Oh, No... Not Again! - Control Global

MAY 2010
Oh, No...
Not Again!
Safety is in the culture, not the systems
How to Implement
a Standards-Based
Safety System
Maximizing Control
Loop Performance
When to Use a
Soft Starter or a VFD
On the Web
AnDreW BonD rePortS on
ProCeSS neWS In eUroPe

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f e at u r e s
S A f e t y
35 / IeC 61511 Implementation –
the execution Challenge
Deciding to use the standard is only the beginning.
by Tom Shephard and Dave Hansen
A d v A N C e d C o N t r o l
41 / Maximizing Control loop
Performance
Tune your processes to stop giving away valuable
commodities. by F. Greg Shinskey
W e B e X C L u s I V e s
Andrew Bond’s European Report
www.controlglobal.com/1005.Bond.html
Cover Story
May 2010 • Volume XXIII • Number 5
26 / oh, No...Not Again!
It’s the culture, not the control systems. by Walt Boyes
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 ad-
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consent of the copyright owner. POSTMASTER: Send address changes to CONTROL, P.O. Box 3428, Northbrook, IL 60065-3428. SUBSCRIPTIONS: Qualified-reader subscriptions are accepted from Operating Management in the control
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M A y / 2 0 1 0 www.controlglobal.com 5

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D E P A R T M E N T S
9 / Editorial
Let’s Do One for the End Users!
11 / Feedback
More on the Great Toyota Fail and what
some of our surveyed readers think about
the state of process automation training.
14 / Lessons Learned
The Control Software Needs of Renewable
Energy Processes, Part 1
.
17 / On the Bus
Wireless Control in the Field
19 / InProcess
WirelessHART is now an IEC standard and
other process automation news.
25 / Resources
Fieldbus information online.
46 / Technically Speaking
Soft Starters versus VFDs. When do you
use which?
CIRCULATION AUDITED JUNE 2009
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
47 / Ask the Experts
Our experts discuss temperature control
with slow boilers and the difference between
smart actuators and positioners.
50 / Roundup
The latest in level instrument technology.
53 / Products
Exclusive product announcement from CyboSoft,
plus more items to make your life in
process easier.
55 / Control Talk
McMillan, Weiner and friends wrap up
their wrestling match with batch data and
explain how you can win the match with
yours.
58 / Control Report
Jim Montague would like to finish his next
plant safety article before another process
plant explodes.
May 2010 • Volume XXIII • Number 5
PRODUCT EXCLUSIVE
CyboSoft’s model-free adaptive
(MFA) technology is now available
for ControlLogix.
PRODUCT ROUnDUP
ABB’s compact DCS800-EP panel
drive.
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
M A Y / 2 0 1 0 www.controlglobal.com 7

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Let’s do one for the End Users!
Five years ago some of the brightest minds in the automation industry began working
on a revision to the HART 6 standard that would include the ability to construct wireless
sensor networks on the HART protocol platform. Unfortunately, some of those same
bright minds also to begin work on an ISA wireless standard that was envisioned at the
very beginning to be completely incompatible
with HART. The result was acrimony, and
we got us a wireless standards war—just like
we had with fieldbus, and just like the FDT/
EDDL conflict we are hopefully close to resolving
with the Field Device Initiative (FDI). End
users really hate standards wars.
Siemens has become the latest major fielddevice
vendor to release products certified for
WirelessHART. Most of the major field-device
vendors now have products that are either in
the certification process or in the final release
to shipping. All the major field-device vendors
are scheduled to ship some WirelessHART-certified
products by the end of this year.
To top it all off, the IEC has approved WirelessHART
as IEC 62591Ed. 1.0, the first global
standard for wireless sensor networks.
ISA100.11a, although approved by ISA last
October, has not been approved by ANSI as
an American National Standard. ANSI made
some suggestions. Clearly, since the ISA standard
is already far behind, this wasn’t ISA’s first
choice.
Shell did a test of a use case that was presented
at the ISA100.11a meeting in February,
which indicated that some serious problems existed
with the ISA100.11a standard. This simple
use case, two temperature transmitters and a
gateway basically did not work. Other use cases
might, but this one did not.
Rather than continue the argument with
ANSI, the ISA100 committee is working on a
“maintenance activity” to clean up the technical
issues and handle the procedural violations
that have kept the standard from being
approved by anybody but ISA. The plan is to
have a revised standard available for approval
in October by ISA and sent to ANSI thereafter.
Meanwhile, the end user community has
gotten so fed up with the wireless standard war
that it spoke out vigorously at the ARC Forum/
ISA100 meeting in February on behalf of a single
wireless standard.
Everybody once believed that ISA100 would
be that standard. Now however, it is becoming
difficult to see where a revised ISA100.11 standard
fits.
If vendor politics would permit, the sensible
thing would be to declare WirelessHART the field
device standard, and continue with the less contentious
Backhaul, Power Harvesting, Discrete
Manufacturing and other committees of ISA100.
My belief is that the success of wireless sensor
networks depends a great deal on how easy
it is to select and install them. Multiple sensor
network standards clearly disrupt and damage
the market, and as the fieldbus standards war
has shown, seriously slow the adoption rate of
new technologies.
There are things I wish WirelessHART
would do that ISA100 was supposed to do, and
probably will, when the “maintenance activity”
is completed. But that is going to take another
six months to a year before working products
are released. By that time, there will be thousands
of WirelessHART devices installed and
working in end-user plants.
Given that the lifecycle of field devices is between
10 and 20 years on average, who’s going to
rip out WirelessHART devices to replace them
with incompatible ISA100.11a devices? Somehow
I don’t see that happening, do you?
So, my fellow ISA100 committee members,
let’s think about the possibility of doing something
for the end users, shall we?
E D I T O R ’ S P A G E
Walt boyes
Editor in chiEf
wboyes@putman.net
We got us a
wireless standards
war, and end users
really hate
standards wars.
M a y / 2 0 1 0 www.controlglobal.com 9

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The Great Toyota Fail
In my opinion, your article ( “Control
Systems and the Great Toyota Fail,”
April 2010, www.controlglobal.com/articles/2010/ControlSystems1004.html)
effectively gives everyone an excuse for
not diligently seeking “the appropriate
amount of perfection.”
Just because software achieves Six
Sigma goals doesn’t mean that it is sufficient.
It all depends on the intended use
of the product. Perhaps Six Sigma is good
enough for consumer electronics, but perhaps
not for mission-critical software, such
as digital control systems in automobiles
and DCS software!
The process industry recognizes quality
software products with minimal bugs
and naturally moves away from those that
don’t have it. And it is willing to pay many
dollars to do so, even when it involves moving
from one DCS to another DCS, which
is very expensive.
Vendor engineer
naMe Withheld By requeS t
Walt Boyes responds:
I didn’t try to provide an excuse, but I
don’t think I need to. The process industry
is saddled with COTS-based software
that is riddled with bugs and exploitable
issues, and the vendors are sitting back and
saying, “Well, our customers aren’t asking
us to do better.” That’s true, and it shames
both the vendors and the users for doing
it. We have process control software that
is genuinely not cyber-secure, and there
is still no great mandate to do anything
about it.
The vendors are right. The end users get
what they’re willing to pay for, including
safety and security, or the vendor loses the
project to someone who doesn’t provide
that level of safety and security, but is significantly
less costly.
Now we have a BP-leased drilling rig
burning and sinking in the Gulf. Offshore
safety is supposed to be so much better
than plant safety.
TANSTAAFL (There ain’t no such
thing as a free lunch.)
Here is where regulation can and
May/2010 www.controlglobal.com 11
T E C H N I C A L L Y S P E A K I N G
FEEDBACK
should play a significant part. As with environmental
legislation, it would make
mandated safety and security part of the
baseline cost of doing business.
And Furthermore
Thank you for your informative insights into
the Toyota control
systems failure. You
are right about the
point that everyone
wants quality, but no
one wants to pay for
it! Drivers want their
vehicles to be as safe
as possible, but the
real problem has almost
always been
the drivers. As the saying goes, “Built “Built by gegeniuses to be operated by fools!”
Fredric Moore
huBco inc.
moore800@mindspring.com
Surveys Say
Control regularly takes the pulse of its
readers. In our our annual salary and a recent
skills survey, there are spots for more
open-ended responses. Here are a few. See
the June issue for more results.
Two views on training:
“Automation has too many amateurs
from other engineering disciplines. Basic
training without formal education isn’t
acceptable in other engineering field and
shouldn’t be tolerated in ours.”
On the other hand, “It is unfortunate
that the profession has become so elitist.
It seems more important to have a degree
than to actually be able to find the root of
a problem. Employers have been sold a
bill of goods, believing that their employees
need a university degree to understand
how to use a shovel.”
On the same subject from our salary
survey respondents:
“No one in upper management seems
to be planning for training the next generation
of engineers. The gap is getting
huge.”
“There are no trained people coming
through the ranks.”

Lessons Learned
Béla lipták
liptakbela@aol.com
To design any
control system
correctly, we must
first understand its
“personality,” both
in terms of opera-
tion and dynamic
characteristics..
12 www.controlglobal.com May/2010
Control Software and Renewable Energy, Part 1
In this series of articles, I will give some examples of the control software that needs to
be developed for renewable energy processes, and will compare it to the traditional
industrial control systems. Traditional controls evolved from using single control loops.
Renewable energy control is a step beyond that. Traditional industrial control concen-
trated on keeping flows, temperatures, pressures,
etc. at their desired values, so these had
only an indirect influence on efficiency, productivity
or profitability of the controlled unit
operation. The main goal of renewable energy
control will be to optimize efficiency and profitability,
while treating the operating conditions
only as limits of the operating envelope.
Traditional industrial control used multivariable
control only in a few simple cases, while
renewable energy control will always be working
with multivariable control. In addition,
while traditional industrial controls often separated
the different states of control for start-up,
normal, emergency and shutdown phases of
operation, renewable energy controls will integrate
these, and will reconfigure themselves
automatically as they respond to market conditions,
energy and raw material costs and other
profitability-related changes.
To design any control system correctly, we
must first understand its “personality” fully,
both in terms of its operation and its gain and
dynamic characteristics. Therefore, in this series,
before giving specific examples of the software
packages needed to automate such renewable
energy processes, I will describe these
processes. I will then describe the optimization
controls for energy-free homes, reversible fuel
cells and solar-hydrogen power plants.
Later articles will describe the software
needed to control the solar-hydrogen processes
(Figure 1) that form a cycle by substituting photosynthesis
with photo-electrolysis (H 2 O + sun
energy = stored H 2 + released O 2 ) and respiration
with fuel cell (H 2 + O 2 = electric energy
+ H 2 O) processes. This way, the increasing energy
consumption of mankind can be met without
releasing any carbon into the atmosphere
and without the use of exhaustible energy resources,
such as fossil fuels or uranium.
Following this general introduction, I will
describe the control software needs of three
solar-hydrogen processes, which can fully automate
the operation of the energy-free homes,
reversible fuel cells and “solar-hydrogen” power
plants of the future.
The renewable energy Processes
During the industrial and post-industrial period
(from the 18th to the end of the 21st centuries)
we will have depended on exhaustible
energy resources (fossil, nuclear, etc.), while, by
the beginning of the 22nd century, our energy
sources will be inexhaustible ones. The present
energy consumption trend (based on NASA
data) is shown in Figure 2. This trend, up to
2009 (solid blue line) represents the actual
global consumption of the exhaustible fossil
energy sources used in units of quads, (Q = 10 15
BTU). After 2009, the fossil fuel consumption
trend (dotted blue line) shows how our fossil energy
supplies will get exhausted. The red line
represents the total global energy consumption
up to 2009, and includes the non-fossil sources,
such as nuclear and hydroelectric.
We might also note that the consumption
rate of fossil fuels has already exceeded their
rate of discovery. Yet, as of today, our resources
are still being spent on building new nuclear
and fossil plants or on replacing our aging refineries.
This is in spite of both nuclear and fossil
fuels being exhaustible, and while both are getting
more and more expensive.
The Biological Life Cycle
The biological life cycle on Earth is based on
the balance and interdependence of animal
and plant life on the planet.
Photosynthesis takes up half of this cycle. In
this half, the vegetation absorbs carbon dioxide
and, using solar energy, splits water into oxy-

