2014 11-12
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2014 11-12
Month/Month
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OM
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PROCESS AUTOMATION
18 Taking denitrifcation
to the next level
By Jaime A. Alba, Peter Loomis, Robert Litzinger,
Bruce P. Stevens, and Paul A. Miller
12
COVER STORY
Motor starter technology has become more sophisticated. To maximize effciencies, engineers can take a
fresh look at motor control options.
SYSTEM INTEGRATION
28 Outsourcing:
Defning key relationships
38 User adoption of
industrial wireless
By Jay Werb
By Rick Anderson
WWW.ISA.ORG
AUTOMATION IT
Report generation is an excellent way to drive continuous improvement through information delivery. Now,
new report tools for automation are making it easier.
Have the reports and dashboards you want, not just
the few you absolutely need. Spend your time on
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www.isa.org/InTech
DEPARTMENTS
Your Letters
Salary humor, defning big data
10 Automation Update
Customer Experience Center, ISA100 wireless standard, and more
45 Channel Chat
Steel manufacturer replaces legacy
energy management system
46 Association News
WEB EXCLUSIVES
Auditing alarm
management systems
In memoriam, symposia;
certifcation review
48 Automation Basics
Distillation column loop tuning
52 Workforce Development
InTech Plus is a new, award-winning mobile app from ISA that lets
automation professionals access, scan, and consume a range of
technical and educational content. InTech Plus is available for free
on the iPad and Android devices. Download today from the Apple
App Store and Google Play, respectively!
53 Standards
Alarm management update
Talk to Me
Automation change agents
44 Executive Corner
Protecting your operational
integrity
56 Index of Advertisers
57 Datafles
57 Classifed Advertising
57 ISA Jobs
2014 InTech
ISSN 0192-303X
Implementing a
calibration system?
Our calibration and IT expertise helps you face calibration process improvement
projects that are typically complex and consume a lot of time and resources.
Only 20% to 30% of a calibration system upgrade is tools and technology, the rest is
business culture and process. Therefore, the success of a new calibration system depends
especially on the implementation of the system and the ability to dene and adopt a new
calibration process. We are the experts in both technology and implementation, so you
can focus on the opportunities, while we support and guide you in the evolution of your
calibration system and successful implementation of the calibration process change.
Learn more at: beamex.com/CalibrationProcessImprovements
Bill Lydon
[email protected]
PUBLISHER
Susan Colwell
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PRODUCTION EDITOR
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ART DIRECTOR
Colleen Casper
[email protected]
SENIOR GRAPHIC DESIGNER
Pam King
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Lisa Starck
[email protected]
CONTRIBUTING EDITOR
Charley Robinson
ISA PRESIDENT
CHAIRMAN
Steve Valdez
GE Sensing
Joseph S. Alford Ph.D., P.E., CAP
Eli Lilly (retired)
Joao Miguel Bassa
Independent Consultant
Eoin Riain
Read-out, Ireland
Vitor S. Finkel, CAP
Finkel Engineers & Consultants
Guilherme Rocha Lovisi
Bayer Technology Services
David W. Spitzer, P.E.
Spitzer and Boyes, LLC
James F. Tatera
Tatera & Associates Inc.
Michael Fedenyszen
R.G. Vanderweil Engineers, LLP
Dean Ford, CAP
Westin Engineering
David Hobart
Hobart Automation Engineering
Allan Kern, P.E.
Tesoro Corporation
Salary humor
Loved your article on salaries [Your
recipe for maximum salary, September/
October 2014 InTech], and these points
were priceless:
n Remain an automation professional
for the rest of your career. Lets be
realistic, what else are you going to
do?
n Editors note: results may vary depending on attitude.
Stephen Rader
STAINLESS STEEL
XIHNS Enclosure
WWW.ISA.ORG
216.267.9000
Source: Automation.com
TRUE STORY
Food-processing and pharmaceutical plants are harsh environments for electronics. Your critical systems must
withstand water and chemicals used during wash-down including the electronics inside every computer
enclosure. The NEMA 4X Titan from ITSENCLOSURES is made specifcally for these extreme conditions. The Titan
is constructed of 14-gauge Type 304 stainless steel to handle corrosive cleaners and chemicals that would break
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does not skip a beat. To learn more about IceStation TITAN, call 1.800.423.9911 or visit ITSENCLOSURES.com.
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Customer Experience
Center
WWW.ISA.ORG
Other CEC highlights include feld instrument technologies, such as transmitters for
monitoring pipelines, that have been transformed in recent years into smart devices
that deliver more relevant information to
operators in the control room and to mobile
operators. The center also demonstrates
how safety, physical, and cybersecurity systems can be integrated in facilities. n
WWW.ISA.ORG
COVER STORY
19921996
19972001
20022006
20072011
0
500
1000
1500
2000
Figure 1. A report issued in 2012 by the Energy Practice of Marsh Ltd., a division of insurer Marsh McLennan, examines the fve-year loss rate (adjusted for
infation) from 1972 to 2011 in the refnery industry. Incidents during startups
and shutdowns continue to be a signifcant factor.
