A

P
R
I
L

2
0
1
2
Save Steam,
Save Money
Microbrewery Grows
Big with Micro PLC
Electronic
Marshalling Charms
Greenfeld Site
ON THE WEB
Using Wireless in
Closed-Loop Control
Control System Object-Oriented Design
Remote access is one of the fastest-growing
and most quickly accepted new technologies
to ever hit the process control industry.
REMOTE
ACCESS GOES
MAINSTREAM
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COPYRIGHT 2012 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED

omega.com

Kakarlapudi Venkata Sivanaga Raju/ Dreamstime.com

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Operator Effectiveness: In order to keep your plant running safely and at its optimum
level, your operators need to be equipped to recognize abnormal situations and
handle them through effective decision making. Advanced alarm management, easy
navigation to plant-wide actionable information, dogged attention to human factors
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April 2Ol2 Volune XXV Nunber 4
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 ), 555 W. Pierce Rd., Ste. 301, Itasca, IL 60143. (Phone 630/467-1300; Fax 630/467-1124.) Address all correspondence to Editorial and Executive Offces, same ad-
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consent of the copyright owner. POSTMASTER: Send address changes to CONTROL, P.O. Box 3428, Northbrook, IL 60065-3428. SUBSCRIPTIONS: Qualifed-reader subscriptions are accepted from Operating Management in the control
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accepted at $200 (Airmail only.) CONTROL assumes no responsibility for validity of claims in items reported. Canada Post International Publications Mail Product Sales Agreement No. 40028661. Canadian Mail Distributor Information:
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A P R I L / 2 0 1 2 www.controlglobal.con 5
F E AT UR E S
W E B E X C L U S l V E S
F L O W
45 / Saving Steam Saves Money
Matt Brewing Co. reduced energy costs to brew beer by
$230,000 per year using mass fow instrumentation.
by Rich Michaels
S C A D A
51 / Microbrewery Goes Big with
Micro PLC
Coastal Electric uses Micro PLC to automate Green
Flash Brewings new plant.
by Jim Montague
D A T A A C Q U I S I T I O N
57 / A Charming New Facility
Recycled equipment, a new automation system, elec-
tronic marshalling, remote I/O, all go into greenfeld
sulfuric acid plant.
by Bryan Beyer
COVER STORY
34 / Remote Access Goes
Mainstream
Remote access is one of the fastest-growing and quickly ac-
cepted new technologies to ever hit the process control in-
dustries. What are its benefts and challenges?
by Dan Hebert, PE
Addressing Control Applications with Wireless Devices
www.controlglobal.com/usingwirelessdevices
Control System Implementation with Standards-Based
Object-Oriented Design
www.controlglobal.com/controlsystemimplementation
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Access important data from the comfort of your control room;
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s Remote, bi-directional communication via the onboard
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Chemicals & Allied Products 12,548
Food & Kindred Products 12,638
Paper & Allied Products 3,470
Primary Metal Industries 5,445
Electric, Gas & Sanitary Services 3,116
System Integrators & Engineering Design Firms 8,912
Rubber and Miscellaneous Plastic Products 4,403
Stone, Clay, Glass & Concrete products 2,057
Textile Mill Products 1,361
Petroleum Rening & Related Industries 3,877
Tobacco Products 115
Total circulation 63,006
CIRCULATION AUDITED JUNE 2010
April 2Ol2 Volune XXV Nunber 4
9 / Editors Page
The League of Competent People
The unsung heroes of manufacturing, en-
gineering and building are the ones who
make the world work.
13 / On the Web
Spring in the Air and Safety on Our Minds
URLs for articles on the causes, effects and
possible cures for industrial accidents.
15 / Feedback
More views on the future of American
manufacturing, PID execution times and
CERTs misplaced priorities.
16 / Other Voices
The Future of Process Manufacturing
The future raises knotty questions. ATPM
2012 can provide some of the answers.
21 / On the Bus
Selling Diagnostics to Management
Step 1: Meet them half way with an elevator
pitch in their language.
22 / In Process
ISA branches out; young engineers to
watch; standards muddy the wireless out-
look.
33 / Resources
Online PLC and PAC information.
61 / Ask the Experts
Expert advice on zero fow and magmeter
maintenance and feed-forward variations.
63 / Roundup
Process analyzers and accessories are here.
65 / Product Exclusive
New optimized, small-footprint Coriolis
fowmeter from ABB.
66 / Products
Stuff you need: fowmeters, valves, surge
protectors, temperature sensors and more.
68 / Control Talk
Whats New in Lab Control.
An interview with Scott Broadley of Broad-
ley James.
71 / Ad Index
This issue is brought to you by . . .
72 / Control Report
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A P R I L / 2 0 1 2 www.controlglobal.com 9
WALT BOYES
EDI TOR I N CHI EF
wboyes@put man. net
E D I T O R S P A G E
They are the
competent people
who quietly keep
the world on track
and running free.
The League of Competent People
paying the mortgage, putting food on the table,
clothes in the closet, setting aside money for
college and retirementthose are the things
that we fnd most important.
But the world still needs saving.
We need manufacturing jobs in North Amer-
ica. We need science, technology, engineering
and mathematics (STEM) students to fll those
jobs when we create them.
We need public policy advocates for manu-
facturing and STEM.
We need advocates for minorities and women
in STEM jobs. We need advocates for a tax and
budget policy that will repair our antique infra-
structure, so that people driving to work wont
get killed when the highway bridge falls down,
as it did in St. Paul, Minn., a few years ago.
We need advocates for incentives for R&D
expenditure by major technology companies.
We need people to think up new technolo-
gies that step lighter on the Earth than we do
now. We need innovators in medicine, in food
science, in logisticsin every area of human
endeavor.
Whos going to do those things?
Rudyard Kipling, the 19th century poet,
wrote The Sons of Martha, a poem that talks
about the people who make the world work.
Kipling describes them this way:
It is their care in all the ages to take the buffet
and cushion the shock.
It is their care that the gear engages; it is their
care that the switches lock.
It is their care that the wheels run truly; it is
their care to embark and entrain,
Tally, transport, and deliver duly the Sons of
Mary by land and main.
Who are the Sons of Martha? They are the
engineers, the technicians, the scientists, the
researchers, the craft workers, the airplane
and turbine builders, the highway laborers,
the bridge-builders and all the other folks who
keep civilization moving through the simple
art and discipline of doing a good job. They are
the ones who go to work every day and deliver
a days work for a days pay. They are the ones
that stay late and work hard because they care
about a job well done.
The Sons of Martha dont think they are any-
one special. They dont tootle their own horns.
They live simply, most of them, because to
them, it isnt about who has the most toys, but
who has the most skills and who employs those
skills the best way.
The Sons of Martha are the competent peo-
ple who quietly keep the world on track and
running free. In manufacturing and in auto-
mation, that would be us.
I call us the League of Competent People.
If we do our own jobs competently, we con-
sciously or unconsciously search for fellow
members and surround ourselves with them.
They (we) are the people everyone trusts to
keep things going. And in our own ways,
each of us is trying to save the part of the
world we can.
That, you see, is the real key. Saving the
world is such a daunting task that nobody can
do it alone, and its so enormous that many peo-
ple dont even start. But heres a thought. Ev-
erybody eats pie one bite at a time. If we each
pick one thing that we know we can do, and
do competently, and we work on just that one
thing, there will be change. And then we can
go on to the next thing, and the next.
So heres to the League of Competent Peo-
ple. Working together, we really can save the
world.
In the 2003 flm, The League of Extraordinary Gentlemen, which starred Sean Connery,
a group of truly remarkable people gathers together to save the world. Id love to save
the world, but what I think I can do is to do my job and live my life as competently as I
know how. Thats what I think most people want to do. Saving the world is fne, but
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Other product and company names listed are trademarks or trade names of their respective companies. 05310
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.
KATHERINE BONFANTE
SENIOR MANAGING EDITOR, DIGITAL MEDIA
kbonf ant e@put man. net
A P R I L / 2 0 1 2 www.controlglobal.com 13
C O N T R O L O N L I N E
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Spring is here and many of us have started making plans for our time offpref-
erably far away from industrial automation systems and processes. But just as
we need to keep our wits about us to prevent the fun from turning bad, vigi-
lance is necessary for the safety of our industrial facilities and automation pro-
cesses as well. We know what letting our guard down can cost.
Remember the Deepwater Horizon oil spill in April 2010? It lasted three
months, killed 11 men, injured 17 and caused extensive damage to marine and
wildlife habitats, as well as to the Gulfs fshing and tourism industry. Process
control consultant Bla Liptk covered the oil spill disaster from a process auto-
mation perspective in his article Can Process Control Prevent Oil Well Blow-
outs? In this article, Liptk asked if we could have pre-
vented the blowout with properly designed process control
systems. Read his answer and much more at www.control-
global.com/articles/2010/OilBlowouts1008.html.
Last month was the frst anniversary of Japans nuclear
meltdown at the Fukushima Daiichi nuclear power plant.
Since the Chernobyl disaster of 1986, last years nuclear
meltdown at Fukushima has been the largest peace-time nuclear disaster seen.
Learn more about the Fukushima meltdown by reading editor in chief Walt
Boyes article, The Nuclear Mess, at www.controlglobal.com/articles/2011/
the-nuclear-mess.html.
If you want to know more about how this tragedy unfolded, and see what
events looked like on the ground, visit our SoundOff! blog and read the entry
Inside Fukushima and Preventing Future Disasters at http://community.con-
trolglobal.com/content/inside-fukushima-and-preventing-future-disasters. See
also Liptks three-part analysis of what went wrong and how to prevent such
accidents in the future at www.controlglobal.com/articles/2011/FukushimaNu-
clear1105.html, www.controlglobal.com/articles/2011/preventing-nuclear-acci-
dents-by-automation.html, and www.controlglobal.com/articles/2011/how-au-
tomation-can-prevent-nuclear-accidents-part-3.html.
If natural disasters arent enough to worry about, now we have cybersecurity
breaches. They happen quickly, wirelessly, remotely and now are weaponized.
Read Stuxnet and the Paradigm Shift in Cyber Warfare by Robert M. Lee
(www.controlglobal.com/articles/2011/stuxnet-paradigm-shift-in-cyber-warfare.
html) for a glimpse at the implications of control system vulnerability.
Here is hoping for a safe spring and a wonderful summer for you and all your
control systems.
Caring for Your pH Sensors
When and how to inspect, clean and
calibrate pH sensors.
Proper Employment of Guided Wave
Radar in Steam Loops
How this technology functions and
differs from more traditional forms of
level indication.
Condition Based Maintenance
Use Real-Time Equipment Data to
Reduce Downtime
To download PDF papers, go to www.
ControlGlobal.com/whitepapers
Automation Fair 2011 Special Report
See the best of the many presenta-
tions from the November meeting.
www.controlglobal.com/wp_
downloads/120306-rockwell-af-
2011specialreport.html
HMI Software Library
A complete solution library full of HMI-
product demos, brochures, datasheets
and success stories. www.control-
global.com/wp_downloads/120306-in-
vensys-hmi-software-library.html
Control Talk Blog
Greg McMillan brings his expertise
and his blog to Control Global. http://
community.controlglobal.com/con-
troltalkblog
Spring Is in the Air and
Safety on Our Minds
MAGNETROL
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Why settle for an educated guess, when you can get true top-of-probe
level readings from the Eclipse Model 705? The level transmitter
that introduced guided wave radar technology to industrial control
applications offers probes that detect true liquid levels without
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that compensate for loss of signal that can occur at the top of typical
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A P R I L / 2 0 1 2 www.controlglobal.com 15
T E C H N I C A L L Y S P E A K I N G F E E D B A C K
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Misplaced ICS-CERT Priorities
[Editors note: The following is a response to
Joe Weiss Unfettered blog post on The
Case of ICS-CERT Misplaced Priorities
(http://tinyurl.com/6s69dsg).]
ICS-CERT is supposed to respond to
requests for assistance. If not asked, they
cant help. Even more of a problem is
that, if they are asked to help, they may
not be allowed to publicly disclose the
problem/response. There are no legal
impediments to sharing sanitized (no
names/locations) reports about building
HVAC systems. Power plants are a com-
pletely different story. If there was an
ICS-CERT response to the December
power plant incident, it would have been
nice if they could have appropriately sani-
tized a report on what caused the prob-
lem. Could this have been one of the 86
control system attacks reported to Con-
gress by DHS?
PATRICK COYLE
||tmi ts| |sti | i | 1ttari | Ntws
Whats the Best PID Execution Time?
[Editors note: This is a response to Greg Mc-
Millans answer to this question in the Con-
trol Talk Blog (http://tinyurl.com/7j3x5rd).]
I have been a great fan of your work for
quite some time. I dont see a lot of replies,
as if this is a non-issue in the industry, or
there is nothing else to say on the subject.
Here is my two cents. When talking about
PID sample rate, we still should remem-
ber the Nyquist sampling theorem. Even
with the great advances of late in A/D con-
version precision and input channel scan
rates, a PID can still be fooled into con-
trolling an alias signal given the right cir-
cumstances. The sampling theorem thus
adds another low limit on the PID execu-
tion rate.
S_KUZNETSOV
Societys Current Values
With regard to your article on revitaliz-
ing manufacturing [We Get What We
Deserve, Feb. 12, p.8], its easy to see
where a society is going by observing what
it values most. Several weeks back, an ini-
tial public offering was made for Facebook.
Analyists said it could be worth upwards
of $100 billion! Further research might
reveal that General Motors market cap is
only $41 billion. An enterprise where a few
software geeks facilitate note passing and
texts between teenagers and allows on-line
Scrabble is worth 2.5 times the largest au-
tomobile manufacturer in the world! Go
fgure! As a nation,
which would you
rather have inside
your borders?
Society has de-
voted the last 40
years to passing the
message that man-
ufactring is dirty,
dangerous and un-
rewarding. Regulatory agencies like the
EPA and its satraps at the state level have
devoted decades to industrial eradica-
tion. As it is pictured today, would you
want your son or daughter to pursue a
career in a factory? No wonder that we
now sit with an economy almost entirely
devoted to fxing things that other, more
farsighted societies make.
The halcyon years for American work-
ers were between 1969 and 1972. They
made the most money relative to infation,
had the most political infuence, were
prouder of what they did and in general
commanded respect at all levels of society.
This is no longer true. People are now in a
race to the fnancial bottom to hang on to
what little of those jobs remain. It said that
fnding qualifed employees is now the
issue. No wonder! The EPAs attitude of
slash and burn, particularly as conducted
in the Rust Belt, has consumed even our
seed corn.
