April 2011 - Control Global

Information
Wants to Be
How ya gonna keep ‘em
down at the plant now
that they got an iPad
for Christmas?
Coriolis Flowmeters
Mean Savings at Ely Lilly
April 2011
SCADA System Newest
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Exclusive to the Web
The Future of Process Management

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System 800xA Extended Automation
The Power of Integration
Profitable collaboration. Operational excellence can only be achieved through collaboration
between people and systems. ABB’s System 800xA Extended Automation platform provides
the collaborative environment necessary for various organizations and departments to work as
one. Utilizing System 800xA’s patented Aspect Object Technology, information is integrated
from various plant systems, applications, and devices and presented as one plant-wide view
enabling informed, real-time decision making. That’s the power of integration.
For more information visit www.abb.com/controlsystems

April 2011 • Volume XXIV • Number 4
f e at u r e s
F l o w
44 / Flowmeter Boosts Solvent
Recovery
Improved measurement accuracy delivers better control
and savings. by Larell Palmer and Erik Schroeppel
S C A D A
47 / Remote Wind Energy SCADA
Control System
Like old-fashioned farming, tending a wind farm is a
24/7/365 job. At Iberdrola Renewables, the new SCADA
system is a key “farm hand.” by Harm Toren
W E B E X C L U S I V E S
The Future of Process Management
by David Beckmann
www.controlglobal.com/1104_FuturePlant.html
Cover Story
32 / Information Wants to Be
Everywhere
How ya gonna keep ‘em down at the plant now that they
got an iPad for Christmas? by Nancy Bartels
The European Report
www.controlglobal.com/IAI
CONTROL (ISSN 1049-5541) is published monthly by PUTMAN Media COMPANY (also publishers of CONTROL DESIGN, CHEMICAL PROCESSING, FOOD PROCESSING, Industrial Networking,
PHARMACEUTICAL MANUFACTURING, and PLANT SERVICES ), 555 W. Pierce Rd., Ste. 301, Itasca, IL 60143. (Phone 630/467-1300; Fax 630/467-1124.) Address all correspondence to Editorial and Executive Offices, same address.
Periodicals Postage Paid at Itasca, IL, and at additional mailing offices. Printed in the United States. ©Putman Media 2010. All rights reserved. The contents of this publication may not be reproduced in whole or part without
consent of the copyright owner. POSTMASTER: Send address changes to CONTROL, P.O. Box 3428, Northbrook, IL 60065-3428. SUBSCRIPTIONS: Qualified-reader subscriptions are accepted from Operating Management in the control
industry at no charge. To apply for qualified-reader subscription, fill in subscription form. To non-qualified subscribers in the U.S. and its possessions, subscriptions are $70.00 per year. Single copies are $15.00 domestic, $17.00 foreign. Subscriptions
for Canada and Mexico are $112.00. Foreign subscriptions outside of Canada and Mexico accepted at $125.00 per year for surface and $210.00 for airmail. 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.
A p r i l / 2 0 1 1 www.controlglobal.com 5

Put a stop to energy loss.
For energy consumption and plant efficiency to be assessed objectively and true savings measures implemented, targeted
energy monitoring is required. At Endress+Hauser we provide tailor-made energy monitoring for steam, air, gas, oil,
water, electricity, heating and cooling. Additionally, we offer everything you need to achieve your energy-savings
potential: precise measuring instruments, intelligent devices for data recording and transfer, and the support you need
to analyze and evaluate measured energy data. www.us.endress.com/ems
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April 2011 • Volume XXIV • Number 4
D E P A R T M E N T S
9 / Editor’s Page
It’s All About the Uptime! The elevator
speech to sell spending for process control
safety and security to the CEO.
11 / On the Web
Good Spring Reads. ControlGlobal links to
must-reads for spring and beyond.
13 / Feedback
Another Look at the Fieldbus Jungle and
Why Some Folks Don’t Tweet.
16 / Security Spotlight
Do Firms Expect Too Much Cyber-Threat
Data? Insisting on too much detail about
possible attacks may be just an excuse not
to implement sound security plans.
23 / On the Bus
Attack of the Mutant Chicken Foot! Not
a cheap horror flick, but a way to manage
your fieldbus installation.
24 / In Process
Siemens challenges gamers to run a process
plant, and other process news.
52 / Ask the Expert
Measuring Drift, Stability, Offset and Bias;
Measuring Steam Quality
54 / Roundup
What’s new in process analyzers
55 / New Products
Things you need to do your job better.
58 / Product Exclusive
OPC/FDT collaborate on the new FDT 2
standard.
60 / Control Talk
The Ultimate Limits of Performance. Mc-
Millan and Weiner look at just how far we
can go with control system performance.
61 / Ad Index
Check these pages.
62 / Control Report
Little company masters wireless and big
data to help customers meet EPA rules.
IN PROCESS
Record attendance at the Fieldbus
Foundation 2011 Annual Meeting in
Mumbai.
PRODUCT SHOWCASE
Low-maintenance, high-accuracy
pH/ORP sensors from Sensorex.
31 / Resources
Online help with your PLCs and PACs.
Circulation aUdited JuNE 2010
Chemicals & Allied Products................................................................................12,548
Food & Kindred Products.....................................................................................12,638
Paper & Allied Products.........................................................................................3,470
Primary Metal Industries........................................................................................5,445
Electric, Gas & Sanitary Services............................................................................3,116
System Integrators & Engineering Design Firms....................................................8,912
Rubber and Miscellaneous Plastic Products...........................................................4,403
Stone, Clay, Glass & Concrete products.................................................................2,057
Textile Mill Products...............................................................................................1,361
Petroleum Refining & Related Industries................................................................3,877
Tobacco Products......................................................................................................115
Total circulation....................................................................................................63,006
A p r i l / 2 0 1 1 www.controlglobal.com 7

Best power to dollar ratio
helps you do more
Use the technology built into the Productivity3000
programmable controller to make your job easier. Its speed
and power make the P3-550 CPU an unbeatable value at
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And power? This CPU does the work of multiple pieces of
hardware compared to other controllers. With its seven
built-in communication ports, you get:
• Plug-and-play USB or Ethernet programming and monitoring
• USB local I/O expansion port (no local I/O master module needed)
• Ethernet remote I/O expansion port
(no remote I/O master module needed)
• High-speed Ethernet port for HMI (up to 32 C-more panels),
controllers, and enterprise system communications
(no Ethernet module needed)
• Two serial ports for peripheral device interface or controller
networking (no serial communcation or ASCII module needed)
• USB port for data logging to removable drive and project transfer
The 50Mb memory supports large programs, complete
with tag name database and program documentation
stored onboard. And with a huge (100,000+) I/O capacity,
the Productivity3000 can handle just about any system
you need.

E D I T O R ’ S P A G E
It’s All About the Uptime!
Ever since President Bill Clinton’s “It’s all about the economy, stupid!,” we’ve been
shoehorning complex ideas into one-liners. They resonate better, make sound bites for
the evening news, and make the “elevator speech” easier. So, when we want people
to listen about safety and security, we’re going to have to have a one-liner to use there.
Walt boyes
Editor in chief
wboyes@putman.net
As I said in this space last month, we are doing
abysmally poorly at creating functioning
safety cultures in manufacturing, and we are
still relentlessly and regularly injuring and killing
people—and we are also losing great big
gobs of money because a plant that goes boom
is a plant that is not making product. I for one
am having a very hard time understanding the
disconnect that has been happening about the
idea that a safe plant is a profitable plant. In
fact, a safe plant is a more profitable plant.
A CEO recently said, “I don’t want to hear
from my plant. When I hear from my plant it
means something is wrong, and I don’t want
things to go wrong. So I don’t want to hear from
my plants.”
In fact, the CEO is right. His job is to measure
and manage the business of which he’s the
chief executive. It’s not his job to engineer or
operate an olefins plant, for example, or a tomato
sauce manufacturing line. CEOs who micromanage
like that aren’t usually around for
very long.
Process safety and industrial control security—although
they are vitally important to us
and to the financial health of the corporation—
are down in the weeds when viewed from the
lofty heights of the boardroom, and they probably
should be.
As I have been saying for years, process
safety, industrial control security, physical security,
alarm management and operations strategies
are really all ways of looking at the same
thing from different points of view. What this
means is that you can’t do any of those things
in a vacuum without considering the effects of
what you’re doing on the others.
But, as we’re finding out from incidents like
Deepwater Horizon and the Stuxnet attacks,
all the safety systems and all the industrial controls
security systems in the world can’t defeat
human beings intent on screwing things up—
whether they are doing it accidentally or on
purpose.
Most people will agree that, to complement
the systems we devise for plant control systems
and equipment, we need the corresponding
culture change in the attitudes and behaviors
of the people involved. And there the matter
stops. We don’t seem to know how to get culture
changed.
Levi Leathers of The Dow Chemical Company
made an essential part of working at Dow
the deep understanding that a safe plant is a
more profitable plant, and that is the hook on
which we need to hang safety and security
practices and procedure. As Leathers found, it’s
great to be the boss. He was able to drive the
development of a safety culture because he was
the boss.
Here’s the one-liner for your CEO. “Safety
and security are all about uptime.” Every CEO
is vitally interested in sustainable manufacturing
practices. CEOs are willing to spend big
bucks on sustainability. The fact that your plant
didn’t blow up is a real sustainability issue. The
fact that you can continue to make product is
sustainability writ large. What a concept!
That’s why we launched www.sustainableplant.com
in February. Uptime improvement
is a vital sustainable manufacturing practice,
and safety and security both make key contributions
to increasing and maintaining your
plant’s uptime.
So let’s go talk to the CEO about improving
uptime and profit from his plants—so that he
won’t have to hear from them.
All the safety
and industrial
controls security
systems in the
world can’t defeat
human beings
intent on screwing
things up.
A p r i l / 2 0 1 1 www.controlglobal.com 9

Name
Peter Simonsen
Job Title
Design Engineer,
Embedded Software
Area of Expertise
Renewable Energy
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Other product and company names listed are trademarks or trade names of their respective companies. 2811

C O N T R O L O N L I N E
KATHERINE BONFANTE
MANAGING EDITOR, DIGITAL MEDIA
kbonfante@putman.net
New Things Come With
Spring – Including Good
Reads
www.controlglobal.com/thismonth
Energy Savings Opportunities
Low-cost operational improvements
that use process condition and control
improvements to unlock hidden energy
saving opportunities. http://tinyurl.
com/4q7wbfdl
I love spring! It is the best season of the year. I don’t say this because there is
more sunlight to absorb, more clean air to breathe in, or more fresh fruits to
eat. I love it because during the spring I spoil myself by having a shopping
spree and getting new things—new shoes, new purses, new clothing items,
new everything.
Don’t worry, I’m not selfish. I’ve also been thinking about you, www.ControlGlobal.com’s
readers, and I’ve been preparing our site with online deals
for you too. The best part is that what I have online for you is free.
The first item available on our site this spring is the white paper, “How
Stuxnet Spreads–A Study of Infection Paths in Best Practice
Systems.” (www.ControlGlobal.com/howstuxnetspreads.html).
There have been extensive reports of
this worm’s internal workings and the vulnerabilities
it exploits, but there is little information on how the
worm might have migrated from the outside world into
presumably secure industrial control system (ICS).
This white paper analyzes potential infection pathways
in a typical ICS system, and gives designers and operators the appropriate
steps to take to make control systems more secure.
This spring you can also learn how to optimize combustion of fuels. Visit
www.ControlGlobal.com/combustion.html to read “A Beginner’s Guide to
Optimizing the Combustion of Fuels.” Optimization improves efficiency,
reduces environmental impact, reduces maintenance requirements and increases
the time between maintenance shutdowns. This guide discusses how
best to optimize combustion efficiency in any application that uses combustion
plants.
There’s more spring reading here in “The Power of Integration.” In order
to be competitive, various plant entities, departments and personnel have
to work as one flexible, integrated team. To do this, an automation platform
with connectivity capabilities is necessary. Find out more about integration
best practices at www.ControlGlobal.com/integrationpower.html.
During the spring, it’s not just the grass that is turning green. Sustainability
is a hot topic during any time of the year. Read “The First Step,” and learn
how global trends, such as higher oil and gas prices and challenges, drive the
need to improve energy efficiency. Read this article at www.ControlGlobal.
com/firststep.html to identify the process improvement opportunities and
see a proposed work process methodology to achieve energy optimization.
Updated every business day, the Control Global online magazine is available at no charge.
Go to www.controlglobal.com and follow instructions to register for our free weekly e-newsletters.
Know Your Flow
Using Coriolis meters as process analyzers;
http://tinyurl.com/36753no
Installing Fieldbus
Fieldbus installations require some additional
considerations over and above
traditional 4-20 mA projects http://tinyurl.com/4t228la
Out of Control Cartoons
Ted Williams, Control’s resident cartoonist,
sketches the light side of the
trials and tribulations of life as a process
engineer. www.controlglobal.
com/extras/OutofControlCartoons.
html.
WeeklyReview
Each week, see the most-read articles,
white papers and most-watched multimedia
fi les. www.controlglobal.com/
enews/weeklyreview.html
Why Manufacturing Is Leading Economic
Recovery
See why at www.controlglobal.com/
articles/2011/ManufacturingEconomy1102.html
ControlGlobal E-News
Multimedia Alerts
White Paper Alerts
Go to www.controlglobal.com and
follow instructions to register for our
free weekly e-newsletters.
A P R I L / 2 0 1 1 www.controlglobal.com 11

