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all 230VAC models drive-related logic and I/O control • Smart keypad stores up to four sets of
• V/Hz control or sensorless vector control • Built-in analog, discrete, high-speed and drive configurations for back-up and
for improved speed regulation relay I/O with expansion capabilities transfer to additional GS4 drives
• 100kA Short Circuit Current Rating (SCCR) • Serial MODBUS RTU/ ASCII and BACnet • Fire mode and circulative control mode
• 50°C temperature rating plus flange mount protocols included • Field upgradeable firmware
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 What’s in our new AC Drive?
Features galore AND a wealth of options starting at only $422!
PLC inside Circulative control mode and
A fully functional PLC is built in to the GS4 drive. Capable multi-motor control
of up to 10k steps, it’s perfect for drive-related logic
requirements. Control the drive and I/O with standard ladder DURA The GS4 drives offer five different control modes for
circulation pump control. A single GS4 can control up
PULSE
logic (and our FREE downloadable PLC software, GS-Logic). to 8 motors in a cyclic or cascading fashion by using a

4
Advanced PLC features include 32-bit math, Gray Code, combination of VFD control and across-the-line control.
drive frequency control, read/write drive parameters,
real-time clock/calendar with support for daylight savings GS Relay outputs on the drive operate contactors that allow
the VFD to control one or more motors, while additional
time and full drive PID control. And it’s all on-board! relay outputs provide across-the-line control of other
motors via separate contactors.
Safe Torque Off
The Safe Torque Off (STO) function is a basic drive-
integrated safety feature. Use this input signal to ensure
that no torque-generating energy can flow to the motor.
This function is often used in emergency stop situations
and/or to prevent unintentional motor starting.

100kA SCCR rating

A 100kA Short Circuit Current Rating (SCCR) is required
for personnel safety in many factory environments and to
meet a host of regulatory requirements including:
• NEC Article 409
• UL508A
• NFPA70E
SCCR is defined as the maximum short circuit current a
component or assembly can safely withstand when PID control – including sleep and wake
protected by a specific overcurrent protective device, or for The GS4 series drives support full PID The Sleep Mode function is actuated when
a specified time interval. The use of high-speed class J or control to automatically apply accurate the frequency of the output command
class T fuses on the incoming power is required for these and responsive corrections to a control or the feedback signal falls below the
installations. function with external influences. Sleep Reference point for a specified period
50°C rating Proportional, Integral, Derivative (PID) of time. When asleep, the drive output is
control is a mainstay in industrial control, off and it simply monitors Wake-up
The excellent heatsink design of the GS4 series provides a bringing complex processes up to speed Reference point. A separate Wake-up
50°C rating, allowing the GS4 drives to operate in harsh with little or no overshoot, or controlling Delay Time can be used to delay the
ambient conditions (that’s 122°F!). GS4 series drives can pressure, force, feed rate, flow rate, Wake-Up routine.
also be “flange mounted” - see details at right. This allows position, etc.
the use of a smaller enclosure, or reduces the need to
cool the enclosure, or both!
Flange mounting
You have several I/O choices:
6 Digital Inputs 4 Digital Inputs
Fire mode All GS4 drives up to 215 HP can frame drives have optional flange
Run Fire mode during emergencies for uninterrupted be “flange mounted”, a through- mount kits, while the D through F
6 Relay Outputs 2 Digital Outputs smoke removal and system pressure. Sometimes called mounting technique that puts the frame models come with the flanges
“run until destruction” mode, this feature should be used as Cooling drive’s heatsinks on the outside of already attached. The largest G
is outside the enclosure. This allows the use frame drive isn’t normally mounted
a measure of last resort; it can be useful, even life-saving enclosure
in certain situations (keeping a stairwell clear of smoke, of a smaller enclosure, or reduces in an enclosure, so it doesn’t have
for instance). The drive will ignore all alarm inputs, and the need to cool the enclosure, provisions for flange mounting.
reset immediately on any trips. Use with caution, especially or both! The smaller A through C
during any testing that is required.

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 MAY 2018 • VOLUME 31 • NUMBER 5

28
COVER STORY
Knowledge on demand
How plants put wisdom at fingertips.
by Jim Montague

Features

37
SAFETY SYSTEMS
43
MODELING

SIS: How testing impacts reliability Dimensionless group models

What is your safety instrumented system proof test coverage, and How insight and a little math can simplify design of experiments
why does it matter? for modeling and optimization.
by William L. Mostia, Jr., P.E. by R. Russell Rhinehart

CONTROL (ISSN 1049-5541) is published monthly by PUTMAN MEDIA COMPANY (also publishers of CONTROL DESIGN, CHEMICAL PROCESSING, FOOD PROCESSING, PHARMACEUTICAL MANUFACTURING, PLANT SERVICES and
SMART INDUSTRY), 1501 E. Woodfield Rd., Ste. 400N, Schaumburg, IL 60173. (Phone 630/467-1300; Fax 630/467-1124.) Address all correspondence to Editorial and Executive Offices, same address. Periodicals Postage
Paid at Schaumburg, IL, and at additional mailing offices. Printed in the United States. © Putman Media 2018. All rights reserved. The contents of this publication may not be reproduced in whole or part without
consent of the copyright owner. Postmaster: Please send change of address to Putman Media, PO Box 1888, Cedar Rapids IA 52406-1888; 1-800-553-8878 ext. 5020. SUBSCRIPTIONS: Qualified-reader subscriptions are
accepted from Operating Management in the control industry at no charge. To apply for a free subscription, email putman@stamats.com. To non-qualified subscribers in the Unites States and its possessions, subscriptions
are $96.00 per year. Single copies are $15. International subscriptions are 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: Frontier/BWI,PO Box 1051,Fort Erie,Ontario, Canada, L2A 5N8.

www.controlglobal.com MAY 2018 • 5

CT1805_05_07_TOC.indd 5 5/9/18 11:22 AM

Ct1805_FPA.indd 6 5/8/18 1:22 PM
 CONTENTS

Departments
9 EDITOR’S PAGE 48 ROUNDUP
Time flies Level playing field
Every good engineer spends part of the Recent and interesting products
day working their way out of a job. under the topic of the month.

11 CONTROL ONLINE 51 EXCLUSIVE

Our most recent, valuable and popular Marshalling for configurable I/O
offerings at ControlGlobal.com Phoenix Contact VIP-ER easily
accommodates late, binding changes.
12 FEEDBACK
OPA is not like fieldbus; 52 EXCLUSIVE
Different worlds More powerful programming package
Opto 22 PAC Project Software Suite
14 LESSONS LEARNED R10 integrates control, HMI and data.
Can we resolve the climate debate?
53 EXCLUSIVE

FAST
Part 4: Energy storage is key, and
hydrogen is best. Wireless combines speed, security
SMC EX600-W does what it takes to
19 ON THE BUS
The brittle panel
What's it worth to be able to touch
provide safe, reliable communcations.

54 PRODUCTS
+ OUTLAST
wiring without causing an incident? The latest and greatest selections
from our editors’ in-boxes.
21 WITHOUT WIRES Plug-and-play
Distributing I/O 55 CONTROL TALK
Our slow climb from DCS to IP is get- Achieving the best APC flowmeter for utilities
ting steeper—and faster. Advanced process control improves
stability despite disturbances.
Picomag
22 IN PROCESS
CSIA conference breaks records; 57 CLASSIFIED/AD INDEX Reliable and easy
OSIsoft PI World says people key to IIoT; Find your favorite advertisers listed • Simultaneous measurement of flow
Siemens brings innovation to Chicago neatly in alphabetical order. and temperature
• Flexible integration into all fieldbus
27 RESOURCES 58 CONTROL REPORT systems via IO-Link
• Commissioning and operation
I/O, terminal blocks deliver reality Need to know
via Bluetooth and SmartBlue App
A monthly topical guide to web-hosted The Mechanics' Institute shows
educational materials. how to meet today's digitalization
challenges.
$ 499.00
11 – 35 pcs.
46 ASK THE EXPERTS
Polymer reactor level measurement
Is it wise or dangerous to back up
differential pressure with nuclear?

CIRCULATION

Food & Kindred Products......................................... 10,106
Chemicals & Allied Products...................................... 8,919
Systems Integrators & Engineering Design Firms........ 8,681
Primary Metal Industries............................................ 4,657
Electric, Gas & Sanitary Services................................ 3,481
Petroleum Refining & Related Industries.................... 4,016
Miscellaneous Manufacturers..................................... 6,982
Paper & Allied Products............................................. 2,856
Pharmaceuticals........................................................ 3,945
Complete product information:
Rubber & Miscellaneous Plastic Products................... 3,762 www.e-direct.endress.com/picomag
Stone, Clay, Glass & Concrete Products...................... 1,686
Textile Mill Products...................................................... 802
Tobacco Products......................................................... 110
Total Circulation....................................................... 60,003

www.controlglobal.com  MAY 2018 • 7

CT1805_05_07_TOC.indd 7 5/9/18 11:22 AM

 Defend Against the
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Ct1805_FPA.indd 8 5/9/18 9:01 AM


Time flies
Every good engineer spends a percentage of their effort on working their way out of a job.
A young man I know is just beginning his career
in engineering, finding himself in a windowless
cube, running simulations for hours, surrounded
by quintessential engineers—nobody talks and
when they do, it’s about work or hitting a bar af-
terwards. He is constantly looking for the path
forward—how can he improve himself to become
the engineer/subject matter expert/manager he
needs to be to become the human being he wants
to be? Should he learn systems engineering? Read
management or self-improvement books? Work
more, or work more on work/life balance? What
will his future bring?
Among his mentors is his group manager, who
has been an engineer for many years. His man-
ager told him, paraphrasing, “In engineering, you
don’t know what the future will bring. I started as
a draftsman. I poured myself into my craft, and
became the best draftsman. Now, we don’t use
draftsmen.”
Will the day come when you just say, “Com-
puter, design our control system. Control system,
commission yourself. Plant, make 100 tons of
polystyrene.” On some level, we know the answer
is yes, we just don’t know when.
Meanwhile, we toil away, each in our own envi-
ronment at our own technical level. A few plants
chafe at the limitations of the available technol-
ogy, and push for better and more. Others invest
in getting the most (the last?) from legacy systems
that were never designed to survive so long.
Spring has finally arrived in the Midwest, so we
can add the lawn work and exterior maintenance
to our list of chores. Spring also means yours truly
can further abuse you with tales of woe related to
resurrecting a 1963 Studebaker Avanti from its
20-year sleep in my uncle’s garage.
Before it went into winter storage, I got it run-
ning well and identified its weaknesses. Now, my
brother has decided he will keep it in the family,
and wants to take it from its place here, near Chi-
cago, to his home near Portland, Oregon.
So now, not unlike the readers tasked with rely-
ing on an end-of-life control system, my task has
www.controlglobal.com MAY 2018 • 9
CT1805_09_Editorial.indd 9
EDITOR’S PAGE
shifted from simply fixing what’s broken to making
sure the car will perform reliably for at least a few
thousand miles, and indefinitely thereafter. Work
has centered around the engine front main seal,
the power steering and miscellaneous items from
the fuel and charging systems to the exhaust.
With every grimy, inaccessible SAE bolt, con-
nection of brittle wiring and bit of barely post-
World War II iron-based engineering, I’m re-
minded what automobiles were like 55 years ago,
halfway between the amazing technology of today
and the twilight of the Age of Steam.
For example, this car has factory air condition-
ing, and the York piston compressor is mounted to PAUL STUDEBAKER
the iron block and heads with two brackets made Editor in Chief
from quarter-inch mild steel plate. Each adaptor pstudebaker@putman.net
weighs more than a modern compressor.
The radiator is solid brass and weighs at least
50 lbs; while the one from my 1991 BMW is plas-
Will the day come
tic and aluminum, weighs about 12 pounds and
when you just say,
handles half again the horsepower. The power
“Computer, design
steering uses a spool valve inserted between the
our control system.
Pittman arm and reach rod, a hydraulic cylinder
Control system,
tabbed onto the bellcrank, and about 14 feet of
commission yourself.
hoses to plumb them together and to the pump.
Plant, make 100 tons
The front end has 18 grease fittings, to be at-
of polystyrene.”
tended to every 1,000 miles.
Compared to a steam engine, a 1960s carbu-
reted V-8 is a miracle of modern technology. You
don’t have to plan an hour or two ahead of a trip
to go out and fire up the boiler, but unlike that
BMW, you probably want to warm it up for a few
minutes before you put it into gear.
From the perspective of 1963, or 1991 or even
2005 (our newest vehicle), it would be hard to
envision a modern hybrid or engine start/stop-
equipped car, designed to deliver full power from
cold in less than a second. Better yet, get a plug-
in electric—it simply doesn’t care.
Or just hop in a self-driving car, and tell it
where you want to go.
5/8/18 12:44 PM
 Automation &
Control Freak?
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JAN18 Allied-AC Freak Ad (CM).indd 1 12/15/17 9:06 AM
 CONTROL ONLINE

NEWS & BLOGS

2018 Control Hall of Fame Process sensor cybersecurity
Joe Weiss offers his thoughts after
New inductees to the Control Process Automation Hall of Fame participating in the Spring 2018 DHS
are chosen by their peers and stand out for three qualities: the ICSJWG meeting.
extent of their process control knowledge, their wisdom in ap- www.controlglobal.com/blogs/unfet-
plying that knowledge and their success in sharing it with oth- tered/still-little-understanding-of-cyber-
ers. This year, Control welcomes two new inductees to the Hall security-of-process-sensors-and-this-is-
of Fame: Thomas McAvoy and Herman Storey. Read about the more-important-than-stuxnet
newest Hall of Fame inductees here:
www.controlglobal.com/articles/2018/2018-control- When is an automation system
process-automation-hall-of-fame-part-1-thomas-mcavoy too slow and too fast?
Greg McMillan looks at how to de-
termine whether a system should be
State of technology: Level measurement eHANDBOOK
faster or slower.
In the latest State of Technology Report, the editors of Control bring to- www.controlglobal.com/blogs/con-
eHANDBOOK

gether the latest information about and trends in level measurement. This troltalkblog/when-is-an-automation-sys-
eBook covers topics including: tem-too-slow-and-too-fast
• Merging the old and new in level
• Virtual sensors validate vital data Educational video series
• The expert inside – better networked devices ControlGlobal.com's new educational
• Levels of inference – what smart engineers are getting video series offers back-to-basics
• A flash of inspiration on field devices and more. information about various aspects of
Level
Download your copy here: Measurement process control starting with part one,
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White paper: Data cable solutions for the flourishing ebook-2018-process-control-basics-
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Data cables are increasingly being used to create more information trans- DATA CABLE SOLUTIONS FOR THE
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CSIA releasing v5 Best Practices
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Sagar Patel, Product Manager, Lapp Group

pieced together into higher-value contextual information. Previously,
A utomation is continuing to increase on the factory floor,
creating a growing need for more data exchange over
sophisticated, high-performance networks. These new
ROBUST FACTORY CONSTRUCTION
In many ways, data cables need to be constructed the same
way as other industrial cabling, ensuring they can withstand

pinpointing the source of a machine malfunction was a time-consuming
developments, known conceptually as the Internet of Things
(IoT), are placing new demands on Ethernet cables, which are
the backbone of the smart factory environment. These system-
specific cables must be able to hold their own in harsh factory
environments while still supporting high data rates.
The Control System Integrators As-
the harsh environment of the factory floor. Ethernet cables in
plant-floor equipment must be able to tolerate a wider range of
vibration and electrical noise than equipment installed in offices
or information-technology areas, for example. The cables must
also be oil resistant, withstand high temperatures and function
reliably and durably in a cable track.

sociation announced the release of the

Because it can be a challenge to combine the design

process. Now, the ability to continuously monitor equipment and receive

requirements of robustness, flexibility and high data rates all in These requirements lend themselves to certain design
one cable, it’s important to know what your options are when considerations, which are universal to all cables:
selecting data cables for your factory.

feedback on their status helps avoid the potential pitfalls of downtime. fifth version of its industry standards.
Read the white paper here: https://www.controlglobal.com/
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Lapp Group 29 Hanover Road, Florham Park, NJ 07932 T. 800 774 3539 www.lappusa.com

tions-flourishing-smart-factory
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best-practices-and-benchmarks-
manual-version-5-0/

State of technology: Oil and gas applications SPECIAL REPORT

Panelists from ConocoPhillips, Chevron and Rice University chart past and
present forces enabling their industry's future and propose a range of pos- E-NEWSLETTERS
2017 STATE OF TECHNOLOGY:
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plants. This eBook includes the following topics:
Multimedia Alerts
• Future relies on innovation, efficiency
White Paper Alerts
• ExxonMobil's standardization of its designs and solutions
• A digital foundation for the chemical, oil and gas industry Go to www.controlglobal.com and
• UOP pioneering 'optimization-as-a-service' follow instructions to register for our
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www.controlglobal.com MAY 2018 • 11