To turn this sad situation around, I
would revert all government regulations
back to June 1970 and only allow changes,
if any, to be made through congressional
approval. It is the only way to bring us
back. Hopefully its not too late.
NORM SCHEELS, PE
Jri | t || |sre| |||
[For more letters go to www.controlglobal.
com/1204_Feedback.html.]
FEBRUARY 2012
Busting Foundation Fieldbus Myths
The Lowdown on Radar Level Measurement
Keeping Process Analyzers On-Stream
EXCLUSIVE TO THE WEB
New Strategy for Controlling HF Alkylation
Three men whose careers changed the
automation industry and the world.
Cast a
GIANT
SHADOW
O T H E R V O I C E S
16 www.controlglobal.com A P R I L / 2 0 1 2
MAURICE WILKINS
VP, GLOBAL MARKETI NG YOKOGAWA
MEMBER, PROCESS AUTOMATI ON
HALL OF FAME
mauri ce.wi l ki ns@us.yokogawa. com
The conference
theme, Focus
on the Future, is
targeted to help
you build your
companys global
competitive
capability.
The Future of Process Manufacturing
For years, weve been watching it happen. We have been saying we need to fx the
problems. And by and large, the problems havent gotten fxed, and theyve just gotten
bigger. These problems include many things that keep plant management up at night:
How can I ensure that my control system is secure? Should I use ASM style graphics for
my new HMI? What would happen to my pro-
cess if we had an incident? Could the operators
cope with the alarms? And what on earth am
I going to do when, Joe, my most experienced
operator retires next year? How will I be able
to train the new guys to the level of skills he
has? I am sure to lose production in the learn-
ing process.
These problems are real, and they are loom-
ing over manufacturing in the process indus-
tries like storm clouds. The recession gave us a
little borrowed time, but were running out of
that now too.
We are losing experienced operations and
maintenance people much faster than we can
replace them. And when they go, they take with
them the wealth of detailed understanding and
situational awareness that makes the plant run.
Process plants are aging in North America and
Europe. The newest oil refnery in the United
States is close to 40 years old. These plants
were not designed for modern production or
productivity, and the control systems are often
patched up, band-aided and cobbled together
without much thought other than keeping the
plant running. Instruction manuals are often
flled with scribbled notes and sticky labels that
are diffcult to decipher, much less understand.
This situation has already killed people (at BP
in Texas City in 2005, for example) and its just
getting worse.
Control systems were never designed to be
secure, and now that they run on Windows op-
erating systems. They all have access to the In-
ternet, and they are diffcult to secure. What
do I do frst? Patch the system? Put in frewalls?
What?
We have been searching for a new HMI met-
aphor for years, ever since we realized that the
use of computer terminal displays had robbed
the operator of the easily-gained, whole-pro-
cess situational awareness of the panel wall. So
weve started to recreate those old panel walls
on huge video screen displays, but isnt that
just back to the 1960s? How do we train new,
young operators who have grown up with video
game consoles and joysticks and want to just
jump right in and start playing?
And what happens if we have an accident
an abnormal situation? Do the operators
know enough and have enough experience
and situational awareness to know how to shut
down the plant in an orderly fashion? Or will
they have to think through the process of shut-
down on the fy in an emergency, like the op-
erators at BP Texas City did, and will they fail
as dismally?
How about the as-built drawings and man-
uals? They are at least 40 years old, in most
cases, and very often bear no real relationship
to whats really installed and operating now.
We are trying to produce products optimized
for the 2010s with devices and control systems
optimized for the 1980s and 1990s. Is it any
wonder that were having problems?
Clearly, we need a way to learn how to han-
dle those issues, and help make our plants op-
erational over the next decades.
We need a targeted way to discuss and learn
how to solve these problems. We need a place
where our peers can gather and share best prac-
tices and benchmarks with each other.
We are happy to report that such a confer-
ence exists and will take place this May. The
conference is called Automation Technol-
ogy in Process Manufacturing (ATPM, www.
atpm2012.org).
ATPM 2012 is a new conference that will fo-
cus on these issues in applying automation and
control technology in process manufacturing.
The conference, to be held May 21-23 at The
Woodlands, Texas, will bring together industry
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O T H E R V O I C E S
18 www.controlglobal.com A P R I L / 2 0 1 2
thought leaders to discuss recent developments and best prac-
tices affecting process manufacturing.
Industry experts will show how the application of some of
the newer standards such as ISA101 (HMI), ISA18.2 (Alarm
Management), ISA99 (Control System Cybersecurity) and
ISA106 (Procedural Automation for Continuous Processes)
can help manufacturing companies to look to the future in
a positive way and address some of the hottest industry is-
sues created by the loss of skills due to the retiring Baby
Boomer generation and the growth in cyber attacks on pro-
cess manufacturing.
They will also address such issues as whether the power
and fexibility of modern control systems is a help or a hin-
drance. Its possible to alarm absolutely anythingbut is
that necessary? Maybe the system itself can decide which
alarms the operator can see and under what conditions.
Then there is the question of gray-scale graphics. Is that
what operators want? Again, a modern control system can
present 3D graphics of any color, with animation included,
but maybe its better to use the power of the control sys-
tem to manage the graphics based on process conditions.
Come and see for yourself what the experts have to say
about these questions and fnd out what some of your peers
are doing to address them.
The conference theme, Focus on the Future, is tar-
geted to help you build your companys global competitive
capability. As global competition becomes a bigger issue for
every manufacturer, it becomes critical to understand and
apply the latest process manufacturing expertise to remain
competitive.
Setting the stage will be two keynote speakers, Eddie
Habibi, the founder and CEO of PAS (www.pas.com) and
myself.
Habibis talk, KM is dead! Long Live Collaboration!
will look at how 21st-century technologies will forever
transform knowledge retention and retrieval. Over the past
three decades, knowledge management (KM) technologies
have yielded mixed results and, more often than not, have
failed to deliver the high-value benefts they promised. In
addition, traditional KM approaches require signifcant
initial effort and cost to implement, rely on humans to fol-
low strict procedures, and are challenging to maintain. In
fact, it is very hard to get experts to tell you what part of
what they know is important and useful, and what part is
magical thinking. (Why do you do that? Because that
is what they told me to do it 15 years ago when I started
here.) Also, KM systems do not easily integrate with daily
work processes, and most important, are diffcult to re-
trieve context-based information from.
Web 2.0 is fast replacing and making obsolete the whole
notion of KM. Collectively, wikis, blogs, Twitter and other
social media are transforming the way humans interact with
and share information. The process automation industry,
traditionally conservative in adopting breakthrough tech-
nologies, is warming up to the idea of Web 2.0 as a modern
platform for aggregating, contextualizing and sharing criti-
cal information and knowledge. This is especially important
as it directly impacts the accuracy of the decisions made by
plant personnel in mitigating abnormal situations and opti-
mizing plant operations.
In my presentation, I plan to ask the question, Digital
Native OperationsIs There an App for That?
We hear much about the looming skills gap and the fact
that many of todays process operators lack the necessary
high-tech skills. But, they have an excuse; they are digital
immigrants. They were born in the days when blackberries
and apples were fruits, and the only use for a phone was for
making phone calls. Having said that, has technology been
used to its best effect in the process industries to help these
operators? What has happened that may have been avoided
with the use of currently available technology? Is it too late
to get these operators on board?
And, waitwhos that coming to the rescue? Its the digi-
tal natives, who were born into digital technology, and mul-
titasking is second nature to them. The last thing they use
a phone for is to make calls, and any type of PC is pass at
best. They want information at their fngertips now. These
are our operators of the future. How will they help us to sur-
vive? And what will the proverbial control room of the fu-
ture, where theyre going to be working, look like? What
will be the effects of the end of the PC era? Will the opera-
tor of the future even be in the control room at all, or will
the plant be the control room, as the operator walks around
doing rounds?
That rescue can happen if we can convince the digital
natives that process manufacturing is as cool as working for
Google or Apple or Bain Capital. Listen to ways to improve
the education process, so that more young people come
into the science, technology, engineering and mathematics
(STEM) tracks in elementary schools and high schools.
Come to The Woodlands for this exciting new conference
and put your mind to rest that the future is in safe hands
yours! Please visit www.atpm2012.org for all the details and
to register.
In addition to a great conference, you get to participate
in the award ceremony for the Process Automation Hall of
Famea dinner that will honor Vern Heath of Emerson
Process Management, Mark Nixon of Emerson Process
Management, and Tom Phinney, retired from Honeywell,
as they are inducted into the hall. Listen to these automation
industry greats talk about their contributions and the issues
they see in automation in the next few years. Celebrate the
history of automation in process manufacturing as we learn
how to create its future.
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O N T H E B U S
JOHN REZABEK
CONTRI BUTI NG EDI TOR
JRezabek@ashl and. com
A P R I L / 2 0 1 2 www.controlglobal.com 21
Measurements and
controls arent an
end in themselves,
but a set of tools
and technologies
we provide to the
enterprise.
the rank and fle revert to their traditional, reac-
tive, fre-fghting ways. But before one can even
recruit for such a role, plant management has
to be convinced to create a position. In a time
when it seems our management is all about re-
ducing headcount and positions, how do you
sell them on the value of a dedicated role for
exploiting smart instrumentation?
A couple years ago when John Berra was re-
tiring as chairman of Emerson Process Man-
agement, he told the story of his meeting with
a plant manager, who told him, I just want you
to know that I think all automation projects
have zero ROI. I wondered whether the guy
was still blending leaded gasoline. Can a plant
manager really be that clueless? Some of you
may be muttering, You have no idea.
But before you dismiss the effort of selling
this idea of techs owning their systems as tilt-
ing at windmills, I suggest that we can make
the value proposition in a way management is
more likely to grasp. One might protest, Its
their job to understand us, but for the most
part, theyre not in a higher pay grade because
their job is simple or easy. Sometimes we have
to meet them more than half way.
Our profession has the pleasure of actually
applying tools and technology directly to the
process. We have a geeks paradise of gadgets,
computers and contraptions, and we can be
spoiled divas with our suppliers if were so in-
clined. Often were so immersed in the technol-
ogy that we forget that its a means to an end. It
took me quite a few years to come to the realiza-
tion that measurements and controls werent an
end in themselves, but a set of tools and tech-
nologies we provided to the enterprise. Im just
a link in the chain of delivering value to the
end user.
Once one enters the realm of management,
all your achievements are through others. Your
infuence is not exerted with the certainty of
a mouse click, but with the feeting hope your
reports will keep your ship off the rocks and
sailing into calm harbors. You accomplish this
through policies, emails, staff meetings and
performance appraisals, all through interac-
tions with people, not specifcations, technol-
ogy and machines. It may not be highly techni-
cal, but its far from uncomplicated. So when
youre talking to your manager, you beneft
from keeping the value proposition succinct.
Running a process plant is risky. Managers
are paid the big bucks to make decisions that
many times boil down to how much insurance
do I want to buy? For example, how many
spare parts do I need to buy, manage and keep
in stock? When the plant goes down, or I lose
production, or I have to rerun off-spec material
and disappoint a customer, will my judgment
be found lacking?
Asset management is risk management. Our
instrument asset management value proposi-
tion should be simple and conveyed in fve Pow-
erPoint slides or less (the higher up the man-
agement ladder youre making your pitch, the
fewer the slides). It should go something like
this: because weve learned to pay attention to
the alerts from our intelligent devices, we will
keep our plant on-line when the other guys are
down; we will be safer and in compliance when
the other guy is running blind; we can prevent
the fare from blazing for days because some-
one believed a bogus or stale number; but to do
this, we need people in roles that are devoted to
creating and maintaining the infrastructure to
bring in feld diagnostics, and then to organize,
prioritize and report on them.
The ROI from this effort isnt easy to quan-
tify. Its always tough to put a number on the
shutdown that didnt happen. Next month:
quantifying diagnostics payback.
Last month, this column suggested that process plants would beneft from assigning
systems-capable technicians to the task of owning smart instrumentation and the as-
set management infrastructure that interacts with them. Experience has demonstrated
that, without a champion, instrument asset management systems can gather dust, and
Selling Diagnostics to Management
22 www.controlglobal.com A P R I L / 2 0 1 2
I N P R O C E S S
Infnity Charter School Team
Wins Nanoline Contest
Middleschoolers win trip to Germany, for their smart, solar, mobile charging station.
A team of seventh- and eighth-grade
students from Infnity Charter School
in Penbrook, Pa., has won a trip to
Hannover, Germany, in Phoenix
Contacts Nanoline Contest. The an-
nouncement came as part of Phoenix
Contacts National Engineers Week
celebration on Feb. 19-25.
The team built a smart, solar, mobile
charging station (SSMCS), which can in-
telligently track the sun for non-station-
ary applications, such as electric vehicles
or boats. It uses solar energy to charge bat-
teries of electric vehicles.
Using Phoenix Contacts nanoNavi-
gator software, the team wrote several
programs to monitor conditions, such
as time of day, level of battery, whether
the car is on or off, and the acceptable
voltage difference. Based on these con-
ditions, the Nanoline controller can
maximize the vehicles charging capa-
bilities. The system also uses the Nan-
olines SMS capability to send the op-
erator a text message about the current
battery level.
Team members are Sam Wille, Wil-
liam Leuschner, James Thompson and
Jerrett King. Theyll travel to Hannover,
Germany, this month, where they will
demonstrate the project at the TectoYou
Hall at Hannover Fair (Hannover Messe),
which is the worlds largest industrial
tradeshow. TectoYou is a special hall ded-
icated to inspiring young people to con-
sider careers in engineering.
Second place ($500) went to Lower
Dauphin High School, Hummelstown,
Pa., for the computerized universal re-
mote table interface system (CURTIS).
Early College East High School, Have-
lock, N.C., took third prize ($250) for
the HydroPal home water manage-
ment system.
For the frst time ever, Phoenix Con-
tact engineers also voted on the proj-
ects. The inaugural Phoenix Contact
Engineers Choice award ($100) went
to the Infnity team.
The Nanoline Contest challenges
students to build a working control sys-
tem using Phoenix Contacts Nanoline
controller and intuitive nanoNavigator
software.
For an overview of the Nanoline
Contest and a look at previous winning
projects, visit www.phoenixcontact.
com/company/59147.htm.
CABA to Promote
ISA Courses
The Continental Automated Build-
ings Association (www.CABA.org) has
agreed the International Society of Au-
tomation (www.ISA.org) to promote
ISAs education and training courses to
CABAs membership.
ISA has an extensive collection of
non-biased, vendor-neutral programs
for automation professionals, including
courses at ISAs regional training cen-
ters, onsite training programs and dis-
tance-education programs. Many of the
courses are lab-intensive to reinforce
important skills.