13
COVER STORY
(www.isa.org/store/products/product-detail/?productId=115958).
Operator As procedure
Best-practices
procedure
Operator Bs procedure
Operator Cs procedure
Figure 2. Many procedures are not well documented, and different operators may
practice them differently. Part of automating such procedures is determining the best
practices and incorporating those approaches, so they will be followed consistently.
WWW.ISA.ORG
COVER STORY
automation. This combination will offer you the best opportunity to demonstrate the capabilities and benefts of procedure
automation. You do not want to bite off too much at frst, and
it will likely take a few executions to work out the bugs.
On the other hand, you also do not want to solve a trivial
problem, as the combination of frequency and complexity will
give you ample opportunity for debugging and later demonstrating the usefulness of procedure automation. Another factor to consider is the opportunity to apply the frst procedure to
multiple operations or operating units.
Another major decision is the degree to automate a given
procedure. There is a wide spectrum, from a system that
merely instructs the operators at each step and perhaps confrms its completion to another that an operator initiates by
pushing the start button and then lets the system execute
unaided, reporting back when complete.
Available hardware in the process will affect this decision
because some operations likely have components (block
valves, pumps) that cannot be remotely activated. In these
cases, the automation system will need to guide the operator
on what and how to manipulate at the appropriate time.
This may be especially likely on your frst project, as management may be initially unconvinced of the value of automation and therefore unwilling to invest in remotely operated block valves, or it may have prejudices against remotely
starting pumps.
A related consideration is what degree of operator action
will be allowed during execution of the automated procedure.
Can an operator override the procedure without disabling it?
Can he or she change set points or controller modes? In my experience, the answer to both these questions should be no,
because procedure automation largely relies on conditions
being followed as written. However, the operator must be able
to take control away from the automation should something
go wrong. In this case, be sure the operator gains access to all
controllers, so he or she can do what needs to be done.
Cyber security
for your
critical assets.
As an expert in industrial controls,
GE Measurement & Control understands
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For more information, visit
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& Control. For the health of industry.
Imagination at work
15
COVER STORY
Dave Emerson is the ISA106 committee editor and director of Yokogawas U.S.
Development Center.
16
WWW.ISA.ORG
of the same design. Automation written for one furnace and its components
can be reused on all furnaces if properly
written (e.g., use of generic logic). This
consideration also applies for different
plants and sites across the enterprise.
Finally, you must consider exception
management. What do you do when
a valve does not go to its commanded
position? What is the response to an
unexpected process condition or an
operator overriding the automation?
How do you detect these exceptions?
How do you recover from an exception? Exception management, especially recovery logic, is a major part of
any automation project. Procedures
can be written for exceptions, but these
may be vague and diffcult to automate
because you simply cannot anticipate
everything that may occur during such
abnormal states.
You may opt to soft fail the automation and turn the process back to
the operatorbut only if it is made
clear that the operator has control. In
this case, you must also decide if reentrant logic for the procedure is desirable, and if so you must consider how
the automation will resynchronize with
the process.
If the exception is critical, a process
shutdown may be required, either an
SIS-actuated shutdown, or perhaps a
more controlled shutdown. Again, you
need to consider synchronization of
the SIS and BPCS. The correct answer
to these questions depends upon your
process and automation capabilities.
COVER STORY
Resources
Most major control system vendors
are participating in the ISA106 standards committee to varying degrees,
Bill Wray, P.E., began his career as a process engineer, later discovering his passion for process control, a feld he entered
in the early 1980s. Beginning with automation of large continuous petrochemical processes, he later moved to batch
automation and is recognized among his
peers for his expertise. Wray was a founding member of World Batch Forum (WBF)
and served in various leadership roles.
Since the merger of WBF and MESA,
he has joined the international board of
MESA. He was the frst chairman of the
ISA95 committee, leading this effort to
publication of the ISA-95 Part 1 standard,
and is currently co-chair of ISA106. Wray
is employed by Bayer Material Science
as a senior engineering consultant and
holds a B.S. in chemical engineering from
Virginia Polytechnic Institute.
View the online version at www.isa.org/intech/20141201.