CT1805_11_ct_online.indd 11 5/8/18 12:45 PM

 FEEDBACK
OPA is not like fieldbus
Great article. (“OPA plugs and plays,”
March ’18, p. 24, www.controlglobal.com/
articles/2018/opa-forum-expands-open-in-
teroperable-standard-for-process-control-
device-interfaces-part-2.) In case anyone
thinks that this is just fieldbus all over
again—it is not. The objectives are similar
to Foundation fieldbus, but that standard
had two major faults: It was directed at
new (greenfield) installations, and it had no
security at all. This OPA-S effort is directed
to provide a fully distributed computing
framework for existing devices (brownfield)
as well as greenfield, and security is in-
cluded from the lowest-level DCN or DCF,
to the network, to the highest-level RTAC.
In many ways, Foundation fieldbus lives
within the function block orientation of the
DCN/DCF, but this time OPAF has pro-
vided both the ability to add function block
capability to existing field instruments with
the DCN, and to allow vendors to build
new instruments with the DCF (function
block engine) built inside.
In case you don't recognize it, this is
Fieldbus 2.0 that includes the field instru-
ment in the OPA Communications Frame-
work (the network). Also, this introduces
the possibility of connecting Ethernet to
field devices, since that is the basis of the
OPA Communications Framework.
RICHARD CARO, CEO, CMC ASSOCIATES
RCaro@CMC.us
Different worlds
John [Rezabek], thank you for your reply to
my comments (“Settling for less,” March
’18, p. 12, www.controlglobal.com/ar-
ticles/2018/is-fieldbus-dead). We're look-
ing at the same situation through two very
different lenses. I work for a small mining/
metal producing facility with definite boom/
bust cycles and occasionally thin operating
margins. The organization is very flat and
our headcount is kept lean. We don't have
the option of hiring E&I employees with
significant experience. We bring in people
fresh out of school, and then train them
on site. Within five to seven years they be-
come very effective—and then they leave.
We are located close to a number of
12 • MAY 2018
CT1805_12_Feedback.indd 12
1501 E. Woodfield Road, Suite 400N
Schaumburg, Illinois 60173
In Memory of Julie Cappelletti-Lange,
Vice President 1984-2012
EDITORIAL TEAM
Editor in Chief
Paul Studebaker, pstudebaker@putman.net
Executive Editor
Jim Montague, jmontague@putman.net
OPA Digital Engagement Manager
PLUGS
Amanda Del Buono, adelbuono@putman.net
Harness
MILLERCOORS
PLAYS
OPTIMIZES Contributing Editor
AND
FERMENTATION
John Rezabek
energy
TEST SAFETY
VALVES SAFELY
MEASURING
PARTICLES
The Open Process Automation
Forum expands and develops
its open, interoperable standard
Columnists
Béla Lipták, Greg McMillan, Ian Verhappen,
IN LIQUID
EASY WINS
FOR WIRELESS
Stan Weiner
Editorial Assistant
Lori Goldberg
DESIGN & PRODUCTION TEAM
VP, Creative & Production
Steve Herner, sherner@putman.net
refineries. Refineries tend to print money, Art Director
have large operating budgets, and can af- Jennifer Dakas, jdakas@putman.net
ford to pay top dollar for the best of the Senior Production Manager
Anetta Gauthier, agauthier@putman.net
best. They only hire experienced people,
and they're almost certain to hold onto PUBLISHING TEAM
those people for the rest of their careers. Group Publisher/VP Content
Keith Larson, klarson@putman.net
For a refinery, it makes sense to expend
the time and effort to develop their people Midwest/Southeast Regional Sales Manager
Greg Zamin, gzamin@putman.net
to the very pinnacle of the technology. 704/256-5433, Fax: 704/256-5434
They have the budget, numbers, time Northeast/Mid-Atlantic Regional Sales Manager
and technical acumen to ensure that a Dave Fisher, dfisher@putman.net
508/543-5172, Fax 508/543-3061
Fieldbus solution will succeed. For us, the
West Coast/Mountain Regional Sales Manager
situation is very different. Our daily task is Jeff Mylin, jmylin@putman.net
847/516-5879, Fax: 630/625-1124
keeping the lights on using a small number
of predominantly rookie employees. Those Classifieds Manager
Lori Goldberg, lgoldberg@putman.net
who have been trained and are fully effec-
Subscriptions/Circulation:
tive can't be counted on to stay. Greener Jerry Clark, Jack Jones, 888/644-1803
pastures beckon, and they will leave.
EXECUTIVE TEAM
We deliberately avoid Fieldbus because
President & CEO
we know that we don't have (and won't John M. Cappelletti
have) the human infrastructure to maintain
VP, Circulation
it. The solutions we implement may not be Jerry Clark
as high-tech as a state-of-the-art Fieldbus VP, CFO
installation, but they do everything we Rick Kasper
need them to, and when they break, our Foster Reprints
Corporate Account Executive
people have the skills to fix them quickly. Jill Kaletha, jillk@fosterprinting.com
219-878-6094
I suspect that our situation is more com-
mon across the U.S. than yours. When a Finalist Jesse H. Neal Award, 2013 and 2016
pinnacle installation berates the rest of us Jesse H. Neal Award Winner
for not joining in the Fieldbus revolution, Eleven ASBPE Editorial Excellence Awards
Twenty-five ASBPE Excellence in Graphics Awards
they don't seem to realize that they're very
ASBPE Magazine of the Year Finalist, 2009 and 2016
much like Marie Antoinette exclaiming "Let Four Ozzie awards for graphics excellence
them eat cake!" Fieldbus isn't dead, but for
most of us, it just isn't a good fit.
MARTIN R. DAVIS
E&I Manager, US Magnesium, LLC
5/8/18 12:46 PM
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No Nodes - Control - Print.indd 1 4/17/18 9:28 AM

Ct1805_FPA.indd 13 5/8/18 1:26 PM
 LESSONS LEARNED

Can we resolve the climate debate?

Part 4: Energy storage is key, and hydrogen is best.

BÉLA LIPTÁK
liptakbela@aol.com
For a couple of decades,
the use of batteries
is likely to rise, but
when mankind fully
converts to renewable
energy, we will not have
enough lithium to meet
the demand.
Monthly usage, kWh
THE process control principles described in the the hydroelectric one, but they're even more lim-
first three parts of this series show that stor- ited and harder to implement.
age and transportation of intermittently available Grid storage: Here, a two-directional electric
renewable energy is the key to stopping climate meter sends excess solar electricity to the grid,
change. The world seems to be reaching the and supplements solar electricity from the grid
same conclusion, as the storage market grew when it's insufficient. In our home, we have a 10
46% in 2017 and is projected to grow ninefold in kW system (40 panels, 250 W each). It cost noth-
a decade, while the cost of storage will drop from ing, because it belongs to Solar City. All I agreed
14 cents per kWh to around 3 cents per kWh. The to is to purchase the electricity, which the system
cost of utility-scale lithium-ion storage systems generates during the next 20 years, at 12.3 cents
have already dropped 29% in 2015, 26% in 2016 per kWh. (The cost of regular electricity from our
and 12% in 2017. grid is 24.1 cents per kWh). In 2017, our total con-
In this last column of the series, I review the sumption was 12,970 kWh, (7,957 kWh from so-
energy storage technologies of both the past and lar), so last year we saved $938. We need another
the future, and outline the process control and au- 5 kW capacity to convert completely to solar and
tomation challanges of both. were hoping to add this capacity this year, but to
Gravity storage: The oldest methods of energy date, Solar City has been too busy to do it.
storage were gravitational, such as pumping water In Figure 1, the green line shows our solar gen-
up into artifical lakes at high elevations and re- eration last year, and the solid black line shows our
leasing it when electricity is needed. This method total consumption. The dotted line represents the
is used with fresh water in places like Austria and expected solar generation when we add another 5
Switzerland, and in Germany using sea water on kW capacity. Last year’s solar generation exceeded
its shores. Gravity storage is limited to mountain- our needs only in the spring and fall. In the sum-
ous regions and limited in capacity, and does not mer, it needed to be supplemented because of air
allow for transportation of the stored energy conditioning and pool pump loads, and in the win-
A similar method is to compess air into under- ter because elecric heat is added to the load and
ground chambers and release it when needed. snow blockage reduces the insolation.
The limitations of this method are similar to that of This "grid method" of storage is adequate in
Connecticut because the use of renewable en-
200 ergy is small, but if it's large (like in Germany), it
400
600
creates problems, because when the sun comes
800 out, electricity generation jumps and conventional

1,000
powerplants can’t reduce output fast enough. Ger-
1,200
1,400 many tried to overcome this problem by lowering
1,600 the price of elecricity, and even paying customers
1,800
2,000
for using more during these periods, but it didn’t
2,200 work (this "market-based" control loop failed).
J F M A M J J A S O N D Battery storage: When one talks about electricity
2017
storage, most people think of batteries. In the past
SOLAR HOME ANNUAL BALANCE few years, the cost of utility-sized, lithium-ion stor-
Figure 1: Total home electricity consumption and solar age systems dropped drastically and larger-capac-
production of a 10 kW system in Connecticut shows ity battery farms are being built everywhere—for
flows to grid (green) and from grid (red). The dashed example, a 129 MWh facility in Jamestown, South
line10,000
predicts the effect of an additional 5 kW capacity. Australia. Batteries are also used in electric cars
1 year
1,000
14 • MAY 2018 1 month
www.controlglobal.com
Hydrogen
100 Compressed air Pumped water
1 day
Discharge time

10
Batteries
1
CT1805_14_16_Lessons.indd 14 1 hour 5/8/18 1:19 PM
 Dow Corning makes

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Ct1805_FPA.indd 15 5/8/18 1:26 PM

90818427.indd 1 23/11/2017 22:02
 2,000
2,200

J F M A M J J A S O N D
2017

LESSONS LEARNED

(in its electrolyzer mode), will generate

10,000
1 year hydrogen from the excess solar eneregy.
1,000 During the night (in its fuel cell mode),
1 month Hydrogen the RFC will generate electricity from
100 Compressed air Pumped water the hydrogen to meet the needs of the
1 day home, including the charging the electric
Discharge time

10
cars, etc. The level of the hydrogen in the
Batteries
1 storage tank will be automatically moni-
1 hour
tored, so when it reaches 90%, it will be
0.1 Flywheels
trucked away, and if it drops to 10%, the
storage tank will be refilled, just as oil or
0.01
propane tanks are today.
0.001 The controls of the RFC will be a chal-
1 kWh 10 kWh 100 kWh 1 MWh 10 MWh 100 MWh 1 GWh 10 GWh 100 GWh 1 TWh 10 TWh 100 TWh lenge, and I will not explain it here, as
Storage capacity I've already done that. (Control, March
HYDROGEN IS BEST ’11, p. 40, www.controlglobal.com/arti-
Figure 2: This comparison of capacity and discharge time ranges of various energy storage cles/2011/controlsoftware1103).
systems shows that hydrogen has the highest potential. Source: www.renewableenergyworld.com In the four parts of this series, using
traditional methods of process control
analyisis, I hope I've proved that climate
change is real, it is caused by the burn-
ing of fossil fuels, and this trend can be
reversed by our full conversion to renew-
able energy. I hope I've also shown that
the Paris Agreement will not stop global
warming because of the immense iner-
tia and "double delayed" nature of this
process. In other words, the propopsed
lowering of the CO2 concentration to only
345 ppmv is totally inadequate, and it
NOT TOO LATE? must be lowered to the 280 ppmv level,
Figure 3: A photo the author took in Iran (Persia) in November 2017 shows people walking in a which was the maximum that existed
large, completely dried-out riverbed. during the past half-million years.
My process control-based evaluation
and in private homes, but they're heavy, energy problems is to completely convert of the time constants also suggests that
their capacity is small, their recharging to renewable energy—to a solar-hydro- the warming will occur fastest in the trop-
time is long and they can’t provide trans- gen economy. Naturally, the conversion ics. This means that possibly as soon as
portation of large quantities of electricity requires storage and transportation of the next couple of decades, the tropics
(say, solar energy from the Sahara). renewable energy, and hydrogen is the will experience unprecedented tempera-
Therefore, for a couple of decades, the best substance to do that (Figure 2). ture rises, water shortages (Figure 3) and
use of batteries is likely to rise, but when In the solar-hydrogen economy, solar weather events of biblical proportions.
mankind fully converts to renewable energy will be collected in places like the It will take a Manhattan Project-sized
energy, we will not have enough lithium Sahara and used to make hydrogen (from R&D effort to solve the technical chal-
to meet the demand (there is a total of water) by electrolysis. Next, the hydrogen langes of converting from our fossil/
some two billion motor vehicles in the will be stored and transported, similarly nuclear-based energy economy to a
world today). to LNG today; and when reaching users, renewable energy base. This conversion
Storage by my reversible fuel cell it will either be burned as a fuel (as it is will create immense numbers of jobs and
(RFC): In the 22nd century, the abbre- done today in space exploration rockets) many Silicon Valleys around the world,
viation RFC will probably be as common or used in fuel cells to generate electricity and its success will depend to a large
as PC is today, and a RFC will sit next to in cars or in private homes. extent on the contributions of our profes-
each home, just as a propane or oil tank Homes will be built with solar-collector sion, that of the automation and control
does today. The permnent solution to our surfaces and during the day, the RFC engineers.

16 • MAY 2018 www.controlglobal.com

CT1805_14_16_Lessons.indd 16 5/8/18 1:19 PM

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The brittle panel
What’s it worth to be able to touch old wiring without inadvertently causing an incident?
JAKE and his assistant were searching. The out-
building had some ambient monitors for oxygen
and carbon monoxide (CO), since it housed the
continuous emission monitoring system (CEMS)
for the nearby boiler. The stack sample being
analyzed was potentially suffocating or otherwise
lethal, so sirens would sound locally and beacons
would flash, alerting any occupants that they
should leave and seek fresh air immediately. Jake
calibrated the monitors every quarter, but a recent
corporate audit recommended that this was insuf-
ficient if the alarm did not also show in the control
house—a continuously attended location. Soon,
the operations manager entered a work order to
bring this alarm into the house.
If your facility has been around for more than
a couple of decades, it’s not uncommon that the
20% spares left in local panels by the original
builders have long ago been consumed. Projects
come through, process specialists come up with
other points to monitor, and before long, local
junction boxes have every spare pair occupied. In
Jake’s case, the next nearest place with a spare
for a new alarm was in the panel for the crude
furnace preheater. This panel accompanied the
addition of the air preheater decades ago, which
was itself installed many years after the original
furnace was constructed. Inside, it was still full of
relays wired for burner management and the or-
derly startup of the preheater. When Jake opened
the panel, it was like a journey back in time. A
routine task got interesting when he tried to move
some wires to check if they were spares; a boring
day became exciting when the furnace unexpect-
edly shut down.
No instrument specialist or operator wants an
exciting day. And so, it’s become common that no
one is eager to poke at anything for fear that some
unforeseen interconnection will cause a process
upset or shutdown. Over years of operation, con-
tacts corrode, vibration loosens once-tight termi-
nations, and heat, cold, humidity and time take
their toll on every sensor and logic solver. What
had been shiny, tight and certifiable decades ago
www.controlglobal.com MAY 2018 • 19
CT1805_19_OnTheBus.indd 19
ON THE BUS
is now a liability—it’s “brittle.”
How do we deal with brittle? Should we do
nothing until months or years in the future when
the process is offline? What if a vital measurement
or interlock means we must open and work in
such scarily fragile enclosures while the process
is running profitably? Although we have cultures
where instrument and electrical—I&E—is consid-
ered infrastructure (a perspective I would argue
is less than optimal), it remains that the conse-
quences of brittle or shabby delivery of measure-
ments and interlocks have grave consequences
for productivity—not to mention other priorities
such as safety and the environment. JOHN REZABEK
If Jake had foreseen the impact of his actions Contributing Editor
before opening the preheater panel, what might JRezabek@ashland.com
he have done differently? 20/20 hindsight says,
why wasn’t someone doing a tug-test and re-
torqueing of all the terminals in the panel during
A routine task got
the last process outage? Often the issue is, people
interesting when he
you’d entrust with such tasks are consumed with
tried to move some
putting out fires—attending to the hot issues of
wires to check if they
recent memory. When production is profitable, the
were spares; a boring
business has little patience for downtime, so “nice
day became exciting
to do” preventive care is usually postponed.
when the furnace
Let’s try imagining what robustness—the op-
unexpectedly shut down.
posite of brittle—would be like. Robustness would
mean even when we inadvertently trigger some
otherwise spurious (false) signal, the control sys-
tem/logic solver doesn’t invoke a trip. But old relay
logic and skid-mounted PLCs don’t normally at-
tempt to use even simple voting to invoke a trip—
mechanical equipment suppliers and consultants
would sooner protect their liability than employ
any cleverness (or expense) to avoid a spurious
trip, unless specifically directed by the client.
Do your specifications address terminal blocks?
Some of us experience pushback from electri-
cal contractors when we suggest spring-clamp
terminals, but perhaps this can be overcome with
a little investment in tools and training. If our proj-
ects endure for decades, this relatively mundane
choice of terminal blocks might be a simple and
effective bulwark against future brittleness.
5/8/18 12:47 PM
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Ct1805_FPA.indd 20 5/8/18 1:27 PM


Distributing I/O
Our slow climb from DCS to Internet protocol is getting steeper—and faster.
DESPITE the name “distributed control system,”
the original systems did not distribute the I/O but
kept all the hardware located near the control
room. Then, in the 1990s when networks im-
proved and fiber-optic became more common,
the I/O started being moved further from the con-
trol room to remote instrument buildings—still in
controlled environments, but closer to the process
units, reducing the need for long multiconduc-
tor cables. This trend is continuing with I/O now
being distributed to the field itself, replacing the
traditional field junction boxes. I/O manufacturers
such as R. Stahl, Turck and Pepperl+Fuchs transi-
tioned products from the manufacturing sector to
the process industries, and now all the major DCS
and PLC suppliers have remote I/O offerings.
One challenge with the available offerings is
their ability to integrate and interoperate. The
Open Process Automation Forum wants to make
remote I/O (distributed control nodes (DCN) in
their nomenclature) not only interoperable, but
also interchangeable, which means being able to
replace a device from one manufacturer with one
from a different manufacturer, and still have iden-
tical capabilities. Integration, on the other hand,
means you're able to incorporate the device into
a broader system and ensure interaction between
all enterprise entities.
Interoperability is the ability of two or more
systems or components to exchange information,
and then use that information, which is one step
up the usability chain from integration. Integration
normally requires more manual effort when the
systems are being built than interoperability, and
for many years, third-party integration (TPI) was
the bane and source of lots of billable hours on
many projects.
With the adoption of Internet protocol (IP)-
based networks and agreement on a single
protocol for a project and facility, the level of in-
teroperability improves significantly, and hence
integration efforts as well. Further improvements
can be made by selecting one protocol from end-
to-end (i.e. controller through to field devices), so
www.controlglobal.com MAY 2018 • 21
CT1805_21_Wireless.indd 21
WITHOUT WIRES
that a gateway (an integration device that trans-
lates from one language or protocol to another) is
not required.
Considering that, for the process industries at
least, the most common protocol is HART; and
though not widely supported, HART/IP is therefore
important to allow the above mentioned end-to-
end integration within a single protocol for wired
or wireless HART. Other common protocols for
remote I/O include EtherNet/IP, Profibus DP and
Profinet, as well as the ubiquitous Modbus/TCP,
though most of these will require mapping of data,
as with a gateway.
Because these units are mounted in the field IAN VERHAPPEN
and therefore will be connected to field power, Senior Project Manager,
care must be taken to ensure they have a reliable Automation, CIMA+
power supply. At a minimum, in a plant environ- Ian.Verhappen@cima.ca
ment, they're fed from two separate sources on
separate buses, or alternately, they contain a
small uninterruptible power supply (UPS) to ride
through any accidental AC source outages. Of
The Open Process
course, knowing when there's an incident and that
Automation Forum
the entire set of I/O is at risk is also good. Unfor-
wants to make
tunately, in most cases, the available option con-
remote I/O not only
sists of a single “power supply common trouble”
interoperable, but also
contact.
interchangable.
Some manufacturers provide a digital interface
to configure the UPS system. However it may be
a USB connection, meaning work must be done
with a local laptop rather than being accessible
over the network via a common protocol using the
available Ethernet in the panel. One reason for not
using a protocol may be the costs associated with
developing and certifying (check marks) for the
individual protocol organizations.
Distributed I/O is definitely coming and if we
believe the Internet of Things (IoT) hype, it will no
longer be required, or will be replaced by rout-
ers and switches because the individual sensors
themselves will connect directly to the associated
cloud-based database from which all the informa-
tion we require will be mined or pulled. A great vi-
sion, and like most things that we do as engineers,
it will be magic to everyone using it.
5/8/18 12:48 PM
 IN PROCESS
CSIA breaks attendance, growth records
Annual executive conference attended by almost 600 visitors, 70 exhibits in San Francisco
ITS longtime call for sound business
practices for members continues to pay
big dividends for the Control System
Integrators Association (CSIA, www.
controlsys.org), which broke all previ-
ous attendance and exhibitor records at
its 2018 Executive Conference on April
24-27 in San Francisco. Almost 600 at-
tendees registered for the annual event,
which featured numerous informative
conference sessions, as well as a record-
breaking 70 exhibitor booths.
In his keynote address, CSIA CEO
Jose Rivera took on the persona of Steve
Jobs to point out that Apple Computer's
co-founder and visionary—like many
entrepreneurs and system integrators—
started out in a garage, but grew through
a combination of innovation, persistence
and sound business practices. "This is
not different from system integrators,
who also dream big, learn from failures,
and rely on teamwork," said Rivera. "And,
just as Jobs was obsessed with the cus-
tomer experience, CSIA is obsessed with
advancing the industry of control system
integration and our members, which is
demonstrated by the recent release of
our Best Practices, Version 5.0, and our
white paper linking best practices and
better company performance."
Rivera reported that CSIA is also ex-
periencing steady growth, and at the end
of 2018, it's projected to have 583 mem-
bers, including 358 system integrator
members, 129 partners, and 96 certified
members. Last year's uptick in certified
members means it now has 25% that
have successfully completed its auditing
and certification/recertification process.
To meet its inclusiveness goal, CSIA
has been reaching out to end users
through its year-old End User Advisory
Board, and just reestablished its task
force to collaborate with the Open Pro-
cess Automation Forum (OPAF, www.
opengroup.org/open-process-automation),
22 • MAY 2018 www.controlglobal.com
CT1805_22_25_InProcess.indd 22
ON THE JOBS
CSIA CEO Jose Rivera channels Apple Inc.'s
late visionary founder, Steve Jobs, in his
keynote address opening CSIA Executive
Conference 2018.
which is seeking to develop an open, in-
teroperable process control system. "Our
next opportunity with OPAF is direct in-
volvement in its technical working group to
provide input into the specification being
created," said Rivera. CSIA has also been
working with the Association for Advanc-
ing Automation (A3), Organization for
Machine Automation and Control (OMAC),
and the International Society for Automa-
tion (ISA) and its Automation Federation.
"We're also planning to concentrate
on another growth opportunity, which is
smaller system integrators in the U.S.," said
Rivera. "It's estimated that the total system
integrator market in the U.S. includes about
3,000 companies and independent con-
tractors, and we believe we could realisti-
cally increase CSIA's membership by about
130 SIs, though we'd have to adjust our of-
fer to them, be less dependent on their at-
tendance at the executive conference, and
focus more on web-based content."
During its annual awards dinner on
April 26, CSIA honored five individuals
and their organizations. They are:
• A&E Engineering Inc. (www.AEengr.
com) in Greer, S.C., won the Integra-
tor Company Member of the Year
Award. A&E has been a CSIA mem-
ber for 15 years, and its president,
Wright Sullivan, has been a driving
force, peer group leader, mentor and
friend to many CSIA members.
• Mitsubishi Electric Automation
(https://us.mitsubishielectric.com/
fa/en) won the Partner Company
Member of the Year Award. It's been
a CSIA member since 2011, and
supported the association with spon-
sorships and its Mitsubishi Electric
System Integrator Program (MESIP).
• MR Systems (www.mrsystems.com)
in Norcross, Ga., won the Social Re-
sponsibility Award. Primarily a water/
wastewater SI firm, MR as been sup-
porting the Wine to Water project
that's rebuilding the water/wastewa-
ter infrastructure in the Dominican
Republic following recent damage
by hurricanes. MR also donated 150
membrane filter systems to Puerto
Rico as part if its hurricane-related
rebuild efforts.
• John Binion, PE, of Hargrove Con-
trols + Automation (www.hargrove-
epc.com) in Mobile, Ala., won the
Rising Star Award. He implemented
safety instrumented systems (SIS)
while at Schneider Electric, and has
focused on project management, im-
plementing DCS and PLC systems in
the chemical and refining industries,
and SIS and safety lifecycle activities
at Hargrove, including SRS docu-
mentation, PHA and LOPA reviews.
• Luigi De Bernardini, CEO of Auto-
ware S.R.L. (www.autoware.it) in
Vincenza, Italy, won the Charlie
Bergman Award. In that spirit, CSIA
reports he's been an invaluable as-
set during his 10-year membership,
provided an international perspec-
tive, and served in many leadership
roles, including treasurer and now
vice chair.
5/9/18 11:38 AM
 IN PROCESS