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Quadrillion Btu/year
Lessons Learned
Fuel Cell
Energy + H 2 O
Figure 1. Energy cycle without releasing carbon.
gen (which is released into the atmosphere) and hydrogen,
which, using a catalyst named chlorophyll, combines with
carbon from the atmosphere to produce food for animals
and humans. (Photosynthesis = H 2 O + sun energy + 6CO 2
= C 6 H 12 O6 + 6O 2 ). The other half of the biological life cycle
is respiration, in which animals and humans inhale the
oxygen generated by plants and obtain their muscle energy
by digesting (burning) the glucose, cellulose, etc. produced
by plants, while exhaling carbon dioxide (Respiration =
C 6 H 12 O 6 + 6O 2 = 6 CO 2 + 6 H 2 O + energy).
When the half-cycles of photosynthesis and respiration
are in balance, the concentration of atmospheric CO 2 is
constant. This concentration was ~ 280 ppm for 500,000
years. Today it is 360 ppm, and it is projected that by 2050
800
700
Global Energy Consumption: Actual and Projected
The blue curve represents the entire lifetime of know fossil resources.
600
500
2020
400
300
1999
200
120 years
100
0
Content 74,424 quads
1800 1850 1900 1950 2000 2050 2100 2150 2200 2250
Data: NASA 1999
Year
Total fossil Total Fuel Fossil envelope
Figure 2. Past and future energy trends (blue = fossil, red =
total, including nuclear and renewable energy sources).
14 www.controlglobal.com May/2010
Photoelectrolysis
H 2
Storage
O 2
H 2
it will be over 500 ppm. This shows that plant and animal
life on the planet is no longer in balance. This imbalance
has passed the point when it could be corrected by planting
trees. In order to absorb the excess carbon dioxide generated
by the burning of fossil fuels, we would need to plant forests
on an area equaling the surface of another Earth.
The goal of renewable energy processes is to reestablish
the balance of the photosynthesis and respiration processes.
The solar-hydrogen processes can supplement the photosynthesis
part, but without the use of carbon.
The yearly solar energy that is received on each square
meter of the Sahara is approximately 3000 KWh. Approximately
2500 KWh/m 2 /yr is the “insolation” in southern California,
and 1250 KWh/m 2 /yr in New York City or in Connecticut
(where I live). I will use my house as an example of
how an energy-free home could be designed, how its operation
could be automated, and how the costs and payback periods
can be calculated.
If my roof (450 m 2 ) was covered by 10%-efficient photovoltaic
(PV) solar collectors, assuming my wife allowed me to
cut down the trees around our home, which she would not,
the collectors would generate 54000 KWh/yr. Our yearly
electricity consumption, including a pool, is 15000 KWh/
yr, for which I pay about $3000. My yearly oil and gas consumption
is equivalent to 864 gallons of oil, having an energy
content of about 32000 KWh.
Today, in this area, the same energy in the form of oil
costs about half as much as it costs in the form of electricity.
(This is due to the low oil and gasoline taxes. In Europe and
in other parts of the world, the cost of gasoline is about twice
what it is here because of higher taxes.) Therefore, my yearly
total energy use (expressed in KWh units) is 47000 KWh.
This quantity is 7000 KWh/yr less than the amount of solar
energy that can be collected on my roof. Therefore, this excess
can be used to recharge a plug-in hybrid or electric car.
The installed cost of 10%-efficient shingles is about $500/m 2
or about $225,000 to cover my roof. In Connecticut, the government
subsidy is 40%, lowering the total investment to $135,000
(without considering the added advantage of having new shingles).
The local power company provides the bidirectional electric
meter needed to connect to the grid free of charge.
The total value of 54000 KWh/yr of electricity (if purchased
in the form of electricity at $0.2/KWh in our area
today) is $10800. (If part of it is purchased in the form of
fossil fuels, it is less, but that cost is also rising). Therefore,
if we base the calculation on the present cost of electricity,
the payback period is 14.5 years. Naturally, if electricity
costs rise or if collector costs drop and efficiencies increase,
the payback period will be shorter. Also, if we deduct from
the total investment the value of covering the roof with new
shingles, or if the location is, say, Nevada instead of Connecticut,
the payback period is further reduced.

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of the system. Regardless of your needs, our 800xA High Integrity solution provides
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of safety automation for more than 30 years. For more information, visit
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Register now at: www.abb.com/a&pworld

are you confident With the
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Wireless control in the Field
When the ISA SP100 committee categorized measurement and control applications, the
two most critical classifications—closed-loop control and safety—were deemed un-
likely candidates for early wireless applications. But within a couple years of widely
available WirelessHART devices, papers and presentations abound on the subject of
using wireless for control. Control using intermittent
signals is not a terribly new topic, but
applying these principles to familiar measurements
like temperature and level is new. The
enthusiasm for applying “control over wireless”
appears to be widespread, and studies show
wireless availability approaching that of wired
devices. So why not use it for control?
Measurements are one thing. Maybe you
can live with updates once a minute, or even
once every 10 minutes or more in an effort to
optimize battery life. But control valves pose
a different problem. How many of the control
valves you’ve specified in your career, didn’t require
a defined fail position?
Fail position means the actuator has a powerful
spring that relentlessly drives the valve either
fully open or fully closed on loss of motive
power. The upshot is that wireless strategies
that worked for measurements; i.e., going to
sleep for 59 of 60 seconds, or for 599 of 600,
doesn’t work so well for control valves. Most
loops won’t tolerate the final element going to
its fail position 99% of the time.
An always-on battery scheme would require
frequent, perhaps daily battery changes, and/
or an enormous and expensive battery. Be surprised
if a wireless, battery-powered throttling
control valve appears any time soon.
But this doesn’t mean that there’s no place for
a locally powered wireless actuator/positioner.
“WirelessHART-based products for valves in
on-off services will be introduced as soon as
the next six to 12 months,” says Kurt Jensen of
Emerson Process Management. These devices
would need wired, local, 24-V DC power and
would be “on” all the time.
A wired-power, wireless-communication device
can be a good thing for a WirelessHART
network, saving nearby battery-only devices
from having to “wake up” only to relay trans-
missions from their neighbors, thereby extending
their battery life. Being continuously powered
also means the wireless actuator can have
a “fail” position. One use case could be a tank
filling or emptying, monitored over wireless,
and tripping a “wireless” on-off valve open or
closed to protect a pump, or prevent an overfill
condition.
Doing control or interlocks in wireless gateways,
or even in the positioners themselves, has
some appeal for some of the same reasons control
in the field (CIF) makes sense for fieldbus.
Wireless gateways are by nature a “mux” (multiplexer),
and control using multiplexed I/O has
been a subject of debate for years. If CIF could
be exploited, control could continue even if
mux-to-host or device-to-mux communications
were interrupted.
WirelessHART even has provisions for PID
control. Ed Ladd of the HART Communications
Foundation says, “PID capability has
been built into HART devices for some time...
[It] opens the door to many new possibilities
including new opportunities [for] CIF.” While
suppliers such as Emerson, Samson and Smar
have tried PID in HART devices, users will
have to exert their influence with suppliers to
get it implemented in WirelessHART.
Powered gateways are good candidates for
PID and logic functions, and those being pondered
for the Foundation fieldbus RIO (remote
I/O) and WIO (wireless I/O) gathering points
would implement the same fieldbus function
blocks found in check-marked devices. Field
trials of the wired RIO versions are scheduled
to start within the next year.
For either Fieldbus WIO or WirelessHART
control solutions to work, consistent and easyto-use
host tools need to exist that accommodate
trouble-free configuration and operator interface
to PID mode, setpoints and tuning.
O N T H E B U S
john Rezabek
contributing Editor
jrezabek@ispcorp.com
Users will have to
exert their influ-
ence with suppliers
to get control in the
field implemented
in WirelessHART..
M a y / 2 0 1 0 www.controlglobal.com 17

I N P R O C E S S
IEC approves WirelessHaRT as First Global
Wireless Communication Standard
The International Electrotechnical
Commission (IEC) has approved the
WirelessHART specification as a full
international standard (IEC 62591Ed.
1.0). The unanimous vote on March
26, 2010, by the IEC National Committees
of 28 countries confirms the
broad global support for WirelessHART
technology as the international standard
for wireless communication in
process automation.
“The overwhelming approval by
IEC fulfills the request of users for a
CFOs Give Economy
Mixed Reviews
In a national survey of U.S. CFOs and
senior comptrollers conducted by Grant
Thornton LLP, the U.S. member firm of
Grant Thornton International Ltd, only
29% plan to increase hiring in the next
six months, while 22% plan to decrease.
Hiring is weaker amongst Fortune 500
firms (firms with revenues of $5 billion
and higher), as 31% plan a decrease in
hiring over the next six months, while
only 23% plan an increase.
A total of 496 CFOs a companies
ranging from $5-billion giants to
smaller than $100-million smaller
fry completed the survey. Of them 92
work for manufacturing companies.
Their responses were a bit more
mixed. Ninety-three percent of them
said they thought the U.S. economy
would either improve or remain the
same during the next six months. (The
number was equally split between
those two options.) Nearly 60% said
they expected their companies’ financial
prospects to improve during that
period, and another 36% expected
single international wireless communication
standard that is supported
by major automation suppliers,” says
HART Communication Foundation
Executive Director Ron Helson.
“WirelessHART technology has been
confirmed by both users and suppliers
to be a technically sound, reliable and
secure solution for wireless communication
in process automation.”
A growing number of WirelessHART-compatible
products are
available today from major global
them to stay the same. Less than 5%
thought they would worsen.
Fifty-five percent of manufacturing
CFOs say they are less worried about
their organizations than last year, and
another 37.5% say their concern level is
about the same as last year. Only 6.8%
are more worried.
At the same time, half of those manufacturers
expected their head counts
to remain the same. Another 25% expected
to decrease head count. Only
25% say they plan to hire during the
next six months.
Only 26% think the recession will
end during the second half of this
year. Fifty percent are betting on
2011, but nearly 18.5% think it will
be later than 2011.
Invensys Releases
Wonderware System
Platform 4.0
Invensys Operations Management
(IOM) has released its Wonderware
System Platform 4.0 software. Won-
suppliers, including ABB, Emerson,
Endress+Hauser, Pepperl+Fuchs, Siemens
and others.
WirelessHART is an open and interoperable
wireless communication
standard designed to address the needs
of industry for reliable, robust and secure
wireless communication in realtime
industrial process measurement
and control applications.
The IEC prepares and publishes
international standards for electrical,
electronic and related technologies.
derware System Platform 4.0 software
delivers new device connectivity functions,
tiered historian capabilities and
web visualization improvements, that
the company says enable plant operators
to manage and control equipment and
processes more effectively; information
systems personnel to integrate and make
use of real-time manufacturing information
more easily; and for all personnel to
be continuously up to date on their overall
operation’s performance.
The System Platform software offers
new tiered historian capabilities, that
simplify data time-stamping, information
aggregation, retrieval and reporting,
as well as. improved information
security and disaster recovery across
distributed operations.
The platform historian is also available
as a stand-alone offering, Wonderware
Historian 10.0. The Information
Server 4.0 component now provides
the experience and performance of
real-time ArchestrA graphics for web
visualization. Now customers’ graphical
configuration efforts can be reused
and managed across their manufacturing
enterprises.
M a y / 2 0 1 0 www.controlglobal.com 19

Orion level gauges take on the
toughest measurement challenges
in the world’s harshest conditions.
Orion level controls are built tough. Our Aurora
Magnetic Level Indicator (MLI) combines floatoperated
and leading-edge electronic measurement in a
single, redundant indicator. Orion MLIs not only serve
industry’s most demanding applications and environments,
they’re built to thrive in these extremes.
Learn more about new or replacement solutions in
liquid level indication at orioninstruments.com.
L I Q U I D L E V E L M E A S U R E M E N T
• Onshore/Offshore Oil & Gas • Oil and Gas Refining
• Thermal & Nuclear Power • Water & Wastewater
• Pharmaceutical & Biotech • Chemical Processing
When the going gets tough,
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Float-based
Magnetostrictive
level transmitter
shown mounted
to an Atlas MLI

Solar Inverters Are
the Next Big Thing
The photovoltaic (PV) industry is the
fastest growing industry in the world,
with a promising chance to remain the
fastest growing industry for the next
decade. The solar inverter market was
$3.1 billion in 2008 and is forecasted to
be over $12.0 billion in 2014, according
to a new ARC Advisory Group study.
Solar inverters are a critical component
in PV systems because the
DC voltage from a solar panel has to
be converted to AC, so the market for
solar inverters of any size in any application
is entirely dependent on the related
market for PV systems.
“This is a very dynamic market that
is going against the tide of the remnants
of the global recession, and while
Europe has been a leader in PV solar
farm implementations, China and the
U.S. are racing to take over the lead.
High growth has attracted the large
automation suppliers, such ABB, Eaton,
Emerson, GE Energy, Schneider
Electric, Siemens and Elettronica Santerno,”
according to Steve Clouther,
the author of ARC’s “Solar Inverter
Worldwide Outlook.”
The worldwide installed capacity of
the solar PV power escalated from 1.3
GW in the year 2001 to a little less than
15.0 GW by 2008. The installed global
solar PV market grew to more than 20.7
GW in 2009, representing growth of
about 38%on 2008. For a point of reference,
in the period from 2001 to 2008,
the solar PV market grew at a compound
annual growth rate greater than 60%.
Despite the current global economic
problems, China and the United States
are aggressively going after Europe’s
leading position in the solar power industry.
China is already the world’s biggest
producer of solar panels.
However, China still exports 90% of
the solar panels it produces to markets
such as Germany, Spain, Japan and
the U.S. China is striving to become
a meaningful market for solar energy
and has adopted the European model
of subsidizing the industry in an attempt
to get it off the ground. It has a
target of 20 gig watts of installed capacity
by 2020.
It is the U.S., however, which has re-
ABB, Inc.
Discrete Automation and Motion
New Berlin, WI
Tel: 800-365-4357
I N P R O C E S S
cently attracted the most attention globally
from the solar industry. Legislation
is a sure way to increase the use of solar
power, so, much attention followed
on the heels of the Obama Administration’s
stimulus package which contained
grants and tax breaks for solar power.
A center-driven winder drive that runs without encoders?
Absolutely.
SIs, OEMs, Users tell us they also control induction (open loop
or closed loop), servo or permanent magnet motors – making
the ACSM1 the most adaptable center-driven Winder Drive in
the market. No encoders required for precise load control. Plus,
a removable firmware/parameter memory module (which means
that, if the power unit or control unit is replaced, the drive can be
re-commissioned by you, in minutes, with identical settings). Get
started at http://www.drivesanswers.com/223 or call ABB at (262)
785-3200.