RESOURCES
www.isa.org/isa106
Automating Procedures in Continuous Process Applications using the
concepts of ISA-106
www.isa.org/store/products/productdetail/?productId=122785
Next frontier: Operator-automation
relationship
www.isa.org/standards-publications/isapublications/intech-magazine/2013/december/
next-frontier-operator-automation-relationship
ANSI/ISA-88.00.01-2010, Batch Control
Part 1: Models and Terminology
www.isa.org/store/products/productdetail/?productId=116649
17
Taking denitrifcation
to the next level
An upgrade of proven technology with 21st century I&C
By Jaime A. Alba,
Peter Loomis,
Robert Litzinger,
Bruce P. Stevens,
and Paul A. Miller
18
WWW.ISA.ORG
Process enhancements
Before the expansion, the plant operated with
10 denitrifcation flters that had insuffcient
surface area to process the full plant capacity of 18 mgd in denitrifcation mode. When the
flters were operated in the denitrifying mode,
fows beyond 12 mgd bypassed the flters to prevent hydraulic overloading. Even though the flters were capable of hydraulically passing the full
plant fow, denitrifcation could not be achieved at
higher fows. Based on the processing limitations
and operational cost savings, the flters were often
operated seasonally, with methanol added only
during the winter for the additional denitrifcation
needed to meet effuent TN requirements. During
PROCESS AUTOMATION
19
PROCESS AUTOMATION
was installed and was unavailable, typical programming utilizes the last known
readings; however, this could result in signifcant over- or underdosing of methanol if the characteristics of the wastewater change, potentially resulting in permit
violations for CBOD or TN. Also, overdosing methanol to the denitrifcation flters
could occur due to the variations in the
secondary effuent nitrate levels while
the analyzer unit is out of service. This
increase of the effuent CBOD level may
cause a permit violation.
Instrumentation
In designing critical process systems,
redundant systems were used. When
permit limits of stringent levels are
implemented, operations must use
the instruments to optimize the facility and then rely on the electronic
components to work reliably over time
to enable compliance.
The analyzer is essentially a lab spectrometer that is automated to read more
Redundant ChemScan
61st International
Instrumentation
Symposium (IIS)
Co-located with MFPT
1114 May 2015
Westin Hotel
Huntsville, Alabama
2015 Water/Wastewater
and Automatic Controls
(WWAC)
46 August 2015
Wyndham Lake
Buena Vista Resort
Orlando, Florida
Earn
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20
WWW.ISA.ORG
PROCESS AUTOMATION
2.5
1.5
mg/LN02-N
of data that stand uncorroborated. Patterns with repeatable trends and occasional outliers in the data are used to
make rational decisions with and after
vetting equipment.
Online monitoring devices can
help run a facility better, but they
are not foolproof and need regular
care and inspection. Maintenance
instructions and protection of transient electrical power surges must
be done to protect the investment in
this data gathering infrastructure.
At the same time, and as part of
the design-build expansion project, a
backup methanol feed pump was installed so that the loss of methanol feed
to the denitrifcation flters (when running in denitrifcation mode) is minimized during a failure or scheduled
maintenance for the main feed pump.
Also, as part of the plantwide DACS replacement, the network backbone was
designed with a self-healing fber-optic
ring to minimize the risk of losing the
A CS SEC
B CS SEC
LAB SEC
A CS FINAL
B CS FINAL
LAB FINAL
0.5
1
1
1
1
1
1
1
1
11
11
11
01
01
01
01
01
01
01
01
/20
/20
/20
5/2
6/2
7/2
8/2
9/2
0/2
1/2
4/2
2/1
2/2
2/3
1/2
1/2
1/2
1/2
1/2
1/3
1/3
1/2
11
/20
2/4
ability of the process, and also reduced the risk of methanol overdose
by more closely matching the methanol feed to the actual demand (fgure
2). Consistent methanol dose control
is challenging when trying to meet
Our HMI had problems and we didnt have any alarming at that point. But Ive never
had an annunciator do that to me in 20-something years. I feel more comfortable
having that annunciator there.
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21
PROCESS AUTOMATION
15.0
400
12.0
300
9.0
250
6.0
Methanol gal/day
350
Nitrogen mg/L
500
450
During construction
22
200
150
3.0
100
50
0.0
0
0
0
10 10
1
1
1
11 11 2011 2011 011 011 2011 2011 2011 011 2011 2011 2011
20 20 /201 /201 /201 011 201 201 201
/
/
/
/
/
5
/1/ /8/
2
9
/2
/20 /20
/2 /9/2 16/ 23/ 30/
/2 3/
0/
7/
12 12 12/1 2/2 2/2 1/5 1/12 1/19 1/26 2/2 2/9 2/16 2/23 3/2
3
4/6 4/1
3/
3/
3/
4/2 4/2
1
1
TN
NO2-N
NO3-N
TKN
Methanol gal
Figure 2. Effuent nitrate and nitrite concentrations, and methanol feed rates after the upgrade
WWW.ISA.ORG
PROCESS AUTOMATION
3.0 mg/L of TN consistently in the aeration basins. The fact that the plant is
currently fowing at about 50 percent
capacity might be an important factor
for this, but if the fows increase and
there is the need for it, methanol can
be fed to the flters again.
