ocotber 2013 - control global

OC

TO

BE

R 2

01

3

Cybersecurity begins with � rewalls and network segmentation, but thesebarriers must be accompanied by constant monitoring and veri� cation

of internal communications and data to protect applications.

WHAT’S INSIDE YOUR ARMOR?

Simulation Speeds Up

Insertion Flowmeters

WEB EXCLUSIVEExcerpt from new book by Walt Boyes

and Peter Martin: Real-Time Controlof the Industrial Enterprise

CT1310_01_CVR.indd 1 9/30/13 4:33 PM

Answers for industry.

usa.siemens.com/clamp

Flow measurement has gone mobile! With the new SITRANS CONNECTION app and connection kit for Apple devices, Siemens gives you total control of your flow – right at your fingertips.

SITRANS CONNECTION enables direct serial communi-cation between an iPhone, iPad or iPod Touch and any SITRANS F US clamp-on ultrasonic flow meter to

enhance all metering functionalities, including programming, operational review, data logging and download. The app makes connectivity possible almost anywhere, without the need for a laptop.

And SITRANS CONNECTION even allows you to share terminal window access with a Siemens technician for instant service and support.

Program your flow meter with your iPhone or iPad!Siemens introduces SITRANS CONNECTION, the first app for Clamp-on flow

© 2

01

2 S

iem

en

s In

du

stry

, In

c.

Scan to explore the first app for flow metering

SITRANS_Connection_Ad_ControlMag_Sept_2013NEWFORMAT.indd 1 9/20/2013 9:48:10 AM

The age ofenlightenmenthas arrived.

Protect

EvoFoxboro

Operate

Engineer

Manage

Maintain

Introducing the Foxboro Evo™ system.You’ve been waiting for a control system that shines light into every corner of the plant. So every member of your team can be enlightened — with the context-rich information they need to manage risk and turn opportunities into profi ts. A system with the power and fl exibility to know the past, collaborate in the ever-evolving present, and even predict the future. This is the next generation of advanced automation. This is Foxboro Evo. See what the Foxboro Evo process automation system can do for you at Foxboro.com/FoxboroEvo

Tel: 1-888-FOXBORO E-mail: [email protected]

© Copyright 2013. All rights reserved. Invensys, the Invensys logo, Foxboro, and Foxboro Evo are trademarks of Invensys plc,its subsidiaries or affi liates.All other brands and product names may be trademarks of their respective owners.

This changeseveryone

1303051_LaunchAd_ControlEngin.indd 1 8/19/13 12:15 PMCT1310_full page ads.indd 2 10/1/13 3:36 PM


usa.siemens.com/clamp

Flow measurement has gone mobile! With the new SITRANS CONNECTION app and connection kit for Apple devices, Siemens gives you total control of your flow – right at your fingertips.

SITRANS CONNECTION enables direct serial communi-cation between an iPhone, iPad or iPod Touch and any SITRANS F US clamp-on ultrasonic flow meter to

enhance all metering functionalities, including programming, operational review, data logging and download. The app makes connectivity possible almost anywhere, without the need for a laptop.

And SITRANS CONNECTION even allows you to share terminal window access with a Siemens technician for instant service and support.

Program your flow meter with your iPhone or iPad!Siemens introduces SITRANS CONNECTION, the first app for Clamp-on flow

© 2

01

2 S

iem

en

s In

du

stry

, In

c.

Scan to explore the first app for flow metering

SITRANS_Connection_Ad_ControlMag_Sept_2013NEWFORMAT.indd 1 9/20/2013 9:48:10 AM

The age ofenlightenmenthas arrived.

Protect

EvoFoxboro

Operate

Engineer

Manage

Maintain

Introducing the Foxboro Evo™ system.You’ve been waiting for a control system that shines light into every corner of the plant. So every member of your team can be enlightened — with the context-rich information they need to manage risk and turn opportunities into profi ts. A system with the power and fl exibility to know the past, collaborate in the ever-evolving present, and even predict the future. This is the next generation of advanced automation. This is Foxboro Evo. See what the Foxboro Evo process automation system can do for you at Foxboro.com/FoxboroEvo

Tel: 1-888-FOXBORO E-mail: [email protected]

© Copyright 2013. All rights reserved. Invensys, the Invensys logo, Foxboro, and Foxboro Evo are trademarks of Invensys plc,its subsidiaries or affi liates.All other brands and product names may be trademarks of their respective owners.

This changeseveryone

1303051_LaunchAd_ControlEngin.indd 1 8/19/13 12:15 PMCT1310_full page ads.indd 3 10/1/13 3:36 PM

CT1310_full page ads.indd 4 10/1/13 3:37 PM

October 2013 • Volume XXV • Number 10

CONTROL (ISSN 1049-5541) is published monthly by PUTMAN Media COMPANY (also publishers of CONTROL DESIGN, CHEMICAL PROCESSING, FOOD PROCESSING, INDUSTRIAL NETwORkING,

PHARMACEUTICAL MANUFACTURING, and PLANT SERVICES ), 555 w. Pierce Rd., Ste. 301, Itasca, IL 60143. (Phone 630/467-1300; Fax 630/467-1124.) Address all correspondence to Editorial and Executive Offices, same ad-

dress. Periodicals Postage Paid at Itasca, IL, and at additional mailing offices. Printed in the United States. © Putman Media 2013. All rights reserved. The contents of this publication may not be reproduced in whole or part without

consent of the copyright owner. POSTMASTER: Send address changes to CONTROL, P.O. Box 3428, Northbrook, IL 60065-3428. SUBSCRIPTIONS: Qualified-reader subscriptions are accepted from Operating Management in the control

industry at no charge. To apply for qualified-reader subscription, fill in subscription form. To non-qualified subscribers in the 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.

O c t O b e r / 2 0 1 3 www.controlglobal.com 5

f e at u r e s

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

c O v e r S t O r y

34 / What’s Inside your Armor?Cybersecurity begins with firewalls and network segmenta-tion, but that’s not enough protection. by Jim Montague

S I m u l A t I O n A n d m O d e l I n g

47 / Simulation Speeds upAs they get closer to real-time, simulations are taking on many more varied applications and helping to optimize them. by Jim Montague

Excerpt from new book by walt Boyes and Peter Mar-tin: Real-Time Control of the Industrial Enterprisewww.controlglobal.com/RealTimeControl

F l O W

51 / Stick It!Insertion flowmeters come in many varieties, but they all share similar characteristics and problems. by Walt Boyes

CT1310_05_07_TOC.indd 5 9/30/13 4:42 PM

Endress+Hauser, Inc2350 Endress PlaceGreenwood, IN [email protected]

Sales: 888-ENDRESSService: 800-642-8737Fax: 317-535-8498

The most simple choices can save a life and some of the best decisions are often the simplest. Empower yourself with the right field instrumentation partner. At Endress+Hauser, our design, manufacturing and Life Cycle Management expertise helps you reduce risk in your process. Your mission is our mission. Get in touch with our people and discover your options. www.us.endress.com/process-safety

Simply reliable: Process safety by Endress+Hauser


D E P A R T M E N T S


October 2013 • Volume XXV • Number 10

Food & Kindred Products.....................................................................................11,430Chemicals & Allied Products ...............................................................................10,731 Systems Integrators & Engineering Design Firms ..................................................9,277Primary Metal Industries ........................................................................................5,073Electric, Gas & Sanitary Services ...........................................................................4,055Pharmaceuticals .....................................................................................................3,749Paper & Allied Products .........................................................................................3,623

Petroleum Refining & Related Industries ................................................................3,417Rubber & Miscellaneous Plastic Products .............................................................3,372Miscellaneous Manufacturers ................................................................................2,141Stone, Clay, Glass & Concrete Products ................................................................1,758Textile Mill Products ..............................................................................................1,248Tobacco Products ......................................................................................................146Total Circulation ...................................................................................................60,000

CirCulation audited June 2012

rOundup

In prOceSS9 / editor’s pageFukushima Crazy ScarySpreading Fud about Fukushima is both unhelpful and bad science.

11/ On the WebTaking the Long WayControlGlobal.com solves the 20-pounds-of-stuff-to-fit-in-a-10-pound bag problem.

13 / Feedbackour readers weigh in on collisions and control systems and hackers.

14 / Other VoicesSupplier Selection and Relationship ManagementPick the right supplier and managing that relationship can make or break a career—or a business.

19 / On the busMaking a Better FoolMitigating the human propensity to mess things up given half a chance.

.20 / Without Wires HMI EverywhereHtMl5, CSS3 and SVG are making scal-able, web-based HMis more practical and ubiquitous than ever.

22 / In processinvensys Foxboro’s evo control system re-leased; Hart and Fieldbus Foundation talk merger; and more process news.

32 / resourcesonline with process analyzers. Videos, eb-ooks, white papers and more.

55 / Ask the expertsHow reliable is a pad-type flange connec-tion? How well do they withstand pressure and leakage? our experts weigh in.

59 / roundupAcquire Your Data Herethe latest daQ hardware and software.

63 / control talkEducating Future Automation Engineersthe rose-Hulman institute of technology combines theory with hands-on experience at the undergraduate level.

65 / Ad IndexCheck these pages.

66 / control reportRasGas Gets a Jump on Safety. How one lnG producer keeps an eye on its control systems to get an early warning of safety issues.

Endress+Hauser execs open up bigger

facilities in Indiana.

The Pepperl+Fuchs VisuNet XT opera-

tor workstation.

CT1310_05_07_TOC.indd 7 9/30/13 4:42 PM

the #1 value in automationOrder Today, Ships Today!

* See our Web site for details and restrictions. © Copyright 2013 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405

Research, price, buy at:www.automationdirect.com/Do-More-PLCs

Watch our videos at:www.n2adc.com/domorevids

more TMDo

The FREE Do-more Designersoftware for Do-more H2 seriesPLCs gives you advanced toolsthat can cost thousands fromothers.

Download at www.do-moreplcs.com and check it out.

Built-in simulatorThe built-in simulator creates a virtual PLC so you can testyour logic without the hardware present. The Windowsapplication runs on your PC and uses the same code as theCPU fi rmware for the most accurate simulation. Test partof your logic or whole programs quickly and conveniently.

• Simulates discrete and analog I/O with access to timers, counters, control bits, etc.

• Simulate PID - use the Simulator coupled with the Trend View for outstanding visibility into your PID processes.

Insightful monitoring andtroubleshooting toolsUse these tools for real-time tuning and testing:• Debug View window can suspend each task and program separately.

• PID View window allows precise tuning of your PID loops

• Data View window monitors your chosen program elements - discrete or analog I/O, and system parameters

• View Trend Data in its own view as well as within specifi c ladder instructions like PID, RAMPSOAK, and High/Low Alarm.

The NEWprogrammablecontroller with

WINNER

2013

Each Do-more CPU comes with a coupon for a 30-day freetrial of online video training. So visit www.do-moreplcs.comfor the details, watch overview videos, and download thefree software to take it for a spin.

helpful control system testingwith the new Do-more PLC

1310-Control-DoMorePLC-Trending-MAG.indd 1 9/13/13 2:35 PM



Walt bOyes Editor in [email protected] t

E D I T O R ’ S P A G E

crazy Scary fukushima reporting

My colleague, Stuart Nathan, at www.theengineer.co.uk, is dead right on in his column

entitled “Fukushima alarmism is a bigger risk than radiation.” Let’s just look at why.

I worked for the old Texas Nuclear Corp., now part of ThermoFisherScientific, in the

1980s and early 1990s. I went through radiation safety training, and carried a license and

a dosimeter for nearly 10 years. So I’m pretty sure of my facts here.

Despite what Nathan calls “breathless cover-age” of “desperate” and “crazy” attempts to cre-ate a “freeze-wall” around the leaking contain-ment vessels, the idea is neither desperate nor crazy, and has been used to deter various kinds of contamination, including nuclear. This type of coverage, including misleading citations and demonstrably false statistics, is the norm when discussing nuclear power, and in fact, is normal when discussing science at all.

This is bad for civilization, for power genera-tion, for engineering and for science education. I’ve written before how teachers-in-training for elementary schools not only do not understand science, but are actually afraid to teach it.

Nuclear power has a phenomenal record of over 50 years of safe operation worldwide, but you’d never know it from the coverage that these accidents get. It was beginning to look like the United States would actually do nu-clear plant projects again until Fukushima and the hysteria surrounding it. Now most of those projects have vaporized. But as Nathan points out, “The reactors at Fukushima Daiichi were old, scheduled for shutdown; their newer neigh-bors at Fukushima Daiini worked perfectly.”

It is sad, too, that the howling about Fukushima Daiichi is drowning out the real tragedy here: the devastating effects of the tsunami on that part of Japan. Again, Nathan points out, “18,500 people lost their lives as a result of the tsunami. Of those, the number attributable to Fukushima is zero, de-spite the meltdowns continually being described as ‘deadly’ and radiation levels as ‘lethal.’ ”

Demonizing nuclear power is stupid. Unless the ITER project actually works and produces fu-sion reactions that give off more power than they require, nuclear reactors are the best source of clean, non-polluting power we have or are likely

to get. Solar, wind and geothermal power can pro-duce somewhere on the order of 20% of the re-quirements of current generation, and coal and oil plants pollute, are severely limited resources, and are major sources of carbon emissions. It’s no ac-cident that China is in the process right now of building and commissioning 72 nuclear plants.

The attitude fostered by the coverage of Fu-kushima by reporters and editors who have no clue is dangerous to the entire body of engi-neered infrastructure. It fosters NIMBYism (that stands for “not in my back yard”) and an unrealistic worldview. It’s one of the reasons children choose as early as grammar school not to enter science tracks. It’s one of the significant roots of the lack of trained engineers and tech-nicians we see in the process industries.

We learned to make safe nuclear plants long ago. We learned to safely dispose of radioactive waste years ago. But with irresponsible and bi-ased reportage of nuclear effects, nobody knows about this, and worse, nobody believes it.

When Texas Nuclear was on Research Boulevard in Austin in the 1980s, there was a Whole Foods across the street. Every so often, the barbarians would come picket us, protest-ing against food irradiation (which also has been shown to be entirely safe), just because we had the word “nuclear” in our name. We were making industrial nucleonic gauges for level, density and elemental analysis and didn’t do food irradiation. But the ignoranti didn’t know that and didn’t care.

You can’t have reasonable decisions in a democratic society with that level of willful ig-norance and partisan reporting.

The attitude

fostered by

Fukushima

coverage by

clueless reporters

is dangerous to

the entire body of

engineered

infrastructure.

CT1309_09_Edit.indd 9 9/30/13 4:44 PM

800 453 6202

>> Accelerate your productivity at ni.com/embedded-platform

©2013 National Instruments. All rights reserved. LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. 12122

Smarter Embedded Designs,Faster Deployment

The combination of NI LabVIEW system design software and reconfi gurable I/O

(RIO) hardware helps small design teams with varied expertise develop demanding

embedded applications in less time. Using this graphical system design approach,

you can take advantage of the same integrated platform to program embedded

processors and FPGAs for faster application development in industries ranging from

energy to transportation, manufacturing, and life sciences.

LabVIEW system design software offers ultimate fl exibility through FPGA programming, simplifi es code reuse, and helps you program the way you think–graphically.

LabVIEW system design software offers ultimate fl exibility through FPGA programming, simplifi es code reuse, and helps you program the way you

12122 NI_2013_Smarter Embedded Design Ad.indd 1 7/15/13 2:07 PMCT1310_full page ads.indd 10 10/1/13 3:37 PM

NANCY BARTELSMANAGING EDITOR

nbar [email protected] t

O C T O B E R / 2 0 1 3 www.controlglobal.com 11

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.

ControlGlobal E-News

Multimedia Alerts

White Paper Alerts

Go to www.controlglobal.com and

follow instructions to register for our

free weekly e-newsletters.

C O N T R O L O N L I N E

www.controlglobal.com/thismonth Search this site | Tips

One of the disciplines—and frustrations—of writing for print magazines is their physical limitation. Each page can hold only so many words. Each issue can have only so many pages.

In some ways that’s good. You learn to cut to the chase. You learn to sti� e the writer’s natural tendency to natter on and on. But there’s a danger: leav-ing out important facts. I often describe my job as a print editor as squeezing 20 pounds of content into a 10-pound bag.

Writing content for online venues eliminates that problem. Space is unlim-ited. You can make a story as long as you want or need it to be. That works to the advantage of even us old-fashioned lovers of the print edition. Frequently, the features you see in the print version are only part of the story. Good content that didn’t make the cut ends up online, as do links to related information. When we have more good material than will � t in the print version, we put the URL at the end of a story, directing you to more content on the same subject online. It’s worth your time to switch on your computer and check it out.

Take, for example, the two-part series on intergenerational communica-tion among engineers that ran in our August and September issues. This great dialog between Greg McMillan, Danaca Jordan, Hunter Vegas and Soundar Ramchandran had to be split in two to � t the demands of the print version, and even then a lot had to be eliminated, including some great charts outlining the differing ways that each generation communicates. All that ex-tra good stuff is found in the complete article at http://tinyurl.com/mlns3nw.

One of our big reader favorites is Béla Lipták’s regular column, “Ask the Experts.” Frequently more experts respond that we have room for. Those ex-tra comments, full of good advice, are found online. When you see a URL at the end of a column, it will be worth your time to check out the story online.

Our feature, “Back from the Grave,” from the June issue, met that same editorial fate. Some details about how multivariable testing of processes and procedures help resurrect the moribund Lincoln Paper and Tissue Co. were left out of the print version. The complete story, as well as some links to re-lated articles, appears at http://tinyurl.com/ke56q4d.

Sure, you can get the nuts and bolts of every feature and column from the print version. We never want to shortchange our print readers. But it’s worth the effort to follow those links at the end of certain pieces to see what inter-esting things couldn’t be squeezed into the 10-pound bag.

PLCs and PACs Simplify Data AcquisitionSee how businesses bene� t from the

in-depth information that new PLCs

and PACs can provide. www.control-

global.com/whitepapers/2013/plcs-

and-pacs-simplify-data-acquisition/

Boost Security with OPC-UALearn how OPC UA provides a secure

information gateway. www.control-

global.com/whitepapers/2013/boost-

industrial-communications-security-

with-opc-uni� ed-architecture-opc-ua/

Upgrade to Ethernet/IPExplore Ethernet over RS-485, a new

approach to the modernization of in-

dustrial automation and distributed

control networks. www.controlglobal.

com/whitepapers/2013/migration-is-

key-to-upgrade-legacy-rs-485-serial-

infrastructure-to-ethernetip-networks/

FUD and FukushimaGood click bait. Bad science. www.

controlglobal.com/blogs/soundoff/fud-

and-fukushima/

Tips for Measurement DynamicsHow to navigate their complexities.

http://www.controlglobal.com/blogs/

controltalkblog/measurement-dynam-

ics-recommendations-tips/

Foxboro/Triconex Newswww.putman.net /newsletter/Inven-

sys13/13/130911.html

Taking the Long Way Around

CT1310_11_WebTOC.indd 11 9/30/13 4:46 PM

Take a closer look at MagneTrol-tough liquid level switches, the no. 1 brand of mechanical buoyancy instrumentation. The fact is, MagneTrol switches work hard, and keep on working, for decades of safe, accurate, repeatable, reliable level detection.

