control

PIG IRON GETS A BRAIN

EMBRACING THE SAFETY LIFECYCLE

SIL FOR FIRE AND GAS

SYSTEMS?

Combining building and process automation

systems can ease plant support, but be prepared

to ante up.

NO

VE

MB

ER

20

14

Combining building

BetterTogether?

CT1411_01_CVR.indd 5 11/5/14 9:41 AM

Collect. Analyze. Act.Avantis Condition Manager. Turning events into improvement opportunities.Why be satisfied with status quo? With Condition Manager, you can collect raw data in real-time, analyze pending equipment failures on the spot and act with informed contextual information. Condition Manager collects information from any asset and drives maintenance workflow in any asset management system.

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Collect. Analyze. Act.Avantis Condition Manager. Turning events into improvement opportunities.Why be satisfied with status quo? With Condition Manager, you can collect raw data in real-time, analyze pending equipment failures on the spot and act with informed contextual information. Condition Manager collects information from any asset and drives maintenance workflow in any asset management system.

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Process and power automationBetter together

It just makes sense. Every industrial process is dependent on power to operate. In order to provide visibility, it's long been the status quo for information from various electrical components to be brought into the automation system through hardwired I/O signals. Using System 800xAs digital fieldbus technologies (IEC 61850, MODBUS TCP, PROFINET, FOUNDATION Fieldbus, Ethernet IP), users can not only import status information without adding to a project's I/O count, but they are afforded better diagnostic and load information, enabling predictive maintenance and opportunities to save energy.

System 800xA. Its all about control.

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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. Wood eld Rd., Ste. 400N, Schaumburg, IL 60173. (Phone 630/467-1300; Fax 630/467-1124.) Address all correspondence to Editorial and Executive Of ces,

same address. Periodicals Postage Paid at Schaumburg, IL, and at additional mailing of ces. Printed in the United States. Putman Media 2014. All rights reserved. The contents of this publication may not be reproduced in whole or part

without consent of the copyright owner. POSTMASTER: Send address changes to CONTROL, P.O. Box 3428, Northbrook, IL 60065-3428. SUBSCRIPTIONS: Quali ed-reader subscriptions are accepted from Operating Management in the

control industry at no charge. To apply for quali ed-reader subscription, ll in subscription form. To non-quali ed subscribers in the Unites States and its possessions, subscriptions are $96.00 per year. Single copies are $15. International subscriptions

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

Frontier/BWI,PO Box 1051,Fort Erie,Ontario, Canada, L2A 5N8.

N O V E M B E R / 2 0 1 4 www.controlglobal.com 5

November 2014 Volume XXVII Number 11

F E AT U R E S2 5 Y E A R S O F C O N T R O L

47 / Pig Iron Gets a BrainOver the past 25 years, valve technology has consistently out-run what you generally nd in the eld. by Paul Studebaker

P R O C E S S S A F E T Y

53 / Embracing the Safety Lifecycle BP and Emerson Process Management show how to prevent systemic failures in safety instrumented systems. by Jim Montague

A S S E T M A N A G E M E N T

57 / Design to the Abilities Use these ve perspectives to improve functionality and reduce lifecycle cost. by William Mostia, PE

Combined building and process automation systems can ease plant support, but be prepared to ante up. by Dan Hebert, PE

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

So Many Tuning Rules, So Little TimeControl Hall of Famer Greg McMillan walks you through the complexities of loop tuning. www.controlglobal.com/whitepapers/2014/so-many-tuning-rules-so-little-time/

Combined building and process

BetterTogether? Together?

32

CT1411_05_07_TOC.indd 5 11/5/14 10:44 AM

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N o v e m b e r / 2 0 1 4 www.controlglobal.com 7

November 2014 Volume XXVII Number 11

Food & Kindred Products.....................................................................................15,398Chemicals & Allied Products .................................................................................9,095 Systems Integrators & Engineering Design Firms ..................................................7,458Primary Metal Industries ........................................................................................4,272Electric, Gas & Sanitary Services ...........................................................................3,847Petroleum Refining & Related Industries ................................................................3,600Miscellaneous Manufacturers ................................................................................3,597

Paper & Allied Products .........................................................................................3,522Pharmaceuticals .....................................................................................................3,496Rubber & Miscellaneous Plastic Products .............................................................2,855Stone, Clay, Glass & Concrete Products ................................................................1,733Textile Mill Products ..............................................................................................1,047Tobacco Products ......................................................................................................100Total Circulation ...................................................................................................60,020

CirCulation audited june 2014

9 / editors PageMeet Us at the Cornersits where the actionand the progressare.

11 / Control onlineraising the next generation of engineers, building better plant information libraries, and chemistry saves the world.

13 / Feedbackour readers on standards, fieldbus and losing the manuals.

14 / Lessons LearnedSIS: Standards by CommitteeCurrent SiS standards are like baby camels; they need more work to make them truly useful.

19 / on the busTwo Buses, One FoundationWhat the merger of the Foundation and Hart fieldbus groups really means.

20 / Without WiresHands-Free ValvesWhy are we still messing about with manually controlled valves?

22 / In ProcessGe intelligent Platforms looks to a cloudy future; aBBs new oil and gas center; Sthrenberg takes control at Phoenix Contact; and other process news.

30 / resourcesPlCs and industrial computers online.

61 / Technically SpeakingBACnet for Process Control? Really.its not a plug-and-play hack, but connecting these systems makes sense in some cases.

62 / Ask the expertsIs SIL Required for Fire and Gas Systems?our experts sort through the complexities of safety systems.

65 / roundupthe latest in level technology is here.

68 / Productsan exclusive look at MaCteks Viator+ uSB Hart interface, plus dataloggers, pressure transmitters and transducers, butterfly valves and more.

71 / Control TalkGetting Started for Start-UpsMcMillan, Weiner and Maverick technologies tim Green talk safe startups and how to do them.

73 / Ad Indexthese folks would like a word with you.

74 / Control report Dig Out of the Buzzword Blizzard What are the next big things actually going to do for you?

Jeff Immelt, CEO of GE, addresses

the audience at the GE Intelligent

Platforms user conference.

MACTeks new Viator+ USB HART

interface offers a novel route to

connectivity.

the ceo speaks

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1411-Control-P3000-ENETIP-MAG.indd 1 10/16/14 9:34 AM


Paul Studebaker Editor in chiEfps [email protected] t

E D I T O R S P A G E


Honeywell is not

the only process

control company

with expertise in

other fields.

i ts common knowledge that innovation of-ten lies at the intersections of developments in established fieldsjust Google innova-tion happens at intersections. You can even read a book about it, titled The Medici Effect: Breakthrough Insights at the Intersections of Ideas, Concepts and Cultures. The point is that we need to get outside our individual fields of expertise to see the possibilities coming from other directions.

