Documenti di Didattica
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DCS MigrationFailure Is Not an Option
Power Supplies Take Sophisticated Paths
ON THE WEB
Using Modular Procedural Automation
to Improve Operations
Serene
The Economic
Recovery is
But like the swan, under the water
its feet are paddling feverishly.
2012 PHOENIX CONTACT
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COPYRIGHT 2012 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED
omega.com
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To access Version
8 information,
use the code
reader on your
smart phone,
snap a picture
and experience.
The Numatics trademark is registered in the U.S. and other countries. The Emerson logo is a trademark and service mark of Emerson Electric Co. 2012 Numatics, Inc.
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D E C E MB E R / 2 0 1 2 www.controlglobal.com 29
R E S O U R C E S
Temperature and Pressure Resources You Can Use
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.
TEMPERATURE/PRESSURE BLOG
APG Sensors has as regular blog that
covers a variety of sensor subjects. In
the section devoted to pressure and
temperature, it covers such subjects as
Top 10 Things Not to Do with Pres-
sure Sensors, Six Common Variables
Affecting Pressure Sensors, How
Temperature Affects Pressure Sen-
sors and Pressure Sensors and Water
Hammer. Access to the blog is free.
The direct link is at www.apgsensors.
com/products/applications/pressure-
measurement.
APG Sensor s
www. apgsensor s. com
DIFFERENTIAL PRESSURE
TRANSMITTER ACCURACY
Differential pressure transmitters are
extremely versatile instruments ftting
a broad range of applications in various
process industries. Accuracy is a key per-
formance measure for any process-mea-
suring device, and is an important factor
for proper device selection and mainte-
nance. Differential pressure devices are
very versatile, but it is not always easy to
understand, calculate or compare accu-
racies between devices. This document
is intended to help the reader better un-
derstand what manufacturers accuracy
statements mean, what specifcations are
important for a given application, and
how to properly compare various product
capabilities. The direct link to this free,
downloadable white paper is at http://ti-
nyurl.com/dx8fx72
Honeywel l Pr ocess Sol ut i ons
www. honeywel l pr ocess. com
HOW TO USE A PRESSURE SENSOR
This tutorial from National Instruments
covers the basics, such as how to measure
pressure with pressure sensors. It also cov-
ers the types of sensors available and the
appropriate hardware to accurately take
pressure measurements. Other subjects
include the anatomy of a basic pressure
sensor, the types of sensors available and
the appropriate hardware to take pres-
sure measurements accurately. This is a
free, downloadable PDF. The direct link
is at www.ni.com/white-paper/3639/en.
Nat i onal I nst rument s
www. ni . com
AVOID TEMPERAURE
MEASUREMENT PITFALLS
For more exacting needs, found in
many scientifc, industrial and com-
mercial uses, the temperature of a pro-
cess must be measured and controlled
defnitively. LAN Extensions for In-
strumentation (LXI) offer a methodol-
ogy to perform these exacting measure-
ments in test and control applications.
What do you need to know to select
the best temperature measurement so-
lution for your application? This pa-
per describes the common pitfalls of
precision temperature measurement
and what you need to consider before
selecting a temperature measurement
solution. This is a free, downloadable
white paper. The direct link is at http://
tinyurl.com/4cmzxmz.
Dat a Tr ansl at i on
www. dat at r ansl at i on. com
TEMPERATURE MEASUREMENT
FOR POWER PLANTS
Irrespective of the type of power plant
(coal-fred, oil- or gas-based), tem-
perature measurement remains high
on the list for operational excellence
throughout the plant. Implementa-
tion of some of the new technologies
results in improved safety and lower
installation and maintenance costs.
Incorrect measurement information
due to temperature effects, non-lin-
earity or stability can result in major
equipment getting damaged. Ensur-
ing that instruments that have mini-
mal downtime from a maintenance
standpoint, not just devices that have
been evaluated to provide safety in-
tegrity level service in safety instru-
mented systems, is crucial for daily
operations in a power plant. The pa-
per covers some of the basics of tem-
perature measurement and leads into
some of the technical advances that
impart a higher degree of safety and
reliability to power plant operation.
Free download at http://tinyurl.com/
bsfs2ts.
Endr ess + Hauser
www. us. endr ess. com
HOW TO SELECT A PRESSURE SENSOR
There are over 200 pressure sensor
suppliers around the world, offering
products that cost from a few dollars
to thousands of dollars. A purchaser or
engineer unfamiliar with pressure sen-
sors can become overwhelmed with
the price range, quality and options.
The frst step is to understand all as-
pects of their application, from the me-
dia being measured to the desired elec-
trical output for indication or control.
The following link takes you to a guide
through a variety of options to make a
prudent decision. The direct link is at
http://tinyurl.com/bnlqkgo.
Ameri can Sensor Technol ogi es
www. ast sensor s. com
30 www.controlglobal.com D E C E M B E R / 2 0 1 2
C O N T R O L / A R C A U T O M A T I O N T O P 5 0
But like the swan, under the
water, its feet are paddling
feverishly.
by Walt Boyes, David Clayton
and Inderpreet Shoker
Serene
The Economic Recovery is
D E C E MB E R / 2 0 1 2 www.controlglobal.com 31
C O N T R O L / A R C A U T O M A T I O N T O P 5 0
TOP 50 GLOBAL AUTOMATION VENDORS
2011 Worldwide
TOTAL (in millions) 102,386.51
1 Siemens 14,763.33
2 ABB Process Automation and ABB Automation Products 11,364.41
3 Emerson Process Management 7,943.82
4 Schneider Electric 5,644.50
5 Rockwell Automation 5,465.47
6 Yokogawa Electric 3,949.26
7 Mitsubishi Electric 3,759.59
8 GE 3,461.19
9 Honeywell Process Solutions/Sensing & Control 3,114.72
10 Danaher Industrial Technologies 3,057.19
11 Omron 2,535.94
12 Endress+Hauser 2,138.85
13 Phoenix Contact 2,131.84
14 IMI Fluid Controls Severe Service PLC 2,063.17
15 Yaskawa 1,824.50
16 Invensys Operations Management 1,759.33
17 Cameron Valves & Measurement 1,663.00
18 Ametek EIG 1,647.20
19 FANUC 1,596.09
20 Spectris 1,551.10
21 Flowserve Flow Control Division 1,448.79
22 azbil Group (Yamatake) 1,054.41
23 Mettler Toledo 1,040.00
24 National Instruments 1,024.20
25 Wika 982.33
26 FMC Energy Processing Systems 964.65
27 Weidmuller 869.57
28 MKS Instruments 822.50
29 Hitachi 812.40
30 IFM Electronics 799.44
31 Samson 740.00
32 Roper Industries Industrial Technology 737.40
33 Bosch Rexroth 726.18
34 Metso Automation 695.65
35 Beckhoff 652.17
36 Wago 645.37
37 Fuji Electric 623.08
38 Teledyne Instruments 621.41
39 Advantech 598.20
40 Krohne 579.24
41 B&R 575.04
42 Turck 559.00
43 Burkert 535.76
44 Pepperl+Fuchs 504.36
45 Horiba 481.36
46 TMEIC 459.90
47 Toshiba 424.15
48 Pilz 398.69
49 Belden Connectivity Products 288.90
50 Thermo Scientifc 287.86
HONORABLE MENTION
2011
Worldwide
Parker Industrial 281.63
Badger Meter 262.90
OSIsoft 259.10
Aspen Technology 198.20
Tyco Flow Control 180.00
SupCon 161.50
Magnetrol 150.00
MTL 134.34
Hollysys 129.00
MTS 105.00
SPX Valves and Controls 104.62
SMAR 87.71
Opto 22 85.63
Cashco 84.30
IDEC 80.71
Vega 72.39
Iconics 42.39
Pyromation 25.40
32 www.controlglobal.com D E C E M B E R / 2 0 1 2
C O N T R O L / A R C A U T O M A T I O N T O P 5 0
The U. S. presidential election is over, as of this writ-
ing, and by the time you read this, politicians are ar-
guing over whether to jump over the fscal cliff, or
whether there is, actually, a fscal cliff or just a fscal
curb. We may be headed into another recessionor
maybe not.
Every major automation company and most of the
smaller ones posted large sales increases throughout
2011 and into 2012. But one by one, at the fall user
groups meetings, vendor executives warned that,
while things looked good now and the pipelines into
next year looked full, things didnt look all that rosy
from mid-2013 onward.
At the recently concluded Automation Fair, I asked
Rockwell Automation CEO Keith Nosbusch if I was
right in concluding that everything was going along
swimmingly. He replied, Its like the swan foating on
the surface of the pond. Everything looks serene as it
glides along, but under the water the feet are churn-
ing furiously.
Dr. Mark Douglass, senior analyst with Longbow
Research, agrees. U. S. demand for automation prod-
ucts is fat to slightly down, he says. Oil and gas activity
appears to be the strongest segment within process au-
tomation, with demand driven by oil felds, shale gas
and biofuels in Texas, California, Florida, Washing-
ton and New York. Specialty chemicals were mixed,
he says, and pulp and paper, along with food process-
ing, were generally weaker.