Entrust your operation’s safety and performance to MagnEtrol – the first name in durable, reliable mechanical buoyancy liquid level switches.

Design Excellence in the Details Makes Magnetrol® the Leader for Trouble-Free Performance.

Heavy-duty flange configuration is designed to perform reliably in service pressures up to 5000 psig (345 bar).

Full-penetration chamber welds meet ASME Section IX and B31 construction and inspection requirements.

The stainless steel enclosing tube completely isolates the switch magnet from the process environment, preventing interference with the magnet, while allowing reliable magnetic coupling with the attraction sleeve.

magnetrol.com • 1-800-624-8765 • [email protected]

Attraction sleeve

Stainless steel enclosing tube(cutaway)

Magnet

Magnetrol_Control_August2013.indd 1 7/12/13 11:17 AM

The Emerson logo is a trademark and service mark of Emerson Electric Co. ©2013 Fisher Controls International LLC. D352200X012 MZ8

You can automate your control signal using the Fisher® Control-Disk™ valve from Emerson. Process control loops containing butterfly valves

are often placed in manual mode due to poor control performance. This results in operators constantly monitoring and adjusting the control signal, significantly reducing efficiency. With a control range comparable to a segmented ball valve, the Control-Disk valve enables control closer to the target set point. This allows you to leave your control loop in automatic mode, regardless of process disturbances. With low maintenance requirements and sizes up to NPS 36, it’s time to put the Control-Disk valve in your loop. Visit www.Fisher.com/automatic to watch an animation video or download a brochure.

YOU CAN DO THAT

Manually inputting the control signal feels pretty primitive. I need to get back in automatic mode for better efficiency.



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

VICE PRESIDENT 1984-2012

555 W. PIERCE RD., SUITE 301 • ITASCA, ILLINOIS 60143

executive teamPresident & CEO: JOHN M. CAPPELLETTIVP, Circulation: JERRY CLARK

publishing teamGroup Publisher/VP Content: KEITH LARSON

[email protected] t

Midwest/Southeast Regional Sales Manager: GREG [email protected] t630/551-2500, Fax : 630/551-2600

Western Regional Sales Manager: LAURA MARTINEZ310/607-0125, Fax : 310/607-0168lmar t [email protected] t

Northeast/Mid-Atlantic Regional Sales Manager: DAVE FISHER508/543-5172, Fax 508/543-3061df [email protected] t

Inside Accounts Manager: POLLY [email protected] t

Subscriptions/Circulation: JERRY CLARK, JACK JONES888/64 4-1803

foster reprintsCorporate Account Executive: JILL KALETHA

866-879-914 4 x 168, Fax 219-561-2033j i l lk@ fos terpr in t ing.com

editorial teamEditor in Chief: WALT BOYES

[email protected] t

Executive Editor: JIM [email protected] t

Senior Managing Editor, Digital Media: KATHERINE [email protected] t

Managing Editor: NANCY BARTELSnbar [email protected] t

Senior Technical Editor: DAN HEBERTdheber [email protected] t

Contributing Editor: JOHN REZABEKColumnists: BÉLA LIPTÁK, GREG MCMILLAN, IAN VERHAPPEN, STAN WEINER Editorial Assistant: LORI GOLDBERG

design & production teamVP, Creative Services: STEVE HERNER

[email protected] t

Art Director: BRIAN HERTELbher [email protected] t

Senior Production Manager: ANETTA [email protected] t

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

Car Collisions and Process ControlIn the Control Talk blog post “What Does a Car Collision Teach us about Process Control,” (www.controlglobal.com/blogs/controltalkblog/what-does-car-collision-teach-us-about-process-control-tips/), Greg McMillan uses a video of a car crash to explain the complexities of the concept of dead time. He says, “The use of the term ‘process dead time’ can mislead us in terms of recognizing the many sources of dead time. Also, we don’t often take into account the profound effect of the speed and the entry point of a disturbance into the process.”

He summarizes the video this way: “The total loop dead time is the sum of the time to recognize the impending colli-sion (measurement delay); to make a deci-sion (controller execution delay); to move the leg to the brake (� nal control element delay); and to noticeably decelerate after the brake is applied (process delay). The disturbance is unmeasured because the car swerving around the line of traf� c and running the red light is unseen and unpre-dictable. Therefore, feed-forward control is not possible, and the driver is relying to-tally on feedback control.”

Javier Galvez Gamboa comments: A good challenge is to improve car process dy-namics, and reduce the � nal control time-element delay. On the other hand, if you take into consideration the cell phone or other distractions for the driver, some ac-cidents can be avoided. I like the way that you describe the whole problem as a con-trol loop. Very interesting.

What Color Is Your Hat? In his Unfettered blog post, “Hard Hat vs. Black Hat,” (www.controlglobal.com/blogs/unfettered/hard-hat-vs-black-hat-hype-versus-reality/), Joe Weiss takes on the hacker community and its relationship to critical infrastructure protection. He says, “Black Hat caters to the hackers and security researchers primarily from the IT community, as well as the press. It does not cater to the control systems engineers who maintain and operate these systems. Many

of the more sensational presentations do not represent what is actually used, or how they are actually used in control sys-tem environments. The wireless oil indus-try hacking presentation was an example of hacking a protocol that is generally not used by the oil in-dustry. The proto-col that was hacked, Zigbee, has known vulnerabilities, and is used in home area networks for smart grid, not large in-dustrial applications such as pipelines or power plants.

“Kyle Wilhoit’s presentation on ICS honeypots was terri� c and demonstrates a point that is too often overlooked. A small end user can be a tar-get because it is small. Several years ago, the ‘Illinois water hack’ was pooh-poohed because many questioned who would want to target a small water utility in cen-tral Illinois. This is important because a small water utility has the same control systems as a large power plant or re� nery. Moreover, a small electric utility is also connected to its larger neighbors, making it a back door into the larger utilities.

“It is not dif� cult to demonstrate the sky could be falling. It is more important to know if the demonstrations have relevance to critical infrastructure applications.”

Bob Radvanovsky adds, “I agree whole-heartedly with this blog article. The black/white/grey/red/yellow hats are looking for something to make them famous. It has nothing to do with ‘doing the right thing’ by protecting our infrastructures If ‘dot-hats’ (use your favorite color) were truly wanting to protecting critical infrastruc-ture cyber assets, they would contact their federal/national governments and coordi-nate with them. The conferences such as DefCon, Black Hat, et. al show this be-cause it is something new for the hackers to prey upon. Remember: Hackers love challenges, even the ones who want to ex-tort, destroy, damage, pillage, etc.”

presentation on ICS honeypots was terri� c

CT1310_13_Feedback.indd 13 9/30/13 5:26 PM

O t h e r V O i c e s

14 www.controlglobal.com O c t O b e r / 2 0 1 3

Making the right

technology choice

for your company

can end your career

or launch it.

Roy KoKaRc advisoRy gRoup

[email protected]

choose and Manage your suppliers carefully

The technologies we choose have a major impact on our careers and the competitive-

ness of our companies. With the total cost of ownership being over four times the initial

acquisition and installation cost, the choices are much more important than they may at

first appear. Making the right choice can end your career or launch it. However, for the

company, the choice that is made, even a bad one, will be in place until the end of its useful life.

With leaner engineering departments and changing technologies to choose from, se-lecting the right solution is an ever-growing challenge. So the question becomes, “What’s the best process for making a strategic selec-tion.” The follow-up is “How can we manage

our supplier performance to achieve opti-mum long-term results.”

First you need to understand that select-ing the right technology will require both re-search and a team effort. You need to clearly define the scope of the project. Have you had a past solution, and why are you considering a change? What are the key benefits you’re seek-ing? Do you want to improve quality? Agility?

Figure 1.Quantifiable goals, checked regularly, are key to managing your supplier relationships.

MaKE a list; chEcK it REgulaRly

CT1310_14_16_Voices.indd 14 9/30/13 5:28 PM

Take a closer look at MagneTrol-tough liquid level switches, the no. 1 brand of mechanical buoyancy instrumentation. The fact is, MagneTrol switches work hard, and keep on working, for decades of safe, accurate, repeatable, reliable level detection.

Entrust your operation’s safety and performance to MagnEtrol – the first name in durable, reliable mechanical buoyancy liquid level switches.

Design Excellence in the Details Makes Magnetrol® the Leader for Trouble-Free Performance.

Heavy-duty flange configuration is designed to perform reliably in service pressures up to 5000 psig (345 bar).

Full-penetration chamber welds meet ASME Section IX and B31 construction and inspection requirements.

The stainless steel enclosing tube completely isolates the switch magnet from the process environment, preventing interference with the magnet, while allowing reliable magnetic coupling with the attraction sleeve.

magnetrol.com • 1-800-624-8765 • [email protected]

Attraction sleeve

Stainless steel enclosing tube(cutaway)

Magnet

Magnetrol_Control_August2013.indd 1 7/12/13 11:17 AM

The Emerson logo is a trademark and service mark of Emerson Electric Co. ©2013 Fisher Controls International LLC. D352200X012 MZ8

You can automate your control signal using the Fisher® Control-Disk™ valve from Emerson. Process control loops containing butterfly valves

are often placed in manual mode due to poor control performance. This results in operators constantly monitoring and adjusting the control signal, significantly reducing efficiency. With a control range comparable to a segmented ball valve, the Control-Disk valve enables control closer to the target set point. This allows you to leave your control loop in automatic mode, regardless of process disturbances. With low maintenance requirements and sizes up to NPS 36, it’s time to put the Control-Disk valve in your loop. Visit www.Fisher.com/automatic to watch an animation video or download a brochure.

YOU CAN DO THAT

Manually inputting the control signal feels pretty primitive. I need to get back in automatic mode for better efficiency.


O t h e r V O i c e s


Performance? Reduce costs? What are the attributes that will make your company more competitive? After all, isn’t that the ultimate question?

Selecting the right supplier will require the develop-ment of an extensive criteria list. A highly technical solu-tion will typically have over 150 criteria to evaluate. These will fall into one of three categories:

1. Capabilities – In this category, you are evaluating the current capabilities of the company and its products or ser-vices. Are they features you need, and can this company provide them? Does the company have technical support in your region? Is there a local training department? Are parts stored locally?

2. Presence – In this category, you are evaluating the current stability, growth and penetration of the supplier and its products or services in your context (region and/or industry). Is the company a relevant supplier of this tech-nology or service? Is it successful in my industry? In my region? Is it growing?

3. Vision – In this category, you are evaluating the align-ment of the company with your corporate goals and future vision. Is the candidate company developing technology that you will be using in the future? Is it investing in this tech-nology? Is it supporting future standards? Is it staffing as you want it to to provide the kind of support you will need?

Your evaluation criteria should be straightforward, easily understandable and, ideally, drive a quantitative response. Make sure your question facilitates a scalable result. For example, a question about support personnel could be, “Do you have support personnel in my region?” However, a better question would be “List the support personnel you have in my region and give their history.” Creating criteria that prompt yes/no responses do little to help compare one solution to another.

Think as broadly as possible about your selection crite-ria. Don’t forget to include categories for integration with other business systems, long-term ownership and career planning (How will ownership transition to new stakehold-ers as careers advance? How will new users be brought up to speed?). Don’t forget to consider items you will encoun-ter over the life of a system; e.g., upcoming technologies, standards or enhancements to your business practices.

Once you’ve made your selection and implemented the system, you’ll need to move on to supplier performance relationship management (SPRM), and focus on maximiz-ing the benefits of this selection over the lifecycle of the solution.

It is a fact that for strategic and complex technology so-lutions, the total cost of ownership over the lifecycle of the product is over four times the initial cost of acquisition and implementation. You have service costs, technology upgrades, spare or replacement parts, training, consulting

and continued engineering. These are all important cat-egories to consider in making the initial selection, but they are also important areas to manage on an ongoing basis to maximize the benefits of the system and the value derived through your relationship with the supplier.

Here too, a formal process to manage the relationship is critical. When you mention supplier relationship manage-ment (SRM), those in the purchasing realm will see it as managing your supply chain. There are many SRM prod-ucts on the market for that purpose.

In the world of automation, where a strategic selections revolves around a technology such as a distributed control, manufacturing execution or enterprise asset management system, the need is not in managing ongoing deliverables and product quality, but in continually evaluating, man-aging and improving your service relationship (Figure 1).

Just as with supplier selection, quantifiable criteria are important. You can’t improve what you can’t measure. and you can’t measure something you can’t put a number to.

This is an area that ARC Advisory Group sees as under-performing across the industry. This area is better known as supplier performance and relationship management (SPRM). Even the companies that have formal SPRM pro-cesses can quickly identify areas that require improvement. These usually involve training and consistency across the organization.

The key to effective supplier performance and relation-ship management involves three areas:

1. KPIs – The right items to measure, year over year, to gauge that your relationship and the services provided are healthy and on track.

2. Process – A regimented and controlled process deliv-ering repeatability, year over year, even with changing per-sonnel or corporate stakeholders.

3. Scorecard – A simple tool that summarizes the rela-tionship performance and helps to guide constructive dis-cussions that will lead to mutually beneficial results.

The KPIs, when properly defined, enable you to man-age one vendor with a single or multi-site deployment and compare multiple vendor performances against each other. The key is to create a framework and process that will en-able continuous measurement and continuous improve-ment. The result will be improved performance, managed costs and maximized adherence to your business objectives (quality, throughput, uptime, etc.).

Many companies implement such programs for supplier selection or supplier management, but in ARC’s experi-ence, rarely are they implemented with a degree of con-sistency or thoroughness that should be expected for such strategic components in the operation of a company. This is an area where improvement can lead to a significant re-turn on investment.

CT1310_14_16_Voices.indd 16 9/30/13 5:28 PM

© Allied Electronics, Inc 2013. ‘Allied Electronics’ and the Allied Electronics logo are trademarks of Allied Electronics, Inc. An Electrocomponents Company.

1.800.433.5700

The Only Thing Bigger Than Our Catalog Is Your Imagination

Over 115,000 products | Over 11,000 new products | Over 300 world-class suppliers

Including new supplier – Panasonic | Order your catalog at alliedelec.com/2014Catalog

2014 Catalog

OCT13 CatalogAd (CM)_Layout 1 9/12/13 4:38 PM Page 1


Survival of the fitteSt

Pepperl+Fuchs, Inc.Twinsburg, Ohio330.486.0002www.pepperl-fuchs.us

endurance to Withstand the environmentPepperl+Fuchs is the clear choice for industrial-grade flat panel monitors and workstations. Our visualization systems range from general-purpose and Div. 2 monitors to fully integrated Class I, Div. 1 systems. Manufactured with industrial-rated equipment, a full family of high-performance visualization solutions include 10 to 22 inch displays, scanners, keyboards, and other peripherals.

Our expert knowledge of hazardous area protection, and our global support are unsurpassed. When you need safe, reliable, and timely visualization solutions, choose Pepperl+Fuchs. Find high-quality operator workstations and monitors at: www.pepperl-fuchs.us/industrial

Document Path DDB:Volumes:DDB:Emerson_Electric:Active_Work:EECRA_Rosemount_Analytical:P25329_EECRA_Climbers:Mechanicals:P25329_EECRA25329_SmartWireless.inddLinks

P25329_CLIMBERS_V4_SIMPLE.psd (CMYK; 615 ppi; 107.21%), PROCESS_4C_Blue.ai (27.49%), Emerson_CIS_ext_white_mac.ai (66.84%)

Revision # 4Date Created 7-6-2012 8:45 AMSaved 7-16-2012 3:34 PMPrinted 7-16-2012 3:35 PMPrint Scale None

Fonts

Slug Font Myriad Pro FamilyDTL Argo T (Regular, Light; Type 1), DTLArgoT (Bold; Type 1)

Inks

Cyan Magenta Yellow Black

CreativeAccount GroupPrint Producer [email protected] Digital Artist [email protected] Artist [email protected] Retoucher [email protected]

Proofreader

Notes Due Date: 7/18

Emerson_ElectricRosemountAd # EECRA25329_SmartWirelessJob # P25329Print_Magazine, Smart Wireless – Mountain Climbers, Page, 4C Bleed

TeamM. Iacobucci, D. McCradden, G. Matusek, J. Loibl, R. Guagliardo, M. Wheeler, K. Siegal, S. Koller, S. Roseberry

Destination(s)to Client

Final Output Scale 100%Bleed 8.25” x 10.75”Trim 8” x 10.5”Safety 7.5” x 10”

Studio PO# 19858 WO# P25329.1

InDesign CS5

For artwork inquiries, contact [email protected] For print inquiries, contact [email protected]

File Name P25329_EECRA25329_SmartWireless.indd

The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2012 Emerson Electric Co.

See more, do more and be more profitable with the most trusted partner in wireless — Emerson. Emerson is your proven partner with Smart Wireless in more customer sites and with more operating hours than anyone else in the process industry. Smart Wireless has the widest range of technologies to expand your vision into more places across your operations. And its self-organizing mesh network delivers the highest reliability available. It is simply the most intelligent, secure and cost-effective operation-wide wireless option available. See how Smart Wireless can empower your bottom line at EmersonProcess.com/SmartWireless

Using wireless here and there is one thing.But using it across my entire operation? There’s no one I could trust to do that.


O N T H E B U S

john Rezabek contribut ing [email protected]

o c t o b e R / 2 0 1 3 www.controlglobal.com 19

they’ll Make a better Fool

So I was checking my corporate email remotely using a browser interface and hap-

pened upon a message I wanted to remember to open on Monday morning. I thought

I’d right-click and “mark it as unread,” but didn’t notice that, unlike the Lotus Notes stan-

dard interface, there was another option I was clicking (bifocals were in my shirt pocket)

called “mark all unread.” Suddenly I had a couple thousand unread messages, dating back many months. Oops.

Sometimes we need not look too far to find the “fool” referred to in the expression “make it foolproof.” Of course, if you make it foolproof, they’ll make a better fool. That bit of cynicism (or realism) is attributed to an anonymous soft-ware engineer, probably the person tasked with creating all those “are you really, really sure?” dialog boxes that pop up when, for example, you click “delete.”

Similarly, we are professional agents in the chain of delivering the value of present-day technology to our end users, such as our process operators, and we can sometimes feel both be-wildered and harassed by all the new ways they find to break our creations. But because we’re working with highly hazardous processes and substances, and the consequences are so severe, it’s become one of our duties to think through the consequences of every errant mouse click.

When we design for digital integration of field devices through fieldbus, there are some innate features that are part of the specification that we get without clicking anything. We need to understand them, so we can direct the con-figuration mindfully.

Let’s start with fault behavior. Control valve fail position is part of the engineer’s strategy for ensuring the process heads toward a safe state when an instrument fails or instrument air goes away. That’s supposed to be foolproof. But what about loss of communication? With Founda-tion fieldbus (FF), “it depends.” If the design is using control in the field, those loops will con-tinue executing even if communication with the host goes down, provided the segment still has power and something is functioning as the Link Active Scheduler (LAS).