IN PROCESS
Industry Briefs
Invensys buys Skelta Software. To extend
an open platform to deliver new
workflow and collaboration applications,
Invensys Operations Management
has acquired Skelta Software, a
Our control technology
works where you do.
SEL devices meet or exceed IEEE and
IEC standards for harsh environments:
• Logic controllers
• Tough computers
• Annunciators
• Switches
Visit www.selinc.com/ct5 to learn more about
tough SEL devices for rough environments.
OPERATING
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software company headquartered in
Bangalore, India. Skelta provides enterprise-wide
business process management
(BPM) and advanced workflow
software solutions for companies
in several industries, including manufacturing
and infrastructure opera-
ELECTROSTATIC
DISCHARGE
15 g
SHOCK
RESISTANT
ontrol_May'10_A3.indd 1 4/9/2010 4:18:23 PM
tions. Skelta’s BPM suite offers capabilities
for business process modeling and
execution, and includes capabilities for
business rules, forms and document
management and business activity
monitoring. Terms of the acquisition
will not be disclosed. The business will
continue to be managed by Skelta’s existing
executive team, and add approximately
130 employees to Invensys’ operations
in India.
Swagelok buys RHPS. Swagelok
Co. has acquired the shares of RHPS
B.V. as part of its strategy to broaden
its offering of products and services for
fluid system technology users worldwide.
RHPS of Nieuw-Vennep, the
Netherlands, manufacturers pressure
regulator products used mostly in oil
and gas, chemical/petrochemical, alternative
fuels, semiconductor and biopharmaceutical
applications. Terms of
the purchase were not disclosed. For
more than 20 years, RHPS has been
designing and manufacturing relief
valves, back-pressure and pressure reducing
regulator products.
Ohmart/Vega introduces Vize,
LLC. Ohmart/Vega has acquired
Houston-based Vize LLC, a supplier
of magnetic level indicators, engineered
bridle solutions and accessories.
An important addition to the
Ohmart/VEGA family, Vize product
lines complete Ohmart/VEGA’s full
offering of level measurement technologies.
Ohmart/VEGA and Vize
share the goal of understanding individual
process and application needs,
to supply a solution that is safe, accurate
and low-maintenance.
Schneider buys SCADAgroup.
Schneider Electric reports its has
agreed to buy SCADAgroup, an Australian
provider of telemetry products
and solutions for the water and wastewater,
oil and gas, and electric power
end-market segments. Schneider says
that SCADAgroup’s telemetry will
help it improve its remote measurement,
monitoring, control and data
transfer capabilities.

When Moore Industries—the #1 company in
Alarm Trips—needs SIL 2 Functional Safety
approval, we look to the #1 company in Safety
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Our STA Safety Trip Alarm is your answer to back
up your PLC or DCS “soft” alarms with 40 years
of fi eld proven “hard” alarm experience.
Confi dently use the STA as a safety logic solver
to act on hazardous process conditions, provide
emergency shutdown, and provide on/off control
in Safety Instrumented Systems.
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• Designed for use in Safety Instrumented
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suitable for a SIL 3 confi guration. This allows
use in a redundant architecture (1oo2,
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• The STA is provided with comprehensive
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Manufacturer Description Allied Stock Number
Omron Industrial
Automation MX2 AC Drives 834-1471
© Allied Electronics, Inc 2010. ‘Allied Electronics’ and the Allied Electronics logo are trademarks of Allied Electronics, Inc. An Electrocomponents Company.
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Fieldbus on the web
Control’s Monthly Resource Guide
HANDY FIELDBUS GUIDES
PePPerl+Fuchs
330-486-0002 w w w.ampepperl-fuchs.com
Pepperl+Fuchs offers two basic guides
to fieldbus technologies in a handy, simplified
form. One is a two-page “pocket
guide” to the high-power trunk con-
cept, exploring such issues as the physical
fieldbus layer, typical physical layer
measurements, cable type and trunk
lengths, and Division 2 installation.
The second one is a poster containing
some of the same information in simplified
form on a single page suitable for
mounting. The direct link to the wall
chart is http://tinyurl.com/y5mrg9f; the
pocket guide is at http://tinyurl.com/
y7xxlv3 (scroll down the page).
FIELDBUS WIRING GUIDE
relcom Inc.
800/382-3765 w w w.relcominc.com
This free, downloadable, 58-page PDF
contains detailed information on wiring
fieldbus systems. Topics covered
include configuration, signals, cable,
terminators, power, reliability considerations,
cable selection and installation
in process plants, hazardous-area
power and more. The direct link is at
http://tinyurl.com/y6os89j.
FIELDBUS OVERVIEW
emerson Process management
512 /835-2190 w w w.emersonprocess.com
A 12-part presentation on fieldbus basics
by experts. Subjects include a
fieldbus overview, justifying fieldbus,
example applications, installation of
fieldbus, fieldbus standards, fieldbus
communication, fieldbus function
blocks, fieldbus diagnostics, fieldbus
EDDL, HSE fieldbus and advanced
fieldbus. A direct link is at http://tinyurl.com/y4veoyk.
FIELDBUS PDF
Yokogawa
800/888-6400 w w w.yokogawa.com
“The Fieldbus Book–A Tutorial” is a 41page
PDF document that covers many of
the details of Foundation fieldbus. The
subjects covered include the physical
layer, data link layer, application layer,
system management protocol, highspeed
Ethernet, function blocks and
more. It’s free for downloading at http://
tinyurl.com/y3m29dd.
COMPARING FIELDBUSES
Pacontrol.com
w w w.pacontrol.com
These two PDFs compare remote
communications technologies. A PDF
chart compares the characteristics of
Foundation fieldbus, Profibus, DeviceNet,
AS-i, Modbus and HART industrial
communication protocols.
The 30-page document includes a
comparison of fieldbus and remote
I/O systems. Both are available free for
downloading at www.pacontrol.com/
Fieldbus.html.
R E S O U R C E S
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.
NOT QUITE A DOZEN FIELDBUS ARTICLES
oPen sYs tems medIa
w w w.opensystems-publishing.com
This website has links to 11 articles
on various fieldbus technologies.
Topics include “Choosing the Right
Fieldbus,” “Eight Popular Open-Architecture
Fieldbuses, Parts 1 and 2,”
“Controlling Fieldbus Systems with Internet
Technology,” “Using CAN as an
Industrial Fieldbus,” and “Using Fieldbus
to Integrate Automated Systems.”
A direct link is at http://tinyurl.com/
y53fets
INSTALLING FIELDBUS
moore Indus trIes InternatIonal
818/894-7111 w w w.miinet.com/moorehawke
Many automation engineers are coming
face to face with real fieldbus applications
for the first time. Fieldbus (using
digital communications networks
for distributed instrumentation and control)
has many benefits, but installation
requires some additional considerations
over and above normal 4-20 mA projects.
This whitepaper from MooreHawke dis-
cusses some of these issues and explains
how to deal with them. To access the paper
go to http://tinyurl.com/y47f5la.
M a y / 2 0 1 0 www.controlglobal.com 25

We plan cover stories fairly far in advance. This was supposed
to be a story of the convergences going on in
safety systems in the process industries. Then the story was, as
they say, overtaken by events. We will still look at those convergence
trends, but we have to do it in a whole new light.
On Friday, April 2, 2010, at 12:30 a.m., employees of Tesoro
Corp.’s Anacortes refinery were starting up the naphtha
unit after it had been down for maintenance. The unit
caught fire and was seriously damaged. Seven workers were
killed. The refinery’s capacity to make unleaded gasoline was
reduced by two-thirds.
Then, on April 5, 2010, in the Massey Energy-owned Upper
Big Branch Mine near Montcoal, W. Va., an explosion
killed 29. There also was a much larger mining catastrophe
recently, killing over 100 miners in China, as well as another
refinery problem in Gujarat, India.
Most recently, BP’s Deepwater Horizon oil rig caught
26 www.controlglobal.com M a y / 2 0 1 0
fire on April 21. Eleven workers are missing and presumed
dead, and the environmental impact remains unclear.
Ever since the Producers and Refiners refinery in Parco,
Wyo., exploded in April 1927, with a loss of 18 lives, the process
industries have been faced with a continuing series of
refinery, chemical plant, mining and even food plant disasters,
which continue to happen with distressing regularity.
Including mining, such as the Massey Coal explosion, there
have been over a dozen accidents in process industry plants
just since the beginning of the year, requiring shutdowns and
causing injuries and some fatalities.
This is made worse by the knowledge that, at least since the
Buncefield explosion and fire in the U.K. and the BP Texas
City disaster, both in 2005, end-user and vendor companies
alike have been trying to understand what causes these accidents,
and seeking actively to prevent them. Based on the record,
we haven’t had a lot of success.

There have been several approaches to preventing accidents.
There has been a global drive toward using safety instrumented
systems (SISs) that are designed and maintained
to shut plants down in the event of failures. But SISs haven’t
stopped the accidents, even where they have been shown to
be working. One of the most important findings in studying
the Buncefield and Texas City accidents was that the
operators were inundated by alarms. So EEMUA, the Engineering
Equipment and Materials Users Association (www.
eemua.co.uk), the Abnormal Situation Consortium (www.
asmconsortium.net/Pages/default.aspx), ISA18 (www.isa.
org), and the Center for Operator Performance (http://operatorperformance.org)
have focused on HMI design and
alarm management. But alarm management hasn’t stopped
the accidents.
The vendor community has moved to incorporatecorporate
the safety systems into the basic basic
process control system (BPCS) interface—evenface—even
while while maintaining maintaining some some
separation—to provide provide a uniform
engineering package, design interface
and operator HMI so that
operators in emergency situations
will not have to interpret data
coming to them in different formats.
But a converged operator
environment has not stopped the
accidents.
So what’s the answer?
A Controversial Convergence of Systems
The strongest movement toward stopping the
nearly continuous stream of accidents is the convergence
of systems. Fire and gas safety systems are being incorporated
into SISs, and alarm management systems have been
redesigned and respecified. (See the EEMUA and the ASM
Consortium guidelines, and the new ISA18.2 standard, for
example.) But is this convergence a good thing, and if it is,
is it enough?
John Rezabek, process control specialist at ISP Corp.
(www.ispcorp.com) in Lima, Ohio, doesn’t think so. “They
are separate efforts and disciplines that need to be done
well,” he says. “Alarm management is an endeavor to help
the humans function on a higher level with better information
(and therefore more safely). SIS is an effort to design an
autonomous interlock to save the humans from themselves
when all else fails.”
Todd Stauffer, director of alarm management services
at exida (www.exida.com), a major safety consultancy, disagrees.
“The disciplines of alarm management and functional
safety have always been interconnected. The release
of the ISA18.2 standard in June 2009 has accelerated the
pace of convergence, and is leading practitioners to take
steps to treat these two disciplines holistically.”
Nicholas Sands, process control engineer for E.I. du Pont
de Nemours and Co. (www.dupont.com) in Wilmington,
Del., and co-chair of the ISA18 Alarm Management Standard,
says, “There are some convergences in safety thinking.
I think the adoption of the performance-based approach
to safety systems is changing some long-held prescriptive
views, especially around burner management systems, and
I think that is a good thing.”
Carl Moore, senior instrumentation engineer, SIS, at
Mustang Engineering (www.mustangeng.com) sees the advantages
of convergence, but says. “The current thinking and
method of implementation for a number of oil-and-gas companies
offshore is to have an independent fire-and-
gas (F&G) system with a SIL 3 logic solver, an
independent independent emergency emergency shutdown (ESD) (ESD)
system system (with another SIL SIL 3-rated logic logic
solver), an independent process shutdown
system (SIS) with with yet another
SIL 3-rated logic solver, and an independent
BPCS. Fire detection
and hydrocarbon leak detection
are implemented in the F&G
system, which must pass this information
on to the ESD system
for trip trip or open action.”
This is more than a little clunky.
“By combining the F&G system with
the ESD system, you eliminate one
level of passing ‘vitally needed information’
along to another SIS type system,” Moore says.
“However, I don’t see combining F&G or ESD with the process
shutdown SIS system”
There are clear arguments for convergence of these systems.
Scott Hillman, director of marketing at Honeywell
Process Solutions (www.hps.honeywell.com), who is a subject
matter expert on fire and gas safety as well as SIS, says, “I
think they will continue to converge because it’s more beneficial
for the plant operator and others involved in actual
operations to have the right information at their fingertips
to make decisions. Having that information is contingent on
two things. First, the operations personnel need to get actual
information instead of just raw data, as a lot of raw data already
exists. So the integration has to be intelligent enough
to provide context-specific, actionable information. Two, it is
contingent on the end users and their work processes.”
Charles Fialkowski, Siemens Industry’s (www.usa.siemens.com/industry/us/en)
safety system product manager
says, “I see these convergences as advantageous and think
they will promote increased safety and security. As systems
become more and more integrated, the need for a proper
May/2010 www.controlglobal.com 27