With the lower fows through the
aeration basins, the plant can operate
year round in the four-stage Bardenpho
mode with maximum anoxic zones. The
mode of operation still allows complete
nitrifcation in the aeration basins and
maximized volume available for denitrifcation. At the same time, with the
higher retention times, the plant can
support a biological phosphorous accumulating organism in the aeration
basins, allowing operations to stop all
ferric chloride feed to the secondary
system while maintaining ferric chloride feed to the primary clarifers to
meet the total phosphorus limit.
On the economic side, the daily average methanol consumption to the
flters went down from about 413 gal/
day to close to 300 gal/day. Methanol
is fed to the flters for an average of
8 months a year, which translates to
about 27,000 gallons less methanol
used per year. Additionally, since currently suffcient denitrifcation is taking place in the aeration basins when
Success
The H. L. Mooney advanced water reclamation facility upgrades became necessary because the average daily fows
were reaching 85 to 90 percent of the
plant capacity and further growth was
expected. Additionally, PWCSA wanted
to maintain a waste load allocation
based upon 3 mg/L of effuent TN at
the future fow capacity of 24 mgd. In
addition to the process upgrades to the
aeration basins and denitrifying flters,
the upgrades included improved controls for the denitrifying flters, allowing a reliable methanol feed control to
minimize methanol costs while also
ensuring adequate feed.
23
WWW.ISA.ORG
FACTORY AUTOMATION
hand, VFDs control voltage and frequency, which allows accurate starting and stopping times with minimal
load dependency.
1. Speed control
4. Constant torque
The frst consideration in choosing a motor control technology is the speed control requirements.
Some soft starters have limited slow-speed control
between starting and stopping. Slow speeds can
vary from 1 to 15 percent of the full speed and can
be used in a maintenance or alignment operation.
Due to silicon-controlled rectifer (SCR) temperature rise and reduced motor cooling, this mode is
meant for relatively short-term operation. Once
the soft starters transition to full voltage, even
though a fxed frequency is applied, the output
speed is actually determined by the motor load.
The operating speed of the motor cannot be varied, because the soft starter only adjusts the voltage to the motor and not the frequency.
VFDs use a DC bus and insulated-gate bipolar
transistor (IGBT) switching to control both voltage and frequency. This allows full and continuous
adjustable speed control. If a process requires tight
speed regulation, the frequency applied to the motor by the VFD can be changed in relation to the load.
In addition, the VFD output to the motor can be any
frequency up to the limits of the IGBT inverter or the
mechanical limits of the motor.
FAST FORWARD
l
25
FACTORY AUTOMATION
Ball Valve
Assemblies
Expertise from a
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Torque
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Global manufacturer of process control
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26
WWW.ISA.ORG
Soft starter
In lower-to-medium starting torque applications
In light-to-medium loaded applications
If little or no speed control is required during run mode
If reduced mechanical wear and damage to system is required
If limiting current is the primary reason for not starting at full voltage
For lower monitoring
VFD
In single-phase applications on certain drives
For speed control and system effciencies operating at reduced speeds during the run mode
For higher starting torque
For continuous feedback for critical position control
FACTORY AUTOMATION
27
Outsourcing:
Defning key relationships
By Paul J. Galeski,
P.E., CAP
28
WWW.ISA.ORG
SYSTEM INTEGRATION
29
SYSTEM INTEGRATION
Basis
Supplier focus
Owner receives
Indicators of success
Approved
vendor
Transactional
Quotes, proposals
Preferred
supplier
Service based
Gathering input
Explaining what is
happening
Timely information
Solutions
consultant
Needs based
Problem solving
Solutions
Strategic
contributor
Relationship
based
Owners organization
Providing insights
Useful ideas
Trusted
adviser
Trust based
30
WWW.ISA.ORG
SYSTEM INTEGRATION
Engineered
for the
Real World.
Designed for
Your Application.
The days of compromised applications are gone.
When you innovate with Daisy, we start with
your input and build a fully ruggedized industrial
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31
SYSTEM INTEGRATION
be no, which may be the correct answer. Do not try to convince yourself otherwise if the situation is not
appropriate.
Deep owner-supplier relationships
require a great deal of mutual effort to
establish and maintain, but when they
work, they are hugely rewarding for both
sides. An integrator is assured of being paid fairly for work delivered without micromanagement, and the owner
knows it can expect the best effort possible from the integrator. All projects are
delivered with the lowest total cost of
ownership, and the owner is assured of
ongoing support to ensure gains made
are preserved and encouraged. Such relationships are rare, but when they happen, all beneft substantially. n
ABOUT THE AUTHOR
NEW!
Includes 18 legends and 23 symbol libraries (AutoCAD) and 18 stencils(Visio)
FEATURE SUMMARY
Pro style symbol attributes and annotations
Text font and color attributes to match drawing and layer
Easily link attributes to external spread sheet and databases
Easily drag and drop palette symbols/shapes sized and confgured
for ease of symbol selection from symbol groups
+1 (803) 699-8085
[email protected]
www.megafex.com
32
WWW.ISA.ORG
RESOURCES
www.isa.org/store/products/
product-detail/?productId=120771
Choosing the Right Partner for Your
Enterprise Integration Project
www.isa.org/WorkArea/Download
Asset.aspx?id=134004
Remember the customer
www.isa.org/templates/news-detail.
aspx?id=126366
How I caused an oil slick
with my laptop and an
internet connection.