So I was a little disappointed, if not surprised, that this months cover story on the state of the art of integrating process and building automa-tion systems doesnt overflow with innovations.

Yes, you can gain the expected efficiencies in energy, manpower, maintenance and de-cision-making by using a single system or by closely integrating building and automation systems, but there are plenty of drawbacks. So like any engineering problem, theres a need to do a cost-benefit analysis, and find the sweet spot thats most likely to yield the highest ROI. Thats the state of the art.

I think that state is in flux. Just as were find-ing that integrating IT and control systems has led to a revolution in critical decision-making, and joining safety and process systems is offer-ing the potential to reduce costs while signif-icantly improving both functions, we can ex-pect merging building and automation systems to bring some surprising benefits.

We were given a glimpse of the possibili-ties at the recent opening of Honeywells new customer experience center in Houston. De-signed to bring to life new, high-tech innova-tions for the companys traditional automa-tion clients in process industries, the center includes a plant control room outfitted with Honeywells Experion Process Knowledge System (PKS). The beautiful Orion console demonstrates large, integrated screens, touch-screen displays, mobile device capabilities and other technologies that assist plant operators who are charged with running some of the

worlds most critical and complex manufac-turing facilities.

The PKS displays and drill-downs are de-signed to support situational awareness, and or-chestration brings relevant graphics up in sets to direct the operators attention where its needed the most. That can include video surveillance with cameras that automatically shift and focus to present a view of a fire or other emergency, or of an intruder breaching the perimeter fence.

Operators can pan through and zoom large displays, and integrated procedures guide and validate their progress through unfamiliar start-up and shutdown procedures. An integrated collaboration station offers the right level of detail for engineers and managers to facilitate real-time, high-level decisions.

As process control specialists, were all familiar with Honeywell as the company that pioneered the distributed control system, but we might forget that it also specializes in cyber and physical secu-rity, as well as process and personnel safety. Hon-eywells new customer center reminds us with dis-plays of personal protective equipment and cyber security systems, as well as field instrumentation.

Honeywell is not the only process control com-pany with expertise in other fields. ABB, Emer-son, GE, Rockwell, Schneider/Invensys and Sie-mens all have notable strengths in both highly and vaguely related fields from power systems and transportation to appliances and, of course, building automation. These other product lines range from industrial to commercial to consumer, where developments in web connectivity, perva-sive sensing, human-centered design and many other areas are coming on hot, heavy and cheap.

Here at Control, were always keeping an eye out for innovations at the intersections, asking questions, and finding out about how theyre relating to process automation. If you know of something we havent covered, drop me a line. If youre interested, stay tuned.

Meet Us at the corners

CT1411_09_Edit.indd 9 11/5/14 9:47 AM

800 453 6202



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

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C o N t r o l o N l i N E

Worms in Your Molassas?Read how American Crystal Sugar got

itself out of a sticky situation with a

new kind of RTD flexible sensor. www.

controlglobal.com/whitepapers/2014/

measuring-molasses-with-a-worm

Attack of the DragonflyThis newest bit of malware is a nasty bug

indeed. This two-part article analyzes it,

its targets, methods of attacks, results,

and how to defend against it. www.

controlglobal.com/whitepapers/2014/

defending-against-the-dragonfly-cyber-

security-attacks-part-a-identifying-the-

targets and www.controlglobal.com/

whitepapers/2014/defending-against-

the-dragonfly-cybersecurity-attack-

part-b-analyzing-the-malware

Accurate, Reliable Temperature MeasurementThis webinar will help you improve

citical temperature measurement

practices. www.controlglobal.com/

whitepapers/2014/emersons-offers-

free-webinar-on-high-accuracy-and-

reliability

Free Ebook on Process AutomationIndustry Guide to Control System En-

gineering has helpful resources and

tips for the specification, design and

installation of automated control sys-

tems. www.controlglobal.com/white-

papers/2014/download-an-industry-

guide-to-control-system-engineering

Our September cover story, Spring Chickens (www.controlglobal.com/articles/2014/auto-mation-companies-prepare-younger-genera-tions-to-replace-retiring-employees), addresses the challenges of growing and acquiring newly minted engineers, and turning them into the seasoned pro-fessionals needed to keep operations running, and has generated a lot of readership. So has the podcast conversation between Controls executive editor Jim Montague and ARCs Dick Hill at www.control-global.com/multimedia/2014/podcast-stem-spring-chickens-.

The Cure for Opaque AutomationThe reason why procedures become opaque is that theyre designed by clever engineers and programmers, who are focused on getting the job done without considering the need for a clear human interface. The result is inscrutable logic encoded into procedures that are not readable by ordinary mortals, assuming that most people dont know a database from first base, writes William Hawkins in The Case for Using Natural Language. Find Hawkins cure at www.controlglobal.com/articles/2014/process-automation-programming-language-one-for-all.

Building a Better Plant Information LibraryThere are four stages of content management maturity: content under control, access anywhere, managing change and integra-tion with the business. Sounds easy enough when put that way, but as with all such projects, the reality is not so simple. Senior Technical Editor Dan Hebert walks you through the process of getting those piles of paperwork everyone needs and no one wants to deal with under control and available where, when and for whom theyre needed. www.controlglobal.com/articles/2014/improve-access-to-plant-information.

Chemistry Saves the WorldPeople such as Steve Jobs and Henry Ford get all the credit, admittedly much of it well-deserved, for world-changing inventions or developments. But that leaves some of the most important inventions that underlie our civilization flying well under the radar (Can you say clean drinking water?). Heres where the Top 10 Chemically Engineered Inventions come in. Check www.controlglobal.com/in-dustrynews/2014/top-10-chemically-engineered-inventions for the complete list. Lets hear it for chemical engineers!

Raising the Next Generation of Engineers

SE

PT

EM

BE

R 2

01

4

A BETTER WAY TO HANDLE CONSTRAINTS

OPERATORS GET WHAT THEY DESERVE

FLEXIBILITY FUELS STRONG MOTORS THE YOUNG ENGINEERS FIRST LIBRARY

How targeted programs are raising a fresh fl ock of fl edglings to replace retiring engineers and technicians.

SpringChickens

CT1409_01_CVR.indd 9 8/26/14 8:49 AM

Projectdenition

Time

Projecttest and

integration

Concepts ofoperations

Requirementsand

architecture

Detaileddesign

Operationand

maintenance

Systemverication

and validation

Integration,test and

verication

Vericationand

validation

IMPLEMENTATION

CT1411_11_WebTOC.indd 11 11/3/14 8:26 PM

The Emerson logo is a trademark and service mark of Emerson Electric Co. 2014 Fisher Controls International LLC. D352316X012 MAA2

You can move forward and run at a higher level with Fisher control valves and instruments. We understand that you need to keep employees safe and equipment in compliance with regulations. And thats getting more difficult as the process industry changes. Fisher products can help you maintain a safer operation and meet growing regulatory demands. You can experience our commitment to innovation in process control firsthand with a visit to the Emerson Innovation Center for Fisher Technology. There, Fisher products are rigorously tested and verified beyond industry standards by a staff of dedicated technologists. Watch a video of Fisher product testing at www.Fisher.com/HigherLevel, then schedule a visit.