Not Again!
Figure 1. Stills of video footage of the Tesoro Refinery at Anacortes, Wash., shot after the fire was knocked
down. Courtesy of KIRO Eyewitness News, Seattle, www.kirotv.com.
blend of industry codes and standards to converge will also
become more important.”
Simon Pate, director of projects and systems at Detector
Electronics Corp. (www.det-tronics.com), agrees with Fialkowski’s
last point. “In my opinion,” he says, “one of the
issues with the F&G systems that is often overlooked is the
legislative requirements.” There are different requirements
in many different jurisdictions. Pate continues, “So it is fine
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Is the convergence process with systems advantageous? “I
really do think so,” says Marcelo Mollicone, technical manager
for SYM Consultoria of Camaçari, Brazil. “Safety culture
is very important to achieve a safe process. Safety is not
only related to SIF or SIS. It is a broad concept that should
be on the mind of all company personnel. The convergences
help ‘spread the word’ to more people.”
In addition, Rockwell Automation (www.rockwellautomation.com)
safety guru Paul Gruhn says it isn’t the equipment
or systems that will really improve safety. “As [British chemical
safety expert and author] Trevor Kletz has said, ‘All accidents
are due to bad management.’ If management does
not believe in the benefits of safety, even though study after
study has shown that productivity improves when safety improves,
then a culture reinforcing safety and security will
not develop.”
Emerson Process Management’s (www.emerson.com)
safety systems product manager Mike Boudreaux says, “Successful
experience going unprotected can be the biggest
obstacle for change. It is so easy to fall into the trap that
‘we’ve been doing it this way for so long, and nothing bad has
happened’…” This is precisely what happened at BP. The
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May/2010 www.controlglobal.com 31

Chemical Safety Board and the Baker Panel reports indicate
that the start-up of the isomerization unit had been done
exactly the same way more than 15 times with no adverse
effects. What had really been happening is that the vapor
cloud had dissipated before anyone applied a spark. Once
there was an ignition source, the explosion was a certainty.”
The Problem of Complex Systems
Donna Kasuska, a chemical engineer with Pegasus Group
Integrated and ChemConscious Inc. (www.everydaychemicals.com)
in Downingtown, Pa., says, “Sophisticated control
systems can significantly reduce plant failures by eliminating
or improving the human interface. But even the most sophisticated
system has to first be considered by humans, and
is also subject to use and maintenance by humans.”
Large automation and control systems are what are called
complex systems. Complex systems do not behave the way
simple systems do. A simple system says, for example, that
cause A leads to effect B. Not doing A means that B does
not happen. A complex system has so many dependencies
and interrelations that it is not possible to predict accurately
32 www.controlglobal.com May/2010
Not Again!
that A will always lead to B. Complex systems often behave
in ways more predictable by chaos theory than by a linear
engineering model. “Understanding these systems and analyzing
or accurately predicting their behavior is often difficult,”
say Karen Marais and Nancy Leveson, from MIT, in
their paper, “Archetypes for Organizational Safety.” Leveson
served on the Baker Commission investigating the BP Texas
City accident in 2005.
“We are seeing a growing number of normal, or system, accidents
that are caused by dysfunctional interactions between
components, rather than component failures. Such accidents
are particularly difficult to predict or analyze. Accident models
focusing on direct relationships among component failure
events or human errors are unable to capture these accident
mechanisms adequately,” Marais and Leveson continue.
Their paper goes on. “One of the worst industrial accidents
in history occurred in December 1984 at the Union
Carbide chemical plant in Bhopal, India. The Indian government
blamed the accident on human error in the form of
improperly performed maintenance activities. Using eventbased
accident models, numerous additional factors in-
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volved in the accident can be identified. But such models miss
the fact that the plant had been moving over a period of many
years toward a state of high-risk where almost any change in
usual behavior could lead to an accident.”
So what happens when a plant, after an accident, for example,
institutes safety actions? “Well-intentioned, commonplace
solutions to safety problems often fail to help,” Marais and
Leveson point out. “They have unintended side effects or exacerbate
problems. A typical ‘fix’ for maintenance related problems
is to write more detailed maintenance procedures and to
monitor compliance with these procedures more closely.”
David Strobhar, president of Beville Engineering (www.beville.
com), the director of the Center for Operator Performance, has a
similar comment. “I recently began thinking again on safety culture,”
he says. “I was at a plant that went to extremes to communicate
and emphasize safety. I didn’t get the feeling that they were all
that safe. So I am still trying to determine what it is that makes a
safety culture. I think of a Dilbert cartoon where it was said that if
you have to have a ‘name’ for it, you probably don’t have it.”
So What Should We Do About This?
Is functional safety an insoluble problem? Scott Hillman thinks
training is one of the answers. “I don’t think it is possible to develop
a safety culture without training. Lives are on the line, and these are
procedures that must be drilled into every single plant employee.
You might install the fanciest equipment in the world, but if you
put it all in the same window in front of the operators without training
them how to read or respond to the data, it will undoubtedly
lead to chaos. So training is a very critical part of the equation.”
Managing risk in complex systems like the process industries
is a dynamic process, incorporating safety systems, security systems,
product design and ongoing training. But it all starts with
For an extended version of this story, go to
www.controlglobal.com/1005_Cover.html.
management. In the 1960s, the Dow Chemical Co.’s Levi Leathers
realized this when he mandated operating safely as Dow’s primary
mission. Dow’s “stateful control” systems and safety culture
have made the company one of the safest in the petrochemical
industry. Leathers showed that if management insisted on a specific
standard of operations behavior, it would become cultural
and ingrained in the operating practices of the company. That’s
the first step in achieving a safety and security culture and making
it work for the long term. “When a company has a publicly
stated goal of ‘Safety is our number one priority,’ ” Paul Gruhn
says, “Ask the plant manager if he’d be willing to live on the property
with his family. Actions speak louder than words.”
Walt Boyes is Control’s editor in chief.
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The Safety Instrumented
System (SIS) standard, IEC
61511, is driving the need for new
engineering tools and Project Execution
Plans (PEPs). The standard is a lifecycle
approach to defining, implementing and managing
a safety instrumented system (SIS). Industry discussions
tend to focus on the technical aspects of the standard,
but project execution is proving to have an equal or perhaps
greater impact on the quality and success of an IEC 61511
project. This article describes a few of the challenges from
the EPC and MAC perspective, and suggests approaches to
enhance IEC 61511 execution and technical outcomes.
Coordinating Project Execution and Functional Safety Plans
Figure 1 shows the elements commonly performed and supported
by EPCs and MACs. The PEP defines the scope of
work, roles and responsibilities, work processes and procedures,
QA/QC plans, etc. A functional safety plan (FSP) is
required by IEC 61511 and encompasses many of these PEP
processes and procedures, but continues beyond the project
to include the entire safety lifecycle through commissioning
and operations. It also includes additional requirements
that are specific to safety systems. The project team needs
to coordinate and cross-reference both documents to ensure
there are no conflicts or exclusions.
As indicated in Figure 1, the application of IEC 61511
increases the number of analysis and design steps that
can lengthen SIS design cycle. The project must be well-
planned, managed and correctly scheduled and resourced
to keep the SIS design off of the project’s critical path.
Layer of Projection Analysis (LOPA)
LOPA is a commonly accepted method for determining layers
of protection and allocating safety functions. The PHA
report is the LOPA starting point. For each PHA hazard and
associated risk values, the LOPA team identifies and assigns
one or more independent protection layers (IPL) until the
risk is reduced to an acceptable level. If a risk remains after
other preferred IPLs are applied, the remaining risk is typically
reduced by a SIF. Like PHAs, LOPA reports are issued
with recommendations and action items that may require
further analysis and assessment. The report in this form is
often handed off to the EPC or MAC to implement.
Once received, the EPC or MAC reviews the LOPA report
to understand its content. A month or more may lapse before
this step is completed. On closer examination, questions may
arise and irregularities may become apparent. A process should
be in place that allows the LOPA team to review the PHA and
if necessary, make changes in the PHA if an error is confirmed.
The LOPA report does not typically provide the following
information required to progress the SRS:
• SIF final elements.
• An answer to the question, “Does SIF activation create
a new hazard?”
• Hazard process response times.
• Potential sources of common cause failure.
• Confirmation that the assessment addresses all modes
of operation.
Often a proposed SIF final element creates a new hazard
when it moves to its safe state or position. This triggers a one-off,
unplanned hazard assessment that may require a revisit to the
PHA or LOPA. Process response time is often difficult to define
and provided by different disciplines and equipment specialists.
A fast response time may trigger a new hazard that also requires
further assessment. Identifying sources of common-cause failure
often requires input from several disciplines. The additional
time needed to assess hazards when operating in different operating
modes is often overlooked.
Suggestions for improving PHA and LOPA outcomes:
• Provide the FSP before the project starts. It should
clearly define the site or corporate approach, tools, processes
and personnel required; and include a process to
resolve problems that are not directly addressed in the
PEP and FSP, as well as instructions on how to provide
May/2010 www.controlglobal.com 35

Safety
the analysis information missing in the LOPA report.
• Resist the temptation to shortcut or truncate the analysis
phase to save money or reduce project schedule.
• Provide equipment- and risk-specific PHA and LOPA
examples that show the expected application of the corporate
and project tools, risk matrices and IPL rules.
• Align the PEP with the FSP. Revise the plan to address
challenges unique to an IEC 61511 implementation.
• Increase training for PHA and LOPA teams on the correct
use and application of the supplied tools, standards
and procedures.
• Provide checklists that define the recommended steps
to assess hazards for common equipment types.
• Provide a documented process to track, expedite and resolve
PHA and LOPA recommendations and action items.
• Provide a quality assurance plan to confirm the requisite
procedures are followed.
• Assign a team to verify and consolidate PHA and LOPA
recommendations and replace “consider” recommendations
and action items with actionable decisions.
• Have technical specialists conduct pre-assessments of
specialty equipments.
• Insure teams include the necessary technical expertise.
• Ensure that management-of-change procedures encompass
all steps in the IEC 61511 process.
Safety Requirements Specification (SRS)
This phase begins the shift from analysis to SIS engineering and
design. When compared to traditional SIS specifications, the
SRS is a major expansion in both depth and breadth (Figure 2).
It may contain one or more documents. The SRS is the master
document, and referenced documents are subordinate to the
SRS. How much time and effort are needed to fully specify individual
SIFs can vary widely. On projects with a large number
of SIFs, this may noticeably increase the SIS engineering effort,
and EPCs and MACs must modify and adapt to this reality.
The simple task of issuing the SRS requires discussion.
The global section should be issued for approval early. Issuing
the SIF section may need to occur on a SIF-by-SIF
basis since completion depends on when PHA/LOPA action
items are completed and information is available.
The information required to fully define and document a
SIF may entail 40 or more unique data items. The source
and detail required to document each item must be defined
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Process Hazard
Analysis (PHA)
The quality of the IEC 61511
implementation project
begins with the PHA and
the PHA team’s ability to
accurately identify hazards
and quantify risk. The
numerical aspect of the
PHA and the accuracy and
consistency of the assigned
Consequence and
Likelihood ratings are
important. PHA teams tend
to ‘calibrate’ their
application of risk ratings
differently. This becomes
apparent when Safety
Integrity Levels (SIL)
resulting from a Layer of
Protection Analysis (LOPA)
are inconsistent for identical
hazards. This variability may
result in SIS over-design or
under-design.Variability can
also impact Operations and
Maintenance if like Safety
Instrumented Functions
(SIF) within a facility differ in
design, maintenance
intervals and operating
procedures.
Modify Design No
PHA/HAZOP
LOPA & SIL
Assignment
Action
Follow-Up &
Closeout
SRS
H/W & Loop
Design
SIL
Calculations
Meet SIL?
Figure 1. Simplified SIS lifecycle (Partial)
S a f e t y
clearly. The effort to gather, track and
review this data can be significant. For
a large project, the work includes migrating
and recording large amounts of
data that may be provided in different
formats, at different times and by different
disciplines and organizations, so
some companies develop in-house SRS
database tools to improve productivity,
reduce errors and track SIF development
and approval status. Information
provided by different disciplines and
organizations represents an interface
challenge that should be addressed in
the PEP Interface Management Plan.
The potential for data transfer and tran-
Target SIL & STR
Target Test Intervals
Vendor Reliability Data
Approved Vendor List
Project Design Standards
PHA/LOPA
SIFs
SIL Calcs
& Studies
Equipment,
Diagnostics,
Standard
Architecture
SOFs
SIL = 1 to 3
LOPA
Report & F/U
SIS & SIF
Loop Design
Instr. Data
Sheets
Ops/Maint
Req’mts
SIF
Requirements
SIL & STR Targets
Test & Diagnostic Req’mts
SIF Change to meet SIL
SIS
Architecture
& Loop
Design
PIFs from
Equipment
Safety Standard,
e.g., NFPA-85
SIL = ?
Incl. PIFs?
SRS
PIFs
Make &
Model
Bypass,
Reset.
Manual
ESD
SRS
M a y / 2 0 1 0 www.controlglobal.com 37
Fn Safety
Plan
Standards,
De�nitions,
Roles
Design
Req’mts
SIS
Architecture &
Interfaces
Valve Failure Mod
Process Response T
Trip Settings
Validation
Results
PIFs from
Secto
Sta
e.g. AP
Re
Applic
Software
Detailed
De�n

