hazardous areas - control global

AP

RIL

2

01

5

Four main methods are available for implementing automation in hazardous areas Herersquos how to select the best one for your application

AutomAtion in HAzArdous AreAs

SCADA MoveS BeyonD the hMI teMperAture

SenSIng In hArD-to-reACh

plACeSthe DISConneCt Between engIneerIng teAChIng AnD prACtICe

CT1504_01_cvrindd 1 33115 543 PM

the 1 value in automationOrder Today Ships Today

See our Web site for details and restrictions copy Copyright 2014 AutomationDirect Cumming GA USA All rights reserved 1-800-633-0405

Research price and buy at wwwautomationdirectcom eldIO

eXactly where you need it The eXact IO you need

$6300(PX-248 8-point DC

Output)

$3600(PX-172-1 2-point

AC Input)

$2400(PX-970 AC Power

Feed Terminal)

$27700(PX-334-K

Thermocouple)

$38400(PX-TCP2 2-port

Modbus TCP Coupler)

bull Rackless design for easy installation in areas with limited space

bull Bus Couplers available in both Modbus RTUASCII and Modbus TCP protocols to integrate with a wide variety of controllers and SCADAHMI packages

bull Discrete terminals available in AC and DC with a variety of point confi gurations including 2 4 8 or 16 points

bull 2 4 and 8-channel analog terminals with 4-20 mA 0-10 VDC and +- 10 VDC capabilities as well as RTD and Thermocouple options

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Xpansion IO has never been so practicalBuilt to be versatile in the eld the new Protos X Field IO system has a slim design with numerous IO point con gurations The small footprint lets you install Protos X IO assemblies exactly where you need them even in tight locations No need for excess eld wiring no need for unused IO points and with the already low price yoursquoll save money again and again with Protos X

TM

Bus Couplers available in both Modbus RTUASCII and Modbus TCP protocols to integrate with a wide variety

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0-10 VDC and +- 10 VDC capabilities as well as RTD

Xpansion IO has never been so practicalBuilt to be versatile in the eld the new Protos X Field IO system has a slim design with numerous IO point con gurations The small footprint lets you install Protos X IO assemblies exactly where you need them even in tight locations No need for excess eld wiring no need for unused IO points and with the already low price yoursquoll save

Distributing IO for your process saves space wiring and

money

1504-Control-FieldIOProtosX-MAGindd 1 3122015 95606 AM

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$6300(PX-248 8-point DC

Output)

$3600(PX-172-1 2-point

AC Input)


Feed Terminal)

$27700(PX-334-K

Thermocouple)


Modbus TCP Coupler)









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April 2015 bull Volume XXVIII bull Number 4

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 ) 1501 E woodfield Rd Ste 400N Schaumburg IL 60173 (Phone 630467-1300 Fax 630467-1124) Address all correspondence to Editorial and Executive Offices

same address Periodicals Postage Paid at Schaumburg IL and at additional mailing offices Printed in the United States copy Putman Media 2015 All rights reserved The contents of this publication may not be reproduced in whole or part

without consent of the copyright owner POSTMASTER Send address changes to CONTROL PO Box 3428 Northbrook IL 60065-3428 SUBSCRIPTIONS Qualified-reader subscriptions are accepted from Operating Management in the

control industry at no charge To apply for qualified-reader subscription fill in subscription form To non-qualified subscribers in the Unites States and its possessions subscriptions are $9600 per year Single copies are $15 International subscriptions

are accepted at $200 (Airmail only) CONTROL assumes no responsibility for validity of claims in items reported Canada Post International Publications Mail Product Sales Agreement No 40028661 Canadian Mail Distributor Information

FrontierBwIPO Box 1051Fort ErieOntario Canada L2A 5N8

s u p e r v i s o r y

c o n t r o l

45 looking over Bigger shoulders

Todayrsquos SCADA systems are easier to deploy and operate which is good because theyrsquore being called on to manage ever larger and more widely distributed process applica-tions by Jim Montague

t e m p e r a t u r e

i n s t r u m e n t a t i o n

49 temperature sticks its neck out

Innovative controls accessories software and other tech-niques are enabling temperature instruments to reach in and help optimize many previously inaccessible applica-tions Herersquos how by Jim Montague

c o v e r s t o r y

36 automation in Hazardous areasFour methods for implementationmdashherersquos how to pick the best one for your application by Dan Hebert PE

a p r i l 2 0 1 5 wwwcontrolglobalcom 5

f e at u r e s

Essentials of Network and Security Serviceswwwcontrolglobalcomwhitepapers2015essentials-of-network-and-security-services

Get the Best Return on Process Assets with EAMwwwcontrolglobalcomwhitepapers2015getting-the-best-return-on-assets-with-process-manufacturing-and-enterprise-asset-management

W E B E X C L U S I V E S

CT1504_05_07_TOCindd 5 33115 600 PM

More than 100000 customers in every industry around the globe trust Endress+Hauser to make their processes safe efficient and repeatable Just like a puzzle many pieces must come together at the right time and place to manufacture a product profitably Endress+Hauser understands there is a world of difference between a good fit and a perfect fit for your critical process measurement needs This is proven by the sustainable value we generate for our customers through the instruments services and solutions we deliver

When you need support Endress+Hauser is the partner you can depend on for

bull Instrumentation and application expertise

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Discover what we can do for you in our library of case studies application notes and white papers wwwusendresscomsuccess-stories

Why choose Endress+Hauser

Competence is knowing how it all fits together

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Anwendung in Magazinen

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Anwendung insw-Publikationen


D E P A R T M E N T S


9 Editorrsquos PageAttract Todayrsquos Talent Industry increasingly sees sustainability as critical to long-term success

15 Control OnlineJust in case you missed them check here for some of our readersrsquo favorite recent links to ControlGlobalcom

17 FeedbackOur readers ask about commissioning control valves and comment on cyberse-curity problems

18 Other VoicesBridging the Gap The ProblemThe disconnect between engineering school and the real workplace

25 On the BusAlarm Management for DevicesHow are we to sort out the information we need from the data deluge that the IoT will bring

26 Without WiresExtreme WirelessHeat cold humidity electro-magnetic in-terferencemdashnew wireless technologies can overcome all of them

28 In ProcessABB promises more growth FDI specs and tools now available new oil-gas wastewater treatment method CSIArsquos new CEO

34 ResourcesOnline Help with Process Analyzers

52 Ask the ExpertsRelief Valve Blowdown Oil Separator Level Measurement Get advice from our experts

54 RoundupProgrammable Control ConfidentialThe latest in PACs and PLCs

56 ProductsGet the best in automation technology here plus sneak peaks at new products from ABB and Foxboro

59 Control TalkLearning What Your Processes Can DoAdvanced control tools and improved PID and tuning software can unleash engi-neersrsquo imaginations to push the process control envelope

61 Ad IndexCheck these pages

62 Control ReportHands-On Wins Hands-DownEndress+Hauser helps open two new ldquouniversitiesrdquo that give students teaching moments that go beyond even the best simulators

Food amp Kindred Products15398Chemicals amp Allied Products 9095 Systems Integrators amp Engineering Design Firms 7458Primary Metal Industries 4272Electric Gas amp Sanitary Services 3847Petroleum Refining amp Related Industries 3600Miscellaneous Manufacturers 3597

Paper amp Allied Products 3522Pharmaceuticals 3496Rubber amp Miscellaneous Plastic Products 2855Stone Clay Glass amp Concrete Products 1733Textile Mill Products 1047Tobacco Products 100Total Circulation 60020

CIrCuLATIOn AuDITED JunE 2015

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Attract Todayrsquos Talent

When I graduated from the University of Illinois in 1981 with a MS in metallur-gical engineering I chose to join a lit-

tle magnet manufacturer in Valparaiso Ind called Indiana Generalmdashnot because the pay was highest or the career paths were most in-viting or even because I liked (or understood) magnets but because the little plant had a foundry on one end and a research lab on the other and in between it did everything you can do to metal casting rolling drawing stamping powdering pressing sintering heat treating machining grinding tumbling plat-ing coating and of course magnetizing

I was reminded of that do-everything plant on a recent visit to the Eastman Chemical fa-cility in Kingsport Tenn to present our Hall of Fame award to 2015 inductee Jim Downs Founded in 1920 the plant sprawls over 900 acres doing the kinds of things with cellulose natural gas and coal that Indiana General did with iron cobalt and rare earths and I learned that it offers the same sort of technological playground for advanced control that the mag-net plant did for metallurgymdashonly way bigger

Downs heads up the Advanced Control Group a smart and handsome selection of chemical engineers that divide their attention among production support projects and its own research and development currently fo-cused on unit integration and plantwide op-timization Like many engineering groups Downsrsquo is top-heavy with incipient retirees and he worries about attracting enough talent to support its esoteric missions

Graduating engineers would rather work for high-tech startups and near big cities Downs told me Itrsquos hard for young people to see the at-traction of a big old plant like Eastmanrsquos in the foothills of the Great Smoky Mountains

My younger son will graduate next year with an MS in aerospace engineering specializ-ing in spacecraft systems The companies that make the highest technology tend to be deeply

involved in military applications a fact which has caused him some soul-searching

However the best ones are also open and adamant about sustainabilitymdashtheir values and goals for emissions energy and water efficiency waste and greenhouse gas reductions and re-sponsible materials usage sourcing and recy-cling Itrsquos also very easy for him to check them out not only by reading their policies and re-ports but whatrsquos said about them on glassdoorcom and what their facilities and surroundings look like on Google Earth and Street View For example therersquos a very impressive array of so-lar panels around Raytheonrsquos missile plant in Tucson Ariz

Your company is probably aware of the im-portance of sustainability for attracting young engineering talent Energy monitoring expert Bill Holmes told me he recently attended ldquothe most amazing and enlightening sustainability (and conservation) event in Wilson North Car-olina that I have experienced in my careerrdquo

Holmes said ldquoPlant managers for the nearby Cummins [forklift manufacturer] NMHG and Bridgestone plants participated in a panel dis-cussion and each emphasized their corporate and plantrsquos commitment to sustainability At the end of the discussion the plant managers were asked what their highest priority was and each said information systems that would al-low them to set priorities make changes get employees involved document the results and meet their aggressive goalsrdquo

If you want to attract young talent itrsquos greatmdashbut not enoughmdashto offer even the most fantastic set of technical resources challenges and rewards You also have to be able to prove that your process plant is a great place to work and a responsible steward of the planet and the environment If you do can do that you can at-tract talent pretty much no matter where you aremdashor what you make

A p r i l 2 0 1 5 wwwcontrolglobalcom 9

pAul StudebAker EdiTor in chiEfps tudebakerputmanne t

E D I T O R rsquo S P A G E

Itrsquos hard for young

people to see the

attraction of a big

old plant like

Eastmanrsquos in the

foothills of the

Great Smoky

Mountains

CT1504_09_Editindd 9 33115 656 PM

800 453 6202



Updated every business day the Control Global online magazine is available at no charge Go to wwwcontrolglobalcom and follow instructions to register for our free weekly e-newsletters

Making the Industrial Internet RealRevisit or check out for the first time

the GE Intelligent Platforms 2014 User

Summit Get context on the technology

wave articles on zero downtime vir-

tualization pervasive data and how to

gauge where you are on the connec-

tion-optimization curve wwwcontrol-

globalcomwhitepapers2015indus-

trial-internet-ge-2014-user-summit

Monitoring Mercury Using ORPLearn about the monitoring require-

ments and how an ORP sensor can

be used to make the measurements

wwwcontrolglobalcomwhitepa-

pers2015monitoring-mercury-control-

using-orp

Best Transmitter Damping or Signal Filter SettingA setting that is too slow can not only

degrade performance but also cause

trips A large filter setting can mislead

operations into thinking the filter has

helped rather than hurt the process

Herersquos how to sort this out wwwcon-

trolglobalcomblogscontroltalkblog

what-is-the-best-transmitter-damping-

or-signal-filter-setting

Big Data and the Death of HypocrisyCan big data overcome this basic hu-

man weakness Find out here www

controlglobalcomblogsin-and-out-of-

controlmonday-big-think-will-big-data-

kill-hypocrisy

ControlGlobal E-News

Multimedia Alerts

White Paper Alerts

Go to wwwcontrolglobalcom and

follow instructions to register for our

free weekly e-newsletters

C O N T R O l O N l I N E

Whatrsquos Next

William L Mostia took a good long look at what process automation is going to look like in 10 or 20 years

He sought out some half dozen process control and long-term planners and asked them to speculate on how rapidly developing operator interfaces comput-ing data analytics and virtual reality will change our craft For a look at the control rooms software practices and challenges of the next decades go to wwwcontrolglobalcomarticles2015control-systems-of-the-future

Calibrate ThisAs natural forces go pressure is pretty straight-forward It involves less mysterious physics than electromagnetism itrsquos easier to observe than thermodynamics and its calculations are simpler than often turbulent flows says Jim Montague But properly calibrating a pressure instrument still has its challenges This article delivers the short version of two 90-minute ISA presentations by Hunter Ve-gas project engineering manager at Wunderlich-Malec Ned Espy technical di-rector at Beamex and Roy Tomalino professional services engineer at Beamex Go here for your pressure calibration Cliff Notes wwwcontrolglobalcomarti-cles2015how-to-calibrate-pressure-instrumentsstart=0

Whatrsquos the DifferenceWirelessHART vs ISA 10011a Mark Nixon presents a brief simple explanation of where these two key wireless standards are similar and where they differ Go to wwwcontrolglobalcomarticles2012nixon-wireless-isa for the answer

Simpler SafetyLeading the Control Hit Parade the last week in March was Beacutela Liptaacutekrsquos column ldquoSafety Stan-dards Must Be Made Simplerrdquo He asks who should have the last word on safety the system or the op-erator and he challenges the standards writers to lose the acronyms and jargon and make their end products simpler Go to wwwcontrolglobalcomar-ticles2015safety-standards-must-be-made-simpler for the complete discussion

100 = 23 ft

LT

Reading 100 = height (in) x SG23 ft x 12 inft x 10 (SG) = 276 in wc

FI nitrogen

N2 blanket(10 in wc)

H

L

SG = 1

CT1504_15_WebTOC_1indd 15 33115 602 PM

The oil and gas you provide are critical to your customersrsquo lives Level and flow control is critical to keeping them flowing For control solutions that work trust Magnetrolreg We have been providing level and flow instrumentation to the oil and gas industry for decades And we offer the most advanced measurement and control technology available today

You can rely on MAGNETROL to keep your process running smoothly and safely So your customers can rely on you

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So this works

So this works

magnetro l com bull 1-630-969-4000 bull infomagnetro l com copy 2015 Magnetrol International Incorporated


A P R I L 2 0 1 5 wwwcontrolglobalcom 17

Commissioning Control ValvesRe the February 2015 Control Talk col-umn on the commissioning of control valves How does one go about proving that the actuator is sized large enough to handle actual process conditions For ex-ample it may be 31 Bar G at 400 degC up-stream and 1 bar G at 150 degC downstream The stroke testing methodology you de-scribe will not show you Then when the plant is live it may be too late The actua-tor may not be sized suf ciently to close against such a high differential pressure

CHARLES PALMERchar les101143gmail com

Greg McMillan repliesGood question The problem of an under-sized actuator is most apparent when the valve tries to close and open at operating pressures Notify the supplier of the require-ment to have 150 of the thrusttorque re-quired for shutoff and opening at the maxi-mum pressure drop You can also ask for test results in the supplierrsquos pressure- ow lab

I advocate doing stroke testing not only at the normal operating point but also at the closed position at worst-case pressure drop Ideally this pressure can be simulated in a shop setup and during water batching With the valve closed 05 increments should be applied and the results moni-tored for stick-slip and overshoot Once the valve opens then 05 decrements should be applied and the results again monitored for stick-slip and backlash (dead band)

This testing at the closed position is of-ten not done Suppliers are reluctant to do it because stick-slip is greatest at the closed position At startup and for low operating rates the valve needs to smoothly open and close

Some tight shutoff valves used for surge control would overshoot to 25 open when asked to open just a few percent due to changes in a downstream user ow re-sulting in a severe upset to the compres-sor and to all users pH reagent valves are notorious for riding the seat due to the ex-treme rangeability requirements from the titration curve nonlinearity

The overhead pressure and condenser

temperature control systems of batch reac-tors have extremely low ow requirements at the start of the batch cycle resulting in control valves rid-ing the seat One of the best things I did for one proteacutegeacute in the ISA Men-tor Program who was experiencing poor overhead sys-tem batch reactor control from the use of a tight shut-off valve for throt-tling was to recommend the tight shutoff valve be used for isolation and a throttle valve with low friction and oversized ac-tuator be added for control

ICS Cybersecurity In response to Joe Weissrsquos blog post (wwwcontrolglobalcomblogsunfetteredob-servations-from-advisen-cyber-risk-confer-ence-march-3rd-in-san-francisco) There are at least three key issues correlated to the symptoms of this problem

1) Lines of ownership and accountabil-ity are generally unclear when it comes to cyber vulnerabilities impacting the ICS infrastructure The question really is who is accountable for industrial infrastructure security and do they have the authority and subject matter expertise to establish the necessary security controls for ICS What is the governance model associated with the security model

2) The primary focus at the organiza-tional level seems to be security for IT systems The distinction between IT and OT is not well understood Infrastructure owners have to recognize that compliance does not necessarily equal protection

3) Control system cybersecurity requires an interdisciplinary approach Again the question is are businesses investing in their workforce to ensure knowledge sharing and skills enhancement between and across the multiple disciplines of security IT OT cyber process etc

AMIT KUMAR akumarieeeorg

TECHNICALLY SPEAKING F E E D B A C K

SENSING LEVEL OF DIFFICULT MATERIALS

NETWORK EASES UPGRADE TO PLANT-WIDE CONTROL

OUR NOBLE BUT UNAPPRECIATED PROFESSION

Our 2015 inductees have earned our honor as wise control

mentors


IN MEMORY OF JULIE CAPPELLETTI-LANGEVICE PRESIDENT 1984-2012

1501 E WOODFIELD ROAD SUITE 400NSCHAUMBURG ILLINOIS 60173

editorial teamEditor in Chief PAUL STUDEBAKER

pstudebakerputmanne t

Executive Editor JIM MONTAGUEjmontagueputmanne t

Senior Managing Editor Digital Media KATHERINE BONFANTEkbonfanteputmanne t

Managing Editor NANCY BARTELSnbar telsputmanne t

Senior Technical Editor DAN HEBERTdheber tputmanne t

Contributing Editor JOHN REZABEKColumnists BEacuteLA LIPTAacuteK GREG MCMILLAN IAN VERHAPPEN STAN WEINER Editorial Assistant LORI GOLDBERG

design amp production teamVP Creative Services STEVE HERNER

shernerputmanne t

Senior Production Manager ANETTA GAUTHIERagauthierputmanne t

publishing teamGroup PublisherVP Content KEITH LARSON

klarsonputmanne t

MidwestSoutheast Regional Sales Manager GREG ZAMINgzaminputmanne t630551-2500 Fax 630551-2600

Western Regional Sales Manager LAURA MARTINEZ310607-0125 Fax 310607-0168lmar t inezputmanne t

NortheastMid-Atlantic Regional Sales Manager DAVE FISHER508543-5172 Fax 508543-3061df isherputmanne t

Classi eds Manager LORI GOLDBERGlgoldbergputmanne t

SubscriptionsCirculation JERRY CLARK JACK JONES88864 4-1803

executive teamPresident amp CEO JOHN M CAPPELLETTIVP Circulation JERRY CLARKVP CFO RICK KASPER

foster reprintsCorporate Account Executive JILL KALETHA

866-879-914 4 x 168 Fax 219-561-2033ji l lk fos terpr in t ingcom

FINALIST JESSE H NEAL AWARD 2013 JESSE H NEAL AWARD WINNER ELEVEN ASBPE EDITORIAL EXCELLENCE AWARDSTWENTY-FIVE ASBPE EXCELLENCE IN GRAPHICS AWARDSASBPE 2009 MAGAZINE OF THE YEAR FINALISTFOUR OZZIE AWARDS FOR GRAPHICS EXCELLENCE

CT1504_17_Feedbackindd 17 33115 237 PM

O T H E R V O I C E S

18 wwwcontrolglobalcom A P R I L 2 0 1 5

Students are taught

engineering

science principles

which is good but

in an idealized and

out-of-context way

which is not

R RUSSELL RHINEHARTSCHOOL OF CHEMICAL ENGINEERING

OKL AHOMA S TATE UNIVERSIT Yrrroksta teedu

Bridging the Gap The Problem

Irsquod like to address the gap between the aca-demic and practice control communitymdashwhy it exists the issues it creates things that can

be done to bridge the gap and the need for in-dustry mobilization to cause change My focus is on the US situation There are two issues One is the general lack of practice experience in the faculty which aligns student perspectives to the scienceresearch ldquowayrdquo and the other is the ab-sence of a control engineering curriculum

Here in Part 1 I will describe the problem In June I will discuss solutions

There seems to be general agreement in both industry and academe that engineering faculty should have engineering practice experi-ence However there is little practice experience among faculty As a result students are guided by the research science perfection individual performance and intellectual values that char-acterize their teachers not the contrasting val-ues related to sufficiency urgency compliance partnership safety personal effectiveness and fruition that are essential for business success Furthermore students are taught engineering science principles which is good but in an ide-alized and out-of-context manner which is not As a result they do not graduate with the per-spectives and expectations to be successful in the disparate context of industrial practice

I am one of those graduates It seems it took me two years of work as a process engineer to understand the new environment to become ldquoindustrializedrdquo to be able to be an indepen-dent and relevant contributor Two years is a typical induction period In all I worked in in-dustry 13 years My last role as supervisor of a group of engineers led me to understand the importance of human resource development and the need to accelerate the transition of en-try-level engineers from academe to industry

The two-year transition period is substantially the result of the misdirection of the student per-sona for engineering function and is often called ldquothe gaprdquo It undermines careers delays produc-

tivity and costs industry It is not the result of which topics are or are not taught I see it as a na-tional productivity issue and industry academe and government are all involved as stakeholders

We need to bridge the gap Unfortunately the ldquowaysrdquo the modus operandi of those three stakeholders are very different If we are going to bridge the gap we need to understand what it is and the environment that creates it

I believe that engineering education is sub-stantially fulfilling its multiple missions that my university is as good a place to work as any and am particularly very proud of the accom-plishment and quality of the students in my program Having gone back to school for my doctorate after working in industry I see that what is taught is useful and relevant even if the instructor is not fully aware of the application context and I find that instructors without in-dustrial experience can be excellent teachers

Although happy about my situation and ed-ucational outcomes much needs to be done to improve education I would like the follow-ing criticism to be accepted as an initiative to add value so that engineering education can achieve what is possible

Why Is there a GapSome think it is about the topics in the curricu-lum We donrsquot teach what a particular entry-level engineer needs to know such as program-ming in a particular DCS or PLC That is not the issue The curriculum topics are directed by Industrial Advisory Committees the ac-creditation agency (ABET) the Fundamentals of Engineering Exam and collective exchange of best practices and curriculum content spon-sored by several professional societies They are the right topics but we canrsquot teach in only four years what one 40-year career needs let alone the needs of every separate career