Internationally, Douglass says, demand for new au-
tomation products and systems is mixed. In Europe,
German demand remains relatively healthy, but his
respondents tell him that while demand appears to re-
main positive, there are signs of cooling off. France
HONORABLE MENTION
2011
North America
Magnetrol 60.00
Burkert 53.58
Beckhoff 52.17
Pilz 50.80
Tyco Flow Control 37.54
TMEIC 37.25
Samson 37.00
Hitachi 29.18
MTS 27.30
Pyromation 25.40
Iconics 25.01
SMAR 23.06
Vega 21.07
IDEC 15.58
Fuji Electric 14.22
TOP 50 NORTH AMERICAN AUTOMATION VENDORS
2011 North America
TOTAL (in millions) 24,348.77
1 Emerson Process Management 3,664.32
2 Rockwell Automation 3,082.52
3 ABB Process Automation and ABB Automation Products 1,737.48
4 Siemens 1,562.56
5 Danaher Industrial Technologies 1,375.73
6 Schneider Electric 1,192.15
7 GE 1,167.26
8 Ametek EIG 840.07
9 Honeywell Process Solutions/Sensing & Control 829.70
10 Cameron Valves & Measurement 698.46
11 Roper Industries Industrial Technology 560.42
12 Invensys Operations Management 491.14
13 Flowserve Flow Control 463.61
14 IMI Fluid Controls Severe Service PLC 430.46
15 National Instruments 411.00
16 Endress+Hauser 395.69
17 MKS Instruments 391.10
18 Spectris 387.78
19 Yokogawa Electric 304.93
20 Omron 304.31
21 Mettler Toledo 298.00
22 Yaskawa 294.42
23 Teledyne Instruments 287.09
24 Badger Meter 231.30
25 Turck 202.00
26 Toshiba 195.18
27 Belden Connectivity Products 176.23
28 Advantech 174.10
29 Weidmuller 170.94
30 FMC 165.92
31 Thermo Scientifc 152.57
32 Mitsubishi Electric 132.96
33 OSIsoft 127.50
34 Metso Automation 125.22
35 IFM Electronics 119.94
36 Phoenix Contact 106.59
37 Wika 98.23
38 Wago 96.35
39 azbil Group (Yamatake) 94.90
40 Bosch Rexroth 93.12
41 Parker Industrial 89.34
42 B&R 86.26
43 Cashco 78.68
44 Horiba 77.02
45 Aspen Technology 70.96
46 FANUC 70.51
47 Krohne 63.72
48 Opto 22 62.95
49 Pepperl+Fuchs 59.61
50 SPX Flow Technology 56.67
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C O N T R O L / A R C A U T O M A T I O N T O P 5 0
is harder to quantify, but here too, demand appears to be
slightly positive.
It is when we get to the BRIC countries (Brazil, Rus-
sia, India and China) that things get very interesting. Chi-
nas economy, the mainstay of the recovery from the 2008
recession, appears to be slowing, and some people report
negative growth. This is diffcult politically as the new gov-
ernment of Xi Jinping takes offce. Mr. Xi, it is universally
acknowledged, will face challenges no Chinese govern-
ment has yet faced.
China is no longer the low cost of manufacturing leader
it once was. Wages, according to Peter Orszag, former direc-
tor of the Offce of Management and Budget, writing in the
Bloomberg View, rose from about $1000 in 1978 to almost
$5500 in 2011. This is in part due to the same shortages of
skilled workers the West has confronted for the past 10 years
or more. It is also because sometime during Mr. Xis term,
China will cross the Lewis point, where the economic gains
from moving workers from agriculture to manufacturing no
longer obtain.
Douglass believes that there are still signs of strength in
Chinas petroleum, chemical and power generation sectors,
though.
Quoted in Steve Minters article in IndustryWeek on
Nov. 14, 2012, Schneider Electrics president of U. S. oper-
ations, Jeff Drees, sees a more positive view. Drees says that
A question that keeps coming up is how
the Top 50 will stay on top. This may be de-
cided by their ability to improve their mar-
keting and sales technologies to 21
s
t-cen-
tury levels. Marketing in the 21
st
century is
a moving target. Large automation com-
panies are at a signifcant disadvantage
because by the time they have spent six
months developing their online marketing
strategy, its time to crumple it up and start
over. The marketing landscape is changing
that quickly thanks to the head-spinning
pace of innovation from the likes of Google,
Facebook, LinkedIn and their ilk.
As if thats not bad enough, automa-
tion companies are at a disadvantage for
another reason. As our business commu-
nication platforms become increasingly in-
tertwined with social media, the computers
are paradoxically forcing us all to become
more human in our marketing. This is re-
ally tough for engineering and technically
based companies to grasp, harder to em-
brace and incredibly tricky to pull off.
What customers want is the freedom to
seek vendors out, instead of vendors fnd
them. Fortunately, there is a proven model
that works under this new paradigm; it is
called inbound marketing, pull rather than
push. This approach fips traditional mar-
keting on its head. Instead of trying to in-
terrupt people from what they are doing
by shoving advertisements under their
nose or cold-calling them, successful
21
st
-century marketers are embracing the
trust economy and delivering valuable
content to their prospective customers,
establishing themselves as benevolent
thought leaders instead of pesky, self-ab-
sorbed chest-pounders. Inbound market-
ing has worked in all the other high tech-
nology markets.
So how are we doing in the industrial
automation market? Well, lets put it this
way: The good news is that the bar is low,
The frst company to grasp, embrace and
execute the new approachis going to fnd
great success. No company has quite
done this yet. Lets take a look the fve ma-
jor components of inbound marketing and
evaluate the current landscape.
Content Marketing
The frst step in inbound marketing is to
generate remarkable content that prospec-
tive customers will value. While download-
able content like ebooks and white papers
are very important in content marketing,
blogging is its bread and butter because it
provides so many peripheral benefts out-
side of the content itself. The industry is
taking baby steps in this direction. While a
few of the major vendors are doing a great
job strategically, most of them are not do-
ing as well tactically.
Visibility
Most corporate websites make it very dif-
fcult to fnd these blogs. It seems that
many companies are uncomfortable with
the word blog, so they use euphemisms
instead. Other companies ignore them al-
together and dont mention them on their
websites or hide them several layer deep.
Consistency
There are a number of industry blogs post-
ing on a remarkably consistent basis. Oth-
ers are very sporadic or have abandoned
their blogs altogether.
Foot-Shooting
Inexplicably, most every industrial automa-
tion blog Ive seen is hosted on a domain
separate from the main corporate website.
Some even have a different domain for each
topica waste of search engine juice. One
of the great benefts of blogging is the way
it can contribute to SEO (search engine op-
timization)keyword usage, back-links and
social media shares. By moving blogs off-
domain, companies are giving it all away.
Search Engine Optimization
Once youre creating remarkable con-
tent, its great if people can fnd it through
search engines. Companies are missing a
huge opportunity with their blogs. But even
basic, on-page optimization techniques
such as using keywords in URLs, page
titles and headings are not as well imple-
mented as they could be.
Social Media Marketing
This is one area where most companies
are making real efforts. There have been
some really clever campaigns executed on
21ST-CENTURY AUTOMATION MARKETING
Continued on Page 36
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C O N T R O L / A R C A U T O M A T I O N T O P 5 0
the rebound in U.S. manufacturing
is real, not just wishful thinking. Ac-
cording to Minter, Drees believes that
Schneider will outperform expected
U.S. GDP growth of 2% in its hard-
ware offerings and move into software
and services.
Satoru Kurosu, executive vice pres-
ident of Yokogawa Electric, appears
to agree with Drees. In his keynote
address to the 2012 Yokogawa USA
user group meeting in October, Ku-
rosu claimed, The U.S. is our newest
emerging growth market, and added
that the reason was the offshore oil and
natural gas markets.
Although his companys feet are
pumping furiously, Rockwells Nos-
busch declared himself bullish on the
Rockwell Process Initiative (PlantPAx
and allied products), and told analysts
at Automation Fair that the Process
Initiative would double its revenues
by 2017.
The Service Economy
Every major automation vendor an-
nounced a new or an expanded ser-
vice offering in the past year. Theyve
all seen the handwriting on the wall:
fewer employees, higher through-
put, less well-trained operators and
engineers, and theyre all lining up
to help their customers remain their
customers by providing cradle-to-
grave service packages for their sys-
tems and other products. The man-
tra seems to be as Emerson Process
Management business leader Steve
Sonnenberg said in his Emerson Ex-
change keynote, We want to be your
trusted partner.
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capacity of 9800 records or
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the device.
21ST-CENTURY AUTOMATION MARKETING (CONTINUED FROM PAGE 34)
Facebook, and were starting to see more
of a presence on Twitter too. However, too
many of them are trying to force an out-
bound peg into an inbound hole. Theyre
spending too much time talking about
themselves and not enough time sharing
remarkable content that is going to make
them a benevolent thought leader.
Another shortcoming I see ignores
one of Sun Tzus warnings from The Art of
War: Tactics without strategy is the noise
before defeat. Jumping into social media
without a comprehensive marketing strat-
egy wont generate the ROI a company
could otherwise realize.
Conversion
This is the one area of inbound market-
ing that industrial automation marketers
almost completely ignore. Once the 21
st
-
century marketer has created remarkable
content that is being found by search en-
gines and discovered via social media,
visitors need to be converted into leads.