Target SIL & STR
Target Test Intervals
Vendor Reliability Data
Safety
Approved Vendor List
Project Design Standards
SIL Calcs
& Studies
Equipment,
Diagnostics,
Standard
Architecture
LOPA
Report & F/U
SIS & SIF
Loop Design
Figure 2. Safety requirements specification inputs and reports.
38 www.controlglobal.com May/2010
Incl. PIFs?
SRS
Instr. Data
Sheets
Ops/Maint
Req’mts
SIF
Requirements
SIL & STR Targets
Test & Diagnostic Req’mts
SIF Change to meet SIL
SIS
Architecture
& Loop
Design
Make &
Model
Bypass,
Reset.
Manual
ESD
SRS
Fn Safety
Plan
Standards,
De�nitions,
Roles
Design
Req’mts
SIS
Architecture &
Interfaces
Valve Failure Mode
Process Response Time
Trip Settings
Validation
Results
SIS
Schematic
Diagrams
Reports
Application
Software SRS,
Detailed Design
De�nition
P&IDs,
Process
Engr
Validation
SIL/STR
Calculations
Test & Inspection
Results
Action List
Validation Status
SIF Design & Status
Required Diagnostics
Minimum Test Frequency
scription errors should be addressed in
the PEP Quality Plan.
Completing the SIF section typically
requires an SIS engineer with depth
and breadth of experience. Once it’s
completed, a competent senior person
should do a “cold eyes” quality check.
The quality plan should define the approach
to these checks.
The SIF specification process may
identify problems that can trigger a secondary
work process or design change.
A common scope question is what are
the project requirements for documenting
protective instrumented functions
(PIF) that are not required by the LOPA/
PHA. Are PIFs documented in the SRS?
Do the SIF analysis and verification steps
apply to PIFs? Will the SRS differentiate
between SIFs and PIFs? These questions
need to be answered before budgets are
firmed up and schedules developed.

To improve SRS outcomes and execution:
• Define what information is included in the SIF specification
section, the level of detail required, who provides
the information, and who records it in the SRS.
• Provide an example specification for common SIF types
and indicate the level of detail required.
• Define the approach to assessing and documenting PIFs
that are not SIL-rated.
• Define if the SRS will differentiate instrumented functions
by type, e.g. safety, environmental, regulatory or
asset protection.
• Define the quality checks required in the PEP quality
plan.
• Complete and approve the global SRS narrative section
before SIF specification work begins.
• Confirm which document is the “master” repository for
alarm and trip settings.
• Define how and when the individual SIF specifications
will be issued for approval.
• Use electronic tools to manage the SRS SIF definition
section, support electronic data transfer and manage
SRS data over the SIS life cycle.
• Develop tools for tracking SIF specification design and
completion status.
SIL and Spurious trip Rate (StR) Calculations
SIL and STR targets are verified using project-approved calculation
tools and reliability data sets. The SRS typically provides
the information needed to correctly model the SIF. Final SIL
calculations are generally provided late in the project. To support
early equipment procurement, preliminary SIL calculations
are often recommended to confirm that SIL 2 and 3 SIFs
Safety
and the more complex SIL 1 SIFs can meet the SIL and STR
targets. Failure to meet a target typically triggers a study to identify
alternate designs, adding time to the schedule.
If not defined in the FSP, the reliability data used in SIL
calculations should be selected early. The FSP or PEP must
define how new data will be assessed and formally approved.
To improve verification calculations and execution:
• Identify the calculation software and the source of the
reliability data used.
• Provide rules to guide how SIFs are modeled, named
and documented, and how they target PFD safety factor,
applicable common cause factors, etc.
• Define what information and detail is recorded in free-
form fields.
• Provide example calculations for common equipment
and complex SIFs.
• Define the process for approving third-party reliability
data used in preliminary and final calculations and its
introduction to the team.
• Define what test interval is used.
• Define the issue and approval of calculations process.
Implementing IEC 61511 requires changes in historical
work processes, procedures, tools and execution plans. Operating
companies, EPCs and MACs should continue to develop
corporate standards, guidelines and tools to guide project
teams and improve consistency between projects, and
the execution and technical plans, procedures, tools and resources
required to successfully implement this standard in
today’s complex project environment.
Tom Shephard is an automation project and (MAC) program manager at
Mustang Engineering.
Dave Hansen is the Safety System Practice lead at Mustang Engineering.

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Motor gasoline is blended at the refinery to specifications that
include octane rating. An engineer I met was proud of how well
octane number was controlled at his refinery—but he always
filled his car at a competitor’s station, although the price per
gallon was the same. His rationale was that the competitor’s
control over octane number was more variable, but still had to
meet the minimum standard of 87 for regular grade—hence its
average octane rating was higher by that variability. The competitor’s
refinery was giving away octane, and he was willing to
accept it. The analysis below can be used to describe the cost
of giving away any valuable ingredient or any operating cost associated
with the variability of control.
Safe-Side Variations
The cost in excess octane giveaway is a direct function of its
variability, with two possibilities shown in the step-load response
curves of Figure 2. The upset could either drive the
controlled variable in the “safe” direction shown in the black
curve, or the “unsafe” direction, shown in red. In this case,
“safe” infers that the controlled variable is driven toward the
favorable side of the specification limit—above the 87-octane
specification. In addition, safe-side variations do not require
any action either by the operator or any automatic response.
This is because product specifications are not thereby violated.
Safe-side variations simply result in an economic loss
that is quantifiable.
If the setpoint in Figure 2 is also the specification limit,
and the measured octane rating rises due to the upset before
returning to setpoint, the octane giveaway is related to
the integrated error of the controlled variable from setpoint.
Integrating this deviation or error e between controlled octane
and its setpoint over time t gives the integrated error
(IE) in terms of octane-minutes. Subsequent multiplication
by the current product flow rate in gallon-per-minute yields
octane-gallons given away during that interval. Multiplying
that result by the cost difference in dollars/gallon/octane
number converts the integrated error into dollars lost.
The cost function may not be linear. For example, the
price difference at the pump between 87 and 89 octane, and
between 89 and 93 octane probably reflects market forces
rather than production cost. Nevertheless, small variations
in the function around a given specification can be assumed
to be linear, allowing IE to be a useful criterion in evaluating
the cost of poor control.
Figure 1. Control loop optimization can produce astonishing
results.
When using PI or PID control over any variable, integrated
error is directly related to the size of the disturbance
and the controller settings. The ideal PID controller is simply
represented in Eq. (1):
m =
100
P
e + 1
I
∫e dt + D de
dt
(1)
where m is the variable manipulated by the controller, and P,
I and D are its proportional band in percent and integral and
derivative time settings respectively. This formula may be
Photo courtesy of Control Station Inc.
M a y / 2 0 1 0 www.controlglobal.com 41

A d v A n c e d c o n t r o l
evaluated both before and after an upset,
when the deviation e and its time
derivative are both zero. If the controller
output has changed between those
two steady states, there will be an inte-
dre-25 control grated error: 4/14/09 9:05 AM Page 1
42 www.controlglobal.com M a y / 2 0 1 0
∆m = 100
P
1
I
∫e dt
(2)
IE = ∫e dt = ∆m PI
100 (3)
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Equation (3) applies equally to interacting
and noninteracting PID controllers
and PI controllers as well. There
are some obvious conclusions to be
drawn: to minimize the cost associated
with IE, minimize the feedback control
effort ∆m required to respond to an
upset, and reduce the P and I settings
without sacrificing stability
Unsafe-Side variations
When the controlled variable wanders
to the unsafe side of the specification
limit, decisions have to be made.
Failed product must be set aside for
blending with better-than-acceptable
product, rejected to a less-valuable use,
or rerun. All of these operations are
costly and cause disruptions affecting
production rate. Operators avoid them
if at all possible.
The alternative is to adjust the setpoint
of the composition controller so
that it exceeds the specification limit
by the expected variations in quality
under all but the worst cases. This is
also costly—it results in quality giveaway
all the time. Yet, this is the normal
condition of most product-quality
controllers in most plants, and it
offers the largest economic potential
for tighter control in processing plants
universally. To minimize giveaway in
the face of unsafe-side variations, the
amplitude of those variations must be
minimized.
The curves in Figure 2 are typical
of a loop responding to a step change
in load—the flow or composition of
one of the ingredients entering the
process—and the subsequent reaction
of a well-tuned PID controller to that
upset. A step was selected, as it is the
most difficult disturbance for a control
loop, containing all the frequencies
from zero to infinity; a step has
the same power spectrum as white
noise. At the zero-frequency end, it requires
a permanent change in controller
output, necessitating integration. At
the other end, its rise time is zero, requiring
vigorous proportional and de-

Octane
rivative action. Finally, it is often encountered
when equipment trips or is
suddenly switched, and is the easiest
test to administer. In 1941, Ziegler and
Nichols used a pneumatic bias regulator
in the controller output to simulate
a load change at the process input. We
can do it by transferring the controller
to Manual while in a steady state, stepping
its output, and immediately transferring
to Auto.
The well-damped step-load response
curve has a first peak much
higher than all the rest. If that can be
cut down, the setpoint can be moved
closer to the specification limit. Since
it is a single peak, it is easily attenuated
by any downstream capacity, allowing
A d v A n c e d c o n t r o l
Figure 2. Octane giveaway is calculated from Integrated Error above specification
limit.
Dev.,
8.9
8.8
8.7
8.6
e
0
Set
Set
Spec.
limit
e1
Margin
τ o
e 2
Time
e 3
the margin between setpoint and specification
limit to be biased somewhat
less than the expected peak deviation.
The amplitude ratio A r of output to input
for a cycle passing through downstream
capacity of time constant τ 1 is
1
A = r
1 + (2πτ /τ ) 1 o 2
√
≈ τ o
2πτ 1
(4)
where τ o is the period of the wave.
Where the time constant of the downstream
capacity is long compared to
the period, the operating margin can
therefore be small. For example, a
one-minute cycle passing through a
10-minute capacity is attenuated by a
factor of 62.8. With very large capacity,
0.00 0.50 1.00 1.50 2.00
Time, t / ∑τ
Figure 3. The minimum-IAE curve is identified by its decay ratio and overshoot.
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A d v A n c e d c o n t r o l
load upsets are equally likely in both
directions, and IE over time can approach
zero.
Peak deviation and period are then
the key factors affecting the operat-
44 www.controlglobal.com M a y / 2 0 1 0
ing cost for unsafe-side variations. The
first step in minimizing peak variation
and period following a load change is
to be sure that the controller is paired
with the manipulated variable hav-
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Figure 4. Increasing proportional band and integral time increases IE.
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ing the most influence over it and less
over other associated variables. Having
made that pairing, performance is
then determined by controller selection
and tuning.
Minimum-IAe tuning
As useful as IE is in evaluating loop performance,
it is incomplete. IE can be
lowered by successive reductions in proportional
band and integral time according
to Equation (3), but that also reduces
the damping of the loop, leading to instability.
A more complete performance criterion
is Integrated Absolute Error (IAE),
which has a minimum value that can
be reached by proper tuning. The sign
of the deviation e is simply removed before
integration. In this way, the IAE of
an oscillating loop will increase without
end—IAE penalizes both load response
and instability, reconciling them. For the
curve of Figure 3, IAE is only 9% higher
than IE, so IE is being effectively minimized
by minimizing IAE.
Other related criteria are Integrated
Square Error (ISE) where the deviation
is squared before integrating, also
eliminating the sign, and the Integral
of Time and Absolute Error (ITAE)
that penalizes errors increasing with
their duration. The square function
has no economic significance, but is
simply mathematically convenient,
and the time function of ITAE is not
applicable to continuous processes.
There can be difficulties in calculating
IAE in the field. For example,
any noise will cause it to increase
without limit. However, it does not
need to be monitored to achieve minimum
IAE tuning, because its closedloop
load-step response curves have
characteristics readily identified in
simulations that can be duplicated in
the field. The characteristics shown
in Figure 3 are found to be common
to most: they are low damping ratio δ,
small overshoot Ω, and short period
τ o . Figure 3 was obtained by stepping
the load to a distributed lag under PID
control with these results:

δ = e 3 - e 2
e 1 - e 2
= 0.2 Ω = e2 -
= 0.1
e 1
(5)
The time scale is normalized by dividing
by Στ, the sum of all the lags in
the distributed process. It is identified by
the time required for 63.2% complete response
from the initiation of a step input
in the open loop. Essentially the same
values of decay ratio and overshoot represent
minimum IAE response for other
processes using other controllers; the period
varies with the process dynamics
and the type of controller.
There are many different methods
used to tune controllers, with a wide
range of effectiveness. Some are intended
to optimize setpoint response,
but these are not recommended, as
they invariably compromise load response.
Once a controller has been
optimized for load response, setpoint
filtering can then be added where necessary.
The economically important
loops in a process plant—controlling
composition, temperature and pressure—operate
at constant set point all
the time, but are regularly exposed to
load variations.
Most tuning methods result in
sluggish load response, costly in IE,
peak deviation and period. Some
methods set integral time equal to
the primary process time constant,
whereas minimum-IAE requires it to
be half that value for a PI controller
and one-fourth for a PID controller.
Two examples are compared in Figure
4 against a minimum-IAE curve.
Doubling the proportional band increases
peak deviation by 44% as it
doubles IE—heavier damping bought
at a high price. Doubling the integral
More on this subject, including discussions
of controller selection, feedforward
control structure and applying
dynamic compensation is at www.controlglobal.com/1005_AdvCont.html.
time has little effect on peak height
as it doubles IE. It principally affects
overshoot. These two responses can
guide the user as to which parameter
needs adjusting.
A common operating concern is robustness,
that is, to remain well away
from stability limits. With minimum-
IAE tuning of the PID controller, the
gain K p of this process can increase by
80% before instability is reached, and
Στ can increase by 75%—very acceptable
margins both. If the process parameters
are more variable than that,
compensation should be applied, either
through valve characterization or
adapting the controller settings as a
function of flow, needed when controlling
heat exchangers.
Another objection to tight tuning
is measurement noise, which the pro-
A d v A n c e d c o n t r o l
portional and derivative gains can pass
along to the valve, causing excessive
wear. Rather than detuning the controller,
filtering may be applied, with
the caution to use as little as necessary,
for it augments the IE function:
IE = ∆m 100
P
(I + τ f + ∆t)
(6)
where τ f is the filter time constant
and ∆t is the sampling interval of the
controller. In addition, the filter time
adds to the dead time in the loop, requiring
a further increase in all three
controller settings. Sampling has a
similar effect.
F. Greg Shinskey is a process control consultant, a
regular contributor to Control and a member of the
Process Automation Hall of Fame.
M a y / 2 0 1 0 www.controlglobal.com 45

T E C H N I C A L LY S P E A K I N G
DAN Hebert
Senior Technical ediTor
dheber t@putman.net
VFDs provide many
advantages over
soft starters, but
they cost more and
are less efficient.
46 www.controlglobal.com M A y / 2 0 1 0
Soft Starters versus VFds
Process plants abound with motors that drive pumps, compressors, mixers and other
equipment. Many of these motors either need or could benefit from some type of
control, and two among possible choices are reduced-voltage soft starters and vari-
able-frequency drives (VFDs). “Both soft starters and VFDs substantially reduce the
electrical and mechanical shock caused by
across-the-line starting, and both help reduce
electrical demand by reducing a motor’s startup
current,” notes Joe Kimbrell, the drives, motors
and motion control product manager at
AutomationDirect.
“Soft starters and VFDs alike can reduce
field building or inrush currents, and thus
machine starting torque, by as much as 30%
to 75% when compared to an across-the-line
starter,” observes Scott Richardson, an application
engineer with Yaskawa Electric America.
“In applications such as pumps and compressors,
which can require many starts per hour
to maintain critical process flows or pressures,
these reduced starting currents result in significantly
less motor heating and longer motor life.
A softer or less rapid increase in motor torque at
motor starting can also greatly extend the life
of belt-driven and mechanically geared equipment,”
adds Richardson.
Although both soft starters and VFDs reduce
inrush current and torque, a VFD can
also “vary the output frequency from zero
to above base motor frequency, allowing for
setpoint control to maintain the constant
flows and pressures required by many processes.
VFDs also offer a larger number of
diagnostic analog and digital signals for interface
with plant control systems, allowing
for much greater automation of the process,”
explains Richardson.
“Variable-torque applications such as centrifugal
pumps and fans can provide very fast
paybacks in energy savings when required process
flows are maintained at reduced speeds,
offsetting initial investment costs. In fact,
many pump and fan applications can pay back
the entire cost of a typical VFD in a matter
of months by reducing energy consumption,”
Richardson continues.
VFDs provide many advantages over soft
starters, but they cost more and are less efficient.
“A soft starter is generally in the neighborhood
of 99.5% efficient, while a VFD is usually
about 95% to 97% efficient,” says Kimbrell.
“Some soft starters also have another energysaving
feature—the ability to dial back the output
voltage going to the motor. In lightly loaded
applications, this reduces the motor’s magnetizing
current, which doesn’t need to be at 100%
when the motor is not running at full load. This
reduced voltage results in less current flowing
to the motor and increases efficiency, all without
sacrificing speed,” explains Kimbrell.
“Finally, some soft starters can be connected
in a motor’s delta. Since the current flow inside
the delta is 58% of the line current, a much
smaller soft starter can be used, further enhancing
the cost advantages of soft starters over
VFDs,” adds Kimbrell.
“For small motors, VFDs can be cheaper, as
sheer volumes make up for the additional components
required in a VFD. But above the 5
hp to 10 hp level, soft starters start to become
much more attractive. One well-known manufacturer
offers a 100-hp soft starter for around
$3000, while selling a VFD for close to $7000,”
he concludes.
For sizes over 10 hp, soft starters are
cheaper and more efficient than VFDs, so
they should be used to limit inrush current
and torque in applications where precise
speed control isn’t required.
“Large pumps, fans, mixers and centrifuges
in the 200 hp to 500 hp range generally require
very few starts and stops, have little or
no integration into plant control networks and
are required to run at full-rated speed during
operation. These characteristics make these
applications a good fit for soft starters,” sums
up Richardson.

Temperature Control with Slow Boilers
a s k t h e e x p e r t s
“Ask the Experts” is moderated by Béla Lipták, process control consultant and editor of the Instrument Engineer’s Handbook
(IEH). The 4th edition of Volume 3, Process Software and Networks, is in progress. If you are qualified to contribute to this vol-
ume or if you are qualified to answer questions in this column or want to ask a question, write to liptakbela@aol.com.
QI’ve read the discussion about the tempered water
system and heating to an exothermic reactor with
interest because we too have systems like that—in
our case, batch reactors. We charge the reactor and then
heat the contents. We want to reach the desired temperature
as quickly as possible, and we want stable temperature
control as we begin charging reactants and start an
exothermic reaction.
We tried moving the split range away from 50% to compensate
for different process gains between heating and cooling,
but we had an additional problem. Our boiler response
is slow, so the steam valve should not open or close too fast.
Because we still want fast control during the exothermic reaction,
when mostly cooling is required, we had to limit the
rate of change of steam valve opening (%/minute). Therefore,
we have not only different gains during heating and
cooling, but the response during heating is also limited.
I have thought of two ways to handle this problem.
The first, as was confirmed in the trial, was to switch
tuning parameters as we move from heating to cooling,
based on controller output. This way we can limit the
speed of steam valve movement to 10%/minute, resulting
Master
setpoint
PID
R/A
HTC
Manual loading
station to set
temperature
limits
Slave #1
TRC TY SP TRC
TAC Output
ER
TT
R/A
PB = 10-20%
I = some
0%
25
50
75
100
H
C
Opens
Slave #2
SS
50-0%
Cold
water
FO (=%) RL
in a very slow response. I think the tuning of the PID in
this service should be such that the output rate of change
limit is not touched. Would a first-order exponential filter
instead of the linear output rate of the limiter be better?
Another way to slow the change in steam flow during
heating would be to slow the setpoint (SP) ramping, so it
would not be too restrictive during the exothermic reaction.
The rate of moving the SP could be set differently
for the two phases. Here, would a first-order exponential
SP rate of change limit not be better than the linear one?
Wouldn’t changing the rate of SP change cause upsets at
the boilers?
Right now, in order to avoid overshooting at the end of the
heat-up phase, I limit the rate of opening of the steam valve.
I don’t allow the percentage opening to exceed the controller
error in percent times a gain factor. This way, when we reach
the target temperature, the steam valve is closed and the temperature
will not overshoot unless the steam valve is leaking.
Do you see any other options ?
Opens Slave #2
50-100%
Steam
FC (=%)
SP = Setpoint
ER = External reset
Steam valve
opening
0%
0
0
Throttling
100
Figure 1.The addition of the functions in red will limit the rate at which steam can be changed during heating.
Rudi HöRcHeRt
rudi.horcher t@ineos.com
Water valve
opening
100%
Throttling
0
0
0
SP = (%)/min
M a y / 2 0 1 0 www.controlglobal.com 47

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a s k t h e e x p e r t s
AInsert a rate limiter between the secondary controller
output and the steam valve. Then connect the limiter
output to the external reset feedback output of the controller,
if available. In this way, the controller will stay tuned
properly regardless of adjustments to the rate limiter. However,
if the valves are split-ranged from a single controller output,
the rate-limiter will have to be bypassed while the coolant
valve is operating.
GreG ShinSkey
shinskey@metrocast.net
AIn a well-designed plant, the availability of utilities
should not limit the control of the process.
As to the best control option, I agree with Greg Shinskey
(above). Figure 1 shows how you might operate the reactor,
while limiting the rate at which the demand for steam
can be changed during heating. This involves the addition of
two functions (shown in red). In black, I show the basic splitrange
reactor temperature control system used in installations
where there is no limitation on the rate at which utility demand
can change.
One software function that I added is the rate limiter
(RL), which has an adjustable setpoint (SP). This way,
the limit on the rate at which steam demand can change
can be automatically changed. So, when the slow heat-up
phase is over and the reactor is switched to the reaction
phase, the response of the temperature control loop is slow
if the changes required in steam rate is larger, and fast if
it is smaller.
The output of RL throttles the steam valve and likewise
provides the external reset (ER) to the cascade master temperature
controller (TRC with PID control modes) only
during heating. The purpose of the switching function (SS)
is to switch the ER to be received from the measurement of
the slave temperature controller (TRC) when the exothermic
reaction is started (the mostly cooling phase). In this
way, during heat-up, the ER signal is received from the RL
during cooling from jacket temperature (TT), and the setpoint
of the RL can be automatically changed to vary the
speed of response as a function of the sizes of upsets.
Naturally, before doing all that, first I would visit the utility
building and would try to speed up the boiler(s).
Béla lipták
liptakbela@aol.com
We always suggest using proper design and appropriate
control strategies; we try to use ramps, limiters and other
handcuffs for security.
Michel ruel
mruel@ topcontrol.com