Ninety-five percent of what we teach in school is useful for any particular career and life but it comprises only 5 of what the indi-

CT1504_18_22_OtherVoicesindd 18 33115 213 PM

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Discover new efficiencies and achieve unmatched throughput with Rosemountreg instrumentation Turn to Emerson measurement experts and Rosemount instrumentation to get more production out of your current equipment maintain a smarter workflow and operate at your full potential Our specialists will show you how to use stable accurate Rosemount instruments to minimize measurement drift and confidently run your facility as close as possible to critical levels And with intuitive Rosemount diagnostic tools and wireless transmitters you can gather more detailed insights into the health of your entire process without adding infrastructure so you can stay optimized longer and avoid downtime To learn how Emerson can help you hit your production targets and maximize the capacity of your assets with measurement instrumentation see case studies at Rosemountcomfullpotential

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vidual needs to be functional happy and successful Educa-tion is to provide graduates with adequacy in the fundamen-tal skills of a discipline and certify their fitness to self-learn Sometimes students and employers think that college educa-tion is about teaching the necessary skills but the subset that can be taught in four years is only the essential minimum Employees must learn the other 95 Sometimes educators think it is about teaching the fundamental skills That also is partly right but what is often missing our understanding is that we need to prepare students to self-learn the other 95

The business of academe contributes to the gap We need funding and stature and how we get both shapes who we hire as faculty and how they understand our discipline

Stature Academic stature comes from public visibility of in-tellectual contributions Academe does not invent manufac-

ture or run businesses Academics investigate pre-commercial years-ahead possibilities and provide the technical and science underpinning of techniques We publish our findings in the open literature (textbooks and handbooks) providing access to knowledge and tools facilitating those in the practice Our job description requires each of us to establish a public reputation as an individual expert who advanced the understanding of sci-ence and technology For journal acceptance engineering un-derstanding must be stated in our mathematical language So we seek individual performers who are competitive in a pub-lic intellectual mathematical one-upmanship game This is probably not the persona that industry is seeking in a business partner but it is the persona that is shaping graduates

Funding A substantial portion of university funding comes from research grants which is our primary metric of success and university ranking Research funding supports the infrastructure our stature and the professorrsquos salary

Most funding comes from the government and is not di-rected for product or process development It is aimed at de-veloping the pre-commercial knowledge base (to position graduates to be able to use technology when it becomes practicable in the future) or solving social problems (such as medical health or biofuels) Most funding steers the faculty away from solving extant problems for industry Although disbursed by government agencies the proposals are judged by the visible national experts primarily senior academics We hire people who can appeal to them to be successful in getting grantsmdashagain probably not the persona that makes a good engineering partner in the private sector

Experience It takes about two years immersed in the in-dustrial environment full-time subject to industrial perfor-mance appraisals within the energy and competitive aspi-rations of other new employees and perceiving industry as your exclusive career path to transition from a student to a partner It takes about five years of experience to be able to identify and articulate the misperceptions of others to coach for the transition Academe recognizes industrial ex-perience as a positive albeit inconsequential to university goals But both the delay in starting a research career and the industrial values that contaminate purity in proposals are often viewed as a significant negative

Research The technical work of professors is related tothe exploration of possibilities It is not even applied research within an entrepreneurial context It is not development and certainly not design or operations within a manufacturing context It is done externally to the context of economics en-vironment health safety and loss prevention (EHSampLP) or the legal issues associated with contracts patents and trade-marks When we find success in analyzing one aspect of a problem we celebrate glorious achievement with a publica-tion but it is far from describing a sustainable implementa-tion The academic environment attracts those who are in-

COMPARING THE STUDENT AND ENGINEERING ENVIRONMENTSTUDENT ENTERPRISE PARTNER

Learning internal Bringing change to fruition value creation external

Follow professorrsquos guidance Leads own studies

General studies probable importance

Task-specific studies necessary

Professor evaluates and assigns grade Self-evaluation of sufficiency

Quantify progress by skill inventory

Quantify progress by trail of contributions

Simple idealized isolated concepts

Complex interactive non-ideal reality

Individual Team

Old and known certainty New and uncertain

No risk little accountability to others

Significant risk accountability to many others

Describe it mathematically Make it work

Abstract (concepts equationsschematics)

Concrete (equipment measurements people)

Answer = equation number report Answer = cash flow

Write to show technical prowess Write to get action

Understand thoroughly andquantitatively Understand qualitatively

Passive Active

Science and skill focus Business impact and market focus

Perfection Sufficiency

Research Development

Unconstrained unbounded freedom

Constrained by laws regulations EHSampLP contracts economics

Self-paced for personal convenience Urgency

Celebrate youth Develop adults

Solve problems Realize opportunities


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ELPRO is now Eaton Same great products plus even more

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terested in mathematical analysis or concept creation It does not attract those who are interested in bringing it to fruition

Pedagogy Pedagogy is the art and science of best prac-tices in getting students to learn We are good at teaching but consider the context students do not yet have industrial practice experience Accordingly they canrsquot relate to the complexity of equipment within the business context Fur-thermore they are learning the fundamental concepts for the rst time so we teach idealized simplistic concepts that are isolated from confounding distractions We must create attainable challenges to keep students incentivized We also have to teach to the masses but test for individual ability So we assign exercises and tests that can be done by novices can be ef ciently graded and have absolutely right or wrong solutions that canrsquot entangle us in grading challenges We have neither the time nor the funding to provide extensive labs or to coach for performance on open-ended projects

Time Four years of college canrsquot prepare a person for a lifetime of skills When I teach the chemical process con-trol course I include many practice-relevant aspects but canrsquot include all There is not time in the one control course within the chemical engineering curriculum to fully pre-pare engineers for process control jobs Presently some edu-

cators are questioning the need for a process control course within the academically perceived priority of all of the other topics and legislative pressure to reduce the credit hours in the degree requirements

Survival of the Fittest The accompanying table summa-rizes the differences between school and practice We pre-pare students for success in school which misdirects their understanding of what life in the practice is all about To be able to lead themselves across the gap they need to un-derstand the ldquowayrdquo that they acquired and the new ldquowayrdquo needed for success in industry

One can also contrast the performance measures be-tween academe and industry We select students for gradua-tion based on their ability to get high grades through knowl-edge accumulation and success in playing the testing game (speed elementary etc) We recognize them for honors courses isolated creativity and intellectual achievement and reward them with letters (after their name) By contrast industry honors employees for project fruition for compre-hensive sustainable solutions to business-relevant opportu-nities by facilitation of others and rewards them with ex-panded responsibility and independence

In June I will describe impacts and reveal solutions


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More Competitive More Reliable More Affordable Make It Daisy amp Make It Right

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To learn more about our Dual Input Temperature Transmitter go toOr call 800-999-2900

p p

900wwwmiinetcomTHZ3TDZ3

105rdquo

7875rdquo

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Demand Moore Reliability

The new THZ3TDZ3 Dual Input Smart HARTreg

temperature transmitters can help you avoid costly process interruptions and maintenance delays by ensuring your measurements always make it safely to your control system Our Sensor Backup and Failover protection feature means you will never miss those critical readings - even if something goes wrong with one of the sensors

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Enhance Automation Systems with Flexible Distributed Control IO Modulesbull Distributed Control with Peer-to-Peer and Graphic Condition Logicbull Popular Protocols Modbus TCP and ASCII UDPbull DHCP configuration export group configurationbull Webpage hosting HTML5 REST Java Scriptbull Supports smart phone and tabletsbull Free universal configuration utility software and NET driversbull Support Daisy-chain Ethernet (ADAM-6200 series)

ADAM-6200 Family ADAM-6000 Family

Putting the IO in IoTComplete Ethernet Remote IO Solutions

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O N T H E B U S

The host of

information-laden

smart devices

obscures or

desensitizes us to

device problems

that would benefit

from prompt

attention

JOHN REZABEK CONTRIBUT ING EDITORJRezabekashlandcom


Alarm Management for Devices

As wersquore hurried forward into the promised new Industrial Internet of Things (IIoT) aka pervasive sensing will we find the

presumed wealth of previously hidden informa-tion useful or interesting Surely there will be something I care aboutmdashlike that ldquothingrdquo that broke and caused the fire that crippled crucial production I wish that thing had been on the network and would have called me at home be-fore the vapor cloud escaped and ignited The thing that caused a spill or releasemdashwill it have an IP address on the Internet The trouble is for every thing that I can imagine communi-cating and potentially saving me from some adversity there are 20 things already flooding the network with data Somewhere among all those hundreds or thousands of messages is one I wish I could read right now but how do I go about finding it

The situation is largely analogous to the pro-cess industryrsquos problem with alarm manage-ment Alarms on process data became ldquofreerdquo with the advent of the PLC and DCSmdasha few mouse clicks and any piece of data could be made to make noise (sound the horn) or change color on the HMI And thatrsquos what we did On my system every module template has a minimum of five alarm parameters config-ured Multiply that times a few hundred or a few thousand and you have the makings of an alarm flood

As for device alerts we donrsquot have to wait for the IIoT wersquore really already there Rather than obscuring the real urgency and priority of pro-cess malfunctions that require timely action the host of information-laden smart devices obscures or desensitizes us to device problems that would benefit from prompt attention It could be the sort of attention that would avert some of those process problems and thatrsquos where the real value lies

When yoursquore applying traditional alarm ra-tionalization to a process HMI like a DCS a team of individuals representing operations

(preferably experienced operators) controls process specialists and possibly machinery and safety specialists consider each alarm in the system to determine if it passes muster For example an alarm should only be an alarm (make a noise and appear on an alarm sum-mary) if it indicates an abnormal condition re-quiring timely operator action While examin-ing a given alarm it makes sense for the team to 1) document the likely causes consequences and corrective actions the operator might take 2) prioritize it based on consequence and ur-gency and 3) store these findings in a master alarm database Doing this for thousands of alarms can be tedious and exhausting It can take months of work

Donrsquot we need to do the same for our device alarms if we expect them to be useful Some-one needs to decide that if the control valve on the feed to the hydrotreater has a high deviation from setpoint it should be inspected for worn packing and scheduled for an overhaul before the week is out Meanwhile all the ldquoconfigura-tion changedrdquo alerts can go straight to the spam bucket Like process alarm management each alert should be meaningful and have a defined action to remedy the issue detected But where do we find the team and the time to do device alert management when we struggle to find the resources for even process alarm management Can our suppliers help out with this

Like our process plants supplier companies are beginning to experience a turnover in ex-pertise A lot is headed out the door as the older generation decides it might be more relaxing to make wine and hit golf balls than design new and better instruments Before all these folks hit the links for good end users could benefit from their years of experience and insight ap-plied to device alarm management Before the tidal wave of IIoT engulfs us letrsquos at least un-derstand what the experts think is really useful Wersquore struggling for the resources and the will to do it on our own

CT1504_25_OTBindd 25 33115 215 PM

W I T H O U T W I R E S


Sensors typically

placed in extreme

environments often

are powered from

near-field sources

and their

associated

antennas

IAN VERHAPPENDIRECTOR

INDUS TRIAL AUTOMATION NE T WORKSiverhappenindustrialautomationnetworkscom

Extreme Wireless

With what many at least on the eastern side of North America might consider an ldquoextreme winterrdquo it is appropriate

that we take a look at how wireless can be ap-plied in extreme environments

Though perhaps not obvious at first glance extreme environments are a natural for wire-less except perhaps for the temperature effect on batteries since as we all know cold temper-ature increases the internal resistance and lin-early diminishes the capacity

We also know that battery output degrades rapidly when cycled at high ambient tempera-tures If a battery operates at 30 degC (86 degF) in-stead of the optimum 20 degC (68 degF) the service life is reduced by 20

Of course not all wireless sensors require batteries Some sensors and the ones typically placed in extreme environments where batter-ies would be more of a risk than benefit often are powered from near-field sources and the as-sociated antennas Most notable among these are the many RFID and passive wireless sen-sor tag (PWST) sensors which have minimum electronics and therefore are better suited to the harsh environments in turbines jet engines rockets and inside automobile engines and trans-missions to manage torque in real time

What are the attributes of a PWST used in these environments They do not have a bat-tery or a wired connection between the sensor and data acquisition unit They have no need for scavenging power over time yet provide a sensor reading along with a unique tag ID with range information so the location and orienta-tion of the signal can be determined

Because these devices are simple and rugged they can be permanently embedded in or behind a structure or added after manufacturing with appropriate adhesives and bonding agents They are also compatible with high-volume produc-tion which once the demand is in place leads to the self-fulfilling advantage of a low cost per mea-surement point For comparison if we look at the

progression of measurement signals and their ap-proximate cost per point we see an approximate order of magnitude improvement for each gener-ation (see table)

Fourth-generation products are available for a wide range of applications such as high-temperature sensors including those for moni-toring power transmission lines and rotating machine elements tire-pressure sensors and real-time tire friction control accelerometers and current water-content humidity hydro-gen and methane sensors

Returning to our original challenge of pow-ering devices such as these in extreme environ-ments the following methods have been success-fully employed in the above list of applications

bull Electromagnetic (EM) couplingmdashSimilar to the wireless chargers for our handhelds de-vice is simple but has a very short range

bull RFID-based devicesmdashUse an antenna for scavenging power and for data return suitable for medium-range applications such as baggage handling and pallet detection

bull Surface acoustic wavemdashApplications use wave reflection plus an antenna to support lon-ger range and higher sample rates

Extreme sensors are available for extreme environments The limitation appears to be our imagination and ingenuity on how to use all this data to provide us with safer more secure environments

CHEAPER BY THE GENERATIONGeneration Type $point

1 wired $10000

2 motes $1000

3 active sensor tags $100

4 passive wireless sensor tags $10

As the wiring technology has improved the price

has gone down

CT1504_26_Wirelessindd 26 33115 219 PM

1 800 463 9275

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1

2

3

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6

7

8

9

Amphenol Industrial MAX-M12 high speed data connectors

AlphaWire EcoCablereg mini foil shielded multiconductor cable

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1

6 7

8

9 10

11

2 3 5

4


28 wwwcontrolglobalcom A p r i l 2 0 1 5

ABB rededicates to responsible GrowthSoftware services RampD and innovations highlighted at Automation amp Power World 2015

Because software is a key enabler of automation and power genera-tion itrsquos been a huge part of ABBrsquos

$10-billion capital investment in North America over the past five years re-ported ABB CEO Ulrich Spiesshofer during his March 2 keynote address at the opening of ABB Automation amp Power World (APW) 2015 in Houston

ldquoMore than half of our offerings today are software-basedrdquo said Spiesshofer

More than 8000 people attended the weeklong event a record number representing a 116 increase since the combined event was first held in 2009 Spiesshofer stressed that soft-ware services and an unwavering commitment to RampD by ABB will be engines of growth for years to come For example the new YuMi collab-orative robot which can work side-by-side with humans is one of ABBrsquos newer developments

ldquoWersquore a very large corporation with a lot to offerrdquo explained Spiess-hofer ldquoWhen I was elected by the board of directors I called my mom to tell her and she asked what ABB does We need to be able to relate that in simple termsmdashwe do power and automation for utilities industry transport and infrastructure and we do it globally It also means being a leader in operational asset effective-ness and efficiencyrdquo

About 45 of ABBrsquos business is in industry 35 in utilities and 20 in transportation and infrastructure The largest share of its $415 billion total revenue in 2014 comes from the Asia Middle East and Africa (AMEA) re-gion with 37 while Europe is at 34 and the Americas at 29

Spiesshofer reported that ABB has experienced significant growth in

North America including a 120 in-crease in sales and 125 uptick in em-ployees from 2010 to 2014

More recently Spiesshofer and his executive team have created five value pairs for running the companymdashsafety and integrity customer focus and qual-ity ownership and performance in-novation and speed and collaboration and trust

Innovations for End UsersFollowing the keynote address APW featured hundreds of technical ses-sions and presentations including many by users employing ABBrsquos solu-tions to help their applications thrive

John Dempsey senior vice presi-dent and project director Energy and Chemicals Fluor Enterprises (wwwfluorcom) reported at APWrsquos Chemi-cal Oil and Gas Forum that his com-pany is becoming more of a solutions provider than just a services provider and is executing projects even more ef-

ficiently to help clients handle recent energy price declines Fluorrsquos innova-tion and improvement program is tak-ing good ideas from its 40000 employ-ees running them past more than 70 senior fellows and turning them into higher efficiencies Itrsquos also using third-generation modularization to bring 85 of electrical and 95 of instru-mentation along with piping wiring and testing to completion in module yards instead of in the field Dempsey reports that about 90 of field hours have been moved to the module yard to make equipment plug-and-play on-site which results in quick project turnaround and schedule certainty

To show how electrical and process systems are coming together to achieve performance gains Leandro Monaco ABB global product manager for Sys-tem 800xA electrical integration re-ported on Vale SArsquos (wwwvalecom) huge iron ore mine in Belo Horizonte Brazil ABB and Vale recently devel-oped a remote asset management and predictive maintenance program for Belo Horizontersquos electrical systems which would also improve the minersquos energy efficiency ldquoThe ideal manage-ment of a plant isnrsquot just increasing production but relating that produc-tion to energy consumptionrdquo said Mo-naco ldquoUnfortunately power systems donrsquot get much attention most elec-trical maintenance is corrective and this usually means hours of lost pro-duction Bringing openclose counts trip counts operating current values spring charging times and trip circuit supervision data into an asset manage-ment can help head off problems with-out doing unneeded maintenancerdquo

During a panel discussion on the Internet of Things (IoT) Frank

I n P r o c E s s

Ulrich Spiesshofer ABB CEO discussed a

$10-billion investment in North America

investing Big time

CT1504_28_32_InProcessindd 28 33115 636 PM

Berry process controls group man-ager for Air Products (wwwairprod-uctscom) reported that it began by building its Remote Operations Cen-ter a few years ago and then connect-ing it 247 to hundreds of manufactur-ing facilities ldquoWersquove enjoyed jumping into IoT with both feet and itrsquos been a big game changer for usrdquo said Barry ldquoWersquove gone from polling our plants for data to having them push it to us This has allowed us to mine cyclic and acyclic data create better KPIs and dashboards and do better predictive maintenance Itrsquos hard to spread ex-pert knowledge across all these sites so our remote center allows us to gather data and do condition monitoring Then we can supply our best techni-cal knowledge to all of them instead going site by siterdquo [Editorrsquos note For more complete ABB

APW coverage or to sign up for the Conference Report PDF visit wwwcon-trolglobalcomarticles2015abb-power-world-1]

FDI Specification Developer Tools AvailableThe FieldComm Group (wwwfield-commgrouporg) has announced that the FDI Cooperation LLCrsquos Field Device Integration (FDI) specifica-tion developer tools and common host components are available for automa-tion suppliers to develop products and host systems compatible with FDI The FDI specification is publicly re-leased and available through the Field-Comm Group It was submitted to the

International Electrotechnical Com-mission (IEC) for final approval in the international standardization process and will be included in the emerging IEC 62769 standard which is expected to be approved in the 1Q2015

At the core of the FDI specification is the FDI Device Package that includes everything a host system needs to inte-grate an intelligent device With FDI one FDI Device Package that can scale according to the complexities and re-quirements of each device makes it eas-ier for suppliers to develop and integrate device information and configurations across a wide range of host systems and protocols With the release of the FDI specification developer tools and host components FieldComm Group sup-ports the development of FDI-based devices and host systems

(Continued on page 31)

I n P r o c e s s


I n P r o c e s s

Cashco Inc middot PO Box 6 Ellsworth KS 67439-0006 middot Ph (785) 472-4461 Fax (785) 472-3539

CHEMICAL PROCESSING SOLUTIONSComplete process control for every aspect of your chemical operation

Ph (785) 472-4461 Fax (785) 472-3539

wwwcashco comInnovative Solutions

For immediate access to our product resource files visit

wwwcashcocomchem

The Model 1049 Secure-Gard is a pilot-operated vent valve intended for installation on atmospheric and low-pressure storage tanks vapor recovery systems and process systems

The Model 1078 Vacu-Gard is a pilot-operated valve specifically

designed to reduce blanketing gas losses on low-pressure

storage tanks

The Model 521 is a sliding stem globe style bellows sealed pneumatically actuated control valve designed for maximum corrosion resistance in pure chemical service



storage tanks



storage tanks



CAS-225Aindd 1 11215 956 AM

bull Rotork (wwwrotorkcom) has increased its range of flow

control products and services for the worldwide marine and

offshore industries with the acquisition of Italy-based Masso

Ind spa which manufactures shipboard valve remote con-

trol systems (VRCSs)

bull Endress+Hauser reports it filed for 259 patents in 2014

mainly in its core flow level and analysis measurement tech-

nologies These patent applications came from 337 submis-

sions produced by different Endress+Hauser teams in differ-

ent locations More than 700 of its employees work in RampD

bull Siemens (wwwsiemenscom) plans to build an open-cloud

platform for analyzing large datasets and provide a platform

for data-based services such as Siemens offers for predic-

tive maintenance asset and energy data management The

new cloud platform will use the technologies of the SAP HANA

Cloud Platform

bull Yokogawa Saudi Arabia (wwwyokogawacom) will supply

DCSs for the PP13 and PP14 combined-cycle power plants

that the Saudi Electricity Company (SEC) is building in Ri-

yadh Saudi Arabia PP13 and PP14 plants will each have a

combined net electric output of 1980 MW

bull Flowserve Corp (wwwflowservecom) has been selected

to supply ball-sector control valves ball valves and butterfly

valves for packaging papermaker Klabinrsquos Project Puma mill

in Ortigueira Paranaacute state in southern Brazil Flowserve will

provide more than 1500 rotary control and automated onoff

valves to the Klabin Puma Project including products under

the NAF PMV Atomac and Worcester brands

bull Functional safety certification provider for the process indus-

tries exida (wwwexidacom) has announced the establishment

of a division in Japan called exida Japan to address functional

safety and cybersecurity concerns in the Japanese industry au-

tomation market according to Kaoru Sonoda exida Japanrsquos

managing director

bull Honeywell Process Solutions (HPS wwwhoneywellpro-

cesscom) will handle critical project management and engi-

neering for a third oil and natural gas platform off the southern

coast of Vietnam Hoang Long Joint Operating Co (HLJOC)

will operate the TGT-H5 wellhead platform in the Te Giac

Trang (TGT) field HPS served as the main contractor and

provided control and safety solutions for HLJOCrsquos two other

TGT platforms

Short runS


(Continued from page 29)Developers can now implement and test FDI Device Pack-ages using the FDI Integrated Development Environment (IDE) which will help device manufacturers create FDI Device Packages for Foundation fieldbus HART and Profi-bus devices Host system manufacturers can also implement FDI Host Components for host systems such as device man-agement tools asset management tools or process automa-tion systems