That can be a comfort or cause you some

trepidation, depending on the process. We had a couple controllers lock up one day while I was sitting there viewing them in the engineering interface. I saw lots of red Xs and no informa-tion whatsoever for a large number of loops on the operator console. One was a loop that con-trolled acid concentration going to a fixed-bed hydrogenation reactor with many millions of dollars of relatively soft catalyst. Had the valve failed shut on communication loss, the ensuing increase in viscosity might have crushed that expensive catalyst. I remember walking briskly out to the unit to alert the operations supervisor to my concerns, but he said all was well. Ap-parently, the valve assumed its designed failure state and saved the catalyst. “Hold Last” is the default behavior for most fieldbus valve posi-tioners on communications loss.

“Hold last position” may be a good choice for process robustness, but what if it causes some concerns for safety? A failed loop is usually an “initiating event” in a process hazards analy-sis (PHA or HAZOP), and so the rule says you can’t take credit for any safeguards provided by that same loop. If it gives some added comfort, the standard analog output (AO) block in FF provides some parameters for fault behavior. With the proper configuration, any FF control valve can be set up to go to a preconfigured po-sition on loss of communication. One param-eter sets the time in seconds that the function block will wait for communications to resume, and another sets the value in percent that the positioner will aim at to open or close the valve.

If this sounds complicated, don’t forget we had the same considerations for many conven-tional I/O cards, which have a configurable be-havior for power-up and communications loss. You can email me your specific concerns, and hopefully I’ll spot them among all those “un-read” messages I now have.

Because we’re

working with

hazardous

processes, we

have to think

through the

consequences of

every errant

mouse click.

CT1310_19_OTB.indd 19 9/30/13 5:31 PM

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


ian verhappenDirector,

inDus trial automation ne t [email protected]

Hmi everywhere

Last month, I talked about how RFID and IPv6 make “lick-‘n-stick” sensors possible, driv-

ing the adoption of real-time measurements, such as energy usage, in the consumer

market. Though not yet mainstream, there are simple sensor products on the market

today that allow you to remotely monitor conditions in such places as a boat, a hot tub,

pool or other parts of your home, including your IP-based security systems, over your smart phone or tablet.

However, there is a difference between mon-itoring and interacting or controlling. Effective control requires an HMI. Now that most HMIs are web-based, the power of open standards is once again being demonstrated in the indus-trial sector.

The critical open standards defining today’s web browser are continuing to evolve with de-velopment and adoption of revised standards, such as CSS3 (www.css3.info), SVG (www.w3.org/Graphics/SVG/) and HTML5 (www.w3.org/html/wg/drafts/html/master/), that sup-port scalable graphics in any browser, solving an important piece of the future HMI puzzle.

What will these new standards bring to the scalable HMI equation?

Cascading Style Sheets (CSS) is a style sheet language used for describing the look and for-matting (presentation semantics) of a docu-ment written in a markup language. Its most common application is to style web pages writ-ten in HTML or XHTML, but it can also be applied to any kind of XML document.

Scalable Vector Graphics (SVG) is an XML-based vector image format for two-dimensional graphics that includes support for interactivity and animation. SVG defines the image’s behav-ior in an XML text file.

HTML5, as the name implies, is the fifth generation of HyperText Markup Language (HTML) used for structuring and presenting content for web pages. HTML5 is intended to subsume not only HTML4, but also XHTML (eXtensible HTML) 1.1 and Document Object Model (DOM) Level 2 HTML.

HTML5 includes detailed processing mod-els to encourage more interoperable implemen-tations. Many features of HTML5 have been

built to run on low-powered devices such as smart phones and tablets.

In particular, HTML5 adds many new syn-tactic features designed to make it easy to in-clude and handle multimedia and graphical content on the Web without having to resort to proprietary plugins and APIs. Other new elements are designed to enrich the semantic content of documents. HTML5 also defines in some detail the required processing for in-valid documents, so that syntax errors will be treated uniformly by all conforming browsers and other user agents.

A recent ARC report (http://tinyurl.com/l99mnfl) cites nine automation industry tech-nologies to watch. These are intelligent devices and the Internet of Things; predictive analyt-ics for big data; cloud computing and services-based solutions; virtualization; 3D simulation and augmented reality; mobility-enabled appli-cations and “wearable” technologies; bring your own devices (BYOD); remote operations/asset management; and additive manufacturing/3D printing.

Notice that all of these imply more open-ness, tighter integration of control and business networks, and access to any data, anywhere, anytime. To deliver on this promise obviously requires security and, I believe, the associated move to HMI on a broad range of platforms (BYOD). Moving to smaller screen sizes makes following principles of high-performance HMIs more important than ever.

The recent announcements by Apple of its new iPhones and the unveiling by Samsung of the Galaxy Gear smart watch reinforce how easy it is for us to always remain connected and to access the Internet, thus increasing the pressure to further open the enterprise to beam us data on demand when, where and how we want it.

There’s a

difference between

monitoring and

interacting or

controlling.

Effective control

requires an HMI.

CT1310_20_Wireless.indd 20 9/30/13 5:32 PM

Survival of the fitteSt

Pepperl+Fuchs, Inc.Twinsburg, Ohio330.486.0002www.pepperl-fuchs.us

endurance to Withstand the environmentPepperl+Fuchs is the clear choice for industrial-grade flat panel monitors and workstations. Our visualization systems range from general-purpose and Div. 2 monitors to fully integrated Class I, Div. 1 systems. Manufactured with industrial-rated equipment, a full family of high-performance visualization solutions include 10 to 22 inch displays, scanners, keyboards, and other peripherals.

Our expert knowledge of hazardous area protection, and our global support are unsurpassed. When you need safe, reliable, and timely visualization solutions, choose Pepperl+Fuchs. Find high-quality operator workstations and monitors at: www.pepperl-fuchs.us/industrial

Document Path DDB:Volumes:DDB:Emerson_Electric:Active_Work:EECRA_Rosemount_Analytical:P25329_EECRA_Climbers:Mechanicals:P25329_EECRA25329_SmartWireless.inddLinks

P25329_CLIMBERS_V4_SIMPLE.psd (CMYK; 615 ppi; 107.21%), PROCESS_4C_Blue.ai (27.49%), Emerson_CIS_ext_white_mac.ai (66.84%)

Revision # 4Date Created 7-6-2012 8:45 AMSaved 7-16-2012 3:34 PMPrinted 7-16-2012 3:35 PMPrint Scale None

Fonts

Slug Font Myriad Pro FamilyDTL Argo T (Regular, Light; Type 1), DTLArgoT (Bold; Type 1)

Inks

Cyan Magenta Yellow Black

CreativeAccount GroupPrint Producer [email protected] Digital Artist [email protected] Artist [email protected] Retoucher [email protected]

Proofreader

Notes Due Date: 7/18

Emerson_ElectricRosemountAd # EECRA25329_SmartWirelessJob # P25329Print_Magazine, Smart Wireless – Mountain Climbers, Page, 4C Bleed

TeamM. Iacobucci, D. McCradden, G. Matusek, J. Loibl, R. Guagliardo, M. Wheeler, K. Siegal, S. Koller, S. Roseberry

Destination(s)to Client

Final Output Scale 100%Bleed 8.25” x 10.75”Trim 8” x 10.5”Safety 7.5” x 10”

Studio PO# 19858 WO# P25329.1

InDesign CS5

For artwork inquiries, contact [email protected] For print inquiries, contact [email protected]

File Name P25329_EECRA25329_SmartWireless.indd


See more, do more and be more profitable with the most trusted partner in wireless — Emerson. Emerson is your proven partner with Smart Wireless in more customer sites and with more operating hours than anyone else in the process industry. Smart Wireless has the widest range of technologies to expand your vision into more places across your operations. And its self-organizing mesh network delivers the highest reliability available. It is simply the most intelligent, secure and cost-effective operation-wide wireless option available. See how Smart Wireless can empower your bottom line at EmersonProcess.com/SmartWireless

Using wireless here and there is one thing.But using it across my entire operation? There’s no one I could trust to do that.



I n P r o c e s s

Invensys Welcomes era of New PossibilitiesNew system launch, pending acquisitions mark ongoing transformation.

As the Invensys Foxboro and Triconex 2013 Client Conference got under-way last month in San Antonio, Texas, company executives paused first to pay homage to the past, acknowledging the 30th anniversary of its Triconex safety system brand. But the look back quickly turned forward, as the assembled sys-tem user community got its first look at the company’s new process automa-tion offering, the Foxboro Evo system. The new system launch, together with the company’s pending acquisition by France’s Schneider Electric, lent an air of excited anticipation and new begin-nings to the proceedings attended by more than 500 of the company’s sys-tem users from 24 countries around the globe.

In talking about the Foxboro Evo system, Mike Caliel, president and CEO of the Software and Industrial Automation division of Invensys, de-clared that the system marks the dawn of a new age of enlightenment for every function with the organization. “To-day’s challenges go far beyond tech-nology; they’re about how do you apply technology to drive bottom-line busi-ness value,” Caliel said. Proliferating mountains of data—presented without context, if presented at all—are hurting operations more than they’re helping. What’s needed is a system that can get out in front of these challenges to en-sure operational integrity while provid-ing operational insight,” Caliel said.

“As the pace of global business accel-erates, automation technology becomes increasingly important in helping man-ufacturers focus on finding more value within their operations and automa-tion assets,” added Chris Lyden, Inven-sys senior vice president. “If users in the control room and in the field can better

interpret the growing volume and com-plexity of the information they receive within the proper context of procedures and operational risk, then they will make more valuable contributions to the busi-ness. The Foxboro Evo system is loaded with new features that will help them do that, and it is structured to evolve with them as they and their companies change and grow.”

Caleil’s opening remarks would have been incomplete without some mention of the company’s pending $5.2-billion acquisition by Schneider Electric, expected to be completed by the end of 2013 or early 2014, pending formal shareholder approval and anti-trust review. Since the companies are required by law to continue to operate independently until then, little of the substance of the plans moving forward can yet be revealed.

Caleil did stress, however, Schnei-der’s stated view that Invensys will be a

key contributor to the combined com-panies’ continued future growth. In a video message to conference attend-ees, Jean-Pascal Tricoire, Schneider chairman and CEO, noted that the new Foxboro Evo system “is an impor-tant step in Invensys’ continued tech-nology leadership. You can feel con-fident in Schneider’s commitment to support the new system when the ac-quisition is finalized.”

Meanwhile, over at IndusoftThose closely following the Schneider/Invensys deal may want to get a score card. With the Schneider acquisition not yet final, Invensys has announced that it has acquired InduSoft, a pro-vider of HMI and embedded intelli-gent device software for the automa-tion market. Headquartered in Austin, Texas, and founded in 1997, InduSoft sells primarily to industrial computer manufacturers and machine and sys-tem builders, who embed InduSoft’s software into their products.

“The acquisition of InduSoft rep-resents the continuing execution of our strategy to strengthen our portfo-lio through inorganic means, enabling us to target additional segments across our portfolio,” said Ravi Gopinath, president of Invensys’ software busi-ness. “InduSoft strengthens and broad-ens our software solutions portfolio, particularly in the embedded HMI segment, and provides a continuing driver for growth.”

Norm Thorlakson, vice president, HMI and supervisory software and solutions, Invensys, said, “With Indu-Soft, we can now offer everything from basic embedded HMI devices to man-ufacturing operations, asset manage-ment and ERP integration.

Mike Caliel, president and CEO of the

Software and Industrial Automation divi-

sion of Invensys, introduces the Foxboro

Evo process automation system.

New SyStem

CT1310_22_30_InPro.indd 22 9/30/13 6:10 PM

Yokogawa began manufacturing single loop controllers in the 1960’s. Yokogawa’s latest SLC, the YS1000 provides a migration path for all of its legacy models by simply removing the existing controller from the housing and replacing it with the new one.

Yokogawa offers a series of highly capable single loop controllers that are qualified for nuclear seismic and safety applications. Many utilities trust the quality and reliability built into all Yokogawa control room instruments. The YS1000 Series is the perfect solution for replacing those old, obsolete controllers in your plant. The programmable controller model

provides multiple control modes as well as user

mode that supports function blocks to program custom control strategies. This unit features dual CPU’s for reliability as well as a hard manual backup output with hot-swap capability. Yokogawa provides a strong migration path for its legacy products.

Yokogawa offers a series of highly capable single loop controllers that are qualified for nuclear seismic and safety applications. Many utilities trust the quality and reliability built into all Yokogawa control room instruments. The YS1000 Series is the perfect solution for replacing those old, obsolete controllers

provides multiple control modes as well as user

mode that supports function blocks to program custom control strategies. This unit features dual CPU’s for reliability as well

A Clear Migration Path

Available in commercial grade or qualified by NTS for safety & seismic applications.

Class 1E Qualified

Yokogawa’s YS Series Controllers are Qualifiedfor Nuclear Safety and Seismic Applications

www.yokogawa.com

Contact Yokogawa at 1-800-888-6400 or NTS at 978-263-2933 or go to www.YS1700.com for more details.

AD13

10?

2013-09-194 Yoko Solutions Control Ad_AD1303.indd 1 9/26/13 1:58 PMCT1310_full page ads.indd 23 10/1/13 3:39 PM

I n P r o c e s s

“InduSoft technology quickly makes us more competitive, and gives us im-mediate entry to new customers and a stronger OEM sales channel with a fo-cus on machine builders and embed-ded systems. We are confident it will

make us much more attractive. Won-derware users will now be able buy in-dustrial devices, machines and com-puters with InduSoft software, while companies that are using InduSoft software will be able to expand their

solutions with Wonderware supervi-sory, historian and manufacturing op-erations management software.”

InduSoft will continue to be man-aged by its existing executive team, adding employees to Invensys opera-tions in the United States, Brazil and Germany.

HART and Fieldbus Foundation Discuss Potential MergerThe Fieldbus Foundation and the HART Communication Foundation announced Sept. 25 that they have entered into discussions on the po-tential for merging the two organi-zations into a single industry foun-dation dedicated to the needs of intelligent device communications in the world of process automation.

The chairmen of the two orga-nizations, Dr. Gunther Kegel of the Fieldbus Foundation and Mark Schumacher of the HART Commu-nication Foundation, issued the fol-lowing statement on behalf of their boards of directors:

“We believe combining the re-sources and capabilities of each foun-dation into a single organization will provide significant benefits to both end users and suppliers. For end users, a single organization that combines the power of both Fieldbus Foundation and HART Communication Founda-tion would provide a full solution that addresses every conceivable aspect of field communications and intelligent device management for the process industries. For suppliers, a single or-ganization would create efficiencies in resource utilization, consistency of processes and procedures, and would deliver significant improvements in member services and support.”

The Fieldbus Foundation and the HART Communication Foundation have worked extensively together in the

MiMiC v3.5Available Now!

CT1310_22_30_InPro.indd 24 9/30/13 6:10 PM

I N P R O C E S S

past and have a long history of cooperation. For example, the two organizations worked together on the development of common international standards, such as Electronic Device Description Language (EDDL) and the development of the Field Device Integration (FDI) speci� cation. The merger offers signi� cant potential to harmonize many aspects of the two protocols, making it easier for end users and suppliers to implement the technology, and obtain the full bene� ts of each technology in plant operations and maintenance.

In preliminary discussions, the presidents of the two or-ganizations, Richard Timoney of the Fieldbus Foundation and Ted Masters of the HART Communication Founda-tion, added that many synergies already exist, and closed by commenting:

“We’re both con� dent that today’s decision to investigate the merger of these two organizations provides momentum for a major step forward in the evolution of intelligent de-vices and the world of industrial communications.”

Endress+Hauser Expanding U.S. ProductionEndress+Hauser is getting bigger in Indiana as part of a strategy to get closer to its customers. “We want to move our production as close as possible to our customers,” stressed Klaus Endress, CEO of the Endress+Hauser Group, dur-ing the inauguration ceremony for two new buildings at the company’s Greenwood, Ind., facility. “Being close allows us

Can I rely on Can I rely on wireless to control wireless to control wireless to control wireless to control remote facilities?remote facilities?remote facilities?

Can I monitor temperatures at known

problem locations without wiring?

Can I collect remote tank-level data

without costly trenching and conduit?without costly trenching and conduit?without costly trenching and conduit?without costly trenching and conduit?

Can I control remote well pumps Can I control remote well pumps Can I control remote well pumps

without line of sight? without line of sight? without line of sight?

Customers F i rs t

In tegr i ty A lways

45 Years of Excel lence

New Solutions — Every Day

In process and industrial automation,

you need accurate monitoring, consistent

uptime and real ROI. Be sure. With the

Banner SureCross Wireless Network. Visit

BannerEngineering.com/ProcessControl.

Or call (888) 373-6767.

Klaus Endress, CEO of the Endress+Hauser Group, Mayor Mark My-

ers, City of Greenwood, Ind., and John Schnake, general manager of

Endress+Hauser USA Automation Instrumentation, open a new building

at the company’s Greenwood facility.

OPEN FOR BUSINESS

CT1310_22_30_InPro.indd 26 9/30/13 6:10 PM

Smart Valve Positioner

Beyond Control. The NEW Research Control® SRD positioner does

everything you expect any valve positioner to do

plus more. The SRD’s comprehensive diagnostics tool

continuously monitors for fugitive emissions, delivers

real-time performance statistics, and facilitates both

proactive and reactive process management. Available

with integrated network communications, the SRD

is compatible with Research Control valves and most

other pneumatically-actuated valves

Visit www.badgermeter.com/valvepos23 or call

800-876-3837 for more information today.

© 2013 Badger Meter, Inc.RESEARCH CONTROL is a registered trademark of Badger Meter, Inc.

Valve Positioner Ad.indd 1 9/24/2013 11:05:20 AMCT1310_full page ads.indd 27 10/1/13 3:40 PM

I N P R O C E S S

to respond quickly to the special needs and requirements of our markets and customers.”

One important element necessary for this concept to work is globally uniform quality standards. “Here in the United

States we manufacture at the highest level,” stressed Hans-Peter Blaser, man-aging director of the � ow engineering plant in Greenwood.

An extension to the new building oc-cupied only � ve years ago has created

nearly 85,000 square feet of additional space. “This gives us the chance to in-crease capacity and to produce addi-tional lines of instruments locally,” Bla-ser added.

The systems for calibrating � owme-ters, unique on the continent, have now grown to include the latest tech-nology for gas calibration.

The plant for level and pressure engineering moves into a new build-ing with more than 105,000 sq. ft. of ground area directly next door. “After years of strong growth, this will make us � t for the future,” says managing director John Schnake. The addi-tional production areas will increase the scope of production, and allow more products to be delivered directly from the Greenwood plant. The va-cated facilities space will allow for a new visitor and training center for the U.S. sales organization.

Over the past years, Endress+Hauser has strongly grown its market share in the United States. Todd Lucey, man-aging director of the U.S. sales cen-ter, believes that one of the keys to this success is owed to this expanded local manufacturing capability. “More than 80% percent of the measurement in-struments we deliver in the U.S. today are now made in the U.S., and we will continue to grow this share into the fu-ture,” he said. “We are a proud Amer-ican company—with strong Swiss roots.”

Endress+Hauser has had its own sales center in the United States since 1970. For more than two decades, the company has also manufactured there for the U.S., Canadian, Mexican, Bra-zilian, Chilean and Argentinian mar-kets. Flow, pressure and temperature measurement devices are produced in Greenwood, where the U.S. sales cen-ter also is headquartered.