OSIsoft PI World it and its flagship OSI PI software are well-

positioned because they've already spent
ing sensor networks and mobile workforces
that can fill data lakes, but they should also
focuses on the many yeas bridging data gaps and pulling feel familiar because OSIsoft can give the

human factor information together for users. "We're fac-

ing many challenges now, such as multiply-
Internet of Things (IoT) and its users the
scale, scope, dimension and infrastructure
Ironically, people may be the key to digital
transformation. That was the essential
message delivered by leaders and pre-
senters alike at OSIsoft's (www.osisoft.
com) 29th annual PI World user confer-
ence on April 23-27 in San Francisco. The
event was attended by about 2,800 visitor,
who took in 51 exhibitors, 160 customer
presentations, and 119 OSIsoft sessions.
"We do what we do for several rea-
sons, and the first is that pervasive data
collection always means more revenue,"
said Dr. J. Patrick Kennedy, founder,
chairman and CEO of OSIsoft. "I've never
seen it fail that data monetizes."
To bring more useful data to more users,
Kennedy stressed that OSIsoft's vision is to

PEOPLE PERSON
Dr. J. Patrick Kennedy, founder, chairman and
CEO of OSIsoft, delivers a human-centered
keynote at OSIsoft's PI World 2018

make information scalable for use by large

and small applications; aggregate process
data for critical operations; and provide it
via its new OSIsoft Cloud Services (OCS)
platform. "Users want innovation and
mobile worker capabilities, and changing
architectures are changing how they work
with their systems, but their number one
desire is still data quality," added Kennedy.
Despite all the upheaval caused by
digital transformations, Gregg Le Blanc,
VP of products at OSIsoft, explained that

www.controlglobal.com MAY 2018 • 23

CT1805_22_25_InProcess.indd 23 5/9/18 11:24 AM

 IN PROCESS
they need. People are key because their natural intelligence is es-
sential to prioritizing and making digitalization useful and success-
ful. There's a billion measurements and a trillion data values from
the edge to onsite to the cloud, and OSIsoft focuses on making
them more scalable and usable."
For example, Penny Gunterman, product marketing manager
at OSIoft, reported that Duke Energy (www.duke-energy.com) in
Charlotte, N.C., is using acoustic sensors to identify boiler leaks,
and applying thermographic devices to spot rising temperatures,
but wasn't able to coordinate the resulting data for better deci-
sions until it integrated OSI Pi and even some artificial intelli-
gence (AI) capabilities.
"Data is gold, but it's in the ground, and OSIsoft helps us
mine and manage it in real time, make sense of it, and get it to
our workers' fingertips to empower them," says Chris Heck, CIO
and VP at Duke. "We've got 5 million PI tags making their way to
5,000 users at Duke, but now we've also got monitoring and reli-
ability diagnostics centers that also deliver data to OSI PI and our
asset framework, which applies algorithms to do predictive and
preventive maintenance that have saved us about $130 million."
Gunterman added, "We're looking at places in plants that
we've never seen before, and users know where this data could
be used, but they also need AI to pick up where their awareness
leaves off. New technologies like AI should complement people's
intelligence, and light up otherwise dark data."
Siemens Innovation Day
plays in Chicago
To take what it calls the Fourth Industrial Revolution from con-
cept to reality, Siemens staged its annual U.S. Innovation Day
on March 27 at the Digital Manufacturing and Design Innovation
Institute (DMDII) in Chicago. The event featured interactive ex-
hibits and showcased real-world applications of digital solutions
enabling users across the company’s largest market to reduce
costs, increase speed, develop new business models, and im-
prove the quality of life for millions of citizens.
Siemens also highlighted:
• Eight new U.S.-based MindSphere Application Centers for
digital applications that transform data into real value for
customers;
• More than $1 billion annual investment in U.S. R&D and a
$175 million increase in R&D spending year-over-year; and
• Hundreds of job openings for talented software developers,
programmers, and cloud and data scientists.
For instance, Chicago is reported to be one customer that's
saved millions of dollars by retrofitting its water supply with Sie-
mens technology. In addition, Siemens teamed with Microsoft to
integrate alternative energy sources for cleaner and more efficient
data center operations, helping establish the world’s first zero-car-
24 • MAY 2018 www.controlglobal.com
CT1805_22_25_InProcess.indd 24
INSPIRE AND INNOVATE
Youngsters and their families play with some of the interactive exhib-
its during Siemens U.S. Innovation Day 2018 at the Digital Manufac-
turing and Design Innovation Institute (DMDII) in Chicago.
bon, waste-to-power data center in Cheyenne, Wyo. With Atlanta
Streetcar, Siemens established a predictive maintenance program
that puts more intelligence behind data points to reduce delays
for streetcar riders as well as save energy. Additionally, Siemens is
teaming up with Chicago-based Commonwealth Edison (ComEd)
to help build and test software that will allow the utility to manage
clusters of microgrids simultaneously.
“With the arrival of the IoT in industry and infrastructure, many
organizations are still trying to understand how to incorporate digital
strategies into their business models,” said Roland Busch, CTO and
managing board member at Siemens AG. “Siemens has reinvented
itself into one of the world’s top 10 software companies, and is con-
tinuing to expand its digital capabilities. With our MindSphere Appli-
cation Centers, we’re combining deep expertise in automation and
electrification with our unique industrial software offering to enable
our customers to leverage digital solutions for their specific needs.”
Honeywell launches batch
solution
Honeywell Process Solutions (HPS, www.honeywellprocess.
com) today introduced a control technology solution, Experion
Batch, which increases productivity for batch operations and
speed-to-market of batch products by allowing operators to “look
ahead” into their processes and see an intuitive and comprehen-
sive timeline of every task required to complete a product batch.
Experion Batch uses patent-pending visualization technology to
provide batch automation processes with the benefits of distrib-
uted control capability. This approach provides operators with
insights into upcoming events or potential delays, which make it
easier for them to conduct multiple tasks, take appropriate ac-
tions sooner and adjust next steps accordingly.
5/9/18 11:24 AM

SIGNALS AND INDICATORS
• T he International Society of Automation (www.ISA.org) released
May 9 the third edition of A Guide to the Automation Body of Knowl-
edge. Co-edited by Nicholas Sands, PE, CAP, senior manufactur-
ing technology fellow at DuPont, and Ian Verhappen, P.Eng., CAP,
senior project manager at CIMA+, the new release is updated to
reflect the evolution of digital technologies and their impact on au-
tomation processes, as well as new automation standards in such
areas as alarm management, HMI design, operational technology
and cybersecurity.
• Bentley Systems (www.bentley.com) reported May 3 its acquisi-
tion of Plaxis (www.plaxis.com), a provider of geotechnical soft-
ware in Delft, Netherlands, and its purchase of soil engineering
software provider SoilVision (https://soilvision.com) in Sasketoon,
Saskatchewan, Canada. These acquisitions, with Bentley’s report-
ing and data management software gINT, will make Bentley a
source for digitalizing geotechnicians.
• Wunderlich-Malec (www.wmeng.com) and Bedrock Automa-
tion (www.bedrockautomation.com) announced May 8 that they're
Globally Certified HMI Systems and Components for Hazardous Areas
 ATEX, IECEx Zone 1/21, Zone 2/22, and NEC Class I & II, Div. 1/2 HMIs
 Operator workstations and panel components designed specifically for adverse conditions in the oil and gas industry
 PCs and thin clients manufactured to meet the stringent demands of cleanroom and hygienic applications in the life
science industry
www.pepperl-fuchs.com/hmi
www.controlglobal.com MAY 2018 • 25
CT1805_22_25_InProcess.indd 25
IN PROCESS
partnering to deliver automation solutions that address 21st-
century cyber threats, while simultaneously delivering powerful
and affordable edge control solutions. As part of the agreement,
Wunderlich-Malec will deliver Bedrock's Open Secure Automation
(OSA) platform from its 32 U.S. locations.
• NovaTech LLC (www.novatechweb.com) announced April 17 that
it will supply process automation equipment and services for the
new Bow River Brewery in Calgary, Alberta, Canada. NovaTech's
D/3 distributed control system (DCS) will manage the brewing
process for the new regional craft brewery. D/3 will provide all
operator interface, recipe management, process control and batch
management functions for the new brewery.
• Maplesoft (www.maplesoft.com) reported May 8 that it's been
named an Encompass Product Partner in the Rockwell Automa-
tion (www.rockwellautomation.com) PartnerNetwork Program.
Through the partnership, joint customers of Rockwell automation
and Maplesoft will benefit from technology that provides model-
based tools for virtual commissioning.
Ensuring process
availability.
Providing flexibility.
Challenging expectations.
VisuNet HMI Systems
5/9/18 11:24 AM
 JOB: 2737 HPS ADS Experion Batch print SIZE: 7.875"x 10.5" + .125" Bleed COLOR: 4-Color process imagery provided at 300ppi

Visualize batch production like never before.

Experion® Batch combines compact Experion
distributed control with batch automation
and patent-pending visualization technology
See More. Do More. to increase flexibility and throughput, and
support compliance for regulated industries.

See it at Honeywell User’s Group:

www.honeywellusersgroup.com

Connected Industrial

Connected Plant For more information, please visit

www.honeywellprocess.com/Batch
©2018 Honeywell International Inc.

Connected Worker

Ct1805_FPA.indd 26
Cyber Security Solutions 5/8/18 1:27 PM

I/O, terminal blocks deliver reality
Control's monthly resource guide
TALK SHOW ON BLOCKS
The 43-minute video, "Terminal Blocks
and Ziplinks Webinar from Automation-
Talk," covers a wide range of technolo-
gies, capabilities and solutions in a
talkshow format with Q&A. It covers Au-
tomationdirect's updated and extended
lines of Dinnectors and Ziplinks, also
known as terminal blocks and prewired
connection cables and modules. It's at
www.youtube.com/watch?v=N8n8
AUTOMATIONDIRECT
www.automationdirect.com
I/O POINTS IN CONTEXT
This 26-minute video, "Solutions for PLC
I/O Modules," from Texas Instruments
covers PLC systems, and dives into I/O
modules used to interface with sensors/
actuators. "I/O modules must meet strin-
gent electrical specifications and can
be classified into current, voltage and
digital input/output types," states TI's
liner notes. "We'll explore the challenges
designers face in conditioning and con-
verting these signals, and touch on solu-
tions to address these challenges." It's
located at https://www.youtube.com/
watch?v=Rf9tPANO9k8
TEXAS INSTRUMENTS
www.ti.com
FIVE CONNECTION TYPES
These two videos, "Terminal block ba-
sics" and "Terminal block connection
types," cover pass-through, ground,
fuse and multi-level blocks and con-
nections, as well as screw, spring,
push-in, tool-less and barrier connec-
tions. They're at www.youtube.com/
watch?v=yz5PMABHfWA and at www.
youtube.com/watch?v=oFSt8Y71WZE
RSP SUPPLY
www.rspsupply.com
If you know of any tools and resources we didn’t include, send them to ControlMagazine@Putman.net with
“Resource” in the subject line, and we’ll add them to the website.
www.controlglobal.com MAY 2018 • 27
CT1805_27_Resources.indd 27
DIGITAL I/O WHITE PAPER
This online white paper, "Digital I/O fun-
damentals," includes basic concepts
like voltage levels, logic families, clocked
digital I/O, termination and industrial
features. It also features common termi-
nology and digital concepts, and well as
digital I/O device verification/character-
ization, functional tests and digital device
interfacing. It's at www.ni.com/white-
paper/3405/en/
NATIONAL INSTRUMENTS
www.ni.com
DIN RAIL, BLOCKS EXPLAINED
This 6.5-minute video, '"What are DIN
Rail Terminal Blocks? Types and Ex-
planation!," goes beyond individual
product features to explain the basic
function and forms of DIN-rail terminal
blocks, as well how to wire and con-
figure them. It's at www.youtube.com/
watch?v=hGZmC2qPSyc
NEVER STOP BUILDING LLC
www.neverstopbuilding.com
DISCRETE VS ANALOG I/O
This short, online article, "Understand-
ing discrete & analog I/O," describes the
physical differences between analog and
discrete I/O signals, and how they're af-
fected by transducer, scaling, resolution
and electrical noise issues. It's at https://
library.automationdirect.com/understand-
ing-discrete-analog-io/
AUTOMATIONDIRECT
www.automationdirect.com
FIELD TO I/O TO PLC
The two videos, "How are field devices
wired to PLCs, Parts 1 and 2," from
PLC training provider RealPars cover
the basics of industrial networking from
field devices to I/O modules on up to
RESOURCES
PLCs. They're at www.youtube.com/
watch?v=qeBAz_XXUWs and at www.
youtube.com/watch?v=4EQtCSrKjLs
REALPARS
https://realpars.com/free
GOOD BLOCK DEFINITIONS
These two short videos, "What are ter-
minals blocks?" and "Types of terminal
block connections," cover the defini-
tions and functions of terminal blocks,
and how they're wired to other compo-
nents and networks. They're at www.
youtube.com/watch?v=75aE18iqtIM
and at https://www.youtube.com/
watch?v=Ua1UXh9l3c4
GALCO TV
www.galco.com
INTERRUPT, PROGRAMMED I/O
Two 50-minute videos, "Lecture
24 – Programmed I/O" and "Lec-
ture 25 – Interrupt driven I/O," pre-
sented by Prof. S. Raman, IIT Madras,
shows I/O devices within the context
of microprocessors and computer sci-
ence. They're at www.youtube.com/
watch?v=aGvMubj8NXk&t=206s
and at www.youtube.com/
watch?v=C02weCM9yWA
NPTEL
www.nptelvideos.in
POINTS, BLOCKS ASSISTANCE
This column, "Help with your I/O termi-
nal blocks," provides references to 10
resources from National Instruments,
Tepergy, IHS Engineering 360, DDC
Online, Lumberg Automation, Festo,
Omega Engineering and others. It's at
www.controlglobal.com/articles/2015/
help-with-your-io-and-terminal-blocks
CONTROL
www.controlglobal.com
5/8/18 12:48 PM
 KNOWLEDGE

Knowledge on demand

How plants put wisdom at fingertips

by Jim Montague

28 • MAY 2018 www.controlglobal.com

CT1805_28_35_CoverStory.indd 28 5/9/18 9:10 AM

 WE all know reach can exceed grasp, but at least in accessing
and using process control information, many longtime hurdles
are shrinking. Finally, knowledge-on-demand is closer at hand—
physically, if not always mentally.
The old chasms were huge between plant-floor operations
and other applications such as utilities, where production data
is generated, and central locations, where users make decisions
to improve their processes. Historically, this is because reaching
remote signals and parameters on legacy equipment was dif-
ficult, and establishing the networking and programming needed
to get information back to users could be even harder.
Fortunately, many tools, software, developers and system inte-
grators are whittling down these obstacles—and simplifying and
flattening networks—until it's often just a short hop or two to get
data and know-how where it can do the most good. In fact, re-
cent technical advances in single-pane displays, Internet-based
network simplification, and mobility enabled by tablet PCs and
smart phones have progressed so much that one of the biggest
remaining snags is getting potential users to realize that many
former barriers to accessing useful data are no longer there.
"Using big data for smart manufacturing is a fabulous concept,
but it can be held back if we're dealing with a 50-year-old paper
plant with a 35-year-old historian, which is why we need to make
certain the information we're getting is correct," says Tim Gellner,
senior consultant in the operational consulting group at system
integrator Maverick Technologies (www.mavtechglobal.com), a
Rockwell Automation company. "There are many handhelds for
data entry and acquisition, and some that can do control, includ-
ing one we designed and built several years ago for the three field
operators at a small, electrical peaker plant in California. We did a
pilot with Apple iPads, but rolled out with Microsoft Surface tablet
PCs running Windows to connect to the control system."
To be ready for dips in the local grid, the plant has four GE gas
turbines, which must go from dead stop to moving in minutes.
They're controlled by GE Mark 6E devices and Cimplicity software.
The balance of plant is controlled by Emerson Ovation DCS hard-
ware and software, with recently added wireless components, as
well as Splashtop remote access software for desktop sharing,
which marries operator stations to laptops or tablet PCs.
"This allows operators to be untethered from the control room
and connect to the two sets of HMIs on the turbines and balance
of plant to receive alarms, perform control and troubleshooting
functions, and monitor the demand requests from the utility,”
explains Gellner. “Security is achieved by adhering to the NERC-
CIP standards for using wireless onsite in critical infrastructures.
The plant also uses secure logins and two-factor authentication.
Remote sessions are encrypted with TLS and 256-bit AES. All pro-
cess data is collected natively by the control system, and though
the operators can make setpoint changes via the tablets, they’re
mostly used for monitoring. The tablets are also easier to set up
because, in the past, the plant’s few, remote operator stations and
their drives had to be accessed in code and manually, which re-
quired a lot more labor."
Close-in reasoning
Users, integrators, developers and suppliers have individual mo-
tivations for getting closer to their data, but there are some com-
mon themes as well.
"We see two main forces at work. Decision-makers and man-
agers are concerned with profit-and-loss statements, and need
better information access to show clients the short-term impact
of what they're doing," says Youssef Mestari, program director,
Connected Plant, Honeywell Process Solutions (https://honey-
wellprocess.com). "The second driver comes from plant-floor