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THE HIDDEN FIELDBUS
NETWORK
THE RIGHT TOOL FOR TRICKY
MEASUREMENT JOBS
ANALYZER SAMPLE
SYSTEMS BASICS
CT1102_01_CVR.indd 3
EXCLUSIVE TO
THE WEB
HOW MUCH THREAT INFO
DO USERS REALLY NEED?
EUROPEAN PROCESS NEWS
1/27/11 9:06 AM
555 W. PIERCE RD., SUITE 301 • ITASCA, ILLINOIS 60143
administrative team
President & CEO: JOHN M. CAPPELLETTI
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Reprints Marketing Manager: JILL KALETHA
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editorial team
Editor in Chief: WALT BOYES
Executive Editor: JIM MONTAGUE
wboyes@putman.net
jmontague@putman.net
Digital Managing Editor: KATHERINE BONFANTE
Managing Editor: NANCY BARTELS
Senior Technical Editor: DAN HEBERT
kbonfante@putman.net
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dheber t@putman.net
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Columnists: BÉLA LIPTÁK, GREG MCMILLAN, STAN WEINER
Editorial Assistant: LORI GOLDBERG
design & production team
Group Art Director: STEVE HERNER
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JESSE H. NEAL AWARD WINNER
ELEVEN ASBPE EDITORIAL EXCELLENCE AWARDS
TWENTY-FIVE ASBPE EXCELLENCE IN GRAPHICS AWARDS
ASBPE 2009 MAGAZINE OF THE YEAR FINALIST
FOUR OZZIE AWARDS FOR GRAPHICS EXCELLENCE
T E C H N I C A L LY S P E A K I N G
F E E D B A C K
Fieldbus Errors
I enjoyed reading the article “Fieldbus
Jungle,” (www.controldesign.com/industrynews/2011/018.html),
but I found a
number of factual errors connected with
Profibus and Foundation fieldbus (FF):
1. Comparing the cost of Profibus PA
and 4-20mA, the author uses the example
of 5 to 10 valves or transmitters for non-
IS. In my experience, most non-IS designs
will use 15 to 20 valves and transmitters.
By the article’s argument, increasing the
number of valves and transmitters would
make Profibus more economical than
4-20mA.
2. The author states that the lead time
for fieldbus devices is longer than for 4-20
mA devices. This is not true for Siemens.
The published lead times for Profibus PA,
HART, FF and 4-20 mA option for Siemens
instruments are the same.
3. When designing a network the author
states that you need to know within
a few feet where devices are installed for a
fieldbus network. The design rules in the
IEC standard state a maximum limit on
the spur lengths based on the number of
instruments. For the most part, this is either
30 or 60 meters, which gives designers
a large range to work from
4. The author states that troubleshooting
fieldbus networks is very hard. A number
of diagnostic tools are available to
troubleshoot fieldbus networks. Several
manufacturers—Procentec, Softing, P+F,
MTL—make them and have case studies
showing how easy they are to use.
5. According to the author, fieldbus lifecycle
costs are high because people do not
understand the technology. Furthermore,
it is implied that it is hard to train instrumentation
people. I have been a technical
trainer at Siemens for more than 10 years
and have seen things change. There is no
doubt that 4-20 mA is easier to teach, but
people of all ages are catching on to the
new technology.
6. The author states that the bus wars
are over and that Profibus and FF are
merging. It is true that FF and Profibus
organizations are now cooperating; however,
I am not aware of any move to a common
control bus. Given the technical differences,
I am not sure if this would even
be possible.
7. The author stated that GSD files
change often. It is possible that the author
is confusing GSD files and EDD files. If
you look at the case of Siemens transmitters
and actuators, GSD files do not tend
to change, while
EDD files tend to
change with each
firmware revision.
What that means is
that you can take an
old instrument and
replace it with a new
one without touching
the control system,
although you will have to update the
engineering station.
JAMES POWELL, P.ENG
SIEMENS MILLTRONICS
james.powell@siemens.com
Why We Can’t All Tweet That
I read with interest your recent article in
the February issue of Control magazine
(“What the Tweet!!?,” www.controlglobal.
com/articles/2011/AutomationTweet1102.
html). I agree that many social media tools
can have a powerful positive effect on being
able to keep up with current trends in
the profession. However, there are many
of us that are actively prevented from using
these tools during our professional
time at the office. Many companies, mine
included, block any access to YouTube,
Twitter and Facebook. Even LinkedIn is
blocked since all “social networking” sites
are not allowed. Yes, I do use my smart
phone to view training videos on You-
Tube, but it is not nearly as convenient as
the large screen on my computer. Please
don’t forget about those of us that are not
able to use these tools.
DEWIGHT REA
ASCEND PERFORMANCE MATERIALS
adrea@ascendmaterials.com
[Editor’s Note: Don’t worry. We never forget
here that we still have a lot of “treeware”
readers. We won’t abandon you for the
“shiny” of social media.]
FEBRUARY 2011
A P R I L / 2 0 1 1 www.controlglobal.com 13

S e c u r i t y S p o t l i g h t
Do Firms Expect Too Much Cyber Threat Data?
Michael Peters
infr as tructure and
cybersecurit y advisor
Michael.Peters@ ferc.gov
A recent U.S. General Accounting Office (GAO) report [GAO-10-628, “Critical Infrastructure
Protection Key Private and Public Cyber Expectations Need to Be Consistently Addressed,”
www.gao.gov/products/GAO-10-628 ] reveals that a key expectation from
industry is for actionable cyber-threat information from the federal government.
Critical infrastructure
companies
should assume
that the threat level
is “1,” meaning a
viable cyber threat
to their control
systems exists.
The dissemination of this tactical level of information
has not been completely met (see
sidebar). Because of this lack of information,
a company may choose not to implement cybersecurity
defenses because it feels there is no
threat. I believe this reliance on tactical threat
information is a false interpretation of the environment,
and is a major impediment to securing
our critical infrastructures from attack.
I do not believe this tactical level of information
is necessary for a critical infrastructure company
to implement cybersecurity defenses. The
federal government has provided strategic-level,
cyber-threat information to the various critical infrastructures,
and this type of information sharing
can easily continue because the strategic threat is
the information that the government most likely
will be able to acquire and distribute.
However, even this level of threat information
really isn’t necessary in order to justify
and implement cybersecurity defenses. Many
threat actors exist today that can impact the
security of a control system—traditional hackers,
criminals, disgruntled insiders, terrorists
and nation-states. All of them have a range of
capabilities and intents, though the common
assumption is that the nation-state is the most
technically sophisticated, and the hacker is the
least. Many of these adversaries are capable of
very structured as well as unstructured operations.
What is crucial is that the level of sophistication,
structure and capabilities varies for
all the adversary types. A security professional
should never assume that a specific type of adversary
has “specific” traits.
Wobbly Threat Leg?
Understanding these adversaries and determining
their capabilities and intents is a very
difficult problem and often results in lessthan-complete
information. However, this information
forms the basis of the “threat leg”
of the traditional risk equation: Risk = Threat
x Vulnerability x Consequences. This lack of
information often results in reducing the perceived
risk to the system. However, what every
critical infrastructure company should assume
is that one or more of these adversaries eventually
will attack them. Critical infrastructure
companies should assume that the threat level
is “1,” meaning a viable cyber threat to their
control systems exists. What threat actor attacks
them is immaterial. What companies
and their customers should care about is that
their system has been exploited, and the services/products
that the company provides are
not available.
Now, a frequent counter-argument raised
by the critical infrastructure companies is that
they can’t afford to address everything, and
that, without this threat information they don’t
know what to fix and how to spend their resources.
While this is true, I believe that there
is a better way of determining where to spend
scarce cybersecurity dollars than waiting for
tactical cyber-threat information that they may
not receive and would probably be constantly
changing, even if it were readily available.
Two Security Perspectives
I think critical infrastructure companies should
examine themselves from two main perspectives,
and not rely on threat information.
The first is most directly tied to the mission of
the company, whether it is providing electricity,
making potable water, refining gasoline or manufacturing
televisions, etc. Companies create “tiger
teams” of specialists, including their most knowledgeable
operators, control system experts and
IT personnel, and charge them with the task of
developing scenarios for causing the most harm,
destruction or danger to company personnel or to
14 www.controlglobal.com A p r i l / 2 0 1 1

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S e c u r i t y S p o t l i g h t
the public. These people have detailed intimate knowledge of
the company’s systems and processes, and they will often know
exactly how to cause the most damage to operations. They can
build on this knowledge and determine how to best mitigate
the attack vectors that they developed.
The second perspective is from a traditional vulnerability assessment/evaluation
arena. Critical infrastructure companies
need to examine their systems looking for vulnerabilities; determine
the consequences/impacts to the company’s operations
of a successful exploitation of the vulnerability; determine the
capabilities that are necessary to successfully exploit the vulnerability
and cause the identified consequences; determine
whether the capabilities needed to successfully exploit the vulnerability
currently exist, and whether these capabilities are
easy to use; and finally, tdetermine how to mitigate the vulnerability
identified and to minimize the impact of a successful
exploitation. The company should also answer all of these questions
for the scenarios developed by its internal tiger team.
Now the company can prioritize what it fixes by working
through the results of the above analysis. Vulnerabilities with
high/major impacts, where the capabilities to successfully exploit
currently exist and are easy to use, should be fixed first.
The overall goal is to improve the security of the system, and
the above methodology only uses the vulnerabilities and consequences—information
that is most likely known—rather than
needing threat information which is typically unknown. (This
is information that is definitely unknown at the tactical level
and often considered not detailed enough at the strategic level.)
Learning from Accidents
One other area where critical infrastructure companies can
gather information they can use to convince senior executives
to authorize the implementation of cybersecurity defenses
is to examine real-world industrial incidents/accidents,
and see if they can extrapolate a purely cyber scenario
that results in the same consequences. For instance, most
industrial accidents involve three legs, including a physical
issue/problem,some form of human error, and a cyber issue,
such as a cyber system not running, cyber system running,
but on incorrect data, or a malicious cyber attack, which are
currently rare.
For some industrial accidents, it is quite simple to extrapolate
to a purely cyber vector to cause the same consequences
as the original accident. However, this is normally done by
considering two main assumptions. The first is that an electronic
pathway exists from the targeted control system to the
outside world. A disgruntled insider needs to be considered
as well. The second assumption is that this electronic pathway
is exploitable, and the likelihood of this is very high. You
could simply assume a supply chain issue that allowed the
adversary to implant his malicious access at an earlier stage.
I believe that by undertaking the above three efforts,
“Threat” vs. “Tactical” InFORMation
The industry uses the general term “threat information.”
However, during more detailed discussions, it seems the
information companies want is more in line with the traditional
military concept of “tactical information”; for example,
individual “Able” from bad guy group “Baker” is planning
on attacking critical infrastructure “Charlie,” specifically
company “Delta,” on Friday at 1500 EST using technique
“Echo.” The government has been providing strategic
threat information for several years. But companies don’t
need such specific information to prepare for threats.
any critical infrastructure company will have developed/
acquired enough information to convince its senior executives
that cybersecurity defenses must be implemented to
ensure that the company can continue to carry out its mission
safely, reliably and securely without needing tactical cyber
threat information from the government before they are
persuaded to act to adequately secure their control systems.
There is one arena where tactical actionable cyber threat
information of a potential attack is needed prior to making
decisions to implement basic cyber defense mechanisms.
Mechanisms must be developed and deployed that allow information
to be shared when an attack is occurring, which
will allow companies not under attack to ramp up their defenses
to prevent the current attack from succeeding. This
assumes, however, that the companies have already implemented
cybersecurity defense measures and have developed
the plans and procedures to rapidly increase their cybersecurity
defense posture.
The Bottom Line
Critical infrastructure companies should not depend on
tactical cyber-threat information to deploy cybersecurity
defense. Instead, they should consider that the cyber threat
is “1,” and focus on understanding their vulnerabilities and
the consequences of a successful exploitation of them. Waiting
for tactical cyber-threat information could delay critical
them from examining their systems from a mission perspective
and implementing appropriate defenses. The discussions
concerning tactical cyber threats and the resulting expectations
(and need for clearances for industry personnel)
are primarily a distraction, and are being used to justify a
lack of action for implementing cyber defenses. The government
and the critical infrastructures need to get past this
self-imposed roadblock.
Michael Peters is an energy infrastructure and cybersecurit y advisor for the
Federal Energy Regulator y Commission’s Of fice of Electric Reliabilit y. He
specializes in analyzing cybersecurit y issues, including those af fecting control
systems. This ar ticle is personal opinion and does not represent the opinion or
position of the Federal Energy Regulator y Commission or the federal government.
16 www.controlglobal.com A p r i l / 2 0 1 1