Q
Is there a difference between the definitions of smart
actuators and smart positioners? If there is, what are
the main features of each considering their capability,
limitation, advantage and future trends?
AbdullAh GhAmdi
abdullah.ghamdi.51@aramco.com
A
An actuator is any device capable of changing the
opening of a valve or modifying the position, speed
or any other operating condition of pumps, compressors,
etc. They can be as simple as a coil operating an onoff
solenoid or more sophisticated pneumatic or electric
throttling devices, including variable-speed drives (VSD).
VSDs are superior to valves because of their speed and energy
savings, and they have no hysteresis.
The actuator by itself is not necessarily provided with
feedback; it does not “know” if the desired position was in
fact achieved. The term “smart”does not mean much. It
usually means fieldbus connectivity, but it can still be just
a sales gimmick, depending on the information provided.
ask the experts
It can have real value in the areas of self-diagnostics, historical
data collection, visual displays, maintenance scheduling,
process property measurements, etc.
The positioner is a position control loop consisting of a
position sensor and a controller. Its job is to eliminate the
difference between the measurement and setpoint of this
position controller. In addition, you can think of a positioner
as a cascade slave controller in which the cascade master is a
temperature, pressure, level, flow or any other variable.
The positioner can also be used to change the characteristics
of the control valve artificially if the wrong valve
was installed, or to change the dynamics of the loop if
needed. Finally, the positioner can be part of and supplied
with the actuator. As to the term “smart positioner,”
it can either imply just a sales gimmick, or provide valuable
extra features, similar to those in “smart actuators.”
To determine what the term really means requires careful
analysis of the bids summitted.
Helping progressive process control companies
run and grow successful businesses
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bélA lipták
liptakbela@aol.com
mAy/2010 www.controlglobal.com 49

R O U N D U P
Level Measurement Technology
Radar, switches, embedded and web-enabled—they’re all here.
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Levelcom LC-100 line of liquid
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continuous flow bubbler level
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of the timing of sample,
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15 seconds to 24 hours. Specific-gravity input, four alarm
setpoints, analog or digital outputs, three power options and
Modbus or Profibus connectivity are standard.
TMS Inc.
503/285-8947; www.levelcom.net
THREE-IN-ONE SWITCH
FlexSwitch FLT93S flow,
level, temperature switch
provides accurate interface
detection and control. It performs
monitoring, controlling
and alarming of flow
rates or levels of foams, emulsion
layers, liquids and slurries.
Dual 6A relay outputs are standard and are assignable
to flow, level or temperature. It operates over a wide setpoint
range in water from 0.003 mps to 0.9 mps.
Fluid Components International
800/854-1993; www.fluidcomponents.com
ISA100.11a-READY WIRELESS RADAR GAUGE
FlexLine wireless radar gauge
captures an array of tank
measurements and transmits
them via OneWireless network
to control rooms. It also
tracks temperature, pressure,
water and overfill, reducing
installation costs and increasing
flexibility by enabling new measurements without additional
wiring. It has been approved by the Dutch Weight and
Measurement Authority.
Honeywell
800/822-7673; www.honeywell.com/ps.
50 www.controlglobal.com M a y / 2 0 1 0
VIBRATORY LEVEL SWITCHES
Sitrans LVL100 and LVL200
vibratory switches signal
when the level of liquid media
is sufficiently high, liquid
media is required or needs to
be refilled. They are used in
storage and process applications,
and can be connected
to any signaling systems. Both switches are equipped with a
special, extremely reliable piezo actuator and are also suitable
for high temperatures.
Siemens Industry
800/964-4114; www.usa.siemens.com/pi
WEB-ENABLED, ULTRA-SONIC SENSORS
LOE web-enabled ultrasonic
level sensors feature Power
over Ethernet (POE) for easy
wiring and can be easily programmed
and configured
remotely—without configuration
software—via APG’s
website and locally via the
sensor’s embedded web page. Sensor level data is transmitted
to a dedicated website that uses an open-source MySQL
database format
Automation Products Group
888/525-7300; www.apgsensors.com
NON-CONTACT RADAR LEVEL MEASUREMENT
VegaPuls 63 non-contact radar
level measurement sensor
is designed for use in corrosive
environments. Its fully
encapsulated antenna system
is available with all wetted
parts constructed of TFM-
PTFE, PVDF or PFA. It is
3A-approved and is available with sanitary tri-clamp connections.
Typical applications are in the chemical, food processing
and pharmaceutical industries.
Ohmart/Vega
800/367-5383; www.ohmartvega.com

WIRELESS VIBRATING FORK LIQUID LEVEL SWITCH
Rosemount liquid level
switch is unaffected by flow,
bubbles, turbulence, foam,
vibration, solids content,
coating, liquid properties
and product variations. It is
designed for use in extreme
temperatures and performs
in harsh process conditions. Typical applications include
overfill protection, high- and low-level alarms, pump control
and pump protection or empty pipe detection.
Emerson Rosemount Measurement Division
800/999-9307; www.emersonprocess.com
NEXT-GEN X96SI/R INTEGRAL MICROPROCESSOR
X96SI/R explosion-proof microprocessor
includes a patented
optical coupling that
allows the microprocessor
and detector assembly to be
mounted to any configuration.
It is fully Ethernet-capable
as standard. Modular to
mount to Ronan’s solid scintillation, flexible scintillation or
ion chamber detectors, X96SI/R is ideal for continuous level
measurement.
Ronan Measurements Division
859/342-8500; www.ronanmeasure.com.
ONLINE DENSITY MEASUREMENT
Liquiphant M density meter
provides analytical process
information on-line or inline
according to customer
requirements. It offers solutions
for applications including
process optimization,
quality monitoring and waste
reduction. It can also be used for monitoring of preliminary,
interim and final products during blending operations and
for verification and documentation of process steps.
Endress+Hauser
317/535-7138; www.us.endress.com
R O U N D U P
SIL-CERTIFIED LEVEL SWITCH
Developed for above-ground
bulk storage facilities, the
Safety IntelliPoint RF switch
meets the American Petroleum
Institute’s 2350 Recommended
Practice (RP) for
overfill and spill protection.
It provides overfill protection
to SIL 1. SIL 2 certification is optional. With a redundant
switch, a SIL 3 rating can be achieved. It is FM-, CSA- and
ATEX-approved.
AmetekDrexelbrook
215/674-1234; www.drexelbrook.com
RADAR LEVEL TRANSMITTER
The non-contact radar level
transmitter Type 8136 measures
open-channel flow and
tank levels of solids and liquids
with dielectric values as
low as 1.6. It is available in
two antenna versions—with
encapsulated horn for liquids
in small vessels or plastic horn for larger vessels or open
flumes. It has a measuring range of 0 ft -65 ft for continuous
level measurement of toxic and corrosive substances.
Burkert
800/325 1405; www.burkert-usa.com.
SENSITIVE LIQUID LEVEL/TEMP CONTROL BOARD
LASC-RTD/THM series
combination liquid level and
temperature control board
offers microprocessor-based
auto-sensitivity. It prevents
faulty operation of the control
relay caused by too much
or too little sensitivity. Using
three push buttons and the on-board digital display, the user
can program on/off liquid level and temperature control
with 1° resolution.
Lumenite Control Technology
847/455-1450; www.luminite.com
M a y / 2 0 1 0 www.controlglobal.com 51

R O U N D U P
FIELDBUS-ENABLED LEVEL TRANSMITTER
Level Plus model MG liquidlevel
transmitter with Foundation
fieldbus protocol satisfies
the demand for a digital
communication interface in
the liquid-level marketplace
for vessels from 508 mm (20
in.) to 22,000 mm (866 in.).
Outputs include Modbus, DDA (proprietary ASCII protocol)
and Foundation fieldbus. MG is accurate to at least 1/16
in. at maximum length.
MTS Sensors Division
919/677-2373; www.mtssensors.com
ROBUST LEVEL TRANSMITTER
ES2 Slimline level transmitter
boasts robust design to
protect against environmental
conditions such as extreme
washdown practices,
aggressive cleaning solutions
and extreme humidity.
The internal electronics
are fully encapsulated. The signal connection is a hermetically
sealed receptacle designed to accept an M12 connector.
Made of stainless steel, it has excellent thermal recovery.
King Engineering
800/242-8871; www.king-gage.com/es2
SIL-2 MAGNETOSTRICTIVE LEVEL TRANSMITTERS
AccuTrak AT100 and AT200
magnetostrictive liquid level
transmitters are certified for
SIL 2 environments. They
feature modular, dual-compartment
designs that separately
house the wiring and
electronics. They can measure
clean or dirty fluids and total level, interface level or
multiple levels from the same sensor. They make accurate
measurements up to 3000 psi (207 bar) or 800 °F (427 °C).
K-Tek
800/735-5835; www.ktekcorp.com
52 www.controlglobal.com M a y / 2 0 1 0
SOLIDS RADAR LEVEL METER
Optiwave 6300 C is a contactless
two-wire 24-26 GHz
radar FMCW meter for
distance, level and volume
measurement of powders,
granulates and other solids.
Thanks to continuous wave
generation and small radar
beam angle, no antenna aiming is required. It has an innovative
drop antenna made of plain PP or PTFE that makes
purging systems obsolete, and it is maintenance-free.
Krohne
800/356-9464; www.krohne.com
MAINTENANCE-FREE LEVEL SENSING
LVL-B Series vibration limit
switches are insensitive to
material build-up, external
vibration and flow noise, and
have no mechanical moving
parts for reliable, maintenance-free
level sensing of
bulk solids materials. They
are FM- and CSA-certified as Dust Ignition Proof (DIP) for
Class II and Class III, Divisions 1 and 2 and Groups E-G,
and are suitable for use in hazardous area applications.
Pepperl+Fuchs
330/425-3555; www.us.pepperl-fuchs.com
ECONOMICAL RADAR TRANSMITTER
Model R82 is the first $995 radar
transmitter. This loop-powered,
non-contact, 26-GHz,
transmitter brings radar to everyday
applications. It measures
up to a 40-ft (12-meter) range,
and provides unsurpassed ease
of configuration with either the
menu-driven, four-pushbutton, two-line by 16-character display,
HART digital communications or PACTware, allowing complete
configuration via the local user interface, or remotely.
Magnetrol Environmental
630/969-4028; www.magnetrolenvironmental.com

P R ODUCT I NTRODUCTIONS
FAN-LESS INDUSTRIAL PCs
The ePC Fan-less Series of
industrial computers have
the reliability of a proprietary
operator interface, and yet
provide the performance and
open connectivity available
from a computer. They are
available in four sizes: 15 in.,
17 in., 19 in. and a newly released 12.1 in. All have five-wire
analog resistive touchscreens and NEMA-sealed, panelmount
front panels. Their ultra-thin size make them ideal
for installation in harsh environments and small spaces.
Nematron Corp.
734/214-2000; www.nematron.com
GAS PRESSURE TEST KIT
Series LPTK gas pressure test
kit is ideal for testing LP and
natural gas lines and controls.
The kit’s gage shows if
proper pressure is present or
if a leak exists. It is available
in two different gage ranges,
and each gage is 3% full-scale
accurate with an easy-to-use calibration screw on the back of
the gage. It is easier to use than a manometer and includes a
sturdy case for added durability and safe handling.
Dwyer Instruments Inc.
800/872-9141; www.dwyer-inst.com
COMPACT PANEL DRIVE
DCS800-EP panel drive is
a pre-engineered solution
for quick, easy design and
installation. In addition, all
required peripheral components
are included on the
space-efficient back panel,
ready to be mounted into an
industrial enclosure. Initially available at up to 150 HP, the
drive also includes AC and DC fusing, AC contactor and a
control transformer. It meets UL 508A, with a 65-kA shortcircuit
current rating and is pre-wired and pre-tested
ABB
800/752-0696; www.abb.us/drives
Keep
Your
Process
Flowing
with our proven solutions
KING-GAGE
ES2 Liquid Level Transmitter
new slimline design embodies robust protection
against a full range of environmental challenges
such as extreme washdown practices, aggressive
cleaning agents, and extreme humidity.
• Flush mount slimline
design
• Loop powered
(4-20 mA output)
• Suitable for washdown
(IP68 rated connections)
KING-GAGE
LP3 Tank Level System
simplifies process control integration, inventory
monitoring, and even shares data plant wide via
Ethernet. Now with data logging for reporting and
compliance monitoring.
• Monitor up to 32 tanks
• 10.4" color touch screen
HMI display
• Data logging and
Ethernet connectivity
CT1005
To learn more call or visit our website.
800-242-8871
734-662-5691
King Engineering Corporation
Ann Arbor, MI Fax 734-662-6652
www.king-gage.com