YOU CAN DO THATIt feels like were running in circles tryingto meet regulations and process demands. I wish we could operate at a higher level.

eclipse.magnetrol.com 1- 800-624-8765 [email protected] 2014 Magnetrol International, Incorporated

ACEIN THE

HOLEAnd the Knock Out Drum. And the Separator.

And the Feedwater Heater. And the Sump.

When process applications require best-in-class level control technology, youve got to play your

cards right. The Eclipse Model 706 guided wave radar transmitter can deal with nearly any process

condition even the most challenging.

Superior signal-to-noise ratio provides the most accurate and reliable level measurement available

Extensive line of probes, including overfill safe probes, handle a variety of level challenges

Advanced diagnostics take the user interface to new levels of convenience and functionality

HART and FOUNDATION fieldbus protocols provide full digital communications capabilities

Convenient pre-configuration reduces installation time apply 24 VDC and walk away

Quick-disconnect probe coupling makes servicing easier

Dont gamble with reliability. Contact Magnetrol the guided wave radar innovator to learn more about

the ECLIPSE Model 706 transmitter.

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N O V E M B E R / 2 0 1 4 www.controlglobal.com 13

TECHNICALLY SPEAKING F E E D B A C KIN MEMORY OF JULIE CAPPELLETTI-LANGE,

VICE PRESIDENT 1984-2012

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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

Lose the ManualAs always, I enjoyed reading your article in Control, Pitch the Manual, (Control,September 2014, www.controlglobal.com/articles/2014/to-toss-or-not-to-toss-paper-manuals-and-reference-books/)

Of course, this is how weve moved. Strangely, I still like to read the hard copy of my Wall Street Journal. Perhaps its the feel of the paper? Or the nostalgic warm feeling that comes with the setting, sip-ping warm coffee and pondering the world? Or perhaps its the fact that I spend most of my day in an electronic world and associate that with work?

No matter what it is, in another related area Im not old fashioned. Yes, Pitch the manual, but way further than where you suggest. We all download apps for that on our smart phones. Free. Sweet. And if we cant gure them out in ve minutes, they get deleted because there is another app-for-that.

No PDF. No F1. Just intinuity. (Google that one.)

Thanks for the wake-up articles. Keep them coming.

DUNCAN SCHLEISS EMERSON PROCESS [email protected]

Users Need to Step Up for StandardsRegarding John Rezabeks September On the Bus column, (www.controlglobal.com/articles/2014/hungry-for-open-net-work-protocol-standards/): John, thanks for sharing your direct experience and for trying to march down the wireless road as far as it would take you. When the ISA100 standards committee was formulating its requirements, we used exactly the same set of speci cations that were used to de-velop the ISA S50.02 standard that became Foundation eldbus H1 and later HSE.

In short, we were attempting to make sure that the ISA100 network would be suitable to become the network for a wire-less Foundation eldbus when the tech-nology was ready. If the eld instruments must be battery-powered, then the tech-nology is not quite ready for high- sample-rate control, such as for ow or pressure

loops, but it should be ready for tempera-ture and most level control loopsexcept that no supplier has yet to offer a wireless Foundation eldbus instrument.

If energy harvesting, as documented by the ISA100.18 subcommittee, is con-sidered, then all process control loops are ready for wireless Foundation eldbus us-ing ISA100 Wire-less (IEC 62734). ISA100 already sup-ports direct, peer-to-peer, dual-path, mesh networking, very low power con-sumption, and a speed thats much higher than hard-wired H1.

Now all we need is for users like you to talk to your instrumentation suppliers about building wireless Foundation eld-bus. Too bad the right components were not available for your last project.

DICK CARO, CAP CO-CHAIR ISA100.8 USERS WORKING [email protected]

Simpli ed FieldbusRegarding The Long Green eld in the August issue (www.controlglobal.com/articles/2014/process-control-innova-tions-what-future-process-plants-can-be-like/#comment-1129): Complex, mac-rocycle calculations are not required for eldbus on DeltaV. Also, complex eld-bus devices are not the case with DeltaV, since with a human-centered design dash-board, Foundation has the same look and feel as a 4-20 mA/HART device. DeltaV makes eldbus very easy, eliminating mar-shalling cabinets, marshalling signals vir-tually from software, etc. Also, its possible to get as much diagnostics from a HART 5 device as a HART 7 device. The diag-nostics arent dependent on the HART version. In fact, you can get more diagnos-tics from some HART 5 devices than from some HART 6 or HART 7 devices.

JONAS BERGEEMERSON PROCESS [email protected]

SE

PT

EM

BE

R 2

01

4

A BETTER WAY TO HANDLE CONSTRAINTS

OPERATORS GET WHAT THEY DESERVE

FLEXIBILITY FUELS STRONG MOTORS THE YOUNG ENGINEERS FIRST LIBRARY

How targeted programs are raising a fresh fl ock of fl edglings to replace retiring engineers and technicians.

SpringChickens

CT1409_01_CVR.indd 9 8/26/14 8:49 AM

CT1411_13_Feedback.indd 13 11/3/14 8:37 PM

14 www.controlglobal.com N O V E M B E R / 2 0 1 4

BLA LIPTKl ip takbela@aol .com

L E S S O N S L E A R N E D

The problem with

the PFD values

is that theyre

determined by self-

certifi cation by the

manufacturer

or a hired

evaluation fi rm.

SIS: Standards by Committee

W e all know the saying that the camel is a horse designed by committee. To-days safety instrumented system (SIS) standard (ANSI/ISA 84.00.01 (2004), which is a relaxed version of IEC 61508/61511 (1996), is not a camel yet, only a camel baby. It can still be trained, but training needs trainers! Before explaining why I say this, let us look at what a safety integrity level (SIL) is.

The Safety Integrity Level The SIS standard considers SIL to be a quanti- able measurement of risk that can be used as a way to establish safety performance targets. The potentially achievable levels of reliability of the expected performance of this safety sys-tem are de ned by Table 1 (page 16).

The required safety availability (RSA) value refers to the reliability of a particular safety

control loop (called a safety instrumented func-tion or SIF) to protect the process from acci-dents. Conversely, the probability of failure on demand (PFD) is the mathematical comple-ment of RSA (PFD = 1 - RSA), expressing the probability that the SIF will fail to do its job. Un-fortunately, its much easier to write three zeros in a table than to increase the safety of a real process a thousandfold.