CU-Boulder Invents Simpler Oil-Gas Wastewater TreatmentEngineers at the University of Colorado Boulder (wwwcol-oradoedu) have developed a simplified microbe-powered battery-type process that can remove salts and organic con-taminants from some of the 21 billion barrels of wastewater produced annually by US oil and gas facilities and pro-duce added energy at the same time This process could reuse increasingly costly water in dry areas and reduce the need to inject wastewater into fracking wells

This electrochemical approach called microbial capaci-tive desalination uses the fact that contaminants in oil-gas wastewater contain energy-rich hydrocarbons The microbes in the treatment process eat the hydrocarbons and release their embedded energy which creates a positively charged electrode on one side of the cell and a negatively charged electrode on the othermdashessentially setting up a battery Be-cause salt dissolves into positively and negatively charged ions in water the cell removes the salt in the wastewater by attracting the charged ions onto the high-surface-area elec-trodes where they adhere Not only does this remove the salt from the wastewater but it also creates energy that could be used to run some equipment

ldquoInstead of a traditional battery which uses chemicals to generate the electrical current we use microbes to generate an electrical current that can then be used for desalinationrdquo says Casey Forrestal CU-Boulder postdoctoral researcher who developed the microbial capacitive desalination pro-cess with Zhiyong Jason Ren CU-Boulder associate profes-sor of environmental and sustainability engineering

ldquoThe beauty of the technology is that it tackles two dif-ferent problems in one systemrdquo adds Ren ldquoThe problems

I n P r o c e s s

Look whorsquos talking

MFC5150 Hartreg CoMMuniCator

w w w m e r i a m c o m 2 16 2 8 1 110 0 bull s a l e s m e r i a m c o m

con201412_meriam_hlfindd 1 11182014 15950 PM


become mutually beneficial in our sys-tem and the process produces energy rather than just consuming itrdquo

Ren and Forrestal also worked with researchers Zachary Stoll and Pei Xu at New Mexico State University The study can be found at httppubsrscorgencontentarticlepdf2015ewc4ew00050a

To determine if their technology is viable for oil and gas companies and turn it into a commercial reality Ren and Forrestal have co-founded a company called BioElectric Inc which will seek to demonstrate that their process can scale up to a size that would be useful in the field

CSIA Picks New CEOThe Control System Integrators As-sociation (CSIA wwwcontrolsysorg) announced March 23 that itrsquos selected Joseacute Rivera as its new CEO CSIArsquos ex-ecutive director Bob Lowe is helping Rivera transition into his new role be-fore retiring on June 1

ldquoCSIA has had tremendous growth and impact on the automation indus-try and our future holds even more

potentialrdquo says P C Romano presi-dent of Avid Solutions and CSIA board chairman ldquoIrsquom confident that with Joseacutersquos experience leadership and pas-sion CSIA will seize that opportunity and further increase our impact on the marketplacerdquo

Most recently Rivera served as se-nior vice president of strategy and com-munications for Schneider Electricrsquos industry business in France Previ-ously he worked for 11 years in process automation sales at Emerson Electric in the US UK Germany and Puerto Rico and as a sales engineer at Sie-mens in Costa Rica and Germany

Rivera holds an MBA from the Kel-logg School of Management at North-western University in Evanston Ill and Lic (MS) and BS degrees in elec-trical engineering from the University of Costa Rica

I n P r o c e s s

wwwmustangengcomautomation

We HaveYou Covered

Joseacute Rivera is taking over as CEO of

CSIA

NEw mAN IN tOwN


JUNE 2-4 bull DALLAS TIA2015ORG

EVERYTHING CONNECTEDFrom Digital Oilfields toConnected Cars toSmart Retail and SmartCities TIArsquos Network ofthe Future Conferenceoffers new insights andconnections

HIGHLIGHTSbull Keynote by ATampT SVPof Embedded DevicesChris Penrose

bull oneM2M Showcase andWorkshop highlightingdeployment of the globalinteroperable standard

bull Digital Oilfields sessionfeaturing Keith LarsonVP of Control Design

In the future every business will be digital The Network of the Future is the platform that powers the digital revolution Join us at the TIA 2015 Conference in Dallas from June 2-4 to see whomdashand whatmdashyou will connect to on tomorrowrsquos network

Register now at TIA2015orgSave up to $150 when you register by May 5 2015

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Online Help with Process AnalyzersControlrsquos Monthly Resource Guide

R E S O U R C E S

NESSI ADDS SMARTSThis free PDF is a discussion of how the New SamplingSensor Initiative (NeSSI) Gen 2 and the ANSIISA 760002 standard can be applied to components mounted in traditional tube-and- tting sampling systems to bring the bene ts of greater con -dence in reported analyzer values bet-ter reliability for process measurements and lower total cost of ownership Itrsquos available at wwwindustryusasiemenscomautomationusenprocess-instru-mentation-and-analyticsprocess-ana-lyticsDocumentsSample-Condition-ing-chem-processinpdf

SIEMENS INDUS TRY800854-1993 w w wf luidcomponentscom

GIMME SHELTER Author Ian Verhappen says that just as we often overlook the infrastruc-ture necessary to support other eld instruments the same happens to the protection of the analyzer systemmdashthe shelter and its design But design-ing a suitable process analyzer shel-ter even for a complex system does not have to be an intimidating task Then he follows up with a discus-sion of design considerations when to use a case cabinet shelter or house for your equipment designing the air exchange system choosing the proper location maintenance dead zones re detection and more The direct link to the article is wwwcontrol-globalcomarticles2012verhappen-gimme-shelterstart=0

CONTROLGLOBALw w wcontrolglobal com

GET YOUR SAMPLES HEREThe book Industrial Sampling Sys-tems offers in-depth analytical instru-

mentation material suited for anyone from a novice to a degreed engineer Written by industry veteran Tony Wa-ters it has more than 750 pages of ma-terial that balances theory and prac-tical examples making it useful to students as well as experienced engi-neers designers and technicians The book also provides readers with a sam-pling of information featured in Swa-gelokrsquos 40-hour complementary pro-cess analyzer sampling system (PASS) training classes It has more than 1000 photos drawings and tables a symbols library examples that illustrate calcu-lations and how to apply equations self-assessment questions and a glos-sary of terms It is available for sale at wwwindustrial-sampling-systemscom or through Swagelok dealers

SWAGELOKw w wswagelok com

PROCESS ANALYTICS DINOSAURSThis PowerPoint is a summary of a presentation from the 2010 ISA Au-tomation Week conference It out-lines in detail the problems with current process analyzer systems suggests some solutions to improve the usability ef ciency and cost-ef-fectiveness of process analytical sys-tems and argues for a change in ap-proaches to keep the techniques from becoming extinct The direct link is at httpdeptswashingtoneducpacActivitiesMeetingsFall2010docu-mentsDuboisetalCPACdinosaurs-Nov2b2010pdf

UNIVERSIT Y OF WASHINGTONw w wwashing tonedu

INFERENTIAL ANALYSISThe most important process variable on the process ow diagram (PFD)

is often the process composition Yet the installed and maintenance costs of analyzers have precluded their widespread use Analyzers are typi-cally only used in equipment and on a stream where the composition has been both problematic and essential for product quality Often overlooked are the process analysis and optimiza-tion opportunities afforded by more extensive use of online composition measurements Greg McMillan and Pierce Wu explain how inferential analysis can eliminate the delays limitations failures and expense of analyzers The direct link is at wwwcontrolglobalcomarticles2014in-ferential-analysis-can-save-process-analyer-costs


PICK MEAutomation expert Beacutela Liptaacutek offers succinct advice on picking the cor-rect process analyzer for your process He presents 10 logical steps to take to clarify your analyzer needs The article also links to a detailed chart of process analyzer criteria that should help with your selection The direct link is wwwcontrolglobalcomarticles2014how-to-select-an-analyzer


Time

Proc

ess

Vari

able

IntegratingRunawayDead time self-regulatingLag self regulating


If you know of any tools and resources we didnrsquot include send them to ControlMagazinePutmannet with ldquoResourcerdquo in the subject line and wersquoll add them to the website

CT1504_34_Resourcesindd 34 33115 240 PM

What was less surprising was the fact that the IceStation - along with the computer and monitor inside it

remained completely unharmed All ITSENCLOSURES are constructed out of 14-gauge steel and built to last

forever and a day Should one of our enclosures ever actually fail due to manufacturer defect we will replace it

as fast as humanly possible so your business does not skip a beat Built to meet NEMA 12 standards IceStation

TITAN protects computer systems from harmful dust dirt and splashing fluids With a large viewing window

designed to accommodate up to 24rdquo wide screen monitors a retractable keyboard drawer oversized work

surface and a track record of 29 years of experience protecting electronics ITSENCLOSURES is the one name

you can trust To learn more about IceStation TITAN call 18004239911 or visit ITSENCLOSUREScom

When an overhead crane accidentally dropped a steel pipe 15 feet onto an IceStation workers were relieved to find the pipe had not been damaged

TRUE STORY

25

ITS14_TITAN_7875x105indd 1 21914 1005 AMCT1504_full page adsindd 35 33115 1219 PM

CT1504_36_43_CSindd 36 33115 357 PM

C o n t r o l i n e x t r e m e e n v i r o n m e n t s

A utomation and instrumentation components and systems must of-ten be installed in areas classified

as hazardous according to IEC or NEC These projects present design installa-tion and maintenance challenges

For all such installations there are four main options (see table) explosion-proof intrinsically safe non-incendive or purged Each has its advantages and drawbacks and many installations are best served by combining two or more

Perhaps the newest development in hazardous-area installation is more wide-spread use of the non-incendive or non-sparking approach which requires AEx nA-rated components ldquoWersquore seeing nu-merous installations using AEx nA (non-sparking equipment) located in Zone 2 areas in relation to remote IO and re-mote PLC installationsrdquo says David Dalke discipline technical authority for systems and networks Wood Group Mus-tang (wwwwoodgroupcom) ldquoThe big-gest issue with this type of installation is making sure internal components are cer-tified for this protection in the enclosurerdquo Wood Group Mustang uses various compliance approaches (See ldquoMaintenance and Engineering Considerationsrdquo sidebar)

explosion-Proof relies on Brute strengthThis is the oldest most familiar and simplest method of protection ldquoAn explosion-proof housing is designed to pre-vent combustible gases or dust from coming in contact with internally mounted components that produce energyrdquo ex-plains Len Laskowski principal technical SIS consultant

Emerson Process Management (wwwemersonprocesscom) ldquoIf enough en-ergy is present and an explosion occurs the housing is designed to contain it to prevent further explosions in the areardquo

Because itrsquos been around so long there are many components available with explosion-proof housings and rat-ings However housings can get large and expensive extreme care must be taken during installation and ongoing maintenance is required

Derek Sackett marketing special-ist Phoenix Contact (wwwphoenix-concom) adds the main advantages of explosion-proof or explosion-contain-ment technology are their ability to use higher-powered devices in enclosures and higher-powered end devices ldquoAlso at least in the US end users seem to be more familiar and comfortable with installation requirementsrdquo he notes

One of the disadvantages he says is maintenance difficulty ldquoOpening an EX enclosure or device isnrsquot permitted without shutting down power to con-tained circuitsmdashcomplicating trouble-

shooting maintenance and inspection Because EX-proofcontainment is based on the enclosuresrsquo mechanical integ-rity periodic inspections are needed Maintenance person-nel and technicians also must be trained on requirementsrdquo

Under ATEX and IECEx rules EX-Proofcontainment technology isnrsquot viewed as safe enough for Zone 0 areas

Likewise Neal Cammy engineering manager at BLAC (wwwblacinccom) which builds severe-service electro-hydraulic linear valve actuators reports ldquoBLACrsquos electro-


Figure 1 A redundant linear position

sensor is mounted externally on a valve

actuator At the top of the photo is the

explosion-proof electronics housing and

at the bottom is the target marker that

tracks valve actuator position

HigH Power CAlls for HArd CAse

Bal

luff

wHiCH APProACH is Best for YouCharacteristic Explosion-Proof Intrinsically Safe Non-Incendive Purged

Component cost High Medium Low Medium

Design cost Medium High requires engineering Medium Low

Installation cost High Low Low Medium

Operating cost None None None High requires airor inert gas

Required maintenance High Low Low Medium

Ease of maintenance Difficult becauseof sealed cabinets Easy Easy Difficult because

of purged cabinets

Zone 0 acceptability No Yes No No

Availability of components High Low Medium High

Acceptance in process industries High High Medium High

CT1504_36_43_CSindd 37 33115 357 PM


hydraulic actuators are mainly used in oil refinery appli-cations such as controlling reactor product temperatures India requires the equivalent of ATEX Zone 2 IIb certifica-tion for hazardous areas so at an FCC unit in India we use Balluff explosion-proof linear position sensors (Figure 1)rdquo

intrinsic safety Considered safestThis method is generally considered the safest because itrsquos the only one accepted for use in IEC Zone 0 and is ac-cepted in all other classified areas ldquoIntrinsic safety is based on limiting energy to a level below that required to ignite hazardous gas or dustrdquo says Robert Schosker product man-ager and team lead for process automation Pepperl+Fuchs (wwwpepperl-fuchscom) ldquoThe energy limitation also per-tains to thermal energy So in normal operation or during a fault no sparks or thermal effects may occur that could ig-nite a potentially explosive atmosphererdquo (Figure 2)

Charlie Norz product manager Wago (wwwwagocom) adds ldquoIntrinsically safe IO modules provide users with all the benefits of a modern fieldbus technology The modules combine digital and analog IO with intrinsically safe barri-


System integrator Wood Group Mustang (wwwwoodgroup

com) in Houston Texas uses all types of hazardous area pro-

tection methods depending on the installation environment

and other factors David Dalke systems and networks expert

at Wood Group Mustang explains some of the considerations

First explosion-proof housings can be a maintenance prob-

lem ldquoMaintenance is an issue as the housing needs to remain

in good working order to function properlyrdquo he notes ldquoThe ac-

tual integrity of protection of explosion-proof housings is a real

soft spot as human factors increase the risk of bolts being lost

or not properly reinstalled following maintenancerdquo

Maintenance is also needed for purging ldquoA key strength of

purged systems is improved accessibility for periodic mainte-

nance but principal problems of purged enclosures are the

cleanliness and moisture content of the purge gas sourcemdashand

monitoring maintenance and testing of the cabinet supervisory

alarmsrdquo Dalke explains

Filter systems for the purge-gas supplies also need routine

inspection and maintenance ldquoIn some facilities where inert

purge gases other than air is used (typically nitrogen) additional

safety considerations labeling and potentially monitoring may

be required depending on the size of the cabinet its location

and the capacity of the purge supply especially if the cabinets

are located inside buildings or sheltersrdquo says Dalke ldquoVirtually

every one of our clients has had some sort of purging and al-

most all our North American projects use explosion-proof hous-

ings on transmitter installationsrdquo

Most of the time Wood Group Mustangrsquos Automation Group

installs purge boxes in classified areas or all the components

are rated to be within the classified area

ldquoWhile intrinsically safe (IS) systems donrsquot require as much main-

tenance theyrsquore difficult to design Added space for the barriers

and separation is required and engineering is needed to perform

IS calculations to confirm they meet intrinsically safe installation re-

quirementsrdquo Dalke adds ldquoPassive barriers can cause a significant

voltage drop if not designed properly and require a low-impedance

ground system Lifecycle inspection and verification are needed to

assure the integrity of the protection systemrdquo

At a chemical plant on the US Gulf Coast the facility stan-

dard was to use non-incendive protection in Class I Div 2 ar-

eas and explosion-proof solutions in Class I Div 1 However

for a truck and rail-loading overflow protection system require-

ments for a lightweight easy-to-manipulate overfill protection

system led the plant to install lower-cost IS level-sensing sys-

tems Dalke reports that use of IS design also enabled improved

integrity of protection in the Div 1 area where the sensor cable

was subject to mechanical abuse with frequent connecting and

disconnecting of the loading arm and railtank car connections

Maintenance and engineering considerations

Wood Group Mustang uses all four protection methodologies

for installing automation systems in hazardous areas such as this

natural gas plant

gas Plant Uses all the tools

Pent

air

Ho

ffman

Figure 2 Intrinsic safety barriers are used to limit the amount of

electrical energy delivered to devices in hazardous areas

Barrier

Intrinsic safety i example Ex iaDivisions 1 2 Zones 0 1 2

VR

IscIo

+VocUo-

Cable

L

C

Hazardous area

3x

no sPark no Fire

Pep

pe

rl+Fu

chs

CT1504_36_43_CSindd 38 33115 357 PM



ers making it easy to engineer and it reduces wiring costsrdquoOne of its brewery customers used Wagorsquos standard and

intrinsically safe (IS) IO modules to optimize operation of its fermentation stage (Figure 3) ldquoThe application used a wall to separate the hazardous and non-hazardous locations The customer mounted our intrinsically safe digital input modules in a non-hazardous location and intrinsically safe sensors and actuators located in the hazardous area were wired directly to these IO modulesrdquo

The main drawback of IS is the limited availability of components because those requiring power above 300 mA at 24 Vdc canrsquot be made intrinsically safe Another drawback is the time required to design an IS system because complex entity parameters and calculations are required

Kelli Malloy leader US process automation Turck (wwwturckcom) says intrinsic safety is gaining popularity in the US and is accepted worldwide in part because itrsquos considered safest for classified areas ldquoInstallation costs are considerably less than explosion-proof enclosures and the ability to install it in an instrument tray even in Class I Div 1 areas is a huge cost savingsrdquo Malloy says

Mike Bond senior program manager at Optimation

(wwwoptimationus) agrees ldquoI think the US uses IS just as much as Europe doesrdquo he says ldquoMy observation is that there are more cord connections to IS devices in Europe whereas the US still prefers conduit systemsrdquo (See ldquoOpti-mation Opts for Dual Protectionrdquo sidebar)

non-incendive Allows Higher PowerNon-incendive is similar to intrinsic safety as both methods limit the energy released to a level insufficient to cause igni-tion of the surrounding atmosphere However a much wider range of components is available with non-incendive rat-ings as compared to IS certification including variable-fre-quency drives (VFDs) rated up 100 hp On the other hand this method isnrsquot suitable for Zone 0 as intrinsic safety is

ldquoNon-incendive installations have gained popularity espe-cially with digital bus technologies because theyrsquore inexpen-sive to installrdquo says Malloy ldquoEase of installation using quick disconnects and junctioning expandability and low equip-ment cost are a huge benefit to users Bus technologies and non-incendive installations are often done in instrument trays rather than conduit another cost savings

ldquoThere are two drawbacks to this technology First in-


Optimation (wwwoptimationus) a systems integrator in

Houston Texas designs and installs automation systems for

process plants and also builds process skids

On a recent acid purification skid the automation systems

had to meet Class I Div 1 requirements After a chemical pre-

treatment step was completed on the skid the system runs

automatically to create purified acid minimizing human inter-

action with the process

ldquoThe fluids recovered from the production process are very

corrosive and can eat through stainless steel so this skid was

fabricated with specialized materialsrdquo says Dan Curry man-

ager of automation and integration at Optimation ldquoThe fluids

are also flammable so the electrical systems had to be de-

signed to meet electrical hazard classificationsrdquo

In addition the immediate area around the skid is Class

I Div 1 and at a distance from the skid the classification

changes to Class I Div 2

ldquoA combination of explosion-proof wiring and intrinsically

safe barriers was usedrdquo explains Curry ldquoSome pumps are

powered by air rather than electricity and some valves were

controlled pneumatically rather than with electrical signals

The IPs and solenoid valves were installed outside the clas-

sified areasrdquo

The combination of explosion-proof wiring and intrinsically

safe barriers was necessary because IS barriers can only

be used for low-voltage applications and the skid had some

high-voltage pump controls ldquoIS systems are generally always

24 Vdcrdquo notes Curry ldquoIrsquom not aware of any 120-Vac IS barriers

due to the available power level being too high and power to

the pump motors is in excess of IS limits

Cost was analyzed for each component to determine which

could accomplish safe operation while staying within budget

and the combination of explosion-proof wiring and intrinsically

safe barriers proved to be workable and affordable

OptimatiOn Opts fOr Dual prOtectiOn

Combining explosion-proof and intrinsic safety methods allows

this acid recovery skid to meet the Class I Div 1 requirements of

highly corrosive and flammable fluids

cOmbO puts safety On skiDs

Op

timat

ion

CT1504_36_43_CSindd 40 33115 358 PM

visibly better

2401 Experion Orion SCADAmdashPrint Ad Trim 200mm x 265mm Bleed 2064mm x 270mm

80 Confi guration Time Reduction Experionreg SCADA radically simplifi es confi guration over thousands of assets

and provides operational effi ciency with a superior human-machine interface

This highly scalable integrated multi-server system provides state-of-the-art

user interaction with pan and zoom displays dashboard style presentation

and task-based fi lters to focus attention on whatrsquos important Combined with

Honeywellrsquos RTU2020 equipment-based templating and display simplifi es

management of upstream oil and gas assets and reduces monitoring and

diagnostics from hours to minutes

copy2015 Honeywell International Inc All rights reserved

wwwhwllcoc3hz


C O N T R O L I N E X T R E M E E N V I R O N M E N T S

terpreting the electrical code and FM requirements can be confusing because of ambiguity in the language and poten-tial for misinterpretation Second non-incendive installa-tions donrsquot account for abnormal conditions and this can

cause users consternation if plant standards require multiple layers of protection However the methodology is safe and has been used widely in Class I Div 2 installationsrdquo

Vacon (wwwvaconcom) provides non-incendive VFDs that have UL approvals for installation in Class I II and III Div 2 hazardous locations Its Vacon X5 HazLo drive was used in a Class I Div 2 location instead of an explosion-proof enclosure providing a 66 weight reduction and a 35 cost reduction (Figure 4)

When in Doubt PurgePurged enclosures are continuously supplied with clean in-strument air or an inert gas either of which wonrsquot allow ig-nition to occur when combined with the energy emitted by the components within the enclosure

ldquoPurged enclosures allow for use of higher powered de-vices and also devices that donrsquot have or couldnrsquot get proper approval for use within a hazardous area but purging does add cost to the enclosure system A source of clean instru-ment air or an inert gas is required and hot permits are re-quired to open the enclosurerdquo explains Sackett ldquoUsing de-vices with no extra approvals for hazardous areas can keep costs down Also lling the internal area of the enclosure

Engineered to Order with Off-the-Shelf SpeedEngineered to Order with Off-the-Shelf Speed

sorinccom

with Solid-State Switch Output

815DT815DT815DTSmart Differential Pressure Transmitter

bull HARTreg7 communication protocolbull Modbus RTU (RS-485) serial communicationsbull 4-20mA and 1-5 VDC outputsbull plusmn010 (URL) continuous output accuracybull lt70 ms response timebull Reverse polarity and EMC protectionbull 316SS housing hermetically sealed leadsbull Stainless steel sensor no o-ringbull FM and ATEX certifications pendingbull Dual Seal approval pendingbull 3 year warranty