COOL SAVINGS IN CONTEXT

Figure 1: Evaporcool added Seeq data analysis software running on remote workstations to organize large volumes of sensor data from
evaporative cooling units that mount on and assist high-capacity HVAC units. The data is integrated into an energy-consumption model they
developed that calculates how much revenue the coolers save in real time, and has graphical look-backs that show pockets of savings.
Source: Evaporcool and Seeq

www.controlglobal.com MAY 2018 • 29

CT1805_28_35_CoverStory.indd 29 5/9/18 9:11 AM

 KNOWLEDGE
technicians, operators and engineers, who need to get the right
data to anyone at any time. If it's like their mobile phones, and
makes their lives simpler and easier, then they'll adopt it."
Mestari adds upcoming data access solutions will take three
main forms:
• Intelligent, wearable devices that can provide real-time ac-
cess to process data;
• Immediate access to remote experts, who can see what op-
erators see via onsite cameras, and provide guidance; and
• Improved guides and step-by-step procedures, so less-ex-
perienced personnel won't have to remember every detail
about their processes, and can share details more easily
with their maintenance teams and managers to identify ab-
normalities and avoid shutdowns.
For instance, Kuwait Paraxylene Production Co. (KPPC), a sub-
sidiary of Kuwait Aromatics Co. and Petrochemical Industries Co.
(www.pic.com.kw), will use two Honeywell Connected Plant ser-
vices to improve its Continuous Catalytic Reforming (CCR) Platform-
ing and aromatics complex, which produces paraxylene for plastic
fibers and films at its Shuaiba petrochemical plant in Safat, Kuwait.
KPPC will deploy Connected Plant Process Reliability Advisor soft-
ware for ongoing monitoring, early event detection and performance
issue mitigation, and deploy Process Optimization Advisor that con-
tinuously monitors streaming plant data and applies Honeywell UOP
process model to determine the most economical operating mode.
"Using big data for smart manufacturing
is a fabulous concept, but it can be held
back if we're dealing with a 50-year-old
paper plant with a 35-year-old historian,
which is why we need to make certain
the information we're getting is correct."
"Information access is transforming how many technicians
and operators do their jobs" says Mestari. "Instead of manually
gathering hundreds of measures during scheduled rounds every
few hours, and not consulting them until an incident occurs, they
can use Connected Plant to learn about production performance
and equipment health in real-time, retrace value captures, and
immediately compare to in-spec or out-of-spec ranges."
Tim Goecke, director of Maverick's enterprise integration prac-
tice, adds that, "Our two main engagements are with people who
have a problem they need to fix and those looking at their 'plant of
the future' and how the Industrial Internet of Things (IIoT) can help
manufacturing. There's a lot of curiosity because they want IIoT
for more accurate forecasting, better planned maintenance and
foreseeing breakdowns. However, we've learned from interviews,
workshops and discovery meetings that their data infrastructures
30 • MAY 2018 www.controlglobal.com
CT1805_28_35_CoverStory.indd 30
aren't there yet. They typically have SQL servers or databases with
transactional, batch or SKU information scattered across multiple
data silos. From a process data perspective, they usually have
legacy historian systems in place that haven't had any structure
or contextualization layer applied, making them encrypted to the
larger data consumer community.
"That's why we promote strong data structures based on
ISA's S95 and S88 standards, using tools like Rockwell Automa-
tion's FactoryTalk AssetCentre, OSIsoft's PI or AspenTech's IP21,
which structure data with contextual layers. And, many people
are starting to get it, and coming to understand that data, ac-
cess, readability and fidelity are crucial to enabling their future
plants, which will be driven by data their operators must be able
to access and read."
Gauging the gaps
Whatever the opportunities and potential rewards, however, it's
still crucial to look before leaping. So, developers, system inte-
grators and users must examine how to make information more
accessible in their individual applications.
"We work at all different levels in manufacturing, from the
plant floor all the way through to business systems. We've seen
enterprise/production links began to get closer with the advent of
application program interfaces (API) that made it easier for pro-
cesses to talk to each other," says James Ruiz, COO at ITG Tech-
nologies (http://itgtec.com), a member of the Control System In-
tegrators Association (CSIA, www.controlsys.org) in Jacksonville,
Fla. "The process control market is moving away from top-down
solutions from one vendor to instead creating niches that can be
filled in by players up and down the line. When users need big
data, no one wants to be the bottleneck, and so everyone must
be able to talk to third parties."
To assist its users, ITG implements its SORBA IIoT (www.sor-
basoft.com) enterprise platform, which applies machine learning
and predictive analytics within four clicks to provide actionable
information to users more quickly, and simplify their ability to
automate, monitor and control their processes. ITG uses SORBA
because it eliminates costly data science agreements or capi-
tal expenditures. Similar IIoT platforms include GE Predix and
Siemens Mindsphere, but implementing SORBA and other rem-
edies still requires evaluating each user's application.
"The lead question is, what's the biggest pain point? What
20% change will give an 80% return?" asks Ruiz. "After identify-
ing the low-hanging fruit, the second step is asking if the users
have the data they need? If not, we design an instrumentation
platform to extract and collect it, and get it to them. Some users
are worried about cybersecurity when going to the cloud, but we
can show how to do it safely with secure protocols. This is impor-
tant because we're also going to be doing more edge computing
soon. Users are learning they don't want to send everything back
to the cloud if they don't need to."
Peter Martin, vice president of business innovation and mar-
5/9/18 9:11 AM

keting at Schneider Electric (www.schneider-electric.us), ex-
plains there are two main types of knowledge that users require:
knowledge they need on an ongoing basis to keep their applica-
tions "on the road," and knowledge for making discrete deci-
sions. "The operator's job is to create profitability safely, but most
don't know if changing a particular setpoint will create value or
destroy it, so they're often left to do what's comfortable," says
Martin. "However, the business context is moving down to opera-
tions, and showing that operators, maintenance personnel and
engineers need more information that can support profitability,
such as verification for engineers that their control strategies are
correct." Schneider Electric's three primary tools for safely boost-
ing profitability are Profit Advisor, Control Advisor and Mainte-
nance Advisor software, which examine operations in real time,
but then allow different plant groups to work together.
In-context data saves
Because the primary aim of data access isn't just applicability
but also speed, Evaporcool (www.evaporcool.com) in Memphis,
Tenn., worked with Seeq Corp. (www.seeq.com) to organize vol-
umes of sensor data coming from its evaporative coolers that re-
duce operating costs for HVAC compressors for large buildings.
They apply evaporative cooling to air drawn through the con-
www.controlglobal.com MAY 2018 • 31
CT1805_28_35_CoverStory.indd 31
KNOWLEDGE
Many people are starting to get it,
and coming to understand that data,
access, readability and fidelity are crucial
to enabling their future plant, which
will be driven by data their operators
must be able to access and read."
densers' coils, which increases the capacity of the HVAC units,
and reduces the electricity they need because they don't have to
run fully loaded to provide the same cooling level.
However, Evaporcool's automation and savings calculations
initially relied on sensor data and measurements that historically
weren't detailed enough or didn't go back in time far enough to
provide a baseline, according to Chris Curry, president of Evapo-
rcool. The sensors monitor condenser air inlet temperatures,
outside ambient conditions, compressor running time and cur-
rent draw, and their raw data is processed using equipment and
performance models to calculate savings.
"We worked with Seeq to create an operational model of the
5/9/18 9:11 AM
 KNOWLEDGE
Main data
warehouse
(Microsoft SQL server)
SAP
Central DCS
Data hub
Modbus
protocol
TOP server
Utilities Ammonia Wastewater
cooling
SIMPLER SUDS IN SOUTHERN AFRICA
Figure 2: Namibia Breweries Ltd. integrated data from 4,000 panels, 66 inverters and four controllers in its 1-MW rooftop solar plant by
using Wonderware Historian from Schneider Electric and a virtual enterprise on two TOP servers from Software Toolbox to coordinate the
utilities with other brewery operations that are controlled by more than 100 PLCs, and display KPIs results over a simplified network that
includes an HTTPS dashboard server. Source: Schneider Electric
system, and show how it performs based
on data from a variety of installations,
combined with heat transfer and air con-
ditioning efficiency constants," explains
Curry. "Data from all the sensors is fed via
the Internet into Seeq's data analysis soft-
ware running on remote workstations."
The model takes relevant parameters,
such as temperatures and humidity, and
builds a picture of what's happening in
real time or at any other operational history
point, compared to what would be happen-
ing without the evaporative cooling system.
32 • MAY 2018 www.controlglobal.com
CT1805_28_35_CoverStory.indd 32
Internet
Web server Dashboards
Historian
OPC server
Solar plant Brewing Water plant
When supplemented with actual histori-
cal data for a given installation, the model
results are even more specific. The energy
consumption models have proven to be
highly accurate with an R-value of .98.
"This with-and-without cost compari-
son is a major benefit for users," says
Curry. "This makes it possible for us and
our building-manager customers and
their remote users to monitor and mea-
sure all aspects of the evaporative cooling
system’s performance via the Internet,
see savings in real time, follow a sum-
Cisco
switches
SNMP Power
protocol meters
UPSs
Siemens
protocol
Boiler house CO2 plant Packaging
mary graph back in time to identify pock-
ets of savings, and establish upper and
lower operating limits, so any crossing of
the line can send an alarm." (Figure 1)
"Data, remote or otherwise, might be
interesting for users to see, but to be
useful, it’s more important to see data
from any source in the context of other
datasets or plant context," says Michael
Risse, VP and CMO at Seeq. "This is the
leap now underway—from a trend line in
a browser on any client, which indicates
access to raw data, to a contextualized,
informed insight on which users can
make decisions for improvement."
Putting fingertips to work
Of course, once quicker access to data is
gained and better decisions are possible,
some users are also confronted with
unexpected capabilities and new tasks.
For example, Wood (www.woodplc.com), a
global vendor-independent system integra-
tor, reports that many of the 1,300 profes-
sionals in its Automation & Control division
develop real-time operations software and
5/9/18 9:11 AM

provide support services. The software and
services monitor key performance indica-
tors (KPIs) and overall performance, many
times running models or "digital twins" in
parallel with physical processes. Examples
include air and water emission applications
in the oil and gas industries that are in-
creasingly using secure networks to quickly
link operations monitoring software like
Wood's to other systems via services such
as Virtuoso (www.woodgroup.com/what-
we-do/view-by-products-and-services/digi-
tal-solutions/virtuoso).
"Because advanced process control
(APC) generates revenue by using produc-
tion data to minimize resource use, much
of our group works on process databases
for emissions monitoring," says Hodge Ea-
gleson, senior principal technical and APC
consultant at Wood. "With today's prolifera-
tion of data and databases, it's possible to
take additional indicators, find trends, and
use them, too. The innovation in APC from
more accessible data is—instead of just
controlling one process—extending the
benefit from monitoring historians and KPIs
to telling more about uptime, and show-
ing how well those benefits can be further
maximized by running against constraints.
Our solution is model-based control, which
predicts the future and adjusts to it. This
goes beyond feedback-based control,
which can't respond until it sees results."
Similarly, Brian Burgio, account man-
ager for advanced solutions, software
and APC at Yokogawa Corp. of America
(www.yokogawa.com/us), confirms that
model-predictive control (MPC) and APC
have not only been gaining speed, but
are also enabling pretests and checkouts,
tuning loops, aiding valve and equipment
repairs, and providing speedier intelli-
gence to remote monitors.
"In many cases, users no longer need
to be physically there," says Burgio. "We've
partnered with Shell on multivariable (MV)
control since 1999, and helped develop
its MV control package, Platform for Ad-
vanced Control and Estimation (PACE),
which was released to Shell in 2015 and
to the overall market a year later. In fact,
Air Liquide just standardized on PACE in
www.controlglobal.com MAY 2018 • 33
CT1805_28_35_CoverStory.indd 33
KNOWLEDGE
North America. It's a comprehensive tool three of the brewery's generator areas,
that combines MV functions, is web-based and make NBL electrically self-sufficient.
to better display operations on HMIs, and This project and managing its utilities
helps run plants in three ways: broad plant prompted NBL engineers and manag-
operations such as manipulating setpoints, ers to better coordinate some of their
performing advanced regulatory control departments, and organize them into a
such as adjustments based on ambient cohesive entity that could make real-time
conditions, and improving MV control so business decisions based on one version
less-experienced engineers can do it." of the facts.
"We have the brewing, packaging
Single pane shifts jobs, too and distribution departments, and each
Ironically, as systems simplify and knowl- focuses on doing their job to the best
edge gets closer to users, the roles of of their abilities, but without necessarily
those users and even their familiar de- much concern for the common denomi-
vices are also evolving. nator that makes it all possible—utilities,”
For instance, Namibia Breweries Ltd. says André Engelbrecht, industrial con-
(NBL, www.nambrew.com) in Windhoek, trol systems manager at NBL.
Namibia, recently implemented a 1-MW, This unification included NBL's CO2
roof-mounted solar plant with more than plant, ammonia cooling system, boiler
4,000 panels, 66 inverters and four clus- house, water treatment and sterile air
ter controllers, which are connected to plants, and power meters. NBL has
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5/9/18 9:12 AM
 KNOWLEDGE
a central DCS that controls its brewing process, but found it
needed more immediate data and collation resources—a living
system—to achieve its goals of accurate decision support based
on reality and real-time production information. Engelbrecht
reports NBL implemented Wonderware Historian and scripting
capabilities of Historian Client, both from Schneider Electric.
NBL configured a virtual enterprise consisting of two TOP servers
from Software Toolbox (www.softwaretoolbox.com) to balance the
facility's load of more than 100 PLCs and other systems, one Data-
Hub server, the Wonderware Historian, a main historian data ware-
house, and a web server. A secure HTTPS dashboard server lets
managers view daily and monthly sales and operational KPIs from
anywhere, and weekly, real-time stock volumes are sent to NBL’s
advanced planning system using Historian Client queries.
“We installed TOP server to retrieve data from our utility plants
and systems, and used the DCS to build a SCADA system," explains
Engelbrecht. "We then developed a web-reporting system for pro-
duction personnel and a dashboard system for management. Most
of our physical servers are now hosted in a virtual environment, and
this made things a lot easier, such as time synchronization between
the old Historian and the OPC server.” (Figure 2)
NBL's simplified data system lets qualified staff view utility
consumption and production information at the same time from
anywhere. They can also view daily, weekly and monthly con-
sumption information on the same platform. In the future, NBL
reports it will be able to switch off non-critical plant equipment to
ensure that maximum demand remains below target. Thanks to
its coordinating operations, Engelbrecht reports that NBL:
• Meets CO2 sales targets by optimizing sales versus storage
capacity and use;
• Complies with water-savings rules required by Windhoek
and local NamWater utility;
• Saves electricity with maximum demand implementation;
FASTER USER/DATA FACETIME
Though there's no one-size-fits-all solution when it comes to
knowledge on demand, there are several basic strategies for ac-
cessing more useful information faster for improved decision-mak-
ing. They include:
• Select HMI/SCADA software that can be displayed and scaled,
typically via HTML 5, on multi-sized tablet PCs, smart phones
and other handheld or mobile devices.
• Adopt easier-to-install and configure commercial, off-the-
shelf (COTS) software with fewer, time-consuming program-
ming/coding requirements and more point-and-click, drag-
and-drop and/or automatic capabilities.
• Combine or remove steps to information access with auto-
mated drivers, data conversion translation, polling, informa-
tion distribution and other functions that eliminate traditional
hurdles to access.
34 • MAY 2018 www.controlglobal.com
CT1805_28_35_CoverStory.indd 34
• Improves solar plant operational effectiveness;
• Enhances fault-finding with Historian Client and video play-
back functionality on the central DCS;
• Improves decision-making about plant requirements, such
as historical thermal energy data that NBL to reduce their
new BioMass boiler requirement from 8 MW to 5 MW;
• Views consumption data in conjunction with production in-
formation to improve loss control;
• Verifies KPIs of new plant and equipment, which makes His-
torian Client is critical to NBL’s business; and
• Achieves more accurate calculation and reconciliation of
project KPIs and ROIs.
Combine, multitask functions
Beyond seeking a single pane for multiple data streams, many
developers and users are merging monitoring and control func-
tions with increasingly software-based tools to remove old barri-
ers, and get more and better information in front of users faster.
For example, U.K.-based Anglo American plc's (www.an-
gloamerican.com) Minas-Rio project includes an iron ore mine
and enrichment unit in Conceição do Mato Dentro and Alvorada
de Minas in the state of Minas Gerais, a 529-km pipeline that
runs through 33 municipalities in Brazil's states of Minas Gerais
and Rio de Janeiro, and an iron ore terminal at Puerto de Açu
(Figure 3). However, these scattered facilities lacked data inte-
gration and operational standardization between them, so Anglo
American enlisted Rockwell Automation and system integrator
IHM Engenharia (www.ihm.com.br), part of the Stefanini Group.
Together, they combined Minas-Rio's controls into four main
parts, including the mine and enrichment plant, pipeline, filtra-
tion plant and port, each with its own controllers, servers, control
room and web-based operating stations. In all, the DCS handles
20,000 instruments, 800 motors and 1,500 intelligent instru-
• Seek single-pane-of-glass displays that provide information
from multiple sources on fewer interfaces, but at the same
time, preserve adherence to human-centered design prin-
ciples, so display don't become too cluttered for operators to
quickly understand what's happening to their processes.
• Combine and flatten network organizational structures where
appropriate, perhaps by using more Ethernet and Internet
methods, but do it securely by maintaining network segmen-
tation, firewalls, managed permissions, traffic monitoring,
anomaly detection and other cybersecurity solutions.
• Consider cloud, virtualization or other software as a service
(SaaS) programs to quickly relay and retrieve information
between plant, enterprise and other departments, but again,
establish and enforce security policies and procedures for all
related personnel, contractors and clients.
5/9/18 9:12 AM