Yet, when a CEO of an insurance company sees this table with all those zeros, particularly if at the same time he is having a nice business lunch with this charming salesman, the table looks pretty good, and by the time the coffee is served, he might agree to insure the plant if its designed for a target of, say, SIL3. Right? Well, lets look at this closer.

Safety at the Component LevelAs shown in Figure 1, at the individual instrument component level (sensor, valve, safety control logic, power supply, communication), the stan-dard only requires determination of PFD, but the components themselves dont have safety integrity levels. The main problem with the PFD values is theyre determined by self-certi cation by the manufacturer or by the manufacturers hired eval-uation rm, and this certi cation doesnt need to be approved by any safety authority. Also, com-ponent PFDs dont determine the SIL level of the loop. They only imply that the loop components are suitable for a particular level.

On top that, the standard doesnt even ap-ply to pneumatic or hydraulic logic systems, nor does it apply to re and gas systems, safety alarms, safety controls or to plants that were in operation before 1996.

SIL Level of a Loop The SIL level of a loop is not the sum of the PFDs of its components, but is the product of the loops safe failure fraction (SFF) and the PFDs of the loop components. The equations for calculating SFF, PFD and SIL are:

Figure 1: Loop components do not have SIL levels, only probability of failure on

demand (PFD) values, and these PFD values do not determine the SIL level of the

loop (as implied here), but only indicate that in the suppliers judgement, these

components are suitable for being used in a particular SIL level system.

PFDPLC

PFDSensor

PFDFCE

A PFD IS NOT A SIL

Bas

ed

on

a d

raw

ing

fro

m E

me

rso

n Pr

oce

ss M

anag

em

ent

.

Total loop SIL = PFDPLC + PFDSensor + PFDFCE

CT1411_14_16_Lessons.indd 14 11/3/14 8:43 PM

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YOU CAN DO THATIt feels like were running in circles tryingto meet regulations and process demands. I wish we could operate at a higher level.

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L E S S O N S L E A R N E D

SFF = (lSD + lSU + lDD) / (lSD + lSU + lDD + lDU)

PFD = (lDU)(Proof Test Interval)/2 + (lDD)(Down Time or Repair Time)

SIL = (SFF)(PFD)

I will not bother to list what each of the terms in these equa-tions mean or explain how they can be determined. I will only note (obviously jokingly) that to apply them takes the collab-oration of an IRS accountant and a rather exible consul-tant, whose conclusions might just happen to coincide with the plants views.

SIL and Our Manual CultureAccording to one survey, 70% of furnace explosions occur dur-ing startup and shutdown, when operator involvement is maxi-mum, and 21% occur because undocumented changes were made by the operators after commissioning. Only 9% of acci-dents were due to non-operator-related causes.

Ive written a lot about the need for overrule safety control (OSC) for critical processes. The key difference between SIS and OSC is that OSC overrules! In other words, it brings the plant into a safe state no matter what the basic control system or the operators do.

SIS doesnt do that because the committee that developed it still lives in a manual culture. They still trust men more than machines. They do not understand that OSC is also made by men, except that the men who design the OSCs are not panicked operators running around in the dark at 2 a.m., but professional control engineers, who had months to iden-tify all potential what if sources of possible accidents and evaluated their potential consequences before deciding on the emergency actions to be triggered when they arise.

It is this hazard and operability (HAZOP) study during the de-sign phase that is the key to safety. It must be conducted by a team whose members are fully familiar with the process from their di-verse perspectives, including chemical, mechanical, heat transfer, electrical, etc. In addition, the team should be lead by a process control engineer who is knowledgeable about the state of the art

of safety automation. This what-if analysis (fault tree analysis) is the key, and SIS standards committees are a long way from un-derstanding that.

What Else?Whats probably the worst aspect of SIL ratings is that they do not apply to entire unit operations such as boilers or distil-lation columns. In fact, its quite possible that a boiler with a SIL3 steam overpressure protection system can also have a SIL1 low water level protection loop.

Its also unfortunate that the SIS committees dont like plain English. Their work is peppered with high-tech buzz-words, abbreviations and acronyms that make these docu-ments harder to read and hence less valuable (see sidebar).

In January, Part 2 will outline the safety system standards that we really need.

Bla L ip tk , PE , con trol consul tan t , is a lso edi tor of the Ins t rument EngineersHandbook and is seek ing new co-authors for the for coming new edi t ion of tha tmul t i-volume work . He can be reached a t l ip takbela@aol .com.

BPCS: basic process control system

ESD: emergency shutdown down

FMEA: failure modes and effects analysis

FMECA: failure modes, effects and criticality analysis

FGS logic: re and gas system logic

FOD: failure on demand (PFD)

F&G: re and gas

FT: fault tolerance

HAZOP: hazard and operational studies

HIPS: high-integrity protection system

IEC: International Electrotechnical Commission

IEC 61508 is generic functional safety standard

IEC 61511 de nes good engineering practices for SIS

IPF: instrument protective functions

ANSI/ISA 84.00.01 (2004): IEC 61511 relaxed for pre-996

plants

LOPA: layers of protection analysis

OSC: override safety controls

MOC: management of change

PFD: probability of failure on demand

PHA: process hazard analysis

RL: reliability level

RSA: required safety availability

SFF: safe failure fraction

SH&E: safety, health and environmental

SIF: safety instrumented function

SIL: safety integrity level

SIS: safety instrumented system

UPS: uninterruptible power supply

THE ALPHABET SOUP OF SIS DISCUSSIONS SIL number

Required Safety Availability (RSA)

Probability of Failure on Demand (PFD)

SIL1 90% to 99% 0.1 to 0.01

SIL2 99% to 99.9% 0.01 to 0.001

SIL3 99.9% to 99.99% 0.001 to 0.0001

SIL4 99.99% to 99.999% 0.0001 to 0.00001

Table 1. A SIL level is a quanti able measurement of risk used to

establish safety performance targets.

SIL LEVELS

CT1411_14_16_Lessons.indd 16 11/3/14 8:43 PM

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O N T H E B U S

john Rezabek contribut ing [email protected]

n o v e m b e R / 2 0 1 4 www.controlglobal.com 19

So why wont HART

and FF beget an

even cuter and

more lovable

protocol like a

Labradoodle of

buses?

Y ouve probably heard by now that theres been a merger of fieldbus protocol founda-tions representing HART and Foundation fieldbus (FF). After 2014, there will no longer be separate foundations governing the HART and FF protocols. There will be one group, one board of directors and one president.

But news of the merger has also created specu-lation and outright dreaming. One end user asked Chuck Micallef, marketing director for the HART Communication Foundation, Will this mean Ill be able to use my HART device for Foundation fieldbus? Sadly, such dreams will have to be left on the pillow. We may sooner see interoperabil-ity between WirelessHART and ISA 100.11a. So why wont HART and FF beget an even cuter and more lovable protocol like a Labradoodle of buses?