Endress+Hauser manufactures sen-sors for liquid analysis in Anaheim, Ca-lif., while its subsidiary, SpectraSensors in Houston, Texas, specializing in gas analysis, operates a plant in Rancho

1-800-343-1001 • www.predig.com/modbus

View A New Dimensionof Display Possibilities

Take Advantage of Your Modbus SignalBy using the Modbus signal from your existing multivariable level transmitters you will unleash a whole new dimension of display possibilities. Paired with a new Precision Digital Modbus Scanner you can display multiple variables including level, interface level, density, temperature and more.

Why Modbus Scanners? > Scan up to 16 PVs > Easy instrallation & setup > Display level in feet & inches* > SafeTouch® thru-glass buttons* > Display PV and tag name > 4-20 mA retransmission

* Available on select meters

PRECISION DIGITAL CORPORATION Since 1974

Call us to discuss your application and receive aFREE 4GB USB DRIVE

density

level

volume

level

interface level

volume

temperature

Modbus

volume

volumemore

CT1310_22_30_InPro.indd 28 9/30/13 6:11 PM

HART Loop Interfaces:• Convert HART to 4-20mA Signals

• “Break Out” Up to Three Analog Signals

• Provide High/Low Process Alarm Trips (Contact Closure)

• Convert HART to MODBUS RTU

• Monitor HART Instrument Diagnostics

• Work with Every HART-Compatible Transmitter and Valve

• Set Up in Minutes Using FREE Con guration Software

Contact Us at 800-999-2900CCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCooooooooooooooooooooooooooooooooooooooonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnttttttttttttttttttttttttttttttttttttttaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaccccccccccccccccccccccccccccccccccccccccctttttttttttttttttttttttttttttttttttttt UUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUssssssssssssssssssssssssssssssssssssss aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaatttttttttttttttttttttttttttttttttttttt 88888888888888888888888888888888888800000000000000000000000000000000000000000000000000000000000000000000-----------------------9999999999999999999999999999999999999999999999999999999999999999999999999999999999999999999999999999999999-------------------------22222222222222222222222222222222222222229999999999999999999999999999999999990000000000000000000000000000000000000000000000000000000000000000000

www.miinet.com/HART

Visit our website and learn more about our Smart HART products at:

10.5”

7.875”

4-20mA Representing the Primary Variable

(Mass Flow)

HIM Smart HART Loop Monitor"Breaks Out" Data from Smart HART Instruments

4-20mA Proportional to 2nd Variable (DP)

4-20mA Proportional to 3rd Variable (P)

4-20mA Proportional to 4th Variable (T)

HART Transmitter Diagnostics Fault Alarmor Additional Process Alarm

Control System

Smart HART MultivariableMass Flow Transmitter

Flow

High Alarm in Response to 4th Variable (T)

HART Digital Signal Carrying Primary, Second, Third andFourth Variable Process Data and InstrumentDiagnostic Information

HART Communicator

can be Connected Anywhere Along the 4-20mA Loop

Flow

Unlock Your Smart HART®

Device’s Hidden Secrets®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®®

CONTROL_2013-10_HART_FullPg_MooreIndustries.pdf

Demand Moore Reliability


I N P R O C E S S

Cucamonga, Calif. More than 700 people work for Endress+Hauser in the United States, while a tight network of representatives with another 350 sales engineers and service technicians sup-ports customers nationwide.

Cyber Criminals Target Energy IndustryFormer Homeland Security Dept. direc-tor Michael Chertoff told oil and gas in-dustry executives gathered in Houston

that it no longer takes an army to � ght a war. The top threat their businesses face in the future is not from physical risks, but cyber attacks, he said. Chertoff’s remarks focused on the increasing threat of cybersecurity in general and its poten-tial impact on the critical infrastructure of energy companies speci� cally.

“Cyber attacks are the biggest threat facing America. Most com-panies have experienced some type of cybersecurity event whether they know it or not. No industry is im-mune, but energy companies are clearly in the cross hairs of these cyber criminals as more than 40% of all reported malicious cyber at-tacks in 2012 were directed at them,” Chertoff added during his remarks. “Specific point solutions have been implemented in most cases, but more needs to be done. We must de-velop a series of corrections to this complex problem across government and industry, taking a holistic ap-proach that addresses policies, reg-ulatory incentives, people, training and technology. Hopefully, it won’t take a cyber 9/11 for the industry to realize the magnitude of today’s cy-bersecurity threat.”

Chertoff addressed about 25 oil-and-gas industry executives, rep-resenting many of the industry’s leading companies, at an exclusive Executive Upstream Innovation and Technology Summit held in con-junction with the IHS Forum in partnership with Honeywell. The twice-yearly IHS forum features in-depth sessions on macroeconomics, energy, chemicals and construction, among others.

“Cybersecurity is a critical is-sue for nations, businesses and in-dividuals,” said Darius Adamczyk, president of Honeywell Process So-lutions, who hosted the business leaders. “Cyber risks are constantly evolving, and we have to work to-gether to find the right combination of solutions.”

WEWEWE CONNECTCONNECTCONNECTMODBUSMODBUSMODBUS

• Energy

• Oil & Gas

• Packaging

• Automobile Production

• Water/Wastewater

• Oil & Gas

• Automobile Production

Where Automation Connects

+1-661-716-5100www.prosoft-technology.com

A S I A PA C I F I C | A F R I C A | E U R O P E | M I D D L E E A S T | L AT I N A M E R I C A | N O R T H A M E R I C A

CT1310_22_30_InPro.indd 30 9/30/13 6:12 PM

© 2013 by AMETEK Inc. All rights reserved.

The new WDG-V.Impressing even theworld’s most demandingcombustion manager.

The new AMETEK Thermox WDG-V extractive combustion analyzer offers industry-leading safety support. First in its class to be third-party certified forSIL-2 implementation in safety-instrumented systems, the WDG-V provides a complete solution for combustion process control and safety.

Reliable detection of low-combustion oxygen and/or high CO in a fired heateror boiler is critical to burner management system effectiveness. The WDG-Vanalyzer monitors hot, wet flue gas to minimize excess oxygen, lower NOx emissions, and improve operating efficiency in power generation and petrochemical refining. It can also monitor methane levels to assure safe burner startup and shutdown.

The all-new WDG-V. Combustion management and safety capabilities so good, they make this guy jealous. Learn more at www.ametekpi.com.

AMETEKPAI 13912-WDG-V-7.875x10.5-Control_1p4cb 09/20/13 12:25 PM Page 1


Control’s Monthly Resource Guide

R E S O U R C E S


Online with Process Analyzers

Every month, Control’s editors take a specific product area, collect all the latest, significant tools we can find,

and present them here to make your job easier. If you know of any tools and resources we didn’t include, send

them to [email protected], and we’ll add them to the website.

LEAK DETECTION WITH pHVirtually all industries from food and beverage to chemical processing use heat exchangers, condensers or jack-eted vessels. Leakage of the process into the cooling water represents a loss of product, and can be a source of

fouling or corrosion in the cooling wa-ter system. Conversely, leakage of the cooling water into the process can be a source of contamination. For a leak to be detected by pH, a small amount of contaminant must cause a measurable change in the pH of the sample being monitored. This application data sheet discusses practical considerations, and lists five rules for effective leak detec-tion. The direct link is at http://tinyurl.com/ljcfwot.

ROsemOunt AnAly t icAl w w w.Rosemount Analy t ical .com

GETTING THE BEST FROM YOUR ANALYZEROn-stream analytical data is crucial to safe and efficient operation in the petro-leum, chemical, pharmaceutical, pulp

and paper, power and other industries. However, if online instrumentation, sample-handling systems and data-anal-ysis software are to realize optimum performance, they will require contin-ual attention from the analyzer support staff, who may need specialized skills. Sourcing such specialized skills can be challenging and expensive. So how do you realize the enormous potential ben-efits of on-stream analysis without the overhead of on-site analyzer specialists? Find out at http://tinyurl.com/mfod4ll.

cOntROlGlObAl.cOmw w w.controlglobal .com

THE BOOK ON SAMPLING SYSTEMSSampling systems expert Tony Waters and Swagelok have created a compre-hensive reference covering the engi-neering involved with designing and operating a sampling system for a pro-cess analyzer. Exclusively available for purchase at Swagelok sales and service centers, Industrial Sampling Systems offers in-depth analytical instrumenta-tion material suited for anyone from a novice to a degreed engineer. The 750-page book in 12 chapters offers three appendices, a +1000-word glossary and self-assessment tests at the end of each chapter. For more details, go to http://tinyurl.com/mupugq3.

swAGelOkw w w.swagelok .com

ONLINE PROCESS ANALYZER TUTORIALSThis website has process analysis tu-torials on many subjects, including chromatography, combustibles mon-itoring, conductivity, dissolved oxy-gen basics, infrared analysis, mass spectrometry, moisture analysis,

ORP and pH basics, sample condi-tioning systems, ultraviolet analyzers and more, plus numbers calculators and conversion charts. The direct link is at http://www.onlineprocess-analyzers.com/tutorials.html.

OnlinePROcessAnAly zeRs.cOmw w w.onl ineprocessanalyzers.com

GOOD TITRATIONThis webinar from Mettler Toledo covers “Good Titration Practice in Petrochemicals.” From the ground to the engine of a vehicle, the qual-ity control of petrochemicals is crit-ical at every stage of the process. Water-sensitivity of petrochemicals as well as their non-aqueous solubil-ity, requires special handling of the samples, and specific sensors and solvents used in their analysis. This GTP Petrochemical webinar offers knowledge and tips to assist you in optimizing your oil and fuel analysis, such as Karl Fischer water determi-nation, TAN, TBN and mercaptans. For more information, including dates, times and registration, go to http://tinyurl.com/nbzog2q.

me t tleR tOledOht tp: //us.mt .com

RELIABLE PROCESS ANALYZERSThis podcast from Control’s senior technical editor, Dan Hebert, asks the question: “Why can’t someone make an analyzer that works as well, and is as reliable as a pressure, temperature or a flow transmitter?” The various answers are located at go to http://tinyurl.com/opgw6po.

cOntROlGlObAl.cOmw w w.controlglobal .com

CT1310_32_Resources.indd 32 9/30/13 6:05 PM

EXPERIENCE MATTERS. With thousands of installations across the globe in some of the world’s toughest conditions and applications, Orion Instruments® proves daily that we are the leading supplier of magnetic level indication. Contact us today to find out how we can apply ORION INSTRUMENTS technology to help solve your level applications.

• Power Utility • Refining • Chemical • Pulp & Paper• Oil & Gas Exploration & Production • Military • Wastewater

www.orioninstruments.com • 2105 Oak Villa Boulevard • Baton Rouge, Louisiana • 70815 • 866-55-ORION • 225-906-2343 • f: 225-906-2344Orion Instruments, Magnetrol, Aurora, and Jupiter are registered trademarks of Magnetrol International. Atlas and Reveal are trademarks of Magnetrol International.

Schedule a visit to our manufacturing facility

ISO 9001

Advanced MLI withintegrated Guided WaveRadar level transmitter.

Basic, high-performance MLI suitable for a variety of applications.

F e a t u r i n g

wide ind icatorpatent pending

Magnetostrictive Level Transmitter

What’s your

of confidence?LEVELLEVELLEVEL

#1 Magnetic Level Indicator

#1 Magnetostrictive Level Transmitter


34 www.controlglobal.com O C T O B E R / 2 0 1 3

P R O C E S S C Y B E R S E C U R I T Y

Cybersecurity begins with � rewalls and network segmentation, but thesebarriers must be accompanied by constant monitoring and veri� cation

of internal communications and data to protect applications.

by JIM MONTAGUE

WHAT’S INSIDE YOUR ARMOR?

CT1310_34_45_CoverStory.indd 34 9/30/13 6:15 PM



rue process security—like true beauty—has to be more than skin deep. So, while a protective metal suit is impressive, it’s nothing without the muscles, bones and brain driving it from inside.

Likewise, all the pipelines, tanks and process vessels in every process application and facility are useless without their sensors, instruments and controls, so securing them requires internal awareness and protections that go beyond external defenses.

Simplify and Standardize Luckily, an excellent way to improve internal cyberecurity is to simplify by turning off or removing unneeded software, hardware, services or access points, and then standardizing the remaining software and components, according to Todd Mortensen II, senior network specialist at Public Service of New Mexico’s (www.PNM.com) San Jose Generating Sta-tion (SJGS), who spoke at Invensys’ Foxboro and Triconex Global Client Conference 2013 in September.

PNM is New Mexico’s largest electrical utility, and in-cludes SJGS, which has four coal-� red units that produce about 1,800 gross megawatts for more than 2 million cus-tomers. Process controls at SJGS use a multi-unit mesh network and off-the-shelf, thin-client devices, which are secured by individual operator accounts, group policy pref-erences, event monitoring, software patches, whitelisting and anti-malware programs, hardware locks for RJ45 and RJ11 components, and physical access protection.

“We � rst have to � gure out what services are running on which boxes. If a device doesn’t need audio, then we remove

it. It’s especially crucial in cybersecurity to shrink the service area for potential attacks, so we get rid of software and services we don’t need,” says Mortensen. “You can turn off the ports on many devices, so you don’t unintentionally connect to the wrong networks or subnet. We also use natively encrypted USB drives, which don’t install or run any software.”

Mortensen adds that PNM and SJGS also use RFID tags to document all kinds of equipment, which helps them separate secure devices from unsecured ones. “The tags help us keep track of equipment, which is good be-cause cybersecurity regulations and legislation aren’t going away,” adds Mortensen. “It’s important to under-stand that cybersecurity isn’t a part-time job, and that it requires time, money and resources, backing from the or-ganization’s bottom to top, and even using outside firms. We recommend using contractors as along as you make sure they have the experience to secure your systems, and have experience with the standards and rules you have to follow. You must also remember that you’re responsible for your cybersecurity and compliance, and make it clear that you’re leading your security project.”

Taking ResponsibilityTo start a cybersecurity project, pretty much everyone agrees that genuine buy-in and long-term support and commitment from management is essential. “Process security has to start with top-level support, but there are many competing cost pressures, too. So, security must be raised to the level of the bottom-line, even though it’s dif� cult,” says Kenneth

One of the latest calls for better cybersecurity arrived in the form of

the Obama Administration’s Executive Order on Feb. 12, which as-

signed the National Institute of Standards and Technology (NIST)

to develop a framework for improving critical-infrastructure cyber-

security. Likewise, NIST’s draft framework includes a draft com-

pendium of informative references, which reviewed more than 320

national and international standards, guidelines, directives, best

practices, models, speci� cations, policies and regulations. Some

of these organizations include: ANSI, ISA, NERC, API, ISO, IEC,

NEI, NIST, NFPA, OIG, OLF, OPC, SANS, TIA and others.

Naturally, some common themes on cybersecurity best

practices have emerged. “The basic cybersecurity process

involves identifying critical assets, doing security risk as-

sessments for them, deciding how the cybersecurity frame-

work applies to them, and coming up a mitigation plan and

actions to comply with it,” explains Michael Martinez, CISA,

principal in Invensys’ (http://iom.invensys.com) Critical Infra-

structure and Security Practice.

NIST’s preliminary framework has � ve steps: know, prevent, de-

tect, respond and recover:

• Know means gaining the institutional understanding to

identify what systems need to be protected, assessing their

priority in light of the organization’s mission, and managing

processes to achieve cost effective risk management goals.

• Prevent consists of categories of management, technical

and operational activities, which enable the organization to

decide on the appropriate outcome-based actions to ensure

adequate protection against threats to business systems that

support critical infrastructure components.

• Detect includes activities that identify, through ongoing

monitoring or other means of observation, the presence of

undesirable cyber risk events, and the processes to assess

the potential impact of those events.

• Respond involves making speci� c risk-management de-

cisions and enacting activities based on previously imple-

mented cybersecurity planning, completed at the Prevent

stage, relative to estimated impact.

• Recover includes categories of management, technical and

operational activities that restore services, which were previ-

ously impaired by an undesirable cybersecurity risk.

NIST IDENTIFIES COMMON SECURITY STEPS

T



Jackson, global process control leader of the Performance Polymers and Packaging and Industrial Polymers divisions at DuPont (www.dupont.com) in Wilmington, Del. “At DuPont, we consider cybersecurity to be in the same class as managing process safety. They’re both line-organization responsibilities.”

Besides its other security efforts, Jackson reports that Du-Pont’s security experts have been developing plans and im-plementing the U.S. Dept. of Homeland Security’s (DHS) Chemical Facility Anti-Terrorism (CFATs) standards and Maritime Transportation Security Act (MTSA) regulations for applications processing “chemicals of interest,” which are de� ned by the government. This effort includes orga-nizing security teams, updating security policies for more than 100 manufacturing sites over the next two or three years, and developing cybersecurity best practices and poli-cies at each site, which can eventually be shared and ap-plied as universal, internal standards. These can include secure log-in procedures, multilayered network architec-tures with � rewalls, physical security for control rooms, en-hanced intrusion detection, and using antivirus software combined with whitelisting.

Inside the BarricadesSo, just how at-risk are today’s process control networks? Well, Leigh Weber, CISSP, senior security engineer at exida Consulting (www.exida.com) in Sellerville, Pa., says that, “Control systems are more vulnerable today than ever before because they use commercial technologies, they’re highly connected, offer remote access, lots of technical informa-tion is publicly available on them, and hackers are now tar-geting control systems.”

For example, Weber reports that the S4 Security Confer-ence in January 2012 included a “Project Basecamp” that involved six researchers looking for vulnerabilities in six different embedded industrial process control devices, such as PLCs, RTUs and substation controllers, and they found backdoors, weak credential storage, ability to change ladder logic and � rmware, buffer over� ows, etc.

“Nessus plugins and Metasploit modules have been pub-licly released, enabling anyone to � nd and exploit these vulnerabilities,” explains Weber. “Much of the code needed to crash PLCs is free, and some companies are selling SCADA-based attack kits, though they’re mostly for IT departments to test their systems.”

D R E X E L B R O O K ’ S U N I V E R S A L I V ™ C U T M O N I T O R

Water-cut measurement so accurate, no other

monitor makes the cut.

First, we bent the rules to enter the oil stream through the elbow. Then we designed a sampling probe that extends well into the line, averaging all readings along its length for superior accuracy — down to 0.03% water.

The probe senses changes in capacitance. The relationship between capacitance and water cut, known as BS&W (basic sediment and water) iscomputed by the unit’s electronics. And, because the Universal IV featuresRF admittance tech nology, it ignores buildup and its rugged sensor won’twear out.

Pre-calibrated to your light or heavy oil needs, it meets worldwide approvals(FM, FMc, ATEX and IECEx) and works in pressures to 1,500 PSI and tem-peratures to 450°F. Why not sample our new Universal IV cut monitor foryourself? Visit drexelbrook.com/cutmonitor to download our white paperor call 800-553-9092.

© 2

013

by A

ME

TE

K. A

ll rig

hts

rese

rved

.

Availablefor quick delivery.

Reliable performance. Easy installation.