CABA has committed to promoting
ISA courses that address building auto-
mation and control systems through the
CABA website. Links to ISA courses are
available for immediate access at www.
caba.org/education-and-training.
CABA is extremely pleased to en-
ter into this agreement, said Ronald
Zimmer, CABAs president and CEO.
One of the most important functions
of CABA is to educate industry stake-
holders and consumers about the ad-
vantages of intelligent buildings and
the process for creating and maintain-
ing intelligent buildings. We believe
our agreement with ISA will lead to a
stronger, educated workforce.
The winners of the 2012 Phoenix Contact Nanoline contest are (l. to r.) Sam Wille, Jerrett
King, James Thomson and William Leuschner.
SMART SOLAR MOBILE CHARGING STATION BUILDERS
www.yokogawa.com/us
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2011-fall-insert-outside:Layout 1 8/25/2011 8:55 AM Page 1
You need quality products
at a great price from a solid supplier. . .
. . . Since 1994 our prices have been
typically 50% less than more traditional suppliers.
Since our industry-changing catalog first hit the mailboxes in 1994,
weve been offering a better value on industrial controls by running
our business efficiently and passing the savings on to our customers.
In 1999, we made it easier to research and purchase by becoming
the first automation supplier with a 24/7 online store.
Weve made the commitment to offer the best products at
the best value we could deliver so you have a better choice.
In this uncertain economy, you need to
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Programmable Controllers
Field I/O
Software
HMI
Drives
Soft Starters
Motors & Gearboxes
Steppers/Servos
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Limit Switches
Encoders
Current Sensors
Temperature Sensors
Pilot Devices
Process
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Power Products
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Tools
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part numbers are available fromvendors. All prices subject to change without notice.
NEMA12 Enclosure, steel,
wall mount (20x 16x 8)
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more info
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Easy for new user
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2011-fall-insert-inside:Layout 1 8/25/2011 8:57 AM Page 1
You need quality products
at a great price from a solid supplier. . .
. . . Since 1994 our prices have been
typically 50% less than more traditional suppliers.
Since our industry-changing catalog first hit the mailboxes in 1994,
weve been offering a better value on industrial controls by running
our business efficiently and passing the savings on to our customers.
In 1999, we made it easier to research and purchase by becoming
the first automation supplier with a 24/7 online store.
Weve made the commitment to offer the best products at
the best value we could deliver so you have a better choice.
In this uncertain economy, you need to
save money and save time . . . we can help.
Programmable Controllers
Field I/O
Software
HMI
Drives
Soft Starters
Motors & Gearboxes
Steppers/Servos
Motor Controls
Proximity Sensors
Photoelectric Sensors
Limit Switches
Encoders
Current Sensors
Temperature Sensors
Pilot Devices
Process
Relays/Timers
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Terminal Blocks
Wiring
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AutomationDirect
Price/Part Number
Competitor
Price/Part Number
All prices are U.S. published prices. AutomationDirect prices are as of October 2011. Hoffman
prices are taken fromwww.hoffmanonline.com 2/14/11. Allen-Bradley list prices are taken from
http://www.rockwellautomation.com/en/e-tools 2/21/11. Prices may vary by dealer. Many other
part numbers are available fromvendors. All prices subject to change without notice.
NEMA12 Enclosure, steel,
wall mount (20x 16x 8)
$243.00
N12201608
$489.30
Hoffman A-201608LP
Supplementary Protector,
Single pole, 5 AMP,
D trip curve
$8.50
WMZS1D05
$42.60
A-B 1492-SP1D050
AC Drive, 5 hp, 460V
$407.00
GS2-45P0
$995.00
A-B 22B-D010N104
Proximity sensor, 18 mm,
3-wire NPN DC shielded,
with 2-meter cable
$21.75
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$81.90
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more info
www.aboutplcs.com
Easy for new user
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control
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2011-fall-insert-inside:Layout 1 8/25/2011 8:57 AM Page 1
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Motion Control
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Comments from our current customers:
Products are a good value for a fair price.
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trying the pneumatic fittings with great success.
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AutomationDirect is the best vendor of automation
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not even close. I make regular decisions to purchase
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This company is by far the easiest to
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2011-fall-insert-outside:Layout 1 8/25/2011 8:55 AM Page 1
I N P R O C E S S
EtherNet/IP Now
Standard in Asia
The National Development and Re-
form Commission of the Peoples Re-
public of China has adopted EtherNet/
IP, along with ControlNet, under the
highest Chinese National Standard
GB/Z. CIP technologies were previ-
ously adopted under Chinese industry
standards JB/T 10308.2-2006 in 2007.
The Korean Agency for Technology
and Standards (KATS) also recently ad-
opted EtherNet/IP under the Korean
Industrial Standards KS C 61784 and
KS C 61158. KATS aims to improve
the international competitive power of
local enterprises through the introduc-
tion of international standards for in-
dustrial communication networks, and
to support Korean enterprise. KATS
harmonizes local industrial standards
with international standards.
ISA Opens Two New
Membership Grades
ISA has added two new member-
ship grades: Automation Community
Member and Automation Affliate
Member, for automation professionals.
The Automation Community Mem-
ber grade is for professionals in the au-
tomation community who would like
to be associated with the society and
learn more about it while enjoying
some popular benefts.
Individuals may join at no charge.
This membership grades benefts in-
clude free access to a library of more
than 40 online, pre-recorded web
seminars; free digital subscription to
InTech magazine (digital) and Auto-
mation Weekly (e-newsletter); mem-
bership in ISA technical divisions for
$10 per division; participation in ISAs
mentoring program; and access to the
ISA LISTSERV for email discussions.
The Automation Affliate Member
grade is open to individual members
or employees of companies belonging
to organizations that are members of
the Automation Federation, includ-
ing ISA, the Institution of Engineer-
ing and Technology (IET), National
Council for Advanced Manufactur-
ing (NACFAM), Society of Manufac-
turing Engineers (SME) Education
Foundation, Continental Automated
Buildings Association (CABA), Control
System Integrators Association (CSIA),
American Small Manufacturers Coali-
tion (ASMC), National Career Devel-
opment Association (NCDA), Society
of Manufacturing Engineers (SME),
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To read the whole story, visit: www.prosoft-technology.com/migration
Minimize
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Legacy networks include: Honeywell, Texas
Instruments, Schneider Electric, Fisher-PROVOX,
GE, PROFIBUS; AB Remote I/O, DH+
ProSoft Technology provides a full suite of migration solutions for Rockwell
Automation control architectures. These modules are designed to help
upgrade legacy control platforms, connecting them via EtherNet/IP to
Allen-Bradley PACs.
- Monltor mode: verlfy new controller
code with live input data
- Laslly swap back to old controller
whlle debugglng new system
- Prove your new control system
before you commlt
- Pe-use exlstlng |/O wlth your new
Logix Controller
- Defer |/O replacement capltal cost
I N P R O C E S S
Society of Women Engineers (SWE), Wireless Industrial
Networking Alliance (WINA) and the Organization for Ma-
chine Automation and Control (OMAC).
Automation Affliate Membership is $50 per year. Ben-
efts include those for Automation Community Members,
plus free online viewing of ISA standards; a 10% discount on
the cost of ISA standards; and a $50 credit towards the pur-
chase of an ISA standard.
Wireless Standards a Mixed
Blessing for Process Industries
The prospect of adding wireless devices to the process au-
tomation architecture is a compelling one from the per-
spective of tangible business benefts and incremental op-
erational improvements. Availability of robust industrial
wireless network protocols, for use with IEEE standard
technology makes the prospect even more attractive relative
to past proprietary, often standalone, wireless implementa-
tions. This potential is somewhat offset, however, by com-
petition between these standards that leads customers to
fear that wireless is emerging as the next platform for the
automation feldbus wars, according to Chantal Polsonetti,
vice president of ARC Advisory Group (www.arcweb.com)
and principal author of ARCs Wireless Devices in Process
Manufacturing report.
From Proprietary to Standard and Integrated
As the WirelessHART and ISA100.11a standards gain foot-
holds at the sensor level, a majority of the process wireless
market will gravitate away from legacy proprietary solu-
tions that continued to account for a large share of the 2011
market. Concurrent with this shift, a migration away from
standalone, point-to-point installations will occur in favor
of mesh-based, inherently redundant device-level solutions
that interface to a Wi-Fi-based plant or facility backbone.
Tighter integration of wireless implementations with the
overall automation scheme is central to this migration. The
addition of incremental measurement points due to availabil-
ity of wireless devices is attractive, but the ability to integrate,
analyze and act on these additional measurements is reliant
on integration with the control or monitoring system.
Availability of industrial wireless standards at the device
level is leading to the mainstreaming of wireless devices and
consequently higher supplier participation. The relatively
recent introduction and certifcation of the industrial stan-
dards means that many products are still in the developmen-
tal pipeline. ARC expects the supplier landscape to expand
dramatically over the next decade as numerous sensor, trans-
mitter, actuator and other device-level product suppliers in-
troduce wireless offerings.
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T
A P R I L / 2 0 1 2 www.controlglobal.com 33
R E S O U R C E S
PLCs and PACsWhat You Need to Know Now
Controls Monthly Resource Guide
Every month, Controls editors take a specifc product area, collect all the latest, signifcant tools we can fnd,
and present them here to make your job easier. If you know of any tools and resources we didnt include, send
them to wboyes@putman.net, and well add them to the website.
PLCs vs. PACs
This white paper describes the ben-
efts and basic differences between
programmable automation controllers
(PAC) and the more traditional pro-
grammable logic controllers (PLC).
This document describes the factors
and criteria you should take into con-
sideration when deciding which plat-
form is better suited for your applica-
tion, depending on your control and
measurement needs. See comparisons
between graphics, measurements, pro-
cessing capabilities, communications
and platforms. The direct link is found
at http://tinyurl.com/ybhzvef.
NATI ONAL I NSTRUMENTS
888/ 280-7645; www. ni . com
GUIDE TO PACS
This website contains multiple re-
sources for understanding PACs, how
they differ from PLCs, what to look for
when specifying or buying a PAC and
more. A selection of white papers, in-
cluding Understanding PACs in In-
dustrial Automation and What Is a
PAC? videos, Flash presentations and
more. Go to http://tinyurl.com/ybjctkf
for a direct link.
OPTO22
800/ 321-6786; www/opt o22. com
YOUR PERSONAL PLC PAGE
This website contains a series of brief
tutorials, some of which are animated,
on all the aspects of the PLCwhat
it is, how it works, how to program it,
ladder logic, the main instructions set,
wiring and communications, Q&As,
a job board and more. All the main
links are free, although the site con-
tains links and ads for additional paid
instruction.
PLCS. NET
www. pl cs. net /cont ent s. sht ml
FAST GUIDE TO PLCS
This site lists the top 20 Internet sites
for PLC/PAC training and informa-
tion, ranked by user popularity. The
direct link is www.top20sites.com/Top-
PLC-Tutorial-Sites.
TOP20SI TES. COM
www. t op20si t es. com
PLC DEEP DIVE
This site contains information on all
manner of PLC issues: history, hard-
ware, operation, communication, pro-
tocols, programming, installation/
commissioning, vendor selection, se-
lection criteria and more.
PLC MANUAL
www. pl cmanual . com
PAC/PLC PDFs
This website offers free, download-
able PDFs on automation topics, such
as PACs. Available PDFs include In-
troduction to PLCs, Understanding
PACs, Programmable Controllers
Theory and Implementation and
Beginners Guide to Programmable
Controllers. Other topics on the site
include automation, pneumatics, actu-
ators, valves, measuring instruments,
computing software, international
standards and motion control.
CONTROLMANUALS. COM
ht t p: //cont rol manual s. com
PROGRAMMABLE CONTROLLERS
Programmable Controllers by Thomas
Hughes is available from ISA. The
book discusses all phases of program-
mable controller applications from sys-
tems design and programming to in-
stallation, maintenance and start-up.
It covers the fundamental principles of
programmable controllers for process
and machine control, including PLC
programming languagesladder dia-
gram, function block diagram, sequen-
tial function chart, instruction list and
structured textand the addition of
numerous programming applications
and examples clearly explain each pro-
gramming language. Go to http://ti-
nyurl.com/7lezexw.
I SA
www. i sa. org
PLC/PAC INFORMATION HERE
This is a one-stop shop for informa-
tion on PLCs and/or PACs. Chapters
include coverage of I/O wiring and in-
teractions, number systems, memory
structure, bit instruction, timers and
counters.
THE PLC TUTOR
www. t hepl ct ut or. com
EBOOKS ON PLCS AND PACS
This site has a collection of ladder
logic and PLC/PAC tutorials. All are
free. The site contains links to white
papers, ladder logic diagrams, simula-
tions and more. Documents come in
multiple common formats. The direct
link is at http://tinyurl.com/4b7ltzz.
EBOOKBROWSE
ht t p: //ebookbr owse. com
34 www.controlglobal.com A P R I L / 2 0 1 2
New automation industry technologies seem to follow a consistent path from in-
ception to adoption. First, suppliers and research organizations tout the technol-
ogy as a game-changer, a paradigm shift, a must-havepick your clich. Maga-
zines such as this one write about the new technology, but we are skeptical, as
are prospective customers.
If some end users and/or system integrators see possible competitive advan-
tage, then these early adopters try out the technology to fnd out if the benefts
outweigh the costs. Simultaneously, suppliers fght it out to establish their pro-
prietary technology as the standard. Meanwhile, trade magazines and websites
try to fnd real application examples, but often fail, as actual end users are few
and far between.
If end users determine the technology delivers promised benefts and required
rates of return with acceptable risk, and if suppliers agree on standards and in-
teroperability, then the technology is widely adopted.
However, this process can take years or even decades.
Remote access has traversed this path successfully in the process industries,
proceeding from supplier promotion to widespread end-user adoption in less
Remote access is one of the
fastest-growing and most
quickly accepted new
technologies to ever hit the
process control industry.
By Dan Hebert, PE
REMOTE
ACCESS GOES
MAINSTREAM
A P R I L / 2 0 1 2 www.controlglobal.com 35
T H E M O B I L E A U T O M A T I O N P R O F E S S I O N A L
AOC Resins (www.aoc-resins.com) is a global supplier of
resins, gel coats, colorants and systems for composites and
cast polymers. The materials are used in products ranging
from bowling balls and Corvette panels to luxury yachts and
sewer pipes.
AOC has seven process plants located across North
America, all of which are accessed remotely from corporate
headquarters. We have a small group of experts to maintain
and improve our systems, says Danny Cox, director of engi-
neering. This has proven much more effective and less ex-
pensive than having these functions at each location. Were
also able to ensure that production standards are the same at
each site. When were speaking with a remote site about an
issue, were both looking at the same screen.