HART and FF do indeed share a lot of the same DNA. Thats one of the reasons the merger makes a lot of sense. Back in the days of the enhanced electronic device description language (EDDL) cooperation group, it was of-ten heard, When we looked at HART, FF and Profibus PA, we found we had 97% of param-eters in common. Humans are said to share 99% of their DNA with chimps and bonobos, too. While we dont expect any chimps to be boarding the bus with the kids in the morning, the three aforementioned protocols merged their DD languages into a single IEC standard a few years ago. Why would these three proto-cols have this much in common to begin with?

While we may think of the communication technologies as separate houses, they are, in fact, composed of nearly the same member compa-nies. I can count on one hand the suppliers that dont have an offering in at least two of the major protocols, if not all three. Most of our favorite sup-pliers belong to all three clubs, and the disparate technologies really are fueled both intellectually and financially by the members of each club, so we shouldnt be shocked or amazed when similar features emerge from all three protocols.

On the system side, the economies of conver-

gence can be even more compelling. A site can easily find itself employing multiple protocols, from HART and Modbus to DeviceNet, Ether-Net/IP, Profibus and Foundation fieldbus. All these are integratedor notinto whats often a single host or asset management system. An abun-dance of intelligence and features on the device side are stranded if there are no services on the system side to interpret, organize and display the useful insights and diagnostics to thinking hu-mans. Having greater uniformity between a few of these more common protocols can only help sys-tem developers deliver new features. The folks at FDT group (www.ftdgroup.org) point out, a sin-gle frame application supports HART, Profibus, Foundation fieldbusand others coming soon.

Which brings us to the FDI Cooperation (www.fdi-cooperation.org), the latest joint venture between HART, Foundation fieldbus and Profi-bus PA, which also includes the FDT Group and OPC Foundation. (FDI stands for field device integration.) By deploying a unified standard for the integration, configuration and management of assets used in process control, FDI aims to make the delivery and utilization of smart assets/devices easier, more uniform and more economi-cal for both suppliers and end users.

Many of the same engineers have been show-ing up at the same meetings and on the same ex-pense accounts, and the supplier companies who largely foot the bill for these non-profits wondered why they belonged to so many clubs. With HART and Fieldbus Foundation both headquartered in Austin, Texas, the logistics and legal hurdles were low enough to make the merger compelling. Thats why its happening.

Next year, theyll be under the same roof. So why wont the HART device speak FF? While the HART device may incorporate many of the same diagnostic capabilities of its seemingly identical FF kin, the protocols are fundamen-tally different both in philosophy and use. Next month, well explore the main distinctions in a little more depth.

two buses, one Foundation

CT1411_19_OTB.indd 19 11/3/14 8:49 PM

W i t h o u t W i r e s

20 www.controlglobal.com N o v e m b e r / 2 0 1 4

iaN verhappeNDirector,

inDus trial automation ne t [email protected]

Hands-Free Valves

By some estimates, 60-80% of valves are used in open-loop control, which effec-tively means theyre controlled manually. Of course, a number of these valves are strictly for isolation purposes, and therefore, have no rea-son to be controlled remotely, since theyll only be changed as a result of an associated manual procedure, such as maintenance work. However, this does leave a significant opportunity for some method of communicating with these valves, es-pecially for those located in awkward locations.

Close coupling the control element (sen-sor and controller) can make this happen by enabling the valve to be mounted in the pipe rack rather than being brought to grade. Wire-less is one way of making the connection from the control system to the control element.

One consideration for any change from the present operating status is the question of the risk or perceived risk of using a wireless sig-nal for control. However, since the loops being discussed here are presently being controlled manually, having the ability to be able to con-firm remotely the actual position of the control element can be considered an improvement.

The most significant consideration, how-ever, is whether or not the infrastructure is in place to implement a wireless system. Infra-structure includes a motive supplyusually air, since a typical wireless transmitter and milli-watt power supply is insufficient to provide the required torqueand the necessary equipment to link the control element to the control sys-tem, such as gateways and repeaters.

Depending on the nature of the infrastruc-ture (IEEE 802.15.4 wireless sensor networks such as ISA100.11a, WirelessHART, ZigBee and IEEE 802.11 or Wi-Fi), it could be dual-purposed, not only to support the backhaul of the control network (IEEE 802.11), but also to provide data to the field operators or technicians to receive real-time information while theyre in the field. For example, a maintenance techni-cian could confirm that the valve is indeed in

manual prior to isolating it and starting work. Then, as he is working on the valve, he could also access related manuals and documenta-tion, or warehouse inventory of necessary parts, while performing the task, and consequently, be a more efficient and safer worker. This re-quires not only the necessary infrastructure, but also changes in work practices, which is a much more difficult process than adding equipment.

Integration of all this is also something that cant be done haphazardly, as it affects many systems across the organization, which means it must be planned and executed as a multidis-cipline project with a strong corporate sponsor.

Wireless communication with valves has been in place for many years already. Several suppliers use protocols such as Bluetooth as a configuration interface to allow maintenance work on the device without having to remove it from service or open the enclosure to connect to the wires. Because Bluetooth has a very lim-ited broadcast range, its not practical for wire-less sensor networks, though it does this partic-ular application well. In fact, since most mobile devices include a Bluetooth radio, the potential (and associated cybersecurity risk) exists that these devices could be used for calibration. All thats required is the appropriate app.

Another alternative is ZigBee. Its being used in some applications, predominantly in the utility sector, where its part of the SmartGrid suite of protocols, not only to communicate to the controller, but also as a local configuration option similar to Bluetooth.

Some applications are end-to-end wireless now, but since most control engineers seem to be from the show-me state, the prefer-ence continues to be hardwiring However, the beachhead has been established, so Im sure that its only a matter of time before we see more wireless final control elements, though they may not always be configured or neces-sarily installed like the traditional control valve used today.

Protocols such

as Bluetooth

can be used as

a configuration

interface to allow

maintenance work

on the device

without having

to remove it

from service.

CT1411_20_Wireless.indd 20 11/3/14 8:53 PM


I n P r o c e s s

Ge Looks to the Future and Sees a CloudImmelts message: Get with the program or get left behind.

GE CEO Jeff Immelts message to the more than 600 attendees of the GE Intelligent Platforms User Summit, Oct. 27-30 in Orlando, Flor-ida, was both exciting and blunt. He predicted a possible future thats bright and glowing for manufacturers, but one with challenges that will have to be faced sooner rather than later and is coming on fast.