ORE MOVING ASSETS
Figure 3: Anglo American's Minas-Rio iron ore mine, enrichment
plant, pipeline, filtration and port in Brazil use a PlantPAx control sys-
tem with integrated asset management to standardize and coordinate
operations, and generate graphs and reports more quickly. Source:
Anglo American and Rockwell Automation
ments networked via Profibus PA or HART. The asset man-
agement system, implemented in all parts of the DCS, assists
parameterization of the smart instruments, while the Plant PAx
control system gets the right data, graphs and reports to users
faster by integrating more closely with the process information
management system (PIMS) and the manufacturing execution
system (MES).
Likewise, Aimee Xia, product marketing manager for DAQ and
control at National Instruments (NI, www.ni.com), reports that NI
and Innovari Inc. (www.innovari.com) collaborated recently to help
utilities optimize their energy grids with edge control and cloud
analytics. "Innovari’s Interactive Energy Platform (IEP) uses artificial
intelligence, big data analytics, proprietary optimization routines
and grid-edge hardware built on NI technology to deliver capacity
and address grid demand," explains Xia. "With this technology, utili-
ties can focus edge-of-grid resources as opportunities, rather than
threats, and users as partners, rather than just bill-paying custom-
ers. Deploying IoT systems like Innovari’s IEP provides real-time,
deep situational awareness into the grid, helping to reduce the likeli-
hood and duration of power outages to optimize performance."
Innovari’s grid-edge hardware, called Energy Agents, attach to
participant buildings to deliver important two-way communica-
tion of energy information back to the utility, and balance edge-
of-grid resources for an optimized grid. The agents are designed
with CompactRIO single-board controllers and LabVIEW soft-
ware for distributed sensing and control.
For instance, NI reports that Kansas City Power & Light (www.
kcpl.com) uses IEP to gain real-time, deep, situational aware-
ness into its grid, reduced the likelihood and duration of power
outages, and gained more than 400 hours of operation per year
with the 15-MW project that engaged more 200 commercial and
industrial customers. Likewise, Mumbai-based electric utility
Reliance Infrastructure (RInfra) implemented IEP on commercial
buildings and mobile generators to stabilize its grid in stressed
www.controlglobal.com MAY 2018 • 35
CT1805_28_35_CoverStory.indd 35
KNOWLEDGE
regional areas. Since 2014, RInfra has responded to hundreds of
grid events using IEP, and has shown that the demand side can
be a real part of their resource plan year-round.
More recently, Jeff Phillips, section manager for software plat-
form monitoring at NI, reports that its LabVIEW software's usual
functions of hardware identification, configuration and docu-
mentation have been combined onto one software palette by the
SystemDesigner function in its new LabVIEW NXG software, and
redistributed by NXG's web module to a wider circle users.
"LabVIEW NXG lets users bring in rich media from added
ports, animate and document devices for a user's entire sys-
tem, and dive more quickly into an interactive workflow. This
lets them automate measurements, acquire data, apply analyt-
ics, and generate reports—all without having to write graphics
code," explains Phillips. "At the end of the workflow, NXG's web
module can build and distribute remote interfaces. This used to
be a big challenge, so we introduced the web module that has
APIs for using and sending data, a web server for deploying data
anywhere, and building and hosting interfaces. NXG has a more
modular code base, so a lot of other software packages can
soon be brought to market built on the same base."
Cloud closes gaps
Of course, the most transformative way to put useful data within
easier reach of users is to replace rigid hardware and dedicated
software with more flexible formats on virtual servers and cloud-
based computing services.
"The other benefits of simplifying on the
cloud is that users can do pilot projects
without major overalls or capital expendi-
tures, and this can cut time to market from
months and years to just weeks and days."
"Big customers can have their own cloud-style infrastruc-
tures with segregated servers on-premise or within larger cloud
services, which co-locate their data using enterprise-level ac-
counts that make sure it's not accessible or mixed with other
servers—but smaller companies can sign up for similarly reliable
and secure services," says ITG's Ruiz. "The other benefits of sim-
plifying on the cloud is that users can do pilot projects without
major overhauls or capital expenditures, and this can cut time to
market from months and years to just weeks and days. It's a lot
easier to subscribe for cloud computing space and data storage
than it is it buy hardware infrastructure, develop code and imple-
ment HMIs, SCADA and MES. Plus, the cloud can also make big
data, analytics, digital twins, machine learning and artificial intel-
ligence easier based on the data pulled in."
5/9/18 9:12 AM
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 SAFETY SYSTEMS

SIS: How testing impacts reliability

What is your proof test coverage, and why does it matter?
by William L. Mostia, Jr., P.E.

PROOF test coverage (PTC) of safety instrumented systems
(SIS), also known as CPT, has recently become an important topic
of discussion. PTC can be defined as the fraction of dangerous,
undetected failures that can be detected by a user proof test,
and is normally expressed as a percentage (%). In the past, it
was commonly assumed in calculation and in practice that proof
test coverage was 100%. However, not all proof tests are com-
prehensive, and the approval agencies often indicate that the
recommended proof test does not have a 100% PTC, new out of
the box.
The PTC concept applies to both partial and complete proof
tests, and PTC is calculated as shown in Equation 1:
fault, (1-PTC)% is the estimated fraction of dangerous, undetected
failures that are not detected by a user proof test. We're primarily
interested in (1-PTC)% because that's what we'll have to address
because the PTC of our devices affects the reliability of the SIS.
Effect of PTC on PFDavg calculation
Simplified equations can show the effect of PTC on calcula-
tions of the average probability of failure on demand (PFDavg)
for a single device. Without PTC, the PFDavg can be modeled as
shown in Equation 2:
PFDavg = ½ x λ DU x TI (2)

PTC% = (dangerous undetected failures detected by the user where:

proof test / total dangerous undetected failures) x 100  (1) λ DU = dangerous undetected failure rate
TI = proof test interval
The device dangerous failure regime (Figure 1) shows the dif-
ferent failure modes when proof test coverage is included. By de- When we factor in PTC, we can model the PFDavg in Equation
3 as:
Failure modes covered Failure modes not covered
Dangerous undetected by proof test by proof test
failures undetected
(1-PTC) by proof test [<------------------->] [<------------------------->]
λDU
PFDavg = PTC x 1/2 x λ DU x TI + (1-PTC) x 1/2 x λ DU x MT (3)
Dangerous undetected
failures detected
λDD PTC λ DU by proof test Here, mission time (MT) is the time interval where the danger-
ous failure modes that aren't detected by the user proof test can
PTC = λDU by proof test exist as latent, dangerous failures. In the PFDavg calculation, PF-
λ DD_U λDU total Davg accumulates over the MT period, which can be many mul-
Dangerous
failures detected Dangerous failures tiples of the proof test interval. One problem with mission time
by user diagnostics detected by device diagnostics is it can be longer than the demand interval. For example, for a
demand interval of once in 10 years, a mission time of 10 years
DANGEROUS FAILURES REGIME can expect at least one demand, and for a mission time of 20
Figure 1: The device dangerous failure regime shows the different years, two demands might be expected. Mission time increases
failure modes when proof test coverage is included. By default, (1- the PFDavg in the part of the PFDavg equation that's due to lack
PTC)% is the estimated fraction of dangerous, undetected failures of proof test coverage. In some cases, it can significantly affect
that are not detected by a user proof test. We are primarily interested the PFDavg and negatively affect the achieved safety integrity
in (1-PTC)% because that is what we will have to address. level (SIL).

www.controlglobal.com MAY 2018 • 37

CT1805_37_42 Feature2_SIS.indd 37 5/8/18 3:29 PM

 SAFETY SYSTEMS

Mission time is loosely related to the useful life of the device.

PFDavg target The useful life is typically the duration of the flat portion of the
device’s “bathtub curve” between the infant mortality stage and
the wearout stage of the device. So, MT should be less than or
PFDavg

Cumulative PFDavg equal to the useful life of the device. Mission time selection is
(1-PTC) due to (1-PTC) a function of the manufacturer’s specified useful life, expected
Test Time process service stresses, and ambient condition stresses. Typi-
interval
Mission time cal values for mission time are given in Table 1. At the end of the
mission time, a device should be evaluated for replacement or
PROOF TEST COVERAGE rebuilt based on local maintenance experience.
Figure 2: The reliability clock for dangerous failure modes tested by As we can see in Equation 3, the reliability clock for danger-
the proof test resets (PFDavg is zeroed) at the end of the proof test ous failure modes tested by the proof test resets (PFDavg) is
interval. The reliability clock for failure modes not tested during zeroed at the end of the proof test interval. The reliability clock
proof test continues to accumulate PFDavg over the full length of the for failure modes not tested during proof test continues to accu-
mission time, then the reliability clock resets if the device is replaced mulate PFDavg over the full length of the mission time, then the
(new condition) or rebuilt (good as new). reliability clock resets if the device is replaced (new condition) or
rebuilt (good as new) (Figure 2).
Equations 2 and 3 are mathematical models used to calcu-
Table 1: Useful life vs mission time
late PFDavg to determine the SIL level to satisfy the require-
Device Useful life1 Typical2,3 ments of IEC 61511. They are one of the engineering tools that
Transmitter 50 years 20 years help SIS engineers design a reliable SIS. Including the PTC in
Logic solver 10-20 years 15 years your SIL verification calculation will negatively affect the
PFDavg based on what PTC values and mission time are used.
Solenoid 3-10 years 5 years
If you compensate for the PTC by including the proof test cover-
Valve 10-15 years 5 years
age, you're potentially making your PFDavg more “accurate,” but
Note 1: From FMEDAs is your SIS more reliable? Essentially, including the PTC in the
Note 2: For devices that are rebuildable, this indicates when to look at calculation is recognizing that PTC must be evaluated for each
rebuilding the device. safety function, and must be improved so it doesn't significantly
Note 3: Typical values based on good SIS maintenance and operational affect the PFDavg calculation.
practices.
Four example, cases of complete safety instrumented functions

Table 2: Example cases

Base case 1 λ DU (/yr) TI (yr) PTC (%) MT (yr) Base case 3 λ DU (/yr) TI (yr) PTC (%) MT (yr)
Sensor 3.00E-03 1 0.9 15 Sensor 3.00E-03 1 0.9 15
Logic solver 1.00E-04 5 0.95 20 Logic solver 1.00E-04 5 0.95 20
Solenoid 1.67E-02 1 0.95 5 Solenoid 1.67E-02 1 0.95 5
Valve 1.67E-02 1 0.9 10 Valve 1.67E-02 1 0.7 10
PFDavg w/o PTC 1.85E -02 PFDavg w/o PTC 1.85E-02
SIL achieved 1 RRF = 54 SIL achieved 1 RRF = 54
PFDavg w/ PTC 2.98E-02 PFDavg w/ PTC 4.48E-02
SIL achieved 1 RRF = 34 SIL achieved 1 RRF = 22
Base case 2 λ DU (/yr) TI (yr) PTC (%) MT (yr) Base case 4 λ DU (/yr) TI (yr) PTC (%) MT (yr)
Sensor 3.00E-03 5 0.9 15 Sensor 3.00E-03 5 0.9 15
Logic solver 1.00E-04 5 0.9 20 Logic solver 1.00E-04 5 0.95 20
Solenoid 1.67E-02 5 0.95 5 Solenoid 1.67E-02 5 0.95 5
Valve 1.67E-02 5 0.9 10 Valve 1.67E-02 5 0.7 10
PFDavg w/o PTC 9.13E-02 PFDavg w/o PTC 9.13E-02
SIL achieved 1 RRF = 11 SIL achieved 1 RRF = 11
PFDavg w/ PTC 9.70E-02 PFDavg w/ PTC 1.05E-01
SIL achieved 1 RRF = 10.3 SIL achieved 0 RRF = 9.5

38 • MAY 2018 www.controlglobal.com

CT1805_37_42 Feature2_SIS.indd 38 5/8/18 3:30 PM

 with typical PTC and mission time values are provided in Table 2. 
We can also look at Equation 3 to see when the lack of PTC starts
to dominate the PFDavg (when (1-PTC) PFDavgMT is greater than
PTC x PFDavgTI) as a measure of importance. We can rearrange
Equation 3 by placing the two parts of the equation greater than or
equal to determine when the lack of proof test coverage (1-PTC) be-
comes dominant:

PTC x ½ x λ DU x TI ≤ (1-PTC) x ½ x λ DU x MT  (4)

(1-PTC) x MT ≥ PTC x TI  (5)

PTC
MT ≥ x TI  (6)
(1-PTC)

Table 3 provides the failure rates, PTC and mission time for the
example safety instrumented function shown in Table 4 and Figure
4. The sensor, logic solver and solenoid have fixed PTC and mission
times, and the logic solver proof test interval is fixed at five years. In
the examples in Table 4 and Figure 4, only the valve PTC and mission
time are allowed to vary.
In Table 4, it should be obvious that the “lack of proof test cover-
age” part of the PFDavg equation can begin to dominate the PFDavg
calculation at lower PTC. The lower the PTC and the shorter the proof
test interval, the quicker the (1-PTC) portion becomes dominant (more
than 50% of the calculation). This indicates that increasing the PTC is
a primary means of improving the reliability of the safety function. The
PFDavg has problems when the proof test interval approaches five MONITOR VISCOSITY SIMPLY
years and the mission time approaches 15 years.
SENSE MIXER MOTOR HORSEPOWER
Figure 4 plots the PFDavg vs test interval for various PTC. It's obvious
WITH UNIVERSAL POWER CELL
that, for the chosen typical cases, we can exceed the limit for SIL 1 when
we start to exceed about a three- to four-year proof test interval. This re- EASY INSTALLATION
• No holes in tanks or pipes
inforces the need to increase the PTC as high as is reasonably possible • Away from sensitive processes
to ensure we don't have untested failure modes hanging around. Even if VERSATILE
your SIL limit is achieved with low PTC, it doesn't mean you should ignore • One size adjusts to motors, from
small up to 150hp POWER
the PTC. SENSOR
• Works on 3 phase, fixed or variable
frequency, DC and single phase power
How can we raise PTC?
SENSITIVE
Proof test coverage comes from two primary sources: the manufac- • 10 times more sensitive than
turer/approval agency and user analysis. The manufacturer or approval just sensing amps

agency’s PTC is typically generated as part of a failure modes effects and CONVENIENT OUTPUTS
• For meters, controllers, computers MIXER
diagnostic analysis (FMEDA). In the FMEDA, PTC is typically assigned to 4-20 milliamps 0-10 volts MOTOR
each identified dangerous failure mode (e.g., 0, 60%, 80%, 90%, 99%)
and then summed up as part of the FMEDA analysis. This method can
identify dangerous failure modes that lack significant PTC, but it can also
result in no clear means to improve coverage if the PTC percentage can't
be easily broken down and addressed (e.g., a number of small PTC add-
ing over a large number of dangerous failure modes).
Users should ask the manufacturer for a breakdown of danger-
ous failure modes not fully covered by FMEDA’s recommended proof
test procedure. Even the recommended proof test procedure can be
improved to increase PTC, and some knowledge of dangerous failure
modes that they consider not testing can go a long way.
CALL NOW FOR YOUR FREE
30-DAY TRIAL 888-600-3247
www.controlglobal.com WWW.LOADCONTROLS.COM MAY 2018 • 39

CT1805_37_42 Feature2_SIS.indd 39 5/8/18 3:30 PM

 SAFETY SYSTEMS

The manufacturer’s PTC doesn't include the local plant and
process conditions, and it's up to the user to analyze their sys-
tem’s effect on the PTC. Essentially, the overall proof test cover-
age is the sum of the devices PTC plus the user's contribution to
the PTC. If you have a low PTC, there is something wrong with
the proof test procedures.
One concern with the manufacturer/approval agency’s num-
ber is whether the manufacturer has the capability to test for
dangerous failures. If not, users could potentially receive a de-
vice with the failure mode already active and waiting for the right
conditions. The user proof test procedure wouldn't catch the
failure at installation.
There are typically two recommended proof test procedures in
the FMEDA: a comprehensive proof test procedure and a partial
proof test procedure. The partial proof test procedure typically al-
lows the user to improve the PFDavg if it's done more often than
the main proof test, or to extend the proof test interval. However,
it doesn’t help you improve your PTC because you're just testing
known “proof testable” failure modes more often to improve your
Mission time 10 years
1.40E-01
1.05E-01
PFDavg
PFDavg. Using the partial proof test to compensate for the lack of
PTC is bad engineering practice.
User proof test coverage
In many cases, the user’s proof test procedure and testing prac-
tices can have a bigger effect on the PTC. The user proof test
coverage generally starts with the user performing a FMEDA/
FMEA on their SIS to identify all the dangerous system failure
modes (random, non-random and systematic). All the dangerous
failure modes should be evaluated for coverage by proof tests or
by user diagnostics. Doing a FMEDA/FMEA of your SIS as part of
your design is good engineering practice, and can be of benefit
in detecting unknown failure modes and weak spots in the de-
sign. If you don’t purchase certified equipment with a PTC pro-
vided, it is up to you to determine the PTC of the SIS devices.
Even with the manufacturer’s PTC %, without further informa-
tion from the manufacturer, reducing the PTC can be a matter of
speculation of potential untestable dangerous failure modes. As
a result, since we don’t have any information on the internal dan-
gerous failure modes, the user must black-box-model the device.
If information isn't available from the manufacturer on what the
significant, untestable, dangerous failure modes are, you may
want to consider selecting a different manufacturer.
Plant history of dangerous failures can be helpful, and un-
usual failures should be flagged as near-misses, analyzed to

7.00E-02 determine the root cause, and documented. One positive note is
PTC = 0.60 that once it’s done, 80% of the work is reusable when consider-
PTC = 0.70
2.00E-02 PTC = 0.80 ing a different device’s PTC.
PTC = 0.90 The FMEDA/FMEA should cover the whole safety function
PTC = 0.95
0.00E+00
from end to end. It should also include an analysis of potential
0 2 4 6 8 systematic failure modes, non-random failure modes (pluggage,
Proof test interval (years)
erosion, corrosion, stickage, etc.), and an analysis of the proof
test procedure’s coverage when not testing at operational condi-
Mission time 15 years
tions. If the proof test procedure is performed at ambient condi-
1.60E-01
tions when the process is down, consideration should be made
as to how to compensate for not testing at operational conditions.
1.20E-01
The FMEDA/FMEA may result in additional coverage in the proof
test procedure, additional user diagnostics, redundancy, proce-
PFDavg

8.00E-02 dural compensations to improve the PTC, and/or design revision.