This is accomplished by placing calls to
action across the website that send visi-
tors to carefully designed landing pages.
These landing pages contain offers and
conversion forms where visitors trade
personal information such as email ad-
dresses for something of value such as an
ebook or webinar or even a direct product
purchase or inquiry.
Analytics
This is a tough one for anyone to analyze
from the outside because its impossible
to know what metrics and KPIs are be-
ing monitored internally. However, the
very absence of landing pages on most
industrial automation websites is strong
evidence that they arent watching the
single most important 21
st
-century mar-
keting metric; conversion rates.
The bad news is that the automation
industry hasnt quite moved into the 21
st-
century yet from a marketing perspective.
The good news is that the playing feld is
wide open. There are a few players on
the sidelines stretching and warming up,
but from my perspective, the opening
whistle hasnt blown yet.
by Jon DiPietro, president,
DomesticatingIT.com
C O N T R O L / A R C A U T O M A T I O N T O P 5 0
Virtualization
The cloud is coming, the cloud is coming! At every user
group this year, there was an offering of virtualization soft-
ware and programs to help clients keep using obsolete soft-
ware and operating systems. Virtualization also provides a
handle on reducing downtime, high availability, automatic
failover and other very critical features that automation us-
ers want and need.
The question is, will they permit their systems to be run
inside the cloud, and not just in a virtual server? Some au-
tomation vendors say no. Others are working hard to con-
vince their customers to virtualize as the frst step toward
cloud-hosted services. After all, how much safer is your data
if you store it on the server rack in the dirty old closet be-
hind the control room than if you stored it at Apples $1-bil-
lion server farm in Maiden, N.C., where there are redundant
power backup, redundant server backup, automatic failover
and high-purity HVAC?
The Charts
The charts pretty much speak for themselves. In the
top 10, Siemens, ABB and Emerson all held position
globally, while Schneider and Rockwell changed
places. GE moved up significantly, while Mitsubishi
and Danaher moved down. A significant move was that
Endress+Hauser, which only manufactures field instru-
ments and analyzers, moved into the 12th spot without
owning a DCS or PLC, or even a valve manufacturing
facility. Its partnership with Rockwell seems to be help-
ing the company greatly.
Amid rumors, Invensys dropped to 16th from 14th, while
the azbil group, formerly Yamatake, rose to 22nd from 25th.
At the bottom of the Global Top 50, Badger Meter moved
from 48th place to the Honorable Mention list.
In North America, the frst three on the list are the same
as last year, and then things start to move around. Siemens
moved to 4th, Danaher moved from 4th to 7th, and Roper
moved up two places. Companies move up and down a cou-
ple of places every year.
We want to remind our readers that this list is a work in
progress every year. Every year, somebody points out a com-
pany we have missed, or a vendor suggests better numbers
than we have been able to fnd. We regret any errors, and we
very much welcome corrections and additions.
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44 www.controlglobal.com D E C E M B E R / 2 0 1 2
P O W E R S U P P L I E S
Using many of the same data processing tools and software as
process controllers, power supplies are diversifying their capabilities
and serving in many new and different applications.
by Jim Montague
Weve gone way beyond on and off. Yes, power supplies al-
ways had to convert and deliver appropriate volts, watts, amps
and other power levels, and meet quality measures to run their
machines and applications. But once confguration was done
and harmonics were tested, most power supplies operated con-
tinuouslyat least until an interruption or outage happened.
Well, those set-it-and-forget-it days are long gone. Digital
monitoring devices enabled by microprocessors and software
are pulling power supplies up to the same awareness level as so
many other process control components.
For instance, Boliden (www.boliden.com) recently spent
$790 million to renovate its Aitik open-pit copper mine in Glli-
vare, Sweden, and it used ABBs (www.abb.com) control systems
and power equipment to increase Aitiks effciency and double
capacity to 36 million tons of ore per year, even though its ini-
tial ore is only 0.25% copper (Figure 1). The mine installed 650
motors ranging from 4 kilowatts (kW) to 5 megawatts (MW);
230 drives and variable-speed drives; and two 22.5-MW gearless
mill drives (GMDs). These are powered by ABBs 23 distribu-
tion transformers and gas-insulated switchgear and controlled
by its System 800xA DCS.
Of course, extracting metal from the 106,000 tons of ore
thats crushed and chemically concentrated to 25% copper at
Aitik each day requires lots of stable, high-quality power for its 7
km of conveyors, the GMDs and other equipment, which must
often run 24/7/365 in very dusty conditions that can get down
to -45 C in winter. So, ABB implemented a 179-kV substation
with its gas-insulated UniGear switchgear thats protected by its
Relion relay protection equipment, and distributes 24-kV power
throughout the mines operations. Also, a harmonic flter and
power-factor correction system help Boliden prevent damage to
its own equipment and avoid disturbing the local power grid.
In addition, Aitik uses the IEC 61850 standard that defnes
communications within and between electrical components,
which enables 800xA to provide one environment for supervis-
ing and controlling process automation equipment, power auto-
mation devices, switchgear, and transmission and distribution
equipment. Boliden reports that integrating Aitiks electrical
controls with its process controls increases productivity and re-
duces stoppages.
Custom-Made Monitoring
While most process applications arent as big as the Aitik mine,
many similar methods of monitoring and proactively maintain-
ing electricity are being adopted by smaller power supplies in
diverse applications.
Power supplies have always been a bit of a stepchild com-
pared to other process control devices, but users in applications
from power generation to food and beverage are recognizing
that power is the most critical element in their applications,
says Roolf Wessels, business unit manager for monitoring and
protection at Pepperl+Fuchs (www.pepperl-fuchs.us). You can
lose a few I/O points and networking nodes and still run an ap-
plication, but losing power means losing your whole application,
so its worthwhile investing in high-reliability, high-effciency
power. As a result, users want more diagnostics in their power
supplies. They already have diagnostics for predictive mainte-
nance and asset management in their controllers and feld de-
vices, and now they want it in their power supplies, too.
Power Supplies Take
Sophisticated Paths
Figure 1. The Aitik copper mine uses ABBs 800xA process controls to coordi-
nate its 179-kV substation, gas-insulated switchgear and power supplies.
MANAGING MINE POWER
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As a result, Pepperl+Fuchs redesigned its PS 3500 power
supply in 2009, and is scheduled to introduce its PS 3500-DM
diagnostic module in January 2013. It plugs into the power
supplys backplane and monitors incoming current quality
and generated dc outputs, checks for brownouts and spikes,
time-stamps any events, correlates them with data from other
sources, and provides alerts and alarms, says Wessels. We
even added a display on the DM module itself, so users see all
their parameters locally too.
Similarly, Emerson Network Power (www.emersonnetwork-
power.com) is integrating its uninterruptible power supplies
(UPSs) with Asset Management Suite (AMS) software to moni-
tor UPS performance. In many cases, power systems and their
backups have been reliable for decades, so users tend to forget
about them after commissioning, and no longer know what to
do when alerts and emergency calls eventually come in, says
David Vasselin, market and business development vice presi-
dent for Emerson Network Powers industrial systems division.
Now users want UPSs that are easier to understand and main-
tain, and this is why weve integrated them with AMS in elec-
tronic device description (EDD) software and human-centered
design principles. We ran through all the UPS alert situations
and added them to the EDDs to give users a hierarchy of alerts
and how to troubleshoot them.
Standard Pieces for Specifc Puzzles
To help reduce the time it takes to integrate power supplies
with their control-based counterparts, Mark Wilkins, chief en-
gineer at Acopian (www.acopian.com), reports his company
is building IP addresses, Ethernet and USB interfaces and
some control functions directly into its 0-30 kV power supplies
Theres a lot more fuctuating inputs these days, typically be-
tween 90 V and 265 V, so we designed a universal input to
handle them without having to fip a switch, says Wilkins.
In general, we now have more programming and communi-
cations options for applying power more effciently, and these
are allowing power supplies to interface with other equipment,
talk to each other and synchronize efforts. For example, in a
water ionizing application to purify water for plating, a control-
ler can tell a power supply to turn on; it can report back in a
few hundred milliseconds; and be adjusted much faster than
manually for more consistent plating with less feathering.
Likewise, some power supplies are adding intelligence that
allows them to be more easily monitored and managed, ac-
cording to Kai-Uwe Bronzel, product consultant for U.S.
power supplies and power security at Siemens Industry (www.
usa.siemens.com/industry). We recently built a relay contac-
tor module into our Sitop power supplies that can bring a sig-
nal back to upper-level control systems, says Bronzel. This
lets users check on their input and output voltages, observe
trends in their 24-Vdc supplies, and prevent more interrup-
tions and potential failures.
Sharonda Wamer, Siemens product marketing manager
for U.S. power supplies and power security, adds that many
power supplies and related systems are following the lead of
Europes suppliers, and moving from 230 Vac or 120 Vac to
24 Vdc. More customers have applications that depend on
critical 24 Vdc power, so we provide solutions to maintain it,
says Wamer. These include our dc ups with battery backup,
redundant solutions with two power supplies for load sharing,
and switched-mode power supplies. These use an electronic
method that draws less current than regular mechanical sup-
plies when reacting to short circuits, and this means fewer
trips, more and better identifcation of potential overloads, and
fewer lost circuits.