He said that whatever it thinks it is now, every industrial company will soon be a software and data analyt-ics company or risk competitive irrele-vance. The advent of the cloud, the In-ternet of Things, pervasive sensing and the deluge of data that these advances bring means every company has to mas-ter that data and use it to its advantage because the companies that do so will leave the laggards in the dust.

Immelt admitted that even GEwith some 400 plants and factories and an annual manufacturing spend of $63 billioncant build out the industrial Internet on its own. Collaboration and co-innovation will be needed to realize its promise.

Clearly, Immelt believes industry must adapt the Internet to its own

needs, even as the need for industrial domain expertise remains front and center. Machines still matter, but theyre surrounded by analytics, ser-vices and information, he said.

As an enabler of business outcomes, however, the industrial Internet is realits not a cartoon and its not Pow-erPoint, Immelt stressed.

Companies that can harness the tri-ple potential of smarter machines; the enabling power of sensors, services and

connectivity; and industrial big data and analytics can help themselves (and their customers) optimize assets and operations, and realize the power of the 1%, which is company shorthand for incremental improvements that pay off big. For example, a 1% improve-ment in fuel efficiency of the global airline fleet is worth $3 billion. Small changes can be worth tens of billions of dollars, Immelt said.

Other speakers reinforced the urgency

Rockwell Automation (www.rock-

wellautomation.com) has purchased

the assets of ESC Services Inc. (www.

escservices.com), a hazardous en-

ergy control provider of lockout-tagout

services and solutions. ESC Services,

based in Franklin, Wisconsin, will be

integrated into Rockwell Automations

Control Products and Solutions seg-

ment it. Terms were not disclosed.

TE Connectivity (www.te.com) has

completed a previously announced ac-

quisition of Measurement Specialties

Inc., a designer and manufacturer of

sensors and sensor-based systems,

including pressure, vibration, force,

temperature, humidity, ultrasonics,

position and fluid, for a wide range of

applications and industries. For re-

porting purposes, Measurement Spe-

cialties will be included as part of TEs

transportation division.

Murata Manufacturing Co. Ltd.

(www.murata.com/en-global) and

Yokogawa Electric Corp. (www.

yokogawa.com) have agreed to co-

operate in developing communica-

tion modules for field wireless de-

vices used in plants. Under the

terms of this agreement, Yokogawa

will license its technology to Murata,

and Murata will develop the commu-

nication modules. Through the alli-

ance, Murata will be able to expand

its communication module busi-

ness to wireless devices for use in

plants, and Yokogawa will be able

to promote wider acceptance of its

field wireless systems based on the

ISA100 wireless standard.

Expansions and ContraCtions

Paul Murrill, a member of the Process Auto-

mation Hall of Fames Class of 2014, receives

his award from Control editor-in-chief, Paul

Studebaker at his home in Baton Rouge,

Louisana, on Sept. 17. Murrill is retired from a

career as an academic, university administra-

tor, CFO and professional board member, all

built on a broad understanding of process

control. He is the editor of a series of 27

books on instrumentation and process

control for ISA, and served as an advisor to

the U.S. Dept of Energys Oak Ridge National

Laboratory. He was also included in InTech

magazines 50 most influential people in

automation, instrumentation and control

technologies.

hall of famEr GEts hand dElivEry

CT1411_22_28_InPro.indd 22 11/5/14 9:49 AM

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I n P r o c e s s

of being prepared for this wave of tech-nological change. Over my career, Ive witnessed three or four major shifts in automation, said Bernie Anger, general manager of GE Intelligent Platforms, in an address on the second day of the

meeting. Right now, were witnessing the next huge wave of change and inno-vation. This wave of industrial Internet and cloud-assisted automation is as big as HMIs and PLCs were.

He added, Hardware matters, but

it matters differently than it did in the past. Hardware is the edge of the indus-trial Internet. Software, meanwhile, is at its core. The new software, comput-ing and communications capability now available mean that, Every no-tion weve had about how much some-thing costs and how long it takes to do it are absolutely false, he added.

The rest of the GE Intelligent Plat-fors User Summit backed up these heady predictions with some new of-ferings. The Predix software platform is a way for GE to develop industrial Internet solutions that close the gap be-tween operations technology, such as PLCs, gateways and SCADA, and busi-ness systems, including ERP, CRM and supply chain systems.

In addition, GEs Proficy Monitor-ing and Analysis Suite (PMAS) is an integrated stack of industrial, data-management and analytics software coupled with industry-specific solutions and cloud services. It comprises solu-tions that match neatly with the points on GEs Industrial Internet Maturity Modelconnect, monitor, analyze, predict and optimize.

Also, Proficy Historian and Historian HD provide the abilities to connect and monitor. Historian can be deployed in a machine control and HMI SCADA all

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Jeff Immelt, CEO of GE, says, The indus-

trial Internet is realits not a cartoon and

its not PowerPoint.

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I n P r o c e s s

the way up to the cloud, explained Da-vid Bell, commercial leader, GE Intelli-gent Platforms. It scales in all of those levels. Were employing some visualiza-tion technology from the Predix plat-form, and its based on HTML5 web technologies. This allows users to have the web browser automatically adjust to their displays.

Analysis capabilities come from Pro-ficy Historian Analysis, the companion product to Historian, which has been fully migrated to the Predix visualiza-tion platform in HTML5. This allows browser-based access to data for ad-hoc analysis, and Proficy Knowledge Cen-ter, which expands on the capabilities in Historian Analysis to be more of a fleet management solution.

It integrates with the Industrial Perfor-mance and Reliability Center (IPRC), a GE monitoring center in Lisle, Illinois, where analysts using Proficy SmartSig-nal can keep predictive tabs on equip-ment on a users behalf. Proficy Smart-Signal detects the very early signs of deterioration and failure, allowing more proactive maintenance strategies.

Optimization is enabled by Proficy CSense. From managing and analyz-ing data to visualization and workflow, users can take data and do something with it. PMAS supports APM through M&D, predictive maintenance and, above all, operations intelligence.

ABB Doubles Down in OklahomaEmployees, customers and public offi-cials celebrated in late October the offi-cial grand opening of ABBs business unit expansion in Bartlesville, Oklahoma. The $14 million project is part of ABBs ongoing investment in its North Ameri-can oil and gas operations, and is in-tended to help meet regional and global customer demand for its measurement products, engineering and project ser-vices. This is ABBs third expansion of the Bartlesville site since 2000.

The facility designs, develops and manufactures natural gas and liquids measurement products and analyzers, as well as software applications and system solutions for the global oil and gas market under the TotalFlow brand.

The expansion effectively doubles the facility size by adding 100,000 square feet of space, and is expected to dou-ble the size of the local workforce over the next 10 years by adding 250 jobs, a majority of which are expected to be in

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I n P r o c e s s

technical and engineering disciplines.The strength of the oil and gas mar-

ket, specifically unconventional drill-ing activity, has provided our business a great opportunity for growth in re-cent years, says Gayle Lester, general

manager of ABBs Bartlesville Mea-surement Products facility. Lester said she was particularly proud that the 17-month project was completed with-out a single lost-time safety incident for ABB or its contractors.