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O N T H E B U S
Attack of the Mutant Chicken Foot!
A few months after start-up, our facility needed to add an alternative purge medium
for a process vessel. Along with a flow loop, we needed a couple trios of new doubleblock-and-bleed
actuated valves in a spot about 90 feet from grade. So did we need
to run nine twisted pairs (or more—up to 20 for conventional on-off valves) all the way
john Rezabek
contributing Editor
jrezabek@ispcorp.com
down to grade? We found we could just extend
an existing fieldbus segment from an instrument
at that level—so maybe 25 feet of light
conduit on a platform were needed instead of
100 feet of 2-in. down the side of a structure.
Why hadn’t we done this from the start? Our
original “chicken foot” network was grafting
eight toes on one of its toes.
In recent issues, we’ve explored how bus
technologies create new challenges for end users’
Engineer, Procure, Construct (EPC) consultants
and systems integrators. Bus technologies
provide a standardized infrastructure,
allowing smart devices to integrate happily
with the host DCS and one another. End users
want this because they see a path to improved
control, process availability and risk/asset management.
But for the EPCs, it’s disruptive.
Bus topology—the ability of multiple devices
to share the same two conductors on a network
or “segment”—is one of the disruptive forces.
We have deployed networks elsewhere, so why
would fieldbus cause consternation?
The challenge is this: process plants have
hundreds or thousands of devices distributed
to scores or hundreds (or more) segments. In
the point-to-point world, there is a one-to-one
relationship between device, single-pair cable,
multi-pair cable “pair,” field JB terminals, marshalling
terminals, scatter wire, all the way to
the I/O processor terminations, so much so that
the whole process can be largely automated.
Designers and engineers work from a database,
whose fields then populate loop drawing templates,
junction box drawings and termination
schedules.
With fieldbus, all the one-to-one relations of
the old world are scrambled: devices can have
multiple roles; home-run cables can serve as
few as two devices or as many as 32; and the
rules for grouping devices are anything but random
and can be crucial to a successful project.
Tools do exist, such as Intergraph’s SmartPlant
INTools CAD products, but they require a new
level of training and effort that was previously
unimportant or automated. So have some compassion
for your EPC and simplify.
For your first fieldbus job, consider a simple
“chicken foot” or “star” topology. By standardizing
on six segments (~72 devices) per field
junction box, your install will look and feel
close to conventional, but you’ll be running
some bigger conduits and raceways. It will look
just like conventional point-to-point from the
JB to the field. If a certain device needs to move
from segment “A” to segment “B” late in the
job, there’s an increased chance they’ll be in
the same JB. While less optimal for the project
in the CAPEX phase, the strategy lends itself
well to future expansion. In this scenario,
the client can still add to the installed “chicken
foot” as every fieldbus node can become an “expansion
point” for future additions.
Users with great confidence in their segment
loading and their team’s fieldbus savvy may
choose what many consider an “optimum” topology,
what I call the “mutant” chicken foot.
Spurs—“toes” if you will—grow on the trunk
wherever needed. The trunk strings these clusters
together as a single pair, so conduit size is
minimized. If local codes allow, using “basket
trays” can be more forgiving for late changes
and future modifications. Physical layer suppliers
such as Pepperl+Fuchs, Relcom, Turck
and Phoenix Contact have some nice modular
hardware to accommodate these multi-drop hybrid
schemes. Every project will have its unique
mix of experience and confidence on both the
client and consultant sides. Making discrete topology
choices in light of your team’s strengths
and challenges can help ensure a smoother and
less stressful journey.
We have deployed
networks elsewhere—so
why
would fieldbus
cause
consternation?
A p r i l / 2 0 1 1 www.controlglobal.com 23

I N P R O C E S S
Game On!
Siemens launches Plantville. Online game simulates a plant manager’s experience trying
to achieve maximum efficiency, productivity, sustainability and overall plant health.
So you think you can run the plant
better than your boss? Well, here’s your
chance to find out. Siemens Industry
has launched Plantville, a new online
gaming platform that simulates the
experience of being a plant manager.
Players are faced with the challenge
of maintaining the operation of their
plant while trying to improve the productivity,
efficiency, sustainability and
overall health of their facility.
Plantville enables players to improve
the health of their plants by
learning about and applying industrial
and infrastructure products and
solutions from Siemens. Gamers will
be measured on a number of key performance
indicators (KPIs), including
safety, on-time delivery, quality,
energy management and employee
satisfaction.
“Siemens is capitalizing on
the tremendous growth of online
engagement to demonstrate
how our expertise can
make industry and infrastructure
more competitive
by increasing
sustainability,
energy efficiency and
productivity in a fun
and educational environment,”
said Daryl Dulaney,
president and CEO,
Siemens Industry. “We also
hope Plantville will generate
excitement in the areas of
math, science and technology,
while inspiring a new
generation of plant managers
and engineers.”
Throughout the game,
players will be able to interact
with Pete the Plant
Manager, whose plant
has just won the “Plant of the Year”
award. Pete shares his best practices
throughout the game to help players
achieve outstanding results in plant
performance. He will use webisodes,
the Plantville Café, Puzzlers and Facebook,
LinkedIn and Twitter accounts
to dialogue with gamers, provide hints
to playing the game, and host a leader
board for contestants.
In Plantville, players can select
which of the three virtual plants they
would like to manage first: a bottling
plant, a vitamin plant or a plant that
builds trains. At the start of the game,
each type of plant is faced with different
challenges. The players must
identify the challenges facing their
plant and implement solutions
to improve the plant’s KPIs.
Gamers will compete with
one another on a number of
levels, including plant-toplant
and on specific KPIs.
Pete’s leader board will keep
track of which players
are performing the
best on each of the
levels.
Pete’s Puzzlers.
These brain teasers test
a gamer’s problem-solving
abilities and provide
tips to enhance their play.
Players attempt to solve a
puzzle or problem, and in
doing so get new insights
for enhancing their plant’s
performance. The first person
to correctly answer the
puzzler will receive bonus
points, and will be recognized
on the Plantville
Facebook page.
Plantville Café.
The Café is a fun and educational platform
within the game that offers periodic
online chat sessions with Pete on
topics such as process control, energy
efficiency, industrial networking and
more. Chat sessions will be kept in a
library as a resource for current and future
players. The sessions will enable
gamers to collect tips that will help
them manage their plants in Plantville
more effectively, while also learning
more about these topics and associated
solutions.
Plantville, like the plants within it,
will undergo updates and changes.
Siemens will continue to develop and
enhance this innovative platform to reflect
the continuing advancement of its
technologies, as well as other elements
that change or have an impact on industry
and infrastructure.
For more information or to play
Plantville, visit www.plantville.com.
Fieldbus Foundation
Holds 2011 General
Assembly in Mumbai
The Fieldbus Foundation reports
that its 2011 General Assembly, held
March 9-10 in Mumbai, attracted
nearly 500 suppliers and end users
of Foundation fieldbus technology,
making it the largest event in the
foundation’s history
India was selected as the site for
the 2011 event because it’s the world’s
fastest growing market for process
automation and the overwhelming
demand for Foundation fieldbus
technology in the area. Many of the
world’s largest Foundation fieldbus
24 www.controlglobal.com A p r i l / 2 0 1 1

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I N P R O C E S S
fieldbus installations are also located in India, and the
amount of application expertise being developed in India
is considerable.
Based on the theme “Achieving Operational Excellence
with Foundation Technology,” the 2011 General
Assembly highlighted the advantages of Foundation
fieldbus as a world-class solution for improving plant asset
management, reliability and economic performance.
Foundation technology continues to advance to meet the
needs of the process industries, with Foundation fieldbus
for safety instrumented functions (FF-SIF), control in the
field, field diagnostics and wireless solutions.
The 2011 General Assembly kicked off with welcoming
remarks by Thampy Mathew, regional sales director-PA
at Pepperl+Fuchs and chairman of the Fieldbus Foundation
India Committee (FFIC). B.R. Mehta, senior vice
president of Reliance Industries Limited and chairman
of the Fieldbus Foundation’s India End User Council
(FFIEUC) also welcomed the assembly.
Fieldbus Foundation president and CEO, Rich Timoney,
addressed the gathering and introduced new
foundation chairman, Dr. Gunther Kegel, CEO of
RECORD CROWD
Figure 1. The 2011 Fieldbus Foundation meeting in Mumbai
attracted a record crowd of nearly 500 vendors and end
users.,
Pepperl+Fuchs. Timoney described the continued growth
of Foundation technology in both established and developing
industrial regions of the world. He also highlighted
the additions to foundation membership in 2010, with total
membership increasing 11.3%. Significant membership
gains have been noted in China, Korea and other
developing areas.
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I N P R O C E S S
Manufacturing Execs Optimistic
Senior management at U.S. manufacturing companies are significantly
more optimistic about their own companies’ growth
than they were just last November, according to a Grant Thornton
LLP survey in February. Nine of 10 managers (91%) report
that they’re optimistic about their companies’ growth in the
next six months, up from 81% in November.
As for the economy, 60% believe that the U.S. economy
will improve in the next six months, up from 49% in November.
However, those planning to increase hiring in the next six
months saw a drop to 44% in February from 49% in November.
“We believe that the decrease in expected hiring despite
an overall high level of optimism is because manufacturing
executives feel some uncertainty about the future of manufacturing
in the United States,” said Wally Gruenes, Grant
Thornton’s national managing partner for Consumer and Industrial
Products and a member of the board of directors of
the National Association of Manufacturers (NAM). “They believe
that the U.S. government has no plan to make American
manufacturing more competitive in order to create more
good-paying jobs. Rather than spending scarce resources on
employees, manufacturing executives are spending on capital
equipment purchases and technology to improve productivity
and lower costs in an effort to be more competitive
globally.”
The survey was conducted Feb. 8-23, 2011, with 70 senior
executives from U.S. manufacturing companies. To see all the
survey findings, please visit www.GrantThornton.com/BOI.
PULS Suzhou Wins LEED Gold
PULS’ Eco-Complex, the Munich-based DIN-rail power
supplies manufacturer’s Asia-Pacific headquarters, has earned
a LEED Gold Certification. The building, opened at the end
of last year, is located in the Suzhou Industrial Park (SIP)
some 80 km west of Shanghai on a 14,000 sq-m plot, and its
shape mimics that of the PULS DIN-rail.
The LEED certification is awarded by the U.S. Green
Building Council. Certified buildings must meet LEED
standards in six areas—health and comfort, material, location
quality, water and energy use and innovation. The
PULS building is one of only five in China that have won
LEED gold certification. It has also won the SIP Award for
Energy Saving and Sustainability.