Control systems at each site are based on Emerson
Process Managements (www.emersonprocess.com) Del-
taV systems and PLCs with T1 connections over a VPN to
all facilities. The engineers connect to each process through
a VPN, using tools such as Remote Desktop, ITAP and PC
Anywhere. Were able to access the system via PCs, tablets
and even smart phones, says Cox.
AOC prefers the wired T1 connection to wireless.
When the connection is wireless, the speed can be an
issue for complex screen updates, Cox explains. Navi-
gation and screen size can make the use of tablets and
smart phones difficult. However, being able to connect
quickly, anywhere, any time is a big plus. We connect
via iPads and iPhones thru the VPN, using Thin Client
arrangements.
When using a thin client, licenses from Microsoft and
Emerson are required. We dedicate at least one license
for corporate use at all sites, Cox explains. Other li-
censes are available to plant personnel. We have browser
access, using third-party graphical interface tools as well.
Remote access has simplifed life for engineers. In a
batch operation, certain events only happen once per batch.
In the past, engineers would come in at odd hours, or work
very long hours to see these events. With remote technolo-
gies were better at optimizing processes, says Cox. Engi-
neers can periodically check status and make adjustments
from anywhere.
AOS has been particularly successful in improving
models that control the air-to-fuel ratios of thermal oxidiz-
ers. Their destruction efficiency has increased, while re-
ducing natural gas consumption by as much as 40% at
some locations. To build the model, an engineer must
view process conditions at various points in the batch pro-
cess, says Cox. This would be very difficult without re-
mote connectivity.
OPTIMIZING PROCESS OPERATIONS FROM AFAR
than 10 years. How do we know? Because
a host of end users and systems integrators
are eager to share remote access success sto-
ries. But, before we get to these successes,
read on to see the advantages that remote ac-
cess provides to process industry end users.
Competitive Advantage
Remote access has no standards-making organization
touting its capabilities. Its not proprietary, and there
isnt widespread agreement on how to accomplish it, yet
its growing at a breakneck pace. When something
comes along that is truly useful and benefcial,
end users jump on it.
By using remote access and other automa-
tion, McCall Farms (www.margaretholmes.
com), a manufacturer of Southern-style foods
in Effingham, S.C., has tripled in size over the
past five years, rising from 75+ million pounds
to over 250+ million pounds of produce per year.
Jeff Crisp, maintenance manager at McCall
Farms, uses a wide range of PC-based remote ac-
cess technologies that enable him to access pro-
cess equipment remotely from different plant
buildings, from his phone and from home, if
theres an urgent need to do so. I can securely and
easily dial into plant systems from my house in or-
der to troubleshoot, says Crisp.
Using our Beckhoff Automation (www.beck-
hoffautomation.com) PC-based control systems, I can
watch any process in the plant run from my office, adds
Crisp. Access from his home is via a VNC server. If
something must be fixed in the middle of the night, this
is a very attractive option.
Other users tell tales about how remote access has al-
lowed them to centralize their engineering operations,
cut travel costs, get help from control equipment ven-
dors, analyze problems and even avoid traveling to dan-
gerous parts of the world (Table 1, p. 38).
There is no overwhelmingly popular method for re-
mote accessprocess automation professionals are us-
ing software technologies such as phone dialing systems,
cell phone messaging systems, virtual private networks
(VPN), virtual network computing (VNC) and various
PC-based software programs that allow remote users to
view and even control PCs at the local site.
Control equipment vendors are also joining the party,
allowing remote access via cell phones apps, providing
software for remote access to their equipment and sys-
tems, and making money by requiring site licenses for
remote access.
T H E M O B I L E A U T O M A T I O N P R O F E S S I O N A L
The cost of getting remote access to
your control system varies from Auto-
mationDirects (www.automationdirect.
com) $4.95 cell phone app to access its
C-More HMIs up to much more expen-
sive and complex systems with gateways,
servers, VPNs, security appliances, ter-
minal servers, site licenses and so on.
Remote Access Fuels Success
Based on the responses we got for this
article, it seems like everybody in the
process industry is using remote access
in one way or another, for a variety of
purposes ranging from equipment di-
agnosis to optimizing control systems.
At AOC Resins in Collierville, Tenn.,
remote access allows AOC to keep all its
engineering experts in one central loca-
tion, where they can tend to the needs
of seven processing plants spread across
the country. (See sidebar, Optimizing
Process Operations From Afar, p. 35,
which shows how AOC can tune batch
reactors at any of its sites from its home
base in Tennessee.)
Likewise, Nor Cal Controls (www.
norcalcontrols.net), a systems integra-
tor in Placerville, Calif., used remote
access to solve a similar problem with
some unfamiliar software. Recently,
we were in the process of providing bal-
ance-of-plant tuning for AEP at one of
its new power plants, says Bob Lopez,
control engineer at Nor Cal. We pur-
chased ControlSofts (www.control-
softinc.com) InTune PID tuning soft-
ware, but because of our unfamiliarity
with the software and the GE ICS PID
controllers, our process models were
generating tuning values that were com-
pletely off in magnitude.
Lopez contacted ControlSoft and
was connected with a process engi-
neer, who assisted them remotely using
TeamViewer software. He was able to
access the control system remotely and
participate in the bump tests and pro-
cess model evaluations, explains Lo-
pez. This allowed him to identify and
correct our PID scaling factors, which
had been the cause of our initial in-
valid numbers.
Saving time and travel expenses is a
major beneft of remote access. For Nor
What
are the
crucial
considerations to
determine the correct
level detection sensor?
askTURCK.com 2012 TURCK
Figure 1. McCall Farms remotely monitors processing equipment in its food plant using
various PC-based technologies.
REMOTE-CONTROL COOKING
By simply attaching his Bluetooth

adapter
to an Agilent handheld DMM, and pairing it to
his Android device running a freeAgilentapp.
Agilent lets you turn your Android smartphone
or tablet into a remote measurement, control,
and reporting device.Accelerate your work
by connecting with Agilent.
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was 3 miles away at a different site?
Dan Cole, Scranton, PA
How?
Download wireless remote connectivity app note
Watch the video to see HOW it works
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T H E M O B I L E A U T O M A T I O N P R O F E S S I O N A L
Cal Controls, it meant the company
didnt have to wait for an InTune ex-
pert from ControlSoft to travel to the
site. For AOC Resins, it means in-
house experts dont have to travel to
process plants. It can be safer, too.
Glenn Givens, principal at Giv-
ens Control Engineering (www.giv-
enscontrol.com), a systems integra-
tor in Burlington, Ontario, Canada,
says he used remote access to avoid
traveling to a location where my
personal safety could not be guaran-
teed, as he puts it. Using a VNC
connection, we quickly discovered
a major roadblock that halted the
project for months. Had I traveled
there, I would have found out after
one day that there was no point in
staying, and the travel costs would
have been extremely wasteful.
When something goes wrong at
a plant, a systems integrator is of-
ten called. The control system is
typically considered the first cul-
prit when things go wrong, says
Phil Murray, principal at FeedFor-
ward (www.feedforward.com), a
systems integrator in Marietta, Ga. Remote access al-
lows a first-hand, real-time view of the control system
that greatly improves our ability to diagnose and solve
problems and provide a rational explanation of events
and possible solutions.
And when there is a problem with
the control system, remote access al-
lows the vendor to help out. At an-
other customer site, we called the
DCS vendor for assistance, and they
logged in via VNC to fnd and cor-
rect the problem, says Givens. The
person with whom we communi-
cated logs in to customer sites all
day, full-time in his technical sup-
port role.
Global systems integrator, Mav-
erick Technologies (www.mavtech-
global.com) also leverages remote
access to service its clients and
ease its internal work. In addi-
tion to the more mature areas like
wireless tank gauging, SCADA and
other remote concepts, weve made
heavy use of the PCs remote ac-
cess capabilities on the newer con-
trol systems, says Chad Harper,
Mavericks director of technology.
Internally, we utilize remote ac-
cess to our internal development
PLCs and DCSs, which allows for
expanded capabilities in training
and project support. We have sev-
eral clients where we perform project and maintenance
work directly in their control system through dedicated
PC-to-PC connections. We also provide network moni-
toring services for clients who have too many remote fa-
cilities to support adequately in person.
Thousands of enclosures
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POWER DISTRIBUTION ENCLOSURES CLIMATE CONTROL
1. Security can be problematic
2. Wireless may slow access
3. Implementation can be complex
4. May require IT involvement
5. Networks may have to be upgraded
6. Site licenses may be required
7. Equipment vendor may not support
remote access
8. Loss of communications may occur at
critical times
9. Usually requires a PC or PAC control
system with Ethernet capability
1. Engineering teams can be centralized
2. Data can be distributed as needed
3. Users, vendors and experts can
diagnose problems remotely
4. Travel costs are cut
5. Travel to dangerous sites can be
avoided
6. Many inexpensive implementation op-
tions are available
7. Standards are in place and widely used
TABLE 2: CHALLENGES OF
REMOTE ACCESS
TABLE 1: ADVANTAGES OF
REMOTE ACCESS
As noted above, equipment vendors are supplying re-
mote access capability, and OEMs use it for their custom-
ers. Process Engineering Resources Inc. (PERI, www.pro-
cesseng.com) in Salt Lake City makes X-ray fuorescence
(XRF) analyzers for the mining/mineral processing indus-
try. The analyzers are used to perform elemental analysis
of slurries in ore concentrator operations.
Dave Taylor, system engineer at PERI, says, We use re-
mote access to the XRF analyzers to assist plant personnel in
troubleshooting issues, analyzer calibration, updating soft-
ware or adding site-specifc features. Since mining operations
are often in remote areas that are diffcult and time-consum-
ing to reach, remote access is crucial for providing timely sup-
port. PERIs analyzers are based on an Opto 22 (www.opto22.
com) PAC, and Taylor gets his remote access via an Opto 22
iPAC app on his iPhone.
There are many ways to skin the remote access cat.
Heres another method, this one used by Sukup Manufac-
turing (http://sukup.com). Sukup, based in Sheffeld, Iowa,
makes grain-handling equipment such as bins, dryers and
conveying equipment. Matt Koch, electrical engineer at
Sukup, says the company redesigned the control system on
its QuadraTouch continuous-fow dryers using a PLC from
Phoenix Contact (www.phoenixcontact.com) with Ether-
net communications.
We offer optional global system for mobile communica-
tions (GSM) functionality, so that our customers can keep
an eye on dryer operations from any cell phone, says Koch.
The GSM modem from Phoenix Contact provides this
add-on functionality. The PLC is already set up to connect
to the modem, so all we have to do is simply plug the mo-
dem into the serial port of the PLC and activate service onto
a SIM card to realize instant GSM functionality.
Some remote access systems do more than just diagnose
problems and monitor operations. Dart Oil and Gas uses it
to provide data to feld engineers. And, unlike typical systems
that use browsers and cell phones to view conventional HMI
displays, Darts displays were designed from the beginning to
be web pages. (For more on how Dart uses remote access, see
the sidebar, Distributing Production Data, p. 42).
Meanwhile, Malisko Engineering (www.malisko.com), a
systems integrator in St. Louis, Mo., has been using remote
T H E M O B I L E A U T O M A T I O N P R O F E S S I O N A L
SOFTWARE & SERVICES IT INFRASTRUCTURE
Figure 2. Sukup Manufacturing lets customers monitor operations of
their grain dryers via remote access over a cell phone.
REMOTE DRYING
T H E M O B I L E A U T O M A T I O N P R O F E S S I O N A L
access for 10 years, so its in a good po-
sition to summarize the advantage of
remote access. Dan Malyszko, senior
systems engineer, sums it up: Remote
access to industrial automation systems
has proven to be an extremely cost ef-
fective component of a plants support
system. Remote access provides plant
personnel, OEMs and integrators with
timely, interactive troubleshooting
when issues arise.
Getting a process line back up
and running in minutes rather than
hours by giving technical support re-
sources via remote access can help
a plant avoid thousands of dollars
of downtime. Another benefit is re-
duced costs when making control
system programming changes. De-
pending on the nature of the pro-
gramming change request, travel
costs can be eliminated entirely
when performing the work via re-
mote access.
Challenges Can Thwart Remote Access
Two major and related challenges
face engineers who want to employ
remote access: security concerns and
their own IT department.
Hackers are getting so good these
days, they can penetrate a control
system through any portincluding
even the maintenance port of a UPS.
Space does not permit an analysis of
all the cybersecurity problems fac-
ing industry today, but suffice it to
say that users need to be very careful.
Thats where the IT department
comes in, for better or worse. Due
to NERC/CIP requirements, were
seeing some of our customers mov-
ing us to a secure VPN, only allow-
ing access to PCs a layer removed
from the control network, says Lo-
pez of Nor Cal Controls. While still
extremely helpful, its less functional
than being directly connected to the
control system.
In some cases, bypassing the cor-
porate IT system is the best option.
In one operation where we could
not access the analyzers from the
corporate network due to IT policy,
we installed a phone line and a mo-
dem directly in the analyzer cabi-
net for dial-up access, says PERIs
Taylor. We have also used satellite-
based Internet connections for re-
mote sites.
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Figure 3. Dart Oil and Gas distributes data to a wide variety of remote clients using
OPC and other technologies.
Smartphone PC OPC trend OPC XL OPC web client/
Internet
OPC database
Corporate HQ
with Windows 7
RTU RTU RTU
Application
(OPC client)
Open data access via OPC
HMI HMI SCADA SCADA
12.252 12.252 12.252
MULTIPLE CLIENTS AND LOCATIONS, ONE SOURCE
42 www.controlglobal.com A P R I L / 2 0 1 2
T H E M O B I L E A U T O M A T I O N P R O F E S S I O N A L
Or you can have your systems integrator or control sys-
tem vendor take care of it. Our primary remote access
technology is via a secured VPN connection using a Cisco
ASA 5500 Series adaptive security appliance or similar hard-
ware, says Malyszko of Malisko Engineering. Oftentimes,
we procure, install and confgure VPN hardware for our cli-
ents as an option to the base cost of a project.
James Burnand, director of the Mid-Atlantic region for
Grantek Systems Integration (www.grantek.com), uses remote
access technology from Rockwell Automation (www.rockwell-
automation.com) and others, and he advises limiting remote
access to just the control system. To maintain strict control of
remote access, its best to keep automation and control proto-
cols at home in the manufacturing zone. Limiting the proto-
cols to this zone helps ensure that the automation and control
devices are communicating with known devices and applica-
tions, with user authentication and role-based authorization.