Control ExC l usivE
CyboSoft’s MFA Technology Now Available for ControlLogix
CyboSoft, General Cybernation Group, Inc. has announced that its model-free adaptive (MFA) control tech-
nology is now available in Rockwell Automation’s ControlLogix programmable automation controller (PAC)
platform. Running inside ProSoft’s PC56 industrial in-rack PC, CyboSoft’s CyboCon high-speed MFA con-
trol software is seamlessly integrated with the ControlLogix system, providing high-speed, mission-critical
control for industrial and equipment control applications.
ControlLogix PACs offer high-speed, multi-discipline
control for sequential, process, drive and motion-control
applications. Developed by ProSoft, PC56 is an industrial
in-rack PC for the ControlLogix platform. Plugged and
operated in a ControlLogix chassis, PC56 enables a direct
connection to the ControlLogix backplane. CyboSoft’s CyboLink
for ControlLogix interface software running in PC56
provides high-speed, twoway
communications between
ControlLogix data
tables and the CyboCon
real-time database. Via
this configuration, all the
hardware and software are
seamlessly integrated.
According to CyboSoft
director of engineering,
Steve Mulkey, all a ControlLogix
user needs to
implement the system is
a PC56 and the CyboCon
and CyboLink software.
CyboSoft CEO Dr. George Cheng explains the advantages
of the company’s MFA controllers this way: “Modern
automation systems require good automatic control for both
continuous and discrete variables. Most PACs and PLCs
lack user-friendly advanced control capabilities to control
critical, yet difficult continuous process variables effectively.
CyboSoft’s MFA controllers now allow ControlLogix users
to solve various tough control problems with ease and
achieve significant economic benefits.”
CyboCon is the flagship MFA control product that includes
a number of MFA controllers, each of which can be
used to solve certain control problems. For example, the
single-input-single-output (SISO) MFA replaces PID to control
simple to complex processes, and the multiple-inputmultiple-output
(MIMO) MFA controls multivariable processes.
Other controllers in the package handle extremely
nonlinear processes, processes with large time delays, pH
processes, including those with large time delays, open-
54 www.controlglobal.com May/2010
loop oscillating processes, processes with large process-time
constants and delay-time changes, and exothermal reaction
run-away processes with large time delays. CyboCon also
has the capability to force the process variable to stay within
defined bounds, deal with measurable disturbances, and
control processes that change signs.
The adaptive capability of MFA is illustrated when
compared with PID (see illustration). The performances
of MFA (top) and PID
(bottom) are compared
to show how
MFA adapts when process
dynamics change.
From the beginning,
MFA and PID are controlling
two identical
processes with similar
control performance.
Then both processes
have a major dynamic
change, causing the
systems to oscillate.
The PID system will continue to oscillate, while MFA
quickly adapts to an excellent control condition. When
the setpoints are changed again, the MFA system no longer
shows oscillation.
Since MFA is “model-free,” the MFA control algorithm
can be computed with very little CPU time so that high-speed
adaptive control signals can be generated. The high-speed
version of CyboCon software running in PC56 allows MFA
controllers to run at a 1-millisecond control update rate. In
contrast, model-based self-tuning PID or identification-based
adaptive controllers usually have difficulties in providing
high-speed adaptive control because online identification or
training of mathematical models can be too time-consuming.
CyboSoft’s MFA for ControlLogix is available now. MFA
controllers are also available for systems from other major
process automation vendors.
For more information, call 916-631-6313 or go to www.
cybosoft.com.

Drowning in Data, Starving for Information, 4
Greg McMillan and Stan Weiner bring their wits and more than 66 years of process con-
trol experience to bear on your questions, comments and problems.
Write to them at controltalk@putman.net.
Stan: We conclude this series by talking with
Brian Hrankowsky a specialist in modeling and
control at a major pharmaceutical company,
and more remarks from PAT expert, Randy Reiss,
to get a better perspective of the opportunities
and problems of so much data availability.
Brian, how important is a better use of data?
Brian: The dollars per deviation are huge in
the pharmaceutical industry. We are often in a
reactive mode due to lags in availability of analytical
data and review of data and often don’t
know much about cycle times, yields, problems
or the impact of process improvements until
well after a batch has been completed.
Greg: What are the problems with current
tools?
Brian: The commercially available tools offered
for batch were originally for continuous
processes, and batch features were tacked
on later. In some cases, the only feature provided
is the use of a “batch running” or “look
at the loop now” flag. This makes batch and
batch-to-batch analysis very hard. Batch systems
have many more dimensions than just
batch on and batch off. Data collection systems
can’t handle the query loads of routine
analysis, as they are optimized for storage, not
retrieval. The event record formats are not
easy to query, as they were designed for operators,
printers and loggers, not detailed metrics
analysis. Why do users need to combine
several records to find out how long an alarm
went unacknowledged? Analysis tools assume
all necessary events are already available and
can be detected in real time.
Users always come up with triggers after implementation
of the analysis system, for example,
determining when the loop was in control.
This trigger is defined as the start of a window
where the process remained within certain
limits, so the trigger has to be backward timestamped
to the start of the window. Statistical
tools require manual exclusion pre-analysis, so
there is a lot of spreadsheet work outside the
tool. Batch operations require an exceptional
rangeability of utility systems, as batch volume
and reaction or crystallization rates go from
zero to a maximum. This throws loop-analysis
tools because the process is never stationary,
and tends to trick the tools into thinking the
problem is with the equipment.
A batch has many dimensions. It’s amazing
how a simple change in tank level can make
a loop-analysis tool useless. The workaround
is treating the loop like multiple loops, which
works, but costs a lot more in licensing and effort.
Uncompressed data is not going to happen.
The data we have is what we have, and
switching to uncompressed data would push
users to historize less to make it affordable. The
CONTROL TALK
GreG McMillan
Stan weiner, pe
controltalk@putman.net
May/2010 www.controlglobal.com 55

C O N T R O L T A L K
compression requirements change
with process variables and their importance,
but the tools don’t allow the
compression to be adjusted dynamically.
We don’t want to have to write
custom code, but the answer to most
batch process-related implementation
issues is to do so.
Stan: What are users trying to do?
Brian: We are working on role-based
dashboards, complete data integration,
a simple query analysis environment,
exception-based, end-of-batch reports,
automation of routine analysis tasks
and exception-based notifications. We
want to know at a glance how the process
and equipment is performing relative
to normal. We want metrics on
cycle time, alarm rates, quality and assays,
PV maximums and minimums,
and raw material and energy use. The
ultimate goal is reporting and visualization
of everything that could have
significant causal relationship and the
root cause of a specific deviation, yield
change, impact to cycle time or change
in efficiency.
Greg: What questions do various users
want dashboards to answer?
Brian: For operators: “Is there something
wrong that needs my attention
now? What actions are coming up for
me to plan for?” For production and
technical support: “How is the process
and equipment performing compared
to normal? Where should we focus
to optimize?” For quality assurance:
“Were there any exceptional events on
the current batch? Did we stay within
spec and execute correctly? Have any
deviations been filed and, if so, what
is their status?” For business leaders:
“Why are we down? What is our production?
What did we spend? Where
did the money go?”
Stan: What are the requirements for
complete data base integration?
56 www.controlglobal.com M a y / 2 0 1 0
Brian: Presently we have islands of
data. Current analysis requires lots
of data: tickets, external and internal
lab results, maintenance and calibration
data, alarm data, batch historian
data, continuous historian data and
regulatory limits data. Troubleshooting/investigation
also require maintenance
data, equipment specifications
and materials tracking information.
Users should not need to be database
experts or learn different interfaces to
access data. They also should be able
to access the data electronically all the
time. Essentially, the tools need to get
to the point where users can extract information
as easily as they can describe
what they want in words.
Greg: What are the biggest challenges
for database integration?
Brian: Maintenance is not integrated
with process data. When there is a
problem, the first thing a process engineer
will ask is what maintenance
was done on the equipment or automation
system. Potentially, there are several
times the number of variables to
review on a daily basis with a fully integrated
data system. Operations, maintenance
and engineering do not have
time to check every potential trend or
measurement every day. To make use
of the data efficiently, the exceptions
have to “bubble up.” Better yet, notify
only when the data must be reviewed.
Stan: Why is there so much more data
with batch operations?
Brian: We are not just interested in the
“make medicine” portion of the process.
For example, there are clean-in-place
and sterilization operations and the need
to detect leakages and blockages. Multiple
transfer operations for one unit operation
cause variable numbers of events
to seek per run. We use events to mark
transitions in process and control windows—S88
recipe object boundaries
aren’t granular enough. Different prod-
uct grades and formulations are different
enough to require recipe-driven tuning
parameters. In essence, every phase is a
process unto itself that tends to require
complete analysis.
Randy: Much of what Brian is talking
about with data mining is critical
to a successful implementation of analytics.
Misalignment of data is a common
pitfall because the process data
is usually in one historian and the lab
analysis data is in another. Yet another
database may be used to store feed
stock quality that can be used as initial
conditions for the analysis. Start
and stop times for each stage of a batch
must be defined, and the data used for
modeling must be extracted from the
historian with the same criteria as are
used on-line. All this must be consistent
across all sources of data. Any discrepancies
will compromise the model
and/or the on-line analysis. Proper data
mining is the most underestimated
part of an analytics project.
Greg: We conclude this informative
series with another memorable Top 10
List from Randy.
Top 10 Auxiliary Quantitative Data
Sources of “Value Add” to the Process
10. Shoe-sole height of the guy who
puts the stick in tank 42 to read the
level
9. Number of clouds in the sky during
the feedstock delivery.
8. Clicks it takes the ignition to fire up
the burner for the boiler
7. Diet Cokes consumed during the
second break of the AM shift.
6. Questions asked at the start of shift
meeting.
5. Questions asked after a shutdown.
4. Gallons of coffee consumed during
a production run.
3. Dollar amount of the maintenance
staff cell phone bill.
2. Remaining shopping days until
Christmas
1. Weeks since last tuning seminar.

Advertiser� � � � � � � � � � � � � � � � � � � � � � � PAge No�
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claudia@fostereprints.com
M A Y / 2 0 1 0 www.controlglobal.com 57

C O N T R O L R E P O R T
Jim montague
e xecutive editor
jmontague@putman.net
More effective
process safety
rules are good
and a good invest-
ment. Maybe the
weight of both will
be enough to make
it happen.
58 www.controlglobal.com m a y / 2 0 1 0
Not Again–Again and Again
How do you get to be an idea whose time has come? You know, like Abraham’s mono-
theism, Buddha’s middle way, Moses’ 10 commandments, one person one vote, Christ’s
golden rule, “All men are created equal,” smoking causes cancer, women are equal
too, global warming is caused by humans, and universal health care is a good idea.
What all these ideas needed to succeed is just
a slight mental shift, first by their inventors, and
then by the larger community. Likewise, process
and machine safety both require this same
small shift in perception. In this case, safety
is moving from being thought of as a burden
and a costly drag on production to becoming a
worthwhile investment that can protect life and
limb, but also contribute to reducing downtime
and generating savings. I keep hearing the term
“lean safety” buzzing around lately.
But old habits and prejudices die hard. Safety
measures and guards are still shut off, disabled
and circumvented all the time, usually so operators
can meet unrelenting production demands
from their management and indirectly
from all of us consumers. This is one of the
main reasons why refineries, chemical plants
and coal mines keep blowing up.
Wait a second. What? When? (Reporters and
editors always ask the same questions, even of
each other.) Okay, let’s shift gears here a second.
So, here I am, writing this column early
on Wed., April 20, and Yahoo! News spits out an
item that at least 11 workers are missing and 17
injured following an explosion the night before
at the Deepwater Horizon oil drilling platform
located 50 miles southeast of Venice, La., near
New Orleans. The rig is owned by Transocean
Ltd., and is under contract to BP. More details
will emerge by the time this is published, but
that’s what we know now.
Not again always seems to happen again.
As always, our thoughts, prayers and condolences
go out to those killed and injured in this
tragedy, and to their families and co-workers,
and to everyone affected by this latest disaster.
Also, I don’t want to seem like a pandering
pundit, and so I apologize ahead of time to
all those close to these events and others concerned
if what I say next seems like I’m not
treating these events as seriously and respectfully
as they deserve.
Still, from my own selfish little perspective,
it would be nice to finish a danged column or
story on the topic of safety without another process
facility exploding. It’s way beyond sad and
depressing. I know cubicle-chair commentary
has little genuine impact, but if something
blows up every time we write about safety, covering
it can begin to seem pretty pointless.
Plus, it’s hard not to wonder if there might be a
curse or voodoo at work.
In fact, almost three years ago, I was writing
the second of two process safety columns,
“Maybe You Didn’t Hear Me,” for the July 2007
issue of Control, when we learned that contract
worker, Richard Liening, was killed at BP’s
Texas City refinery on June 5.
Now I know some accidents are unavoidable,
both in practical and statistical terms, and investigations
may show this latest tragedy to be
one of these. Small consolation, I know. But,
if we could limit disasters to the unavoidable
ones, then there would sure be far fewer than
now. Everyone knows process safety in the U.S.
could and should be way better practiced, regulated
and enforced. than it is now.
We need some process safety rules and laws
with teeth, and we need then now. Enforcement
after the fact is a joke. At long last, the
biggest process end users should show a little
backbone and help support some European or
Australian-style process safety regulations here.
It’s just a little mental switch. Whether
driven internally or externally, more effective
process safety rules are good behavior and a
good investment. Maybe the weight of both
will be enough to make it happen where simple
morality hasn’t been enough. Whatever. Just
as long as it gets done and the number of accidents
and tragedies is reduced.

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