Ohmart/VEGA is now proud to be
VEGA Americas, Inc.
The inventor of the modern nuclear-based measurement system and the first to introduce
two-wire, loop-powered radar, Ohmart/VEGA has a strong tradition of product development.
Starting March 1st, we are proud to continue this tradition under the name
VEGA Americas, Inc. Officially becoming part of the larger, worldwide VEGA organization
helps us better serve our customers with a cohesive product offering, including what were
traditionally Ohmart nuclear products.
Through evolution and growth, our mission endures: “to deliver innovative measurement
technology solutions worldwide”.
www.vega-americas.com
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R E S O U R C E S
Where to Go for Help with Your PLCs and PACs
Control’s Monthly Resource Guide
Every month, Control’s editors take a specific product area, collect all the latest, significant tools we can find,
and present them here to make your job easier. If you know of any tools and resources we didn’t include, send
them to wboyes@putman.net, and we’ll add them to the website.
PACs FOR COMMUNICATIONS
AND DATA HANDLING
cONTROL
w w w.controlglobal.com
Many process control applications require
much more than just real-time
control, and extensive communications
and data handling can tax the
functionality of PLCs. In these instances,
a programmable automation
controller (PAC) can be a good fit.
Most PACs are derived from the PC
world, hence, their relative strength
when it comes to communications
and data handling. Control’s senior
technical editor, Dan Hebert explores
some PAC basics. Go to www.controlglobal.com/articles/2008/026.html
for
his insights.
PLCs, PACs AND POWER OVER ETHERNET
Advantech
880/205-7950 w w w.advantech.com
Field level wiring used to be very simple.
A sensor was either powered or
passive. But, when networking PLCs
and PACs coming into the control system
network became both practical
and popular, engineers started thinking
about how to provide power over
the same set of wires as the network
connection. This white paper discusses
how Power over the Ethernet is
fast becoming the standard. The link
to the free registration page is http://
tinyurl.com/47mvsqm.
DESIGNING PLC MODULES
Analog De vices
w w w.analog.com
This webcast deals with the requirements
and challenges associated
with the design and implementation
of analog input/output modules used
in industrial control applications,
with a particular focus on programmable
logic controller (PLC) modules.
Design and applications tips
and techniques will be presented,
and examples of Analog Devices’
solutions will be discussed. A direct
link to the webcast is at http://
tinyurl.com/4kg28z8.
GUIDE TO PLCS AND OTHER DEVICES
work .com
w w w.work.com
This link-rich page provides the user
with basics for determining whether
you need a programmable logic device,
tips for finding training, and
lists of available sources. A direct
link to the pages is at http://tinyurl.
com/4jlodm5.
PLC/PAC PDFs
pdf4me.ne t
w w w.pdf4me.net
This site contains dozens of downloadable
PDFs on a variety of PLC
and PAC subjects, including “Understanding
PACs,” “A Controller
System for Industrial Automation,”
“The Design of a Portable Programmable
Logic Controller,” “Introduction
to Programmable Logic Control,”
“Logic Control Systems” and
“Embedded and Industrial Automation.”
Each selection offers both a
full download and a preview page to
aid in selection. The direct link is at
http://tinyurl.com/4sqatud.
HOW TO RECONFIGURE A CONTROLLER
Control
w w w.controlglobal.com
Process control expert F. Greg Shinskey
discusses the power of external-reset
feedback in this article from Control
magazine. He says that preventing
windup requires reconfiguration of the
controller, and external-reset feedback
is the most satisfactory method of accomplishing
it. The article includes
techniques and equations for this process.
The direct link is at http://tinyurl.
com/4lwngsg.
PLC/PAC TUTORIAL
The PLC Tutor
w w w.theplctutor.com
If you have the desire to learn about
programmable logic controllers and/or
programmable automation controllers,
or if you need a refresher or some tutoring,
then this is the place to go. Chapters
include coverage of I/O wiring and
interactions, number systems, memory
structure, bit instruction, timers and
counters. There is also a list of external
links to more resources.
PLC/PAC EBOOK SHELF
Ebookbrowse
ht tp://ebookbrowse.com
This site holds a collection of ladder
logic and PLC/PAC tutorials from a variety
of sources. All are free, although
registration is required. The site contains
links to white papers, tutorials,
ladder logic diagrams, simulations and
more. Documents come in .doc, .docx,
PDF, .rtf, .xls, .ppt, .pptx and .pps formats.
The direct link is at http://tinyurl.com/4b7ltzz.
A p r i l / 2 0 1 1 www.controlglobal.com 31

T H E M O B I L E W O R K E R
Information wants to be
EVERYWHERE
How ya gonna keep ‘em
down at the plant now
that they got an iPad
for Christmas?
By Nancy Bartels
Okay, people, take out your notebooks and write down this
phrase: “The consumerization of workplace tools.” Everyone
from the CEO to the technician is seeing the ease, benefits
and, yes, fun of using mobile tools in their personal lives,
and they’re wondering why, when they can carry around
a phone, a camera and hundreds of tunes, videos, games
and books all in one device in their pockets, they have to
slog through a 3-inch stack of spreadsheets, lug around a
5-pound laptop or be tethered to a desktop computer or a
control room console to get to the data they need at work.
It’s a question that isn’t going to go away. Research group
International Data Corp (IDC) predicts that the global mobile
workforce will increase to over 1 billion workers in 2011,
totaling 30% of the workforce worldwide. In the United
States, numbers are higher still. A total of 70% of the American
workforce will be mobile by 2012. If that sounds like a
lot, remember that the survey defines “mobile worker”as everyone
from the iconic “road warrior” to the contract worker
on another company’s site to mobile field workers.
Chris Stearns, senior product manager at Honeywell Process
Solutions, says, “We’re still in the early adopter phase,
but there’s momentum here, and it’s not going to slow down.”
Mobility Drivers
The fact is, says Paul Brooks, business development manager
for the networking business at Rockwell Automation (www.
rockwellautomation.com), during a phone interview conducted,
by the way, on a VoIP connection between Chicago
and Brussels, “We are all mobile workers—both the CEO and
the technician. You can’t constrain where individual workers
are going to want information and what information they
want to get. And the most important thing is that they want
10 SECURITY QUESTIONS
The technology to secure your mobile network is there, but it is critical
to tailor it to fit your operation’s particular needs. Begin by asking
some basic questions.
1. Why are you enabling mobility plans at your facility? What are
your business goals? The answer to that question will determine
the rest of your plan.
2. How will you define “mobile worker?” Do you mean those working
in remote areas of your facilities, or do you mean those at other
facilities, contract workers, traveling employees or all of these?
3. Who needs mobile access to plant information and what specific
information do they need? Security experts recommend asking
tough questions about who really needs access and what kind
of information and access they need at the start of the project. It is
best to start conservatively with strict limits, and then relax them on
a case-by-case basis over time
4. Is your system configured for secure logons, authorization and
authentication? Do users have to prove they are who they say they
are and that they are entitled to the data they are asking for?
5. Is some of your data best presented in “read-only” format?
6. Have you considered encrypting sensitive data?
7. Are you going to mandate what mobile equipment employees are
to use? Issuing company-mandated phones or computers or allowing
employees to use their personal favorite device each presents
its own set of management, cost and security challenges.
8. How are you going to manage individual devices? How are you
going to roll out upgrades? How are you going to disable a device,
or at least wipe out its data, if it is lost or stolen or if an employee
leaves the company? If employees are using their personal devices,
do you have a way of segregating your company data from a
user’s personal information?
9. Do your needs require access to the Internet? Not every industrial
mobile application does. A robust corporate intranet may be
a much better option.
10. If employees are going to have Internet access, do you have
a clear acceptable-use policy regarding it? Do your employees
know what it is? How are you going to enforce it?
32 www.controlglobal.com A P R I L / 2 0 1 1

T h e M o b i l e W o r k e r
information where they are rather than move to where the
information is.”
It’s not just the perennial attraction to the new and shiny
pushing these tools into the process automation workspace.
The usual suspects are all there: the drive to do more with
fewer workers; the aging workforce and the correlative need
to transfer its years of hard-won knowledge to less experienced
workers and get them up to speed quickly;
globalization that spreads facilities around the
world; vital assets and operations in remote locations;
and, above all, the demand for greater efficiency
and productivity.
“If we have non-productive time, and the workers are
supposed to be putting us back in business, they needs access
to information,” says Mark Miller, director of solution
sales for Cisco’s Energy Operation Division
(www.cisco.com). Ideally, technicians will have access
to that information where they are—in front
of the machine—not back in the control room or
buried in a stack spreadsheets somewhere.
“One thing companies need is improved
visibility for edge customers—those out
in the process plants,” says Kevin Davenport,
global solutions manager for
industrial automation at Cisco. “Improved
decision-making in those
places and improved efficiency for
field workers [is crucial].”
Charles Mohrmann, vice president
of sales at Wonderware Mobile
Solutions, (www.global.wonderware.
com) adds, “Good technology does
one or both of these things: Improve
a process or sustain it. The two uses
with the best ROI are building a highreliability
organization and process improvement.
Mobility tools can have a
very high payback. Some of these can
get payback in six months.”
Early Experiments
Already the early adopters are out there trying
things out in the field. (See Dan Hebert’s
“Wireless Workers Unchained,” Control,
April 2010, www.controlglobal.com/
A p r i l / 2 0 1 1 www.controlglobal.com 33

T h e M o b i l e W o r k e r
articles/2010/WorkersUnchained1004.html). Vendors large
and small are lining up with large-scale solutions and simple
apps to access everything from KPIs to simulations via a cell
phone or tablet. Others are offering complex arrays of collaboration
enablers, including audio, video, phone and Internet
conferencing, all predicated on the notion that no meeting
requires all the participants to be in the same room—or even
on the same continent—at the same time. Hardware vendors
are also stepping up with everything from ruggedized
phones and laptops to Internet-enabled video cameras.
Some companies are experimenting, not just with mobile
apps in general, but with the iPad in particular. Jeff Sibley,
a control engineer at the Dow Chemical Co. in Freeport,
Texas, and a member of the Siemens Users Advisory Board,
is part of a group at Dow researching the feasibility of using
of iPads in Dow’s research and development unit.
“We have put all manuals and project documents on
them. We also tried hooking them up to a wireless router
strictly for commissioning.” Sibley says.
Dow’s researchers are also experimenting with instructing
the control system remotely through the iPad. “Say you
have one guy at the operator station telling the guy at the
valve to move it. What we’re hoping to do is have that one
guy move the valve remotely,” he says. “We’re very much still
in the research phase. The software is still wonky.”
He also adds that, at Dow, the iPads may be limited to the
R& D department. “Project notes and commissioning documents,
etc. will be the first use. Also PDFs and spreadsheets.
[You can put] lots and lots of information in a very portable
form, and they’re more convenient than a netbook.”
Sibley adds the advantage of the iPad or other tablet over
the smart phone is its size. “The problem with the iPhone is
that it’s small. Things are easier to read on a tablet,” he says.
There’s an App for That
Aurora Industrial Automation, (www.aurora-ia.com) a system
integrator in Portland, Ore., has developed Aurora Mobile
Apps, an Apple iPad/iPhone application that gives users realtime
access to plant-floor data through Rockwell Automation’s
FactoryTalk View, ViewPoint and VantagePoint software. Using
Mobile Apps, FactoryTalk VantagePoint users can see pertinent
KPIs wherever they are. Plant-floor workers working off
an iPad can see the same information they would see via the
FactoryTalk View application on their PC or inline HMIs.
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T H E M O B I L E W O R K E R
Fred Bossard, president of Aurora,
says that the iPhone/iPad is not a good
solution for every situation, but that his
application has many uses, especially
in quality control situations. One of
the companies pilot-testing Mobile
Apps is a wholesale craft brewery. “It’s
worked out great there, although there
was some apprehension going in. Now
they can focus on making better beer,
rather than on what their sensors are
doing. They can compare what they
did before with the next batch and really
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A BY-NO-MEANS COMPREHENSIVE
LIST OF MOBILE TOOLS
Even vendors that don’t specialize in mobile
solutions are making at least pieces of
their solutions accessible to “consumerized”
tools. Below are some available applications.
Just because you don’t see your favorite vendor
listed here, doesn’t mean it doesn’t “have
an app for that.” New ones are being released
almost every day.
• HMI/Scada application for supervising variables
(tags) and memory of PLCs and RTUs.
http://itunes.apple.com/us/app/scadamobile/
id324515280?mt=8
• Counterpoint Intuition Mobile provides realtime
remote access to production data and
KPI information directly on your iPhone. http://
itunes.apple.com/gb/app/intuition-mobile/
id418126639?mt=8
• Canary Labs’ Canary Mobile for smartphones
uses graphical web page applications
specifically designed for viewing on smartphones,
including the iPhone, BlackBerry and
Droid. http://tinyurl.com/4kyuvrr.
• Emerson Process Management delivers
data from DeltaV Mobile Platform v10/3/1
and Syncade Suite, which can be accessed
from smartphones and other mobile devices.
www2.emersonprocess.com.
• ExperTune’s PlantTriage real-time process
variable trending data is accessible on mobile
phones. http://www.expertune.com/plantTriage.html
• Honeywell’s Mobile Station is at http://tinyurl.com/4dlrmab
and Intelatrac PKS is at
http://tinyurl.com/4qt63eq
• Invensys Operations Management has
mobile applications for its IntelaTrac (http://tinyurl.com/4vcdt2y)
and its EyeSim simulation
software (http://tinyurl.com/4la66xd).
Rockwell Automation and Meriduim will
jointly release a tablet app for Rockwell’s Plant
Baseline parts management system in May.
• Siemens offers a WinCC/AddOn for its
Alarm Control Center for fast and reliable
alarms in the event of faults. http://tinyurl.
com/4ovcy3y
• Transpara’s Visual KPI for mobile phones
including Apple iPhone and iPod Touch, Palm
Pre, Android phones, Blackberry and any
mobile device with a modern browser. www.
transpara.com.