AMETEK 12407-half Page_AMETEK 12407-Unv-IV 3/12/13 2:16 PM Page 1

Jackson, global process control leader of the Performance Polymers and Packaging and Industrial Polymers divisions at DuPont (www.dupont.com) in Wilmington, Del. “At DuPont, we consider cybersecurity to be in the same class as managing process safety. They’re both line-organization responsibilities.”

Besides its other security efforts, Jackson reports that Du-Pont’s security experts have been developing plans and im-plementing the U.S. Dept. of Homeland Security’s (DHS)


Jackson, global process control leader of the Performance Polymers and Packaging and Industrial Polymers divisions at DuPont (www.dupont.com) in Wilmington, Del. “At DuPont, we consider cybersecurity to be in the same class as managing process safety. They’re both line-organization

Polymers and Packaging and Industrial Polymers divisions at DuPont (www.dupont.com) in Wilmington, Del. “At DuPont, we consider cybersecurity to be in the same class as managing process safety. They’re both line-organization responsibilities.”

Besides its other security efforts, Jackson reports that Du-Pont’s security experts have been developing plans and im-plementing the U.S. Dept. of Homeland Security’s (DHS) Chemical Facility Anti-Terrorism (CFATs) standards and Maritime Transportation Security Act (MTSA) regulations for applications processing “chemicals of interest,” which

DuPont, we consider cybersecurity to be in the same class as managing process safety. They’re both line-organization

Pont’s security experts have been developing plans and im-plementing the U.S. Dept. of Homeland Security’s (DHS) plementing the U.S. Dept. of Homeland Security’s (DHS) Chemical Facility Anti-Terrorism (CFATs) standards and Maritime Transportation Security Act (MTSA) regulations for applications processing “chemicals of interest,” which are de� ned by the government. This effort includes orga-nizing security teams, updating security policies for more than 100 manufacturing sites over the next two or three years, and developing cybersecurity best practices and poli-cies at each site, which can eventually be shared and ap-plied as universal, internal standards. These can include secure log-in procedures, multilayered network architec-tures with � rewalls, physical security for control rooms, en-hanced intrusion detection, and using antivirus software

years, and developing cybersecurity best practices and poli-cies at each site, which can eventually be shared and ap-plied as universal, internal standards. These can include secure log-in procedures, multilayered network architec-tures with � rewalls, physical security for control rooms, en-hanced intrusion detection, and using antivirus software hanced intrusion detection, and using antivirus software


Communication is Key.Are Your Disparate Control Systems Talking? The PlantPAx™ process automation system offers one platform for true plant-wide control – including process, discrete, power, safety and information. Utilizing EtherNet/IPas its backbone, it delivers increased communication and real-time information tooptimize processes, performance, maintenance and profitability. Now you’re talking.

PlantPAx. It’s More Than a DCS.

Learn more atwww.rockwellautomation.com/go/processPlantPAx is a trademark of Rockwell Automation, Inc. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. AD2013-28-EN



Weber adds that there are many more pathways into most control systems than users and managers realize. These include unauthorized, unchecked USB devices, infected laptops, incor-rectly setup � rewalls, old modems, external PLC networks and unprotected � eldbuses, RS-232 links and other devices. “Do you still have any modems in your system? Are you sure?” asks We-ber. “A lot of networking hardware isn’t removed when updates are done. As a result, these threats are realistic, sophisticated and readily available.”

So, besides maintaining segmenting and � rewalls, the traditional defense-in-depth strategy must include network traf� c monitoring and malware scans of communications, adds Mike Baldi, chief cybersecurity architect at Honeywell Process Solutions (www.honeywellprocess.com).

“Many of these tools, like Security Information Event Management (SIEM), come from the IT and enterprise side, and so we’re working on adapting them for the process control world. The good news is that scanning and bench-marking are easier on the process control side. In fact, we already have many rigid rules about who can talk to whom, and so it will be much simpler for us to detect any abnormal traf� c deviations.”

Encryption Aids Wireless, TooSimilar to � eldbuses, wireless gives users the nimbleness to take on new monitoring and control tasks more easily. Ter-ri� c, but this � exibility and wider reach demands better se-curity, too.

Figure 1: Martin Midstream Partners implemented Rotork’s IQ40

actuators and Pakscan wireless modules and antennas, and

encrypted their communications, on four booster pumps at its

six-tank farm at the Port of Corpus Christi, so the facility could

handle two types of hydrocarbon products.

BOOSTING, ENCRYPTING PUMP SIGNALS

Pho

to c

our

tesy

of R

oto

rk

Weber adds that there are many more pathways into most control systems than users and managers realize. These include unauthorized, unchecked USB devices, infected laptops, incor-rectly setup � rewalls, old modems, external PLC networks and unprotected � eldbuses, RS-232 links and other devices. “Do you still have any modems in your system? Are you sure?” asks We-ber. “A lot of networking hardware isn’t removed when updates are done. As a result, these threats are realistic, sophisticated and readily available.”


Weber adds that there are many more pathways into most control systems than users and managers realize. These include unauthorized, unchecked USB devices, infected laptops, incor-rectly setup � rewalls, old modems, external PLC networks and unprotected � eldbuses, RS-232 links and other devices. “Do you

control systems than users and managers realize. These include unauthorized, unchecked USB devices, infected laptops, incor-rectly setup � rewalls, old modems, external PLC networks and unprotected � eldbuses, RS-232 links and other devices. “Do you still have any modems in your system? Are you sure?” asks We-ber. “A lot of networking hardware isn’t removed when updates are done. As a result, these threats are realistic, sophisticated and readily available.”

So, besides maintaining segmenting and � rewalls, the traditional defense-in-depth strategy must include network traf� c monitoring and malware scans of communications,

rectly setup � rewalls, old modems, external PLC networks and unprotected � eldbuses, RS-232 links and other devices. “Do you still have any modems in your system? Are you sure?” asks We-

are done. As a result, these threats are realistic, sophisticated and

So, besides maintaining segmenting and � rewalls, the traditional defense-in-depth strategy must include network traf� c monitoring and malware scans of communications, adds Mike Baldi, chief cybersecurity architect at Honeywell Process Solutions (www.honeywellprocess.com).

“Many of these tools, like Security Information Event Management (SIEM), come from the IT and enterprise side, and so we’re working on adapting them for the process control world. The good news is that scanning and bench-marking are easier on the process control side. In fact, we already have many rigid rules about who can talk to whom, and so it will be much simpler for us to detect any abnormal

Management (SIEM), come from the IT and enterprise side, and so we’re working on adapting them for the process control world. The good news is that scanning and bench-marking are easier on the process control side. In fact, we already have many rigid rules about who can talk to whom, and so it will be much simpler for us to detect any abnormal and so it will be much simpler for us to detect any abnormal

Tel: +1 512 434 2850 Toll-Free: +1 800 880 9333 www.ultra-nspi.com

New MX Multiplexers Transmit Up To 16 Channels, No Programming Required

Features/Benefi ts:• Base unit supports up to 16 channels

• I/O Modules are available in 2 and 4-channel versions

• Transmit over single- or multi mode fi ber

• -40º to +85ºC operating temperature

• No programming required!

• Mounts on standard 35mm DIN-Rail

Applications:• Remote analog data acquisition

• Signal transmission in hazardous areas

We deliver critical measurements

RS-232/485

Dry Contact Input

4-20 mA to 0-10 Vdc

0-10 Vdc to 4-20 mA

Transmits up to 80 km in either direction

Call us today for complete information.

UE-22-12-mxmp ad 7x4.625.indd 1 7/3/12 12:20 AM


Made and supported in the U.S.A.Call us toll-free at 800-321-6786.Made and supported in the U.S.A.Call us toll-free at 800-321-6786.

Visit op22.co/mobilehandor scan this QR code withyour smartphone.

Visit op22.co/mobilehandor scan this QR code withyour smartphone.

Connect to your systems with OPC-UA. Build your screens in a web browser.

View on your mobile devices. groov on.

Connect to your systems with OPC-UA. Build your screens in a web browser.

View on your mobile devices. groov on.

See more atwww.groov.com

See more atwww.groov.com

mobilemade

simple.™

from

®

Control October 2013


or call 1-800-998-1020

Visit our website at

•

Regulates Flow Over a WideRange of Pressure Fluctuations

•

100% Maintenance Free

•

Self-Actuating Design RequiresNo External Power Source

Features

•

Compact Design

Specifications• Flow Rate: 0.13...10.57 GPM (Water)

•

Max. Pressure: 2900 PSIG

•

Fitting: 3/4” NPT, Female/Femaleor Female/Male

•

Max. Temperature: 572 °F

•

Easy Installation

•

Materials: Brass, Stainless Steel

•

Universal Mounting Capabilities

www.koboldusa.com

•

Automatic Flow Regulating Valve

Model: REG

Viscosity Limit: Max. 30 cSt Max. Differential Pressure: 145 PSI

• Water Flow Limiter

Min. Operating Pressure: 29 PSIG•

P r o c e s s c y b e r s e c u r i t y

For instance, Martin Midstream Partners LP (MMLP, www.martin-midstream.com) in Kilgore, Texas, specializes in terminal operations, stor-age, processing and packaging services for petroleum products and byprod-ucts. However, during construction of a single-product, hydrocarbon tank farm with six 100,000-barrel tanks and four booster pumps at the Port of Cor-pus Christi in 2011, MMLP decided to enable the facility to handle a second product, which required automated valves to isolate the tanks and prevent cross-contamination.

So, MMLP adopted 16 of Rotork’s (www.rotork.com) IQ40 explosion-proof, non-intrusive, electric, valve actuators and its Pakscan P3 digital, wireless, valve actuation monitoring system. Pakscan’s 2.4-GHz master station and wireless in-terface and actuator modules use Mod-bus via serial or Ethernet connections to establish a secure, wireless mesh network to control actuators and field devices, and gather operating data (Figure 1).

To maintain MMLP’s security and prevent unauthorized commands from being sent to the tank farm’s devices via its wireless network, all of its control data is encrypted using the Advanced Encryption Standard (AES). Further encryption is incorporated into the sys-tem to prevent unauthorized devices from joining the network and to pre-vent a message replay attack.

“I installed the wireless antennas on each actuator and gave each unit its unique address,” says Chris Duke, Ro-tork’s lead service technician. “When this was done, I powered up the master station, and all 16 actuators populated the network within a few minutes.”

staying Awake and AwareProbably the most psychologically beneficial way to establish the eter-nally vigilant mindset needed for cy-bersecurity is to bring it under the better-known process safety umbrella, which also demands continual and longstanding attention. Just as control

Besides its longstanding ISA99 standard, the ISA’s (www.isa.org) Security Compliance

Institute (ISCI) recently developed and launched its ISASecure Certification program.

“ISCI is a consortium of asset owners, suppliers and industry organizations formed in

2007 under the ISA Automation Standards Compliance Institute (ASCI),” says Leigh We-

ber, CISSP, senior security engineer at exida Consulting (www.exida.com) in Sellerville,

Pa. “Its mission is to establish a set of well-engineered specifications and processes for

testing and certifying critical control systems products, as well as decrease the time, cost

and risk of developing, acquiring, and deploying control systems by establishing a collab-

orative industry-based program among asset owners, suppliers and other stakeholders.”

Similar to well-know safety integrity level (SIL) certifications, ISASecure (www.ansi.

org/isasecure) is a recognizable designation that suppliers can achieve for their prod-

ucts by allowing them to be thoroughly tested.

ISASecure is an Embedded Device Security Assurance (EDSA) certification, and

its evaluation process has three steps. A supplier submits device to an ANSI A-CLASS

charted lab, and the lab:

• Physically evaluates device for functional security (FSA)

• Conducts communication robustness test (CRT) using ISCI-approved test tools; and

• Completes supplier audit (SDSA) on software development practices.

“These devices get every kind of malformed bit stream thrown at them to see, and

then the lab sees if they’re still standing when it’s over,” adds Weber. “Then, the lab is-

sues a final assessment report and certification upon successful test and audit. The

next step is for ISASecure is System Security Assurance to look at security across

whole systems, and it’s being developed now.”

Seeking iSASecure certificAtion


secure plan(t)

Proactive Protection for your Process Control Systems.

Honeywell offers a systemic approach to help mitigate the risks of the evolving cyber threat landscape. Industrial IT Solutions is a complete portfolio of services and tools that employ best practices in process control and cyber security. Honeywell global experts help users develop a security scheme to preserve key assets and ensure data availability, integrity and confi dentiality. Honeywell’s Industrial IT solutions deliver a more predictable and secure environment – regardless of control system vendor or location.

Securing a reliable, productive operation.

For more information go to becybersecure.com Or visit our blog at insecurity.honeywellprocess.com Also, follow us @insecculture

©2013 Honeywell International, Inc. All right reserved.



engineers and operators woke up to the fact that process safety is just another way to run ef� ciently, many are begin-ning to appreciate that cybersecurity can also reduce.

DuPont’s Jackson adds another thread common to both process safety and cybersecurity is that both begin

with performing a thorough risk assess-ment (RA) to identify vulnerabilities and determine appropriate solutions—though some differences remain.

“Safety RAs look at the likelihood of certain occurrences, while cyber-security assessments focus more on outcomes and what the effect will be

LPD-3

• 100% LOOP OR SIGNAL POWERED

• AUTO TRI - COLOR BAR

• LOOP FAIL ALARM

• NO REWIRING REQUIRED

• USB, RS485, ETHERNET I/O

Experience The Power of Experience The Power of

POWERLESS™The

www. otekcorp.comwww. otekcorp.com(520) 748 - 7900

www. otekcorp.com

( )LPDSeries(BAR-METER

LOOP POWERED Tri - Color LED

NEW

MADEIN

USA

LIFE TIME WARRANTY!

Simple AnalogReplacement

To establish and improve cybersecurity in existing process applications and facilities,

there’s a series of basic tasks users must perform. Many are recommended by Syman-

tec Security Response (www.symantec.com/security_response).

• Switch on virus-protection software, and install patches and updates regularly.

• Employ complicated passwords that include lower- and upper-case characters and

numerals, and alter them every few months.

• Implement fi rewalls, check them routinely, and determine who’s accessing the net-

work and what software they’re using. In general, all incoming connections should

be denied, and users should only allow services they’re certain they want to offer

externally.

• Close down all unnecessary ports and components, and only allow devices and ap-

plications that users need to do their jobs.

• Make sure that people and programs have only the lowest-level privileges needed

to do their work.

• Restrict software and computers used as much as possible. For example, an HMI

should only run its required SCADA programs, and only interact with required com-

ponents. Delete programs that PCs shouldn’t be using. When prompted for a root

or UAC password, ensure that the program asking for administration-level access

is a legitimate application.

• Turn off AutoPlay to stop automatic executable fi le launching, and disconnect the

drives when not required. If write access isn’t required, enable read-only mode, if

available.

• Disable fi le sharing when unneeded. If fi le sharing is required, use ACLs and pass-

word protection to limit access. Turn off unnamed access to shared folders. Grant

access only to user accounts with strong passwords to folders that must be shared.

• Disable and remove unnecessary services, such as non-critical auxiliary services,

which can be attack vectors.

• When an intrusion of attacks exploits a network service, disable or block access to

it until a patch is applied.

• Keep patch levels updated-to-date, particularly on any public-service-hosting PCs

that are accessible through the fi rewall, such as HTTP, FTP, mail, and DNS ser-

vices.

• Set up e-mail servers to block or remove messages with fi le attachments that are of-

ten used to spread threats, such as .vbs, .bat, .exe, .pif and .scr fi les.

• Quarantine compromised computers fast to stop threats from spreading. Conduct a

forensic analysis, and restore the PCs with trusted media.

• Train and retrain staff to follow security policies, and not work around them.

• Disable Bluetooth if it’s not required for mobile devices. If it’s needed, make sure

the device’s visibility is set on “hidden,” so it can’t be scanned by other Bluetooth

devices. If device pairing must be used, make sure they’re all set to “unauthorized,”

and require authorization for each connection request.

PUNCH LIST FOR CYBERSECURITY


F E A T U R E E Y E B R O WP R O C E S S C Y B E R S E C U R I T Y

if a system is compromised,” explains Jackson. “To pro-tect against advanced persistent threats, we’re working on whitelisting to make sure our operating systems are only running executable programs that they know are safe, and we’re applying application-speci� c software patches when they make the most business sense because each site has to run its own systems. Again, business and plant managers at each DuPont facility are responsible for cybersecurity just like they’re responsible for other pro� t and loss items. If they have 42 critical operations tasks to perform, then we have to make cybersecurity just one more job that has to get done.”

Compliance on Road to Security Many rules crop up as demands for cybersecurity � ood the process industries, but some like the North American Elec-tric Reliability Corp.’s (www.nerc.com) Critical Infrastruc-ture Protection (NERC-CIP) standards for protecting power plants are criticized for focusing too much on document-ing compliance, while falling short on actual protection. But, supporters argue that NERC-CIP compliance can help users progress towards cybersecurity. For instance, PNM’s SJGS was designated as a NERC-CIP critical asset in 2009,

complies with Version 3, and is preparing for Version 5.“It’s true that you can be in compliance with security

standards, but still be susceptible to many security prob-lems. So, compliance isn’t true cybersecurity, but it can be a step in the right direction,” says Mortensen. “For example, NERC-CIP requires us to have a patch management pro-gram, so twice a month we check for updates on every piece of equipment. However, � rst we put our patches on a robust test bed, do some functional security testing, and � nd out from operations when we can upload them. After adding the patches, we run software scripts and collect data to make sure everything is running as it’s supposed to, and check that there aren’t any unauthorized services.

“These tasks are crucial because disruptions, particularly malicious ones, can cause large amounts of damage. But, this also means that cybersecurity can be a good investment, and can show reductions in downtime and fewer job tickets.”

One for All for OneAnother of the most helpful—but still often overlooked—ways to improve process cybersecurity is to cooperate and form partnerships between IT and control engineers.


standards, but still be susceptible to many security prob-lems. So, compliance isn’t true cybersecurity, but it can be a step in the right direction,” says Mortensen. “For example, NERC-CIP requires us to have a patch management pro-gram, so twice a month we check for updates on every piece of equipment. However, � rst we put our patches on a robust

F E A T U R E E Y E B R O W


standards, but still be susceptible to many security prob-lems. So, compliance isn’t true cybersecurity, but it can be a step in the right direction,” says Mortensen. “For example,

“It’s true that you can be in compliance with security standards, but still be susceptible to many security prob-lems. So, compliance isn’t true cybersecurity, but it can be a step in the right direction,” says Mortensen. “For example, NERC-CIP requires us to have a patch management pro-gram, so twice a month we check for updates on every piece of equipment. However, � rst we put our patches on a robust test bed, do some functional security testing, and � nd out from operations when we can upload them. After adding the patches, we run software scripts and collect data to make

lems. So, compliance isn’t true cybersecurity, but it can be a step in the right direction,” says Mortensen. “For example, NERC-CIP requires us to have a patch management pro-

of equipment. However, � rst we put our patches on a robust test bed, do some functional security testing, and � nd out test bed, do some functional security testing, and � nd out from operations when we can upload them. After adding the patches, we run software scripts and collect data to make sure everything is running as it’s supposed to, and check that

“These tasks are crucial because disruptions, particularly malicious ones, can cause large amounts of damage. But, this also means that cybersecurity can be a good investment, and can show reductions in downtime and fewer job tickets.”