PTC = 0.60
PTC = 0.70 One of the user areas for analyzing PTC involves testing for
4.00E-02 PTC = 0.80 non-random dangerous failure modes (e.g., degradation failure
PTC = 0.90
PTC = 0.95 modes). Examples of these are impulse line pluggage, valve ero-
0.00E+00 sion, valve corrosion and valve sticking. All of these are a func-
0 2 4 6 8
Proof test interval (years) tion of time, process and ambient conditions. Since the PFDavg
calculations assume that the dangerous failure rate is constant,
PFDAVG VS PROOF TEST INTERVAL this introduces an error. There is a need to have a new failure
Figure 4: Plotting the Table 4 data for a valve PTC at mission times of model to cover both the random and non-random failure modes
10 and 15 years, it is obvious that we can exceed the limit for SIL 1 (Reference 3). Users must consider these degradation failure
when we start to exceed about a three- to four-year proof test interval. modes when performing their FMEDA/FMEA.
This reinforces the need to consider proof test coverage and increase The analysis of the user-written proof test procedure should
the PTC until it is as high as reasonably possible to ensure that we do include evaluation of test steps or actions that can facilitate hu-
not have untested failure modes. man errors by the maintenance technician. While the failure of

40 • MAY 2018 www.controlglobal.com

CT1805_37_42 Feature2_SIS.indd 40 5/8/18 3:30 PM

 SAFETY SYSTEMS

the written proof test procedure to cover all the dangerous failure sites. Quantifying systematic failures that affect the PTC because
modes (systematic failure by commission, omission or error) can they're not random can be difficult, and trying to add them to
be a problem, so can failure of the technician to perform the random failures can be like adding apples and oranges. System-
test procedure properly due to lack of resources, complicated atic failures should be minimized in the proof test process, so
test procedure (too long, too hard, too confusing, etc.), or hu- they don't significantly contribute to the unreliability of the SIS.
man error (error is facilitated by procedure, lack of training, test Testing should be done for identified random and non-random
equipment error, incompetence, laziness, etc.). Operational and failures. Non-random failures such as erosion, corrosion and
maintenance discipline are important concerns in SIS testing. pluggage typically require inspection.
The best practice is to have a procedure for evaluating proof test
procedures, use it to improve your test procedures, and continu- Dealing with PTC problems
ously improve your proof test practices. It's common practice when there's a problem achieving the
A walkthrough review with the technicians should be per- desired SIL to improve the PFDavg by decreasing the proof test
formed to determine how the test procedure flows, where it's interval or performing online partial tests. If your SIL level is in
complicated, where it's unclear, etc. A job safety analysis (JSA) trouble because your PTC is too low, decreasing the test interval
should be done to ensure safe performance of the proof test. or applying partial testing of known failure modes can bring the
All test procedures should have a step signoff for the technician SIL level back under control, but you won't resolve the under-
performing the work, and double-check and signoff if necessary. lying problem of lack of PTC. The key question is, is your SIS
Once we've completed the FMEDA/FMEA and identified all more reliable when you do this? If the safety function has a PTC
the tested and untested-by-proof-test dangerous failure modes, of 90%, this means that 10% of the dangerous failure modes
determining the PTC becomes an issue of how to allocate the will not be tested over the mission time, which could be several
PTC. Many times, the decision is a qualitative estimate based
on values floating around in industry, user-determined values, or
Table 3: Device failure rates, coverages and mission times
values based on the analyst’s experience. The percent coverage
is commonly, simply an educated guess by the analyst because Device Failure rate, λ DU PTC Mission time
there's no recognized means to easily calculate PTC. Some users Sensor 3.00E-03/yr 0.90 15 years
and analysts assign coverage for specific proof testing actions in Logic solver 1.00E-04 0.95 20 years
a checklist, then add them up to get the PTC. An example of this
Solenoid 1.67E-02 0.95 5 years
can be found in Reference 1, which is given only as an example
Valve 1.67E-02 Varies 10 & 15 years
as the selected values may be different for different people or

Table 4: Mission time vs proof test coverage dominance

(1-PTC) (1-PTC)
PFDavg MT (yrs.) PFDavg w/ PTC & PFDavg w/ PTC
PTC TI (yrs.) dominance at dominance at
w/o PTC >50% point MT = 10 yrs. & MT = 15 yrs.
MT = 10 yrs. (%) MT = 15 yrs. (%)
95% 1 1.50E-02 19 35% 2.60E-02 44% 2.81E-02
95% 5 9.11E02 95 10% 9.47E-02 14% 9.68E-02
90% 1 1.50E-02 9 53% 2.97E-02 63% 3.39E-02
90% 2 3.66E-02 18 36% 4.65E-02 45% 5.07E-02
90% 5 9.11E02 45 18% 9.68E-02 25% 1.01E-01
80% 1 1.50E-02 4 71% 3.72E-02 79% 4.56E-02
80% 2 3.66E-02 8 56% 5.32E-02 65% 6.15E-02
80% 5 9.11E02 20 33% 1.01E-01 43% 1.09E-02
70% 1 1.50E-02 2.3 81% 4.47E-02 87% 5.72E-02
70% 2 3.66E-02 4.7 68% 5.98E-02 76% 9.84E-02
70% 5 9.11E02 11.7 46% 1.05E-01 56% 1.18E-01
60% 1 1.50E-02 1.5 87% 5.22E-02 91% 6.89E-02
60% 2 3.66E-02 3 77% 6.65E-02 83% 8.32E-02
60% 5 9.11E02 7.5 57% 1.09E-01 67% 1.26E-01

www.controlglobal.com MAY 2018 • 41

CT1805_37_42 Feature2_SIS.indd 41 5/8/18 3:30 PM

 SAFETY SYSTEMS

proof test intervals. Would you like to operate 24/7 with 10% of
your safety functions not verifiable? I can guess what the opera-
tor’s answer to this question would be.
Reducing the mission time will improve the PFDavg, but does
not address the primary problem of lack of proof test coverage.
It also requires us to replace or rebuild the device sooner and
before it reaches the end of the useful life, which represents an
undesirable cost.
If you don’t know all the dangerous failure modes, ask the
manufacturer/approval agency what they are; do a FMEDA/
FMEA to determine what local conditions, design, procedures
and practices contribute to PTC; and systematically reduce un-
failure modes are being tested, or user diagnostics.
PTC is an important parameter to consider in the reliable de-
sign of SIS systems. It's not sufficient to just plug it into the
PFDavg calculation, make your SIL, and go on, happy as a clam.
[I want to thank Erik Mathiason, Jessica Lo, and Nicholas
Wienhold of Emerson for an excellent discussion, and Steve
Gandy of exida for additional information on the subject.]
Frequent contributor William (Bill) Mostia, Jr., P.E., principal, WLM En-
gineering, can be reached at wlmostia@msn.com.
References:

tested dangerous failure modes to an acceptable level (typically 1. “ Proof Test Procedure Effectiveness on Safety Instrumented Systems,”
greater than 95%). Careful selection of instrumentation with high Mohamed Abdelrhafour, Naresh Bajaj, Stephane Boily, 2012 Safety
PTC, with advanced diagnostics, automatic online proof test, Control Systems Conference.

etc., can reduce the analysis load to determine PTC and result
in a more reliable SIS. Doing a FMEDA/FMEA on all your safety
instrumented functions is good engineering practice, and can
detect unrecognized dangerous failure modes and weaknesses
that should be corrected by the design, how well your dangerous
2. “Are Your Safety Instrumented Systems Proof Tests Effective?,” ValveMag-
azine, Loren Stewart, June 2017.
3. “Novel Model of Proof Test Coverage Factor,” György Baradits, János
Madár, János Abonyi, 10th International Symposium of Hungarian Re-
searchers on Computational Intelligence and Informatics.

Focus on the essentials

Looking for a refresher course? Need to get back to basics?

We’ve brought together all of our most in-demand
content into one complete training resource.
www.controlglobal.com/essentials

CT1805__EssentialsAd_FINAL_1_2_H.indd 2 5/8/18 2:59 PM

42 • MAY 2018 www.controlglobal.com

CT1805_37_42 Feature2_SIS.indd 42 5/8/18 3:30 PM

 DIMENSIONLESS
GROUP MODELS
How insight and a little math can simplify design of experiments for modeling and optimization.
by R. Russell Rhinehart
OFTEN, we desire a mathematical model of a process or prod-
uct. For example, I've needed to know: How does waste genera-
tion depend on the processing properties and controller coef-
ficient values during a product changeover? How does column
flooding depend on fluid properties and operating conditions?
How does a particle filter performance depend on its structure
properties?
Once we have an adequate model, it can guide our choices
to improve design and operation. It may be possible to obtain a
phenomenological model, but in each of the cases mentioned
above, the complexity of the mechanisms and associated equa-
tions have been beyond my reach. When this happens, we need
to generate empirical models—models from data. There are
many approaches. I recommend you consider using dimension-
less group models.
For this article, I’ll use flooding in a packed column absorber
as an example. This is not an article about unit operation. It’s
about dimensionless group models, a practicable and effective
approach to modeling complex phenomena. However, a brief de-
scription of the process and modeling objective is necessary.
Gas absorption
In a gas absorption column, gas travels upward through a
packed column. The packing is generally open, but it creates a
tortuous path splitting and recombining the upward flowing gas.
Liquid enters the top of the column, falls by gravity, and splashes
downward, coating, then dripping off of the packing and splash-
ing on the packing below. The column is not filled with liquid.
Most of the space within the column is upward flowing gas. The
liquid is raining and splashing as it falls downward through the
www.controlglobal.com MAY 2018 • 43
CT1805_43_45_Feature3.indd 43
packing matrix. The objective of the packing is to create liquid-
gas surface area, so the liquid can absorb a component in the
gas. The liquid cleans the gas.
Such absorption unit operations (and their converse, strip-
ping) are common in the chemical and fuel processing indus-
tries, and flooding is an operating issue in the unit.
In flooding, sections of the column undesirably fill with liquid.
Here’s why: if the gas is flowing upward too fast, then small liquid
droplets that should be falling are blown upward, and extra liquid
accumulates on the packing above. Eventually, the lift of droplets in
the gas makes the gravity rate-of-fall of the liquid within the column
less than the flow rate entering the column. Then the column fills
up with liquid, and the gas becomes bubbles rising within the liquid.
This flooding has many undesirable aspects.
This modeling exercise is to determine a mathematical relation
between liquid and gas properties to indicate the non-flooding, safe
operating region. Data will be generated on a pilot-scale unit by
selecting gas, liquid and operating conditions, progressively step-
ping up the gas flow rate (G), and observing the pressure drop (dP)
of the gas through the column. At each step increase of G, this dP
increase is larger, but at flooding, dP does not asymptotically ap-
proach a steady value—it accelerates in an open-loop, unstable
manner. When this is observed, flooding will be declared.
Developing a model
Start by asking the generic question, “What influences might
affect the outcome?” For the column flooding, it is “What condi-
tions might affect flooding, and thereby define a limit on the gas
flow rate, G?” Here are some: Liquid flow rate, L, and the liquid
properties of density, ρL, and viscosity, µL; column diameter
5/8/18 3:31 PM
 MODELING
16000
15000
14000
13000 Flooding region
12000
Re air
11000
10000
9000
Non-flooding region
8000
7000
6000
2500 3500 4500 5500
Re water
FLOOD PREVENTION AND RESPONSE
Figure 1: Reynolds number (Re) data from a pilot-scale packed tower
absorber (circles) define a model (solid line) with 95-percentile limits
indicated by dashed lines. Source: Trey Holloway, Jeffrey Kibler and
Callouts
Zach Spiegel
[remove title from figure]
Label Y axis “”
(or some other characteristic dimension that restricts the flow
[label X axis “”]
paths); and gas properties of density, ρG, and viscosity, σG. Since
the column properties (length, diameter, packing type) will not
be changed, we're left with G = f(L, ρL, µL, d, ρG, σG ). In general,
this can be expressed as a response variable y, which is a func-
tion of the six influences, x1, x 2, …, x6. Of course, you might be
considering the model of another case, in which there could be a
larger or smaller number of influences.
A classic statistical approach to developing empirical models is to
express the cause-and-effect relation as a polynomial model. Justi-
fication for this is grounded in a Taylor Series expansion of any func-
tion. If a quadratic model has adequate functional relations, then
the model has this form:
Y = a + bx1+ cx2 + dx3 + ... + jx12 + kx22
+ lx32 + ... + rx1x2 + sx1x3 + ... + tx2x3 + ...
The first coefficient, a, is the intercept. Coefficients b, c, d, and
so on, represent the linear terms. Coefficients j, k, l, and so on,
represent the homogeneous quadratic terms; and r, s, t, and so on
represent the cross-product terms. In this quadratic model, with the
six influence variables, there are 28 coefficients. A rule of thumb
in empirical modeling is that there should be three independent
experiments for each coefficient, so here, about 84 independent
experiments. That's a lot. And still, the quadratic functionality may
not be adequate—more terms may be needed. Further, consider-
ing how to independently adjust viscosity and density, perhaps by
operating pressure and temperature, suggests some very expensive
experimentation.
Here is where dimensionless group models save the day.
You're probably familiar with many dimensionless groups. The
Mach number is the ratio of speed in air to the speed of sound.
The Reynolds number is the ratio of momentum advection to dif-
44 • MAY 2018 www.controlglobal.com
CT1805_43_45_Feature3.indd 44
fusion, which is the determining factor as to whether flow is tur-
bulent or laminar. Dimensionless groups are ratios and products
of constituent variables in which the units cancel. For example,
the Reynolds number is a characteristic length times velocity
times density divided by viscosity:
Dµρ
Re =
µ
Using the classic “English” units of feet, feet per second,
pounds mass per cubic foot, and pounds mass per foot-second,
6500 7500 it is easy to see that the units cancel, and that Re is dimension-
less. Regardless of the system of units you might choose, Re is
dimensionless and retains its same numerical value.
In this particular example, the six variables are combined into
two dimensionless groups. (To see how, look for instruction on
the Buckingham Pi method, although intuitive arrangements are
often fully adequate.) One is the Reynolds number for the liquid:
DuLρL
ReL =
µL
and the other for the gas:
DuG ρG
ReG =
µG
Mathematical analysis indicates that the model can be ex-
pressed as just the two variables:
ReG = f (ReL)
Here, the independent aspects of density, diameter and vis-
cosity are combined, and it doesn’t matter what the constitutive
variable values are; it's the combined impact that's relevant, and
the dimensionless groups define that relation.
Now, if a quadratic relation was acceptable, one might use:
ReG = a + b (ReL) + c (ReL)2
This is a great reduction in the number of model coefficients,
work in generating coefficient values, and experimental costs
to generate the data. However, the relation might not be well
described with a quadratic, and experience has shown that a
power law model is often better:
ReG = a (ReL)p
This power law model is more flexible, and only has two coef-
ficients. Using the heuristic of three independent experiments
per coefficient, only six experiments are now desired. Further,
the individual values of viscosity and density are not important.
Since the value of the dimensionless group is what is important,
it doesn't matter what variable is used to change the ReL value
to generate experimental data; what matters is the ReL value. So,
5/8/18 3:31 PM

although there must be an assessment of viscosity and density
to calculate ReG and ReL , the experimental design can be fully
defined by simply changing the liquid and gas flow rates, again
providing a great convenience.
Data and model
The open circles in Figure 1 reveal data from the pilot-scale packed
tower absorber from our undergraduate chemical engineering lab
at Oklahoma State University. The column is about 8 in. in diameter
with about 12 ft. of packed length over two sections. The data are
from air-water trials generated by Trey Holloway, Jeffrey Kibler and
Zach Spiegel in the spring of 2014, and appreciatively used with
their permission.
The solid curve represents the model. Since there is uncer-
tainty in both the independent and dependent variables, coef-
ficients were adjusted to minimize the squared normal residual
(this is variously termed total SSD or perpendicular SSD), not the
conventional vertical SSD. I used Akaho’s method to approxi-
mate the normal SSD as an idealization of a maximum likelihood
method. It accounts for variability in both the x and y variables.
The model is the solid line, and the 95-percentile limits of the
model due to variability in the data (calculated by a technique
called bootstrapping) are indicated by the dashed lines.
If you're seeking more information (including model valida-
tion, experimental design, total least squares, and bootstrapping
to determine the confidence limits of a regression model), refer
to my book: Nonlinear Regression Modeling for Engineering Ap-
plications, John Wiley & Sons, 2016, ISBN 9781118597965. Di-
rections on the Buckingham Pi method to develop dimensionless
groups are easily accessed in Internet searches. A great starting
place is https://en.wikipedia.org/wiki/Buckingham_%CF%80_
theorem.
The pilot-scale modeling invites a number of observations:
1. The data reveals a hyperbolic sort of relation. The value of
coefficient p in the model is -0.869, which is definitely nei-
ther linear nor quadratic, which indicates the simplicity of the
power law structure in finding the right functionality over the
classic power series representation.
2. Although the experimentation led to selecting ReL as the inde-
pendent variable and ReG as the dependent variable, the reverse
choice would have been as easily made. In some years, the stu-
dents set the water flow rate and increase the air flow rate to the
flooding point. The user choice does not specify a cause-and-
effect mechanism.
3. The fundamental nature of dimensionless groups in modeling
can be revealed in several ways. Here, students used the Buck-
ingham Pi method. Classically, scaling of a differential equation
to make each term non-dimensional reveals the groups, which
also reveals that the coefficients to the equation (hence its solu-
tion) are not fundamentally the individual primitive variables,
but are the ratios and products that create the dimensionless
groups.
www.controlglobal.com MAY 2018 • 45
CT1805_43_45_Feature3.indd 45
MODELING
4. T he utility of dimensionless analysis is evidenced in the de-
sign scale-up and model scale-down classic in fluid dynamics
and design of ship hulls, furnaces, airplanes and automo-
biles. The reader should also be familiar with charts that use
dimensionless variables to unify similar trends to a common
graph. These include fluid drag factor response to Reynolds
numbers, and cooling rate response to Fourier number. And,
many of our fundamental design models are developed with
dimensionless groups: Consider the Dittus-Boelter relation.
5. Often, conversion factors need to be included to make terms
dimensionless. These include the often missing gc in F = ma
and the various Bernoulli relations, the conversion equivalents
of mechanical to thermal energy, or of centipoise to system
units of the other variables.
The results of the first modeling attempt
will reveal aspects that shape the second
attempt. But, of course, this is true
for any approach to modeling.
6. T his method doesn't mean that you've included all of the
relevant variables, and excluded irrelevant variables. Intuitive
guidance and progressive insight as you develop the models
is important. The results of the first modeling attempt will re-
veal aspects that shape the second attempt. But, of course,
this is true for any approach to modeling, whether it be phe-
nomenological, classic empirical or big-data.
7. Any dimensionless number can be expressed in any number of
ways, for instance, multiplying and dividing the classic Re expres-
sion by cross sectional area, A = πD 2 / 4, and combining Aup to
represent mass flow rate, M, results in Re = (πM) / 4Dμ. Note
that π is dimensionless, and Re can be expressed as the product
of two dimensionless groups, Re = (π)(M / 4Dμ). And any dimen-
sionless number can be inverted and redefined as “my” number,
My = 4Dμ / M. You might devise such a number, which might
not be easily recognized as the reciprocal of the classic Reynolds
number. My experience indicates that initially devised dimen-
sionless groups can usually be rearranged to classic dimension-
less groups: Reynolds, Nusselt, Froude, Galileo, Fourier, Eckert,
Peclet, Sherwood, etc.
8. The column internals (packing supports, flow redistributors
and such) will have a significant impact on the flooding curve,
making the data-regressed model a unit-specific model.
9. The power law relation is not derived from fundamentals. It
has been found to provide adequate models from diverse ap-
plications. It is a useful tool. Sometimes extrapolation of the
model to very large or small values provides insight about al-
ternate model forms or segregated regions of validity.
R. Russell Rhinehart, engineering coach, R3eda, North Carolina State Uni-
versity, can be reached at russ@r3eda.com.
5/8/18 3:32 PM
 ASK THE EXPERTS

Polymer reactor level measurement

Is it wise or dangerous to back up differential pressure with nuclear instrumentation?