Mavericks Harper adds, PC-to-PC connectivity has the ad-
vantage of being secure and fairly intuitive. That makes it easier
for everyone to buy in to the idea of remote support. For cut-
ting-edge smart phone apps and wireless control system prod-
ucts, such as tablets in the process areas, there are still too many
concerns about safety and security for those to be strongly con-
sidered in the process automation arena at this time.
Hardware and software vendors offer tools to help uses ad-
dress some security issues. Ken Eldridge, president of Open
Automation Software (www.opcsystems.com), explains, All
of our components and services support Windows Commu-
nications Foundation. We work with Homeland Security
closely to make sure all of our products are not vulnerable to
security threats. All of this is done by just utilizing the .NET
Framework in the Windows operating system.
Apart from security issues, other disadvantages of remote
access include slow display updates over wireless connec-
tions, loss of communications at critical times and the need
to use a PC or PAC that supports Windows-based software
and Ethernet connections (Table 2, p. 38).
In spite of these disadvantages, end users are climbing
aboard the remote access bandwagon faster than theyve ad-
opted any other technology we can remember. Today, any
company that doesnt offer remote access to its automation
systems is behind the times.
Dan Heber t i s Cont r ol s Seni or Techni cal Edi t or
Dart Oil and Gas (www.dartoilandgas.com) has approxi-
mately 500 remote methane well sites in the Cherokee ba-
sin of Kansas. The company uses electronic fow comput-
ers to monitor and record gas fow data at well, compressor
and pipeline monitoring sites. These fow computers are
equipped with 900-MHz spread-spectrum radios, enabling
them to communicate data back to a central location.
The problem that Dart faced was its inability to make
production data from its methane wells available to feld
personnel. All of the feld data was consolidated at the main
office and couldnt be accessed remotely, forcing a physi-
cal trip back to headquarters from the feld to obtain data.
Dennis Brown, senior measurement engineer at Dart,
says they designed the data acquisition system from the
beginning for remote access. Our goal was to use mobile
devices to access the data in real time, says Brown. This
would give us the fexibility to create new data reports as
the need arose and not be at the mercy of another company
to manage the data through standardized reports.
To accomplish this, Dart used an OPC server to poll the
fow computers and created a temporary database avail-
able for access, using OPC Systems.net and other tools
provided by Open Automation Software (www.opcsystems.
com). OPC Web HMI is used to create Ajax web pages that
display real-time data accessible by any remote device with
a browser. OPC Database is used to log data to an SQL
server for trending and analysis. OPC Excel is used to ac-
cess data in a spreadsheet format, enabling use of Excels
functions and macros.
Dart also uses Win-911 alarm software from Specter In-
struments (www.specterinstruments.com) for voice call-out
and reporting, and for text messaging to feld personnel.
Field personnel without smart phones can call in and re-
ceive voice reports about existing conditions after receiv-
ing alarm notifcations, allowing very rapid troubleshooting
of problems before they reach the site.
The OPC server, OPC Systems.net and Win-911 are
running on the same dedicated server using a Windows
Server 2003 operating system with a modem connected to
the USB port for voice call-out. For local access to feld
data, Dart uses the Excel module from OPC Systems.net
to display the data on desktop computers in spreadsheets
for individual office users.
OPC Systems.net has allowed us to create a web-
based HMI using MS Visual Web Developer in a relatively
short span of time with little prior knowledge of Visual Basic
programming, says Brown. Customer support from Open
Automation Software has been great. We had only one is-
sue that needed to be addressed during the installation,
and a fx was sent to me in a matter of minutes. The soft-
ware has functioned fawlessly for the two years it has been
in service.
DISTRIBUTING PRODUCTION DATA
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A P R I L / 2 0 1 2 www.controlglobal.com 45
F L O W
Matt Brewing Co. reduced energy cost to
brew beer by $230,000 per year using mass
fow instrumentation.
by Rich Michaels
The Matt Brewing Company is a family-owned business
founded in 1888. We make the Saranac brand of specialty
products. Nick Matt and his nephew, Fred Matt, cur-
rently head the management team at the brewery. Under
the leadership of these third and fourth generations of the
Matt family, the brewery continues to craft beer to the ex-
acting standards set forth more than a century ago. The
brewery currently makes up to 30 varieties of Saranac beer
during the course of the year, with distribution to about
20 states.
The heart of a brewing operation is boiling the wort. Brew-
ing starts with the addition of malted barley grain and water
to the mash cooker. Mashing allows the enzymes in the malt
to break down the starch in the grain into sugars, typically
maltose, to create a malty, sugary solution. After mashing,
the resulting solution fows to a flter press that separates out
the grain. Matt Brewing Company sells the fltered grain by-
product to local farmers as animal feed.
From the flter press, the solution, now called wort, goes
into one of two steam-heated, 500-bbl (15,000 gallon) ket-
tles for boiling (Figure 1). One of the kettles boils the wort
while the other is cleaned and prepared for the next cycle. A
manually operated coil for steam at the bottom of the kettle
preheats the wort.
Figure 1. Wort, the basic beer solution, goes into one of two steam-
heated, 500-bbl kettles for boiling.
COPPER KETTLES
46 www.controlglobal.com A P R I L / 2 0 1 2
The boiling operation continues for
90 minutes, evaporating about 5% to
10% of the solution. This operation,
which includes the addition of the hops,
sterilizes the wort and affects favor, sta-
bility and consistency. The hops provide
bitterness and favor. Following wort
boiling, the solution goes through a pe-
riod in fermentation tanks and fnally
packaging in bottles and kegs.
Steam pressure management is cru-
cial. Depending on the atmospheric
pressure, we need to control the steam
pressure to get more or less BTUs of
heat into the kettle. A pound of steam
represents a certain value of BTUs.
Steam cost is one of the most important
energy variables Matt Brewing deals
with. We were looking for a way to im-
prove steam quality and reduce steam
use. We consulted with R.L. Stone Co.
(www.rl-stone.com), Syracuse, N.Y., on
instrumentation to optimize the wort
boiling operation.
The new instrument system measures
and computes mass fow rates of steam
to control heat for boiling the wort. As
the wort temperature reaches the boil-
ing point, the steam in the bottom pre-
heat coil shuts off, and the recently in-
stalled automatic steam heating system
takes over. From the steam header, the
saturated steam fows through a control
valve and an ABB Swirl fowmeter be-
fore reaching the kettle. (Figure 2)
The Swirl meter is a vortex precess-
ing meter, somewhat akin to a vortex-
shedding fowmeter, except that the
Swirl meter has far better turndown
at low fows and requires minimal up-
stream and downstream straight pipe,
compared to other fowmeter types.
We selected this type of meter because
our piping geometry was tight, leaving
very little space for straight pipe to con-
dition the steam fow (Figure 3). The
Swirl meter contains a built-in inlet
fow conditioner and outlet straighten-
ing vanes, which saved the expense of
re-piping the brewhouse.
From the fowmeter, the saturated
steam fows to the top of an internal
boiler in the kettle called a calandria
(Figure 4, p. 48). The calandria is a shell-
and-tube heat exchanger. Wort rises
through the tube bundle in the calandria
while heated by the down-fowing steam,
which begins to condense. A defector at
the top of the calandria distributes the
wort and prevents foam formation. The
internal caldaria effciently provides
both heating and mixing of the wort.
When starting a batch, the operator
dials data representing the volume of
wort in the kettle into an ABB Control-
Master CM10 fow computer. (Figure
5, p. 48) This unit calculates the opti-
mum mass fow rate of steam based on
wort volume and feeds that rate to the
ControlMaster CM30 single-loop con-
troller as a setpoint. The CM30 pro-
vides indication, recording, math func-
tions and proportional/integral control
of the steam mass fow.
F L O W
Figure 2. This schematic shows the fow of saturated steam through a control valve and
a Swirl fowmeter.
Mash cooker
Wort Wort
To vent To vent
Filter press
CM30
Steam
out
Calandria
heat
exchanger
Steam
in
Steam
in
Preheat
steam
coil
Swirl
meter
Swirl
meter
CM30 CM10
Control
valve
TZIDC
positioners
Boiler
CM10
THE ENGINEERS GUIDE TO BREWING
Figure 3. Matt chose the Swirl meter because its piping geometry left little room for
straight-run piping to condition the steam fow.
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F L O W
The CM30s receive the steam mass
fow rates from the Swirl meters and
convert them to engineering units used
in the brewing process. The CM30s
compare the actual versus desired fow
rate, and develop a control signal to
maintain the predetermined setpoint.
The 4-20 mA DC control signal goes
to a set of ABB TZIDC intelligent
electro-pneumatic positioners we in-
stalled on our existing Fisher control
valves. An I/P (current to pneumatic)
module within the TZIDC positioner
precisely regulates air fow to pressurize
and depressurize the valve while mini-
mizing air consumption.
The displays for the CM30s indicate
the desired steam mass fow rate (the
control setpoint) based on the kettle vol-
ume, the measured steam mass fow rate
in lbs/hr, and the percent control valve
opening. The CM30 controller can
also display steam fow rate trends. The
CM10 displays wort volume in the kettle
dialed in by the operator.
Prior to the installation of the
new instruments, we collected three
months of data for the wort boiling
operation. Measured and calculated
variables included kettle volume,
steam pressure and temperature, per-
cent evaporation, and necessary water
additions. We compared the data we
collected to what we believed to be
optimum operating conditions and
estimated possible savings.
Our savings have resulted from
reduced natural gas costs and water us-
age. The new system for controlling
steam pressure has generally reduced
required steam pressures from 24 psi to
12 psi. The new system reduces steam
use by approximately a third, depend-
ing on the brew volume and the opera-
tor. It also saves about 1200 gallons of
water per brew cycle. We estimate the
savings at approximately $630 per day
(about $230,000 per year), and the pay-
back time for the instrumentation proj-
ect is about three to four months.
The results of the new control sys-
tem are better quality and shelf life for
our products with the added benefts of
reduced energy and water use. Were
considering adding a system to automati-
cally send a signal value for wort kettle
volume to the CM10 controller. This
would eliminate manual entry errors.
Were also planning to add a system for
reclaiming energy from plant wastewater
to generate electricity for the plant.
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Figure 4. The calandria, a type of heat ex-
changer, both heats and mixes the wort.
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Figure 5. An operator sets the wort kettle volume
on a fow computer prior to batch start.
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S U P E R V I S O R Y C O N T R O L
Coastal Electric uses Idecs Micro PLC to automate
Greenfash Brewings new plant in San Diego and
preserve its small-batch processes, while brewing fve
times more beer.
by Jim Montague
Maintaining success is often harder than achieving it. For instance, a mi-
crobrewer may come up with an amazing new beer, but it quickly becomes
so popular that its high-quality process is stressed by cries for high-volume
production. Well, Green Flash Brewing Co. (http://greenfashbrew.com) in
San Diego, Calif., may have resolved some of this eternal quality vs. quantity
tug o war. Its new plant is controlled by a micro-programmable logical control-
ler (PLC) that gives its meticulous microbrewing process some of the added
effciencies needed to produce more beer and compete with larger operations,
while maintaining the quality and taste that made it famous in the frst place.
Until recently, the 10-year-old microbrewer operated in a 4000-square-
foot plant, and produced just 20,000 barrels (bbls) per year of its 20 brands,
including its award-winning IPA Pale Ale. However, demand grew so fast
that Green Flashs small facility couldnt keep up with demand. So it began
working with Coastal Electric Co., a San Diego-based contractor, process en-
gineer and system integrator, to design and build a new plant.
Automating the Artisan
Efforts to build Green Flashs new brew house began in summer 2010, and it took
about nine months to design and construct. The new 45,000-square-foot plant was
up and running at the end of last June.
Figure 1: Green Flash Brewing uses a fve-vessel initial production process, which
is automated by Idecs micro PLC, and can turn around a typical 50-barrel batch in
just three hours.
WORTS IN THE VAT?
S U P E R V I S O R Y C O N T R O L
In the microbrewing industry, we usually fnd a shell of
a building and then add brewing equipment to it, so thats
what we did with this project. Next, we did the process
engineering, P&IDs, piping design, and installed all the
new equipment, says Keith Brushett, Coastals president.
Demand for Green Flashs beer was super high, and they
just couldnt make it fast enough. So the new facility was de-
signed to produce about 100,000 bbls per year. But the only
way to accommodate this capacity was to turn around the
fve vessels in the initial production process as fast as pos-
sible, and this required better automation. (Figure 1)
To automate Green Flashs new brew house, Coastal and
Green Flash decided to implement Idec Corp.s (www.idec.
com) new Pentra FC5A-D12X1E micro PLC, which can per-
form the functions of larger PLCs at one-third the usual cost.
Wed used Idecs PLCs in several smaller projects, but this was
the frst time we used them to run an entire brewhouse, adds
Brushett. We counted all the inputs and outputs needed in the
brew house and balanced them against the Pentra micro PLCs
capabilities. It now has a faster microprocessor and faster I/O
capability, so it was big enough to handle our job.
Consequently, while other brewing processes take fve or
six hours, Green Flashs brewmaster, Chuck Silva, and his
staff can run a typical 50-bbl batch through their fve vessels
in just three hours. These vessels include a grist bin and malt
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Figure 2: Idecs Pentra micro PLC and related process control and network-
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inputs and seven analog outputs, 176 digital inputs and 186 digital outputs,
and 11 Hitachi variable frequency drives (VFDs) via Modbus RS-485.
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handler, mash mixer, lauter tun unit for
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wort, and a whirlpool unit that processes
the beer before its sent to the fermenter.
After this initial production process is
complete, the beer goes to the ferment-
ing facility for up to three weeks.
Older brewing plants use a lot more
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run a lot slower, use more power and
cost more to operate and produce big,
hoppy beers, says Brushett. This new
brew house has a lean, mean, turbo-
charged process. The brewmaster sets
the benchmark, and our automation
makes sure each batch is identical and
maintains the brewers touch.
Controlling the Craft
Inside the brew houses fve-vessel pro-
cess, Pentra micro PLC manages 37 ana-
log inputs and seven analog outputs, 176
digital inputs and 186 digital outputs,
and 11 Hitachi variable frequency drives
(VFDs) via Modbus RS-485 communi-
cations (Figure 2). Also, Idecs TCP/IP
protocol and Ethernet cabling is further
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other parameters. This allows Green
Flash to archive a profle for each batch,
track favor performance in summer,
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optimize that performance, explains
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Previously, we would have had
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only cost about $10,000. And we also
have web browsers built into the brew
houses touchscreen controllers, so we
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For now, the new micro PLC-con-
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D A T A A C Q U I S I T I O N
Recycled equipment, a new automation system, electronic marshalling
and remote I/O all go into a greenfeld sulfuric acid plant.
by Bryan Beyer
Wilmington, N.C.-based Southern States Chemical
(www.sschemical.com), a division of Dulany Industries
Inc., is the Southeastern United States largest provider of
sulfuric acid. Two locations (Savannah, Ga., and Wilm-
ington, N.C.) combine to produce over 1800 tons per day,
with total marketable tons exceeding 750,000 annually,
and combined storage capacity exceeding 35,000 tons.