The rugged loop-powered SORreg 815DT smart pressure transmitter provides ldquoset it and forget itrdquo dependability in mid and upstream oil and gas production power generation chemical and petro-chemical applications

bull HARTbull Modbus RTU (RS-485) serial communicationsbull 4-20mA and 1-5 VDC outputsbull plusmn010 (URL) continuous output accuracybull ltbull Reverse polarity and EMC protectionbull 316SS housing hermetically sealed leadsbull Stainless steel sensor no o-ringbull FM and ATEX certifications pendingbull Dual Seal approval pendingbullbull 3 year warranty3 year warranty

The rugged loop-powered SORpressure transmitter provides ldquoset it and forget itrdquo dependability in mid and upstream oil and gas production power generation chemical and petro-chemical applications

Figure 3 This brewery uses intrinsically safe IO modules

installed in a non-hazardous location connected to sensors and

actuators located in the hazardous area

Diagram 1

Non-hazardous area

Wago IO 750-439

Hazardousarea

Onoffswitch

Fermentationtank

Limit switch

Brewery fermentation processNot to scale

Wall

IS WORKS THROUGH WALLS

Wag

o

CT1504_36_43_CSindd 42 33115 358 PM


with either clean instrument air or a clean inert gas has the two-fold effect of increasing the lifetime of electrical com-ponents and preventing an explosion by isolating the elec-trical components from the corrosive hazardous materialrdquo

Purged enclosures often house HMI displays Louis Szabo business development manager at Pepperl+Fuchs notes that one of its customers had older display systems in Class I Div 1 areas that were beginning to fail and the origi-nal supplier had long since gone out of business ldquoP+F in-stalled its Div 2-certified KVM display to replace the old HMI This certification is important as non-certified equip-ment will not get past the safety inspectors risk assessment personnel and insurance underwritersrdquo says Szabo

Wireless Avoids issuesIan McDonald wireless solution architect at Emerson Process Management points out that wireless can allevi-ate many problems and costs in hazardous areas ldquoWire-lessHART devices certified to the relevant protection level can reduce equipment installed in a hazardous area such as the wiring and supporting infrastructure needed with a traditional wired installationrdquo he explains ldquoWirelessHART process transmitters are battery-powered which eliminates

the need for power wiring and battery power is safe for use in most hazardous areasrdquo

Dan Heber t is Control rsquos senior technical edi tor

Automating functions Simplifying operationsModernizing protection

Bebco EPSreg 5500 Series

Advanced high-end Zone 2 Div 2 purge system Automatic systems for alarm purging and power to the enclosure Programming and temperature control with leakage compensation

wwwpepperl-fuchscompurge

Figure 4 This Vacon X5 HazLo non-incendive AC variable-fre-

quency drive (VFD) is being used to control the flow rate of an

oil pump on a system designed to capture wellhead produc-

tion rates in an outdoor Class I Div 2 environment

Motor Drive Wonrsquot BloW

Vac

on

CT1504_36_43_CSindd 43 33115 359 PM

15-0288_DCDC Power_7875x105indd 1 3172015 12055 PMCT1504_full page adsindd 44 33115 1220 PM

s u p e r v i s o r y c o n t r o l

T he downside of being responsible for everything is obvi-ousmdasheven more so when jobs and jurisdictions swell in size and scope However just like responsible parents

plant operators and their supervisory control systems donrsquot walk away from their duties when stressed or tired out

Luckily just as moms and dads are spelled by relatives babysitters and daycare providers better supervisory control and data acquisition (SCADA) tools are arriving to help us-ers and supervisory systems cope even as they take on new and bigger jobs And as usual wireless tablet PCs and the cloud are getting in on the act

For instance Solvay Chemicalsrsquo (wwwsolvaychemicalscom) trona ore mine and refinery in Green River Wyoming recently migrated from Yokogawa Corp of Americarsquos Cen-tum CS3000 distributed control system (DCS) to its new Centum VP-R5 control system and updated 21 field con-trollers and numerous other support components Trona ore contains sodium sesquicarbonate a relatively rare sodium-rich mineral thatrsquos used to make soda ash Solvay mines about 11000 tons of ore per day from the mine which is refined into about 6000 tons of pure trona

Solvayrsquos control system at Green River has about 7000 indi-vidual hardwired IO points and about 3000 communication IO points for its SCADA system PLCs Honeywell FSC sys-tem and other packages Its controls cover processes that are up to 20 miles apart and its Yokogawa system resources include two domains 21 reconfigurable IO (RIO) and field-network IO (FIO) field control stations 17 operator stations six engi-neering stations and eight different plant servers (Figure 1)

ldquoWe had to upgrade because our Microsoft Windows XP components were no longer supported in 2014 and so their costs were going to go way uprdquo says Kevin Kelley process control foreman at Solvay Chemicals ldquoWe were scheduled

for a five-year total plant outage and we needed update our RIO field control stations with new templates and offline downloads that had never been done since they were ini-tially installed We also needed to upgrade our system secu-rity to meet Solvayrsquos overall corporate IT standardsrdquo

streamlining scADABesides installing servers cabinets control room equipment and other VP-R5 components that were much less cluttered than their CS3000 counterparts Kelley adds that some of Solvayrsquos staff traveled to Yokogawarsquos Houston office for Cen-tum VP graphics evaluation and training They determined what their new graphics would look like and evaluated Sol-vayrsquos existing CS3000 database of over 350 graphics to make sure it would cut over to VPrsquos graphics

ldquoWith our short cutover timeframe it was important to maximize our time to do the offline downloads and oper-ator station replacementsrdquo reports Kelley ldquoThis meant we needed all the infrastructure in place as much as possible when Yokogawa arrivedrdquo

The upgradersquos three main phases included pre-loading and staging workstations in new cabinets cutting over by down-loading software to field control stations and running reports to compare changes to block nodes and upgrading and verifying that Green Riverrsquos OPC server was up and gathering data in its AspenTech plant historian

ldquoFinally our operator and engineering stations were changed out liverdquo adds Kelley ldquoWe changed out one station at a time until each area had one VP station and one CS sta-tion This gave the operators time to get accustomed to the new stations It worked well

ldquoFor the total upgrade we experienced no loss of produc-tion and the plant came back online without any problems


Todayrsquos SCADA systems are easier to deploy and

operate which is good because theyrsquore being

called on to manage ever larger and more

widely distributed process applications

by J im Montague

CT1504_45_48_Feat2indd 45 33115 240 PM

S U P E R V I S O R Y C O N T R O L

About one month after the outage and cutover a Yokogawa engineer returned to the site to do a follow-up This gave us an opportunity to ask questions about VP-R5 and to tie up any loose ends Next wersquore undertaking a project to convert

our graphics from the old 1990s style graphics to more high-performance alarm-oriented graphicsrdquo

Strengthening Outsize InfrastructuresBesides assisting plant operations improved SCADA sys-tems can also meet the needs of more geographically dis-tributed process applications Following Hurricane Katrina in 2005 the US Army Corps of Engineers started building the $1-billion Gulf Intercoastal WaterwayndashWest Closure Complex (GIWW-WCC) to protect three parishes in the New Orleans District with levees oodwalls water control structures navi-gable oodgate foreshore protection dredged material envi-ronmental stewardship and the largest US drainage pumping station (Figure 2) When the oodgate closes during a storm this pumping station must evacuate rainwater pumped to it from other stations To handle a 100-year storm surge original speci cations called for 11 5500-hp pumps capable of moving nearly 20000 cubic feet of water per second

As a result GIWW-WCC needed a reliable and secure SCADA system before its scheduled completion in 2013 so the corps worked with system integrator Prime Controls (wwwprime-controlscom) and consultant Arcadis (wwwarcadis-uscom) to implement a redundant Integrated Ar-

Interface Level

Product Level

Temperature

3 - in - 1M E A S U R E M E N T

Measure more with less3-in-1 Measurement - measure more process variables with less hassle by using a single instrument to measure up to three different process variables MTS provides the ability to measure the product level interface level and multipoint temperature in a tank from a single level instrument

The Measureable Difference

MTS Systems Corporation Sensors Division bull 3001 Sheldon Drive Cary NC bull Tel 800-633-7609 bull wwwmtssensorscom bull infousmtssensorscom

Level Plusreg

Liquid Level Transmitters

Figure 1 Solvay Chemicalsrsquo Green River trona ore mine in

Wyoming recently migrated from Yokogawarsquos Centum CS3000

DCS to its Centum VP-R5 control system and updated 21 eld

controllers and support devices

OVERSEEING ORE

Yoko

gaw

a an

d S

olv

ay

CT1504_45_48_Feat2indd 46 33115 240 PM


chitecture platform from Rockwell Automation (wwwrock-wellautomationcom) which includes Allen-Bradley Con-trolLogix PACs and FactoryTalk View SE visualization software running on a redundant Ethernet ring network Al-len-Bradley CompactLogix PLCs manage the fuel delivery and return systemrsquos distributed IO

ldquoThe critical nature of the pump stations requires re-dundancy in every systemrdquo says Gary McNiel senior vice president at Prime Controls ldquoHot-standby dual Control-Logix controllers and hot-standby SCADA servers supply the backup We chose FactoryTalk View because it provides monitoring control graphics reporting and data loggingrdquo

The resulting SCADA solution supplies all data needed to operate GIWW-WCCrsquos pumping stations including pump engine electrical generator and water-level data from the in-take and discharge areas It also monitors the pumprsquos die-sel fuel levels and incorporates weather information and closed-circuit television (CCTV) surveillance for security Also the same SCADA system controls the sector gates that regulate the water level across the navigational waterway

More recently when Hurricane Isaac and its 12-foot storm surge arrived in 2012 GIWW-WCC successfully protected much of New Orleans

ldquoWi-Fi and iPads arenrsquot new for many users but theyrsquore very new for operators in many water treatment plants and other process applications To them getting process data from

Foxboro measurement devices offer you reliable accurate safe and efficient process control no matter what you need to control mdash flow rate temperature pressure levels and more Along with valve positioners that offer the highest accuracy in the industry

With more than 200 years of combined experience Foxboro ensures that your

plant will operate with maximum safety and efficiency And your finished products will emerge with impeccable quality

Robust field-proven performance in the most demanding environments Precision measurement and control for the most exacting process management Thatrsquos the promise of Foxboro

Learn more by calling your Foxboro representative at Schneider Electric today Phone 866-746-6477 Or visit us online at wwwfielddevicesfoxborocom

The one name for all the control in your plantFoxboro

Flow bull Temperature bull Pressure bull Level

Figure 2 The GIWW-WCC protects three New Orleans parishes

from ooding includes the largest drainage pumping station in

the US and uses Rockwell Automationrsquos hot-standby SCADA

servers and dual hot-standby ControlLogix PLCs for redun-

dancy as well as FactoryTalkView SE software for monitoring

control data logging and reporting

SCADA FOR STORM SURGES

US

Arm

y C

orp

s o

f Eng

ine

ers

and

R

ock

we

ll A

uto

mat

ion

CT1504_45_48_Feat2indd 47 33115 240 PM


a smart phone is still Star Trek stuffrdquo says Dennis Wylie product manager for ControlLogix at Rockwell Automa-tion ldquoHowever tablet PCs and smart phones are available so they need en-abling technology Security is the key so SCADA has been evolving Wersquore adding more and faster embedded com-munication throughputs new ways to

handle IO data enhanced diagnostics and more security This means we can identify whatrsquos happening know whatrsquos wrong and take action soonerrdquo

Green and the cloudBeyond managing operations and in-frastructures some supervisory control solutions are spreading their wings to

help out with sustainability in their ap-plications and even using cloud-based data processing services to do it

For example Sofidel (wwwsofidelit) reports it recently needed to up-grade automation at its Deacutelipapier plant in Frouard France It decided to work with Metso (httpmetsocom) to virtualize the DCS and quality control system (QCS) on its Tissue Machine 1 to reduce computer hardware needed by the upgrade and reduce the cost of maintaining multiple operating plat-forms at the mill

Virtualization allows the tissue ma-chinersquos computer hardware to be sepa-rated from the software by creating vir-tual machines (VMs) in a host server to provide a more fault-tolerant and stable environment Fabrizio Lapucci Sofi-delrsquos corporate automation manager reports its upgrade at Deacutelipapier is the worldrsquos first virtual process and quality control system on a tissue machine

ldquoAn added advantage is that the serv-ers are now located in a clean and con-trolled environment which will maxi-mize their service liferdquo adds Lapucci

To improve process visibility new tools on Tissue Machine 1 include Metsorsquos DNA Historian software which collects process data includ-ing measurements setpoints control-ler outputs device status motor starts alarms and operation tracking and sends them to the history database

ldquoWe have immediate access to de-tails about a problem whether it oc-curred at the weekend or six months agordquo adds Stephane Bonnet Deacutelipa-pierrsquos production manager ldquoWe use it to improve the process Recently during a problematic color change it made it easy to see that a small mistake had been made with consistency and in the future wersquoll be able to avoid it Previously this problem with a con-sistency setpoint would not have been seen Improvements like this have a big impact on productionrdquo

Jim Montague is Control rsquos execut ive edi tor

Graphic HMIs Achieve Control Today

What does your machine control Whether requirements lie in control automation food and beverage or packaging Maple Systems Graphic HMIs streamline your process and reveal new possibilities

What are you waiting for

wwwmaplesystemscom

4257453229Call Today to Learn More

CT1504_45_48_Feat2indd 48 33115 241 PM

T E M P E R A T U R E

Innovative controls accessories software and other techniques are enabling temperature instruments

to reach in and help optimize many previously inaccessible

applications Herersquos how by Jim Montague

Not much seems to change on the temperature front Thermodynamics follow physical laws after all and not guidelines or suggestions Processes get hot and cold

and theyrsquore measured by thermocouples RTDs thermistors and other instruments just as theyrsquove been for decades

Whatrsquos different and evolving quickly are all the com-ponents controls software and other enhanced methods surrounding the basic roots of temperature measurement These devices are allowing more and better temperature sensing and data acquisition in many locations that used to be inaccessible and theyrsquore gathering and organizing that information for better archiving analysis and eventual pro-cess optimization than was possible before So just like pres-sure ow and other immutable process variables tempera-ture isnrsquot changing but the world around it sure is

Smart Heat SavesFor instance Hydro Aluminum (wwwhydrocom) in Aringrdal Norway recently sought to adopt low-temperature Oxyfuel burner technology to increase its cold-metal melting capac-ity and save energy so it worked with Linde Gas (wwwlinde-gascom) and Eurotherm by Schneider Electric (wwweuro-thermcom) to provide an intelligent burner control system for four aluminum furnaces in its cast house (Figure 1) In general Oxyfuel increases thermal ef ciency because its furnace gases donrsquot contain nitrogen like air does so its radi-ant heat transfer is more ef cient and its exhaust gas volume and heat loss are reduced

Hydro Aringrdal produces more than 125000 tons of foundry alloys per year and Oxyfuel combustion in its four furnaces

is managed by Eurothermrsquos Foxboro T2550 process automa-tion controller a safety PLC to comply with regulations and an HMI which operate in conjunction Lindersquos Gas Oxyfuel burners As expected Hydro reports it can replace 20000 tonnes of liquid primary aluminum by remelting cold metal Previously the charge mix was 8 tonnes cold and 22 tonnes liquid metal and now the mix is 13 tonnes cold and 17 tonnes liquid metal As a result Oxyfuel helped the two pri-mary foundry alloy production lines at Hydro Aringrdal achieve a 60 increase in remelting capacity a 50 reduction in fuel consumption a cut in CO2 and NOX emissions and a reduction of waste dross to less than 2

ldquoBy using low-temperature Oxyfuel we can melt 50 more cold aluminum in the same amount of time as we did previ-ouslyrdquo says Wenche Eldegard cast house manager at Hydro Aringrdal ldquoIn addition our propane consumption and CO2 emis-sions have been halvedrdquo

Controls Optimize Acid Cook Biomass Just like a chef perfecting a recipe todayrsquos controls can sur-pass babysitting their temperature instruments and applica-tions by analyzing data reducing variability and improving their processes and the quality of their products

For example Sterling Chemicals (wwweastmancom) in Texas City Texas produces acetic acid by reacting carbon monoxide and methanol with a catalyst and then purify-ing it in a distillation train (Figure 2) Greater ef ciency was possible with a better catalyst but this decreased reac-tor temperature control stability and the PID-based controls couldnrsquot prevent temperature excursions during upsets


Temperature Sticks Its Neck Out

CT1504_49_51_Feat3indd 49 33115 400 PM


To better control reactor temperature despite the interac-tion of feed heat-reducing effluent and recycle flows Ster-lingrsquos engineers implemented a QuickStudy adaptive process controller which was first used to create temperaturereac-tor disturbance variable models from off-line historical data and was then put in simulate mode to learn how well the models could predict reactor temperature using more pro-duction data QuickStudy is built and integrated by Adap-tive Resources (httpadaptiveresourcescom) Correlation between predicted and actual temperature was good and steady-state gains from QuickStudy were similar to those in a calibrated unit model

Next the reactorrsquos PID temperature controller was re-placed by a QuickStudy predictive controller setup (PCS) block which manipulated the existing boiler pressure con-troller The dynamic models developed earlier were loaded and then the QuickStudy block was placed in control after a short online learning period Improvements in temperature stability appeared within hours as QuickStudy refined its in-ternal models and disturbances that would normally have caused upsets were attenuated The whole process was car-ried out in two days without the need for bump tests

ldquoQuickStudy reduced variation in the acetic acid reactor temperature and increased throughput by more than 5rdquo says Trevor Arnold senior process control engineer at Ster-ling Other benefits included reducing Sterlingrsquos tempera-ture standard deviation from 36 to 08 eliminating high-temperature trips and stabilizing purification columns

Similarly GranBio Investimentos SA (wwwgranbiocombr) in Sao Paulo Brazil recently built its Bioflex 1 second-generation ethanol plant in Alagoas Brazil to produce in-expensive clean-burning biofuel from readily available

biomass The facility started operations in early 2014 can produce about 82 million liters of biofuel per year and relies on Yokogawa Electric Corprsquos (wwwwyokogawacom) Cen-tum VP integrated production control system csTuner con-trol loop tuning software and Centum VP Batch software They manage Bioflex 1rsquos pretreatment enzymatic hydroly-sis fermentation and distillation separation units field in-struments including Foundation fieldbus Admag AXF mag-netic flowmeters DPharp FJA series pressuredifferential pressure transmitters and control valves and Plant Resource Manager (PRM) asset management software

During the pretreatment process agricultural materials and waste from energy cane bagasse and straw must be care-fully cooked at steady temperatures to break down the cellu-lose in their cell walls and remove polymers like hemicellu-lose and lignin This is necessary before the pretreated fibers are further broken down using enzymes to obtain double glucose and single glucose which is then fermented by mi-crobes to produce ethanol

Pretreatment and fermentation settings are preconfigured in Centum VP Batch and then automatically downloaded to and executed by individual controllers depending on which recipe the operators select based on which raw materials need to be processed All-in-one HMIs with ergonomically de-signed process graphics show production trends alarm sum-maries control information and performance data for each completed batch Also because many of Bioflex 1rsquos nearly 2000 IO points are exposed to high-temperature processes and are mounted in high narrow or difficult-to-access loca-tions the plantrsquos PRM allows their status and health to be


Figure 1 Hydro Aluminum adopted low-temperature Oxyfuel

technology with help from Eurothermrsquos Foxboro T2550 process

automation controller and safety PLC and Linde Gasrsquo Oxyfuel

burners and increased remelting capacity by 60 reduced fuel

consumption by 50 and cut CO2 and NOX emissions

More Melt less energy

Hyd

ro A

lum

inum

and

Lin

de

Figure 2 Sterling Chemicals used an adaptive process control-

ler to create temperaturereactor disturbance models reduce

variation in its acetic acid reactor temperature and increase

throughput by more than 5

QuickStudyPCS block

Boilerpressure Recycle

owsPID

PID

ReactorEfuent

temperature

Efuent ow

Well-Balanced reactor

Ad

aptiv

e R

eso

urce

s an

d S

terli

ng C

hem

ical

s

CT1504_49_51_Feat3indd 50 33115 400 PM

T e m p e r a T u r e

monitored from its central control room with a Windows Ex-plorer-like interface that enables maintenance engineers to quickly identify devices that need online diagnosis

ldquoBrazil is a dominant player in the bio-ethanol market and the biofuel market is growing so second-generation bio-fuel is attracting attention as an environmentally friendly energy sourcerdquo says Manoel Carnauba GranBiorsquos vice president ldquoOur reliable field instruments and control sys-tem from Yokogawa also allowed us to complete the specifi-cations for this second-generation ethanol plant at an early stage maintain consistency with all specifications which re-duced the total cost of the control system and complete our project on schedule and on budgetrdquo

Wireless Is CoolNot surprisingly one of the primary aids to collecting more and better data from temperature instruments is wireless networking ldquoTemperature sensing and instrumentation via thermocouples for wide-range RTDs and PTC thermistors for narrower ranges is the same as always but whatrsquos new is wireless temperature thermostats and transmitters which also have added microprocessors that can collect histories alarm detection safety and other datardquo says Paul Gobeille senior automation engineer at system integrator Stellar Re-frigeration Services (wwwstellarnet) in Jacksonville Flor-ida ldquoSo where yoursquod previously have a temperature switch for safety now you can have transmitters for your safety in-strumented system (SIS) achieve high SIL performance and comply with IEC 61511 and ANSI ISA S84 standardsrdquo

Gobeille reports that Stellar uses reliable wirelessly net-worked temperature devices such as intelligent HART trans-mitters for cooling air and water and heating water in its design build and integration projects ldquoWe need to reduce field wiring and improve commissioning wherever we can and wireless means wersquore not running around with ladders as much which is a big helprdquo he adds ldquoWireless components are also easier to install very reliable less likely to get dam-aged and most provide access to saved and stored data for asset management and for performing more accurate cali-brations We estimate that using wireless for temperature ap-proaches 40 less cost in wiring and commissioning timerdquo

Likewise system integrator Patti Engineering (wwwpat-tiengcom) in Auburn Hills Michigan recently helped Hill Country Bakery (wwwhillcountrybakerycom) in San Anto-nio Texas upgrade the temperature monitoring and control system in its multi-zone 55000-square-foot cold-storage and distribution center which must be kept within a nar-row temperature range to ensure product quality and safety However the bakeryrsquos old temperature monitoring system had been degrading causing gaps in data collection and had no tracking of corrective actions Plus the centerrsquos mul-tiple zones had hardwired temperature probes which re-

quired manual data collection and were prone to damage Consequently Patti implemented a wireless temperature

monitoring and SCADA system with real-time data collec-tion central SQL database for report generation and the ability to monitor and receive alarm notifications via mobile devices The integrator installed wireless temperature sen-sors from FreshLoc Technologies (wwwfreshloccom) and used Web Studio software from InduSoft (wwwindusoftcom) to develop the systemrsquos HMI and SCADA system

Besides allowing the temperature probes to report re-motely and via mobile devices Patti also programmed them to communicate to their network gateway via Modbus TCP which enables Hill Country engineers to cut out any PLCs or other controls between the sensors and the SCADA sys-tem saving hardware and development time As a result its new temperature monitoring system allowed Hill Coun-try to establish a Hazardous Analysis and Critical Control Points (HACCP) food-safety plan that was benchmarked by the Global Food Safety Initiative (GFSI) and enabled it to achieve Safe Quality Food (SQF) Level 2 Certification