Merging Power and Control
To combine control and power even more tightly, National
Instruments (www.ni.com) and the National Renewable En-
ergy Lab have combined NIs single-board Reconfgurable I/O
(RIO) and added its standard General Purpose Inverter Con-
troller (GPIC) board for 50-kW and up power supplies, which
primarily use custom circuit boards.
In fact, Dynapower Corp. (http://dynapower.com) has de-
veloped power converters for grid-tied energy storage based on
NIs LabView RIO architecture and RIO GPIC (Figure 2). Ad-
vanced carbon batteries are useful for grid storage because they
have a long lifecycle, fast charge/discharge and deep-cycling
capability, but they require a unique power conversion and in-
verter system such as Dynapowers to stabilize performance
and provide these benefts.
LabView and GPIC development platforms reduced our
development cost and risk compared to a full-custom control-
ler design, says Kyle Clark, Dynapowers advanced systems en-
gineering manager. We were able to reduce development time
for our power converters from 72 weeks to 24 weeks. FPGA
devices in particular, which now include embedded DSP cores
inside the fabric, are a real game changer. We can precisely
control the fow of power, run multiple control loops in paral-
lel and reconfgure the hardware at a silicon level even after its
deployed to the grid.
Jim Montague is Controls executive editor
P O W E R S U P P L I E S
Figure 2. Dynapowers 50 kVA dc-to-dc power converter and
the SmartPowerStack Consortiums 100 kVA power inverter
(bottom right) are based on National Instruments General
Purpose Inverter Controller (GPIC).
MERGING POWER
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46 www.controlglobal.com D E C E MB E R / 2 0 1 2
A S K T H E E X P E R T S
Emergency Shutdown of LPG Tank Farms
Q
We have four liquifed petroleum gas (LPG) spherical
tanks complete with low-level transmitters connected
to the shutdown system to stop the outlet pumps in
case of low level, and high-level transmitters providing high
level alarm. The following modifcations are planned:
- Inslallalion ol a new shuldown valve al lhe inlel ol each
tank to be closed in case of high level and in case of common
planned shutdown (PSD) or emergency shutdown (ESD).
- Inslallalion ol new shuldown valves al lhe oullel ol each
tank, which will be closed in case of low level in the corre-
sponding tank and in case of common PSD or ESD.
- Inslallalion ol a new shuloll valves in lhe vapoi line ol
each tank. The vapor lines will be connected together to
equalize the pressure in the vapor spaces of the four tanks.
- Inslallalion ol a new slandalone hydiaulic conliol sys-
tem complete with a dedicated PLC system to manage the
operation of the new shutdown system.
- A seiial inleilace lelween lhe new IIC and lhe exisling
DCS which presently monitors the operation.
- A haidwiied inleilace lelween lhe exisling ISD/IC
syslem and lhe new hydiaulic/IIC syslem.
Now my queslion is lhis Is il allowed liom lhe slandaid
poinl ol view lo use lhe exisling level liansmilleis lo conliol
lhe inlel and oullel shuldown valves In olhei woids, is il al-
lowed lo conveil lhe exisling analog level signals liom lhe
exisling ISD syslem inlo digilal, and send lhem as digilal
input into the new PLC system, or do we have to install new
dedicated transmitters?
RAGAB ABDEL FATTAH
r agab. abdel f at t ah@t ecnomar eegypt . com
A
Iiislly, congialulalions lo all ol you loi gelling iid ol
the dictatorship in Egypt, and taking your nations fu-
ture into your own hands by successfully conducting a
free election.
1he queslion you ask is veiy lamiliai. I come acioss il on
many projects when users are converting from a semi-man-
ual mode of operation, such as yours, where the DCS auto-
matically stops the outlet pumps on low level, but on high
level, it provides no automatic action, only monitors, leaving
the closing of valves to the operators or to an automatic con-
trol system serving emergency shutdown (ESD). Your choice
of operating the new shutoff valves by a separate PLC is a
logical one, and your plan to hardwire the PLC to the sen-
sors is the correct one. Given the state of the art and reli-
alilily ol wiieless liansmission, I iecommend using wiieless
only for monitoring, but not for control and certainly not for
ESD purposes.
Youi queslion conceining lhe ieuse ol lhe exisling level
deleclois and lhe salesl melhod loi inleilacing lhe exisling
DCS with the new PLC is also often asked. On some proj-
ecls, I lound people gelling in lioulle ly ielying on slan-
daids, inslead ol liusling lheii common sense. In my view,
you should always follow your common sense.
Conceining lhe ieuse ol exisling level deleclois, lhe com-
mon sense answer is that using two sensors is better than
one! Detecting the occurrence of an unsafe condition by
redundant sensors improves safety if either will trigger the
ESD action. Naturally, if only one of the two sensors sig-
naled abnormal level and triggered an ESD, then, before
the operation is restarted, both sensors should be recali-
lialed. In olhei woids, lhe salely inlegiily level (SII) ol a ie-
dundant-sensor-based system is always better than a single-
sensor-based one if the above approach is used. Therefore,
on lhe one hand, you should conlinue using lhe exisling
detectors, and, on the other, you should install another set
of backup sensors.
The other rule dictated by common sense is that the fewer
the number of components between the sensor and the ac-
tuated device, the safer the ESD system. Therefore, the new
level detector signals should be hardwired directly to the
PLC. Naturally, you should also hardwire the DCS outputs
to the PLC, so that shutdown will be initiated whenever ab-
normal level conditions are detected by either sensor.
Il you lnd lhal a pailiculai slandaid disagiees wilh lhe
above two points, it is the standard that should be revised,
not lhe design. In olhei woids, I would keep using lhe exisl-
ing level sensors and, in addition, install backup level de-
tectors on each tank. This way, safety will be improved, be-
cause each of the level measurements will be redundant,
and the cost of adding these backup sensors is small relative
to the cost of the project.
I would inslall non-conlacling, iadai-lype level deleclois
as the new sensors, and would hardwire them directly to
lhe IIC. I would do lhal lecause, lhis way, we aie always
measuring the actual level, regardless of the swelling that
This column is moderated by Bla Liptk (http://belaliptakpe.com/), automation and safety consultant, who is also the editor of
the Instrument and Automation Engineers Handbook (IAEH). If you would like to become a contributing author of the 5th edi-
tion, or if you have an automation-related question for this column, write to liptakbela@aol.com
A S K T H E E X P E R T S
D E C E MB E R / 2 0 1 2 www.controlglobal.com 47
occurs whenever the vapor space pressure drops or the
LPG temperature rises. I would install a single, fre-
quency- modulated carrier wave (FMCW) type radar
transmitter on the top of each spherical LPG tank and
wire it to the PLC, and would continue using the exist-
ing level transmitters through the DCS as a backup in
the redundant ESD.
I do not know what type level transmitters you have now,
but if they are the differential pressure (d/p) type, they do
not correct for swelling variations or density changes. They
measure weight, not volume. Therefore, if in addition to
EDS, you also want to provide weight-based inventory
management, weighing is recommended because the radar
readings cant be directly used for that purpose.
BLA LIPTK
l i pt akbel a@aol . com
A
If your goal is to separate the existing S/D systems to
comply with IEC 61511/ISA 84-2005 with all these ad-
ditions of proposed components, keep in mind your
risk tolerance levels and company policy. I expect it is in
line with industry practices to meet the highest level of
safety integrity levels.
Points to keep in mind:
- Il is nol a good idea lo use exisling analog liansmilleis,
signals or share them due to common-mode failures, handi-
capped testing and nuisance trips.
- Using swilches in place ol independenl digilal lians-
mitters with self-diagnostic features will limit the avail-
ability numbers if you plan to use quantitative methods to
validate your design, test frequency and completeness of
testing to meet the SIL levels selected. Safety instrumented
functions (SIFs), as you well know, depend on calculations
based on mean time between failures of components. Pub-
lished data tables indicate switches at 15 years; digital trans-
mitters at 50 years: smart valves at 100 years; and digital
logic solvers at 10,000 years.
- In geneial, SII lailuies aie ialed al liansmilleis <10,
logic solveis <10, and lhe lig conliilulois, lnal conliol
elemenls al <0. 1heie is no pullished dala iegaiding
human error and wiring mistakes.
- In geneial, lank laim aieas localed lai liom opeialing
areas are considered to be SIL 1 or SIL 0 or SIL-a, depend-
ing on the product stored.
- You can eliminale all switches by installing two inde-
pendent, reliable transmitters with deviation alarms input-
ting to the DCS and SIS. That kind of system can share to
meet SIL 0 requirements, including trip designs.
- 1he liend nowadays is lo avoid islands ol IIC opei-
ations dedicated to hydraulic systems, alarms and S/Ds.
PLCs per se contribute to common-mode failures if they
are not triple-redundant systems. It is easier to integrate the
systems in DCS, and the standard gives you that fexibil-
ityif you use the right transmitters, test procedures and
completeness of testing to meet availability numbers.
- Keep in mind lhal simple syslems wilh minimum com-
ponents that are tested frequently are better than complex
systems that are not tested, leading owners to face covert
failures unforeseen at the time of design.
Many of us here join Bla in complimenting your youth
revolution to bring the country to the digital age.