This column is moderated Q: Our project involves a reactor 5 m in diam- this a batch or a continuous reactor?
by Béla Lipták eter and about 25 m in height. Presently, its If it's a batch reactor and if you have good
(http://belaliptakpe.com/), level is being measured by a differential pres- flowmeters on the charging side, you might not
automation and safety sure (DP) gauge, capillary type, and I was told to measure the level at all, but just depend on the
consultant and editor of the install, in addition, a radiation level detector. Is batch flowmeters for recipe formulation and add
Instrument and Automation the addition of a radiation-type unit advisable, a high-level interlock for safety. If the accuracy
Engineers’ Handbook and what are the advantages and disadvantages or reliability of the flowmeters is insufficient, and
(IAEH). If you have an of these two options? Is the radiation-type a bet- if the full weight of the reactor is more than four
automation-related question ter choice? Can radiation sensors be dangerous times its empty weight, you might put the reactor
for this column, write to if the reactor walls are thick and hot? on load cells.
liptakbela@aol.com. RAHIM SALAMAT To consider nuclear sensors, you need an
rahim1356@gmail.com NRC license, an on-site certified radiation of-
ficer, and if you have heavy coating, it will still
A: For a couple of decades, I was the chief affect accuracy. In addition, you must also ar-
instrument engineer at C&R, and during that range for source disposal. For DP, extended dia-
period, we must have designed nearly 100 poly- phragms (Figure 1) with equal-length capillar-
mer reactor control systems. So your question is ies and temperature compensation for ambient
familiar, but it is lacking the key information: is temperature and sun exposure variations can
also give reasonable performance.
While in batch reactors, the residence time is
Capillary measured by a timer; in continuous reactors, resi-
dence time is a ratio of reacting volume divided
X X X by the outflow (V/F), where V is a function of level.
X Therefore, in controlling continuous polymer reac-
tors, level measurement is not optional, but a must.
Filled elements Figure 2 illustrates such a control system.
X The selection of the level sensor should con-
To controller sider the comments I made in connection with
the batch reactors, and some people might also
X
consider the use of self-diagnosing laser (up to
300 °F, if the transmittance in the vapor space
X and the reflectance of the polymer surface is
acceptable) or noncontacting and self-diagnos-
ing radar (up to 500 °F, if there is no coating,
X X
condensation or crystallization on the antenna).
X X BÉLA LIPTÁK
Differential pressure transmitter liptakbela@aol.com

EXTEND THE SEALS A: The biggest reasons not to use radioactive

Figure 1: In differential pressure (DP) applications,
extended diaphragm seals can prevent plugging, and
with equal-length capillaries and temperature com-
pensation for ambient temperature and sun exposure
variations, DP can give reasonable performance.
measurement are:
1. The instrument rays have to shine through
the walls of the reactor, so the receiver can
absorb them, but the radioactive beam is
not concentrated in one point like a laser, so

46 • MAY 2018 www.controlglobal.com

Set
Production rate
FRC

Ratio setting Manual setting

CT1805_46_47_ATE.indd 46 X 5/9/18 9:13 AM
FY of adjustable

sometimes you will have scatter-
ing of the radioactive beam, which
could harm personnel.
2. Generally, reactors have extremely
thick walls requiring a very high-
energy source, which, over time,
may make the reactor walls radio-
active around the the beam area.
3. Most radioactive systems need to
be close if not in contact with the
surface of the walls of a hot reac-
tor. This could damage the source,
which could cause radiation to leak.
ALEX (ALEJANDRO) VARGA
vargaalex@yahoo.com
A: I have not come across DP level
used in polymer reactors. Even with de-
signs from 40 years ago, we were using
nucleonic/radiation level. However, that
is a small sample of the total number of
polymer reactors in the world.
Most of the reactors I worked with
did not use level. They just batched in
a certain quantity and called it good.
In the cases I'm familiar with, there
is no real benefit to knowing level in
a batch reactor. Perhaps most of the
modern polymer reactors are now
semi-continuous.
There are regulatory difficulties in-
volved with nucleonic installations. In
the jurisdictions I know about, you have
to have a trained and certified radiation
officer on-site. There is also a percep-
tion that such devices are very danger-
ous and difficult to monitor/maintain/
control.
SIMON LUCCHINI, CFSE, MIEAUST CPENG
(AUSTRALIA)
Chief controls specialist, Fluor Fellow in
Safety Systems
Simon.Lucchini@fluor.com
A: I lived with this question for 15
years. The only successful approach
was a blow-back dip tube. This did
plug now and then, and we used a long
rod with a drill bit welded to the end to
clear it. It plugged because the blow-
back air was supplied at too low a pres-
www.controlglobal.com MAY 2018 • 47
CT1805_46_47_ATE.indd 47
ASK THE EXPERTS
Set
Production rate
FRC
Ratio setting Manual setting
X
FY of adjustable
FT residence time (V/F)
HIC
Feed A
FRC
FT V/F
M LT V LY
Feed B
F
SP
FRC
FT
Product
CONTINUOUS REACTOR CONTROLS
Figure 2: In continuous reactors, residence time is a ratio of reacting volume divided by the
outflow (V/F), where V is a function of level, and maximum production rate equals maximum
volume divided by minimum residence time. Therefore, in controlling continuous polymer
reactors, level measurement is not optional, but a must.
sure. The reactor normally ran at a high supply regulator has downstream pres-
vacuum, but we discovered (by watch- sure protection, and when the down-
ing the operators late at night) that stream rises, the regulator vents and
when the valves became plugged, the allows backflow.
operators would turn off the vacuum It took a long time to discover this.
and pressurize the vessel until the valve Our installation did have a radioactive
plugging cleared. And the blow-back source in the agitator shaft, and the
tube was filled with polymer. detector outside. A "micro-micro-am-
The proper installation sequence meter" amplified the signal. Most of the
would be: air supply header with filter time it worked well. The problem was
(not regulator) > check valve > needle the way the various parts were electri-
valve > rotameter > dip tube. cally grounded, so it appeared to be
The polymer would not be pushed unreliable. Any welding in the building
into the dip tube because the pressure caused a panic.
downstream of the needle valve would CULLEN LANGFORD
rise to block backflow. The standard air cullenl@aol.com
5/9/18 9:18 AM
 ROUNDUP

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CL-10 G Series level detectors 1100 Series magnetic level gauge has
handle precipitated and fine, a Vista lenticular lens indicator with an
lightweight chemical powders ultra-wide viewing angle that recently
with bulk density as low as 1 received U.S. Patent No. 9638565B2.
lb/ft3, which keeps them ac- Vista uses a curved polycarbonate lens
curate and consistent in dusty with flattened ridges on the inside, so
environments and applica- light enters through the front, reflects
tions that can bridge and “pack-out,” such as food products (12x off the colored flippers, and is redi-
to silk sugar) and heavier bulk solids in the 10-15 lbs/ft3 range. rected in all directions by the patented
Specialized units can serve in temperatures exceeding 300 °F. CL- lens, allowing for a 200° viewing angle
10 G level detectors are factory calibrated, and are approved for that's reported to be the industry's larg-
Class I, Group D; Class II, Groups E, F & G; and Class III services. est, eliminating the need for armored sight-glass devices.
AUTOMATION PRODUCTS INC., DYNATROL DIVISION SOR CONTROLS GROUP LTD.
800-231-2062; www.dynatrolusa.com www.sorinc.com/products/product-category/magnetic-level-indicators

48 • MAY 2018 www.controlglobal.com

CT1805_48_50_RoundUp.indd 48 5/9/18 9:20 AM


SAFETY SWITCH IS SIL 2, IEC 61508 COMPLIANT
IntelliPoint RF certified SIL 2 safety
point-level switch achieves overfill pro-
tection with advanced RF admittance
for applications requiring safety instru-
mented functions (SIF). SIL IntelliPoint
RF has measurement probes for any pro-
cess application, meets API 2350 Over-
fill Protection standards, achieves SIL 3
with a redundant switch, and has Auto
Verify circuitry that self-tests the system.
It also complies with IEC61508-2, and has worldwide hazardous
area approvals, including FM, FMc, ATEX and IECEX-pending.
AMETEK DREXELBROOK
215-674-1234; www.drexelbrook.com
SIL 2 FLOW, LEVEL SWITCH
FlexSwitch FLT93S flow/level/
temperature switch is a dual-
function, insertion-style device
with advanced thermal dispersion
sensing technology, and it's SIL
2-rated. FLT93S operates over a
wide setpoint range in hydro-
carbon liquids from 0.01 to 5.0 fps (0.003 to 1.5 mps); in gas/
air from 0.25 to 120 sfps (0.08 to 37 smps); and in water from
0.01 to 0.3 FPS (0.003 to 0.9 MPS). Level/interface accuracy is
±0.25 in. (±6.4 mm), and measurement repeatability is ±0.125
in. (± 3.2 mm).
FLUID COMPONENTS INTERNATIONAL
800-854-1993; www.fluidcomponents.com
TWO TRIOS OF 24-, 80-GHZ TRANSMITTERS
Optiwave two-wire, loop-
powered, FMCW radar level
transmitters have added three
24-GHz (5400/6400/7400
models) and three 80-GHz de-
vices (3500/6500/7500 mod-
els). Optiwave's connections
start at ¾ in. They have lens, drop and horn antennas. Their
measuring range is up to 100 m (328 ft.) from antenna edge
with accuracy of ±2 mm (±0.08 in.). Optiwaves can measure
products with dielectric constants as low as 1.4.
KROHNE INC.
http://us.krohne.com/en/products/level-measurement/non-contact-level-
transmitters
www.controlglobal.com MAY 2018 • 49
CT1805_48_50_RoundUp.indd 49
ROUNDUP
RADAR FOR AGRESSIVE MEDIA
Type 8136 is a non-contact radar device
for continuous level measurement that
comes in two versions: one has an en-
capsulated horn antenna for level mea-
surement of aggressive liquids in small
vessels, while the other has a plastic horn
antenna for measurement in open flumes
or gauge measuring waters. It also fea-
tures level measurement up to 20 meters
with 4-20 mA/HART–two wires; adjust-
able via display, key operation or PC with DTM; ATEX approvals;
and insensitivity to temperature, pressure, etc.
BURKERT FLUID CONTROL SYSTEMS
949-223-3100; www.burkert-usa.com
INFRARED LASER FOR REFLECTIONS
OptioLaser S300 liquid laser uses
infrared 905 nanometer (nm) tech-
nology to detect all types of liquids,
regardless of their dielectric prop-
erties. Its narrow beam divergence
measures through grates and nar-
row passages, and even next to flat
walls. OptioLaser S300 uses an
infrared, low-gain GaAs laser diode with light energy of 905 nm;
operates without the need of any calibration; is unaffected by
background noise and vapor pressure; and handles low dielec-
tric substances and acoustically absorbent materials.
HAWK MEASUREMENT SYSTEMS
888-429-5538; www.hawkmeasure.com
SAFE MAGNETIC LEVEL
KM26 magnetic level gauges are cus-
tom engineered to meet ANSI/ASME
B31.1, B31.3 requirements, and offer
continuous total and/or interface level
indication for a variety of liquids, includ-
ing corrosive, flammable and toxic ma-
terials in industries such as oil and gas,
chemical and power generation. Inte-
grating it into the range of reliable level
transmitters and point level switches
provides one platform that's reported to save money and
space, reduce weight, minimize leaks and increase safety.
ABB INC.
800-829-6001; www.abb.com/level
5/9/18 9:20 AM
 ROUNDUP

ULTRASONIC, VIBRATING FORK, BUOYANCY HIGHER ACCURACY RADAR LEVEL

Flowline level sensors now in- Extensive testing has proven an
clude: LU10 series ultrasonic accuracy of ±1 mm can now be
level switches, available in two specified for the VegaPuls 64, an im-
styles and intrinsically safe: provement over the original accuracy
LZ12 vibration fork level switch specification of ±2 mm. The level
for reliable level detection of instrument is reported to be the first
dirty liquids; LP15 capacitance through-air radar for continuous liq-
level switch for non-metallic tanks; LV10 general-purpose buoy- uid level measurement that operates
ancy level switch for reliable liquid level detection of relatively with a transmission frequency of 80
clean water and chemical solutions; and Switch-Pro remote, GHz. Its small antenna—approximately the size of a quarter—al-
general-purpose level controllers offered in three configurations lows it to be used in small tanks and compact vessels where ra-
for alarm, pump and valve control. dar technology has previously been unsuccessful.
AUTOMATIONDIRECT VEGA AMERICAS INC.
www.automationdirect.com/level-sensors 513-272-0131; www.vega.com/radar

SMARTER, NON-CONTACT RADAR FLOAT PRINCIPLE FOR RELIABILITY

Pulsar Model R86 is designed to MM level sensor/transmitter deliv-
change how users think about non- ers constant level indication/moni-
contact radar transmitters. Its 26- toring, regardless of conductiv-
GHz radar signal has a smaller wave- ity, pressure and temperature. Its
length, resulting in smaller antennas simple design, based on the float
and improved 1-mm resolution. With principle, ensures reliability. Avail-
improved performance, circular able materials include stainless
polarization, high-temperature/high- steel, PVC, PP or PVDF. It comes in
pressure antennas, and advanced models up to 236 in. for pressures
diagnostics, R86 offers a smarter, up to 435 psi and for temperatures up to 266 °F. The fittings are
more reliable solution for process either ANSI flange or NPT. Options include interface measure-
level applications. ment, Pt100 or a temperature switch.
MAGNETROL INTERNATIONAL KOBOLD INSTRUMENTS INC.
www.magnetrol.com 412-788-2830; www.koboldusa.com

PARABOLIC ANTENNA FOR RADAR OPTICAL LEVEL SENSOR IN PLASTIC

Model W-100 PiloTrek 25-GHz VP02E is a photoelectric level
pulse radar level transmitter sensor for liquid level detection,
has a 148-mm (5.8 in.) diam- and its Type VP is an optical
eter parabolic antenna with a 6 level sensor with unmodulated,
in., ANSI R.F. flange, or it can infrared light for detection of
use another suitable mounting liquids. Manufactured by Carlo
flange. The compact, parabolic Gavazzi, it's fitted with a built-
antenna is rated for 1.4 dielectric measurements at 49 ft. and up in amplifier. VP02E's transmit-
to 75 ft. for 1.8 dielectric media. Model W-100’s design is suit- ter and receiver are completely self-contained in a solid plastic
able for working pressures of 363 PSIG at 248 °F. It also has a housing designed for mounting into a container wall. VP02E is
0.04-in. resolution, minimal 15.3-in. transition zone, and tight 6° also available in a polysulfone housing that's resistant to most
beam angle for installation in vessels with internal false targets. acids and bases.
NIVELCO PROCESS CONTROL CO. NEWARK ELEMENT 14
630-848-2100; www.nivelco.com 800-463-9275; www.newark.com

50 • MAY 2018 www.controlglobal.com

CT1805_48_50_RoundUp.indd 50 5/9/18 9:20 AM

 CONTROL EXCLUSIVE

Marshalling system supports configurable I/O

Plug-in I/O accessories easily accommodate late, binding changes.

THE introduction of configurable I/O has given users a new

world of opportunity and advantages. With this evolution
though, there remain traditional requirements and challenges
like safely marshaling signals, converting voltages and simplify-
ing loop checks.
“The Honeywell Universal I/O solution is fantastic because
it’s software- rather than hardware-based, so people who want
to can keep their marshalling,” says Michael Hardman, product
specialist, Phoenix Contact. But traditional marshalling requires
I/O-specific components for each point, such as relays, fuses
and isolators, which traditionally must be individually wired.
Phoenix Contact’s new VIP-ER system allows users to con-
figure the wiring functionality for any type of signal, and easily
choose or change the conditioning and protection features via
plug-ins at the marshalling base. Engineers can plan the overall
I/O count during FEED stage, and assign input/output accesso-
ries (IOAs) during installation to easily accommodate late binding
project changes.
“Once you know the number of points, you select the num-
ber of bases (eight points per base), and marshal to the VIP-ER
base. Then, up until the last minute, you can slide in the appro-
priate input/output accessory (IOA),” Hardman says. “When you
know exactly what type of I/O—analog, digital, temperature—
then you use the IOA with the appropriate functionality for the
signal type.”
IOA options range from passive feed-through, 24 V to 230
V relay, fused with test point and disconnects, to HART-trans-
parent current isolators, so each channel can be individually
matched to the programmed I/O function. Each channel also
can be wired for compatibility to two-, three- and four-wire field
devices, as well as provide multiple shield options. The IOAs
are equipped with a hinged cover to allow access to removable
fuses, signal disconnects, and test points for quick and easy sys-
tem validation and maintenance.
Along with adding project flexibility, VIP-ER decreases inven-
tory overhead by providing a common base that spans 24 V –
240 V. Its agency approval package allows worldwide use, and
though it’s designed for Honeywell Universal I/O, it’s compatible
with configurable I/O-based controllers from any manufacturer.
“You can place any IOA in any channel without lifting any
control wiring,” Hardman says. “So you can have all the wiring
done—the base wired up—and both the type of I/O and the
type of marshalling can be switched at the last minute. You can
change the wiring functionality as easily as you change I/O type
QUICK CHANGE ARTIST
Phoenix Contact’s VIP-ER system with Input/Output Accessories
provides wiring functionality to match the flexibility of software-
configurable I/O.
with Universal I/O. The ability to easily change wiring functional-
ity at the last minute and reduce inventory requirements allows
for a significantly shortened project lifecycle.”
Each IOA variant is equipped with a unique pair of male/fe-
male plugs, preventing a different IOA from being installed by
mistake. “The IOAs have keys, so once they're snapped in, only
the same kind will fit in that slot unless the key is pulled out,”
Hardman says. “You can easily pull it out to make a change, but
it requires a conscious decision, so the wrong IOA won’t be used
by accident.”
Accessory cables make the solution fully pluggable to the
Honeywell DCS. “You can use a Honeywell-specific cable, or an
open-ended cable to a different controller, now on the market or
yet to come,” Hardman adds. “Today, you can migrate an older
PLC or DCS using mixed I/O, or use VIP-ER as a junction to a
new controller.
“No matter how large or small, most projects will have last-
minute, late binding changes. VIP-ER helps simplify and reduce
the domino effect from changes because the terminal blocks,
fuse blocks and relays don’t have to be swapped out. You can
just switch the IOAs.”
For more information, see www.phoenixcontact.com/viperioa.

www.controlglobal.com MAY 2018 • 51

CT1805_51_ProdExclusive.indd 51 5/9/18 9:22 AM

 CONTROL EXCLUSIVE

More powerful programming package

Real-time control, HMI and data handling are now in a single, integrated environment.

LONG gone are the days when a process automation project was
solely focused on real-time control. Nowadays, operator interface
and data handling are often just as important, sometimes more so.
Therefore, it’s more important than ever for programming soft-
ware to include not only a powerful real-time control engine, but
also closely integrated human machine interface (HMI) and data
handling functions, all in one integrated development environment.
Addressing these requirements, Opto 22 announces PAC
Project Software Suite R10. This release supports its new groov
EPIC system, adds eight new control commands, and provides
the ability to designate individual I/O and variable tags as Public
Access for read-only or read-write use in data communications
via MQTT/Sparkplug. HMI programming is still included, and it
uses the same tag name database as the real-time control en-
gine, creating automatic integration between the two functions.
Opto 22’s industrial controllers—SNAP PAC programmable
automation controllers and now groov EPIC edge programmable
industrial controllers—are typically programmed using the PAC
Project Software Suite. PAC Project Basic, free for download,
includes flowchart-based control programming with optional
scripting, a configuration utility and HMI development. PAC Proj-
ect Professional adds an OPC server, database connectivity, PC-
based control configuration and support for legacy Opto 22 I/O
units. The Pro version sells for just under $1,000.
The suite’s control programming software, PAC Control, is
full-featured and easy to use, with more than 450 commands in
plain English, plus graphical PID tuning and debugging.
HMI programing is provided with PAC Display. PAC Display
Basic is a user-friendly HMI package for building operator inter-
face applications to communicate with groov EPIC processors,
SNAP PAC controllers and Ethernet-based I/O units. PAC Display
offers rich features including alarming, trending, security and a
library of more than 3,000 industrial automation graphics.
PAC Display Professional adds the capability to use redundant
scanners and redundant Ethernet links on groov EPIC proces-
sors and SNAP PAC controllers. PAC Display Professional also
enables logging of SuperTrends, historical logs and runtime op-
erator logging data files to an ODBC database.
The most important new feature with this new release is sup-
port for groov EPIC. Its control logic and I/O can be programmed
with PAC Control, and customers can use PAC Display to de-
velop a Microsoft Windows-based HMI to run on a separate PC.
The groov EPIC’s integrated high-resolution touchscreen is not
configured with PAC Display, but is instead configured with groov
EXPANDED CAPABILITIES
Opto 22’s PAC Project Software Suite R10 uses a flowchart-based control
programming language with optional scripting to create real-time control
strategies for download to groov EPIC or SNAP PAC controllers.
View software, supplied free with groov EPIC.
New commands added to PAC Control include two specifically
for groov EPIC: Get I/O Channel Quality and Get I/O Unit Quality.
The groov EPIC I/O modules incorporate LEDs that change color
based on the health of the module, revealing data quality to a local
technician, and this information can also be configured or retrieved
programmatically in control logic using these two new commands.
Another major new feature is full support for MQTT/Spark-
plug data communication, provided by Ignition Edge, which is
embedded in groov EPIC. MQTT’s publish-subscribe communi-
cation architecture is superior to request-response methods, and
Sparkplug optimizes MQTT for industrial applications.
Public Access tags are a new PAC Control capability, improv-
ing MQTT/Sparkplug security. During configuration the developer
can use Public Access to designate which tags to expose, and to
designate each exposed tag for read-only or for read-write.
Tags in PAC Control include I/O channels and program vari-
ables, some of which can be represented in the Public Access
space in more than one way. For example, an integer can be
represented as an integer, a Boolean value or an individual bit
within the integer. A table can be represented as a table, one
element in the table or even one bit of one element—providing a
great deal of flexibility in how tags are exposed or protected.
For more information, see https://op22.co/pacproject10.

