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JULY 2013
Vol. 60 Number 7
C OV E R I N G C O N T R O L , I N S T R U M E N TAT I O N , A N D A U TO M AT I O N S YS T E M S W O R L D W I D E
30
26
Features
34
Courtesy: InduSoft
26 The HMI of the future will look very familiar
HMI/SCADA applications enable companies to benefit from commercial off-the-shelf technologies adapted for industrial automation to lower costs and improve operations.
30 Reducing peak demand as electrical consumption patterns change

Proliferation of electric vehicles and other rechargeable devices can create new peak demand patterns. Planning and renewable sources can mitigate the effects.
34 Service offerings expand from automation distributors
Todays distributors offer more than warehouses full of the latest gadgets, providing a diversity of services to ease buying, installation, start-up, and more.
CONTROL ENGINEERING (ISSN 0010-8049, Vol. 60, No. 7, GST #123397457) is published 12x per year, Monthly by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. CONTROL ENGINEERING copyright 2013 by CFE Media, LLC. All rights reserved. CONTROL ENGINEERING is a registered trademark of CFE Media, LLC used under license. Periodicals postage paid at Oak Brook, IL 60523 and additional mailing offices. Circulation records are maintained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Telephone: 630/571-4070 x2220. E-mail: customerservice@cfemedia.com. Postmaster: send address changes to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: customerservice@cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA, $ 145/yr; Canada, $ 180/yr (includes 7% GST, GST#123397457); Mexico, $ 172/yr; International air delivery $318/yr. Except for special issues where price changes are indicated, single copies are available for $20.00 US and $25.00 foreign. Please address all subscription mail to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.
JULY 2013 CONTROL ENGINEERING www.controleng.com
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JULY 2013
C OV E R I N G C O N T R O L , I N S T R U M E N TAT I O N , A N D A U TO M AT I O N S YS T E M S W O R L D W I D E
Inside Process
Starts after p. 37. If not, see www.controleng.com/archive for July.
P1
Temperature sensors: Make the right choice, RTD vs. TC

When you need a temperature measurement, one of the most basic decisions is choosing which kind of sensor to deploy. The application should guide your decision.
P4 P9
Diagnosing faults in engineering models

Method of minimal evidence techniques help identify invalid modeling assumption variables.
NASA becomes service provider for private space ventures

After the Space Shuttle program closes, launching systems get a new life with new customers, with new requirements for monitoring services. The tricky side of measuring helium and nitrogen use calls for sophisticated flowmeters.
PRODUCT EXCLUSIVE
departments
8 Think Again
Lessons, opportunities from NASA
19 Technology Update
Wireless network: Field testing benefits
10 Product Exclusive
Motion card integrates high performance amplifiers
20 Machine Safety
Farming out functional safety?
12 Cyber Security
PRODUCTS Time to step up: Actions you can take today
21 Legalities
21 legal takeaways for the automation industry
14 IT & Engineering Insight

Who is building your HMI?
23 News
Will your automation business survive, thrive?
16 Round Table
Engineering systems in manufacturing, industrial buildings
52 Products
Sensors, electric actuator, handheld communicator
18 International
Industry prepares for next industrial revolution
56 Back to Basics
Cost accounting for process manufacturing
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editorial
THINK AGAIN
Lessons, opportunities from NASA
Learn how to avoid failures and innovate, according to NASA experts involved in Space Shuttle program and the in-progress Mars Curiosity robotic mission.
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ASA, the same organization that ignored engineering-based predictions of the Space Shuttle Challenger explosion, also designed, launched, and landed one of the worlds most famous robots, the Mars Curiosity Rover. Engineers can learn from NASA tragedies and successes, said speakers at two June technology conferences. Mike Mullane, retired USAF officer and NASA astronaut, provided lessons on Normalization of deviance, which lead to the disaster and should not be repeated, he suggested. Mullane spoke at the RSTechED conference by Rockwell Automation. Doug McCuistion, director, NASA Mars Exploration Program (ret.), gave details related to launching a successful new robotic platform, the Mars Curiosity rover. While the rover can be remote controlled, wireless signals take at least 7 minutes each way, so most landing decisions were automated. McCuistion spoke at the Siemens Summit. Mullane described space flight as a boundlessly joyful, fear-for-your-life experience. He also called the Shuttle Challenger explosion, Jan. 28, 1986, a predictable surprise, foretold by documents warning of pending O-ring failure on the solid-rocket boosters. Why do bad things happen to people and teams with stellar histories? They fall victim to normalization of deviance. Usually first time, nothing happens. Those involved start believing they always will get away with it. Deviance becomes the norm. Seven perished; four were Mullanes classmates. Three prior NASA rockets had human escape systems. Challenger did not. The personal success lesson is that you are vulnerable; 13 years separated Apollo success with Challenger disaster, with many of the same personnel from the same organization. Yet, adversity can be overcome. Most of us are ordinary, but the ordinary can do the extraordinary when they move the bar out and keep that laser focus,
Mullane said. Success... is a life journey.