Drive
continuous
improvement
with information
Report generation
is much easier to do T
than you think
By Roy Kok
34 34INTECH
NOVEMBER/DECEMBER
2014 WWW.ISA.ORG
WWW.ISA.ORG
INTECH
MONTH/MONTH 2014
hese days, lack of data is not the problem, it is the visibility into
that data that is challenging. But do not get caught up into thinking that the solution is advanced analytics. There is a step that is
far more valuable and easy to accomplish.
We are surrounded by gigabytes and terabytes of data, being dutifully
archived by our human-machine interface/supervisory control and data
acquisition (HMI/SCADA) systems, historians, and SQL databases. There
is comfort in knowing that the data exists should you want to jump in and
analyze it. And, no doubt, that is a valuable capability. But if that is your
modus operandi, then you will be diving into that sea of data without a
suitable context with which to view it. The ability to recognize the unusual in data requires familiarity with the data and systems generating that
data. Operators develop that familiarity through their day-to-day interaction with a process. Operators have been known to step into a control
room and know through the hum and buzz that the process is running as
AUTOMATION IT
Ease of use
Ease of use is a feature critical to quality (CTQ)
to meet the requirements of industrial reporting.
In the world of automation, ease of use also means
Connectivity
A report solution for industry must understand
industrial data sources. Users beneft most when
a report can aggregate and analyze data from a
variety of data sources, both business and industrial. From a product perspective, this refers to
drivers that can be installed to connect the reporting engine to any source of data that exists inside
or outside your plant. Data in enterprise systems,
wherever they are, can be queried through business standards, such as OLE-DB or ODBC or by
importing CSV or Excel fles. BI tools can address
only some of these requirements.
Data sources also include industry standards,
such as OPC DA, OPC AE, OPC HDA, Modbus,
BACnet, and proprietary interfaces to HMI, SCADA, Historian, analyzer, custody transfer, batch,
and myriad vendor-specifc solutions. Often,
these data sources can analyze and return data in
advanced ways, and performance is maximized
when leveraging this functionality. For example, if
you need hourly averages for a day, it is best to ask
the source for that statistic rather than request a
day of data (potentially tens of thousands of samples) to produce the hourly stats. Of course, if that
level of analysis is required, an industrial reporting
INTECH NOVEMBER/DECEMBER 2014
35
AUTOMATION IT
Industrial metrics
WWW.ISA.ORG
AUTOMATION IT
37
User
adoption of
industrial
wireless
Applications, technology,
and systems
By Jay Werb
38
WWW.ISA.ORG
FAST FORWARD
Product performance
Performance
demanded at the high
end of the market
in
d
n
W ir e
ta ti o
m en
s tr u
am
tr e
i n s ti o n
Ma d o p
a
in
s
n
es
r e l a ti o
W i ent
m
u
r
st
Industrial wireless users are quickly learning wireless performs well for a wide
range of applications.
Performance
demanded at the low
end of the market
Time
Figure 1. Christensen innovation model adapted for industrial wireless
Source: AIW LLC
Installation
Wired instrumentation
Wireless instrumentation
Infrastructure equipment
Instrumentation
Continuous reporting
Performance
Bus capacity
l e.g., 420 mA
Reliable until the wiring fails
l Corrosion, vibration, etc.
Management
Security
Periodic reporting
Data freshness and availability
l e.g., 30 seconds @ 99.99 percent
Shared channel capacity
l e.g., 90,000 time slots/minute
Channel transients
l Fading, interference, blockage, etc.
Short-term management:
l Redundancy for automatic self-healing
Long-term management:
l Monitor network diagnostics
l Anticipate systematic problems
l Reconfgure wireless infrastructure
l Battery management
l Radio spectrum management
Redundancy
Radio mesh
Radio as complement to wired link
39
Disadvantages of battery-powered
operation include:
l Battery maintenance. Maintaining the
batteries of wireless devices somewhat
offsets wireless cost savings. A welldesigned wireless solution should ensure that battery replacement occurs
in conjunction with an instruments
general maintenance interval.
l Limited wireless instrumentation. An
ISA100 Wireless adapter can convert
40
WWW.ISA.ORG
Condi:on
Hours
Open loop
Closed loop
Process
Safety
Process
Minutes
Seconds
Timeliness
Extend
your Ethernet
network where
you need it most
NEW!
According to ANSI/ISA-18.2-2009,
an alarm is an audible and/or visible
means of indicating to the operator an
equipment malfunction, process deviation, or abnormal condition requiring a
response. The essential element of this
defnition is the response to the alarm.