The companys existing Wilmington plant had pro-
duced around 500,000 tons of product per year, but the
aging plant was almost entirely manually operated, and
meeting EPA emissions limits was a concern. So to ex-
pand production capacity and ensure conscientious envi-
ronmental stewardship, the company looked beyond ex-
panding and upgrading the existing facility to building
a new state-of-the-art plant on a 15-acre site next to the
old plant with ready road and rail access to transport raw
materials and finished product.
Another important consideration was the fact that this par-
ticular site meant that the principal byproduct of the sulfu-
ric acid manufacturing processsteamcould be converted
into a marketable commodity energy source. The new plant
is located adjacent to the plant of Invista Wilmington, a large
synthetic polymer and fber manufacturer, which made a
ready customer for a reliable supply of clean, high-pressure
steam. The new plant would have three absorbing towers, a
sulfur furnace, two waste heat boilers, two SO
2
-to-SO
3
con-
verters, gas-gas heat exchangers, four liquid heat exchangers,
four storage tanks, and truck and rail loading facilities.
Southern States also went all in with high-tech tools,
abandoning its largely manual operations in favor of the
latest in automation technology, including HART com-
munications, remote terminal displays, f low elements,
DeviceNet networking and a DeltaV automation system
from Emerson Process Management (www.emersonpro-
cess.com) along with Emersons electronic marshalling
system, the new characterization modules (CHARMs).
All this technology comes together to regulate temper-
ature, pressure, f low, level, conductivity and weight by
means of around 235 I/O points.
Shopping in Wisconsin
The company was challenged with keeping down the ex-
pense of building a new plant from the ground up. Among
the solutions it found was the recycling of major compo-
nents from a decommissioned government munitions plant
in Baraboo, Wis., and transporting them to the Wilmington
site. The Baraboo imports included all three towers, two
gas heat exchangers, some acid pumps and most of the struc-
tural steel. To this equipment were added two new convert-
ers, a new furnace, new waste heat boilers, two new econ-
omizers, a new cooling tower and new storage tanks. This
recycling effort gave the new plant its nameWilbara, in
recognition of the two contributing cities located 1100 miles
apart. It also saved Southern States an estimated 20% on the
cost of the new facility.
Relocating the old equipment and integrating it with the
new was only the frst challenge. With Southern States new
supplier relationship, reliability became a crucial parameter
for the new plant. Southern States not only had to be a reli-
able supplier to sulfuric acid customers, but also reliable as
a supplier of steam under a contract with its neighbor. The
company could not afford to have delivery delays caused by
start-up glitches or problems getting employees up to speed
on the new systems.
A CHARMING NEW FACILITY
Other Challenges
Furthermore, Southern States had little previous automation
infrastructure within the corporation. Everyone from upper
management to the junior operators had to be shown how
to look at things from an automation point of view. Training
the on-the-ground personnel to operate the new system from
a computer screen was another challenge. Working with auto-
mated equipment was a completely new experience for them
and a challenge to the new plants operational schedule. But
staff took to the new equipment thanks to hands-on, in-the-
feld training.
Another potential challenge to the new system and
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Figure 1. Because the I/O points are in clusters, Southern States placed 10
CHARM panels strategically near the clusters throughout the plant.
CLUSTERED I/O
Figure 2. Dual Ethernet cables connect the CHARM cabinets to the Delta V
cabinet (see yellow star).
DUAL ETHERNET CONNECTIVITY
D A T A A C Q U I S I T I O N
technologys installation and start-
up was the fact that Southern States
was working with two different frms
for system confguration and support,
so coordinating the two teams efforts
without costly overlap, omission or
schedule deviation was a concern.
Integration of technology between the
two different companies went smoothly.
Process automation consulting and engi-
neering frms Control Southern of Su-
wanee, Ga. (www.controlsouthern.com),
and R.E. Mason of Charlotte, N.C.
(www.remason.com), the local distribu-
tor of Emerson and Fisher valve prod-
ucts, worked together during the entire
project to provide a seamless handoff
from inception to operation. The for-
mer frm ordered all the feld devices,
performed programming and graphics
design. The latter was involved in the
initial concept, FAT, on-site installation
and commissioning, then took over all
on-going programming and site support.
One R.E. Mason employee worked with
Control Southern from the beginning to
get an overall perspective on the project,
and then the Mason team took over com-
pletely upon start-up.
The Heart of the System
To automate its processes, Southern
States implemented Emersons DeltaV
v11 digital automation system. While
that system has proven itself a reliable
performer, Southern States took a leap
of faith in the systems new CHARM
technology. In fact, this project was
one of North Americas frst installa-
tions of the new I/O technology.
The decision to use the new I/O
technology came late in the planning
process. Southern States had looked
at a standard feldbus system incorpo-
rating wiring all the way from the I/O
point into the cabinet in the control
room, but when the new feld junction
cabinets and I/O system became avail-
able, the company opted for them, as
they appeared to promise big savings in
engineering and construction costs, as
well as increased reliability.
The characterization modules
(CHARMs) enable I/O anywhere in
the plant regardless of signal type
from a local I/O cabinet to remote
enclosures. In the Wilbara project,
Southern States terminated the total
I/O among 10 junction boxes located
throughout the plant, running all the
signals from each junction box to the
control room and I/O cards via two
Ethernet cables. Traditional marshal-
ling cabinets were completely elimi-
nated, decreasing the amount of feld
wiring by half and cutting wiring cost
by 40% (Figures 1 and 2).
The electronic marshalling technol-
ogy eliminated one of the most tedious
and costly tasks that almost invariably
become a part of any plant construc-
tion or expansion project: late engi-
neering changes. The I/O systems fex-
ibility showed its value in several cases
where an I/O point was located in a
different cabinet from that originally
planned, and it was very easy for the
team to relocate the I/O module and
reconfgure it in the control system.
The Results Are In
Plant operation has been reliable,
aided by the systems redundant con-
trollers and CIOC, dual Ethernet com-
munications and smart transmitters in
key areas.
Emerson provided all the feld de-
vices, including valves, transmitters,
thermocouples, RTDs and fowme-
ters. Among these, the companys mass
fowmeters now allow truck and rail
car tanks to be flled with acid in a very
streamlined process. By tying the truck
scale in with the fowmeter, operators
input the target weight and, with the
press of a button, can fll the tank ac-
curately and concurrently print the
loading bill. This dramatically reduces
traffc, while increasing both reliabil-
ity and throughput. The control system
and feld devices all came from a single
supplier with local representation, an
added reliability assurance.
FAT had an added component of
key operator/supervisor training. These operators and super-
visors became our mentors during operator training and site
commissioning. The digital control systems ease of under-
standing and operation reduced operator training and costs,
with training completed in two weeks.
Southern States achieved substantial capital cost savings, with
construction and wiring costs 50% less than a standard DCS.
The start-up schedule was met by taking advantage of the
characterization modules fexibility when feld I/O changes
were implemented during construction. I/O additions were
quicker and less costly because of the Ethernet communications
backbone already in place. One of the changes made in the I/O
during construction concerned a point originally planned for
location in the feld, which ended up requiring location in the
control room where the system controller is. Connection in the
new location was extremely quick and easy.
Integration with Southern States business systems is still
a work in progress, but the production data now available is
showing the way to continuous improvement. The digital
automation system provides a wealth of production data that
every segment of the corporation can use, enabling South-
ern States to provide outstanding quality, predict required
maintenance quicker, control the process better and make
better business decisions
Payoff Time
The gamble to entrust a new plant start-up and ongoing pro-
cess automation to a single supplier and its new electronic
marshalling technology clearly paid off. The new plant is
producing roughly 575 tons of sulfuric acid per day, versus
around 150 tons per day at the old plant with the same num-
ber of personnel. Recent state SO
2
and acid mist emissions
tests fell signifcantly below requirements. Further, the Wil-
bara plant is delivering as much or more steam per month
to its neighboring customer as promised in its contract. The
construction, wiring and change management savings pro-
vided by the electronic marshalling technology, along with
subsequent reliability and performance have served as a
model for future plant automation engineering.
Using this state-of-the-art technology, Southern States
Chemicals new Wilmington plant stands as the crown jewel
of the company.
Br yan Beyer i s t he aci d oper at i ons manager at Sout hern St at es Chemi cal .
D A T A A C Q U I S I T I O N
Cashco, Inc.
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A P R I L / 2 0 1 2 www.controlglobal.com 61
Magmeter Maintenance, Feed-Forward Variations; Robots
Q
Magnetic fowmeters: Is there a term related to a mag-
meter with respect to measurement of zero fow? What
maintenance is required for a magmeter?
WILLI AM P. REED
Emai l wpr@azdeq. gov
A
DC-pulsed, automatic zeroing, state-of-the art mag-
meters, (operating on Faradays law), accurately detect
the velocity of conductive fuids (0.5% of actual fow)
and have a high turndown ratio, which in dual-range units
can reach about 100:1.
Temperature variations and vibration can change the
magnetic feld. Coating, moisture, coil and electrode dete-
rioration, corrosion or electronics can also cause drift and
other errors. Magmeter performance is also subject to pro-
cess property variations (changes in conductivity, air bub-
bles, slurries or in the potential in the fowing fuid, etc.) or
to corrosion, grounding or cable shield deterioration. There-
fore, maintenance is important.
My recommendation is to check (recalibrate) the elec-
tronics (transmitter and power supply) monthly by the use of
a millivolt simulator (Figure 1). This checks and allows reca-
libration or rezeroing the electronics. In smart fowmeters,
the magnetic feld strength and the electrode resistance can
also be checked and compared to their original values auto-
matically. Besides being quick and inexpensive, such verif-
cation can also be remotely triggered.
In old fowmeters, it is essential (often required by law)
to yearly check the accuracy of the fow tube itself, the mil-
livolts generated by the electrodes (E in Figure 1). This is
done by checking the meter reading against that of another
fowmeter (such as a clamp-on ultrasonic unit). For higher
accuracy recalibration, see Dick Furnesss advice below.
Naturally, the resulting calibration accuracy will not be bet-
ter than that of the reference meter. Consequently, if maxi-
mum accuracy is desired, the meter should be removed and
after checking its condition and maintaining the electrodes,
lining, etc., the meter should be recalibrated.
As to zero-fow condition, any signal under no-fow con-
ditions is an error. It is common practice that, at the time of
commissioning, the full and empty pipe zero-fow outputs are
captured manually and stored, so that during operation these
threshold values will trigger alarms. In smart, DC-pulsed au-
tomatic zeroing meters, the magnetic feld strength is zero
between pulses. Therefore, if the electrodes detect any volt-
age, it is automatically subtracted from the signal voltage as
extraneous noise. Such features reduce maintenence cost and
improve reliability.
In comparison to such state-of-the-art systems, old instal-
lations of conventional magmeters can have very high er-
rors. Last year, as an expert witness, I reviewed a magmeter
installation and found that the meter was under-reporting
for decades by some 40%, due mostly to uncorrected zero-
shift. This condition existed because only the electronics
were recalibrated (Figure 1) and the fow tube itself was not
removed, checked and recalibrated for decades.
This column is moderated by Bla Liptk (http://belaliptakpe.com/), automation and safety consultant, former Chief Instrument
Engineer of C&R, former Yale professor of process control, and the editor of the Instrument Engineers Handbook. If you have
automation-related questions for this column, write to liptakbela@aol.com
Figure 1. The typical method of monthly magmeter recalibration using a
millivolt simulator is shown. This method checks only the electronics of the
loop and ignores other conditions that may affect the unit.
E (voltage)
E (voltage)
Signal from simulator
Signal to transmitter
Flow = E (meter constant)
E = Induced voltage
V = Average liquid velocity
B = Magnetic feld
D = Distance between electrodes (pipe I.D.)
D (diameter)
Electrode
Liquid product
Flow tube
Magnetic
feld
coil
Flow
V
(velocity)
B
(magnetic
feld)
E = VBD
MAGMETER CHECK
62 www.controlglobal.com A P R I L / 2 0 1 2
A S K T H E E X P E R T S
So, while magmeters are good fowmeters, their yearly
total maintenance and recalibration is essential.
BLA LIPTK
l i pt akbel a@aol . com
A
I have had a lot of experience with magnetic fowmeters.
In the last decade they have become very reliable, and in
the lab we have run tests with velocities as low as a few
millimeters per second and they record pretty well. As you
approach zero fow, errors go frst high and then fall to zero.
Zero stability is an issue, as electrode ageing and coating do
cause offsets as well as a measurement error. This is more no-
ticeable in pipes that are oversized and old. Regular checks of
the electronics and periodic verifcation using both dry cali-
brators as well as in situ fow assessment is essential.
Here in the U.K., magmeters are assessed rather haphaz-
ardly, and the use of insertion probes can lead to bias being
introduced where previously there was very little. I also sug-
gest an annual fow check should be the norm rather than
the exception. I use two insertion probes in different planes,
as well as multiple sets of ultrasonic probes clamped around
the pipe, and all of this is done simultaneously. Both profle
distortion and swirl can be evaluated, and from this, one can
more correctly estimate the bias within the magnetic meter.
This changes with time, so this is why periodic tests have to be
made. My methods are now accepted by the U.K. Regulator as
a bona fde means of verifying in situ. As a result of testing over
many years, I know the ageing coeffcients of most instruments.
In a couple of decades signifcant errors always ensue.
DICK FURNESS
r ydal hal l 46@aol . com
A
Empty pipe detection is provided in most magnetic
fowmeters with cut-off to force the fow reading to zero
at no fow to eliminate false counts in the totalizer. In
some cases they serve to prevent the coil from overheating.
Magnetic fowmeters need calibration, but using smart
meter verifcation, it is possible means to determine if cali-
bration is really required or if it can wait a few months.
To learn more about empty pipe detection and smart
meter verifcation, read more in this article: www.eddl.org/
SiteCollectionDocuments/Articles/pg42-47-1-MAG3.pdf.
JONAS BERGE
j berge@si ngnet . com. sg
Q
Please can you explain the difference between posi-
tional feed-forward and incremental feed-forward
in PID control? What are the pros and cons of these
feed-forward algorithms. I understand that positional feed-
forward is adding predefned value to the PID output. In
what situations can we use with lead lag or without lead lag?
What is the incremental feed forward.