Robotic spacecraft, rover
Contributing Contributing Content Content Specialists Specialists

Jeanine jkatzel@sbcglobal.net Jeanine Katzel, Katzel jkatzel@sbcglobal.net Vance Ph.D.,P.E., P.E., Vance VanDoren, VanDoren Ph.D., controleng@msn.com controleng@msn.com Suzanne Suzanne Gill, Gill, European European Editor Editor suzanne.gill@imlgroup.co.uk suzanne.gill@imlgroup.co.uk Frank Frank J. J. Bartos, Bartos, P.E., P.E., braunbart@sbcglobal.net braunbart@sbcglobal.net
McCuistion described the Mars Exploration Programs strategically defined project-by-project approach. Of 40 attempted Mars landings globally, only 16 have succeeded. The rovers weight, 1 metric ton (the size of small car), required a new landing system. Amid variable wind and dust, the robotic lander used embedded intelligence to optimize trajectory and number of S-turns needed, McCuistion said. After a 254-day journey of 352 million miles and 7 minutes of terror, the design (with heat shield, parachute, and rocket-based skycrane) allowed safe-speed rover landing on Aug. 5, 2012. Advances included instrumentation miniaturization, new complex actuators to move and steer the rover and its tools, and new computer processors. Amid successes, project leaders postponed launch to address challenges. Had we launched as originally planned, we would have made a smoking hole, McCuistion said. Simulation software verified the design and helped collaboration from teams in 33 U.S. states and 10 countries, creating high-technology jobs. After 5 months of a two-year mission, Rover Curiosity proved that the environment to support life existed on Mars. While robotics can do wonders, a roundtrip human landing on Mars could achieve even more for science and engineering, McCuistion suggested. We need to think again about funding to and benefits from space exploration. ce
Marek Marek Kelman, Kelman, Poland Poland Editor-in-Chief Editor-in-Chief marek.kelman@utrzymanieruchu.pl marek.kelman@utrzymanieruchu.pl Luk Luk Smelk Smelk, , Czech Czech Editor-in-Chief Editor-in-Chief lukas.smelik@trademedia.us lukas.smelik@trademedia.us Andy Andy Zhu, Zhu, Control Control Engineering Engineering China China andyzhu@cechina.cn andyzhu@cechina.cn
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EXCLUSIVES
PMD Prodigy/CME Machine Controller Card integrates up to four amplifiers and a positioning motion controller on one printed circuit card. Courtesy: Performance Motion Devices Inc.
Motion card: high-performance amplifiers, motion control

PMD Prodigy/CME Machine Controller Card integrates up to four amplifiers and a positioning motion controller on one printed circuit card.
erformance Motion Devices Inc. (PMD) announces a new family of Prodigy motion cards that combines a full-featured fouraxis motion card with high-performance on-card amplifiers. The PMD Prodigy/ CME Machine Controller Card uses PMD Atlas digital amplifiers to eliminate the need for external amplifiers, allowing new levels of convenience, integration, and cost savings for applications in life sciences equipment, scientific automation, robotics, and general purpose automation. Machine Controller cards in 1, 2, 3, and 4-axis configurations can control the torque, velocity, and position of dc brush, brushless dc, and step motors. They measure just 7.8-in. x 4.88-in. (19.8 cm x 12.4 cm), providing a small form factor. Card communications include 10/100 Mbps Ethernet with UDP and TCP protocols, serial RS232, serial RS485, and CANbus. The motion cards are based on PMD Magellan Motion Processors, which perform motion command interpretation and numerous other real-time functions. Users can program motion profiles including S-curve, trapezoidal, velocity contouring, and electronic gearing. Servo loop compensation uses a full 32-bit position error, PID with velocity and acceleration feedforward, integration limit, and dual biquad filters for sophisticated control of complex loads. Machine controller cards include a powGo Online erful C-Motion Engine module Read more: (CME), which www.controleng.com/products allows developers to download and execute application code directly on the card. Program development is simplified through use of the PMD C-Motion development suite, with a library of motion control code, and development and debug tools.
Performance Motion Devices www.pmdcorp.com
10
JULY 2013 CONTROL ENGINEERING
cyber
SECURITY
Time to step up: Actions you can take today