RAM.G.RAMACHANDRAN
r am@mi cr omi x-usa. com
A
The answer to your question, based on the fact that
the transmitters are being used as a part of a safety
syslem is, mayle.` You need lo do a piolalilily-ol-
failure analysis and determine what, if any, SIL rating the
transmitters can have, and whether they should be used in
a safety system at all.
Theres no real reason, other than conformance to stan-
dards, that you cant do what you want to dobut youre
opening yourself to point failures in your control system
and safety system simultaneously. Im a cautious person,
and I prefer the belt and suspenders approach. Id put in
new transmitters just for the redundancy that provides. The
cost of doing so is miniscule in comparison to the cost of
the current project, or God forbid, the cost of the damage
an oveillled IIC sloiage vessel could cause.
WALT BOYES
wboyes@put man. net
A
I understand the narrative description to indicate that
Mr. Fattah has two limited-range transmitters, one for
low-level safety and one for high-level. With a limited
range, there is little value or need for correction for change
in density.
The general tone of the discussion seems to be that they
intend to improve the safety of the system. Adding new lim-
ited range transmitters for high and low levels would fur-
ther reduce the dangers. It all depends on the value of the
measurements. A safety analysis should indicate if the re-
quiied SII is salisled and possilly indicale lhe need loi ad-
ditional measurements.
There may also be a need for inventory management.
For this, a wide-range transmitter based on weight and
thus, value, is usually desired.
I believe that inventory control and physical level in-
leilock aie measuiemenls lhal aie lesl sepaialed. Use all
the measurements in managing the system, but do not
compromise measurement robustness in order to save a
few parts.
CULLEN LANGFORD
Cul l enL@aol . com
R O U N D U P
48 www.controlglobal.com D E C E M B E R / 2 0 1 2
IMPROVE YOUR GRAPHICS
Create professional-looking
graphics and displays us-
ing InfoLink. Incorporating
industry standard graphics
symbols, users can view the
real-time graphical represen-
tation of their equipment and
process. Alert your operators
quickly when critical values change. Including TrendLink
trends and graphs, visualization into the Canary Enterprise
Historian data is easily combined with the graphic symbols.
Canary Labs
814/793-3770; www.CanaryLabs.com
INNOVATION IN PLANT DIAGNOSTICS
Intune+ Process Navigator
is software that guides plant
management to excellent per-
formance and increased ca-
pacity through faster start-ups,
reduced variation and im-
proved stability. It is a key part
of making sure the control sys-
tem, control strategy and fnal elements are all doing their part.
Intune+ enhances existing technical expertise, and returns con-
trol to the hands of management.
ControlSoft
440/443-3900; www.controlsoftinc.com
CALL A COPPER FOR SWITCHGEAR DESIGN
The Copper add-on mod-
ule for EPlan Pro Panel
Professional allows design,
confguration and virtual as-
sembly of control cabinets
and the necessary busbar sys-
tems. Users can simply trans-
fer the results of the design
process into the Eplan overall project for further virtual
setup and assembly. Any busbar and associated connecting
elements can be designed and assembled virtually.
EPlan Software
248/945-9204; www.eplanusa.com
SELF-SERVICE ASSET MANAGEMENT
Avantis Decision Support
System software, Version
5.0, leverages Wonderware
Intelligence software to give
manufacturing and executive
decision-makers role-based
asset management analytics
and reporting. The software
is pre-confgured to support a comprehensive set of KPIs
based on asset management best practices. Users can con-
solidate reporting across sites, create analytics and more.
Invensys Operations Management
http://iom.invensys.com/EN/Pages/Avantis.aspx
THE LATEST IN SCADA
Fast/Tools R9.05 is the lat-
est release of this web-based,
real-time management and
visualization software. It fea-
tures collaboration and deci-
sion support, alarm system
performance analysis, mo-
bile device support, a remote
gateway station that connects Centum VP DCS and the
Stardom RTU environment with Fast/Tools, an OPC UA
client function and support for IEC61850 MMS.
Yokogawa Corp. of America
800/-888-6400; www.yokogawa.com/us
ELECTRONIC FLOW MEASUREMENT AND MORE
Top Server is an OPC and na-
tive HMI device connectivity
software with more than 130
device drivers and plug-ins.
Version 5.9 has new applica-
tions for the oil and gas in-
dustry. The Electronic Flow
Measurement (EFM) Suite
enables EFM data export for midstream applications The
EFM plug-in provides users with export capabilities for the
Flow-Cal proprietary CFX fle format.
Software Toolbox
704/849-2773; www.toolboxopc.com.
Control Software
Upgrades, new features, mobile apps and more.
R O U N D U P
D E C E MB E R / 2 0 1 2 www.controlglobal.com 49
SOFTWARE-BASED AUTOMATION
SimaticS7 AS mEC RTX
is a software-based automa-
tion system inside an AS 300
form factor. Its compact auto-
mation system based on Si-
matic Microbox PC 427C is
designed for 24-hour, main-
tenance-free operation. It is
ideally suited for distributed installation close to the plant,
for OEM installations like package units, and for plants with
large distributed infrastructures.
Siemens Industry
215/646-7400; www.usa.siemens.com/pi
MOBILE ALARM APP
TopView Mobile Web App
provides access to TopView
alarms and monitored data
values from mobile devices.
Support for any platform
with a modern browser al-
lows phone, tablet and desk-
top access to your tag data
and alarms. Users can monitor alarms and data values, ac-
knowledge alarms, flter by alarm category and examine tag
details. It works on most modern mobile devices.
Exele
585/385-9740; www.exele.com
EVOLUTIONARY DCS SOFTWARE
Unique in its ability to con-
tinuously preserve applica-
tions from the frst version
to the latest, D/3 is the most
powerful and adaptable DCS
on the market. The Process-
Vision console software and
D3Express mobile app en-
sure that operators are informed, not overwhelmed. When
abnormal situations arise, D3v14 keeps operators and auto-
mation at their combined best.
NovaTech, LLC
800/253-3842; www.novatechweb.com/process
SIMPLIFY LEVEL CONTROL
ExperTune software now
includes non-steady-state
(NSS) modeling features for
integrating control loops.
These tools provide fast, sim-
ple modeling and tuning of
level controls. Users can de-
velop excellent tuning for
level controls, even when little data is available. NSS tuning
integrates seamlessly with ExperTunes PlantTriage and PID
Loop Optimizer software.
ExperTune Inc.
262/369-7711; www.expertune.com
PAC SOFTWARE UPGRADE
PAC Project9.2 is an upgrade
to PAC Project suite that pro-
vides control programming,
HMI development, OPC
connectivity and database in-
tegration. PAC Control, the
fowchart-based program-
ming application, adds the
capability of sending email directly from a PAC controller,
with or without attachments, and has new commands for
using the HTTP protocol to exchange data with web servers.
Opto 22
951/695-3000; www.opto22.com
SCADA FOR YOUR IPAD
The iPad ProfcySCADA app
extends the control room by
providing users with informa-
tion anywhere, increasing vis-
ibility and effciency of oper-
ations. The iPad app enables
users of either iFix WebSpace
or Cimplicity GlobalView to
instantly connect to their HMI/SCADA runtime projects. It
supports the same full-featured capabilities of a standard cli-
ent, and delivers full HMI/SCADA functionality.
GE Intelligent Platforms
www.ge-ip.com/automation-software
R O U N D U P
50 www.controlglobal.com D E C E M B E R / 2 0 1 2
ARE YOU BEING SERVED?
KepServerEX is a fexible,
scalable solution for connect-
ing, managing, monitoring
and controlling diverse auto-
mation devices and software
applications. Communica-
tions are managed through a
platform that supports an ar-
ray of open standards, such as OPC, propriety communica-
tion protocols, APIs and various automation systems inter-
faces. Free, downloadable demo available.
Kepware Technologies
207/775-1660; www.kepware.com
COLLECT OPERATION AND MAINTENANCE DATA
SILStat software captures key
operational and maintenance
data, including equipment
failures, process demands, suc-
cess or failure of protection lay-
ers and proof test results. The
data is reviewed and analyzed
as required by the IEC 61511/
ISA 84.00.01-2004 standard and as part of compliance with an
OSHA PSM mechanical integrity program. SILStat can help
determine risk and the effectiveness of layers of protection.
exida
215/453-1720; www.exida.com
AUTOMATION TOOLBOX
RT Toolbox2 software is now
integrated into Melsoft iQ
Works software platform, and
has added robots to the Mel-
soft Navigator environment.
The addition of RT Tool-
box2 allows programming,
maintaining, retroftting and
monitoring of Mitsubishi Electric robots, along with PLCs,
HMIs, servos and motion controllers from the same plat-
form.
Mitsubishi Electric Automation
847/478-2100; www.MEAU.com
NEW LABVIEW
The newest version of Lab-
View provides recommended
application architectures de-
signed to save time, ensure
scalability and lower main-
tenance costs. It includes
stability improvements and
environment enhancements
designed to increase productivity, and it supports a large
portfolio of new hardware products showcasing a commit-
ment to expanding platform capabilities.