Sthrenberg to Take Reins at Phoenix ContactFrank Sthrenberg, executive vice president, global sales, will become chairman of the executive board of Phoenix Contact GmbH & Co KG at the beginning of 2015. He will take over the office as well as the tasks that so far have been held by Klaus Eisert as managing partner. Sthrenberg will remain in charge of global sales. The joint responsibility and tasks of the other four executive vice presidents will also remain unchanged.

Meanwhile, Eisert will focus his attention on establishing an advisory board composed of shareholders and external personnel.

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Georg Fischer LLC and GF Machin-

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October. The 105,000 ft2 campus in-

cludes 23,000 ft2 of office, engineering,

technical support and training space;

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house space; and more than 100 em-

ployees. The manufacturing/fabrica-

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specific customer requirements, and

can cut large pipe diameters as large

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Honeywell (www.honeywellprocess.

com) has opened a new, interac-

tive demonstration center in Hous-

ton to give its industrial customers a

glimpse into the future of managing

their manufacturing operations. The

new Customer Experience Center

(CEC) is located at Honeywell Pro-

cess Solutions global headquarters.

The $5 million CEC will be a destina-

tion showcase site for Honeywells

customers from process industries

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GRand OPeninGS

CT1411_22_28_InPro.indd 28 11/5/14 9:50 AM

R E S O U R C E S


Where to Find IPC and PLC Information Online Controls Monthly Resource Guide

IPC, DCS OR PLC?An industrial PC (IPC) can perform just as well as a DCS or a PLC, says Controls senior technical editor, Dan Hebert, PE. And thin clients may offer additional benefits. Let Dan walk you through some of differences between these technologies and help you decide which may be best for your particular application. www.controlglobal.com/articles/2013/hebert-ipc/.

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HOW IS YOUR CELL PHONE LIKE YOUR PLC?This seven-page PDF explores the un-likely connection between the relent-less push toward increasing energy efficiency and processing power that drives improvements in consumer electronics and the same forces at work in industrial automation. The indus-trial automation customer does ben-efit from the chip manufacturers per-petual goal to create processors that do more while using less energya goal that requires cramming a great deal of functionality onto ever fewer chips. Industrial automation users may not worry about the processor energy re-quirements, but these new powerful chips offer many advantages to the au-tomation world in terms of price, time-to-market, flexibility and reliability. Read more at www.controlglobal.com/assets/14WPpdf/140916-AD-Proces-sorPower.pdf.

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REDUNDANCY IN PACsApplications that require high avail-ability, advanced data handling and superior communication capability are a good fit for PAC redundancy.

This whitepaper looks at the ben-efits of redundancy, options and im-plementation details. Most PLC and PAC controllers exhibit a high de-gree of reliability, but certain critical industrial automation applications simply cant tolerate downtime. Tra-ditionally, redundant automation sys-tems have been very expensive and complex, particularly as compared to standard automation systems. Upfront hardware costs have been high and implementation has been difficult, requiring extensive software devel-opment efforts. But now, redundant PAC automation systems are available that greatly reduce cost and complex-ity. These solutions simply require the purchase of an extra power sup-ply and CPU, and implementation just requires an extra configuration step to select the redundant option. Find out more about what to look for when redundancy is a must in your ap-plication. This whitepaper is free, but registration is required. Go to www.controlglobal.com/whitepapers/2013/pac-controller-redundancy/.

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THE CARE AND FEEDING OF YOUR PLCSGood maintenance of your PLCs is basic to the successful, efficient, safe and profitable operation of your plant. So whos looking out for the care and maintenance of your PLCs? This arti-cle outlines the basics required to en-sure your control systems are operating at their best. It has samples of effective recordkeeping formats, checklists of questions your maintenance depart-ment should be able to answer, lists of necessary records required and more.

The direct link is at http://bin95.com/maintenance_management_plc.htm.

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A BEGINNERS GUIDE TO PLCSAvailable for less than $10, this ebook, Beginners Guide to PLC Programming, by Neal Babcock, and its accompanying tutorial provide an introduction to PLCs and PLC control. It contains real-world examples, tips and routines you can start using immediately to write your own PLC programs. The ebook will de-fine the most commonly used terms; ex-plain relay ladder logic in simple, easy to understand terms; give you the 13 marks of a well-written PLC program; explain machine diagnostics and how to use them in your PLC program; and introduce you to PLC control and how its used in plant automation. It sum-marizes dozens of techniques that are needed to write a solid program. Go to www.engineer-and-technician.com/be-ginners-guide-to-plc-programming/ for more information or to buy and down-load the book.

engIneer anD teChnICIanw w w.engineer-and-technician.com

SHOCK PROTECTION FOR YOUR IPCProtecting an IPC from shock is not as hard as you might think. This free tutorial provides the basic lowdown on what is needed to protect the machine from vibration, jostling and other haz-ards during shipping, installation and operation. Discussions of vibration the-ory, resonance and drive dynamics are included. The direct link is at http://www.chassis-plans.com/white_paper_shock_and_vibration.html.

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If you know of any tools and resources we didnt include, send them to [email protected] with Resource in the subject line, and well add them to the website.

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Better Together?

Combining building and process automation systems

can ease plant support, but be prepared to ante up.

by Dan Hebert, P.E.

CT1411_32_44_CoverStory.indd 32 11/5/14 9:52 AM


b e t t e r t o g e t h e r ?

M ost process plants have a need for some type of facili-ties management and corresponding building auto-mation systems. The degree of sophistication ranges from very simple for a plant with mostly outdoor equipment, such as a petrochemical facility, to quite complex for phar-maceutical and other plants where climate control and air quality are integral parts of the process.

These degrees of sophistication, along with other factors, drive the decision to use one system or two for process control and building automation. Other key factors include upfront costs, operating expenses and staffing requirements.

Sometimes theres no choice. Paul Darnbrough, engi-neering manager at system integrator KDC Systems (www.kdc-systems.com) in Los Alamitos, California, explains, Most places we go already have an embedded building au-tomation vendor, and future work almost always goes to that product line. For larger projects we typically are involved with, the specifying engineer seems to drive the choice of using a single, common system or multiple independent sys-tems for manufacturing and facility automation.

But if theres a choice, some plants find a unified system to be the preferred solution for their specific applications.

one System Is SimplerEnd users are looking hard at single-source solutions, and in all cases, its a process automation system controlling both the process and the facility. Building automation systems simply arent capable of controlling anything but the sim-plest processes, and thus, arent used as a single system for both process and building automation.