The term alert is generally used for
applications with less rigorous requirements than alarms, for example maintenance alerts where the user response is
not specifc or time critical.
A safety-related alarm designation
can be applied to an alarming application that is a candidate for safety credit as an IPL. To simplify approvals, less
than 0.9 availability may be claimed,
thereby classifying an alarm as a basic
process control system. Regardless of
an alarms classification, high reliability is invariably a key objective.
It is well established that an alarm
system must be designed to effectively handle individual alarms during
normal operation and handle many
alarms during a major plant upset.
Wireless has the potential to support
many more alarms than has been feasible in the past, so alarm management is an essential consideration in
a scaled wireless implementation.
WWW.ISA.ORG
Figure 4. ISA100 structured network design: One network scaled through an IP backbone
Figure 5. ISA100 ad hoc network design: Multiple small networks scaled by duplication
Figure 5 shows an ad hoc network design. A series of small, typically singlepurpose, networks are installed over time.
Each network is attached to a device called
a gateway. The diagram shows that each
gateway also hosts a management function. The connections on the other side of
the gateway are shown as a series of question marks, suggesting that the high-side
interface is not specifed by the standard
and could be just about anything. ISA100
Wireless is designed to scale through IP.
In practice, small systems or evaluation
systems will tend to use ad hoc methodologies as illustrated in fgure 5. However,
as systems scale, most users will prefer to
leverage the IP backbone as illustrated in
fgure 4. Ad hoc systems tend to be rolled
out organically, one project at a time, and
can result in unmanageable chaos at scale.
For example, unplanned battery failure
and communication path instability are
typical symptoms of an ad hoc methodology that is inappropriately scaled.
Jay Werb ([email protected]) is the technical director of the ISA100 Wireless Compliance Institute (WCI), where he manages
the organizations compliance and other
technical programs. He is also the editor
and author of the data link layer (mesh)
section of the ISA100.11a standard. Werb
has more than 30 years of experience in
the computer feld, with the past 20 years
focused on wireless. He has been the
technical founder of multiple technology
companies and holds more than a dozen
patents. In addition to his work with WCI,
Werb is a consultant with AIW LLC, where
he assists end users with strategic adoption of industrial wireless instrumentation.
He has a B.S. in biology and a masters degree in management, both from the Massachusetts Institute of Technology.
View the online version at www.isa.org/intech/20141206.
43
N
ABOUT THE AUTHOR
44
ew powerful and capable industrial control systems and software solutions have
created more opportunities for manufacturers to pursue and achieve greater levels of effciency, performance, and proftability. Businesses
now have more data to measure and analyze, as
well as more opportunities to use that data to drive
effciency. This greater interconnectivity between
systems and software has also enabled producers
to be more agile, particularly in reacting to changing business variables and process conditions.
But these new offerings and capabilities have also
created new business vulnerabilities. As manufacturers apply technologies, they must ensure they
are not jeopardizing the operational integrity of the
plant. Operational integrity is simply the unhindered
ability of the system and plant to remain sound and
to continue production. In other words, operational
integrity means safely and securely mitigating and
eliminating threats to business continuity, while
meeting or exceeding production targets.
Producers are correctly looking at the promise
new technologies bring, namely the ability to use
real-time information to better understand their resources, improve how they control costs and business variables, and increase their proftability. The
need for real-time operational data to achieve this
promise has propagated the use of commercial
off-the-shelf information technology solutions in
industrial environments and shifted the industry
toward connected network solutions. Now with
the Internet of Things, big data, and other emerging trends, connectivity has reached a new level of
focus in the discussion, as well as in investments.
Because almost everything can be connected to
anything from anywhere at any timeat a low
costnew opportunities for improving business
processes and performance seem unlimited. For
example, at its Rabigh, Saudi Arabia, refnery complex, Rabigh Refning & Petrochemical Company
implemented a plant information management
system, fully and tightly integrated with its control,
SAP, and other production and corporate business
applications, to optimize output, improve quality,
and increase overall business performance. The solution covers the entire refnery and petrochemical
complex comprising 23 plants.
But regardless of what that new technology and
better connectivity promise for improving business
performance, eliminating and responding to poten-
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45
In memoriam
Ed Sullivan
SA instructor Ed Sullivan passed away on 11 October 2014. Sullivan was a veteran instrumentation professional who began his career
in the U.S. Air Force. He was an instrumentation technician, a design
engineer in both the offce and the feld, and an instructor in the classroom and plant. He worked in education, agriculture, aviation (licensed
commercial pilot), chemical, food, medical, pharmaceutical, and textiles
for organizations including Allied Chemical Corporation, Toledo Scales
Distributors, Lockwood Greene Engineers, and the U.S. government. He had an extensive
background in instrumentation and electrical design, application, documentation, and
feld startups. Sullivan was a member of the National Occupational Competency Testing Institute and the author of numerous calibration documentation procedures. He also
developed calibration data formats and established preventative maintenance programs.