National Instruments
800/258-7022; http://ni.com/labview/whatsnew/
UNIFIED DESIGN AND ENGINEERING
Studio 5000 unifed engi-
neering and design environ-
ment sets the foundation for
design tools that allow engi-
neers to enter confguration
and programming informa-
tion once, and leverage it
across their entire control sys-
tem architecture. It includes the Logix Designer application
for programming and confguration of Allen-Bradley Con-
trolLogix 5570 and CompactLogix 5370 PACs.
Rockwell Automation
414/382-2000; www.rockwellautomation.com
MANAGE CHANGE
AutoSave PC Backup and
Recovery module manages
the creation of disk images
and incremental revisions. It
takes a snapshot of the disk
using patented disk imaging
technologies, and then stores
each data set as a unique re-
vision while maintaining prior revisions. It has one change
management system for automation and PC imaging needs
and a backup solution for PC-based controls and HMIs.
MDT Software Inc.
678/297-1000; www.mdt-software.com
P R O D U C T I N T R O D U C T I O N S
D E C E MB E R / 2 0 1 2 www.controlglobal.com 51
PLUMB-AND-PLAY CHLORINE DIOXIDE ANALYZER
The low-maintenance, eco-
nomical CDA-22 chlorine
dioxide analyzer features a
panel-mounted, plumb-and-
play design and automatic
fow control. It is a complete
chlorine dioxide (ClO
2
) mea-
surement system. Easy to in-
stall and maintain, it can run for up to a year between elec-
trolyte/membrane changes, and features a polarographic
gold/silver PTFE membrane amperometric ClO
2
sensor. Its
output is fow-independent at values greater than 0.5 ft/sec.
Electro-Chemical Devices
949/336-6060; www.ecdi.com
SECURE ZERO-FAILOVER SWITCHES
The Hirschman RSP switch
series supports the new IEC-
standard redundancy proto-
cols, making them ideal for
environments where uninter-
rupted data communications
are a requirement. They sup-
port the parallel redundancy
protocol (PRP) and high-availability seamless redundancy
(HSR). Security functions include authentication, Radius
support, role-based access, port security, SSHv2, HTTPS
and SFTP.
Belden
314/854-8000; www.Belden.com
UNIVERSAL WATER CUT MONITOR
Universal IV CM Model wa-
ter cut monitor offers supe-
rior water cut measurement
accuracy in low ranges (0-1%,
0-5% and 0-10% water). Accu-
racy is 0.03% water, and mea-
surement resolution is down
to 0.0002% water. The sens-
ing element extends a minimum of 15 ins. into a main pro-
cess line. The probes are designed to handle pressures up to
1500 psi and temperatures up to 450 F. Approved for Class
1 Div 1 and Zone 0 hazardous locations.
Ametek Drexelbrook
215/674-1234; www.drexelbrook.com
PRECISION COMPACT PRESSURE TRANSDUCER
Heise Model HPK compact
pressure transducer is avail-
able with a choice of pressure
and electrical connections.
HPK offers either current
or voltage outputs to indi-
cate readings from vacuum
through 20,000 psig and ab-
solute ranges to 150 psia. An advanced sensor design deliv-
ers long-term stability and 0.15% F.S. accuracy. Each Heise
Model HPK pressure transducer is authenticated with a
nine-point, NIST-traceable calibration report.
Ashcroft
800/328-8258; www.heise.com
FEATURED PRODUCT
SUPER-ACCURATE MASS FLOWMETERS
The QuadraTherm 640i/780i Thermal Mass Flowmeter Series marks a breakthrough
in thermal dispersion technology. With its sensor design advancements, coupled with a
proprietary iTherm Brain, the 780i inline version achieves gas mass fow rate measure-
ment accuracy of 0.5% of reading above 50% of the full scale (air), making it the most
accurate thermal meter in the industry. At the heart of the 640i/780i is its revolutionary
patented QuadraTherm sensor and proprietary iTherm algorithm set. QuadraTherm in-
troduces four sensorsthree precision platinum temperature sensors and one patented,
no-drift DrySense mass velocity sensor. The QuadraTherm sensor isolates forced convection by calculating and
then eliminating unwanted heat-transfer components, such as sensor stem conduction. QuadraTherm and iTherm cal-
culate stem conduction and all other unwanted heat loss components, subtract them out, and then compute the mass
fow rate from the remaining forced convection component.
Sierra Instruments
800/866-0200; www.sierrainstruments.com/quadratherm
52 www.controlglobal.com D E C E M B E R / 2 0 1 2
P R O D U C T I N T R O D U C T I O N S
OPERATIONS FROM YOUR IPHONE
The free Operations App
for the iPhone, iPod Touch
and iPad lets users download
specifc documentation for
Endress+Hauser products.
Just enter the serial number
or scan the data matrix code
on the device with the phone
and gain access to the information. The app can be down-
loaded at https://itunes.apple.com/en/app/endress+hauser-
operations/id556777232 or by scanning the QR code above.
An Android version will be released soon.
Endress+Hauser
888/ENDRESS; www.us.endress.com/operations-app
SMART REDUNDANCY MODULES
Quint ORing active redun-
dancy modules use auto-
current balancing (ACB)
technology for precise load
sharing. Coupled with load
current monitoring, remote
diagnostics and visual indica-
tions, they ensure maximum
reliability in redundant power systems. ACB technology au-
tomatically and symmetrically distributes load current with-
out regard to effects such as temperature drift. A balanced
current draw increases life expectancy of power supplies.
Phoenix Contact
800/322-3225; www.phoenixcon.com
PROGRAMMABLE TEMPERATURE/PROCESS PID CONTROLLERS
The Dpi32 and CNi32 1/32
DIN programmable tem-
perature/process meters and
PID controllers with RS-232
and RS-484 communications
are user-friendly instruments
with programmable color dis-
plays. The CNi32 features
two outputs: control, alarm or retransmission of process vari-
able and universal inputs. This series has free software, Ac-
tive X controls and built-in 24-VDC excitation, standard on
units without DC power or communication options.
Omega
888/826-6342; www.omega.com
EXPLOSION-PROOF PRESSURE SWITCH
The AST46SW explosion-
proof pressure switch offers
a single-pull, double-throw
confguration with factory-
set switch points and hystere-
sis, and a one-piece, stainless
steel sensing element. It has a
maximum operating pressure
range up to 20,000 psi (1378 bar). It is CSA-approved for use
in hazardous areas, including Class 1, Div 1 explosion-proof
Groups A, B, C and D, and for mining applications, includ-
ing Class 2, Div 1 in Groups E, F and G.
American Sensor Technologies
973 /488-1901; www.astsensors.com
ULTRASONIC LEVEL SENSORS AND TRANSMITTERS
The Flowline EchoPod and
EchoSonic II ultrasonic liq-
uid level sensors and trans-
mitters are made with PVDF
transducers and NEMA
Type-6P polycarbonate en-
closures. They replace foat,
conductance and pressure
sensors that fail due to contact with dirty, sticky and scal-
ing media. Ideal for chemical, water and wastewater applica-
tions, they are available with single and multi-function capa-
bilities, including continuous level measurement.
Automation Direct
770/889-2858; www.automationdirect.com
STAINLESS STEEL EXPLOSION-PROOF ENCLOSURES
Adalet now offers Division 1/
Zone 1, 316L stainless steel,
explosion-proof enclosures.
Theyre designed for use in
highly corrosive areas where
environmental conditions
require additional corrosion
protection. Rated for Class I,
Division 1/Zone 1 hazardous locations, the XCESX series
carries UL, cUL, ATEX and IECEx approvals. Five stan-
dard sizes from internal dimensions of 10 in. W x 14 in. H x
8 in. D up to 24 in. W x 36 in. H x 10 in. D.
Adalet
216/267-9000; www.adalet.com
P R O D U C T I N T R O D U C T I O N S
D E C E MB E R / 2 0 1 2 www.controlglobal.com 53
SEAMLESS UPGRADES
The next generation of the
High-Performance Process
Manager (HPM) industrial
process controller, the En-
hanced High-Performance
Process Manager (EHPM),
allows 25 years of distributed
control system installed base
to seamlessly migrate to the Experion Process Knowledge
System. Cost of migration is signifcantly reduced by pre-
serving control strategies and wiring. Ease the risk of legacy
system upgrades.
Honeywell Process Systems
800/822-7673; www.HoneywellProcess.com
FLOW SWITCH/MONITOR
Model FS10A Analyzer fow
switch/monitor for analyz-
ers and sampling systems is
designed for use with tub-
ing from 1/8 in. to in. The
electronics may be either in-
tegrally or remote-mounted
from the sensor element.
There are no moving parts and no cavities, orifces or dead-
legs to trap or contaminate samples. It is suitable for applica-
tion in liquid or gas analyzer sampling systems. It is small,
lightweight and features a choice of electronic outputs.
Fluid Components International
800/854-1993; www.fuidcomponents.com
MIX IT UP
Kenics KMX-V static mixer
is ideal for applications in-
volving fuids with extreme
viscosity or volume ratios. It
features a design that gener-
ates superior mixing per unit
length for laminar fow and
high/low viscosity ratio ap-
plications. It uses cross-stream mixing and fow splitting to
achieve rapid blending. Each element is one pipe diameter
in length, and consists of multiple intersecting blades, which
generate fuid layers as the mixture fows downstream.