PROTECT PUMPSDRY RUNNING bull CAVITATION bull BEARING FAILURE bull OVERLOAD

MONITOR PUMP POWERbull Best Sensitivitybull Digital Display

TWO ADJUSTABLE SET POINTSbull Relay Outputsbull Adjustable Delay Timers

4-20 MILLIAMP ANALOG OUTPUT

COMPACT EASY MOUNTINGOnly 325rdquo x 625rdquo x 2rdquobull Starter Door bull Panel bull Raceway bull Wall

UNIQUE RANGE FINDER SENSORbull Works on Wide-range of Motorsbull Simplifi es Installation

CALL NOW FOR YOUR FREE 30-DAY TRIAL 888-600-3247WWWLOADCONTROLSCOM

bull Works on Wide-range of Motors

CT1504_49_51_Feat3indd 51 33115 401 PM


Relief Valve Blowdown Oil Separator Level Measurement

Q Relief Valve BlowdownI want to know what blowdown percent-age we should consider for pressure relief

valves in liquid gas and vapor services Is there any reference that gives the percentage of blow-down for different services

Medhi poormehdipoormehdigmail com

A Blowdown (blowback) is the difference be-tween the set pressure and the reseating (reclosing) pressure of a relief valve (Fig-

ure 1) It is expressed in percentage of the set pressure Values of blowdown pressures are set by codes (ASME API NFPA) and their typical values range from 7 to 10 while their lower and upper limits are typically adjustable from 2 to 20 For a detailed discussion see Vol-ume 1 of my handbook starting on page 973

BeacutelA liptaacutekl ip takbelaaol com

Q Oil Separator Level MeasurementWe have a process unit to regenerate caus-tic in sweetening LPG in a gas plant

During this regeneration process disulfide

oil (DSO) is produced To separate DSO and lean caustic a horizontal vessel is used (Figure 2) To control the level of this vessel we are us-ing displacer-torque tube-type level transmit-ters (LDT) but theyrsquore always out of service Please explain which type of LDT is suitable

The specific gravity (SG) of caustic varies be-tween 101-14 and the SG of DSO is changing be-tween 09 -11 The heavier phase is always caustic The LDT is calibrated to indicate the dense layer level (caustic) So we calibrate the LDT according to caustic density but during operation the caus-tic density varies and the system is not working properly So wersquore planning to purchase a guided wave radar (GWR) but I read somewhere that if the dielectric of fluid varies it will not work prop-erly and the dielectric of caustic will vary because of the variation in the caustic concentrationSiA

SiAMAk Moridsmor idi57gmail com

A This is a very common problem in many separators so let me comment on the ca-pabilities and limitations of the two tech-

niques you mentioned displacement and guided wave radar (GWR)

Displacement Displacers detect the buoyant force If you calibrate them to read 100 when fully submerged in the bottom layer (it is all in caustic) and the density of that layer varies be-tween 101-14 SG the readings will be useless This is what you are experiencing now

In order to make the measurement mean-ingful you also need to measure and compen-sate for that variable (the density of the caustic) To make the measurement perfect you would also have to measure the density of the DSO but since it doesnrsquot vary much (between 09 -11 SG) you probably donrsquot need to After all you donrsquot need high accuracy

Guided wave radar (GWR) Radar using time domain reflectometry (TDR) has the abil-ity to measure both the upper and lower liquid levels if the following conditions are met

bull The upper liquid is a low-dielectric me-dium (ε lt 10)

a s k t h e e x p e r t s

This column is moderated

by Beacutela Liptaacutek

(httpbelaliptakpecom)

automation and safety

consultant and editor

of the Instrument and

Automation Engineersrsquo

Handbook (IAEH) If you

have an automation-

related question for

this column write to

liptakbelaaolcom

Figure 1 Relief valve blowdown is the difference between the set pressure and

the reseating (reclosing) pressure

Figure 1

Caption Hed BLOWDOWNCaption

Figure 1 Blowdown is the difference between the set pressure and the reseating (reclosing) pressure of a relief valve

Credit Leser LLC

82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 Max blowdown Max overpressure

Reseating pressure Set pressure Max proportional lift ange

Relieving pressure

Vesselpressure()

Operatingpressure

Lift ()100

80

60

40

20

0

Popping pressure

Maximum allowableworking pressure

Maximum allowable

accumulation pressure

single valve

Maximum allowable

accumulation pressurere case

BLOWDOWN LOWDOWN

Lese

r LL

C

CT1504_52_53_ATEindd 52 33115 402 PM

bull The lower liquid has a higher dielectric (Δεgt 10)bull Both dielectrics are reasonably constant and bull The interface is clean and distinct with no emulsion

layerIf the above conditions were satisfied in your application

(which they are not) the system would work as follows a small reflection would be generated by the upper DSO layer (low dielectric) while most of the energy continued down the probe and a larger reflection would be generated by the lower caustic layer (high dielectric) The key to accuracy is to accurately compensate for the change in pulse propaga-tion velocity while itrsquos traveling through the upper medium

I wouldnrsquot recommend GWR for your application be-cause your dielectric constants change and because you have an emulsion layer in which the dielectric changes grad-ually For this reason detectable pulses are not generated from the emulsion layer

GWR with Float As caustic is always heavier and the SG of DSO is always lighter a simple float having a density equaling the maximum density of the light layer is all that is needed as it will always follow the interface (emulsion) and detecting the position of the float by GWR would give a good enough reading I do not elaborate on this option since it is explained in detail below by my colleague Hunter Vegas

Beacutela liptaacutekl ip takbelaaol com

A A displacer level transmitter assumes a consistent SG for both fluids and is usually calibrated to detect the difference of those SG readings in order to determine

the level of the interface between the two fluids However in your case the SGs of both fluids are varying

dramatically so a consistent calibration and reading is virtu-ally impossible

I agree that a GWR also may not work It stands a chance if the dielectric properties are reasonably consistent and sig-nificantly different In other words if the oil is generally non-conductive and the caustic is generally very conduc-tive then it might work OK but if the conductivity of either fluid can drift dramatically then your readings will drift all over as well

I can think of one possible solution that you might con-sider You said the SG of caustic can vary from 101 to 14 and the SG of the oil can vary from 09 to 11 Are you cer-tain of this I am always talking about the process specific gravity at the normal process temperature often if you take a sample and it cools the gravities will get heavier If the oil gravity can rise higher than the caustic then the levels would invert and oil could drop to the bottom I presume this isnrsquot happening and the SG of the caustic is at least 11 Assuming that is the case you could install a float-type level transmitter that uses a float with an SG of 11 As long as the caustic SG was gt 11 and the oil SG is lt11 the float would

indicate the interface position even as the SGs of both fluids drifted There are several different devices that use a float like this Some use small reed switches to pick up the float location others use bounced guided wave radar etc

In Figure 3 it is assumed that the caustic SG is always greater than 11 and the oil SG is always less than 11 There-fore in this case if you had a float with a SG of 11 it would always float on the caustic and sink in the oil so it would ride on the interface and provide the indication you need So you need to determine if there is some SG that will al-ways be greater than the caustic and less than the oil and that is what you set the float to be

Hunter Vegashvegasavidsolu t ionsinccom



Figure 2 Using a displacer torque tube level transmitter to

control the level in this disulfide oil (DSO)caustic separation

tank is unreliable due to varying specific gravities

Figure 2

Caption Hed SEPARATE ELEMENTSCaption Figure 2 In this application to control the level in the DSOcaustic separation tank a displacer torque tube level transmitter is used

No credit

Air

DSO + caustic + air

Torque tube LDT

DSO outlet

DSO layer

Mesh Caustic layer

Interface

SEPARATE ELEMENTS

Figure 3 A float-type level transmitter may be the best way to

measure level in a separator tank taking into account the vary-

ing specific gravities of the materials

Figure 3

Caption hed FLOAT TYPE INTERFACE DETECTIONFigure 3 A float type level transmitter may be the best way to measure level taking into account the differing specific gravities of the materials in this tank No credit

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20Time

Spec

ic gr

avity

08

09

1

11

12

13

14

15 Caustic Oil Float

FLOAT-TYPE INTERFACE DETECTION

CT1504_52_53_ATEindd 53 33115 402 PM

Programmable Control ConfidentialThe workhorses of process control PLCs and PACs are learning some new tricks

R O U N D U P

COMPACT AND ATEX-CERTIFIEDPFC200 Series performance-class PLCs are ATEX certi-fied and offer compact com-puting PFC200 also features a 600-MHz ARM Cortex A8 processor multiple fieldbus ports 256 MB on-board and 32 GB removable memory and web server supporting Wagorsquos Web-Visu mobile app PFC200 communicates between Modbus TCPUDRTU CAN Profibus Smart Grid and RS-232RS-485 Wago800-DIN-RAIL (346-7245) wwwawagous


EMBEDDED ETHERNET AIDS CONNECTIVITYCP1L-E compact PLCrsquos em-bedded Ethernet connects to the Internet for remote access monitoring and data logging Its embedded Ether-net port with socket services adopts UDP TCP Modbus TCP and Omron FINS Eth-ernet There are three Ethernet-enabled versions of the CP1L-E available offering 20 30 or 40 IO points expand-able to 160 IO points Omron Automation and Safety866-88-OMRON (886-6766) wwwOmron247com

HMI AND PLC WITH ANALOGFT1A Touch14 IO micro programmable controller combines HMI and PLC units and provides up to 158 discrete and analog inputs and outputs (using FT1A con-trollers as remote IO slaves) PID control Ethernet com-munications and a built-in 38-in touchscreen HMI PID control functions include auto-tuning anti-reset windup and bumpless transfer Idec Corp800-262-IDEC (4332) wwwIDECcomtouch

HIGH-AVAILABILITY WITH PROFINETPACSystems control platform has added Profinet commu-nications and provides one point of connect for system configuration so all remote IO nodes can be config-ured from one location PAC-Systemsrsquo built-in Ethernet switches and media conversion provide point-to-point plug-in connectivity Users can also employ their cable of choice on a node-by-node basisGE Intelligent Platforms800-433-2682 wwwgeautomationcom

FULLY INTEGRATED WITH SOFTWAREStandalone Snap PAC S-se-ries and rack-mounted Snap PAC R-series industrial con-trollers are fully integrated with PAC Project software Snap PAC brains and Snap digital and analog IO mod-ules to form a complete con-trol system Snap PAC controllers can log data to a remote PC controller or microSD card in the controller itself Free PAC Control programming software is includedOpto 22800-321-OPTO (6786) wwwopto22com

CONTROLLER SUPPORTS ETHERNETIPProductivity3000 controller supports EtherNetIP as stan-dard protocol via its P3-550 CPU and embedded Ether-net port P3-550 can support EtherNetIP configurable as a scanner adapter or both si-multaneously and can com-municate to devices using explicit messaging or implicit IO messaging methods In scanner mode P3-550 CPU supports up to 128 total connections with a maximum of 32 devices AutomationDirect800-633-0405 wwwautomationdirectcom

CT1504_54_55_Roundupindd 54 33115 403 PM

R O U N D U P


LOGIC IN EXTREMELY SMALL SPACESNanoline nano-class control-lers include a NLC-035 logic module At just 40 mm wide NLC-035 is half the width of the NLC-055 series NLC-035 has four digital inputs and two relay outputs rated 5 A with LED indicators It also has a built-in RJ11 programming port and integrated real-time clock Users can expand IO count with the NLC-IOX expansion modulePhoenix Contact 800-322-3225 wwwphoenixcontactcomnanoline

COMBINE CONTROL AND COMMUNICATIONMerging an embedded com-puter with data acquisition and control APAX-6572 has an Intel Atom D510 166-GHz CPU 2-GB RAM con-troller with three GbE LAN two COM VGA and four USB 20 ports A maximum of 32 APAX DAampC IO modules provide up to 768 digital and 192 analog IO points It supports the IEC-61161-3 stan-dard for LD FBD IL SFC C C++ and CAdvantech Corp888-576-9668 wwwadvantechcomea

CONTROLLER SIMPLIFIES SAVES SPACE Allen-Bradley Armor Guard-Logix PAC is IP67- SIL 3- PL(e)- CAT 4-rated with 4 MB of application code stor-age space and two EtherNetIP device-level ring (DLR)-capable connections It pro-vides access to the controller-mode switch USB port secure digital (SD) card and power supply switch along with 24-Vdc power pass-through to sup-ply power to other On Machine products Rockwell Automationwwwrockwellautomationcom

MULTI-CORE EMBEDDED PC SERIESCX5100 embedded PC series are fanless compact control-lers with optimum scalability via single- dual- or quad-core Atom CPUs with 22-nm tech-nology that enables high per-formance thermal balance and extended -25 to +60 degC operating temperatures CX5100 offers out-of-order com-mand execution which allows TwinCAT 3 software users to employ full availability of multi-core processorsBeckhoff Automation 877-TwinCAT (894-6228) wwwbeckhoffautomationcom

INTEGRATED FIELD WIRING EZWire1616 PLC is one of the first of its kind in the PLC market with integrated field-wire-ready IO terminals Ev-ery sensor and actuator in the control system can be wired directly to the PLC without needing added screw termi-nal blocks and wire harnesses which saves system integra-torsrsquo and OEMsrsquo time material costs and panel space and aids wiring error recovery efforts during installationTriangle Research International Inc877- 874-7527 wwwtriplccom

COMMUNICATE WITH SECURITYModicon M580 Ethernet PAC (ePAC) uses open Ether-net standards and multi-core data processing to enable pro-cess efficiency and flexibility while ensuring cybersecurity through Achilles Level 2 cer-tification M580 is tested ac-cording to Ethernet services and protocols such as ARP ICMP TCP IP and others Its firmware integrity is checked at start-up and compiled and stored in memory Schneider Electric877-Dial-1-SE (342-5173) wwwschneider-electriccom


C o n t r o l E x C l u s i v E


Transmitter Covers Multiple Ranges

Due to the non-linear output of the transducer a typical pressure transmitter is calibrated and rated

for a limited pressure range Specifiers and maintenance departments must choose and stock multiple models to cover the various applications in a typ-ical plant and each application must consider carefully the ramifications of turndowns start-ups and operating conditions that take the transmitter out of its accurate range

Foxboro by Schneider Electric has in-troduced a new series of pressure trans-mitters that store 11 calibration points in firmware As the pressure input changes the transmitter automatically selects the proper calibration curve for that specific input ldquoWe call this patented technol-ogy FoxCalrdquo says Patrick Cupo prod-uct manager pressure and temperature Foxboro ldquoThe result is a very accurate output that covers three to four ranges of competitive instrumentsrdquo

S series models cover pressure ranges to 1000 inWC (25 bar) to 2000 psi (138 bar) and to 6000 psi (414 bar) Each is calibrated at 25 5 10 20 30 40 50 60 70 85 and 100 of upper range limit (URL) ldquoThe Fox-Cal calibration points are stored in the transmitter firmware forever and canrsquot be deleted accidentallyrdquo says Cupo

Using this multiple calibration ap-proach the reference accuracy of the transmitter is maintained even at high turndowns (The accompanying figure shows the effect of FoxCal on transmitter accuracy) Common pressure transmit-ter reference accuracy typically begins degrading at turndowns greater than 101 ldquoThe S series allows turndowns on the order of 801 without sacrificing ac-curacyrdquo Cupo says ldquoCustomers are no longer forced to use algebraic equations to determine the accuracy at high turn-down The S series offers a simple per-cent of reading specificationrdquo

The benefits to the user are enhanced turndown performance along with fewer sensor ranges required for inven-tory stock ldquoA 2000-psi S series in-line gauge can be used down to 50 psi and still maintain reference accuracyrdquo says Cupo ldquoThe 6000-psi S series in-line gauge can be used down to 150 psi The 1000-inWC differential pressure trans-mitter is calibrated down to 25 inWCrdquo

The S series pressure transmitter is available in both in-line gauge (2000 and 6000 psi) and differential pres-sure (200 and 1000 inWC) The dif-ferential pressure transmitter is avail-able with traditional and low-profile process connections Wetted material selections include 316ss and Hastel-loy and FM CSA ATEX and IECEx safety approvals are available

Other features include a time-in-ser-vice odometer for predictive and pre-ventive maintenance and a standard five-year warranty

By storing 11 calibration points and automatically selecting the right curve based on

the input Foxbororsquos S series maintains accuracy over a much broader range than

other pressure transmitters

of r

eadin

g

of URL

18

16

1

2

1

8

6

4

2

00 10 20 30 40 50 60 70 80 90 100

TraditionalFoxboro

Accuracy of transmitter

CoMpRehensive CalibRaTion

Foxboro S series pressure transmitters

are accurate at turndowns on the order

of 801 For more information see www

fielddevicesfoxborocom

aCCuRaTe aT 801

CT1504_56_Exclusive2indd 56 33115 505 PM



Swirl Meters Measure More than Flow

In a conventional vortex flowmeter a shedder bar separates the fluid flow causing vortices with high- and low-pressure pulses at a frequency proportional to fluid velocity Pres-

sure sensors measure the pulse frequency and electronics calculate volume and mass flow

ldquoSwirl is a little different twistrdquo says Steve Pagano senior product manager for ABBrsquos vortex swirl and Dp flow meter-ing ldquoInstead of a shedder bar a swirler at the meter entry puts the fluid into rotation The flow delaminates into pres-sure pulses which are measured much like a vortex meterrdquo However the swirl meter offers significant advantages

First the swirl meter reduces upstream and downstream straight piping requirements from the typical 15 to 50 pipe diameters needed for vortex technology ldquoThe specially de-signed entry of the swirl meter profiles the flow like a built-in flow conditioner reducing the upstream piping to a mini-mal three to five diametersrdquo Pagano says

Second the swirl meter is accurate to lower flows at the bottom end of the range ldquoWhere vortex drops off at about 201 turndown swirl is accurate at 351 or 401rdquo Pagano says ldquoWe can put the meter into and catch lower flows For ex-ample nighttime steam flows can be below measurability for vortex and still be caught by swirlrdquo

Third in order to have enough velocity vortex meters of-ten must be sized one or two sizes smaller than the pipe Pa-gano notes ldquoSwirl meters can be the same diameter as the pipe run eliminating the cost and space of reducing cones and in some cases offer a lower pressure drop than the se-lected vortex resulting in an energy savingsrdquo

ABBrsquos new SwirlMaster flowmeters replace its Trio-Wirl series to measure volume mass and energy flow in a single device The new SwirlMaster comes as a standard (FSS430) or as an extended version (FSS450)

FSS450 features functions that are normally found in flow computers such as steam-power calculation (with and without condensation return) and the ability to receive 4-20 mA signals for density temperature and pressure FSS430 omits the flow computer algorithms but provides an analog output with HART communication Both models feature ABBrsquos universal graphical display (HMI) digital outputs configurable as pulse contact and frequency output and an optional integrated temperature sensor

SwirlMaster is accompanied by a new VortexMaster se-ries that follows the same philosophy with a lower-cost entry-level version (FSV430) and an extended version (FSV450) that offers the same functions as SwirlMaster FSS450 ldquoThe simple and robust designs feature no moving mechanical parts and high accuracy with plusmn050 of rate for the Swirl-

Master and plusmn065 (liquid) or plusmn09 of rate (gas) for the VortexMasterrdquo says Pagano

Sensor response time is significantly improved Reaction time for a change in flow rate is reduced from 3-6 seconds to less than 1 second At the same time the measuring ranges have been extended (depending on the diameter of the de-vice) in some cases significantly

Advanced diagnostic and verification functions monitor device health through regular self-checks on the flow and temperature sensor data storage and electronics Diagnostic status messages are in accordance with the NAMUR direc-tive NE107

Both series have a piezo sensor with multiple elements to register the measured signals as well as pipe vibrations which are used for compensation The sensor transmitter and general setup for both device series are identical for easy commissioning and spare part management Pagano says ldquoA single set of electronics and one sensor cover the entire range making this a very frugal meter from a maintenance standpointrdquo

A swirl meter might cost 10-15 more than a vortex me-ter but has a lower installation cost uses less real estate and offers higher performancerdquo says Pagano ldquoIts five-year cost is less than a vortex meter and with lower maintenance itrsquos much less than using turbine meters In applications where a turbine meter wears out in six months a swirl meter lasts five to 10 years with no maintenancerdquoFor more see wwwabbcommeasurement

ABBrsquos new VortexMaster and SwirlMaster flowmeters measure

volume mass and energy flow with functions normally found in

flow computers such as steam-power calculation and the abil-

ity to receive signals for density temperature and pressure

A New TwIST oN VorTex



P R O D U C T I N T R O D U C T I O N S

APM SOFTWARE MANAGES RISKAssetWise APM v73 asset performance management (APM) software manages in-tegrity of safety systems and hazardous processes includ-ing safety instrumented func-tion (SIF) analysis safety in-strumented systems (SIS) safety integrity level (SIL) and safety provisions overrides and incidents The new release adds version control and ap-proval analysis of loss of containment scenarios and iden-ti cation and assessment of risks to the existing functionsBentley Systems 800-BENTLEY (236-8539) wwwbentleycom

SPARKS SEALED FOR SAFETYEU2B family of pushbuttons pilot lights selector switches and ammeters comply with ATEX C-UL IEC and ULNEC safety standards for use in hazardous areas Sealed to prevent release of suf cient electrical energy to ignite ex-plosive gases or particles the devices are ULc-UL approved for use in Class I Zone 1 applications and rated AEx de IIC T6 Gb for use in explosive gas atmospheres Rated IP65 and Type 4X for protection from waterIDEC 800-262-IDEC (4332) wwwIDECcomEU2B

SIM SUITE UPS OPERATOR COMPETENCEUniSim Competency Suite improves console and eld operator competency through realistic training experiences UniSim Operations training simulator is a dynamic plant simulation system UniSim Curriculum tracks operator progress UniSim Tutor captures and propagates knowledge UniSim Field View uses facility photographs and extends simulator training to eld operators and UniSim 3D Con-nect integrates a 3D virtual environmentHoneywell 800-822-7673 httphwllcoUltimateOperator

PUT SPECTRAL ANALYSIS ON-SITEMA-5000 Series spectro-scopic sensors are optimized for speci c applications in liquid gas-phase or solids analysis using a miniature on-board computer loaded with the appropriate range of Symbion Systems software Typical components include Symbion RTM rapid deploy-ment package and Symbion QT chemometrics Secure web-based communications provide cloud-based data storage and remote monitoring in real time Symbion Systems 949-757-9300 wwwgosymbioncom

NODE PC HANDLES HAZARDOUS AREASnPC20 fanless rugged in-dustrial-strength industrial node computer offers choices of Atom dual-core E3826 146-GHz CPU or quad-core E3845 191-GHz CPU 2-8 GB DRAM and 80-300 GB solid-state storage and Win-dows or Ultimate operating system It sports dual video out-put via HDMI and VGA AC or DC power dual Gigabit Ethernet ports standard USB 30 ports audio line out port and serial communication port (RS-232422485) Nematron 800-NEMATRON (636-2876) wwwnematroncom