52 • MAY 2018 www.controlglobal.com

CT1805_52_ProdExclusive_Opto.indd 52 5/9/18 9:23 AM


Wireless system combines speed, security
Frequency hopping and multiple slave units provide safe, reliable communications.
THE EX600-W series wireless system
is designed to provide safe and reliable
communications by using 2.4-GHz radio
frequency bands reserved for indus-
trial, scientific and medical (ISM) use. It
provides stable communications using
various forms of radio-wave propagation,
including direct wave, transmitted wave
and reflected wave, with communication
between master and slave possible in a
10-m (33-ft) radius.
The system has a signal response
time of 5 ms and a high-speed connec-
tion of 250 ms for a wireless slave from
power on. It accommodates a maximum
of 1,280 inputs/1,280 outputs, and
registration and communication of up
to 127 slave units is possible. One to 15
units are recommended for simultane-
ous operation, and it's possible to install
multiple wireless masters in the same
area. However, while a wired system
with one master and 15 units requires
29 communication connections, EX600-
W's wireless master and 15 wireless
slaves only need one connection.
“The EX600-W wireless system
means reduced wiring work, space and
cost,” says Andy Thedjoprasetyono,
head of project management at SMC
Corp. of America. “Disconnection risk
is minimized. And 5-ms frequency hop-
ping guarantees a stable wireless envi-
ronment is established using an original
protocol that’s not affected by interfer-
ence. Interference from other wireless
equipment is prevented.”
The communication technology rapidly
changes frequency to prevent interference
from other wireless equipment. When the
frequency of Wi-Fi and other wireless com-
munications compete, or radio wave inter-
ference is present, then other frequencies
are used for communication. Unauthor-
www.controlglobal.com MAY 2018 • 53
CT1805_53_ProdExclusive_SMC.indd 53
INCREASING INTENSITY
Beyond determining installation location using intensity levels of received radio waves,
EX600-W wireless system from SMC can add a wireless master to increase wave intensity
to level 2 or 3.
ized access from outside is prevented
by using data encryption.
Wireless status can be monitored
during operation according to the diag-
nostic data, such as when communica-
tion from the slave can’t be received
or when communication retry has ex-
ceeded the upper limit of 32 times.
Installation location can be ascer-
tained according to the intensity level of
the radio wave received by the unit dis-
play. For example, a received radio-wave
intensity level of 1 means intensity is
weak. A wireless master can be added
to increase wave intensity to level 2 or 3,
or users can remove obstacles between
the master and slave, or reduce the dis-
tance between them.
Communication status also can be
downloaded by a PC. By connecting
the wireless master to a PC, it's pos-
sible to view log files that show the
number of retries or the received radio-
wave intensity. Log files are accessed
by using a web browser to connect to
the built-in web server.
The wireless environment and in-
stallation location can be optimized
CONTROL EXCLUSIVE
by checking the number of retries and
received radio-wave intensity. The log
files, showing the number of retries or
the received radio-wave intensity, can
be downloaded in the form of a CSV file.
Settings are possible using a near
field communication (NFC) reader/
writer and setting software. Some items
can be set when there is no power
supplied. Using a PC and NFC reader/
writer, users can:
• Write IP address to the master,
• S et the I/O points for the system
and unit,
• Pair the master and slave, and
• Monitor I/O.
EX600-W wireless system consists of
a wireless master unit for EtherNet/IP
and wireless slave units. Slave options
include digital input units, digital output
units, digital input/output units, analog
input units, analog output units, analog
input/output units, D-side end plate
and U-side end plate.
For more information, call 317-688-0164,
email athedjoprasetyono@smcusa.com, or
visit www.smcusa.com
5/8/18 12:49 PM
 PRODUCT INTRODUCTIONS

MONITOR WALL ADJUSTS FOR SIT/STAND DESKS iNTELLIGENT WEARABLES EMPOWER FIELD WORKERS
M-View Rize motorized, Skills Insight intelligent
auto-height adjustable mon- wearables feature a head-
itor wall requires no tools mounted visual display
or lifting effort to preserve that responds to voice and
proper sight lines for op- shows live data, documents,
erators as they adjust their work procedures, and health
workstation or console from and safety information. The
sitting to standing or for wearables can connect with
different operator heights. remote experts in real time,
Available in 43-in. wide, single-monitor or 83-in. wide, dual-mon- and allow workers to assimilate skills and knowledge on the job.
itor configurations, height adjustments are via an onboard control They combine the RealWear HMT-1Z1 hands-free wearable com-
switch or optional wireless remote control, and can be synchro- puter with the company’s Movilizer cloud-based workflow solu-
nized when paired with the company’s Impulse sit/stand console. tion to support field service,including in hazardous locations.
WINSTED HONEYWELL
www.winsted.com www.hwll.co/ConnectedPlant

USB 3.0 DIGITAL I/O OFFERS SUPER SPEED CABINET COOLERS FIT IN TIGHTER SPACES
USB-5800 series isolated Type 316 side mount kits make
digital I/O modules with Su- mounting a NEMA 4X cabinet
perSpeed USB 3.0 work with- cooler possible when an enclo-
out PCI/PCIe slots, and give sure has limited space on the
high data transfer speeds (up top or side. Type 316 kits are
to 5 Gbps), extend system I/O corrosion-resistant and offer a
functions, and support daisy low-cost way to purge and cool
chaining for expansion. Front- panels using compressed air
facing LEDs, ID switch and terminal blocks ease installation and cooled to 20 °F without refrigerants. Capacities range to 5,600
maintenance, and Auto Recovery and surge protection prevent Btu/hr., and units include a filter to assure no moisture or dust is
sudden failures. Supported development tools include C#, C++, introduced. Optional thermostat control minimizes compressed
LabVIEW, VB.Net, MFC, BCB, VB6, Java, Delphi and Qt, and air use. Coolers are UL-listed, conform to the CE general safety
they’re compatible with Windows XP/7/8/10 and Linux. directive, and have no moving parts.
ADVANTECH EXAIR
www.advantech.com www.exair.com/smsidecc.htm

GATEWAYS CONNECT TO POWERLINK SUPPORT COMPUTING AND VIRTUALIZATION

Anybus X-gateway now connects to NCA-5520 1U,
Ethernet Powerlink, the 17th industrial 19-in. rack-mount
network to be included in the offering, network appliance
allowing its connection to other fieldbus is built with Intel
and industrial Ethernet protocols includ- Xeon processor
ing Profinet, EtherNet/IP, EtherCAT, scalable family
Ethernet Modbus-TCP, CC-Link IE Field, (codenamed Skylake-SP) to maximize packet processing ef-
Profibus, DeviceNet, CANopen, Modbus ficiency for virtual network functions, accelerate cryptography
RTU, CC-Link and others. A USB inter- for deep packet inspection, and support next-generation fire-
face allows easy configuration via the wall and UTM/IPS/IDS applications. It comes with either 4x
Windows-based tool Anybus Configu- GbE RJ-45 or 4x 10G SFP+ ports, and LAN expansions can
ration Manager, and dual-port Ethernet interfaces and an inte- use its 4x NIC module slots that support 10G/25G/40G/100G
grated switch remove the need for external switches. fiber/copper/bypass specifications.
HMS INDUSTRIAL NETWORKS LANNER ELECTRONICS INC.
www.anybus.com www.lannerinc.com

54 • MAY 2018 www.controlglobal.com

CT1805_54_Products.indd 54 5/9/18 9:23 AM


Achieving the best APC
APC improves stability despite measured—and unmeasured—disturbances.
GREG: Advanced process control (APC) is on the
verge of resurgence because of the increased
capability of today’s digital control systems for
advanced regulatory control (ARC) that offer in-
herent structural advantages, ability to reject load
disturbances, inclusion of soft sensors, proven
functionality developed by key experts, and pro-
cedure automation (state-based control). In the
ISA 2017 Process Control & Safety Symposium
panel on APC with Dr. James R. Ford, senior con-
sultant at Maverick Technologies, I was impressed
with his ARC knowledge that was in synch with
my experience. Here we gain insight to the best
APC by ARC.
Jim, what is the starting point to understanding
the ARC’s successful history?
JIM: Automatic process control was initially
developed to respond to unmeasured distur-
bances. The development of the automatic con-
trol valve ushered in the era of modern process
control. The first truly automatic control valves
were developed to replace manual valves to
control flow. The flow control loop has become
the foundation of all automatic process control,
for several reasons.
Unlike pressure and temperature, which are
intensive variables, flow is an extensive variable.
Intensive variables are key control variables for
stable operation of process plants because they
relate directly to composition. Intensive variables
are usually controlled by adjusting flows, the ex-
tensive variables. What this means, practically, is
that, unlike the intensive variables, a flow control-
ler has no predetermined or “best” target for any
given desired plant operation. The flow will be
wherever it needs to be to maintain the higher-
level intensive variable at its best value.
The above comments apply to almost all flow
controllers, even important ones like the main unit
charge rate controller. The target for this control
will be adjusted to achieve an overall production
rate, to push a constraint, to control the inventory
of feed (in a feed drum), etc.
www.controlglobal.com MAY 2018 • 55
CT1805_55_56_CT_Talk.indd 55
CONTROL TALK
GREG: What about additional feed flows, such
as flow of solvent in an absorption or extraction
process?
JIM: In this case, there is a more important,
higher-level control variable, an intensive variable,
namely, the ratio of the solvent to the unit charge
rate. The flow of solvent will be adjusted to main-
tain a “best” solvent/feed ratio.
Many major types of process disturbances
are measured. Common examples are changes
in charge rate, cooling water temperature, steam
header pressure, fuel gas header pressure, heat-
ing medium temperature and ambient air tem-
perature, etc., where instruments are installed GREG MCMILLAN
to measure those variables. The first 20 years of
developing APC technology focused primarily on Gregory K. McMillan captures the
using measured disturbance information for im- wisdom of talented leaders in
proving the quality of control. process control, and adds his
The main techniques for improving the control perspective based on more than
system’s response to measured disturbances 50 years of experience, cartoons
were called "feedforward," "compensating" and by Ted Williams, and (web-only)
"decoupling." An example of feedforward is the Top 10 lists. Find more of Greg's
preemptive fuel flow adjustment to a fired heater conceptual and principle-based
for changes in heater charge rate and inlet tem- knowledge in his Control Talk blog.
perature based on an energy balance. A second Greg welcomes comments and col-
area of initial APC development effort focused on umn suggestions at ControlTalk@
controlling process variables that are not directly putman.net
measured by an instrument.
An example is reactor conversion or severity.
Hydrocracking severity is often measured by how
much of the fresh feed is converted to heating oil
and lighter products. If the appropriate product
flow measurements are available, the conversion
can be calculated and the reactor severity can
then be adjusted to maintain a target conversion.
Work in this area of APC led to the development of
a related body of engineering technology referred
to as “inferred properties” or “soft sensors.”
GREG: It has been proven that for unmeasured
disturbances, no other algorithm can do better
than PID. Model predictive control (MPC) does not
do as well because it is essentially integral-only
5/9/18 9:24 AM
 CONTROL TALK
control via a bias correction over its time
horizon, lacking the benefits of propor-
tional and derivative modes, particularly
for lag-dominant processes. Also, flow
ratio control is critical in many unit opera-
tions, especially reactors and columns.
MPC lacks this fundamental capability.
Columns are often started up on local
flow ratio control with a ratio set by the
operator until the temperature is repre-
sentative of composition.
JIM: Intensive variables call for a different
closed-loop response for process vari-
able (PV) changes due to disturbances
versus SP changes. Modern digital con-
trol systems can provide some help in
this area. For example, the control loop
can be configured to take proportional
action on PV changes only, ignoring the
effect of SP changes. Then, following an
SP change, integral action will grind away
on correcting the offset between SP and
PV. However, these features do not fully
correct the deficiency discussed above.
This dilemma plagues control systems to
this very day, and is a major justification
For the Top 10 things you don’t want to hear from advanced process control (APC) software
suppliers, visit www.controlglobal.com/articles/2018/achieving-the-best-apc.
56 • MAY 2018 www.controlglobal.com
CT1805_55_56_CT_Talk.indd 56
for implementing advanced controls that
directly address this and other shortcom-
ings of basic process control.
We have been particularly success-
ful in this area with development of our
“smart” PID control algorithm. In its
simplest form, it addresses the biggest
weakness of PID, namely, the overshoot
that occurs because the algorithm con-
tinues to take integral action to reduce
the offset between SP and PV, even
when the PV is returning to SP. Our
algorithm turns the integral action on
and off according to a proven decision
process made at each controller execu-
tion. This algorithm excels for lag-domi-
nant and deadtime-dominant loops. We
use this algorithm on virtually all APC
projects.
GREG: In his books, Greg Shinskey
has shown how you can use a setpoint
lead-lag to enable a good SP response
with tuning for maximum rejection of
load disturbances. He also shows how
external reset feedback (ERF) of the
manipulated variable (e.g., flow) can
eliminate oscillations from slow second-
ary loops or slow valves. Furthermore,
the insertion of a deadtime block in
the ERF path can provide performance
better than a Smith Predictor or MPC.
I have expanded the ERF potential op-
portunities to include directional move
suppression to prevent upsets to other
loops, prevent unnecessary crossings
of the split-range point, and provide a
smooth approach to an optimum and
fast getaway for valve position control-
lers as detailed in the Control article,
“Don’t Over Look PID in APC” (www.
controlglobal.com/articles/2011/dont-
over-look-pid-apc). ERF has also been
extended to prevent oscillations and
eliminate retuning for wireless and
analyzer applications where the update
time and sample time exceeds the 63%
process response time.
What is the structural advantage of
ARC?
JIM: Prior to MPC, the most successful
APC engineers used a process engi-
neering-based, hierarchical approach in
developing ARC solutions. At the bottom
of the control hierarchy, its foundation is
what we referred to as "basic" process
control, the single and simple cascade
loops that appear on P&IDs and provide
the operator with the first level of regula-
tory control. The hierarchical approach
to ARC design identifies the causes of
the disturbances in each part of the pro-
cess, then layers the solutions that deal
with the disturbances on top of the basic
control system, from the bottom up. Each
layer adds complexity and its design
depends upon the disturbance(s) being
dealt with.
GREG: The ARC hierarchical approach is
more understandable by operators and
by process and automation engineers,
enabling a synergy. Consequently, the re-
sulting APC has a greater onstream time,
and is more amenable to continuous pro-
cess control improvement.
5/9/18 9:25 AM
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CT1805_57_Classified.indd 57 5/8/18 1:20 PM

 CONTROL REPORT
Need to know
The Mechanics' Institute shows how to meet today's digitalization challenges.
SO I'm walking around San Francisco a few weeks
ago, ferrying between the Control System Integra-
tors Association (CSIA, www.controlsys.org) and
OSIsoft's PI World (https://piworld.osisoft.com/
US2018) conferences, when I ran across a third
organization—the Mechanics' Institute Library &
Chess Room (www.milibrary.org). Just another
fine payoff for keeping my eyes open.
Now, don't misunderstand me, both the OSIsoft
and CSIA events were terrific, with lots of useful
sessions that you can read about in this issue's
In Process news section (p. 22). However, I was
already expecting enlightening input from them.
JIM MONTAGUE What I wasn't anticipating was randomly stumbling
Executive Editor into one of the city's historic, cultural institutions,
jmontague@putman.net and learning how many lessons it has for today's
engineers and technical professionals.
Just like the hundreds of mechanics' institutes
Even during times that sprouted in Scotland and the U.K. to teach
of great technical, much-needed vocational and technical skills dur-
demographic and even ing the Industrial Revolution, the San Francisco
geological change, local version was established in 1854 to help former
communities can quickly gold miners and thousands of others gain the
organize and marshal abilities required by the businesses and industries
the resources they need that would drive its true success in the long run.
to solve those problems. The city had grown from 800 residents in 1848 to
34,000 in 1852 with 100,000 more arriving each
year, but most of the workforce was unskilled,
and most supplies had to be outsourced or im-
ported at great expense. I don't know about you,
but rampant growth and desperate need for new
knowledge and skills seem mighty familiar to me.
Starting with 400 books and a collection of sci-
entific curiosities in two rented rooms, the found-
ing directors of the Mechanics' Institute wanted:
• A library with open stacks, so all the books
are accessible to members;
• A game room where members could spread
out their chess and checker boards;
• Classes and lectures that would stretch the
mind and teach new skills;
• To be an organization that welcomed every-
one regardless of race or gender; and
• To cost as little as possible.
58 • MAY 2018 www.controlglobal.com
CT1805_58_CT_Report.indd 58
The institute also held expositions to fund its
classes, library and other services; moved into
a three-story building in 1866; helped start the
University of California; rebuilt just four months
after its home and collections were destroyed by
the San Francisco Earthquake and Fire of 1906;
and moved into its present nine-story building in
1910, where it now houses 160,000 volumes, its
world-renowned chess program, and numerous
cultural events.
My point is that, even in times of great techni-
cal, demographic and even geological change,
local communities can quickly organize and
marshal the resources they need to solve those
problems. As usual, it starts with a few questions
about what's needed, who knows what, where it
can be obtained, how quickly, and is whoever will-
ing to maybe donate it or at least give a discount?
This let huge, overwhelming jobs be broken up
into small, approachable tasks.
Today's transition to virtual, cloud, Internet of
Things (IoT) and other digital technologies aren't
as catastrophic as earthquakes and fires, but
many industries and businesses are undergo-
ing shifts and reorganization comparable to those
during the Industrial Revolution, and more coop-
eration, collective action and simply cutting each
other some slack could be a big help.
You don't have to start a library. Today, we have
all the tools and interactivity allowed by the Inter-
net to seek answers, gain skills and collaborate.
However, these resources ironically seem to make
many feel more isolated, rather than part of a sup-
portive community. Overexposure and too many
distractions, I guess.
Just like San Francisco rebounding after its
famous and less well-known earthquakes, I'm al-
ways a little stunned to be reminded that following
the Chicago Fire of 1871, many businesses were
up and running within just a few days—or even
hours. Do we still have that kind of desire and
optimism? I'd like to think so, but decades of pros-
perity have made us fragile and fearful. We just
have to prove ourselves again.
5/8/18 12:50 PM
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