Chemineer
937/454-3200; www.chemineer.com
NEXT-GEN GAS FLOWMETER
The Altosonic V12 ultrasonic
gas fowmeter for custody
transfer applications has 12
measuring chords, two dedi-
cated to diagnostic functions.
Once commissioned, it con-
tinuously checks the operat-
ing status. The chords are po-
sitioned in fve horizontal parallel planes to compensate for
swirl and provide reliable measurements, even with highly
distorted fow profles. Its diagnostics can reliably assess de-
posits, contamination or changes in wall roughness.
Krohne
800/FLOWING; www.us.krohne.com
NON-CONTACT CALIBRATION
The BBSL Black Body Cali-
brator is a non-contact IR py-
rometer calibration system
that features a temperature
range of 10 C above ambi-
ent to 350 C. It also offers
an accuracy range of 0.5%
or minimum 1C; emissivity
of 0.97 to 0.98; stability of 0.5% or minimum 1 C, plus an
auto-tine PID controller and a stabilization time of 20 min-
utes. Calibration certifcation is included with the calibra-
tor unit.
E-Instruments
215/750-1212; www.E-Inst.com
FOUR-WIRE TRANSMITTERS WITH USB
TT330 series of four-wire pro-
cess transmitters is designed
to deliver maximum eff-
ciency and optimal perfor-
mance and versatility. It sup-
ports high-density mounting
on DIN rails, and has a USB
connection to a PC for sim-
ple, precise confguration. The series is DC-powered (12-
32V) and supports a bussed rail power option for primary
or redundant power. The design features -40 C to +80 C
operation, electrical noise immunity and surge protection.
Acromag
248/295-0880; www.acromag.com
54 www.controlglobal.com D E C E MB E R / 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
Diagnosing Final Control Elements
Greg: I have known James Beall since way
back to his days at Eastman Chemical, when
he generated some eye-opening data on the re-
sponse of valve positioners. James started out as
instrument engineer. When he moved to the
feld, he had to make the instrumentation and
valves that he had selected actually work! This
lead to a career in process control improvement
at Eastman and his present position as princi-
pal consultant at Emerson. I have always been
impressed with James feld experience, practi-
cal approach and open mind.
Stan: Since automation systems generally af-
fect the process by manipulating a fow, the
control valve is the key fnal control element.
What was the biggest step forward that helped
you improve valve performance?
James: The biggest revelation was getting the
actual valve or more accurately the actuator
position into the data historian and my process
control data analysis system. Before the advent
of the high-performance digital positioner with
readback, we had to install temporary or per-
manent position transmitters.
Greg: I installed position transmitters on surge
valves because it was essential for making sure the
pre-stroke dead time was less than 0.2 seconds,
and the stroking time was less than one second.
It would haven been helpful to have this indica-
tion for all control valves, but the cost of the sepa-
rate transmitter and wiring relegated the installa-
tion to special cases. Not knowing what the valve
was actually doing led to creative explanations of
process variability. The Control feature I wrote at
an ISA conference in the early 1990s, Valve Po-
sition: The Missing Link, revealed the absurdity
of the situation. The feature ended up as a chap-
ter in the ISA book How to Become an Instrument
EngineerPart 1.523, coauthored with Monsanto
engineers with a similar sense of humor. (See
http://tinyurl.com/c9p7hw7.)
James: Without actual valve position (AVP)
in the data historian, it is particularly diffcult
to diagnose when a valve moves despite a steady
signal. If something was strange, the frst thing
to do was plot the AVP. In one case the valve
would move on its own at a certain spot in the
piston due to a worn O-ring. In another case,
the valve cycle was following the instrument air
compressor pressure cycle. We found there was
no air pressure regulator for the valves, but even
so, after checking the positioner specifcations,
the double-acting pistons should not have been
moving. The real problem turned out to be that
the cross-over pressure was set to zero, so there
was no stiffness, except for the spring that as-
sisted fail action. Since the pressure could not go
below zero, the actuator was acting like a single-
acting rather than a double-acting piston.
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.
C O N T R O L T A L K
D E C E MB E R / 2 0 1 2 www.controlglobal.com 55
Stan: Can you fgure out everything from the control
room?
James: You always need to look at what is out in the feld,
or it will bite you. Once, on a level loop on a decanter boot,
a relatively fast integrating process, showed a limit cycle in-
dicating a dead band of about 1%. When we checked the
valve in the feld, it would respond to a 0.1% change in
signal if you waited long enough, so technically the sup-
plier could say the valve had a resolution of 0.1%. The po-
sitioner had a two-stage relay. For changes larger than 1%,
the high-capacity relay would kick in, and the valve would
respond within a second or two. For smaller changes in sig-
nal, the valve would take 40 seconds or more to respond.
The fast integrating loop effectively revealed the real reso-
lution limit because the level was ramping while waiting
for the valve to respond. We put on a digital valve controller
(DVC) that is a high-performance digital positioner, and
the problem went away. Since then, I have recommended
putting this type of positioner on all valves.
Greg: It seems a lot of poor performance can be related
to suppliers and users not realizing that response time,
dead band and resolution are important. The ISA Stan-
dards ISA-75-25 sheds light on how to measure these met-
rics, but stops at revealing the implications and providing
guidelines for various applications. I got burnt big time in
1975 as lead engineer for the worlds largest acrylonitrile
plant when the contract design and construction frm said
we could save big bucks by omitting positioners on several
hundred loops. The lead engineer pulled out a Nyquist
plot study from a supplier that showed positioners would
hurt performance, and if speed was needed, a booster
should be used instead of a positioner. During start-up,
I ended up putting positioners on all the valves because
many did not move unless the signal changed by 25%. I
got burnt again about 10 years later when I tried to replace
positioners with boosters on surge valves. The huge but-
terfy valves slammed shut when the compressor started.
The instrument tech showed me how he could manually,
easily move the 24-in. butterfy valve by simply grasping
the shaft. When the positioner was put on, he could not
budge the valve, as you might expect. The high outlet port
sensitivity of the booster led to positive feedback with the
diaphragm actuator. A couple of years later at a factory ac-
ceptance test, the valve supplier made the same mistake. I
went up to the 30-in. valves and showed how I could stroke
them with my hand on the shaft.
James: Without a positioner, the dead band on a brand
new valve in perfect condition can be anywhere from 5%
to 25%, and imperfect bench settings manifest themselves
as offsets. I restated the old rule that fast loops should not
have positioners to fast loops have a chance to work satis-
factorily without a positioner, but will perform better with
positioner, especially a modern DVC type positioner.
Greg: The main concern about the violation of the cascade
rule where the valve positioner as a secondary loop needed
to be faster than the fow loop as a primary loop was over-
stated because the fow loop was tuned with mostly reset ac-
tion and not much gain action, partly due to the unknown
nonlinearity of the installed valve characteristic. The new
positioners, such as the DVC with excellent resolution, can
be tuned for exceptionally fast response. Also, external-re-
set feedback can be used if a fast position readback is avail-
able to prevent the burst of oscillations from the process
loop output changing faster than the valve can respond,
allowing violation of the cascade rule.
Stan: What can go wrong with even a good valve, actuator
and positioner?
James: I once worked on a loop that had a green control
valve with a DVC, yet the data historian showed there was
an 1/8% dead band. Normally, I would have been happy
with 1/8% dead band, but the other green valves in the
plant were doing better than this! When I went out in the
feld (remember, you will get burnt every time you do not
go to the feld!) I saw the feedback arm spring clip on the
bonnet of the actuator. The feedback arm was missing its
spring clip in the slot to rotate the positioner, resulting in
the observed backlash. The spring clip got knocked off.
Someone realized the part belonged to the valve, but didnt
notify anyone.
Greg: Much worse is when the control valve and actuator
are an inherently poor design and a DVC connected to the
actuator shaft says everything is OK. The Control feature
article in November 2012, Is Your Control Valve an Im-
poster (www.controlglobal.com/articles/2012/mcmillan-
control-valves-imposter.html), gives the details of perhaps
the greatest deception in the automation business.
James: In this case, a good on-off valve had been modi-
fed in an attempt to make it also provide throttling action.
However, it wasnt performing well and was limiting pro-
duction. Just 0.008-in. slack in the key ways of a shaft con-
nection combined with the slop in a scotch yoke actuator
caused an 8% dead band. The DVC feedback measurement
was on the actuator shaft position before the backlash took
effect. The DVC said things were not that bad. The ad-
dition of integral action in the positioner helped the slow
level control loop do better. As a temporary fx, we made
C O N T R O L T A L K
56 www.controlglobal.com D E C E MB E R / 2 0 1 2
some mechanical modifcations to the valve and actuator,
and then planned to replace the valve with a real regu-
lating control valve at the frst opportunity! When the new
control valve was replaced, the process capacity could be
increased by 10%!
Greg: The combination of the integrating response of the
piston and in the positioner caused a fast limit cycle from
dead band in the positioner. I think the limit cycle average
value from the fltering action of the process was closer to
the desired position than the offset if there was no integral
action in the positioner. Thankfully, the limit cycle wore out
the valve.
Stan: Given that you need to use a rotary valve, what do
you look for?