Another of the most helpful—but still often overlooked—ways to improve process cybersecurity is to cooperate and

this also means that cybersecurity can be a good investment, and can show reductions in downtime and fewer job tickets.”

Another of the most helpful—but still often overlooked—ways to improve process cybersecurity is to cooperate and ways to improve process cybersecurity is to cooperate and form partnerships between IT and control engineers.

3D DESIGN SOFTWARE & DESIGN SERVICESDownload our free WELS 3D software that lets you design, visualize and cost

your ideal control room solution. Or contact us for free design services.

GET IT AT: WINSTED.COM/WELS

3D DESIGN SOFTWARE FREE

WEB: winsted.com • EMAIL: [email protected] • TEL: 800.447.2257 • FAX: 800.421.3839

From single control room consoles to the largest integrated command centers, only Winsted has more fl exible solutions for you to meet your exact requirements for function, style and cost. Select the confi guration, design and features you want in modular, modifi ed or full custom console environments. WITH WINSTED YOU’RE IN CONTROL.

Choose from 6 modular platforms built to order, or design your custom consoles

CONTROL ROOM CONSOLES THAT PUT YOU IN CONTROLCONTROL ROOM CONSOLES

Versatile Slat-Wall Accessory Mounting

Multiple Work Surface Options and Styles

Curved, Corner or Linear, Multi-Bay Confi gurations

Articulated Tilt/Pivot Monitor Versatility

Dozens of Accessories, Hundreds of Confi gurations,

Unlimited Possibilities

Multiple Depths and Confi gurations

PC/Device/Instrument Security with Swing-Out Authorized Accessibility

Standard Modular, Modifi ed or Full Custom Console Solutions

Monitor Mounts to 63-inch, Up to Full Video Walls 19-Inch Rack

Mount Solutions

3 Monitor MountPost Heights

Integrated Power and Data

Accessible Cable Management Solutions

End Panel Color, Material and Graphics Options



“We train the IT and process sides to be aware of all their PCs, switches, networks and security components and other equipment, and then form partnerships,” says Chris Tunstall, critical infrastructure IT manager at Marathon Oil Co. (www.marathon.com) in Houston, Tex., who spoke at Honeywell Us-ers Group Americas 2013 this past June.

“This is critically important because IT has more cyber-security skills, but often doesn’t know how to deploy them in control settings. So, we collaborate, develop internal secu-rity tools, and deploy them on the control side, where they can run without relying on IT as much. Building trust is important because sometimes IT still can’t get it out of their heads that they just want to reboot, and need to be reminded about control priorities. This partnership also helps us carry out our main strategy of developing our own security stan-dards, such as patching most PCs and software immediately, but patching process controls on a later cycle to help manage their schedules and migrations.”

Keep On Keeping OnAfter developing and implementing a thorough cybersecu-rity plan that focuses both internally as well as externally,

the next most important task is to look into the future, and evaluate and update it regularly. No surprisingly, looking into the past for consistent, stalwart behavior can be help-ful again here.

Jackson adds, “Safety has been ingrained at DuPont for 210 years, but cybersecurity really only got going in the past � ve years. So, we’re applying Microsoft’s patches as soon as possible, and developing our own best practices and standards. We’re also aware that DHS’s Industrial Control Systems Cyber Emer-gency Response Team (ICS-CERT) collects and publishes vul-nerabilities, and sends them to process vendors. It also helps if we can get cybersecurity � xes from controls vendors, but it doesn’t help if they’re not installed. So, I’d urge Control’s read-ers to lobby all of our vendors to move toward building in more security functions into their products at the lowest possible level—at the control layer. We’re adding whitelisting packages on systems ahead of time, securing network connections, and doing more training, too. Cyber security has to be treated in a step-by-step, organized way. It’s an ongoing problem, but we feel like we’re making good progress.”

Jim Montague is Control ’s execut ive edi tor

BE PREPARED

Learn more online at: novatechweb.com/d3v14

Safeguard Plant Personnel and Profitability

D/3® Version 14 incorporates ANSI 18.2 Alarm Management and High Performance

HMI graphics to keep operators informed - not overwhelmed.

“We train the IT and process sides to be aware of all their PCs, switches, networks and security components and other equipment, and then form partnerships,” says Chris Tunstall, critical infrastructure IT manager at Marathon Oil Co. (www.marathon.com) in Houston, Tex., who spoke at Honeywell Us-ers Group Americas 2013 this past June.

“This is critically important because IT has more cyber-security skills, but often doesn’t know how to deploy them in control settings. So, we collaborate, develop internal secu-


“We train the IT and process sides to be aware of all their PCs, switches, networks and security components and other equipment, and then form partnerships,” says Chris Tunstall, critical infrastructure IT manager at Marathon Oil Co. (www.marathon.com) in Houston, Tex., who spoke at Honeywell Us-

PCs, switches, networks and security components and other equipment, and then form partnerships,” says Chris Tunstall, critical infrastructure IT manager at Marathon Oil Co. (www.marathon.com) in Houston, Tex., who spoke at Honeywell Us-ers Group Americas 2013 this past June.

“This is critically important because IT has more cyber-security skills, but often doesn’t know how to deploy them in control settings. So, we collaborate, develop internal secu-rity tools, and deploy them on the control side, where they can run without relying on IT as much. Building trust is important because sometimes IT still can’t get it out of their

critical infrastructure IT manager at Marathon Oil Co. (www.marathon.com) in Houston, Tex., who spoke at Honeywell Us-

security skills, but often doesn’t know how to deploy them in control settings. So, we collaborate, develop internal secu-control settings. So, we collaborate, develop internal secu-rity tools, and deploy them on the control side, where they can run without relying on IT as much. Building trust is important because sometimes IT still can’t get it out of their heads that they just want to reboot, and need to be reminded about control priorities. This partnership also helps us carry out our main strategy of developing our own security stan-dards, such as patching most PCs and software immediately, but patching process controls on a later cycle to help manage their schedules and migrations.”

After developing and implementing a thorough cybersecu-

dards, such as patching most PCs and software immediately, but patching process controls on a later cycle to help manage

After developing and implementing a thorough cybersecu-After developing and implementing a thorough cybersecu-rity plan that focuses both internally as well as externally,


©2013 Fluke Corporation. All trademarks are the property of their respective owners. AD 4331549D_EN

Uptime or Downtime. yoUr resUlts matter.only the new infrared cameras from Fluke have lasersharpTM auto Focus for consistently in-focus images.eVery. sINGle. tIme.

see lasersharp auto Focus in action: fluke.com/lasersharp

©2013 Fluke Corporation. All trademarks are the property of their respective owners. AD 4331549D_EN

Uptime or Downtime. yoUr resUlts matter.only the new infrared cameras from Fluke have lasersharpTM auto Focus for consistently in-focus images.eVery. ery. ery sINGle. tIme.

see lasersharp auto Focus in action: fluke.com/lasersharp

4331549D-EN-Ti400-control.indd 1 9/13/13 5:05 PMCT1310_full page ads.indd 46 10/1/13 3:42 PM


S I M U L A T I O N A N D M O D E L I N G

As they get closer to real time, simulations are taking on many more varied applications and helping to optimize them.

by Jim Montague

Simulations used to be so simple. They might involve a huge amount of data, but it could be chewed on for awhile. Then researchers could draft a report a few days or weeks later and make recommended adjustments to optimize a process ap-plication. Well, events are moving a bit more quickly now.

Simulations that long ago moved from static to dynamic are now so close to real time that they basically optimize processes on the � y. This can enable faster performance, but it also means coping with more complexity in much less time. In short, simulation is another job for data processing and software that can have big-time paybacks.

Optimizing Biofuels from PulpFor instance, Chemrec’s (www.chemrec.se) plants in Pitea and Domsjö, Sweden, recently implemented UniSim sim-ulation software from Honeywell Process Solutions (www.honeywellprocess.com) to simulate and optimize its process of turning waste from pulp and paper mills into biofuels.

Chemrec’s process uses high-temperature, entrained-� ow gasi� cation of black liquor, which produces syngas—a gas mixture of mostly hydrogen and carbon monoxide that’s the feedstock for several biofuels. Chemrec wanted to capitalize on its process and needed an in-house technology to help test and simulate its processes, so they could move beyond pilot-scale operation and engineer a full-scale plant.

Consequently, Chemrec selected UniSim Design software to design and simulate its process. UniSim helps evaluate alter-native uses of syngas and trys out different process con� gura-tions and products. Chemrec can also use UniSim to simulate

properties of concentrated electrolyte solutions, which are very important for pulp mill integration.

“UniSim Design is one of the tools we used to design the full-scale plant, and it can also be used to evaluate alterna-tive uses of syngas,” says Erik Furusjö, Chemrec’s process design engineer. “By trying out different process con� gu-rations, processes and products, Chemrec can now answer questions such as, ‘What can we use the syngas for?’ and ‘What is technically and economically feasible?’ ”

Modeling MovesEven motion control in process applications is getting in on the simulation act. For example, Woodings Industrial Corp. (http://woodingsindustrial.com) in Mars, Pa., recently had just nine months to develop a new hydraulic circuit and distributor for two 4150 m3 iron blast furnaces in China to provide better burden distribution control, improve motion control and endpoint accuracy, and increase ef� ciency and production to up to 16 million metric tons of iron per year.

“The way iron pellets and coke are charged in layers in-side a blast furnace really affects the melting process,” says Al Colucci, Woodings’ engineering vice president. “The lay-ers are created by a hydraulic distributor, which rotates at 8

Figure 1: Woodings Industrial’s burden distributor uses four

hydraulic cylinders to precisely control its chute, which rotates

though 360° and is lifted and lowered to precise endpoints

to carefully add tons of iron ore and coke pellets to two blast

furnaces in China for more ef� cient melting and production.

SIMULATION SPEEDS UP

Photo courtesy of Bosch Rexroth

CT1310_47_49_F2_Simulation.indd 47 9/30/13 6:03 PM

S I M U L A T I O N A N D M O D E L I N GS I M U L A T I O N A N D M O D E L I N G

A History Steeped in Innovation.

Cashco, Inc.P.O. Box 6, Ellsworth, KS 67439-0006 | Ph. (785) 472-4461, Fax: (785) 472-3539 | www.cashco.com

Think Product Innovation.

Think Cashco Control Valves

CELEBRATING 100 YEARS

Whether specifying new or searching for a replacement, Cashco control valves and regulators define industry standards for quality, dependability and environmental responsibility. The 2296 features the new C27 actuator that can be coupled to any one of several assemblies or valve body models. This allows you to use a “single” actuator design for multiple products. This in turn helps customers reduce inventory levels and ultimately lower costs.

Call today and ask for one of our sales representatives. Learn first hand why we say our quality is only surpassed by the service we provide.

Figure 2. A simulation model of Woodings Industrial’s hydraulic distributor circuit shows how it uses Bosch Rexroth’s Modular Simulation

of Hydraulic System (MOSIHS) software to model cylinder actuation forces in a closed loop and improve chute position and velocity.

CLOSED-LOOP OPTIMIZATION

MOSIHS hydraulics and closed loop simulation

Cylinder actuation forces

Cylinder position and velocity

Multi-bodysimulation

Gra

phi

c co

urte

sy o

f Bo

sch

Rex

roth


ItPumps!

BetaGauge 330Pressure

CalibratorHandheld Pressure

Calibrator with IntegralElectric Pressure Pumpfor vacuum to 300 PSI.

- NEW-

300 PSI Electric

330 Control1_3VertAd.qxd:Layout 1 1/25/12 3:01 PM Page 1

S i m u l a t i o n a n d m o d e l i n g

rpm, and then tilts a chute in the throat of the blast furnace to deposit iron ore and coke pellets in precise locations. Our challenge was to develop more accurate hydraulic distributor control and achieve unheard of control levels.”

While most burden distributors use electromechanical gearing, it’s hard to maintain and repair in the heat above the blast furnace. These high tempera-tures also require the hydraulic valves controlling the distributor’s four hydrau-lic cylinders to be located away from it. This requires long hydraulic lines, which create spring-like expansion and contraction of the fluid in them, and makes motion control even harder. The cylinders are controlled by Bosch Rexroth’s (www.boschrexroth.com) 4WRPEH directly operated, high-re-sponse, directional, proportional valves with electrical position feedback.

Woodings adds that its Chinese cli-ent wanted to limit chute movement at the endpoint to no more than 0.25 mm, which is one-tenth of a degree. Typical distributor endpoint accuracy is within inches, but the steelmaker was certain greater accuracy would make its fur-naces more productive.

To verify the targeted accuracy and repeatability of its new hydraulic sys-tem, Woodings used Bosch Rexroth’s Modular Simulation of Hydraulic Sys-tem (MOSIHS) software and library of parameterized hydraulic devices. Sub-models of the hydraulics, mechanicals and controls also were coupled with each other and simulated together, which al-lowed designers to investigate dynamic behavior of the whole system. The dis-tributor’s hydraulic circuit and controls provided input data for the MOSIHS software, while CAD drawings of the distributor, chute and rotating distributor head were imported into a commercially available, multi-body simulation pro-gram coupled with MOSIHS (Figure 2).

The simulation showed that the dis-tributor’s large, moving mass and long hydraulic lines caused low natural fre-quency of the hydraulic distributor

system, so special control algorithms with dynamic-pressure feedback could damp system oscillations and optimize performance. “As it turns out, the cylin-der load changes with the chute angle,” says Charles Erdo, Bosch Rexroth’s in-dustrial machinery engineer. “The drive and controls have to react quickly to load variations as the chute working point changes and cope with centrifugal forces and dynamic loads. The simulation veri-fied our closed-loop control strategy and demonstrated that all four cylinders re-mained synchronized as required.”

Better Software toolsNot surprisingly, one force enabling simulations to get closer to real time and be applied in new applications is improvements in software, especially for handling several applications.

For instance, AspenTech (http://as-pentech.com) has launched the latest version of its aspenOne software, V8.3, to enable faster optimization of upstream, midstream and refining processes and improve plant safety. New capabilities of Aspen Hysys software include: Acid Gas Cleaning, which models gas sweeten-ing units in one environment in Aspen Hysys, and Pressure Safety Valve Siz-ing, which lets users size pressure safety valves as part of the process design.

“We can now access the aspenOne and Hysys simulation environments in one click, and users are immediately informed about their target’s present performance, what optimization op-portunities exist and what changes are needed to get there,” explains Vi-kas Dhole, engineering and product management VP at AspenTech. “We’re also able to show economic analysis and the costs of opportunities and po-tential profits of making changes. We also have a web and mobile interface for aspenOne that combines model and plant data, and a new aspenOne Exchange that allows a community to share multiple solutions.”

Jim Montague is Control ’s execut ive edi tor



f l o w

Insertion flowmeters come in many varieties, but they all share similar characteristics and problems.

by Walt Boyes

You can get flowmeters in insertion versions that are paddle-wheel, propeller, turbine, magnetic, vortex and differential pressure sensors. Insertion flowmeters are popular in many in-dustries, because they appear to be easy to install, inexpensive, and come in technology variations that mimic full-pipe meters.But with no exceptions, insertion flowmeters are not the same as their full-pipe counterparts. In fact, there is some evidence for David W. Spitzer’s claim in his book Industrial Flow Measurement that insertion flowmeters are a type all their own.

How Does This work? In Figure 1, you see turbulent flow and laminar flow. These are based on the concept of the Reynolds number, which is a dimensionless number relating to the ratio of viscous to iner-tial forces in the pipe. Laminar flow, where the flow profile is straight and smooth, occurs at Reynolds numbers of less than about 2500. Turbulent flow, where there are eddies, vortices and swirls in the pipe, occurs above 4500 Reynolds numbers. Tran-sitional flow, which is neither fully laminar nor fully turbulent, occurs between about 2500 and 4500 Reynolds numbers. Lam-inar flow profiles are usually visualized as being bullet-nosed, while turbulent flow profiles are seen as plug flows.

Without getting too far into the math, flow studies have shown that in a pipe with a fully developed flow regime, either fully turbulent or fully laminar, the average velocity in the line can be found at a point somewhere between 1/8 and 1/10 of the way in from the side wall, depending on the flow study you read.

Insertion Paddlewheels, Propellers and TurbinesThere are three very similar types of insertion flowmeters that use a rotor that spins with the velocity of the fluid.

The first is a paddlewheel because the rotor is parallel to the centerline of the pipe, just like a paddlewheel steamboat. Paddlewheels range from very inexpensive to inexpensive, and are designed to be disposable. The least expensive use polymer bearings, which go out of round, and cause the rotor to wobble before the rotor shaft cuts through a bearing and goes downstream. The best use jeweled bearings and ceramic shafts, so they have much more longevity and less drag.

The spinning of the rotor is sensed by either a magnetic pickup that generates a sine wave the frequency of which is proportional to velocity, or a Hall-effect sensor that gener-ates a proportional square wave.

The advantage of the magnetic pickup is that it generates the sine wave without additional power. The advantage of the Hall- effect sensor is that it does not cause “stiction” (the momentary friction stop when the rotor sees the magnetic pickup’s magnet). Hall-effect sensors generally are able to read lower flow rates, and are more accurate at lower flow rates as well.

Paddlewheel flow sensors are designed to be easily in-serted into a small hole cut into the pipe using a custom fitting. Some paddlewheel sensors can be inserted into the pipe using a hot tap assembly, which allows the sensor to be inserted and retracted without shutting down the flow or re-lieving the pressure in the pipe.

Propeller meters use a prop shaped very much like an outboard motor’s propeller and are generally connected to a mechanical or electromechanical totalizer with a cable very much like a speedometer cable. Some more modern propel-ler meters use embedded magnets and either magnetic pick-ups or Hall-effect sensors.

Like paddlewheels, propeller meters have a pulse output that is proportional to the average velocity in the pipe. Be-cause propeller meter rotors are large and located at the cen-terline of the pipe, they’re likely to be quite accurate, and even insertion propeller meters have been certified for bill-ing purposes for decades.

Propeller meters, because their prop is significantly larger than a paddlewheel, are inserted using a flange that mounts into the upright member of a tee fitting.

Turbine meters come in both electronic and electrome-chanical styles, but the only insertion turbine flowmeters are electronic. They, like paddlewheels, use either a mag pickup or a Hall-effect sensor to produce an output pulse that’s proportional to the velocity of the fluid. Like paddle-wheels, they must be inserted to the “average velocity point, which exists somewhere between 1/8 and 1/10 of the inside diameter away from the pipe wall.

Most insertion turbine meters have very small rotors, so

CT1310_51_53_F4_Flow.indd 51 9/30/13 6:00 PM

F L O WF L O W

they can be inserted through a small-diameter � tting or through a small di-ameter, hot tap assembly. Sometimes, especially in the municipal water in-dustry, this is called a “corporation cock assembly,” but it is essentially the same thing—a way of inserting a probe through a valve and still maintaining the pressure in the pipe without leaks.

Propeller meters are almost always used for water service, either in potable water systems or in irrigation systems.

Paddlewheels and insertion turbines can be used in a variety of applications, with materials of construction varying based on the requirements of the ap-plications, such as acids, bases, and hot or cold � uids.