T H E M O B I L E W O R K E R
Not So Fast
Having said all that, bringing smart phones, laptops and tablets
on to the factory floor also brings a load of problems that
have to be addressed before they will live up to their potential.
The Big Three are security, safety and ruggedness.
Security is arguably of the most concern. As Sibley puts it,
“Security needs to be much better. You can live with [a mobile
device] not being ruggedized, but not with lack of security.”
You can, of course, simply refuse to play the game says
Honeywell’s Stearns. This is the easiest, simplest way to handle
the issue, and many companies do just that. No wireless.
No Internet connection. No mobile devices. Period.
But that attitude may also be a last-century artifact. “Security
by obscurity is a myth,” says Cisco’s Miller. “What most
smart folks have figured out is that what we can do today costs
less and is more secure than what we were doing previously.”
The good news is that while securing these mobile systems
is not necessarily simple, it is also doable, and many of
the best proven techniques are already out there.
Ian Nimmo, president of User Centered Design Services
(http://mycontrolroom.com) adds, “We’ve already fought the
security battle. If companies have appropriate security in place
tune_bottom-half_4.pdf 1 3/21/11 5:17 PM
for other things, it will also work for cell phones, netbooks, etc.”
Neil Peterson, senior manager, wireless marketing at Emerson
Process Management (www.emersonprocess.com),
says, “You can be as secure as you want to be. Security is
highly configurable. [The question is] how much effort do
you want to put into this.”
One problem is that no one solution fits all. “Every company
is so far different because there are so many ways to
skin the cat,” says Michael Saucier, CEO of Transpara,
maker of the Visual KPI application (www.transpara.com).
Deciding your preferred method of cat-skinning can take a
lot of time and effort.
The other stumbling block for process operations is safety.
As cool as they are, smart phones and tablets are not explosion-proof
or non-incendive. This fact will limit—at least for
now—the use of smart phones and tablets in the plant.
But that limitation may be temporary. Mobile software will
offer a way around some of these problems. “One of the things
driving this is the common operating systems and the applications
written for them,” says Cisco’s Miller. “It’s going to be
easy for developers to put them in a form factor that can be
used.” In other words, it’s only a matter of time before some-
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T h e M o b i l e W o r k e r
body builds a mobile device useable in
explosion-proof, non-incendive and corrosive
environments.
Even now there are workarounds.
Bossard says that while there are places
he wouldn’t take an iPad, “We have a
few options even in wash-down areas.
It’s not the most attractive option, but
you could use a zipped plastic storage
bag. You can also get very hard neoprene
exterior skins with the inner part made
of a softer rubber.” And ultimately, he
adds, “As long as the device isn’t going
to interfere with safety it should be OK
in about 75% of applications.”
And there are always the ruggedized
laptops. Panasonic has been selling its
Toughbooks (www.panasonic.com/business/toughbook/laptop-computers.asp)
for years. At least one model, the 29s, is
Class 1, Div 2-certified.
Stone Energy of Lafayette, La.,
equipped its offshore oil rig workers
with Model 29s Toughbooks to give
them real-time access to sensor information
near the drill bit.
Dave Kennedy, Stone’s director of
information technology, says, “Having
the Toughbook connected wirelessly to
information systems behind the drill
bit facilitates real-time decision making.
That information can translate to
the accelerated completion of operations
and huge cost savings.”
And not every plant-floor situation
will require these ruggedized or specially
certified units. “The consumer
market is far bigger than the industrial
market,” observes Rockwell’s
Brooks. “There’s a huge cost benefit
in using consumer devices because
of the size of the market. If
you have a $300 netbook
with a vir-
Courtesy Cisco Systems. Copyright 2010, Cisco Systems
Just How Many Mobile Devices Are Out tHere?

When should I start to modernize my
APACS+ system to SIMATIC PCS 7?
Keep your plant functioning with the highest levels of
performance and the most advanced technology by using
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Utilizing a step-wise approach, we can help extend the lifecycle of your system at a pace that matches your
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systems by visiting us online at www.usa.siemens.com/apacs2020.
Answers for industry.

T h e M o b i l e W o r k e r
tual desktop accessing information off a server, and you
drop it, you lose a $300 netbook. Compare that to the price
of a Toughbook. There’s going to be enormous pressure to
use the consumer model. That doesn’t override the safety
issues, but it does create a pressure and a dynamic.”
Taming the Beast
Integrating smart phones and tablets into your operation is
in many respects no different than any other project. Begin
by having a clear idea of what it is you want to accomplish,
adds Brooks. “Focus on the objectives. You can’t afford to
deploy it just because it’s cool technology. You do it because
there’s a real business advantage.”
Wonderware’s Mohrmann adds, “First decide what process
improvement you want to make. See what others have
done. Then get a scope to the project. Go about it in a stepby-step
way.”
Then focus on the risks. Bob Huba, DeltaV product manager
and cybersecurity expert at Emerson, says, “Make sure
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Emerson’s Peterson adds, “Map the solution out. Lay out
the architectures. Configure everything and roll out the solution
in a methodical fashion. Then check it out after it’s
done. You can absolutely do a secure system. It’s really a matter
of coordinating a good plan and then executing it.”
You will also need a holistic view of your wireless operation,
says Brooks. “Spectrum is a finite resource. It’s a shared
medium, and you need strong policies and procedures to
control access. That may be the single biggest challenge.
You have to have an integrated wireless network, because
isolated ones don’t work.”
Which brings us to the knotty problem of the relationship
between your operations and IT departments. You can’t
successfully bring these mobility tools on to the plant floor
without some input from IT. “There’s going to be some resistance
on the part of IT,” says Honeywell’s Stearns. “The
IT group has to be the enabler. The control system might
look at everything below Level 2. IT might not even care
about that.”
“You need to get the decision-maker on the operations
side,” recommends Transpara’s Saucier. “IT often wags the
dog and doesn’t want to do the security to make these tools
available. In companies that have embraced the idea that IT
is a support function, there is no push-back.”
Consider starting small. Take a page from Dow’s playbook
and try out a pilot project in one area. “Try to roll it out in
part of the plant. See if it meets your objectives. Then roll it
out elsewhere,” recommends Cisco’s Miller.
Or look for an easy win. Western Power, an Australian
electricity provider, gave Blackberries equipped with
Transpara’s mobile application to 1100 technicians in trucks
all over Western Australia so they could better monitor their
substations. The entire rollout went from prototype to use in
one week, according to Saucier.
If Not Now, When?
So, you’re not ready to wrap your head around iPads on the
factory floor and Android phones for all your engineers?
Well, you can hold out, of course, but you may have to cave
eventually.
“This is looking like a when, not an if. There’s going to
be a plethora of innovations,” says Brooks. “In manufacturing,
we are going to have to have solutions that allow things
to be displayed on iPhones and Blackberries because their
usefulness has been proven. We can’t stop these commercial
devices coming into the manufacturing zone. People
will find ways of using them if they make their jobs easier.
It’s better to work with disruptive technologies rather than
block them. People will accept ‘yes, but,’ but typically, they
won’t accept ‘no.’ ”
Nancy Bar tels is Control’s Managing Editor.

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F L O W
Flowmeter Boosts
Solvent Recovery
Improved measurement accuracy delivers
better control and savings.
BY LARELL PALMER AND ERIK SCHROEPPEL
The Eli Lilly and Co. (www.lilly.com) processing plant in Clinton,
Ind., uses a fermentation-based process to produce animal
health products. Solvent is recovered from the fermentation medium
and reused in the production process, providing environmental
benefits as well as raw material cost savings.
Three recovery columns distill the fermentation medium
to recover the 1% to 2% of solvent it contains. Vaporized
solvent is condensed to provide a very pure liquid for recycling.
Maintaining high efficiency and speed of separation
requires precise control of the temperatures, pressures and
flows of components along the column.
The separators also are very important to the overall process
mass balance. Inefficient operation can lead to energy
waste, output-product-purity problems and poor yield.
The solvent recovery process is continuous and runs yearround.
The flow rate into each column is roughly 300 liters/
minute. This amounts to 125 million liters/
year per column, which requires extracting
RAISING THE CORIOLIS FLAG
Figure 1. Eli Lilly & Co.’s plant in Clinton, Ind., installed the
first Coriolis flowmeter in its solvent recovery application
in the “flag” orientation on a vertical section of pipe on
the feed line of Column 1 during a routine maintenance
shutdown.
around 6 million liters/year of solvent from each column. The
uptime of each column has been around 80% due to maintenance,
upsets and planned downtime.
Drivers for Change
Companies like Lilly now expect a lot more from process
control and instrumentation than in the past. We’re continually
looking to minimize waste, maximize output and optimize
efficiency throughout the plant. There’s much more
focus on the accuracy and reliability of measurements. With
the solvent recovery columns, we needed to upgrade the instruments
to provide greater accuracy and reliability.
The existing differential pressure/orifice flowmeters,
which measure feed, overhead and bottom flows of the separator
columns, were around 25 years old and had reached
the end of their useful lives. In fact, we actually had stopped
performing time-consuming maintenance on these devices.
When first installed, they had provided adequate flow measurements
that even now would be good enough for inventory
management. However, they no longer were giving the
accuracy or reliability required for the recovery process.
As a result, much of the operation of the columns became
manual. Columns were put in recycle mode due to more frequent
process upsets. Lost uptime was estimated to cost an
average of $3,000 per upset.
Once or twice a month, the feed flow measurements were
so poor that we experienced excursions outside of the control
limits. These excursions could be very costly, requiring
isolation of the waste streams and further testing/treatment,
as well as disruption of other plant processes. We estimated
the cost to be as high as $50,000 per upset.
Photo by Christopher Meyer, Rosemount
44 www.controlglobal.com A P R I L / 2 0 1 1