KUMAR
kumar al st om@hot mai l . com
A
Incremental feed-forward is essentially an impulse func-
tion that is applied to the manipulated variable only on a
change in the load variable--it has no steady-state compo-
nent. To minimize integrated error following a load change,
the feed-forward signal must be applied in the steady state, that
is, positionally. It can either be additive with a fxed gain, as typ-
ical when controlling liquid level, or multiplicative, where the
gain of the multiplier is set by the output of the feedback con-
troller, used when controlling temperature and composition.
Avoid incremental algorithms at all coststhey foat and
will cause all kinds of trouble and confusion.
GREG SHINSKEY
shi nskey@met r ocast . net
A
Google tells me from the list of hits that positional
feed-forward is associated with robots and incremen-
tal feed-forward is associated with neural networks.
Where they are explained there is a forest of complex
math that I am unable to penetrate. Never heard of them in
process control. You should ask your vendor.
BILL HAWKINS
bi l l @i axs. net
Q
I see that in the proposed index of the ffth edition of
your handbook, you plan to have a chapter on robots.
Is it because that technology utilizes the principles that
were developed by the process control industry? In other
words, did they learn from us in the area of modeling?

HARRY CROWNEY
HCr owney@aol . com
A
The short answer is yes; the long answer would take vol-
umes. What I plan to cover in the ffth edition of Vol-
ume 1 is only the measurement aspects, not the control
algorithms or the manipulated variables. They will come in the
second and third volumes. The sensors of this industry are in-
teresting because they are drastically less expensive, lighter and
smaller than in the traditional industries, while depending to-
tally on wireless technology. You can see an example below:
www.ted.com/talks/a_robot_that_fies_like_a_bird.html.
BLA LIPTK
l i pt akbel a@aol . com
R O U N D U P
A P R I L / 2 0 1 2 www.controlglobal.com 63
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combination of various pa-
rameters, including nitrate,
turbidity/suspended solids,
dissolved oxygen, pH/ORP,
chlorine, concentration and conductivity. It is powered by
100-230 Vac 50/60 Hz, 24 Vac 50/60 Hz, or 24 Vdc; con-
forms to Type 4X (IP66/IP67); and is NRTL-certifed.
Endress+Hauser
888/ENDRESS; www.us.endress.com
Analyze This
Ten process analyzer applications.
R O U N D U P
TWO-WIRE LIQUID TRANSMITTERS
The new family of Rosemount
Analytical 1066 two-wire liq-
uid instruments are suitable for
many industrial applications,
including pharmaceutical and
food and beverage, chemical
plants, metals processing and
effuent monitoring. They
have the latest version of HART 7, and they are the industrys
frst pH transmitters to be registered under the Fieldbus Foun-
dations Interoperability Test Kit 6 (ITK6).
Rosemount Analytical
800/999-9307; http://tinyurl.com/86mj89q
ACCURATE OXYGEN MEASUREMENT
TDLS220 measures percent
level oxygen with no interfer-
ence from background gases.
Tunable diode laser spectros-
copy technology (TDLS) is
used for critical gas measure-
ments, including oxygen and
CO concentrations for com-
bustion control; detecting ammonia and hydrochloric acid
in exhaust gas; and monitoring ppm moisture levels in ag-
gressive gas streams.
Yokogawa Corp. of America
800/888-6400; www.yokogawa.com
SPRING-LOADED REGULATOR
RHPS series LRS(H)4 spring-
loaded pressure regulator
provides high accuracy for an-
alyzer applications. It is con-
structed of 316L stainless steel
and available in many con-
fgurations. It is designed to
handle 400 bar (5,801 psig)
inlet pressure (2.2mm seat), and features a low-torque, no-
wear stem and removable hardened cap. Temperature perfor-
mance range is from -20 C to +80 C (-4 F to +176 F).
Swagelok
www.swagelok.com.
PURGE CONTROLLER
The ePurge X is a purge con-
troller with fully automated
purge and pressurization
functions. Its digital mass fow
sensor self-regulates purge du-
ration. The purge pressure
range is minimum 4 bar (60
psi) and maximum 8 bar (115
psi). The operating temperature range is -20 C to 55 C.
ePurge X is certifed in hazardous areas to NEC Class 1, Di-
vision 1, Groups C, D and IEC: Zone 1, Group IIB.
Applied Analytics
978/287-4222; www.a-a-inc.com
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Optimized, Small-Footprint Coriolis Flowmeter
because user maintenance can be reduced up to 90% us-
ing Coriolis mass fowmeters. This, according to both ARC
Advisory Group and Flow Research Inc., is one of the key
reasons why the market for Coriolis mass fowmeters is grow-
ing rapidly.
ABB has been making Coriolis mass fowmeters since the
early 1990s, and theyve just introduced their latest design,
the CoriolisMaster. This meter is very different, according
to ABB, and is a state-of-the-art product.
When we were looking at our Coriolis mass fow product
line, says ABBs global product manager for Coriolis fow-
meters, Frank Frenzel, We wanted to leverage our experi-
ence and design an optimized Coriolis fowmeter with an
easy-to-program interface.
ABB, through its predecessor companies, is justifably
proud of its 100-year record of innovation in fow measure-
ment and other automation products. Frenzel says the new
CoriolisMaster fowmeter is no exception. With thousands
of Coriolis mass fow products in the feld, we felt we had a
very good grasp of what features would actually make a fow-
meter better.
Using complex modeling and simulation techniques, the
design team optimized the sensor design for higher perfor-
mance, too. Frenzel notes. Finite element simulations and
several design loops created an optimized design with su-
perior zero-point stability and superb temperature stability,
he says. New node point designs, shorter tube lengths and
stiffer housings are reasons we believe weve developed one
of the best sensor designs in the industry.
Frenzels team designed a shorter laying length meter,
so the CoriolisMaster would have one of the shortest laying
lengths (end-to-end or fange-to-fange dimension) in the
industryup to 40% smaller in length and meter volume.
This permits the meter to be used in tighter quarters, with
less re-piping than other meters from ABB or other vendors.
We also re-designed the fow tube diameters to provide
50% to 90% lower pressure drop, one of the lowest in the in-
dustry, Frenzel says, which gave us nearly double the max-
imum fow of competitive fowmeters of the same diameter.
Frenzel points out that this wide fow range per meter
means end users can use a minimum number of meter sizes.
The new lower pressure drop measuring tube design also
saves energy. The end user can save pump power by up to
50% with our double tube design and one of the lowest pres-
sure drops on the market, Frenzel says.
The new design is also equipped with a new transmit-
ter design. Using ABBs intuitive interface, it is capable of
being programmed without a manual, Frenzel says. The
transmitter provides excellent turndown and zero point sta-
bility, he goes on, and the signal conditioning algorithms
are designed to handle tough applications.
The CoriolisMaster is being released in three line sizes,
0.5-in. (DN15), 1-in. (DN25) and 2-in. (DN50), with three
more sizes to be released yet this year: 3-in. (DN80), 4-in.
(DN100) and 6-in. (DN150). Tests of the new design at the
Clean Energy and Environmental Sustainability Initiative
(CEESI) and metrology services provider NMi Netherlands
show just how highly accurate the CoriolisMaster is, and
ABB claims 0.1% of rate accuracy for both fow and density.
The CoriolisMaster is available immediately in the three
released line sizes.
For more information, contact ABB at www.abb.com/fow.
In the past 10 years, Coriolis mass fowmeters have taken over the market spaces of many other fowmeter
technologies. Their ability to provide mass fow, volumetric fow, density and temperature measurements on
a highly accurate basis is unrivaled by other types of meters. Coriolis mass fowmeters have been replacing
mechanical meters (positive displacement and turbine meters especially in custody transfer applications)
Figure 1. The CoriolisMaster has one of the shortest laying
lengths and pressure drops in the industry.
MASS FLOW MASTER
66 www.controlglobal.com A P R I L / 2 0 1 2
P R O D U C T I N T R O D U C T I O N S
VORTEX-SHEDDING FLOWMETERS
These rugged inline fowme-
ters are ideal solutions for ap-
plications using water, water/
glycol coolant and other low-
viscosity fuids. They have
no moving parts and oper-
ate with NPT ports ranging
from ins. to 2 ins., and can
handle fows from 4 gpm to 200 gpm with occasional over-
ranging up to 125% of capacity without damaging the meter.
They feature 4-20 mA fow rate transmitters and can with-
stand working pressures from 10 psig to 300 psig.
Parker Fluid Control
800/825-8305; www.parker.com
LOOP CONTROL
ControlLogix PACs provide
multi-disciplined, scalable
control, and include several
native capabilities for exe-
cuting loop control. PID in-
structions are provided for
basic, cascade, feed-forward
or split range applications,
including options for embedded auto-tuning. Model-based
instructions are available for loops with long dead times to
optimize them using up to three manipulated variables or to
decouple interacting loops. They also have tools available to
create fuzzy logic instructions and soft sensors.
Rockwell Automation
414/382-2000; www.rockwellautomation.com
SURGE PROTECTION
ZoneMaster PRO Type 1 and
ZoneSentinel Type 1 models
allow users to install UL1449
3rd Edition-listed premium
surge protection before or af-
ter the main building discon-
nect. These models, listed
at 20kA, can be installed in
a UL96A-certifed lighting protection system. ZoneMaster
features all-mode protection and options to meet the most
complex protection requirements. ZoneSentinel can be
used alone or in combination with a ZoneMaster to provide
the lowest suppression voltages available.
MTL Instruments
888/746-4685; www.mtl-inst.com
SOLENOID VALVES
Series SBSV solenoid valves
are compact, general-service,
110-Vac, two-way guide type
solenoid valves for air, gas,
water and other liquid ap-
plications. The brass valves
come with an NBR seal with
a maximum process tempera-
ture of 80 C (176 F). The stainless steel valves come with
a fuoroelastomer seal with a maximum process temperature
of 120 C (248 F). They come in sizes from 1/8 in. to 2 in.
NPT and with orifces from 3 mm to 50 mm.
Dwyer
800/872-9141; www.dwyer-inst.com
INTELLIGENT UPS
Quint UPS-IQ is now avail-
able for 120 VAC/240 VAC
applications. It uses intelli-
gent battery management to
provide advanced diagnos-
tics. The AC unit automati-
cally detects the input volt-
age of either 120 VAC or 240
VAC, making it suitable for global use. To simplify system
troubleshooting or start-up, the AC UPS can start indepen-
dent of an AC input. This allows users to power up an indus-
trial PC or controller during a blackout to simplify system
diagnostics.
Phoenix Contact
800/322-3225; www.phoenixcontact.com
PLATINUM TEMPERATURE SENSING
The SNAP-AIRTD-1K is a
two-channel, isolated analog
input module for use with
1000-ohm platinum resis-
tance temperature detectors
(RTDs). It has a nominal in-
put temperature range of
-200 C to +850 C (-328 F to
+1562 F) and an input range of 0 ohms to 4000 ohms. The
module has an average resolution of 0.042 C (0.16 ohms).
Used primarily with RTD probes to provide temperature in-
puts, SNAP-AIRTD-1K module can also be used for making
high-resolution resistance measurements.
Opto 22
800/321-6786; www.opto22.com
P R O D U C T I N T R O D U C T I O N S
A P R I L / 2 0 1 2 www.controlglobal.com 67
LOW-FLOW AIR SENSORS
The Zephyr analog and dig-
ital airfow sensor portfolio
now has four standard fow
ranges between 50 SCCM
and 750 SCCM to provide
high sensitivity at very low
fows. The sensors provide an
analog or digital interface for
reading airfow over the specifed full-scale fow span and
temperature range. The thermally isolated heater and tem-
perature sensing elements help these sensors provide a fast
response to air or gas fow.
Honeywell Sensing & Control
http://sensing.honeywell.com
24-PORT ETHERNET SWITCH FOR HARSH ENVIRONMENTS
SEL-2730M supports high-
speed control, real-time au-
tomation and SCADA traffc.
It withstands vibration, elec-
trical surges, fast transients,
electrostatic discharge and
extreme temperatures (-40
C to +85 C). It meets or
exceeds IEEE 1613 (Class 2) and IEC 61850-3 communi-
cations standards. The base-model has 20 copper Ethernet
ports16 are 10/100 Mbps and 4 are Gigabit Ethernet. You
can upgrade the 10/100 Mbps drop ports to fberoptic inter-
faces and add up to 4 additional Gigabit Ethernet ports.
SEL
509/332-1890; www.selinc.com
INLINE VORTEX MASS FLOWMETER
The VLM10 combines an
inline vortex meter, a built
in fow computer and an in-
tegral temperature sensor for
mass, volumetric, and energy
fow measurement on steam,
liquid, and gas applications
in sizes from 1 in. to 12 in. It
has a steam or gas mass fow accuracy of 1.5% of range over
a 20:1 fow range and delivers digital communications in-
formation on demand using Modbus RTU, BACnet MS/TP
and Modbus TCP/IP technology with standard analog and
pulse outputs.
Spirax Sarco, Inc.
800/883-4411; www.spiraxsarco.com/us
CALIBRATE YOUR FLOWMETERS EASILY
The ST100 Series Thermal
Mass Flowmeter now comes
with the VeriCal In-Situ Cal-
ibration Verifcation System.
It includes service up to 850
F (454 C) and is available
with both integral and re-
mote electronics versions. It
is agency-approved for hazardous environments, including
the entire instrument, the transmitter and the enclosure. Ap-
provals include FM and FMc, Class 1, Division 1, hazardous
locations, ATEX and IECEx, Zone 1, II 2.
Fluid Components International
800/854-1993; www.fuidcomponents.com
HAZARDOUS-AREA WORKSTATIONS
VisuNet IND SlimLine oper-
ator workstations have Zone
2 certifcation for use in haz-
ardous environments and
provide HMI visualization
in Class I, Div. 2 hazardous
locations. They are available
in NEMA 4/4x IP 64 stainless
or painted steel housings and as a full PC, remote monitor
or KVM monitor solution. The remote monitor (RM) tech-
nology requires no software installation, provides standard
Ethernet networking connections to the server and access to
multiple servers from a single workstation.
Pepperl+Fuchs
330/486-0002; www.pepperl-fuchs.us
MULTIVARIABLE DIGITAL TRANSMITTER
The MDT500 is a direct-
mounted, multivariable mea-
surement digital transmitter.
Applications include leak de-
tection, calibration reference
standards, critical gas fow
measurements, combustion
air fow to engines and many
more. It delivers system accuracy of 0.8% FS or better and
a less-than-0.1-sec response time. With long-term stabil-
ity and no moving parts the unit is maintenance-free. The
MDT500 offers linear response, and a low-head-loss model
is also available.