Electronic paddlewheels and tur-bines can be set up to be bidirectional, using quadrature detectors, which en-able the signal to indicate either for-ward or reverse � ow, as well as � ow rate. These are often used in HVAC applications where chill water and hot water � ow through the same lines de-pending on the season.

The signal from the paddlewheel or turbine or electronic propeller meter is

sent to a transmitter, which uses the pulse (or frequency) output to display � ow rate and to increment a totalizer (usually elec-tronic). These transmitters generally have a pulse output, an analog output (usually 4-20 mADC), and often have one or two programmable relay contact closure out-puts. These can be used as � ow alarms, as diagnostic alarms or as a rudimentary, dead-band controller.

Insertion dP FlowmetersThe most commonly used � ow sensor in the world is the differential pressure transmitter connected to a primary de-vice, such as an ori� ce plate or Ven-turi tube. In its insertion incarnation, the differential pressure sensor is con-nected to a pitot tube inserted in the � ow stream, and just as a pitot tube measures velocity on the outside hull of an aircraft, it measures the velocity in the � uid � owing in the pipe.

These devices must also be inserted to the “average velocity point,” which is assumed to be somewhere between 1/8 and 1/10 of the diameter of the pipe inbound from the pipe wall. If the average velocity point is not calculated

www.flexim.com

F601 and G601 for liquids and gases

Highly mobile through their low weight and ergonomic design Measurement ready in less than 5 minutesVery accurate and reliable – for inner pipe diameters between 1/4 inch and 20 foot Li-Ion battery for over 14 hrs. of remote measurementHighly reliable even at high gas / solid containing mediaAlso the ideal tool for heat quantity measurement

The measurement system:for the temporary replacement of stationary systems,for check metering,plant optimisations,as well as the examination of heating and chiller plants.

Flow measurement On-the-Go

FLEXIM AMERICAS Corporation Toll free: 1 888 852 74 73 [email protected]

Figure 1. Turbulent � ow from 4500+ Rn. Laminar � ow from 0 to 2500 Rn.

Laminar Flow

Turbulent Flow

FULLY DEVELOPED FLOW

CT1310_51_53_F4_Flow.indd 52 9/30/13 6:00 PM

F l o w

correctly, the single point pitot tube meter will not be accurate.

Several companies now manufac-ture multiple-point pitot sensors. These sensors are mounted perpendicular to the diameter of the pipe, from one side wall to the other, and have several pitot ports located along their length.

The way these multi-point sensors work is that the differential pressure sensed is the average of all the differ-entials across the pipe—producing an output signal that very closely corre-sponds to the average velocity in the pipe. This way, the sensor is connected to a standard differential pressure transmitter, not several of them.

Multiple-port pitot tube flowmeters can be calibrated to take very disturbed flow profiles, such as that in a 90° el-bow, into account, and can, therefore, be used in locations where no other flowmeter can be used.

Insertion Mag MetersInsertion magnetic flowmeters are not the same as spool-piece magnetic flow-meters, even though they share the op-eration of Faraday’s law. In a spool-piece magnetic flowmeter, the design geome-try of the coils and the electrodes cause the signal output on the electrodes to be directly proportional to the average ve-locity in the pipe. Insertion mag meters use the same concept of “average velocity point” as the insertion paddlewheel does, and are about as accurate. Where a spool-piece magnetic flowmeter can reliably be assumed to be close to 0.5% of rate accu-racy, an insertion mag meter can often be 10% or 15% of rate, or worse.

Insertion mag meters have a great advantage over other insertion types: They have no moving parts, and are usually highly resistant to acids, bases and abrasives.

Insertion Vortex and Target MetersInsertion vortex-shedding flowmeters have their proponents. These devices have accuracies similar to insertion turbine sensors, but have fewer moving

parts and no rotor. This makes them the clear favorite from a maintenance point of view.

Design and Specifcation If you can use a spool-piece flowmeter for your application, do it. They are in-herently more accurate and have volu-metric calibrations instead of just ve-locity calibrations. Generally, you will use insertion flowmeters where you can’t use a spool-piece, either for safety or expense reasons. Insertion paddle-wheel flowmeters are often used in in-dustrial water treatment applications and for driving chemical feed systems. Even the multiple-port pitot tube flow-meters are less inherently accurate or repeatable than a spool-piece flowme-ter, regardless of technology.

Accuracy and CalibrationThe accuracy problem with insertion flowmeters is that they’re inserted into an uncalibrated spool section of pipe or even an elbow. The “average ve-locity point” theory is dependent on a fully developed flow profile with no swirling or distortion.

It’s almost certain that insertion me-ters will not be “accurate,” but they can be quite repeatable, which, in a flow control loop application may be all you really need.

When you design an application for an insertion meter, you need to be much more careful of piping issues than if you were using a calibrated spool-piece meter. Be aware that the accuracy is going to be substantially less than you can get otherwise. The reason to use an insertion meter is nearly always that it was not designed into the piping originally, or it is being used as a low-cost sensor or a low-cost replacement for an original meter.

For these applications, the insertion flowmeter can be a useful tool in the design engineer’s tool bag.

Wal t Boyes is Control ’s edi tor in chief.

[Extended version at www.control-global.com/1310_flow]

F l o w

One Series Transmitter-Switch

for Process Monitoring• Monitors pressure or temperature • Provides analog 4-20 mA signal• Programmable switching capability• Smart self-diagnostics• SIL 2 suitable

United Electric Controls180 Dexter Avenue

Watertown, MA 02471-9143

For more information on the One Series,

call United Electric at 617-923-6977 or visit us at

www.ueonline.com

CT1310_51_53_F4_Flow.indd 53 9/30/13 6:00 PM

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


Pad Type D/P Level Installation; Orifice Plate Location

QMy current project uses a pad-type flange connection for level differential pressure (d/p) on tanks and ex-changers. My concern is the reliability of the pad-type

flange to withstand pressure and leakage. Will this affect the installation of my transmitter? And does it require additional consideration?

Glai MendOzaglai .mendoza@gmail .com

A I had no leakage problems with the many flat or ex-tended diaphragm d/p transmitters I’ve used on vis-cous, sludge, slurry or other plugging services (Figure

1). If the low-pressure side of the d/p cell also required pro-tection from plugging, I also often used dual chemical seals, which are convenient if one wants to locate the transmitter above or away from the tank.

bÉla liptÁkl ip takbela@aol .com

A I see two questions. The first is the structural one. De-signed and fabricated per the codes and standards, pads have been used for a long time and are consid-

ered reliable and safe. The only disadvantage I see is that the threaded holes for the studs could be damaged and are difficult to repair.

The instrument issue is that, without a nozzle to ac-cumulate “stuff,” the measurement might be somewhat more reliable, especially, if the pressure connection is a remote diaphragm. Beyond that, I see no problems unless there are other significant aspects not mentioned in the question.

cullen lanGfOrdCul lenL@aol .com

A By your mail, I understand that you have a chemical seal capsule and capillary connected transmitters. If so, we have used these without any problem of leakages or

extra maintenance issues. However, you may need a block-and-bleed manifold to re-

lease the pressure before you open the flange for the sake of safety.

H S GaMbHirHar v indar.S.Gambhir@ril .com

Q I am supposed to install an orifice plate to measure the water flow in a pipe, which is 0.3 m above ground. Therefore, we do not have room to install the d/p

transmitter below the pipe. Is there any way to locate a d/p transmitter above the pipe tapping point?

As per ISO 5167, we should provide straight up and down-stream pipe run, but we don’t have enough space for this either. What should we do? Rosemount has a new orifice plate that needs only four pipe diameters total up and down-stream, but I can’t find anything about its pressure drop. Is there a way I can calculate its pressure drop?

HaSSan MOMMadzadeHmohammadzadeh@gmail .com

A The Rosemount compact orifice meter design allows one to locate the d/p cell above the pipe. (I do not rec-ommend this because of possible air accumulation.)

The manufacturer claims that the inaccuracy of this flow-meter is under 1% of actual flow over a flow range of 8:1, and that it requires only two straight pipe diameters up and downstream when installed. I emphasize that these capa-bilities are only claimed by the supplier, and I have not seen any reports from any independent testing laboratories that

This column is moderated by Béla Lipták (http://belaliptakpe.com/), automation and safety consultant, who is also the editor of

the Instrument and Automation Engineers’ Handbook (IAEH). If you would like to become a contributing author of the 5th edi-

tion, or if you have an automation related question for this column, write to [email protected].

Figure 1. This design can be used in viscous, sludge, slurry or other plug-

ging services.

DrainDrain

Low-pressureconnection



Diaphragm capsulehigh-pressure side

FlushDiaphragm capsulehigh-pressure side

Extended diaphragm sealto match tank nozzle length (2” to 9”)

DIAPHrAGm D/P TrAnSmITTerS

CT1310_55_56_ATE.indd 55 9/30/13 5:58 PM


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

supported these claims. Similarly, the claim that two-pipe diameters of straight pipe are sufficient both up and down-stream is hard to believe, and I would like to see that substan-tiated by independent testing—when 90º elbows are up and downstream.

My understanding is that the up and downstream pressures are measured by corner taps right on the two sides of the ori-fice plate, and therefore, the performance is likely to be similar to corner tap installations (Figure 2).

Because the transmitter has to be installed 50º below the horizontal (to protect against gas accumulation), you probably have enough room to do it. But, if your water isn’t clean, I would not use this flowmeter design because of the possible plugging of the pressure taps.

As to pressure drop, it’s similar to that of the traditional ori-fice at the same beta ratios (see ΔPct in Figure 2).

bÉla liptÁkl ip takbela@aol .com

A Use the Darcy Equation (an approximation only, be-cause velocity immediately at the outlet of the orifice is unknown). Normal calculation of outlet velocity is based

on a mature velocity profile, such as at 10 diameters down-stream of the orifice:

[(2.gc.144.ΔP) /ρ] = 1.5 v2

where v is the inlet velocity in feet/second.P is pressure in psi.ΔP is pressure drop in psi.ρ is density in lbm/ft3.gc is universal gravitational constant, 32.2 (lbm ft)/(lbf.s2).1.5 is the loss coefficient of the orifice plate with four holes.

(Reference to Crane Technical Publication 410: Inlet loss co-efficient of sudden contraction is 0.5; outlet loss coefficient of sudden expansion is 1).

These four holes are in parallel. Therefore, their effective loss coefficient equals that of one orifice of equivalent hydrau-lic radius due to the four holes. (See the online version for an illustration.)

The loss coefficient due to line loss is usually negligible compared to the loss coefficient of the orifice. Note that the orifice plate with four holes was not in any approved standard.

I hope to see experiments showing 4D is all that is required for establishing a mature velocity profile for the orifice plate with four holes.

Gerald liu, p. enG.geralda. l [email protected]

[For more answers, go to www.controlglobal.com/1310ATE.]

Figure 2.The compact orifice meter design may function similarly to corner tap installations.

Staticpressure

Unstable region,no pressure tap can be

located here

Pressure atvena contracta(PVC)

Minimumdiameter

Corner taps (CT), D<2”

Flange taps (FT), D<2”Radius taps (RT), D<6”Pipe taps (PT)

Flow

Flow

Ori�ce

D

D1” 1”

D/22.5D 8D

(0.35 - 0.85)D

∆PPT

∆PCT∆PFT

∆PRT = ∆PVC

the corner tAp

CT1310_55_56_ATE.indd 56 9/30/13 5:58 PM

Process ControlTemperature/Process Limit Controllers

• Universal Inputs• High Accuracy• 2 Relay Alarm Outputs• Totally Programmable Color

Displays (Visual Alarms)• User-Friendly,

Simple to Configure

• Built-In Excitation• AC or DC Powered Units• Front Removable and

Plug Connectors• Programmable Digital Filter• High/Low Limit• Remote Reset Input

CNi-AL Series Starts at

$164

© COPYRIGHT 2011 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED

© COPYRIGHT 2012 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED

omega.com

®

© COPYRIGHT 2013 OMEGA ENGINEERING, INC ALL RIGHTS RESERVED

1-888-826-6342

PR-26 Series Starts at

$95

OS-MINI Series Starts at

$511

Visit omega.com/pr-26_standard

Visit omega.com/os-mini

Visit omega.com/cni-al

RTD Sensor with M12 Connector for Process Control and Test and Measurement Applications

Miniature Infrared Temperature SensorWith Optional High-Ambient Sensing Head and Touch Screen Display

Visit omega.com/px409-usbh

PX409-USBH SeriesStarts at

$545

High Speed USB Output Pressure TransducerConnect Directly to Your Computer


Visit our Automation Fair in Houston, Texas and see the star of industrial automationAutomation Fair® 2013, November 13-14, 2013 George R. Brown Convention Center, Houston, TX USA

Automation Fair® from Rockwell Automation is one of the world’s premier automation events, a unique opportunity to explore smart, safe, sustainable manufacturing solutions that improve profitability, productivity and efficiency while reducing costs.

Find out how Automation Fair® 2013 can help your business to shine. www.automationfair.comAutomation Fair is a trademark of Rockwell Automation, Inc. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

Indefatigable! Continuous Emission Monitoring System (CEMS)

usa.siemens.com/cems-ad


Satisfy your 40 CFR Part 60 and 75 requirements with our indefatigable CEMS!

Do you need to continuously measure NOx, CO and O

2 emission from furnaces and boilers in Refining,

Hydrocarbon or Chemical proccessing plants? If so, this CEMS is a low cost emission monitoring package designed to operate in a climate controlled shelter or cabinet, for general purpose or electrical hazardous environment.

We offer a plant proven turnkey solution with: • Sample extraction with blowback • Heated sample transport • Sample preparatrion with cooler • Automatic validation / cabliration • Paramagnetic, IR and CLD analyzer

The CEMS maintainability, proven reliability and long term stability offer you nonstop performance. In one word: INDEFATIGABLE!

Scan for more CEMS information

© 2

01

3 S

iem

ens

Indu

stry

, In

c.


R O U N D U P


CERTIFIED COMPUTERS AND I/O CALIBRATIONUNO-4683 is a fanless sub-station computer that’s IEC 61850-3 and IEEE 1613 cer-tified. It comes with an Intel Core i7 processor, compact 2U, rack-mount form factor, dual power input and ad-vanced computing. It has six Ethernet ports, six USB ports and two RS-232/422/485 iso-lated serial ports. The UNOP-1624D I/O module is a four-port isolated RS-232/422/485 card with IRIG B support. Advantech 888-576-9668; www.advantech.com/ea

SMART DAQ GX and GP data acquisition station models have a new touchscreen operator inter-face and fully modular and scalable I/O. GX is a NEMA-4-rated, panel-mount system, and GP is a portable bench-top. Both share the same per-formance specifications and high-capacity SD flash memory data storage. Enter information via on-screen keyboard, an external USB keyboard or with a pen stylus.Yokogawa Corp. of America www.yokogawa.com/us

REDUNDANT SD CARDS The 750-885 media redun-dancy controller provides network redundancy and greater data processing. The Ethernet 2.0 750-885 PLC features two redundant net-works backed by dual, inde-pendent Ethernet interfaces and 1MB of data memory. SD Card provides up to 32GB of extra memory for back-up-and-restore, file transfer and time-stamping/data-logging. Wago 800-DIN-RAIL; www.wago.us

DAQ AND CONTROLMAQ20 data acquisition and control system features two software options: IPEmotion for test and measurement, and ReDAQ Shape for easy, effective data acquisition, monitoring and control. It also has integral PID con-trol, a built-in Modbus server for standalone operation and a built-in FTP server. Typical applications are flow, tank level, heat-exchanger/reactor temperature and pressure control. Dataforth 800-444-7644; www.dataforth.com

START A TRENDTrendview data recorders with advanced analysis soft-ware come in three models with screen types that display various combinations of hor-izontal and vertical charts, digital values and bar graphs. Trendview helps in graphing continuous and batch data, analyzing and archiving data, configuring paperless recorders, setting up scheduled up-loads of recorder data or acquiring data in real time. Honeywell Process Solutions www.honeywellprocess.com

NO PROGRAMMING REQUIREDMX-Series multiplexers can transmit up to 16 channels of bidirectional electrical data over a pair of fiber-op-tic cables. They feature I/O module selections, including 4-20mA, 0-10 VDC, contact closure and RS-232/485. The I/O modules are available in two- and four-channel versions, and mount on a 35-mm DIN rail. No programming is re-quired, and installation doesn’t require an engineer.Ultra Electronics 512-434-2800; www.ultra-nspi.com

Acquire Your Data HereThe latest hardware applications and software to get your information under control.

CT1310_59_62_Roundup.indd 59 10/1/13 3:47 PM

R O U N D U P

WIRELESS DATA LOGGER Log-HC2-RC data logger is the most advanced and pre-cise humidity and tempera-ture data logger of its kind. The versatile Log-HC2-RC works with any Rotronic digi-tal HygroClip 2 probe with Airchip 3000 technology. It can transmit from distances of up to 100 meters back to a computer running Rotronic HW4 software. It also meets all requirements for CFR 21 part 11 compliance. Rotronic 631-426-3898; www.rotronic.usa.com

EXTREME RIG MONITORING VisuNet XT operator work-station HMI features a high-bright, LED-backlit, LCD panel display with an opti-cally bonded, glove-friendly and sunlight-readable, 15-in. (38.1-cm) or 19-in. (48.3-cm) touchscreen. This Type 4/4x operator workstation can help maximize productivity in harsh oil exploration and extraction applications in tempera-tures from -40 °C to + 65 °C. Pepperl+Fuchs 330-486-0002; www.pepperl-fuchs.us

MODBUS RTU I/O WITH DATA LOGGING The microNCS Modbus RTU master and distributed I/O system can be used to send just a few or hundreds of process signals between the field or factory floor and a control system. The stand-alone microNCS functions as an economical Modbus RTU master. It features simple pro-gramming and a data logger with a back-up battery that can archive up to 64,000 time and date stamped values. Moore Industries-International 818-894-7111; www.miinet.com

SPLASH-PROOF DATA LOGGER OM-CP-RFOT splash-proof, wireless, temperature data loggers are designed for the meat processing industry. Their rugged design allows them to be used in the harsh-est environments, so they’re ideal for smokehouses, ovens and other cooking processes. They’re also CE-compliant, feature real-time operation, two-year battery life, long-term field deployment, and are HACCP- and USDA-compliant.Omega 888-826-6342; www.omega.com


R O U N D U P

When machinery breaks down, you need to diagnose the problem with as little downtime as possible. Having the right tools to identify the source of the issue can make all the difference.

The lightweight and easy-to-use Dash MX is the tool that you need. Connect the malfunctioning equipment through 4 input modules and run tests across 8 data channels. You’ ll be able to see and analyze the data in real-time, on the Dash MX’s 12-inch, color touch-screen display—no PC needed!

Now easily diagnoseequipment problems.