Sullivan started teaching for ISA in 1999 with the objective to share my knowledge and
experience with those who are to follow me. He will be sorely missed by members of his ISA
family, but remembered as a valuable colleague and individual to have known and worked
with. He contributed much of his knowledge and expertise to the success of ISA courses. He
challenged his students to think beyond what was on paper or right in front of them.
Keith Otto
ormer chair of the InTech editorial advisory board, Keith David Otto,
P.E., passed away on 14 October 2014. After serving in the U.S. Navy
as a gunfre control technician and earning a B.S. in electrical engineering, Otto worked on the Thor and Titan missile/rocket projects early in his
career at AC Spark Plug. His career also included positions at American Can
Co., Fischer & Porter Co., and Marathon Engineering, where he also served a
13-year term as president. Otto went on to work for James River Corporation
as director of manufacturing technology and later cofounded Neenah Engineering Inc., where
he worked until May 2014.
He was an active member of several technical societies, including ISA, TAPPI, IEEE, IAAI,
and IAEI. Otto is the namesake of the Keith Otto Award, which is presented each year to the
author of the best article in InTech. Otto was a lifelong member of ISA who served on the
editorial advisory board. Colleague Walt Boyes remarked, Keith was always a voice of professionalism and moderation on the publications board and on the InTech editorial advisory
board. He was one of those fantastically competent, quiet engineers who was much more
interested in getting things done than in self-aggrandizement. He will be truly missed.
Jerry Voss
SA67 member and ISA instructor Jerry Voss passed away on 1 November 2014. Voss was a highly qualifed instrumentation and control
systems specialist with many years of experience in U.S. naval and
commercial nuclear reactor facilities. He specialized in project management and programmatic/design support in the areas of software quality
assurance, digital process improvement, set point analysis, drift analysis,
and licensing of instrumentation.
Voss was a longtime POWID Symposium supporter, presenter, and session chair. He was
also a valued ISA course instructor, course developer, and standards leader. Colleague Ron
Jarrett wrote that we have lost a great leader and more importantly a dear friend. His
family explained that he really much preferred to be working toward a goal, getting things
done, and helping someone than having all eyes on him. He was passionate about getting
things right. Voss cared deeply about his colleagues, friends, and family and was willing to go
out of his way to help out, share a laugh, or just listen to someones concerns. In his professional life, he strived to give of his best to clients and colleagues alike.
46
WWW.ISA.ORG
CAP answer
The most important measure for production equipment support is operational
availability, or uptime.
Automation equipment that operates
for 365 days x 24 hours per day = 8,760
total possible up hours. This equipment gets preventive maintenance for 1
hour every month (12 hours per year),
plus additional quarterly preventive maintenance of another 2 hours each quarter
(8 more hours per year).
There was one failure that resulted in
6 hours of downtime and a second failure that resulted in 4 hours of downtime.
Thus, total downtime for all maintenance
was 12 + 8 + 6 + 4 = 30.
The correct answer is A, 99.66%.
CCST answer
The correct answer is C, Proportional,
integral, and derivative modes on error.
The standard PID algorithm is confgured so that each of the three terms operates on the error (SP PV). Proportional
and derivative actions can also be confgured to operate on PV (measurement),
but not integral. Integral requires a reference against which to integrate (i.e., SP
as a reference, and error as the quantity
over which to integrate).
Answers A, B, and D all include integral on measurement, and therefore are
not valid forms of the PID algorithm.
Reference: Goettsche, L. D. (Editor),
Maintenance of Instruments and Systems, Second Edition, ISA, 2005.
47
By Harley Jeffery
48
WWW.ISA.ORG
AUTOMATION BASICS
LC
FC
Figure 2. Bottoms level-to-fow cascade strategy
49
AUTOMATION BASICS
knl
knl=1
knl=NL_MINMOD
e=PV-SP
NL_TBAND
NL_GAP NL_HYST
WWW.ISA.ORG
Standards
Certification
Education & Training
Publishing
Conferences & Exhibits
ecause previous columns have focused on the intricacies of developing the workforce of the future,
I want to take a slightly different twist
on this important topic. From primary
education through graduate learning,
workforce development is vital to our
growth as a profession. ISA has formed
a partnership with FIRST (For Inspiration
and Recognition of Science and Technology), and the Automation Federation has
developed the Automation Competency
Model and is working with various learning institutions to develop automationspecifc curriculum. With all of this work
going on, what are we, the professionals
who currently make up the automation
workforce, doing to enhance our careers
and support our own profession?
What is your career path?
Over the years, I have seen that an overwhelming majority of automation professionals do not have a solid, actionable career plan. I cannot explain why this is the
case, but it seems to be the reality. How
many of us have determined what we
want from our careers? What do we want
to be in fve, 10, 15 years? The norm is
the passive path, where we put our careers in the hands of others. As we gain
more seniority in a company, often we are
expected to take on more responsibility
or we are placed in a position where our
expertise and passion are misplaced. For
instance, a great senior technical person
may be placed into a project management role in which he or she will likely
struggle to be successful and will feel out
of place.