James: A diaphragm actuator, splined shaft connection, an
offset of stem-to-closure member, low sealing friction, low
packing friction, a contoured disk butterfy or segmented V-
notch ball with an equal percentage characteristic, and rotary
feedback of stem position to a high-performance digital posi-
tioner. Surprisingly, there is a lot technology in the packing. A
mom-and-pop service shop, unbeknownst to us in the plant,
put Graphoil packing not made by the valve manufacturer
in a valve, creating horrendous resolution (stiction). However,
we ran diagnostics on the valve, and the signature plot looked
dandy. The full-scale traverse of position did not reveal much
of a resolution issue. Only when we slowed the ramp rate of the
input signal during the signature test did we see the stair-step
response of stick and slip caused by poor resolution. Apparently,
the generic packing had a large difference between the static
and dynamic friction coeffcients, causing the stick and slip
issue and resulting in poor control. The problem was solved by
putting in the low-friction, high-temperature packing from the
control valve manufacturer that was carefully designed to have
a small difference between the static and sliding friction coeff-
cient. By the way, most pneumatic positioners can cause a limit
cycle similar to the packing induced stick-slip, but its actually
caused by a slow response of the positioner when the valve posi-
tion is close to the target. This problem is easily solved with a
high-performance digital positioner that has a consistent (fast)
speed of response for small changes.
Stan: Looks like another example of the consequences of
poor valve dynamic performance not being commonly un-
derstood. If your service shop or control valve supplier cannot
talk intelligently about response time, dead band (backlash)
and resolution (stick-slip), you should look for one who can.
Greg: The positioner, like any other controller, performs
only as well as the tuning. The pneumatic positioner was
a proportional-only controller with a gain of about 150. To-
days positioner offers incredible fexibility and something
akin to PID control. How do you tune the DVC?
James: The DVC has recommended tuning sets for differ-
ent actuator and valve combinations, but many applications
do not ft a set of rules, just as in tuning process controllers. I
frst knock the heck out it, maximizing the speed of response
with proportional action. Often a positioner has a hidden gain
multiplier, like 15, which means that a gain factor of 10 is ef-
fectively a proportional mode gain of 150. Once the valve is
responding well, I reduce the overshoot with derivative ac-
tion from the shaft position. The minor loop feedback helps
by providing very fast motion control of the pneumatic relay
kind of like a very fast inner loop. We still have a lot to learn
about tuning positioners. I do not recommend integral action
in the positioner in most applications.
Stan: What can users do to better understand stick-slip?
James: Static friction sets stick, and dynamic friction de-
termines slip. The static friction of tight shutoff rotary valves
can be so large that there is shaft windup where the actua-
tor shaft moves, but the internal closure member (e.g., ball
or disc) does not move. When the change in actuator torque
becomes large enough, the shaft unwinds. We have seen as
much as 1% to 2% shaft windup!
Stan: What have you learned about the valve characteristics?
James: Gas pressure loops where the valve pressure drop
is so large compared to other pressure drops in the system,
or where it has a critical pressure drop, can beneft from a
linear trim characteristic. This is because the valve drop
is so large compared to other pressure drops, resulting in
an installed characteristic close to the inherent character-
istic. In general, we need to pay attention to the change
installed characteristic when the valve drop is small com-
pared to frictional losses in the piping system.
Greg: I also recommend linear trim for reagent valves for
pH control, since the valve drop is the system drop. For most
other loops, a linear inherent characteristic is undesirable
because it distorts to a quick opening characteristic as the
valve drop as a fraction of the system drop decreases. Todays
emphasis on minimizing energy has taken a wrong term in
allocating insuffcient pressure drop to the control valve,
causing severe distortion and loss of rangeability.
[Editors note: For more, including Top 10 Signs Your Valve
Is an Imposter, go to www.controlglobal.com/1212_Con-
trolTalk.html.]
ADVERTISER . . . . . . . . . . . . . . . . . . . . . . PAGE NO.
ABB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Advantech Automation . . . . . . . . . . . . . . . . . 25
Ametek. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ARC Advisory Group. . . . . . . . . . . . . . . . . . . 40
AutomationDirect . . . . . . . . . . . . . . . . . . . . . . 8
Banner Engineering . . . . . . . . . . . . . . . . . . . 24
Emerson Process Mgt/Saab . . . . . . . . . . . . . 15
Emerson Process Mgt/Systems . . . . . . . . . . . 60
Endress + Hauser. . . . . . . . . . . . . . . . . . . . . . . 6
Flexim Americas . . . . . . . . . . . . . . . . . . . . . . 43
Fluke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Magnetrol International . . . . . . . . . . . . . . . . 12
Martel Electronics. . . . . . . . . . . . . . . . . . . . . 36
National Instruments . . . . . . . . . . . . . . . . . . 10
NovaTech Process Solutions . . . . . . . . . . . . . 37
Numatics, Inc. . . . . . . . . . . . . . . . . . . . . . . . . 28
Omega Engineering . . . . . . . . . . . . . . . . . . . . 3
Opto 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Orion Instruments. . . . . . . . . . . . . . . . . . . . . 33
Pepperl+Fuchs . . . . . . . . . . . . . . . . . . . . . . . 18
Phoenix Contact . . . . . . . . . . . . . . . . . . . . . . . 2
Siemens Process Automation . . . . . . . . . . . . 27
Winsted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Turck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Wago . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Yaskawa America . . . . . . . . . . . . . . . . . . . . . . 59
Yokogawa . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
C L A S S I F I E D S
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C O N T R O L R E P O R T
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EXECUTI VE EDI TOR
j mont ague@put man. net
58 www.controlglobal.com D E C E MB E R / 2 0 1 2
BP and Oobleck
Sometimes I dont know what to write about. Other times I cant choose which of sev-
eral tales to tell. At frst, I was going to write Too Little, Too Late, and slam BP again
following the $4.5 billion settlement it announced Nov. 15 to resolve U.S. Securities and
Exchange Commission and other criminal claims related to the Deepwater Horizon dis-
aster. You know the drill. Why didnt BP and its
contractors have suffcient blowout preventers
and other inexpensive automatic controls and
safety equipment to prevent killing 11 of its rig
workers and fouling the Gulf of Mexico? Why
does BP perform many complex tasks well, but
then persist decade after decade with a culture
that cuts so many stupid corners and inevita-
bly leads to catastrophe? And, fnally, why does
BPs board and its major investorsnot to men-
tion those at so many other frmscontinue to
reward ignorant and destructive behavior?
Because its highly proftable, of course, at
least in the present fscal quarterwhich is as
far ahead as many companies and people seem
to look these days. Its well known that satisfy-
ing fnancial analysts is often more important
now than building actual products. Merely
moving money around shell-game/con-man
style is the way to get the biggest payoff with
the least effort. Cash trumps everything else
nowlogic, common sense, professional pride
and basic integrity. And, if pursuing it happens
to injure others? Well, just make sure theyre
at a distance. Out of sight, out of mind, right?
But, where does this short-sightedness come
from? I think maybe its the relative prosperity
so many of us grew up in that weakens us. It
causes us to focus only on short-term lifestyles,
unhealthy consumption levels and Black Friday
deals at the expense of traditional self-sacrifce,
delaying immediate gratifcation and investing
in innovation with long-term benefts. No more
saving for a rainy day or slow and steady wins
the race. A little severe, self-imposed austerity
might help. Ill let you know how it goes right
after I fnish this next bag of Cheetos.
The other rehashed column I was think-
ing about, Really Little Engineers, was in-
spired by two of my co-workers here at Putman
MediaMichele Vaccarello Wagner, who is
expecting a baby, and Derek Chamberlain,
whose wife is also about to give birth. I fgured
the new arrivals might enjoy some of the pic-
ture books that my daughters and I grew out
of long ago. You know the drill here, too. Nur-
turing new engineers looks like it begins with
Science Technology Engineering and Math
(STEM) programs, but it really starts with read-
ing to babies, and keeping them away from the
danged TV and all the other video drivel.
The Cat in the Hat, Mike Mulligan and His
Steam Shovel, Curious George Takes a Job and
many other stories opens kids minds to the
world, and then wood blocks, Legos and all the
other building sets let them get their hands on
it. Theres your holiday shopping list. De nada.
Surprisingly, while packing the books, I ran
across a forgotten Dr. Seuss masterpiece, Bar-
tholomew and the Oobleck. Its about King Der-
win of Didd, who gets tired of the usual rain,
snow, sunshine and fog, and orders his magi-
cians to invent something newoobleck. Un-
fortunately, this new weather phenomenon
turns out to be a sticky, green adhesive that
pours down on the kingdom, and almost de-
stroys it. Sound familiar? Anyway, the country
looks doomed until the king says hes sorry and
means it, which makes the oobleck evaporate.
Of course, apologies only make environmen-
tal damage disappear in fairy tales, but the les-
son is precious anyway. Sadly, some people just
cant seem to even begin to say theyre sorry.
Sounds familiar again? Thats because public
apologies after strings of disasters and earlier
apologies just arent enough. I know its impor-
tant to limit liability, but theres a point where
honesty and self-respect should kick in, and it
should be a lot earlier than it is now. Maybe we
can sit a few CEOs and board members down
with the babies, read Horton Hatches the Egg,
and learn to keep some promises.
Sadly, this new
weather turns out
to be a sticky,
green adhesive
that pours down on
the kingdom, and
almost destroys it.
Sound familiar?
WHAT YOU
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