To schedule a demo call 877-867-9783 or visit Astro-med.com/demo-request

Portable Data Acquisition Recorder

• Grab & Go Diagnostic Tool• Portable and Battery Powered• Sample rates up to 1 MHz• Pre- & post-trigger capability• 160 GByte data capture hard drive

Introducing the

DO YOU KNOW WHERE YOUR ENERGY IS?OptoEMU Sensor DR is a compact unit for monitor-ing energy use. Connected to utility meters, plant equip-ment and facility systems, it gathers real-time energy con-sumption and demand data ,and delivers it to enterprise business and control systems and web-based applications for monitoring and analysis, helping businesses take advantage of lucrative demand-response (DR) programs.Opto22 951/695-3000; www.opto22.com

HIGH-PERFORMANCE, COMPACT DAQThe CompactDAQ platform with standalone data acquisition systems is compatible with more than 50 sensor-speci� c I/O modules for � exible, mixed-measurement data logging. It includes a built-in, dual-core Intel processor and onboard storage to deliver high-performance processing in one portable system. Using NI LabView software, engineers can customize a data-logging or embedded-monitoring solution.National Instruments 800/258-7022; www.ni.com

COMMUNICATIONS GATEWAYSPLX30 gateways can support multiple I/O connections to EtherNet/IP-enabled PACs, providing real-time transfer of up to 4000 words of data between devices, such as HMIs and SCADA systems, power monitors and � ow computers. All Modbus serial ports are individually con� gu-rable for master or slave, RS232, RS422 or RS485, and pro-vide a � exible host or device interface solution.ProSoft 661/716-5287; www.prosoft-technology.com


R O U N D U P

SAVE STEAM HEATEngyCal RS33 steam cal-culator records steam, mass and energy flow in systems with saturated or superheated steam. The calculation is based on volume flow, tem-perature and/or pressure. Data logging allows process values, calculated values and counters to be stored in de-finable intervals. Comprehensive data analysis options are available in Field Data Manager software.Endress+Houser www.us.endress.com/#product/RS33

TWICE THE USB DAQ USB-1608FS-Plus is a high-speed, multifunction USB DAQ device with sampling rates up to 400 kS/sec and 800 kS/sec in burst mode. This new module offers twice the throughput of Measurement Computing’s present USB-1608FS at the same price. It provides eight, 16-bit, simultaneously sampled analog inputs, eight digital I/O (high-current 24 mA), and one counter input. Measurement Computing 508-946-5100; www.mccdaq.com

USB DATA LOGGER FOR FLOWMETERS USB data logger maintains a history of an Exair digital flowmeter’s measurements for analysis. Use the included software to configure the data logger to record your flow rate. Record from once a second up to once every 12 hours. Data can be viewed in the included software or exported directly into Microsoft Excel. USB data logger is available pre-installed on the digital flowmeter. Exair 800-903-9247; www.exair.com/data.htm

Get Upto Speed QuicklyWith the Control Essentials Series

Now available at ControlGlobal.com/Essentials

Essentials of

Industrial Ethernet

Made possible by

Written by the editors of CONTROL, our new Control Essentials series is designed to provide process industry professionals with an up-to-date, top-level understanding of a range of key process automation topics. Our intent is to present essential engineering concepts in a practical, non-commercial fashion, together with a review of the latest technology and marketplace drivers—all in a form factor well suited for onscreen consumption. Get in and get out quickly with just the information you need.

To download your complementary copy, visit ControlGlobal.com/Essentials

CT1310_ABB_Essentials_Half.indd 1 10/2/13 12:15 PM


C O N T R O L T A L K

GreG McMillanStan weiner, pecontrol ta [email protected] t


How to Train a Future Automation Engineer

Greg: Students going from the university class-room into the control room are faced with con-siderable challenges in translating four years of intense education into practical industrial ap-plications. Internal courses at companies like the six weeks of hands-on training I got when starting at Monsanto have largely gone by the wayside. Just understanding the jargon and working with control systems is a tough hurdle.

Stan: The use of experienced personnel to guide new employees is increasingly scarce. I spent a good part of my career helping new au-tomation engineers, who were thrown into ac-tion as the lead instrument and electrical (E&I) engineers on projects at Monsanto—most nota-bly John Berra, now-retired CEO of Emerson Process Management. I helped Greg take over John’s project when he left to start his journey to extraordinary executive accomplishments.

Greg: Today there are fewer experienced peo-ple and less time to provide this one-on-one guidance on the job. Anything a university can do to prepare a graduate for working in indus-try is increasingly important. When I was in-troduced to the professors at Rose-Hulman In-stitute of Technology (www.rose-hulman.edu), while giving some presentations to a major pharmaceutical company on the use of virtual plant for optimizing bioreactor control, I got the impression this university was doing some-thing exceptional in the preparation of gradu-ates for careers in the process industries. For-tunately, I recently had the opportunity to talk with Ron Artigue and Atanas Serbezov, profes-sors of chemical engineering at Rose-Hulman.

Stan: In our experience, universities tend to be most interested in getting funding and recogni-tion for graduate research projects. The sense of accomplishment is more about invention leading

to tenure. Publish or perish is the thought behind the scenes. How is Rose-Hulman different?

ron: The focus at Rose-Hulman is mostly on undergraduate education, and providing a hands-on experience using industrial process control systems. Approximately 80% of the graduates go on to work in the process indus-tries. More than 90% of the students will have internships in industry, and 80% have more than one. We also have a master’s degree pro-gram for those who want to do research before moving to industry.

Greg: What types of companies do you work with in the process industries?

atanas: We have strong working relationships with companies in the pharmaceutical, corn processing, oil and gas, polymer and consumer personal care industries.

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 [email protected].

CT1310_63_64_ControlTalk.indd 63 9/30/13 5:55 PM

C O N T R O L T A L K


Stan: How are the professors involved in these industries?

ron: Many Rose-Hulman professors work in industry and bring in projects. For example, professors have available the equivalent of one day a week, plus summers, for consulting. Typically courses are taught Monday-Tuesday and Thursday-Friday, giving Wednes-day as a free day for professional devel-opment activities. Many professors go out and seek opportunities in industry.

Greg: How does this translate to stu-dent education?

Atanas: The student internships and professor collaboration and consult-ing are put to work on projects brought in by professors. The industrial expe-rience changes the dynamics in the classroom. Students can relate to ap-plication problems and contribute to the solutions. The small instructor-to-student ratio in these project-based courses (typically 1:9) provides the one-on-one guidance on the job Stan and Greg were talking about earlier.

Stan: How do students get hands-on experience with industrial process con-trol systems?

ron: Each student spends consider-able time in our Unit Operations Lab-oratory courses with seven unit opera-tions monitored and controlled by a state-of-the-art distributed control sys-tem and industrial instrumentation. We have a two-story Corning distil-lation column (separating isopropyl and isobutyl alcohol), a filter press, a control and instrumentation skid with centrifugal and positive displacement pumps, a plug flow reactor (reacting ethyl acetate and caustic), a micro-filtration system and a 20-liter biore-actor vessel for temperature and dis-solved oxygen control studies. These pieces of equipment are pilot-plant scale, whereas some universities are

using bench-top experiments more than ever. Many students also have the opportunity to learn design and production plant techniques by help-ing design and construct new unit op-erations projects complete with mea-surements and control.

Greg: Using bench-top scale equip-ment often leads to lab-type of mea-surement and control systems not seen in industry. The lab experience has less practical value, unless the student is going to end up being a chemist or biochemist. This does not have to be the case, as noted in the April 2012 Control Talk, “New Paradigm for Lab Control Systems” (www.controlglobal.com/articles/2012/mcmillan-weiner-paradigms-lab -cont rol- systems/ ), where a lab- optimized industrial DCS is used for bench-top bioreactors. This DCS was augmented with industrial wireless instrumentation for pilot-plant bioreactors on carts to make the system portable and flexible.

Stan: The days of accomplishment by holing up in a cubicle to the exclusion of others are long gone. The depth and spectrum of skills needed are too great for an individual to work alone, plus successful implementation requires mutual understandings between de-sign, operations and maintenance. To what extent do you couple hands-on experience with communication skills?

Atanas: The students start using the lab in the third quarter of their junior year. The students run five projects working with faculty to achieve objec-tives that many times include a design of experiments (DOE). The students write multiple project reports and give a formal presentation on project results in each quarter. A lot of emphasis is given on improving written and oral communication. We give first-hand ex-perience in today’s workplace where al-most everything is a team effort.

Greg: What do students get in terms of a practical process control education?

ron: The course in advanced process control uses a DCS configuration and instrumentation system design done by the students. A development system is used for modeling and design. Two-person teams work together simultane-ously to transfer the results to a produc-tion system.

Stan: What kind of support has en-abled you to take this approach?

Atanas: We recently received Dean’s funding to purchase new servers, while Emerson Process Management donated DeltaV DCS software licens-ing, and Cornerstone Controls gave us significant discounts on hardware. In addition, Endress+Hauser donated a large number of instruments, and gave significant discounts, as well, on process instrumentation, such as Coriolis mass flowmeters. We also received instrumentation donations from Eli Lilly and Co., and Marathon Petroleum Corp. provided funds for the development and simulation of the new DeltaV systems.

Greg: How would you sum up your program?

ron: We’re preparing our students to be able to contribute immediately upon graduation by having a practi-cal engineering focus in many of our courses, including process control. We also provide lots of courses and research experiences for those des-tined for graduate school. We provide a hands-on experience with real sys-tems and automation to solve real ap-plication problems.

[Editor’s note: For more of this con-versation and a list of the Top 10 reasons to become a chemical engi-neer, please go to www.controlglobal.com/1310ControlTalk.]

CT1310_63_64_ControlTalk.indd 64 9/30/13 5:55 PM

Advertiser � � � � � � � � � � � � � � � � � � � � � � PAge No�

ABB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Advantech Automation . . . . . . . . . . . . . . . . . 25Allied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Ametek Drexelbrook . . . . . . . . . . . . . . . . . . . 45Ametek Process . . . . . . . . . . . . . . . . . . . . . . . 31Aspen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54AstroMed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61AutomationDirect . . . . . . . . . . . . . . . . . . . . . . 8Badger Meter . . . . . . . . . . . . . . . . . . . . . . . . . 27Banner Engineering . . . . . . . . . . . . . . . . . . . 26Cashco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Emerson Process Mgt/Fisher . . . . . . . . . . . . 15Emerson Process Mgt/Systems . . . . . . . . . . . 68Emerson Process Mgt/Wireless . . . . . . . . . . 21Endress + Hauser . . . . . . . . . . . . . . . . . . . . . . . 6Exida . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50FCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Flexim Americas . . . . . . . . . . . . . . . . . . . . . . 52Fluke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Honeywell . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Invensys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Kobold Instruments . . . . . . . . . . . . . . . . . . . . 40Magnetrol International . . . . . . . . . . . . . . . . 12Martel Electronics . . . . . . . . . . . . . . . . . . . . . 49Moore Industries . . . . . . . . . . . . . . . . . . . . . . 29Mynah Technologies . . . . . . . . . . . . . . . . . . . 24National Instruments . . . . . . . . . . . . . . . . . . 10NovaTech Process Solutions . . . . . . . . . . . . . 44Omega Engineering . . . . . . . . . . . . . . . . . . . 57Opto22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Orion Instruments . . . . . . . . . . . . . . . . . . . . . 33Otek . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Pepperl+Fuchs . . . . . . . . . . . . . . . . . . . . . . . . 18Precision Digital . . . . . . . . . . . . . . . . . . . . . . 28ProComSol . . . . . . . . . . . . . . . . . . . . . . . . . . 60Prosoft Technology . . . . . . . . . . . . . . . . . . . . 30Rockwell Automation . . . . . . . . . . . . . . . 37, 58Siemens Energy & Automation . . . . . . . . . . . 3Siemens Process Analyzers . . . . . . . . . . . . . . 67Ultra . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38United Electric Controls . . . . . . . . . . . . . . . . 53Winsted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Yokogawa . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

C L A s s i F i e d sA d i N d e X

usa.siemens.com/searchjobs

Don‚t follow the leader.

Join their team. If you’re in sales and want to work for a leading supplier of control and electrical solutions, contact Siemens today!

Siemens is a leading supplier of control and electrical solutions to the power industry. We are currently looking for outside sales professionals with the drive and talent to apply their skills in positioning a broad line of high-quality products and services.

We offer a totally integrated, complete solutions portfolio that will meet your customers’ business drivers. And we offer a competitive compensation and benefits package that will meet your needs. Join the Siemens team. We’re making a difference through empowered people.

Siemens_Recruitment_PM_3.25x4.875.indd 1 9/10/13 11:10 AM

ADVERTISE?LOOKING to

Contact: Polly Dickson, [email protected], 630-467-1300 ext.396




Contact: Polly [email protected] 630-467-1300 ext.396



07_Looking_House.indd 1 12/2/08 4:51:20 PM

equipment & materials

We Love to BuyPLC/DCS

Sensors/DrivesMotor Control

from Allen Bradley to Xycom

Industrial Automationwww.santaclarasystems.com

Contact Seth Kostek at 888.450.0301 x215

[email protected]

SCS_1111_Classified.indd 1 11/11/11 9:53 AM

Dry run protectionThe PMP-25 Pump Load Control guards against dry running, cavitation and over-load. It monitors true pump power for maximum sen-sitivity. The display shows pump load, trip points and delays. Its NEMA 4X enclosure is small enough to fit on Size 1 starters and can be door-, panel- or wall-mounted. Load Controls Inc., (888) 600-3247, www.loadcontrols.com.

CT1310_65_Classifieds.indd 65 10/1/13 12:30 PM

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

Jim montague e xecut ive editor

[email protected] t

66 www.controlglobal.com o c t o b e r / 2 0 1 3

rasGas Gets a Jump on Safety

Forewarned is forearmed. Nowhere is this old saying more true than it is for process

safety. To secure the leading indicators it needs to tell further in advance what bad ac-

tors might potentially cause safety issues, RasGas Co. in Doha, Qatar, began a demand

on safety system (DOSS) project about nine months ago on the seven liquid natural gas

(LNG) production trains that make about 37.1 million tonnes of LNG per year from the 95 kilometers of pipelines, wellhead platforms and onshore facilities serving its huge, offshore North Field in the Arabian Sea.

“DOSS determines the frequency and quan-tity of the demands against the process param-eters operating on the verge of safe operating limits (SOL), and provides an added oppor-tunity to identify and correct weakness in the control systems,” says Navid Farooqi, safety in-strumented system (SIS) engineering advisor at RasGas, who spoke on Sept. 12 at Invensys’ Fox-boro and Triconex Global Client Conference 2013 in San Antonio, Texas. “DOSS monitors the performance and flaws in process designs, instruments, always-in-demand DCSs with continuous control, and operator responses.”

Farooqi reports that RagGas started its DOSS program by seeking and defining initi-ators that were or might get triggered, and by determining the criticality of the loops where they were located. Next, it analyzed events to identify bad actors and is addressing applicable issues to rectify any flaws in its overall loops.

To secure data for its DOSS, Farooqi and his colleagues developed DOSS key performance indicator (KPI) reporting procedures and score-cards. These reports include SIS process trip indicators such as valid signals from process high-high (HH) and low-low (LL) alarms; acti-vation of mechanical shutdown events, such as turbine over-speed trips and mechanical trips; and activation of mechanical shutdown events. Exclusions include alarms due to startups, pre-ventive maintenance or overrides; initiators due to routine tests or planned shutdowns; machine monitoring system (MMS), chattering, dupli-cate or bad I/O alarms.

To generate DOSS reports, engineers and operators at RasGas use a “Consequential

Alarm Report” utility in the alarm manage-ment system in its Plant State Suite (PSS) soft-ware. “This utility generates a report of defined alarm tags, which have HH, LL or shutdown block names, such as UZ, as part of their tag-names,” explains Farooqi. “Corresponding to every alarm, whether it’s HH or LL, is a set of consequential alarms. This includes all the HH, LL or UZ alarms that appeared one min-ute before or after any event. The same is re-peated for all HH and LL alarms. We must generate reports with well-defined alarm tags to make sure we’re not getting any fake data.”

Farooqi adds the DOSS reports also include: • A database of safety integrity level (SIL)

loops, which is a collection of SIL references generated through RasGas’s SAP system. This database is a reference to assign the SIL level against each initiator in the DOSS report.

• Segregation of initiators categorized based on their asset, SIL level, number of times an initiator get triggered, and type of initiator, such as process HH or LL alarms or manual shutdown, such as by pushbutton or mechani-cal shutdown from over-speed or vibration.

• Filters configured in the report. For exam-ple, the initiator must have the UZ as “follow-ing” against it; all the alarms must be “state” alarms, which are valid alarms coming from the TMR system; data removed due to planned shutdown; chattering alarms removed because they appear more than three times; and data re-moved due to LNG loading tests offsite.

The DOSS KPI reports also summarize and present their results on scorecards with user-friendly spreadsheets, bar charts and pie charts. These scorecards also group all appli-cable events by number of occurrences, initia-tor counts and if they’re at SIL-1, SIL-2 or SIL-3 levels. Farooqi says the reports and scorecards make it easy to see any bad actors.

DOSS determines

the frequency and

number of

demands against

the process

parameters

operating on the

verge of safe

operating limits.

CT1310_66_ControlReport.indd 66 9/30/13 5:34 PM

Visit our Automation Fair in Houston, Texas and see the star of industrial automationAutomation Fair® 2013, November 13-14, 2013 George R. Brown Convention Center, Houston, TX USA

Automation Fair® from Rockwell Automation is one of the world’s premier automation events, a unique opportunity to explore smart, safe, sustainable manufacturing solutions that improve profitability, productivity and efficiency while reducing costs.

Find out how Automation Fair® 2013 can help your business to shine. www.automationfair.comAutomation Fair is a trademark of Rockwell Automation, Inc. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

Indefatigable! Continuous Emission Monitoring System (CEMS)

usa.siemens.com/cems-ad


Satisfy your 40 CFR Part 60 and 75 requirements with our indefatigable CEMS!

Do you need to continuously measure NOx, CO and O

2 emission from furnaces and boilers in Refining,

Hydrocarbon or Chemical proccessing plants? If so, this CEMS is a low cost emission monitoring package designed to operate in a climate controlled shelter or cabinet, for general purpose or electrical hazardous environment.

We offer a plant proven turnkey solution with: • Sample extraction with blowback • Heated sample transport • Sample preparatrion with cooler • Automatic validation / cabliration • Paramagnetic, IR and CLD analyzer

The CEMS maintainability, proven reliability and long term stability offer you nonstop performance. In one word: INDEFATIGABLE!

Scan for more CEMS information

© 2

01

3 S

iem

ens

Indu

stry

, In

c.


YOU CAN DO THAT

My system architecture shouldn’t stop me from having a modern safety system. I need the best technology available today.


Whether your choice is standalone, interfaced or integrated–DeltaV SIS. That’s modern. You shouldn’t be limited by your existing control environment to employ today’s state-of-the-art technologies. DeltaV SIS with Electronic Marshalling and CHARMs technology simplifies design,installation, wiring and commissioning of SIS projects. Modern technology increases capacity and reducesthe footprint of your SIS system by eliminating traditional marshalling cabinets. Now you can implement astandalone safety system or integrate with your current control system for even more benefits–either way, the choice is yours. Scan the code below or visit: ModernSafetySystem.com to learn more.

DeltaV SIS Modern Standalone_8x1075_Layout 1 9/18/2013 7:24 AM Page 1


ocotber 2013 - control global

Documents