F l o w
Even without these excursions, we knew the instruments
were losing the plant money every day. The lack of optimized
control due to inaccurate flow measurements was
leading to inefficient energy use, lost solvent and added
waste-treatment costs.
A Cost-Effective Option
We initially considered magnetic flowmeters because they
provide accurate measurement and long-term reliability at
the right price. However, they require external power, and
no power wiring ran to our separator columns. We estimated
the cost to run power to the 50-ft. columns at about $4,000
per column. Coordinating the efforts of separate groups for
electrical and instrumentation work also would affect project
cost and schedule. With everything factored in, the total
cost to run power was prohibitive.
Fortunately, Coriolis technology also appealed to us. After
all, Coriolis is the most accurate technique available for
measuring process mass and volume flows. However, while
conventional Coriolis meters also require external power,
the recent introduction of Emerson Process Management’s
(www2.emersonprocess.com) Micro Motion 2200 two-wire
transmitter made our use of Coriolis meters possible.
We’d already standardized on Micro Motion Coriolis
flowmeters wherever possible throughout Eli Lilly. Around
200 devices are installed at the Clinton plant, mostly working
directly on the manufacturing process. We also have
some meters reading natural gas flows into the plant. When
the availability of the new two-wire device came to our attention,
it was an easy choice for the recovery process.
In September 2009, the first Coriolis meter was installed
on the feed line of Column 1 during a routine maintenance
shutdown. The device was positioned in the “flag”
orientation in a vertical section of pipe (Figure 1). Because
Coriolis technology doesn’t require a long, straight pipe
run before or after the device, it was very easy to fit without
serious pipe-work reconfiguration. Installation was simple
and incredibly smooth. It took just a few minutes to get the
meter up and running, and after a couple of calls to the
control room to confirm it was performing correctly, we
were done.
The installation cost totaled $3,258, which included electrical
and piping contractors’ charges. We incurred some additional
costs for piping changes not essential for the new
meter install because we decided to put the meter at a height
that would provide easy ergonomic access rather than 12 feet
in the air as was the case with the old meter.
Impressive Results
The Micro Motion two-wire Coriolis device ideally suits
continuous process and mass balance applications. The new
meter delivers ±0.2% liquid flow and ±0.002 g/cm 3 liquid
Flowmeter Fellows
Figure 2. Authors Larell Palmer and Erik Schroeppel and
Joseph Almon of Emerson Process Management’s Micro
Motion (l. to r.) gather around a two-wire flowmeter at the
Clinton plant.
density accuracy. Once the device was in place, we immediately
found that feed flow rates were about 100 liters/minute
higher than expected. This was far more than we had anticipated
and demonstrated the difficulties we had to overcome
when controlling the process.
We’ve also seen a good improvement in the stability of the
recovery process. While operators before often were shooting
in the dark regarding feed flow rates, they now have a stable
starting point from which to make process adjustments.
As a result, there were no upsets caused by the feed.
Not needing to move the process into recycle mode also
means we no longer waste energy by being in that mode.
Early last September we replaced three of the remaining
eight meters for feed, overhead and bottom flows on the
three columns. We also planned to swap out the rest by the
end of September. The new devices will allow us to perform
an accurate mass balance on the separator. The mass balance
information will enable us to optimize the process,
maximizing solvent recovery while minimizing energy
costs. We hope to improve the efficiency of the process by at
least 5% if not much more.
An added bonus is that the Coriolis flowmeters have no
moving parts and require very little maintenance. We expect
that over time this will create more savings and further
improve the uptime and efficiency of the recovery process.
[Editor’s note: This article originally appeared in Control’s
sister publication, Chemical Processing, in its October
2010 issue.]
Larell Palmer is a senior instrument engineer for Eli Lilly & Co. in Clinton, Ind.
Erik Schroeppel is a process engineer for Eli Lilly & Co . They can be reached at
Palmer_Larell_K@Lilly.com and Schroeppel_Erik_F@Lilly.com.
Photo by Christopher Meyer, Rosemount
A p r i l / 2 0 1 1 www.controlglobal.com 45

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S C A D A
Remote Wind Energy
SCADA Control System
Like old-fashioned farming, tending a wind farm is a 24/7/365 job.
At Iberdrola Renewables, the new SCADA system is a key “farm hand.”
By Harm Toren
At Iberdrola Renewables (www.iberdrolarenewables.us/),
our National Control Center is professionally staffed
24/7/365, performing operations, energy management,
scheduling and generation dispatch functions. This
helps us to better manage risks and uncertainty while
fulfilling energy requirements with sustainable and
clean power. Originally called PPM Energy and part of
Scottish Power, our company began operating in Oregon
in 2001 with 12 employees. As of 2010, more than 850
workers throughout the United States maintain, develop,
build and operate nearly 5000 megawatts of wind power
and other power plants.
Our recent addition to the Iberdrola Renewables fleet is the
National Control Center located in Portland, Ore., the nerve
center of the Iberdrola Renewables generation portfolio. In
a room that looks a little like NASA’s Mission Control, our
A P R I L / 2 0 1 1 www.controlglobal.com 47

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S C A D A
generation dispatchers and systems analysts oversee every turbine
at every wind farm (and soon solar and biomass projects)
throughout the country, around the clock. They monitor the
performance and efficiency of every turbine. They keep an
eye on approaching storms to warn technicians in the field to
get to safety before harsh weather hits. They even have helped
scientists conduct groundbreaking wildlife research. And they
coordinate in real time with the nation’s various transmission
system operators to insure grid reliability to help keep the
lights on.
The SCADA System
A vital element of our operation is our newly developed
SCADA system, supplied by PcVue (www.pcvuesolutions.
com) and integrated by the Iberdrola Renewables team.
Among other things, each wind turbine has a control box
containing a PLC, power converter, control boards and
I/O device. Sensors for wind speed, wind direction, shaft
rotation speed and numerous other factors collect and
transfer data to the PLC. By detecting the wind’s direction,
the control system can use a motorized yaw gear to
turn the entire wind turbine in the proper wind direction
for maximum power generation. Our wind turbines
are connected to a local area network (LAN) via a fiberbased,
redundant ring connection. Although the turbines
are designed to operate autonomously, they also are connected
to a remote-control station running the control
system that manages and collects data, adjusts turbine
settings, and provides intelligent alarm, troubleshooting
and reporting capabilities via our central data center and
control facility in Portland.
The National Control Center connects via long-haul
networks to the plant-based systems and ultimately to the
individual turbines, substations, meteorological stations
and avian radar surveillance systems. It provides visibility
for our operators to manage the behavior of all the wind
turbines and all the wind farms as a whole. By keeping a
record of the activity on a time-interval basis, the SCADA
allows our operators to determine what adjustments and
corrective actions, if any, need to be taken. It records energy
output, availability and error signals, and we are designing
the ability to control (among other things) power
factor, voltage and reactive power production, allowing
for the management of wind farms’ contributions to network
voltage and frequency control. It also gives our operators
the capability to manage power output based on
real-time grid requirements.
The SCADA communicates with the turbines via a
communications network that almost always uses optical
fibers. We have multiple turbine types in our fleet and
each turbine supplier provides its own control/HMI system.
We have found that the major advantages of using

S C A D A
REMOTE WIND ENERGY SCADA CONTROL SYSTEM
Figure 1. “Mission Control” at Iberdrola Renewables monitors every turbine at
every one of its wind farms across the country 24 hours a day.
PcVue as the main SCADA system
is that it is turbine supplier-agnostic.
It is not tied to any one PLC vendor,
so that it can be free to provide data
reporting and analysis formats irrespective
of turbine type.
This was of particular importance
to us because our wind farm operators
use multiple turbine types and a myriad
of various PLCs. In addition, our
team really liked how PcVue was enduser
friendly and easy to configure. Its
ability to iconize animated mimics and
use pop-up windows reduced the risk
of overlaying crucial information and
helped simplify the view for our team.
The creation of templates for contents
and behavior associated with each
mimic and GUI (graphical user interface)
animation, ensures consistency of
the window display. We use multi-level
access rights and menus associated
with each user to ensure that navigation
within the application is tailored
to the needs and the permissions of
each individual. This allows us to have
a layer of security, traceability and control
of users’ actions.

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The control room personnel
monitor every turbine at every
wind farm, keep an eye on approaching
storms, coordinate with
other transmission systems in real
time to ensure grid reliability and
even help scientists do groundbreaking
wildlife research.
Historically, when we had a small
number of wind turbines transmitting
into the grid, it was a relatively
simple operations process. As renewable
energy continues to contribute
more and more to the grid, transmission
and generation management become
larger issues. Requirements are
quite strict; thus, we have designed an
integrated system with operator controls
in order to manage the generation
profile on a real-time basis. We
are designing and building a scalable
system to meet the next generation of
renewable energy transformation. We
are installing wind turbines to operate
in harmony with other sources, such
as nuclear power, solar, hydro and
other energy in a netting arrangement
to optimize performance.
In order to manage our growing
business, we also have developed
multi-point monitoring, fiber-optic
networks and local systems on our
wind farms in the United States that
all tie into the National Control Center.
We use a similar system in Toledo,
Spain, called CORE (Centro de Operación
de Energías Renovables, or
Renewable Energies Operation Center).
In each case, there is a central facility
where the SCADA system is able
to remotely access facilities throughout
the country and access alarm and
event conditions.
Our management of multi-station
configurations uses PcVue’s advanced
tools to ensure the coherence of the
configuration data and deployment
on all of the stations, especially for
all of our geographically remote applications.
PcVue’s centralized configuration
provides the capabilities
for the management and traceability
of the various versions of applications
and their changes. It also supports automatic
updating of the stations that
make up the supervisory system. At
each start-up of a station on the network,
PcVue automatically runs consistency
checks of the versions in use.
In the United States, we are currently
producing nearly 5000 megawatts
of wind power from more than
40 independent power plants using
about 2500 wind turbines. Each wind
turbine supplies up to about 300 data
points, which equates to approximately
700,000 to 850,000 I/O data
points on several servers. To cope
with the diverse demands of maintaining
our wind farm, the PcVue
application alarms are highly configurable.
Alarm messages may be
printed, viewed in alarm lists and archived.
Our operators can configure
alarm behavior using groups, filters,
sorting, acknowledgement and masking.
They also create alarm counters
and associate specific actions with an
alarm. Alarms can be acknowledged
by our operators directly from mimics,
and automatically broadcast to
all nodes on the network.
Iberdrola Renewables also is using
OPC (www.opcfoundation.org) and
others as the communications protocol
to pull data from the various PLCs.
Many wind farm applications often
use OPC and the KEPServerEX driver
from Kepware (www.kepware.com)
to communicate seamlessly with disparate
systems. We use PcVue’s OPC
Data Access Client and OPC DA
XML Client for exchange of real-time
data with communication servers, and
OPC DA Server to facilitate data exchange
with third-party applications.