Ive been involved with co-gen power plants where they had four different systems, including their chilled water sys-tem, all on separate control systems with their own HMIs, says John Boyd, technology leader at Maverick Technologies (www.mavtechglobal.com), a systems integrator in Columbia, Illinois. We finished one plant project about two years ago where everything was integrated into a single control system. It may actually have separate processors, but its all with one supplier, and it looks like one system to the operators.

All plant subsystems should be integrated into one over-all monitoring and control solution, says Dennis Runo, president of Custom Automation (www.CustomAutoma-tion.com), a system integrator in Mesa, Arizona. Success-ful plant processing is inextricably linked to the supporting building facilities. With two separate systems, information can be made to bridge the gap, but its much easier when you have a unified system.

One reason is to reduce operator confusion. A well-exe-cuted system will have predictable equipment control and alarm behaviors, he notes. Pop-up information, alarm and control windows will be consistent across all equipment and subsystems. Many HMIs have templates to make this easier.

Multiple systems could theoretically achieve this as well, but think of the added work and expense to get them there and keep them synced.

The U.S. Dept. of Energys Waste Isolation Pilot Plant (WIPP) in the Chihuahauan Desert of southeastern New Mexico, some 26 miles east of Carlsbad, processes radioac-tive waste and safely entombs it in deep underground cham-bers (Figure 1). Thirteen critical subsystems are managed in the control room on a single system that handles every-thing including ventilation, electrical distribution and en-ergy monitoring, HVAC, fire protection, radiation monitor-ing and plant protection (Figure 2).

The WIPP site uses redundant KEPServerEX servers with OPC and OPC UA to communicate with numerous subsys-tems using BACnet and other protocols. The interconnected subsystems talk to each other and accept commands from the operators on duty. The system is also designed to act in-dependently to maintain a safe environment.

Reasons for choosing a single system typically involve sim-plicity, single-vendor responsibility, reduced maintenance costs and standardized operations.

If the process has many different solutions in place, it can be expensive to support and maintain, says Paul Matatall, network specialist at Optimation (www.optimation.us), a sys-tem integrator in Boston. The facility will need support staff that understands how all this equipment works and how to resolve any issues that arise. It will increase their training bud-gets because their support teams will need to be trained on the different equipment used in their facility. Theyll also have increased cost in their spare parts inventory because of the need to have many different products on hand.

Erik Dellinger, product manager at Kepware Technologies (www.kepware.com) in Portland, Maine, adds, The one-sys-tem approach affords the facility the expected benefits of min-imized spare part requirements, consolidated training, inte-grated communications and a common look and feel.

Ripon Cogeneration (Figure 3), a power plant in Ripon, California, had multiple systems, but saw the advantage of bringing them all together, so the operators could run the system more efficiently.

Customers ask us to integrate all the systems into one, says Boyd. For companies looking to be more efficient, thats a positive thing. The benefit of one system is the ability to be more efficient, and thats in the context of large, enclosed plants

Successful plant processing is inextricably linked

to the supporting building facilities. With separate

systems, information can bridge the gap, but its

much easier when you have a unified system.


B e t t e r t o g e t h e r ?

where they have extensive HVAC and climate control units. Those systems now are very intelligent and automated, and they have their own web portals and pages to control them. It doesnt make sense to keep them separate if you can bring them into one. I dont know any reason why you would want to keep them separate unless the operators are already so busy that they cant be distracted by the building control system.

Another advantage of a single system is simplified com-munications, making it easier to perform integrated control, obtain cost and operating data across the plant, send data to a historian and allow building controls to handle load changes smoothly and efficiently.

But it isnt all rosy in single-system land. Dellinger points out, If its all in one system, and that system goes down, you lose control of manufacturing and the building. If an opera-tor on the manufacturing floor logs in and accidentally turns off the HVAC, that could be a problem.

Another drawback arises during system upgrades. Obsoles-cence is a big reason against consolidating process automation, building automation and utilities, says Kelli Malloy, leader of U.S. process automation at Turck (www.turck.com). While many DCS companies have obsolescence plans and product

Figure 1: Used for underground ventilation at a U.S. DoE nuclear

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support, the reality is that one day these products will need re-placing. In addition to the cost of replacing an entire system, there are other disadvantages to forced migrations when ev-erything is on a single system. These include extensive repro-gramming and possible operational disruption, as well as the potential for point-by-point revalidation on particularly sensi-tive DCS changes.

Another reason for separates is that building automation suppliers understand climate control much better than process control vendors, making several companies lean toward the two-system approach.

Separation Can be SensibleCan standard process control equipment and systems handle building automation? Yes, but Darnbrough points to a harsh reality about using them for that: Building automation sys-tems offer preconfigured features specific to HVAC and other extended capabilities, such as calendar scheduling, that make sense for the application. These same options might need to be manually created and coded into a PLC or DCS system at great effort. We rarely use PLC controls for building automation. Furthermore, building automation systems are much cheaper

than process automation systemsoften less than half the price.Matrix Technologies (www.matrixti.com), a system inte-

grator in Maumee, Ohio, prefers using two systems for pro-cess control and building automation. Charles Sheets, direc-tor of the industrial systems division at Matrix, says, Since standard automation components can perform many func-tions, the same hardware and software can be used to con-trol many different devices including HVAC, boilers, secu-rity access, compressors, water, etc.

Sheets adds that the physical separation is beneficial for maintenance, security and to ensure that a problem with one system wont affect the other. But he wants to use the same components. Using standard automation components such as PLCs allows one service organization to support

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both systems for troubleshooting and spare parts.Support problems often come up with existing plants

that have older controls. One of our projects involved an industrial power plant where the original HVAC controls had been subcontracted to a third party, Sheets explains. Technical support was very difficult to obtain for their pro-prietary systems. Some of their equipment used PLCs, and those could be readily supported. The systems with propri-etary hardware could not. Using the same controlsbut in separate systemseliminates the problem.

Another project of ours involved optimizing energy re-covery from both HVAC and process equipment for a ma-jor food manufacturer. In this case, both systems use PLC controls developed by Matrix Technologies. Since the two systems communicate, we orchestrated a strategy based on real-time process and HVAC conditions to optimize overall plant performance, resulting in significant savings.

Control and security issues are different between process and building automation. For example, if third-party monitoring of fire, emergency and security is needed, then it might be better to use a full-service building controls organization, Sheets says.

Theres also some value in dealing with experts in the field.

Proprietary building control systems virtually eliminate unau-thorized access, Sheets notes. Building control companies typically have established knowledge of environmental and other control equipment, and often use a pricing model of lower initial costs with guarantees of a long-term service/monitoring contract. Depending on cash flow, this could be a benefit.

Process control vendors and equipment can perform building automation, too, but maybe not as well. Often, the intellectual property of building control vendors is con-cealed as

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