MANAGE NETWORKS IN REAL TIME AND SPACEPcVue v111 software for monitoring geographically distributed assets and IP net-works has added GEO Map Control for live interactive maps from services such as Google and Microsoft with animations and display of real-time asset status and alarms without scripting or pro-gramming CIMWay supports SNMP for monitoring and controlling devices on IP networks real-time analysis en-hancements to BACnet Scheduling and morePcVue 781-460-3272 wwwpcvuesolutionscom

CT1504_58_Productsindd 58 33115 405 PM

Learning What Your Process Can Do

Greg We are into a copy approach to au-tomation projects with the objective of just keeping the plant running This step

backward can be attributed to the retirement of specialists downsizing of corporate and plant staffs overwhelming emphasis on project sched-ule and cost lack of technical resources that provide practical guidance on the implementa-tion and value of process control improvements (PCI) and an attitude that the profession is ma-ture and it has all been done before In reality new advanced control tools and an increase in PID and tuning software functionality can em-power the individual to the point where imagi-nation is the limit We conferred with Todd Jaco a recent graduate of the Missouri University of Science and Technology (Missouri SampT httpchemengmstedu) and new business manager for Mynah Technologies (wwwmynahcom) to see what we can do to turn this around and open up minds Todd has extensive practical experi-ence as a simulation consultant

Stan When did you become interested in pro-cess control

Todd In the Chemical and Biochemical En-gineering Department of Missouri SampT there were very practical courses on the application and importance of process control The focus at Missouri SampT is preparing engineers to be immediately productive in the process indus-tries The partnering with companies such as Emerson Monsanto and Mynah has strength-ened this approach as seen in the new Bertels-meyer Hall with a state-of-the-art virtual plant and unit ops lab with an industrial distributed control system (DCS) Most Mynah employees and interns are from Missouri SampT My inter-est in process control started at Missouri SampT and was fostered by Gregrsquos Series on Dynamics (wwwmynahcomknowledge-basegreg-mc-millans-series-dynamics) with demos by Pierce Wu using Mimic simulations to make control

technology come to life This led to numerous questions and a motivation to see what more can be done The series was supported by the ISA book 101 Steps for a Successful Automa-tion Career (wwwisaorg) which helped detail more of the practical aspects of the job includ-ing how the knowledge translated to better au-tomation project execution

Greg What do you see as the next step

Todd We plan to develop the ability to provide the customer with online process metrics These metrics can show what the process and automa-tion system is currently doing and how well the operator is managing and improving the process operating conditions We can put more detail into the automation system model as part of a virtual plant to show how knowledge of automa-tion system design and process objectives can affect the metrics using the new Momentum

C O N T R O L T A L K

GREG MCMILLANSTAN WEINER PEcontrol ta lkputmanne t


Greg McMillan and Stan Weiner bring their wits and more than 66 years of process control experience to bear on your questions comments and problems

Write to them at controltalkputmannet

Young engineers leverage university facilities to learn the advantages of virtual process

control in areas where it really matters

CT1504_59_60_ControlTalkindd 59 33115 536 PM


Press book Tuning and Control Loop Performancendash4th Edition (wwwmo-mentumpressnet) as a guide This will open the door to seeing how automa-tion details such as analyzer cycle time measurement span and update time sensor lag and transportation delay valve size flow characteristic stroking time resolution and dead band affect tuning and performance The chapters on process control improvement and batch optimization can be employed to see how control strategy innovations can improve plant performance

Stan What do you envision as process metrics

Todd I would start out with metrics of process capacity and efficiency on an in-dividual unit operation basis The equip-ment component outlet raw material and utility flows would be totalized over various time intervals Shorter time inter-vals would be used to provide a more cur-rent view (eg last hour or batch phase) and longer time intervals would be used to provide a longer-term view (eg last shift or last batch) The time interval would start at the beginning of raw mate-rial and utility flows (eg start-up of con-tinuous operations and the beginning of a new phase for batch operations) The component outlet total divided by each individual raw material total provides a metric of raw material efficiency (eg yield) and the component outlet total divided by a utility flow total provides a metric of energy efficiency The utility flow can be converted to an energy us-age rate to give metrics in units of kilo-grams per kilojoule By using totals over sufficiently large intervals (eg time in-tervals larger than equipment residence time) the synchronization issue is largely avoided until the metric is extended to process areas

Greg I expect each flow would be av-eraged over a time increment (eg one minute) to smooth out short-term changes and errors in synchronization

and to reduce the array size for totaliza-tion The oldest flow in the array is sub-tracted from the total as the newest flow is added to the total after each is mul-tiplied by the time increment and the phase speed-up factor Synchronization of input flows with the product output flow could be achieved by passing input flows through dead time and filter blocks corresponding to equipment delays lags and residence times How do you intro-duce the user to these capabilities

Todd We plan to offer a half-day exten-sion to our short course to cover metrics and a hint as to how PCI can play an important role to get the user interested As interest grows a one-day basic and two-day advanced course on PCI would be offered A key part of these courses would be the use of advanced modeling objects to bring home the possibilities

Stan What do you expect are some of the PCI opportunities

Todd The most straightforward op-portunity is the simple change of a loop setpoint to gain a more productive or efficient operating point Good pro-cess simulations can reveal this oppor-tunity The setpoint improvement may be done up-front based on better pro-cess knowledge by exploring the oper-ating region If reduction in variability is needed to get closer to the optimum greater attention in the model to auto-mation system design and dynamics can demonstrate these possibilities of better control strategy and tuning

Stan How do you expect this initia-tive to progress

Todd We will encourage and help users to present and publish their applications so we can all learn from their successes and difficulties Application examples and demos will be given to Missouri SampT and the Rose-Hulman Institute of Technology (wwwrose-hulmanedu) for use in their well-established exten-

sive process control labs These virtual plants can increase the communication between industry and academia and motivate new engineers to look for pro-cess control opportunities These appli-cations can provide the momentum to eventually have user group sessions on the use of virtual plants for PCI

Greg A good portion of my deeper un-derstanding of process dynamics that led to process control improvements was gained by doing simulations You can quickly explore possibilities in a matter of hours that would take months in a real plant In many cases operating plants no longer allow such exploration A simulation is needed to build the case and work out the details before improve-ments are implemented More recently Irsquove developed a Bioreactor Model (wwwmynahcomknowledge-basebioreactor-modeling-object) running 1000 times real time in a virtual plant for knowledge discovery process con-trol development and exploration that can lead to more repeatable batches Todd has opened his mind to the in-credible possibilities offered by the in-creased power and flexibility of simula-tion software and the DCS Have you

We conclude with theTop 10 Uses of a Virtual Plant in a University10 Predict the questions and answers on the next exam9 Develop ldquofantasy controlrdquo kind of like ldquofantasy footballrdquo8 Develop metrics like ldquotime to com-plete lab assignmentrdquo7 Optimize capacity ldquocredit hours per semesterrdquo 6 Optimize efficiency ldquocredit hours per hour of time investedrdquo 5 Optimize quality ldquogradesrdquo4 Explore and prototype new opportu-nities ldquointernshipsrdquo3 Have more fun than a Sunday after-noon at Cracker Barrel2 See if you can stump the professor1 Demonstrate production of crafty beers



ADVERTISER PAGE NO

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Emerson Process MgtRosemount 19

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Endress+Hauser 6 7

Honeywell Process Control 41

ITS Enclosures 35

Load Controls 51

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Maple Systems 48

Meriam Process Technology 31

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Orion Instruments 3

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C H E C K O U TC O N T R O L G L O B A L C O M


For additional information please contact Foster Printing Service the official reprint

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PMS 370 C

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RepRints aRe ideal foRn New Product Announcementsn Sales Aid For Your Field Force n PR Materials amp Media Kitsn Direct Mail Enclosuresn Customer amp Prospect CommunicationsPresentationsn Trade ShowsPromotional Eventsn Conferences amp Speaking Engagementsn Recruitment amp Training Packages

Custom REPRINts

CT1504_61_Classifiedsindd 61 33115 128 PM

rdquoWe can even

unexpectedly

introduce problems

like entrained air

and teach students

and users to

solve themrdquo

C O N T R O L R E P O R T

Jim montague e xecut ive editor

jmontagueputmanne t

62 wwwcontrolglobalcom a p r i l 2 0 1 5

Hands-on Wins Hands down

onscreen simulations are terrific but they arenrsquot the ahem whole picture Even using the latest virtual-reality headsets

theyrsquore still flat images seen though a small window and canrsquot reflect all the sensory input of the physical reality they mimic Pretty im-ages canrsquot replace all the sights sounds touches and smells of physical events and abundant re-search shows that stronger neural pathways more vivid memories and better learning are created by real experiences

To give future young and even vet-eran process engineers and operators more real-life hands-on training or retraining Endress+Hauser (wwwusendresscom) and friends recently designed and built their ninth and 10th process training units (PTUs) nation-wide at its US headquarters in Greenwood Indiana and at 52-year-old distributor George E Booth Co Inc (wwwgeboothcom) in Ro-meoville Illinois The two-story PTUmdashthe ldquourdquo also stands for ldquouniversityrdquomdashincludes tanks pumps pipelines valves gauges flowmeters instruments transmitters and many other de-vices controls and software that students and other users can operate to learn how real pro-cess systems run and most importantly how experienced operators solve problems and op-timize performance

ldquoOne-half of the PTU focuses on industrial ap-plications found in chemical plants steel mills and other processes while the other features sani-tary and stainless-steel facilities found in food and beverage pharmaceutical and cosmetic applica-tionsrdquo says Nick Hryniw area sales manager at George E Booth ldquoHowever this isnrsquot just a show-place or static tabletop demonstration Itrsquos an op-erating lab where we can run classes and even un-expectedly introduce problems like entrained air and teach students and users to solve themrdquo

The PTU construction team and contribu-tions at George E Booth include Waner En-terprisesrsquo building construction AampR Erectorsrsquo mezzanine and PTU structure BMW Con-

structorsrsquo mechanical piping Endress+Hauser process instrumentation Samson Controls control valves Gebco II on-off valve automa-tion Rockwell Automation process control systems Jogler sight glassesstilling wells and Sharpe Valves on-off valves

Besides hosting tours training programs at George E Boothrsquos PTU include basic instru-mentation pH and conductivity measurement liquid analytical measurement Coriolis flow introductory and advanced flow introductory and advanced level time of flight free space and guided-wave radar level pressure and tem-perature and certified Profibus PA

Finally to really put the ldquouniversityrdquo in PTU Hryniw adds George E Booth is talking with nearby Joliet Junior College about running some of its process control classes at the PTU Other than taking over an actual process plant therersquos probably no better way to teach control and develop all those engineers that everyone will need soon if not immediately Bravo

Nick Hryniw area sales manager at George E

Booth Co shows the PTU to Rick Isemonger

control engineer at Ferrara Candy during the

March 25 Process Solutions Summit it hosted with

Endress+Hauser and Rockwell Automation

Process training unit ndash and university

CT1504_62_CRindd 62 33115 508 PM


Itrsquos time to LOOK AT PROJECTS DIFFERENTLYLooking for a way to avoid unforeseen and unrecoverable risks budget overruns schedule slippage and unreliable partners With Emersonrsquos global project services team providing guidance you will reduce cost and schedule risk throughout the project

PROJECT SCHEDULE RISK

56millionAT RISK

65

35projects under $500M

INEFFECTIVEcommunication

For every $1 billion spend on a capital project $135 million is at risk 56 of that ($75 million) is at risk due to ineffective communicationndash2013 Pulse of the Profession Project Management Institute

65 of mega projects (over $1B) around the world fail 35 of projects under $500M failndashSpeed Kills Klaver Ali 2012 Project Manager Magazine

Up to 30 percent of anticipated value disappears during the turnovercommissioning and ramp-up phases of new asset lifecycles ndashDeloitte Effective Operational Readiness of Large Mining Capital Projects - Avoiding value leakage in the transition from project execution into operations Article 2012

anticipated valueDISAPPEARS

30 3920

Good front end planning leads to as much as 20 cost savings and 39 schedule reduction for total project design and constructionndashConstruction Industry Institute Adding Value Through Front End Planning CII Special Publication 268-3

cost savings

schedule REDUCTION

budget amp schedule

OVERRUNS

40 percent of projects in the oil and gas industry are subject to budget and schedule overrunsndashCapital Project Execution in the Oil and Gas Industry M McKenna H Wilczynski D VanderSchee 2006 Booz Allen Hamilton survey from 2006 of 20 companies (super-majors independents and EPC firms)

40

FAIL

PERSONNEL

67TO

YEARS

It takes an average of six to seven years to develop new employees into autonomous petrotechnical professionals who can make non-standard original technical decisionsndash2010 SBC Oil amp Gas HR Benchmark Schlumberger Business Consulting Energy Institute March 2011

50 of experienced and managerial personnel in national and international oil gas processing companies are expected to retire in the coming decadendashSociety of Petroleum Engineers ldquoThe Great Crew Change A Challenge for Oil Company Profitabilityrdquo April 16 2011

expected to

RETIRE50

E ME R SO N CO N SI D ER IT SO LVED

$135

Bring the most complex projects to SUCCESSFUL IMPLEMENTATIONwwwemersonprocesscomprojectcertainty

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FUTURE




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Vari

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TRUE STORY

25


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Bal

luff








of purged cabinets




CT1504_36_43_CSindd 37 33115 357 PM

























































natural gas plant


Pent

air

Ho

ffman



Barrier


VR

IscIo

+VocUo-

Cable

L

C

Hazardous area

3x

no sPark no Fire

Pep

pe

rl+Fu

chs

CT1504_36_43_CSindd 38 33115 357 PM



































sified areasrdquo

















Op

timat

ion

CT1504_36_43_CSindd 40 33115 358 PM

visibly better











wwwhwllcoc3hz









sorinccom










Diagram 1

Non-hazardous area

Wago IO 750-439

Hazardousarea

Onoffswitch

Fermentationtank

Limit switch


Wall


Wag

o

CT1504_36_43_CSindd 42 33115 358 PM
















Vac

on

CT1504_36_43_CSindd 43 33115 359 PM




















by J im Montague

CT1504_45_48_Feat2indd 45 33115 240 PM






Interface Level

Product Level

Temperature





Level Plusreg






OVERSEEING ORE

Yoko

gaw

a an

d S

olv

ay

CT1504_45_48_Feat2indd 46 33115 240 PM





















US

Arm

y C

orp

s o

f Eng

ine

ers

and

R

ock

we

ll A

uto

mat

ion

CT1504_45_48_Feat2indd 47 33115 240 PM















wwwmaplesystemscom


CT1504_45_48_Feat2indd 48 33115 241 PM
















CT1504_49_51_Feat3indd 49 33115 400 PM
















Hyd

ro A

lum

inum

and

Lin

de





QuickStudyPCS block


owsPID

PID

ReactorEfuent

temperature

Efuent ow


Ad

aptiv

e R

eso

urce

s an

d S

terli

ng C

hem

ical

s

CT1504_49_51_Feat3indd 50 33115 400 PM



















CT1504_49_51_Feat3indd 51 33115 401 PM





























have an automation-



liptakbelaaolcom



Figure 1



Credit Leser LLC



Relieving pressure

Vesselpressure()

Operatingpressure

Lift ()100

80

60

40

20

0

Popping pressure


Maximum allowable


single valve

Maximum allowable


BLOWDOWN LOWDOWN

Lese

r LL

C

CT1504_52_53_ATEindd 52 33115 402 PM




















Figure 2


No credit

Air

DSO + caustic + air

Torque tube LDT

DSO outlet

DSO layer

Mesh Caustic layer

Interface

SEPARATE ELEMENTS




Figure 3


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20Time

Spec

ic gr

avity

08

09

1

11

12

13

14



CT1504_52_53_ATEindd 53 33115 402 PM


R O U N D U P









R O U N D U P























of r

eadin

g

of URL

18

16

1

2

1

8

6

4

2

00 10 20 30 40 50 60 70 80 90 100

TraditionalFoxboro







aCCuRaTe aT 801


































































ADVERTISER PAGE NO

ABB 4





AVG Automation 63

Cashco 30


Eaton 21



Endress+Hauser 6 7


ITS Enclosures 35

Load Controls 51


Maple Systems 48


Moore Industries 23

MTS Systems 46


Newark 27

Orion Instruments 3


Phoenix Contact 44

ProComSol 42


SOR 42

Wago 39















PMS 370 C

C 60M 0Y 100K 28



Custom REPRINts


rdquoWe can even

unexpectedly

introduce problems

like entrained air

and teach students

and users to

solve themrdquo



jmontagueputmanne t

















CT1504_62_CRindd 62 33115 508 PM




56millionAT RISK

65







30 3920


cost savings

schedule REDUCTION

budget amp schedule

OVERRUNS


40

FAIL

PERSONNEL

67TO

YEARS



expected to

RETIRE50


$135







$6300(PX-248 8-point DC

Output)

$3600(PX-172-1 2-point

AC Input)


Feed Terminal)

$27700(PX-334-K

Thermocouple)


Modbus TCP Coupler)









TM






money




LEVEL

viewing angle140deg

+ 200 ft (60 m)







sight glass gauges

B O O T H 1 6 0 4

VIS

IT

US IN HOUSTO

N

ORION



Absolutely















c o n t r o l







c o v e r s t o r y



f e at u r e s




CT1504_05_07_TOCindd 5 33115 600 PM









































E-direct





CT1504_05_07_TOCindd 7 33115 601 PM


18004335700





















people to see the

attraction of a big

old plant like


foothills of the

Great Smoky

Mountains

CT1504_09_Editindd 9 33115 656 PM

800 453 6202


















using-orp














kill-hypocrisy


Multimedia Alerts

White Paper Alerts





Whatrsquos Next






100 = 23 ft

LT


FI nitrogen


H

L

SG = 1

CT1504_15_WebTOC_1indd 15 33115 602 PM



Magnetrol works

So this works

So this works






















mentors












shernerputmanne t



klarsonputmanne t













Students are taught

engineering

science principles

which is good but

in an idealized and

out-of-context way

which is not











































Individual Team










Passive Active





























httpkaywamefbQ5H





p p


105rdquo

7875rdquo








wwwadvantechcom




C

M

Y

CM

MY

CY

CMY

K



O N T H E B U S

The host of

information-laden

smart devices

obscures or

desensitizes us to

device problems

that would benefit

from prompt

attention












CT1504_25_OTBindd 25 33115 215 PM



Sensors typically

placed in extreme

environments often

are powered from

near-field sources

and their

associated

antennas



Extreme Wireless
















1 wired $10000

2 motes $1000




has gone down


1 800 463 9275






IDEC smart relays





1

2

3

4 10

115

6

7

8

9




1

6 7

8

9 10

11

2 3 5

4


















I n P r o c E s s



investing Big time








I n P r o c e s s


I n P r o c e s s



Ph (785) 472-4461 Fax (785) 472-3539



wwwcashcocomchem




storage tanks




storage tanks



storage tanks



CAS-225Aindd 1 11215 956 AM
















Cloud Platform


















managing director








TGT platforms

Short runS







I n P r o c e s s














I n P r o c e s s


We HaveYou Covered


CSIA

NEw mAN IN tOwN










NETWORK

OF THE

FUTURE




R E S O U R C E S















Time

Proc

ess

Vari

able














TRUE STORY

25


CT1504_36_43_CSindd 36 33115 357 PM






















Bal

luff








of purged cabinets




CT1504_36_43_CSindd 37 33115 357 PM

























































natural gas plant


Pent

air

Ho

ffman



Barrier


VR

IscIo

+VocUo-

Cable

L

C

Hazardous area

3x

no sPark no Fire

Pep

pe

rl+Fu

chs

CT1504_36_43_CSindd 38 33115 357 PM



































sified areasrdquo

















Op

timat

ion

CT1504_36_43_CSindd 40 33115 358 PM

visibly better











wwwhwllcoc3hz









sorinccom










Diagram 1

Non-hazardous area

Wago IO 750-439

Hazardousarea

Onoffswitch

Fermentationtank

Limit switch


Wall


Wag

o

CT1504_36_43_CSindd 42 33115 358 PM
















Vac

on

CT1504_36_43_CSindd 43 33115 359 PM




















by J im Montague

CT1504_45_48_Feat2indd 45 33115 240 PM






Interface Level

Product Level

Temperature





Level Plusreg






OVERSEEING ORE

Yoko

gaw

a an

d S

olv

ay

CT1504_45_48_Feat2indd 46 33115 240 PM





















US

Arm

y C

orp

s o

f Eng

ine

ers

and

R

ock

we

ll A

uto

mat

ion

CT1504_45_48_Feat2indd 47 33115 240 PM















wwwmaplesystemscom


CT1504_45_48_Feat2indd 48 33115 241 PM
















CT1504_49_51_Feat3indd 49 33115 400 PM
















Hyd

ro A

lum

inum

and

Lin

de





QuickStudyPCS block


owsPID

PID

ReactorEfuent

temperature

Efuent ow


Ad

aptiv

e R

eso

urce

s an

d S

terli

ng C

hem

ical

s

CT1504_49_51_Feat3indd 50 33115 400 PM



















CT1504_49_51_Feat3indd 51 33115 401 PM





























have an automation-



liptakbelaaolcom



Figure 1



Credit Leser LLC



Relieving pressure

Vesselpressure()