The data acquisition that occurs is
routed back to the National Control
Center. I manage the teams developing
integrated control systems at the
National Control Center. We chose
PcVue’s software, as it had already
proven itself to be scaleable, userfriendly
and highly functional in the
Spanish operations. PcVue provides a
single-user view that allows an easy visual
display and overall management
of the myriad systems in place from
the PLCs, HMIs and the control systems
equipped on the turbines. As we
monitor avian migration and weather
in addition to controlling and managing
our turbines, we needed a system
that would provide a simple, easy-toread
GUI, so that we can react at a
moment’s notice.
The new PcVue SCADA software
integrates and connects with the wind
turbines via the PcVue GUI interface
acting as a light client to the PcVue
application and managing up to 2.5
million data elements. This configuration
provides our operators with the
necessary information about the turbine
signals. We are using this distributed,
client-server architecture
with redundancy in order to ensure
that the design is fault-tolerant. Using
PcVue’s built-in redundancy features,
we are able to ensure continuity
of data collection in the event of the
failure of a system component. PcVue
also supports dual networks both for
communication with field equipment
and among PcVue stations. Each component
and each station in the configuration
has a validity status to enable
operators to view the condition of the
system in real time. These client stations
are communicating via OPC
with the redundant communication
front ends connected to the highspeed
network.
Two-Level Architecture
Using the PcVue architecture, our
operators can see in-depth details on
the data of the remote wind farms in
S C A D A
a real-time display status. Given the
large volume of information, and in
order to facilitate operation and maintenance
of the facilities, the supervision
appears in two levels.
A first supervision level gives us an
overview of the most relevant alarms,
values and counters, enough to supervise
the turbines in a usual situation
and detect failures that need to be
corrected. A second, detailed supervision
level, triggered on an operator’s
request, enables supervision of all of
the turbine’s data selected, so that our
operators can immediately and accurately
diagnose failures that occurred
and determine the necessary operations.
Data received can be processed
as setpoints, historical storages, alarm
management, trending, etc.
Our control system in each installation
collects the operational information
from the generators, associated
substation and other components.
The control system is connected to
the control center through a remote
communication channel, and, therefore,
facilitates maintenance tasks.
Our National Control Center receives
this information and processes it into
an organized and simplified structure
that enables easy identification and
diagnosis of failures. This diagnosis
triggers the appropriate actions for its
solution: remote reset or activation of
local maintenance teams. As a result,
average downtime decreases, thus increasing
availability. Our operators
can see in-depth data from the remote
wind farms.
Iberdrola Renewables in the United
States continues to expand the systems
for both legacy and new generating
stations, and, so far, it has met our
expectations, and the system is working
very well. This will become the
standard process for all later facilities,
so that it becomes our typical “out-ofthe-box”
solution.
Harm Toren is managing director of
Operations Services/Wind Operations for Iberdrola
Renewables in Portland, Ore.
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a s k t h e e x p e r t S
Measurement of Drift, Stability, Offset, Bias.
“Ask the Experts” is moderated by Béla Lipták, process control consultant and editor of the Instrument Engineer’s Handbook
(IEH). He is now recruiting new contributors for the 5th edition. If you are qualified to contribute to this volume, or if you are
qualified to answer questions in this column or want to ask a question, write to liptakbela@aol.com.
QIn determining some of the static and dynamic characteristics
of sensors and other instruments, I find the
definitions of the following terms somewhat confusing.
I find it difficult to differentiate between them. For example.
the ISA dictionary gives the definitions for drift and
stability as follows:
Drift:
ANSI/ISA-S51.1-1979 (R1993). [ISARP67.04.01-2000.ISA-
RP67.04.02-2000]. — An undesired change in output over a
period of time, where the change is unrelated to the input,
environment or load.
[ANSI/ISA-75.05.01-2000] 3. — An undesired change in
the output/input relationship over time.
[ISA-37.1-1975 (1992)] — An undesired change in output
over time that is not a function of the measurand. Drift is
usually expressed as the change in output over a specified
time with fixed input and operation conditions. It is usually
used in the context of analog transducers, analyzers, etc.
Repeatability
Random error
(Precision)
Systematic error
(Bias)
Stability:
[ISA-37.1-1975 (R1982)] — The ability of a transducer to
retain its performance characteristics for a relatively long period
of time. Unless otherwise stated, stability is the ability of
a transducer to reproduce output readings obtained during its
original calibration, at room conditions, for a specified period
of time. It is then typically expressed as being “within X percent
of full scale output for a period of Y months.
[SA-RP55.1-1975(R1983)]— In data processing, a measure of
the ability of a device to maintain constant volumes for one or
more parameters that describe its operation. Freedom from undesirable
deviation. A measure of the controllability of a process.
In our work, these two terms are used quite interchangeably.
When we are calibrating an instrument, and it has an
offset, we say it has drifted. Similarly most test equipment,
such as dry bath calibrators, has stability (both long-term and
short-term) in its specifications. As an aside, stability is also
used to define a process controller that brings the process to
new setpoint after a disturbance. But, at that time, we know
that we are dealing with a process.
I would like to know how we differentiate between these
two characteristics? How do we measure them separately
when evaluating a sensor or another instrument? Similarly,
in order to correctly determine and publish offset and bias
of the various instruments, how should we better understand
what they are?
Yusaf Muti
yousaf_ zai_khan81@ yahoo.com
Illegitimate
error
definition of terms
Total error
(Inaccuracy)
Figure 1. Terms describing the error (inaccuracy) of a sensor
AThe first 150 pages of Volume 1 of the Instrument Engineers’
Handbook deals with such general topics. In
this age of advertisements that show attractive people
and places instead of guaranteed and clearly defined performance
data, it is hard to know how good a sensor is. Some
manufacturers do not even test all their sensors, and their
specifications do not even state how the published numbers
have been arrived at.
For this reason, it would be useful if ISA recommended
the testing methods and also recommended that the performance
found be printed on all instrument specifications, no
matter where the device was produced around the world.
For example, ISA could recommend that all drift specifi-
52 www.controlglobal.com A p r i l / 2 0 1 1

a s k t h e e x p e r t S
cations state if the sensors were individually tested (or only
sampled), and state that the drift was measured, say, “for a
period of X hours and was found to be Y% of output span.”
Also. as I have illustrated in Figure 1, the total error (inaccuracy)
of a measurement is the sum of its systematic and its
random errors.
The error caused by drift (some also call it shift), illustrated
in Figure 2, is the difference between the specified
and the actual performance of a sensor over a time period.
The total drift error is the sum of two error components: the
zero and the span shifts over some time period. When running
a test to determine these values, one has to be careful
to evaluate the whole system, not only the transmitter electronics.
Let me illustrate that point by a recent experience:
In connection with a lawsuit I, as an expert witness, was
asked to evaluate the performance of a flow loop that was
periodically calibrated only by checking the electronics of
the transmitter using a simulator (not the actual signal from
the sensor). Based on the simulated input signal to the analog
transmitter (the secondary), the calibration appeared to
be fine; the transmitter was generating a 4-mA output when
the simulated input corresponded to a zero flow signal, and
20 mA at a simulated 100% measurement signal. Yet, while
the transmitter correctly measured the simulated input signal,
the actual signal from the sensor (because of zero and
the span shift) has drifted so much over the decades of uncalibrated
operation of the primary that the total system error
amounted to 50% when the flow averaged about 20% of
span. (Naturally, as shown in Figure 2, this error percentage
becomes a smaller fraction of the total flow.)
Therefore, the evaluation of the drift should also be based
on testing the primary and the secondary together using the
actual measurement signal and not a simulated one.
Stability is a more general term, as it can include not only
drift (which is a function of the passage of time), but also
the environmental effects (pressure, temperature, humidity,
vibration), process effects (coating, corrosion, aging) and
other factors, such as cycling, hysteresis, linearity, noise, etc.
Offset (some also call it droop) is a term used in connection
with proportional-only controllers because such devices
(thermostats, pressure regulators, etc.) start making a correction
only after an error has already developed. The amount
of offset rises as the gain of the controller drops (proportional
band increases).
Bias occurs when a constant amount is added to or subtracted
from a signal. For example, zero shift can bias the
output of a sensor. A positive bias of a sensor output results
in over- reporting and a negative bias in underreporting the
variable measured.
Béla Lipták
liptakbela@aol.com
100
% Output y
0
0 % Input x
100
the drift test
Actual calibration curve
Figure 2. The results of a drift test should state the time period of
testing and should report the errors caused by both the zero and
the span shift that was measured at the end of that period over the
full range (span) of the sensor.
Q
I read your article on steam quality measurement
with great interest. I am working in a thermal project
pilot plant and would like to measure the steam
quality at the injection well where the line size is 3 ins.
Can you give me some information on “throttling calorimeters”?
Also please recommend a steam quality measurement
device that is not cumbersome to measure SQ in the
3-in. line.
Vijay Ramlal
VRamlal@kockw.com
A
Standard technique in large power plants in the United
States to assure steam quality on super heated steam is
to measure sodium ion concentration, usually in ppb
in two or more locations. Particular attention should be paid
to obtain representative samples before and after the mud
flow cycle. Several companies offer products, but sample
conditioning is difficult. After several manufacturers’ trial
application, I found one English company’s product to be
easy to maintain and reliable. You can write to me directly if
you need more information.
Ram.G.Ramachandran
ramacg@cox.net
Specified characteristic curve
Span
Span shift
Zero shift
Elevation
A p r i l / 2 0 1 1 www.controlglobal.com 53

R O U N D U P
The Latest in Process Analyzer Technology
All the newest devices to help you see what’s really going on in your processes.
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RHPS series LRS(H)4
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The ePurge X is a purge controller
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281/340-3800; www.us.yokogawa.com
54 www.controlglobal.com A p r i l / 2 0 1 1

P r o d u c t i n t r o d u c t i o n s
SMALL FORM-FActor soLID-STATE RELAYS
The new Termopto solidstate
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all in one compact module
for space savings in the control cabinet. Sixty versions include
standard input voltages from 5-230 VAC and DC, with
three optional output voltages of 5–48 VDC and 0.1mA, 5
– 48 VDC and 0.5mA, or 24 – 230 VAC with 0.1mA.
Weidmuller
800/849-9343; www.weidmuller.com
RUGGED PRESSURE SEnsors
PS300 series pressure sensors
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Turck
800/544-7769; www.turck.us
SMART, ruGGED PositionER
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also features SIL-certified, partial-stroke testing (PST).
Siemens Industry
800/964-4114; www.usa.siemens.com/Industry
HEAVY-DUTY SLURRY KNIFE GATE VALVE
Series DX Slurry Knife gate
valve is designed especially
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When it opens, reinforced
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The seats isolate and protect all metal parts from coming
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Red Valve Co.
412/79-0044; www.redvalve.com.
LOW-MAINTENANCE, HIGH-AccurACY pH/ORP SEnsors
The new S651CD submersible
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S651CD is an upgrade to
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S656CD is an upgrade to the S656CD electrode, and can
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Sensorex
714/895-4344; www.sensorex.com
REALLY cooL 60W POWER suPPLIES
These 60W power supplies
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They have universal, widerange
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Puls Power Supplies
630/587-9780; www.pulspower.us
A p r i l / 2 0 1 1 www.controlglobal.com 55

P r o d u c t i n t r o d u c t i o n s
HAZARDOUS-DUTY FLAT-PANEL Monitors
VisuNet IND Series industrial
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NTSC inputs from a PC or video camera source.
Pepperl+Fuchs
330/486-0002; www.pepperl-fuchs.us
VIRTUAL CHART REcordER
The Omega iTHX-SD transmitter
lets users monitor and
record temperature, relative
humidity and dew point over
an Ethernet network or the
Internet with no special software
except a web browser. It
serves Active Web Pages to
display real-time readings, display charts of temperature and
humidity, or log data in standard data formats for use in a
spreadsheet or data acquisition program, such as Excel or
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Omega
888/826-6342; http://omega.com
INTRINSICALLY SAFE WEIGHING TERMINAL
The IND560x intrinsically
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REGULATORS WITH OVERPREssurE PROTEction
The Fisher CS800 Series direct-operated,
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ISOLATED PREssurE instruMEnts
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56 www.controlglobal.com A p r i l / 2 0 1 1

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C o n t r o l E x c l u s i v e
FDT and OPC Collaborate on FDT 2 Standard
The joint FDT and OPC Foundation FDT OPC UA Working Group will develop an OPC UA information model for
the major upgrade to the current FDT standard that is now in preparation. The new version, described by Glenn
B. Schulz, the managing director of the FDT Group, as a “major update” to the current Version 1.2.1, will be released
by the end of this year.
The FDT Group is an open, independent, not-for-profit association of
international companies dedicated to
establishing the FDT Technology as
an international standard with broad
acceptance in the automation industry.
FDT standardizes the communication
and configuration interface
between all field devices and host systems
and provides a common environment
for accessing the devices’ most
sophisticated features.
The OPC Foundation defines standards
for online data exchange between
automation systems. The OPC
Unified Architecture (OPC UA) unifies
the existing standards and brings
them to state-of-the-art technology
using service-oriented architecture
(SOA). OPC UA can run on Windows-based
PC systems., embedded systems and Linux/
UNIX-based enterprise systems.
“This is a unique opportunity to take the best-of-breed
data and information models for the applications and devices
supported by the FDT architecture and leverage the
OPC Unified Architecture (UA) information modeling and
corresponding services for complete application-to-device
integration,” says Thomas J. Burke, president and executive
director of the OPC Foundation. “This exemplifies the
device-to-cloud computing strategy that supports configuration,
communication, run-time and historical data access,
and alarming and event services for existing and upcoming
devices supported through FDT Group technology.”
Schulz adds, “We were looking for a good way to bring devices
together to get information throughout the enterprise.
Now we have two great platforms that enable getting data
across the enterprise, and we are making them interoperable.
We are seamlessly integrating FDT and OPC.”
The implicit and explicit information model specified by
FDT will be defined in a UA companion specification using
OPC UA constructs for the purpose of sending FDT data
to external applications. Further enhancements will be supportable
due to modular construction.
Ready by Year’s End
The Working Group wants to get the
technology out as quickly as possible.
They plan to have a deliverable
product ready by the end of the year.
“Technology changes very quickly,”
says Burke. “We want to take every
step to foster the rapid and wide adoption
of OPC UA/FDT as a standard.”
Another goal is to provide for incremental
adoption. The cooperation
between FDT and OPC will simplify
the technical challenges for end users.
A clear migration path will exist
for legacy equipment or that which
conforms to earlier standards.
“We anticipate many new applications
and places not currently served
by OPC or UA also will be able to take advantage of this
unique collaboration. This strategy of incremental adoption
facilitates easy and simplified deployment into real products
and solutions,” says Burke.
The group will also proved for backward compatibility
and easy customization. The standard’s extensibility makes
possible the creation of value-added, machine- or installation-specific
software and tools without jeopardizing compatibility
with other equipment or software.
Finally, the Working Group is committed to maintaining
the non-proprietary nature of the standard, keeping it unencumbered
by intellectual property restrictions on licensing.
“We each dominate our specific markets—FDT in multinetwork
intelligent device confirguration and OPC in data
interchange,” says Schulz. “For us to be able to bring out an
out-of-the-box solution marrying the two will be a huge win
for end users.”
A draft version of the updated FDT 2.0 standard was on
display at Hannover Fair, Hannover, Germany, earlier this
month.
For more information on the OPC UA or FDT, go to www.
fdtgroup.org or www.opcfoundation.org.
58 www.controlglobal.com A p r i l / 2 0 1 1

