeters of mercury (mmHg, Torr) and inches
of mercury (in.Hg). People get confused because there are so many units, and then ambient pressure is also affected by altitude, temperature, humidity and even latitude, adds Vegas.
Depending how your scale is set, at sea level
you may see any of these: 0 psig (gauge), 14.7
psia (absolute), 1 atmosphere, 30 in.Hg or 760
mmHg. In.H2O is based on the weight of a 1-in.
cube of water, and 27.7 in.H2O equals 1 psi.
Besides using or converting to the right
units, pressure measurements also depend on
where on the scale those measurements start.
Espy adds, while absolute pressure begins with
zero in a vacuum and gauge pressure begins
with zero at ambient barometric pressure, dP
happens in a closed system that looks at the difference between two pressure signals coming
from a high leg and a low leg, and zero differential happens when both legs are connected.
After struggling to understand the second
webinar, it was a relief to get some grounding
from the first. It probably would have helped to
not view them bass-ackwards, but my loss can
be your gain. Check them out.
www.controlglobal.com m a r c h / 2 0 1 5
CT1503_58_CTreport2.indd 58
3/3/15 1:22 PM
3/3/15 10:20 AM
It feels like were running in circles trying

to meet regulations and process demands.
I wish we could operate at a higher level.
YOU CAN DO THAT

You can move forward and run at a higher level with Fisher control valves and
instruments. We understand that you need to keep employees safe and equipment in compliance
with regulations. And thats getting more difficult as the process industry changes. Fisher products can
help you maintain a safer operation and meet growing regulatory demands. You can experience our
commitment to innovation in process control firsthand with a visit to the Emerson Innovation Center
for Fisher Technology. There, Fisher products are rigorously tested and verified beyond industry
standards by a staff of dedicated technologists. Watch a video of Fisher product testing at
www.Fisher.com/HigherLevel, then schedule a visit.
The Emerson logo is a trademark and service mark of Emerson Electric Co. 2014 Fisher Controls International LLC. D352316X012 MAA2
3/3/15 10:20 AM

Through The: Looking Glass

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THROUGH THE

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