Operatingpressure

Lift ()100

80

60

40

20

0

Popping pressure


Maximum allowable


single valve

Maximum allowable


BLOWDOWN LOWDOWN

Lese

r LL

C

CT1504_52_53_ATEindd 52 33115 402 PM




















Figure 2


No credit

Air

DSO + caustic + air

Torque tube LDT

DSO outlet

DSO layer

Mesh Caustic layer

Interface

SEPARATE ELEMENTS




Figure 3


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20Time

Spec

ic gr

avity

08

09

1

11

12

13

14



CT1504_52_53_ATEindd 53 33115 402 PM


R O U N D U P









R O U N D U P























of r

eadin

g

of URL

18

16

1

2

1

8

6

4

2

00 10 20 30 40 50 60 70 80 90 100

TraditionalFoxboro







aCCuRaTe aT 801


































































ADVERTISER PAGE NO

ABB 4





AVG Automation 63

Cashco 30


Eaton 21



Endress+Hauser 6 7


ITS Enclosures 35

Load Controls 51


Maple Systems 48


Moore Industries 23

MTS Systems 46


Newark 27

Orion Instruments 3


Phoenix Contact 44

ProComSol 42


SOR 42

Wago 39















PMS 370 C

C 60M 0Y 100K 28



Custom REPRINts


rdquoWe can even

unexpectedly

introduce problems

like entrained air

and teach students

and users to

solve themrdquo



jmontagueputmanne t

















CT1504_62_CRindd 62 33115 508 PM




56millionAT RISK

65







30 3920


cost savings

schedule REDUCTION

budget amp schedule

OVERRUNS


40

FAIL

PERSONNEL

67TO

YEARS



expected to

RETIRE50


$135




Absolutely















c o n t r o l







c o v e r s t o r y



f e at u r e s




CT1504_05_07_TOCindd 5 33115 600 PM









































E-direct





CT1504_05_07_TOCindd 7 33115 601 PM


18004335700





















people to see the

attraction of a big

old plant like


foothills of the

Great Smoky

Mountains

CT1504_09_Editindd 9 33115 656 PM

800 453 6202


















using-orp














kill-hypocrisy


Multimedia Alerts

White Paper Alerts





Whatrsquos Next






100 = 23 ft

LT


FI nitrogen


H

L

SG = 1

CT1504_15_WebTOC_1indd 15 33115 602 PM



Magnetrol works

So this works

So this works






















mentors












shernerputmanne t



klarsonputmanne t













Students are taught

engineering

science principles

which is good but

in an idealized and

out-of-context way

which is not











































Individual Team










Passive Active





























httpkaywamefbQ5H





p p


105rdquo

7875rdquo








wwwadvantechcom




C

M

Y

CM

MY

CY

CMY

K



O N T H E B U S

The host of

information-laden

smart devices

obscures or

desensitizes us to

device problems

that would benefit

from prompt

attention












CT1504_25_OTBindd 25 33115 215 PM



Sensors typically

placed in extreme

environments often

are powered from

near-field sources

and their

associated

antennas



Extreme Wireless
















1 wired $10000

2 motes $1000




has gone down


1 800 463 9275






IDEC smart relays





1

2

3

4 10

115

6

7

8

9




1

6 7

8

9 10

11

2 3 5

4


















I n P r o c E s s



investing Big time








I n P r o c e s s


I n P r o c e s s



Ph (785) 472-4461 Fax (785) 472-3539



wwwcashcocomchem




storage tanks




storage tanks



storage tanks



CAS-225Aindd 1 11215 956 AM
















Cloud Platform


















managing director








TGT platforms

Short runS







I n P r o c e s s














I n P r o c e s s


We HaveYou Covered


CSIA

NEw mAN IN tOwN










NETWORK

OF THE

FUTURE




R E S O U R C E S















Time

Proc

ess

Vari

able














TRUE STORY

25


CT1504_36_43_CSindd 36 33115 357 PM






















Bal

luff








of purged cabinets




CT1504_36_43_CSindd 37 33115 357 PM

























































natural gas plant


Pent

air

Ho

ffman



Barrier


VR

IscIo

+VocUo-

Cable

L

C

Hazardous area

3x

no sPark no Fire

Pep

pe

rl+Fu

chs

CT1504_36_43_CSindd 38 33115 357 PM



































sified areasrdquo

















Op

timat

ion

CT1504_36_43_CSindd 40 33115 358 PM

visibly better











wwwhwllcoc3hz









sorinccom










Diagram 1

Non-hazardous area

Wago IO 750-439

Hazardousarea

Onoffswitch

Fermentationtank

Limit switch


Wall


Wag

o

CT1504_36_43_CSindd 42 33115 358 PM
















Vac

on

CT1504_36_43_CSindd 43 33115 359 PM




















by J im Montague

CT1504_45_48_Feat2indd 45 33115 240 PM






Interface Level

Product Level

Temperature





Level Plusreg






OVERSEEING ORE

Yoko

gaw

a an

d S

olv

ay

CT1504_45_48_Feat2indd 46 33115 240 PM





















US

Arm

y C

orp

s o

f Eng

ine

ers

and

R

ock

we

ll A

uto

mat

ion

CT1504_45_48_Feat2indd 47 33115 240 PM















wwwmaplesystemscom


CT1504_45_48_Feat2indd 48 33115 241 PM
















CT1504_49_51_Feat3indd 49 33115 400 PM
















Hyd

ro A

lum

inum

and

Lin

de





QuickStudyPCS block


owsPID

PID

ReactorEfuent

temperature

Efuent ow


Ad

aptiv

e R

eso

urce

s an

d S

terli

ng C

hem

ical

s

CT1504_49_51_Feat3indd 50 33115 400 PM



















CT1504_49_51_Feat3indd 51 33115 401 PM





























have an automation-



liptakbelaaolcom



Figure 1



Credit Leser LLC



Relieving pressure

Vesselpressure()

Operatingpressure

Lift ()100

80

60

40

20

0

Popping pressure


Maximum allowable


single valve

Maximum allowable


BLOWDOWN LOWDOWN

Lese

r LL

C

CT1504_52_53_ATEindd 52 33115 402 PM




















Figure 2


No credit

Air

DSO + caustic + air

Torque tube LDT

DSO outlet

DSO layer

Mesh Caustic layer

Interface

SEPARATE ELEMENTS




Figure 3


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20Time

Spec

ic gr

avity

08

09

1

11

12

13

14



CT1504_52_53_ATEindd 53 33115 402 PM


R O U N D U P









R O U N D U P























of r

eadin

g

of URL

18

16

1

2

1

8

6

4

2

00 10 20 30 40 50 60 70 80 90 100

TraditionalFoxboro







aCCuRaTe aT 801


































































ADVERTISER PAGE NO

ABB 4





AVG Automation 63

Cashco 30


Eaton 21



Endress+Hauser 6 7


ITS Enclosures 35

Load Controls 51


Maple Systems 48


Moore Industries 23

MTS Systems 46


Newark 27

Orion Instruments 3


Phoenix Contact 44

ProComSol 42


SOR 42

Wago 39















PMS 370 C

C 60M 0Y 100K 28



Custom REPRINts


rdquoWe can even

unexpectedly

introduce problems

like entrained air

and teach students

and users to

solve themrdquo



jmontagueputmanne t

















CT1504_62_CRindd 62 33115 508 PM




56millionAT RISK

65







30 3920


cost savings

schedule REDUCTION

budget amp schedule

OVERRUNS


40

FAIL

PERSONNEL

67TO

YEARS



expected to

RETIRE50


$135












c o n t r o l







c o v e r s t o r y



f e at u r e s




CT1504_05_07_TOCindd 5 33115 600 PM









































E-direct





CT1504_05_07_TOCindd 7 33115 601 PM


18004335700





















people to see the

attraction of a big

old plant like


foothills of the

Great Smoky

Mountains

CT1504_09_Editindd 9 33115 656 PM

800 453 6202


















using-orp














kill-hypocrisy


Multimedia Alerts

White Paper Alerts





Whatrsquos Next






100 = 23 ft

LT


FI nitrogen


H

L

SG = 1

CT1504_15_WebTOC_1indd 15 33115 602 PM



Magnetrol works

So this works

So this works






















mentors












shernerputmanne t



klarsonputmanne t













Students are taught

engineering

science principles

which is good but

in an idealized and

out-of-context way

which is not











































Individual Team










Passive Active





























httpkaywamefbQ5H





p p


105rdquo

7875rdquo








wwwadvantechcom




C

M

Y

CM

MY

CY

CMY

K



O N T H E B U S

The host of

information-laden

smart devices

obscures or

desensitizes us to

device problems

that would benefit

from prompt

attention












CT1504_25_OTBindd 25 33115 215 PM



Sensors typically

placed in extreme

environments often

are powered from

near-field sources

and their

associated

antennas



Extreme Wireless
















1 wired $10000

2 motes $1000




has gone down


1 800 463 9275






IDEC smart relays





1

2

3

4 10

115

6

7

8

9




1

6 7

8

9 10

11

2 3 5

4


















I n P r o c E s s



investing Big time








I n P r o c e s s


I n P r o c e s s



Ph (785) 472-4461 Fax (785) 472-3539



wwwcashcocomchem




storage tanks




storage tanks



storage tanks



CAS-225Aindd 1 11215 956 AM
















Cloud Platform


















managing director








TGT platforms

Short runS







I n P r o c e s s














I n P r o c e s s


We HaveYou Covered


CSIA

NEw mAN IN tOwN










NETWORK

OF THE

FUTURE




R E S O U R C E S















Time

Proc

ess

Vari

able














TRUE STORY

25


CT1504_36_43_CSindd 36 33115 357 PM






















Bal

luff








of purged cabinets




CT1504_36_43_CSindd 37 33115 357 PM

























































natural gas plant


Pent

air

Ho

ffman



Barrier


VR

IscIo

+VocUo-

Cable

L

C

Hazardous area

3x

no sPark no Fire

Pep

pe

rl+Fu

chs

CT1504_36_43_CSindd 38 33115 357 PM



































sified areasrdquo

















Op

timat

ion

CT1504_36_43_CSindd 40 33115 358 PM

visibly better











wwwhwllcoc3hz









sorinccom










Diagram 1

Non-hazardous area

Wago IO 750-439

Hazardousarea

Onoffswitch

Fermentationtank

Limit switch


Wall


Wag

o

CT1504_36_43_CSindd 42 33115 358 PM
















Vac

on

CT1504_36_43_CSindd 43 33115 359 PM




















by J im Montague

CT1504_45_48_Feat2indd 45 33115 240 PM






Interface Level

Product Level

Temperature





Level Plusreg






OVERSEEING ORE

Yoko

gaw

a an

d S

olv

ay

CT1504_45_48_Feat2indd 46 33115 240 PM





















US

Arm

y C

orp

s o

f Eng

ine

ers

and

R

ock

we

ll A

uto

mat

ion

CT1504_45_48_Feat2indd 47 33115 240 PM















wwwmaplesystemscom


CT1504_45_48_Feat2indd 48 33115 241 PM
















CT1504_49_51_Feat3indd 49 33115 400 PM
















Hyd

ro A

lum

inum

and

Lin

de





QuickStudyPCS block


owsPID

PID

ReactorEfuent

temperature

Efuent ow


Ad

aptiv

e R

eso

urce

s an

d S

terli

ng C

hem

ical

s

CT1504_49_51_Feat3indd 50 33115 400 PM



















CT1504_49_51_Feat3indd 51 33115 401 PM





























have an automation-



liptakbelaaolcom



Figure 1



Credit Leser LLC



Relieving pressure

Vesselpressure()

Operatingpressure

Lift ()100

80

60

40

20

0

Popping pressure


Maximum allowable


single valve

Maximum allowable


BLOWDOWN LOWDOWN

Lese

r LL

C

CT1504_52_53_ATEindd 52 33115 402 PM




















Figure 2


No credit

Air

DSO + caustic + air

Torque tube LDT

DSO outlet

DSO layer

Mesh Caustic layer

Interface

SEPARATE ELEMENTS




Figure 3


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20Time

Spec

ic gr

avity

08

09

1

11

12

13

14



CT1504_52_53_ATEindd 53 33115 402 PM


R O U N D U P









R O U N D U P























of r

eadin

g

of URL

18

16

1

2

1

8

6

4

2

00 10 20 30 40 50 60 70 80 90 100

TraditionalFoxboro







aCCuRaTe aT 801


































































ADVERTISER PAGE NO

ABB 4





AVG Automation 63

Cashco 30


Eaton 21



Endress+Hauser 6 7


ITS Enclosures 35

Load Controls 51


Maple Systems 48


Moore Industries 23

MTS Systems 46


Newark 27

Orion Instruments 3


Phoenix Contact 44

ProComSol 42


SOR 42

Wago 39















PMS 370 C

C 60M 0Y 100K 28



Custom REPRINts


rdquoWe can even

unexpectedly

introduce problems

like entrained air

and teach students

and users to

solve themrdquo



jmontagueputmanne t

















CT1504_62_CRindd 62 33115 508 PM




56millionAT RISK

65







30 3920


cost savings

schedule REDUCTION

budget amp schedule

OVERRUNS


40

FAIL

PERSONNEL

67TO

YEARS



expected to

RETIRE50


$135











































E-direct





CT1504_05_07_TOCindd 7 33115 601 PM


18004335700





















people to see the

attraction of a big

old plant like


foothills of the

Great Smoky

Mountains

CT1504_09_Editindd 9 33115 656 PM

800 453 6202


















using-orp














kill-hypocrisy


Multimedia Alerts

White Paper Alerts





Whatrsquos Next






100 = 23 ft

LT


FI nitrogen


H

L

SG = 1

CT1504_15_WebTOC_1indd 15 33115 602 PM



Magnetrol works

So this works

So this works






















mentors












shernerputmanne t



klarsonputmanne t













Students are taught

engineering

science principles

which is good but

in an idealized and

out-of-context way

which is not











































Individual Team










Passive Active





























httpkaywamefbQ5H





p p


105rdquo

7875rdquo








wwwadvantechcom




C

M

Y

CM

MY

CY

CMY

K



O N T H E B U S

The host of

information-laden

smart devices

obscures or

desensitizes us to

device problems

that would benefit

from prompt

attention












CT1504_25_OTBindd 25 33115 215 PM



Sensors typically

placed in extreme

environments often

are powered from

near-field sources

and their

associated

antennas



Extreme Wireless
















1 wired $10000

2 motes $1000




has gone down


1 800 463 9275






IDEC smart relays





1

2

3

4 10

115

6

7

8

9




1

6 7

8

9 10

11

2 3 5

4


















I n P r o c E s s



investing Big time








I n P r o c e s s


I n P r o c e s s



Ph (785) 472-4461 Fax (785) 472-3539



wwwcashcocomchem




storage tanks




storage tanks



storage tanks



CAS-225Aindd 1 11215 956 AM
















Cloud Platform


















managing director








TGT platforms

Short runS







I n P r o c e s s














I n P r o c e s s


We HaveYou Covered


CSIA

NEw mAN IN tOwN










NETWORK

OF THE

FUTURE




R E S O U R C E S















Time

Proc

ess

Vari

able














TRUE STORY

25


CT1504_36_43_CSindd 36 33115 357 PM






















Bal

luff








of purged cabinets




CT1504_36_43_CSindd 37 33115 357 PM

























































natural gas plant


Pent

air

Ho

ffman



Barrier


VR

IscIo

+VocUo-

Cable

L

C

Hazardous area

3x

no sPark no Fire

Pep

pe

rl+Fu

chs

CT1504_36_43_CSindd 38 33115 357 PM



































sified areasrdquo

















Op

timat

ion

CT1504_36_43_CSindd 40 33115 358 PM

visibly better











wwwhwllcoc3hz









sorinccom










Diagram 1

Non-hazardous area

Wago IO 750-439

Hazardousarea

Onoffswitch

Fermentationtank

Limit switch


Wall


Wag

o

CT1504_36_43_CSindd 42 33115 358 PM
















Vac

on

CT1504_36_43_CSindd 43 33115 359 PM




















by J im Montague

CT1504_45_48_Feat2indd 45 33115 240 PM






Interface Level

Product Level

Temperature





Level Plusreg






OVERSEEING ORE

Yoko

gaw

a an

d S

olv

ay

CT1504_45_48_Feat2indd 46 33115 240 PM





















US

Arm

y C

orp

s o

f Eng

ine

ers

and

R

ock

we

ll A

uto

mat

ion

CT1504_45_48_Feat2indd 47 33115 240 PM















wwwmaplesystemscom


CT1504_45_48_Feat2indd 48 33115 241 PM
















CT1504_49_51_Feat3indd 49 33115 400 PM
















Hyd

ro A

lum

inum

and

Lin

de





QuickStudyPCS block


owsPID

PID

ReactorEfuent

temperature

Efuent ow


Ad

aptiv

e R

eso

urce

s an

d S

terli

ng C

hem

ical

s

CT1504_49_51_Feat3indd 50 33115 400 PM



















CT1504_49_51_Feat3indd 51 33115 401 PM





























have an automation-



liptakbelaaolcom



Figure 1



Credit Leser LLC



Relieving pressure

Vesselpressure()

Operatingpressure

Lift ()100

80

60

40

20

0

Popping pressure


Maximum allowable


single valve

Maximum allowable


BLOWDOWN LOWDOWN

Lese

r LL

C

CT1504_52_53_ATEindd 52 33115 402 PM




















Figure 2


No credit

Air

DSO + caustic + air

Torque tube LDT

DSO outlet

DSO layer

Mesh Caustic layer

Interface

SEPARATE ELEMENTS




Figure 3


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20Time

Spec

ic gr

avity

08

09

1

11

12

13

14



CT1504_52_53_ATEindd 53 33115 402 PM


R O U N D U P









R O U N D U P























of r

eadin

g

of URL

18

16

1

2

1

8

6

4

2

00 10 20 30 40 50 60 70 80 90 100

TraditionalFoxboro







aCCuRaTe aT 801


































































ADVERTISER PAGE NO

ABB 4





AVG Automation 63

Cashco 30


Eaton 21



Endress+Hauser 6 7


ITS Enclosures 35

Load Controls 51


Maple Systems 48


Moore Industries 23

MTS Systems 46


Newark 27

Orion Instruments 3


Phoenix Contact 44

ProComSol 42


SOR 42

Wago 39















PMS 370 C

C 60M 0Y 100K 28



Custom REPRINts


rdquoWe can even

unexpectedly

introduce problems

like entrained air

and teach students

and users to

solve themrdquo



jmontagueputmanne t

















CT1504_62_CRindd 62 33115 508 PM




56millionAT RISK

65







30 3920


cost savings

schedule REDUCTION

budget amp schedule

OVERRUNS


40

FAIL

PERSONNEL

67TO

YEARS



expected to

RETIRE50


$135




18004335700





















people to see the

attraction of a big

old plant like


foothills of the

Great Smoky

Mountains

CT1504_09_Editindd 9 33115 656 PM

800 453 6202


















using-orp














kill-hypocrisy


Multimedia Alerts

White Paper Alerts





Whatrsquos Next






100 = 23 ft

LT


FI nitrogen


H

L

SG = 1

CT1504_15_WebTOC_1indd 15 33115 602 PM



Magnetrol works

So this works

So this works






















mentors












shernerputmanne t



klarsonputmanne t













Students are taught

engineering

science principles

which is good but

in an idealized and

out-of-context way

which is not











































Individual Team










Passive Active





























httpkaywamefbQ5H





p p


105rdquo

7875rdquo








wwwadvantechcom




C

M

Y

CM

MY

CY

CMY

K



O N T H E B U S

The host of

information-laden

smart devices

obscures or

desensitizes us to

device problems

that would benefit

from prompt

attention












CT1504_25_OTBindd 25 33115 215 PM



Sensors typically

placed in extreme

environments often

are powered from

near-field sources

and their

associated

antennas



Extreme Wireless
















1 wired $10000

2 motes $1000




has gone down


1 800 463 9275






IDEC smart relays





1

2

3

4 10

115

6

7

8

9




1

6 7

8

9 10

11

2 3 5

4


















I n P r o c E s s



investing Big time








I n P r o c e s s


I n P r o c e s s



Ph (785) 472-4461 Fax (785) 472-3539



wwwcashcocomchem




storage tanks




storage tanks



storage tanks



CAS-225Aindd 1 11215 956 AM
















Cloud Platform


















managing director








TGT platforms

Short runS







I n P r o c e s s














I n P r o c e s s


We HaveYou Covered


CSIA

NEw mAN IN tOwN










NETWORK

OF THE

FUTURE




R E S O U R C E S















Time

Proc

ess

Vari

able














TRUE STORY

25


CT1504_36_43_CSindd 36 33115 357 PM






















Bal

luff








of purged cabinets




CT1504_36_43_CSindd 37 33115 357 PM

























































natural gas plant


Pent

air

Ho

ffman



Barrier


VR

IscIo

+VocUo-

Cable

L

C

Hazardous area

3x

no sPark no Fire

Pep

pe

rl+Fu

chs

CT1504_36_43_CSindd 38 33115 357 PM



































sified areasrdquo

















Op

timat

ion

CT1504_36_43_CSindd 40 33115 358 PM

visibly better











wwwhwllcoc3hz









sorinccom










Diagram 1

Non-hazardous area

Wago IO 750-439

Hazardousarea

Onoffswitch

Fermentationtank

Limit switch


Wall


Wag

o

CT1504_36_43_CSindd 42 33115 358 PM
















Vac

on

CT1504_36_43_CSindd 43 33115 359 PM




















by J im Montague

CT1504_45_48_Feat2indd 45 33115 240 PM






Interface Level

Product Level

Temperature





Level Plusreg






OVERSEEING ORE

Yoko

gaw

a an

d S

olv

ay

CT1504_45_48_Feat2indd 46 33115 240 PM





















US

Arm

y C

orp

s o

f Eng

ine

ers

and

R

ock

we

ll A

uto

mat

ion

CT1504_45_48_Feat2indd 47 33115 240 PM















wwwmaplesystemscom


CT1504_45_48_Feat2indd 48 33115 241 PM
















CT1504_49_51_Feat3indd 49 33115 400 PM
















Hyd

ro A

lum

inum

and

Lin

de





QuickStudyPCS block


owsPID

PID

ReactorEfuent

temperature

Efuent ow


Ad

aptiv

e R

eso

urce

s an

d S

terli

ng C

hem

ical

s

CT1504_49_51_Feat3indd 50 33115 400 PM



















CT1504_49_51_Feat3indd 51 33115 401 PM





























have an automation-



liptakbelaaolcom



Figure 1



Credit Leser LLC



Relieving pressure

Vesselpressure()