C O N T R O L T A L K
Ultimate Limits to Performance
Greg McMillan and Stan Weiner bring their wits and more than 66 years of process control
experience to bear on your questions, comments and problems.
Write to them at controltalk@putman.net.
Stan: Sometimes we get so caught up in sophisticated
control strategies and control system technologies
that we forget the ultimate limits to what
we can achieve. Whether you are talking about
advanced PID control or model-predictive control,
the dead time, noise, speed and resolutionsensitivity
of measurement and the final control
element determine how well you can achieve your
control objectives.
In this column, we are going to talk about some
of these ultimate limits. We are grouping resolution
with sensitivity, which set, respectively, the
quantization and threshold for detection, communication
and actuation. For speed, we are focusing
on the rate of change of the process and the
sample rate of the control system.
Greg: Dead time is the deadliest of the limitations.
Without dead time, I would be out of a job.
During the loop dead time, the controller does
not see or does not affect the process. The ultimate
limit for peak error for rise time is proportional
to the loop dead time. The ultimate limit
for integrated error is proportional to the dead
time squared. The sources of dead time are insidious.
The measurement and final control element
sensitivity divided by the signal rate of change and
one half of a sample or scan time are additional
sources of deadtime not commonly recognized.
The phase shift and ultimate period are proportionally
increased. Sensitivity and sample time
are particularly important in silicon wafer/circuit
manufacturing. nTrolus Inc. (http://ntrolus.com/
Default.aspx) is a leader in model-based control
for semiconductor production and green energy
systems. We talked to its president, Mark Ekblad,
who understands the significance of these limits.
Mark: Most of the applications involve temperature
control. In general, we can only turn off heat.
There are no brakes. We have only ambient cooling
or sometimes a fixed static cooling load provided
by cooling jackets. Consequently, the speed
of temperature change for heating and cooling is
drastically different.
The process often has a near-integrating response
where the temperature essentially ramps.
Setpoint overshoot must be minimized because of
the sensitivity of the process and the long settling
time. The aggressive performance of the PID with
conventional Ziegler-Nichols tuning relying on
feedback action leads to quality problems. Fuzzy
logic and gain scheduling is sometimes used, but
the special tuning requirements complicate the
implementation.
Greg: Bioreactor temperature control has similar
requirements and problems, particularly in singleuse
bioreactors with disposable liners, bench-top
and pilot plant units, and the small production-
Greg Mcmillan
Stan weiner, pe
controltalk@putman.net
Stan: What are manufacturers predominantly
controlling in semiconductor production?
A p r i l / 2 0 1 1 www.controlglobal.com 59

C O N T R O L T A L K
scale units that have only heaters. Large
bioreactors have jackets with temperature-water
systems that can provide a
cooling rate commensurate with the
heating rate. Even here, the tuning for no
overshoot is not easy. The dynamic reset
limit PID option is essential to prevent
the integral action of the primary temperature
loop from changing the setpoint
of the secondary loop or the final control
element too quickly. (See my February 18
blog post, “Dynamic Reset Limit, www.
modelingandcontrol.com/2011/02/dynamic_reset_limit.html)
Stan: What are the final control elements
that are used in the semiconductor
industry?
Mark: The temperature controllers
are typically manipulating power to a
heater. Pulse-width modulation is used
to vary the amount of on time in a cycle.
The typical power controllers used
today and their performance values
from the least to the most expensive
are shown in Table 1.
The electromechanical contacts are
only suitable for very slow systems with
very loose control requirements. Solidstate
relays offer tighter control, but are
not fast enough for many wafer temperature
control systems used in silicon
wafer processing. Silicon control
rectifiers (SCR) offer the fastest and
most reliable control with the longest
life. The phase-fired SCR commands
true power regardless of line voltage
or heater resistance. It also offers the
tightest control, but filtering must be
employed to reduce EMI noise.
Greg: What are some of the faster rates of
temperature transitions?
Mark: The temperature of semiconductor
wafers goes from room temperature to
1150 °C. The ramp rate might be 100 °C/
min. Yet customers think they can use
a 1-sec controller cycle time that corresponds
to a 1.6 °C error. For rapid thermal
processing, the ramp rate could be
Type Cycle Time Resolution Noise Heat Generation
Electromechanical Contactors 30 sec 3% Low Low
Solid State Relays (SSR) 1 sec 1% Moderate Moderate
Silicon Control Rectifier (SCR)
Zero-Crossing 16 msec 2% Low High
Phase-Fired 16 msec 0.1% High High
power controller performance
Table 1. Typical power controllers and their performance values are listed here from the
least to the most expensive, with electromechanical contracts costing the least.
200 °C/sec. A sample rate of 100 Hz is
then needed. Faster-than-required sample
rates cause unnecessary wear of contactors
and relays, and reduce the signalto-noise
ratio because the true change
in the process temperature becomes a
smaller percentage of the noise from the
process, EMI and resolution limits.
Stan: What about the precision of control
needed?
Mark: The temperature of the wafer
for some applications needs to be held
within 0.1 °C in order for the gases to react
and the substrate layers to grow. For
example, the temperature must reach
999.9 °C to exceed the activation energy
for the reaction, but must be kept from
exceeding 1000 °C. An improper temperature
causes not only an inconsistent
uniformity, but also different layer thicknesses
that create problems for feature
size and other key electrical properties.
Greg: What are the temperature measurement
requirements?
Mark: Besides the need for contactless
sensors, the resolution must be better
than 0.1 °C. Optical pyrometers without
any emissivity errors have a resolution
that ranges from 0.1 °C for standard devices
to 0.02 °C for special devices. The
response time must be faster than sample
time. For rapid thermal processing, the
response time must be less than 10 ms.
Optical pyrometers can be as fast as 2 ms.
Stan: What about measurement noise?
Mark: The prongs holding the rotating
wafer can cause a 40 °C to 60 °C drop.
The EMI noise from a zero-crossing
SCR can also cause noise of 1% to 3%.
Intelligent filtering is needed, as well as
an incredibly fast model-based control
system to smooth out noise and push out
the bandwidth.
Greg: Besides reducing the effect of process
and EMI noise, why is model-based
control important?
Mark: Model-based control reduces the
adverse effect of resolution on the signal-to-noise
ratio by relying less on feedback
control. The multivariable nature
of model-based control provides optimal
coordination that eliminates interaction
in wafer zone control. The radial zones
must be controlled at different temperatures.
The outermost radial zone must
be kept at the highest temperature due to
heat loss at the edge.
Stan: What type of model-based control
technology do you use?
Mark: We use the best controller for the
system under control given the process
characteristics and performance requirements.
This includes the sensors, actuators
and the process dynamics. The controller
might be a multivariable PID or
one of the many possible model-based
controller methodologies with a Kalman
filter to overcome system noise issues.
Go to www.controlglobal.com/1104_ControlTalk.html
to see Greg’s “Believe It or Don’t” list.
60 www.controlglobal.com A p r i l / 2 0 1 1

A d i N D E X
Advertiser Page No.
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Advantech Automation.. . . . . . . . . . . . . . . . . 37
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American Business Conf/SCADA. . . . . . . . . 46
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Emerson Process Mgt/Systems . . . . . . . . . . . 64
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TekSupply.indd 1
ClassicAutomation.indd 1

C O N T R O L R E P O R T
DAQ in the Delta
Every business has to change with the times and the demands of its customers, but
Jim Montague
e xecutive Editor
jmontague@putman.net
smaller ones are usually more agile because their “bosses” and customers are literally
the same people. For example, Luckett Pump and Well Service Inc. in Dublin, Miss.,
about 80 miles south of Memphis, is a three-man company that services many of the
“This is not a
wealthy area, so
we try to do more
patching than
replacing of tank
and pressure
controls on our
remote wells.”
water and wastewater facilities in dozens of
small, widely distributed towns spanning the
entire northern half of Mississippi.
The firm was founded in 1990 by Steve and
Jim Luckett and started out maintaining and
repairing all types of agricultural irrigation
wells in and around the Mississippi Delta region.
However, about three or four years later,
many customers began asking for gas chlorination
equipment, so they began repairing those
systems. And, about a year later, they expanded
into servicing certified water and wastewater
systems for municipalities.
“Over the years, water and wastewater regulations
have become more involved and restrictive,
and put more limits on what water treatment
plants can allow to leave their systems,”
says Steve Luckett. “So eventually, we went
full-time doing pumps and operations services
for the water systems in our small towns,
and we worked with a lot more controls, pressure
transducers, starters, control panels and
tanks probes to keep the pumps running and
the tanks fixed. This is not a wealthy area of
the United States, so we always try to do more
patching than replacing of tank controls and
pressure controls on our remote wells.”
Increasing water and wastewater rules also
require more data gathering and reporting, so
Luckett took on many of those jobs, too. He
previously used wired telephone lines to remote
locations, but ongoing costs, service problems
and potential short-circuits inspired him
to adopt Banner’s DX 80 remote radio gateways
and nodes about three years ago. The 900-
MHz unlicensed radios are organized as slaves
and repeaters and let Luckett and its municipal
clients collect all the I/O data they need about
every five minutes. Gaining this capability
was fortunate because in December 2009, the
U.S. Environmental Protection Agency’s latest
groundwater rules took effect, which required
towns with more than 3300 residents to have
24/7 monitoring of residual chlorine based on
samples collected every 15 minutes.
However, because each town it serves has
two to 15 wells coming into its water system,
and each has a residual monitor/analyzer for
added chlorine with 4-20 mA data outputs,
Luckett was soon faced with organizing a flood
of data. Fortunately, he worked with longtime
associate Joe Waszgis at Automatic Dynamic
Controls (ADC) in Irving, Texas, which represents
Banner and Red Lion, and also hired his
nephew, Boyd Mitchell, to join the company as
an applications engineer. After some training
and experimenting, Luckett implemented Red
Lion’s G310 data logging and HMI equipment
with its Crimson 2.0 and 3.0 software, which
takes in real-time sample data from the well’s
chlorine analyzers via Internet Protocol (IP) addresses,
Ethernet-based connections and Banner’s
radios and organizes it using Microsoft’s
Excel spreadsheet format.
“If we didn’t have G310, we’d have to use
chart recorders with SDS cards. Previously, we
had to work like crazy to keep up with all the
data coming in,” says Luckett. “It was a steep
learning curve to implement the radios and
program the G310 HMI, but we had good support
from our suppliers, and Joe and Boyd were
a big help. Eventually, we learned to use the
HMI to see all our data, its programming got
much easier, and it solved a lot of headaches.”
So far, just a few of north Mississppi’s municipal
water systems have converted to Luckett’s
radio-based data-acquisition method, but others
are waiting to do it. “We can even use G310
to remotely update our clients’ device software,
adjust chlorine levels and turn pumps on or off
from our office, so they don’t have to pay us to
come out,” adds Luckett. Agile, indeed.
62 www.controlglobal.com A p r i l / 2 0 1 1

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