Automation professionals can fnd
themselves in a variety of roles, such as
technicians, engineers, managers, sales,
service, feld techs, commissioning specialists, technical gurus, and process experts. We can work for end users, systems
integrators, vendors, engineering frms,
ourselves, and many other employers. The
possibilities are endless. With all these options, how do you differentiate yourself
52
WWW.ISA.ORG
NSI/ISA-18.2-2009, Management
of Alarm Systems for the Process
Industries, has found wide use
across the process industry sectors. The
standard addresses the development,
design, installation, and management of
alarm systems in the process industries.
Alarm system management includes multiple work processes throughout the alarm
system life cycle. The standard defnes
the terminology and models to develop
an alarm system and the work processes
recommended to effectively maintain the
alarm system throughout the life cycle.
The IEC version of the standard, IEC
62682, has been completed and will be
published by the end of 2014. ISA18 cochairs Donald Dunn and Nick Sands led
the IEC work as convener and secretary/
editor, respectively. Dunn is the director
of engineering in the Amarillo Division for
Phillips 66. Sands is the global alarm management leader for DuPont and a Manufacturing Technology Fellow for DuPont
Protection Technologies.
InTech caught up with the two at the
ISA Leaders Meeting in Kansas City, Mo.,
in early November for a brief interview
following a one-day meeting of ISA18.
Are there any signifcant changes in the
forthcoming IEC version from the original
ISA standard?
Dunn/Sands: IEC 62682 eliminates country-centric criteria that were present in the
original standard. In addition, there was a
shift of the normative criteria (should to
shall) within IEC 62682. The IEC work
utilized one editor (Sands) of the document
in lieu of the clause editors used in writing
the original ISA-18.2, promoting a more
cohesive document with consistent wording and terminology throughout.
What are the key goals for ISA18 in 2015?
Dunn/Sands: The bulk of the subjectmatter experts on alarm management participate on ISA18. The starting point in the
IEC work, of course, was ANSI/ISA-18.22009. As co-chairs of ISA18, we elected
53
WWW.ISA.ORG
Temperature controllers
The PXU series of proportional-integralderivative controllers is designed for machine builders, systems integrators, and
commercial equipment manufacturers.
The series enables tighter, more reliable
control over a wide range of processes,
including temperature, fow, and pressure, from a single model.
Capable of being deployed in precision process applications within the
food and beverage, plastics, packaging,
energy, gas, heat-treating, commercial,
and medical industries, the PXU series
offers 1/16, 1/8 and 1/4 DIN-size models.
The series has a bezel design with large
displays for better visibility from long
distances, optional RS-485 communications for integration with PCs, PLCs, and
HMIs, and 1-inch shorter depth to save
panel space. It is programmable via the
front panel push buttons or the companys Crimson confguration software,
and it has on-demand auto-tuning.
Universal inputs support thermocouple,
RTD, 010 VDC, and 420 mA (050).
Red Lion, www.redlion.net
George C. Bentinck
Karen McMillan
Lorne D. Brackenbury
Dale C. Merriman
Thomas J. Burke
Michael J. Murray
Donald C. Clark
Kevin Patel
Paul Gruhn
Philip C. Harris
Bill R. Hollifield
ISA Calgary Section
ISA Process Management
and Control Division
A. Vimala Juliet, Ph.D.
Hector R. Perez
J. Prakash, Ph.D.
James F. Tatera, CSAT
Ultra Electronics, 3eTI
Enio Jose Viana
Ludwig Winkel
10 November 2014
Arvest Bank Theatre at The Midland
Kansas City, Missouri, USA
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56
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classifeds
datafle
Datafles list useful literature on products and services that are available
from manufacturers in the instrumentation and process-control industry.
To receive free copies of this literature, please contact each manufacturer
via their provided contact information.
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STATEMENT OF OWNERSHIP
MANAGEMENT AND CIRCULATION
(Required by 39 U.S.C. 3685)
Title of Publication: InTech
Frequency: Bimonthly
Number of Issues
Published Annually: 6
5,511
35,472
40,983
1,478
230
1,708
42,691
725
none
43,416
96%
5,367
34,890
40,258
1,454
224
1,677
41,935
577
none
42,512
96%
57
W
ABOUT THE AUTHOR
Rick
Zabel
(rick@
automation.com) is vice
president, publisher, and
occasional editor of Automation.com, and has
been with the company
since its inception in
2000. Previously, Zabel
worked with Wunderlich-Malec Engineering Inc. of Minnetonka,
Minn., where he was
the marketing manager
for the process control
and software integration business groups.
Zabel has a B.S. in electrical engineering.
58
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peace of mind
rosemount.com/stopsteamloss
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