Operatingpressure

Lift ()100

80

60

40

20

0

Popping pressure


Maximum allowable


single valve

Maximum allowable


BLOWDOWN LOWDOWN

Lese

r LL

C

CT1504_52_53_ATEindd 52 33115 402 PM




















Figure 2


No credit

Air

DSO + caustic + air

Torque tube LDT

DSO outlet

DSO layer

Mesh Caustic layer

Interface

SEPARATE ELEMENTS




Figure 3


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20Time

Spec

ic gr

avity

08

09

1

11

12

13

14



CT1504_52_53_ATEindd 53 33115 402 PM


R O U N D U P









R O U N D U P























of r

eadin

g

of URL

18

16

1

2

1

8

6

4

2

00 10 20 30 40 50 60 70 80 90 100

TraditionalFoxboro







aCCuRaTe aT 801


































































ADVERTISER PAGE NO

ABB 4





AVG Automation 63

Cashco 30


Eaton 21



Endress+Hauser 6 7


ITS Enclosures 35

Load Controls 51


Maple Systems 48


Moore Industries 23

MTS Systems 46


Newark 27

Orion Instruments 3


Phoenix Contact 44

ProComSol 42


SOR 42

Wago 39















PMS 370 C

C 60M 0Y 100K 28



Custom REPRINts


rdquoWe can even

unexpectedly

introduce problems

like entrained air

and teach students

and users to

solve themrdquo



jmontagueputmanne t

















CT1504_62_CRindd 62 33115 508 PM




56millionAT RISK

65







30 3920


cost savings

schedule REDUCTION

budget amp schedule

OVERRUNS


40

FAIL

PERSONNEL

67TO

YEARS



expected to

RETIRE50


$135



















people to see the

attraction of a big

old plant like


foothills of the

Great Smoky

Mountains

CT1504_09_Editindd 9 33115 656 PM

800 453 6202


















using-orp














kill-hypocrisy


Multimedia Alerts

White Paper Alerts





Whatrsquos Next






100 = 23 ft

LT


FI nitrogen


H

L

SG = 1

CT1504_15_WebTOC_1indd 15 33115 602 PM



Magnetrol works

So this works

So this works






















mentors












shernerputmanne t



klarsonputmanne t













Students are taught

engineering

science principles

which is good but

in an idealized and

out-of-context way

which is not











































Individual Team










Passive Active





























httpkaywamefbQ5H





p p


105rdquo

7875rdquo








wwwadvantechcom




C

M

Y

CM

MY

CY

CMY

K



O N T H E B U S

The host of

information-laden

smart devices

obscures or

desensitizes us to

device problems

that would benefit

from prompt

attention












CT1504_25_OTBindd 25 33115 215 PM



Sensors typically

placed in extreme

environments often

are powered from

near-field sources

and their

associated

antennas



Extreme Wireless
















1 wired $10000

2 motes $1000




has gone down


1 800 463 9275






IDEC smart relays





1

2

3

4 10

115

6

7

8

9




1

6 7

8

9 10

11

2 3 5

4


















I n P r o c E s s



investing Big time








I n P r o c e s s


I n P r o c e s s



Ph (785) 472-4461 Fax (785) 472-3539



wwwcashcocomchem




storage tanks




storage tanks



storage tanks



CAS-225Aindd 1 11215 956 AM
















Cloud Platform


















managing director








TGT platforms

Short runS







I n P r o c e s s














I n P r o c e s s


We HaveYou Covered


CSIA

NEw mAN IN tOwN










NETWORK

OF THE

FUTURE




R E S O U R C E S















Time

Proc

ess

Vari

able














TRUE STORY

25


CT1504_36_43_CSindd 36 33115 357 PM






















Bal

luff








of purged cabinets




CT1504_36_43_CSindd 37 33115 357 PM

























































natural gas plant


Pent

air

Ho

ffman



Barrier


VR

IscIo

+VocUo-

Cable

L

C

Hazardous area

3x

no sPark no Fire

Pep

pe

rl+Fu

chs

CT1504_36_43_CSindd 38 33115 357 PM



































sified areasrdquo

















Op

timat

ion

CT1504_36_43_CSindd 40 33115 358 PM

visibly better











wwwhwllcoc3hz









sorinccom










Diagram 1

Non-hazardous area

Wago IO 750-439

Hazardousarea

Onoffswitch

Fermentationtank

Limit switch


Wall


Wag

o

CT1504_36_43_CSindd 42 33115 358 PM
















Vac

on

CT1504_36_43_CSindd 43 33115 359 PM




















by J im Montague

CT1504_45_48_Feat2indd 45 33115 240 PM






Interface Level

Product Level

Temperature





Level Plusreg






OVERSEEING ORE

Yoko

gaw

a an

d S

olv

ay

CT1504_45_48_Feat2indd 46 33115 240 PM





















US

Arm

y C

orp

s o

f Eng

ine

ers

and

R

ock

we

ll A

uto

mat

ion

CT1504_45_48_Feat2indd 47 33115 240 PM















wwwmaplesystemscom


CT1504_45_48_Feat2indd 48 33115 241 PM
















CT1504_49_51_Feat3indd 49 33115 400 PM
















Hyd

ro A

lum

inum

and

Lin

de





QuickStudyPCS block


owsPID

PID

ReactorEfuent

temperature

Efuent ow


Ad

aptiv

e R

eso

urce

s an

d S

terli

ng C

hem

ical

s

CT1504_49_51_Feat3indd 50 33115 400 PM



















CT1504_49_51_Feat3indd 51 33115 401 PM





























have an automation-



liptakbelaaolcom



Figure 1



Credit Leser LLC



Relieving pressure

Vesselpressure()

Operatingpressure

Lift ()100

80

60

40

20

0

Popping pressure


Maximum allowable


single valve

Maximum allowable


BLOWDOWN LOWDOWN

Lese

r LL

C

CT1504_52_53_ATEindd 52 33115 402 PM




















Figure 2


No credit

Air

DSO + caustic + air

Torque tube LDT

DSO outlet

DSO layer

Mesh Caustic layer

Interface

SEPARATE ELEMENTS




Figure 3


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20Time

Spec

ic gr

avity

08

09

1

11

12

13

14



CT1504_52_53_ATEindd 53 33115 402 PM


R O U N D U P









R O U N D U P























of r

eadin

g

of URL

18

16

1

2

1

8

6

4

2

00 10 20 30 40 50 60 70 80 90 100

TraditionalFoxboro







aCCuRaTe aT 801


































































ADVERTISER PAGE NO

ABB 4





AVG Automation 63

Cashco 30


Eaton 21



Endress+Hauser 6 7


ITS Enclosures 35

Load Controls 51


Maple Systems 48


Moore Industries 23

MTS Systems 46


Newark 27

Orion Instruments 3


Phoenix Contact 44

ProComSol 42


SOR 42

Wago 39















PMS 370 C

C 60M 0Y 100K 28



Custom REPRINts


rdquoWe can even

unexpectedly

introduce problems

like entrained air

and teach students

and users to

solve themrdquo



jmontagueputmanne t

















CT1504_62_CRindd 62 33115 508 PM




56millionAT RISK

65







30 3920


cost savings

schedule REDUCTION

budget amp schedule

OVERRUNS


40

FAIL

PERSONNEL

67TO

YEARS



expected to

RETIRE50


$135



800 453 6202


















using-orp














kill-hypocrisy


Multimedia Alerts

White Paper Alerts





Whatrsquos Next






100 = 23 ft

LT


FI nitrogen


H

L

SG = 1

CT1504_15_WebTOC_1indd 15 33115 602 PM



Magnetrol works

So this works

So this works






















mentors












shernerputmanne t



klarsonputmanne t













Students are taught

engineering

science principles

which is good but

in an idealized and

out-of-context way

which is not











































Individual Team










Passive Active





























httpkaywamefbQ5H





p p


105rdquo

7875rdquo








wwwadvantechcom




C

M

Y

CM

MY

CY

CMY

K



O N T H E B U S

The host of

information-laden

smart devices

obscures or

desensitizes us to

device problems

that would benefit

from prompt

attention












CT1504_25_OTBindd 25 33115 215 PM



Sensors typically

placed in extreme

environments often

are powered from

near-field sources

and their

associated

antennas



Extreme Wireless
















1 wired $10000

2 motes $1000




has gone down


1 800 463 9275






IDEC smart relays





1

2

3

4 10

115

6

7

8

9




1

6 7

8

9 10

11

2 3 5

4


















I n P r o c E s s



investing Big time








I n P r o c e s s


I n P r o c e s s



Ph (785) 472-4461 Fax (785) 472-3539



wwwcashcocomchem




storage tanks




storage tanks



storage tanks



CAS-225Aindd 1 11215 956 AM
















Cloud Platform


















managing director








TGT platforms

Short runS







I n P r o c e s s














I n P r o c e s s


We HaveYou Covered


CSIA

NEw mAN IN tOwN










NETWORK

OF THE

FUTURE




R E S O U R C E S















Time

Proc

ess

Vari

able














TRUE STORY

25


CT1504_36_43_CSindd 36 33115 357 PM






















Bal

luff








of purged cabinets




CT1504_36_43_CSindd 37 33115 357 PM

























































natural gas plant


Pent

air

Ho

ffman



Barrier


VR

IscIo

+VocUo-

Cable

L

C

Hazardous area

3x

no sPark no Fire

Pep

pe

rl+Fu

chs

CT1504_36_43_CSindd 38 33115 357 PM



































sified areasrdquo

















Op

timat

ion

CT1504_36_43_CSindd 40 33115 358 PM

visibly better











wwwhwllcoc3hz









sorinccom










Diagram 1

Non-hazardous area

Wago IO 750-439

Hazardousarea

Onoffswitch

Fermentationtank

Limit switch


Wall


Wag

o

CT1504_36_43_CSindd 42 33115 358 PM
















Vac

on

CT1504_36_43_CSindd 43 33115 359 PM




















by J im Montague

CT1504_45_48_Feat2indd 45 33115 240 PM






Interface Level

Product Level

Temperature





Level Plusreg






OVERSEEING ORE

Yoko

gaw

a an

d S

olv

ay

CT1504_45_48_Feat2indd 46 33115 240 PM





















US

Arm

y C

orp

s o

f Eng

ine

ers

and

R

ock

we

ll A

uto

mat

ion

CT1504_45_48_Feat2indd 47 33115 240 PM















wwwmaplesystemscom


CT1504_45_48_Feat2indd 48 33115 241 PM
















CT1504_49_51_Feat3indd 49 33115 400 PM
















Hyd

ro A

lum

inum

and

Lin

de





QuickStudyPCS block


owsPID

PID

ReactorEfuent

temperature

Efuent ow


Ad

aptiv

e R

eso

urce

s an

d S

terli

ng C

hem

ical

s

CT1504_49_51_Feat3indd 50 33115 400 PM



















CT1504_49_51_Feat3indd 51 33115 401 PM





























have an automation-



liptakbelaaolcom



Figure 1



Credit Leser LLC



Relieving pressure

Vesselpressure()

Operatingpressure

Lift ()100

80

60

40

20

0

Popping pressure


Maximum allowable


single valve

Maximum allowable


BLOWDOWN LOWDOWN

Lese

r LL

C

CT1504_52_53_ATEindd 52 33115 402 PM




















Figure 2


No credit

Air

DSO + caustic + air

Torque tube LDT

DSO outlet

DSO layer

Mesh Caustic layer

Interface

SEPARATE ELEMENTS




Figure 3


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20Time

Spec

ic gr

avity

08

09

1

11

12

13

14



CT1504_52_53_ATEindd 53 33115 402 PM


R O U N D U P









R O U N D U P























of r

eadin

g

of URL

18

16

1

2

1

8

6

4

2

00 10 20 30 40 50 60 70 80 90 100

TraditionalFoxboro







aCCuRaTe aT 801


































































ADVERTISER PAGE NO

ABB 4





AVG Automation 63

Cashco 30


Eaton 21



Endress+Hauser 6 7


ITS Enclosures 35

Load Controls 51


Maple Systems 48


Moore Industries 23

MTS Systems 46


Newark 27

Orion Instruments 3


Phoenix Contact 44

ProComSol 42


SOR 42

Wago 39















PMS 370 C

C 60M 0Y 100K 28



Custom REPRINts


rdquoWe can even

unexpectedly

introduce problems

like entrained air

and teach students

and users to

solve themrdquo



jmontagueputmanne t

















CT1504_62_CRindd 62 33115 508 PM




56millionAT RISK

65







30 3920


cost savings

schedule REDUCTION

budget amp schedule

OVERRUNS


40

FAIL

PERSONNEL

67TO

YEARS



expected to

RETIRE50


$135



















using-orp














kill-hypocrisy


Multimedia Alerts

White Paper Alerts





Whatrsquos Next






100 = 23 ft

LT


FI nitrogen


H

L

SG = 1

CT1504_15_WebTOC_1indd 15 33115 602 PM



Magnetrol works

So this works

So this works






















mentors












shernerputmanne t



klarsonputmanne t













Students are taught

engineering

science principles

which is good but

in an idealized and

out-of-context way

which is not











































Individual Team










Passive Active





























httpkaywamefbQ5H





p p


105rdquo

7875rdquo








wwwadvantechcom




C

M

Y

CM

MY

CY

CMY

K



O N T H E B U S

The host of

information-laden

smart devices

obscures or

desensitizes us to

device problems

that would benefit

from prompt

attention












CT1504_25_OTBindd 25 33115 215 PM



Sensors typically

placed in extreme

environments often

are powered from

near-field sources

and their

associated

antennas



Extreme Wireless
















1 wired $10000

2 motes $1000




has gone down


1 800 463 9275






IDEC smart relays





1

2

3

4 10

115

6

7

8

9




1

6 7

8

9 10

11

2 3 5

4


















I n P r o c E s s



investing Big time








I n P r o c e s s


I n P r o c e s s



Ph (785) 472-4461 Fax (785) 472-3539



wwwcashcocomchem




storage tanks




storage tanks



storage tanks



CAS-225Aindd 1 11215 956 AM
















Cloud Platform


















managing director








TGT platforms

Short runS







I n P r o c e s s














I n P r o c e s s


We HaveYou Covered


CSIA

NEw mAN IN tOwN










NETWORK

OF THE

FUTURE




R E S O U R C E S















Time

Proc

ess

Vari

able














TRUE STORY

25


CT1504_36_43_CSindd 36 33115 357 PM






















Bal

luff








of purged cabinets




CT1504_36_43_CSindd 37 33115 357 PM

























































natural gas plant


Pent

air

Ho

ffman



Barrier


VR

IscIo

+VocUo-

Cable

L

C

Hazardous area

3x

no sPark no Fire

Pep

pe

rl+Fu

chs

CT1504_36_43_CSindd 38 33115 357 PM



































sified areasrdquo

















Op

timat

ion

CT1504_36_43_CSindd 40 33115 358 PM

visibly better











wwwhwllcoc3hz









sorinccom










Diagram 1

Non-hazardous area

Wago IO 750-439

Hazardousarea

Onoffswitch

Fermentationtank

Limit switch


Wall


Wag

o

CT1504_36_43_CSindd 42 33115 358 PM
















Vac

on

CT1504_36_43_CSindd 43 33115 359 PM




















by J im Montague

CT1504_45_48_Feat2indd 45 33115 240 PM






Interface Level

Product Level

Temperature





Level Plusreg






OVERSEEING ORE

Yoko

gaw

a an

d S

olv

ay

CT1504_45_48_Feat2indd 46 33115 240 PM





















US

Arm

y C

orp

s o

f Eng

ine

ers

and

R

ock

we

ll A

uto

mat

ion

CT1504_45_48_Feat2indd 47 33115 240 PM















wwwmaplesystemscom


CT1504_45_48_Feat2indd 48 33115 241 PM
















CT1504_49_51_Feat3indd 49 33115 400 PM
















Hyd

ro A

lum

inum

and

Lin

de





QuickStudyPCS block


owsPID

PID

ReactorEfuent

temperature

Efuent ow


Ad

aptiv

e R

eso

urce

s an

d S

terli

ng C

hem

ical

s

CT1504_49_51_Feat3indd 50 33115 400 PM



















CT1504_49_51_Feat3indd 51 33115 401 PM





























have an automation-



liptakbelaaolcom



Figure 1



Credit Leser LLC



Relieving pressure

Vesselpressure()

Operatingpressure

Lift ()100

80

60

40

20

0

Popping pressure


Maximum allowable


single valve

Maximum allowable


BLOWDOWN LOWDOWN

Lese

r LL

C

CT1504_52_53_ATEindd 52 33115 402 PM




















Figure 2


No credit

Air

DSO + caustic + air

Torque tube LDT

DSO outlet

DSO layer

Mesh Caustic layer

Interface

SEPARATE ELEMENTS




Figure 3


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20Time

Spec

ic gr

avity

08

09

1

11

12

13

14



CT1504_52_53_ATEindd 53 33115 402 PM


R O U N D U P









R O U N D U P























of r

eadin

g

of URL

18

16

1

2

1

8

6

4

2

00 10 20 30 40 50 60 70 80 90 100

TraditionalFoxboro







aCCuRaTe aT 801


































































ADVERTISER PAGE NO

ABB 4





AVG Automation 63

Cashco 30


Eaton 21



Endress+Hauser 6 7


ITS Enclosures 35

Load Controls 51


Maple Systems 48


Moore Industries 23

MTS Systems 46


Newark 27

Orion Instruments 3


Phoenix Contact 44

ProComSol 42


SOR 42

Wago 39















PMS 370 C

C 60M 0Y 100K 28



Custom REPRINts


rdquoWe can even

unexpectedly

introduce problems

like entrained air

and teach students

and users to

solve themrdquo



jmontagueputmanne t

















CT1504_62_CRindd 62 33115 508 PM




56millionAT RISK

65







30 3920


cost savings

schedule REDUCTION

budget amp schedule

OVERRUNS


40

FAIL

PERSONNEL

67TO

YEARS



expected to

RETIRE50


$135





Magnetrol works

So this works

So this works






















mentors












shernerputmanne t



klarsonputmanne t













Students are taught

engineering

science principles

which is good but

in an idealized and

out-of-context way

which is not











































Individual Team










Passive Active





























httpkaywamefbQ5H





p p


105rdquo

7875rdquo








wwwadvantechcom




C

M

Y

CM

MY

CY

CMY

K



O N T H E B U S

The host of

information-laden

smart devices

obscures or

desensitizes us to

device problems

that would benefit

from prompt

attention












CT1504_25_OTBindd 25 33115 215 PM



Sensors typically

placed in extreme

environments often

are powered from

near-field sources

and their

associated

antennas



Extreme Wireless
















1 wired $10000

2 motes $1000




has gone down


1 800 463 9275






IDEC smart relays





1

2

3

4 10

115

6

7

8

9




1

6 7

8

9 10

11

2 3 5

4


















I n P r o c E s s



investing Big time








I n P r o c e s s


I n P r o c e s s



Ph (785) 472-4461 Fax (785) 472-3539



wwwcashcocomchem




storage tanks




storage tanks



storage tanks



CAS-225Aindd 1 11215 956 AM
















Cloud Platform


















managing director








TGT platforms

Short runS







I n P r o c e s s














I n P r o c e s s


We HaveYou Covered


CSIA

NEw mAN IN tOwN










NETWORK

OF THE

FUTURE




R E S O U R C E S















Time

Proc

ess

Vari

able














TRUE STORY

25


CT1504_36_43_CSindd 36 33115 357 PM






















Bal

luff








of purged cabinets




CT1504_36_43_CSindd 37 33115 357 PM

























































natural gas plant


Pent

air

Ho

ffman



Barrier


VR

IscIo

+VocUo-

Cable

L

C

Hazardous area

3x

no sPark no Fire

Pep

pe

rl+Fu

chs

CT1504_36_43_CSindd 38 33115 357 PM



































sified areasrdquo

















Op

timat

ion

CT1504_36_43_CSindd 40 33115 358 PM

visibly better











wwwhwllcoc3hz









sorinccom










Diagram 1

Non-hazardous area

Wago IO 750-439

Hazardousarea

Onoffswitch

Fermentationtank

Limit switch


Wall


Wag

o

CT1504_36_43_CSindd 42 33115 358 PM
















Vac

on

CT1504_36_43_CSindd 43 33115 359 PM




















by J im Montague

CT1504_45_48_Feat2indd 45 33115 240 PM






Interface Level

Product Level

Temperature





Level Plusreg






OVERSEEING ORE

Yoko

gaw

a an

d S

olv

ay

CT1504_45_48_Feat2indd 46 33115 240 PM





















US

Arm

y C

orp

s o

f Eng

ine

ers

and

R

ock

we

ll A

uto

mat

ion

CT1504_45_48_Feat2indd 47 33115 240 PM















wwwmaplesystemscom


CT1504_45_48_Feat2indd 48 33115 241 PM
















CT1504_49_51_Feat3indd 49 33115 400 PM
















Hyd

ro A

lum

inum

and

Lin

de





QuickStudyPCS block


owsPID

PID

ReactorEfuent

temperature

Efuent ow


Ad

aptiv

e R

eso

urce

s an

d S

terli

ng C

hem

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CT1504_49_51_Feat3indd 50 33115 400 PM



















CT1504_49_51_Feat3indd 51 33115 401 PM





























have an automation-



liptakbelaaolcom



Figure 1



Credit Leser LLC



Relieving pressure

Vesselpressure()

Operatingpressure

Lift ()100

80

60

40

20

0

Popping pressure


Maximum allowable


single valve

Maximum allowable


BLOWDOWN LOWDOWN

Lese

r LL

C

CT1504_52_53_ATEindd 52 33115 402 PM




















Figure 2


No credit

Air

DSO + caustic + air

Torque tube LDT

DSO outlet

DSO layer

Mesh Caustic layer

Interface

SEPARATE ELEMENTS




Figure 3


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20Time

Spec

ic gr

avity

08

09

1

11

12

13

14



CT1504_52_53_ATEindd 53 33115 402 PM


R O U N D U P









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CT1504_62_CRindd 62 33115 508 PM




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CT1504_25_OTBindd 25 33115 215 PM



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natural gas plant


Pent

air

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ffman



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Diagram 1

Non-hazardous area

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Hazardousarea

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Limit switch


Wall


Wag

o

CT1504_36_43_CSindd 42 33115 358 PM
















Vac

on

CT1504_36_43_CSindd 43 33115 359 PM




















by J im Montague

CT1504_45_48_Feat2indd 45 33115 240 PM






Interface Level

Product Level

Temperature





Level Plusreg






OVERSEEING ORE

Yoko

gaw

a an

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olv

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CT1504_45_48_Feat2indd 46 33115 240 PM





















US

Arm

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and

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CT1504_45_48_Feat2indd 47 33115 240 PM















wwwmaplesystemscom


CT1504_45_48_Feat2indd 48 33115 241 PM
















CT1504_49_51_Feat3indd 49 33115 400 PM
















Hyd

ro A

lum

inum

and

Lin

de





QuickStudyPCS block


owsPID

PID

ReactorEfuent

temperature

Efuent ow


Ad

aptiv

e R

eso

urce

s an

d S

terli

ng C

hem

ical

s

CT1504_49_51_Feat3indd 50 33115 400 PM



















CT1504_49_51_Feat3indd 51 33115 401 PM





























have an automation-



liptakbelaaolcom



Figure 1



Credit Leser LLC



Relieving pressure

Vesselpressure()

Operatingpressure

Lift ()100

80

60

40

20

0

Popping pressure


Maximum allowable


single valve

Maximum allowable


BLOWDOWN LOWDOWN

Lese

r LL

C

CT1504_52_53_ATEindd 52 33115 402 PM




















Figure 2


No credit

Air

DSO + caustic + air

Torque tube LDT

DSO outlet

DSO layer

Mesh Caustic layer

Interface

SEPARATE ELEMENTS




Figure 3


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20Time

Spec

ic gr

avity

08

09

1

11

12

13

14



CT1504_52_53_ATEindd 53 33115 402 PM


R O U N D U P









R O U N D U P























of r

eadin

g

of URL

18

16

1

2

1

8

6

4

2

00 10 20 30 40 50 60 70 80 90 100

TraditionalFoxboro







aCCuRaTe aT 801


































































ADVERTISER PAGE NO

ABB 4





AVG Automation 63

Cashco 30


Eaton 21



Endress+Hauser 6 7


ITS Enclosures 35

Load Controls 51


Maple Systems 48


Moore Industries 23

MTS Systems 46


Newark 27

Orion Instruments 3


Phoenix Contact 44

ProComSol 42


SOR 42

Wago 39















PMS 370 C

C 60M 0Y 100K 28



Custom REPRINts


rdquoWe can even

unexpectedly

introduce problems

like entrained air

and teach students

and users to

solve themrdquo



jmontagueputmanne t

















CT1504_62_CRindd 62 33115 508 PM




56millionAT RISK

65







30 3920


cost savings

schedule REDUCTION

budget amp schedule

OVERRUNS


40

FAIL

PERSONNEL

67TO

YEARS



expected to

RETIRE50


$135