Meriam
216/281-1100; www.meriam.com
68 www.controlglobal.com A P R I L / 2 0 1 2
GREG MCMILLAN
STAN WEINER, PE
cont rol t al k@put man. net
C O N T R O L T A L K
Greg: Scott Broadley, president of Broadley-
James Corp., broke wide open what our view
of what lab control systems can and should do
for commercialization of biopharmaceuticals.
I met Scott as a result of a shared interest in
pH measurement and bioreactor modeling and
control. Scott supported the exploration of a
virtual plant as described in the PAT Tools for
Accelerated Process Development article in
BioProcess International Journals Supplement
Series in March 2008, and available at www.
bioprocessintl.com/journal/supplements/2008/
March/PAT-Tools-for-Accelerated-Process-De-
velopment-and-Improvement-183947.
Stan: How did you get into providing bioreac-
tor systems for research and development?
Scott: I always had a fascination with biotech-
nology. After our development of the steam ster-
ilizible, gel-flled, pH electrode in the 1980s, I
started a dialog with biopharmaceutical com-
panies. I always answered the phone, gave frst
hand info, and got involved with what the cus-
tomer needed. We gave seminars on the Top
10 Practices for DO and pH Measurement.
This led us to the idea of a better solution for
the process development (PD) lab. The original
concept was to start with a DCS scaled down to
bench-top applications with sophisticated con-
trol capability to deal with complex processes.
Greg: What was the biggest surprise?
Scott: We didnt anticipate the networking
implications in process development. The PD
Lab vessels acquire large amounts of data in
historians, including PID outputs that create
the ability to adjust the PID based on batch
phases using gain scheduling, steps and ramps.
The DCS system also has advanced control
tools, such as adaptive control, model predic-
tive control and data analytics. We brought the
best of automation technology developed over
decades in commercial processes to the PD lab.
These BioNet lab-optimized DCS systems are
little powerhouses of data, which is what a PD
lab is all about.
Stan: Why is the demand for data so great?
Scott: Besides the design of experiments (DOE)
to determine optimums and operating condition
limits in the defnition of the process for the
Food and Drug Administration (FDA), statis-
tical analysis requires a large number of vessel
runs. Each vessel run takes two weeks, and with
project time always being critical, many more
bioreactor runs are required to run in parallel
for the same experiment. In one of our larger in-
stallations, we had over 60 glass benchtop bio-
reactors at two different sites for a particularly
visionary and astute biopharmaceutical PD lab.
Greg McMill an 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.
New Paradigms for Lab Control Systems
C O N T R O L T A L K C O N T R O L T A L K
The data was networked, revealing essentially the same re-
sults independent of site and operator. Furthermore, the auto-
mation of the labs at both facilities enabled many more runs
to be completed with far fewer operators. The data obtained
had minimal variance, was reproducible, and was explainable
within the design space. The data variance was actually cut
in half. With all biopharmaceutical budgets being squeezed
this several-fold improvement in productivity is drawing a lot
of attention.
Stan: The 1-liter bench top bioreactor requires incredibly
precise dosing and extremely small samples for at-line ana-
lyzers. Why so small?
Scott: A matter of economics. The PD Lab may do 50 to 200
small-vessel runs in their development of scale-up data. A
500-liter pilot plant scale run costs $100K to $200K, whereas
the 1-liter run costs $1K to $5K. However, precise control is
not lost at this small vessel size. The lab system uses mass
fow controllers (MFC) instead of solenoid valves for dos-
ing. The MFC has a thermal fowmeter, PID and an inter-
nal fow element that gets a remote setpoint from either pH
or DO controllers in the DCS. The cascade loop provides
tight control and a fow measurement that provides consider-
able knowledge for data analytics and frst-principle model-
ing and diagnostics.
Greg: The story is in the controller output, but the picture
is much clearer if there is a fow measurement.
Scott: The data historian is such a great tool. The trend in
PID outputs tells us so much more, which has led to sig-
nifcant improvements in product quality. Each large-scale
production run takes six weeks and 30 people in a manu-
facturing plant, not counting delays for trying to solve and
document continuing problems. Consequently, the time
besides the cost benefts of preventing rejected batches are
huge.
Stan: What do contract manufacturing organizations
(CMO) think of the results of these lab-optimized automa-
tion systems?
Scott: The relationship between the biopharmaceutical
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company and the CMO, which can be
contentious at times, has greatly im-
proved when these systems are used.
The BioNet/DeltaV equipped PD lab
can develop large amounts of ana-
lyzed and well-organized data. The
basic control strategy can be worked
out in the PD lab well ahead of the
frst meeting with the CMO. Repeti-
tive PD benchtop runs give their data
statistical signifcance, and this greatly
reduces the risks involved with the
scale-up process. There is much less
risk of a surprise at the 6000 L scale.
Everyone wins if risk is reduced. The
technology transfer to the CMO is ac-
complished with less cost and much
improved time-to-project completion.
This makes both the biopharma client
and their CMO much happier about
the project.
Greg: Besides knowing the fows of
nutrients and gases, the real-time mea-
surement of cells, key components in
the culture and product concentration
provide the knowledge that could be
used not only for online optimization
but for dynamic modeling. The result-
ing virtual plant can be run faster than
500 times real time to develop and test
CMO automation systems.
Scott: An essential part of our lab op-
timized system is an integrated, mul-
tiplexed, at-line Nova BioProfle Flex
analyzer with an automated sample
system that can measure 14 parame-
ters in a sample including cell count,
size, viability and osmolality, substrate
components glucose and glutamine,
and inhibiting components such as
ammonia and lactate. Most recently,
the technology has been developed to
automatically fll and freeze 5-cc vials
for measurement of product concentra-
tion and quality. This product analysis
is done offine with liquid chromatog-
raphy due to analysis complexity. The
sample volume taken per day is about
the same as the substrate and nutrients
added, so there is no appreciable loss of
bioreactor culture, which is critical for
the 1-liter size.
Stan: What do the scientists think of
these sophisticated control and auto-
mation systems?
Scott: They love them. The automa-
tion frees them up to do real science
rather than mundane experimental
procedures. Plus, with ease of the re-
mote connectivity, they can monitor
experiments and tweak something us-
ing their home laptop or even their
iPhone, so they dont have to come
into the lab during the night or on
weekends to tweak a parameter to get
the most out of a run. There is less
stress. The scientists can also be more
innovative with the many automation
features that are pre-confgured and,
hence, selectable and adjustable via
graphics optimized for their PD lab.
Greg: I expect the benefts in terms of
batch repeatability are similar to what
we see whenever we automate manual
operations in industrial plants due to
limitations in human predictability
and monitoring and adjustment scope
and timing. The automation in the
PD lab may translate to even greater
benefts due to the complexity of the
decisions and interactions and the in-
credibly long time horizon before the
consequences are seen. We have a two-
way street and a synergy. The best of
automation technologies and tech-
niques from industrial production can
be moved into the PD lab that can be
translated into more advanced control
systems to be transferred to the CMO.
Furthermore the capability of a CMO
can be evaluated for CMO selection
and improvement by the use of a vir-
tual plant developed from the prolifc
PD lab data.
[Editors note: An extended version of
this column, including Top 10 Rea-
sons to Use an Optimized DCS for Your
BBQ is at www.controlglobal.com/
ControlTalk1204.html.]
ADVERTISER . . . . . . . . . . . . . . . . . . . . . . PAGE NO.
ABB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Advantech Automation . . . . . . . . . . . . . . . . . 32
Agilent Technologies. . . . . . . . . . . . . . . . . . . 37
Allied Electronics . . . . . . . . . . . . . . . . . . . . . 19
AutomationDirect . . . . . . . . . . . . . . . . . 8, 25-28
Badger Meter . . . . . . . . . . . . . . . . . . . . . . . . . 47
Banner Engineering . . . . . . . . . . . . . . . . . . . 30
Beamex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Cashco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Cox Instruments . . . . . . . . . . . . . . . . . . . . . . 49
Dome Exhibitions . . . . . . . . . . . . . . . . . . . . . 58
Emerson Process Mgt/Rosemount . . . . . . . . 17
Emerson Process Mgt/Systems . . . . . . . . . . . 74
Endress + Hauser. . . . . . . . . . . . . . . . . . . . . 6, 7
Expertune . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Flexim Americas . . . . . . . . . . . . . . . . . . . . . . 54
Fluke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Invensys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Krohne . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Magnetrol International . . . . . . . . . . . . . . . . 14
Maple Systems . . . . . . . . . . . . . . . . . . . . . . . . 59
Martel Electronics. . . . . . . . . . . . . . . . . . . . . 48
Maverick Technologies . . . . . . . . . . . . . . . . . 31
MCAA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
MHIAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
National Instruments . . . . . . . . . . . . . . . . . . 10
NovaTech Process Solutions . . . . . . . . . . . . . 52
Omega Engineering . . . . . . . . . . . . . . . . . 3, 55
Opto 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Orion Instruments. . . . . . . . . . . . . . . . . . . . . 43
Pepperl+Fuchs . . . . . . . . . . . . . . . . . . . . . . . . 20
Phoenix Contact . . . . . . . . . . . . . . . . . . . . . . . 2
Prosoft Technology . . . . . . . . . . . . . . . . . . . . 29
Reed Exhibition. . . . . . . . . . . . . . . . . . . . . . . 56
Rittal Corporation. . . . . . . . . . . . . . . . . . 38, 39
Santa Clara Systems . . . . . . . . . . . . . . . . . . . 70
Siemens Process Automation . . . . . . . . . . . . 53
Turck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Yaskawa Electric . . . . . . . . . . . . . . . . . . . . . . 73
Yokogawa . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
C L A S S I F I E D S
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buyer@santaclarasystems.com
Dry run protection
The PMP-25 Pump Load Control guards against dry run-
ning, cavitation and overload. It monitors true pump power
for maximum sensitivity. The display shows pump load, trip
points and delays. Its NEMA 4X enclosure is small enough to
ft on Size 1 starters and can be door-, panel- or wall-mounted.
Load Controls Inc., (888) 600-3247, www.loadcontrols.com.
C O N T R O L R E P O R T
JIM MONTAGUE
EXECUTI VE EDI TOR
j mont ague@put man. net
72 www.controlglobal.com A P R I L / 2 0 1 2
Precious Water
The best things in life may be free. However, in money-focused, self-centered times,
free items may begin to appear to have no value. As a result, everything from true love
to free Internet content to process control is taken for granted. Fresh water is one of
these crucial and ignored items. Pretty unbelievable for a substance thats second only
to air on the list of whats needed to keep us
alive.
Still, todays attitude is, Out of the tap?
Eww! But put it in a package thats not sustain-
able no matter how thin its walls and how tiny
its cap, and most of us will plunk down cash for
it. Just plain crazy, especially when most mu-
nicipal drinking water is just as good as bottled.
In fact, lots of bottled water is just tap water.
So what are we buying? Wasteful plastic, a
little portability and a crumb of prestige. Ive
got bottled water from Fiji, while you peasants
have to drink from a water fountain. However,
beyond simple one-upmanship, why do we do
something so obviously counterproductive? I
think it may just be perceived value caused by
illusory scarcity.
Even in print and online publishing, con-
tent that people have to pay for is more highly
valued than whats freeno matter the use-
fulness of the information. On the reporting
side, I must confess Ive sometimes considered
a moratorium on water and wastewater stories
because Ive written so many of them, and they
seem, well, pretty bland. Theyre just not as
cool as oil rigs, biochemical reactors and micro-
breweries. But why isnt water treatment cool?
Again, its stories are more available, and so Ive
taken them for granted, too. Im sorry.
To cure my prejudice and right this wrong,
Im writing up two case studies on water col-
lection and treatment applications. The frst
is about the Water Production Dept. in Enid,
Ok., which is building a new plant, planning
a reservoir and adding a variety of effcient
process controls to manage its expanding pro-
duction and treatment facilities, including the
implementation of Iconics Genesis64 HMI/
SCADA software.
The second is about the Ontario-based
Windsor Utilities Commission (WUC), which
was also long overdue for some new controls to
maintain the reliability of its water production
system. Its using Rockwell Automations Con-
trolLogix PACs and FactoryTalk VantagePoint
software for its upgrade. Both of these stories
are available online at www.controlglobal.com/
watertreatment.
Still, beyond covering and paying atten-
tion to useful water treatment applications,
what else can be done? Well, how about learn-
ing what life is like in places where water re-
ally is scarce or threatened? To communities,
families and mostly girls and women in East
Africa, available water means freedom from
having to waste hours each day fetching it
hours that can be spent at school. To learn
more, read The Burden of Thirst in National
Geographic at http://ngm.nationalgeographic.
com/201%4/water-slaves/rosenberg-text.
Personally, Ive seen ostentatious displays
and overuse of water in Las Vegas and Palm
Desert, Calif. I thought then that it was almost
like a psychological denial of the severe desert
environment just beyond the unnaturally green
golf course. Anthropologists have long theo-
rized on why the Anasazi left these regions long
ago. Well, they likely went to the same place
many folks now living in those deserts are go-
ing to go when the groundwater runs out, and
the salt rises high enough in the soil to make it
unusable. To learn more, read Cadillac Desert
by Marc Reisner, or view the video about the
book at www.youtube.com/watch?v=hkbebOh
nCjA&feature=player_embedded#!
Or maybe, the next time youre thirsty, just
pay attention to it for few minutes. Get a feel-
ing for what being parched is really like. Being
hungry is uncomfortable, but true thirst is pain-
ful. Just thinking about being thirsty makes me
thirsty, so I know it can quickly remind me not
to take water for granted. How about you?
Just thinking about
being thirsty makes
me thirsty, so I
know it can quickly
remind me to not
take water for
granted.
One red cup sits on a small bleacher area for each of the associates on the line in our Buffalo Grove, Illinois
manufacturing and distribution center. In those cups, we put any screws damaged during our processes.
Know how many screws we collect on average each month? Twenty-ve. Thats
right. Only 25 damaged screws for every 40,000 processed. Pretty impressive,
huh?
At Yaskawa, our people are committed to quality because to them its not just a
job its personal.
Never compromise on quality. Call Yaskawa today.
TWENTY-FIVE
YAS KAWA AMERI CA, I NC.
DRI VES & MOT I ON DI VI S I ON
1 - 8 00-YAS KAWA YAS KAWA. COM
Follow us:
For more info:
http://Ez.com/yai306
2012 Yaskawa America Inc.
YOU CAN DO THAT
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The Emerson logo is a trademark and a service mark of Emerson Electric Co. 2012 Emerson Electric Co.
Another I/O change? Great.
So another wiring schedule.
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And another cabinet...
Just make it all go away!