Your control system cyber assets were not coded with security in mind, so you have to build defenses yourself, always thinking about your complete security posture. Here are ways to start now.
C
Matt Luallen Cybati
Create an inventory of your control system assets. This includes all personnel and skills, controller hardware, networking hardware, communication channels, and operational procedures.
Go Online
https://cybati.org/ http://www.controleng. com/media-library/webcastarchive.html https://www.sans.org/ webcasts/industrialcontrol-systems-securitybriefing-live-houston-tx96727?ref=131632
12
ontrol systems represent a high-value target and are under attack. How bad is the risk? A recent survey conducted by Control Engineering indicated that most respondents recognize that the risk is high to severe. Increasing international tensions are driving threat actors worldwide. A recent vendor briefing highlighted how vulnerable industrial cyber assets and their communications protocols truly are. The vulnerabilities transcend product lines within vendors and across vendors. The situation is improving in some areas, but most industrial control system (ICS) product suppliers and integrators do not have a security process within their software development and system integration lifecycle, or are early in their efforts. So if you know there is risk, what can you do? You have to know what you have, build walls, monitor, and respond to threat indicators. Step one, which you can begin today, is create an inventory of your control system assets. This includes all personnel and skills, controller hardware, networking hardware, communication channels, and operational procedures. Step two, take a look into any regulations impacting your cyber, physical, and operational security requirements. If you do not have any (yet), then consider yourself lucky; it will be up to you to justify a cash outlay for security to your management. However, if you are in the energy or water sectors, several cyber security controls are already impacting you or will be soon. Once you compile your initial inventories, the next steps are: 1. Create a baseline of security needs throughout your organization and its stakeholders. This is a key ingredient, as your organization will most likely have to create new roles and responsibilities to address ongoing threats. 2. Using your inventory of cyber assets, identify which are required for direct control functions. Then, identify what communication channels, applications, and services are required for each ICS cyber asset to perform its operations. This process will not be easy, and your
control system vendors and integrators may not have specific answers for your environment. 3. Remove all other communication channels, applications, and services not necessary for normal and emergency operating conditions. 4. Review the remaining communication channels, applications, and services for vulnerabilities. Using the inventory of firmware, applications, and protocol versions, check them for out-of-date and/or vulnerable components. 5. Identify mitigating controls such as a network intrusion detection system (IDS), configured with specific rule sets for your control system protocols and communication channels, and not generic rules from IT environments. 6. Inventory your current operational procedures used by personnel to maintain the cyber assets and control system communication channels. Review the procedures for vulnerabilities, and modify them as necessary. This is only a start. There are proven IT defensive techniques, but often ICS devices are still vulnerable because many vendors do not have a security process within their software development lifecycle. Therefore, the first step is for you, the asset owner and operator, to learn about what you have, what you need, and how to protect your networks with walls and limited trusts. It is also up to you to request a cyber, physical, and operational vulnerability assessment for all new implementations, including how any new device is coupled to your existing infrastructure. It is then up to you to take the necessary precautions to limit and monitor physical, cyber, and operational interactions with your control environment. For example, a laptop used by a technician should not be categorized as a tool since it may become compromised if not properly handled. This ideology has to transcend all aspects of your ICS environment. The cultural change and new responsibilities required are necessary but will not be an easy shift. ce Matt Luallen is founder of Cybati, a security training and consulting organization.
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IT & engineering
INSIGHT
Who is building your HMI?

Train your development staff in the rules of high-performance HMIs and you will be improving operator performance, reducing operational errors, and potentially saving millions of dollars per year due to missed critical information.
W
Dennis Brandl President of BR&L Consulting
U.S. Chemical (CSB) has
ho is building your HMI system? If you are a vendor, then who are the designers of your standard HMI screens? If you are an owner-operator, then who are the designers of your operational screens? If the answers to these questions are your programmers, engineers, or web designers, then you probably have a low-performance HMI (human machine interface). If your graphical displays look like P&IDs (piping and instrumentation diagrams) covered with hundreds of numbers and multiple colors, then you definitely have a low-performance HMI. Operational screens are not like web pages where flash and glitter are used to draw attention to text and where the user can move a mouse over the screen to discover active links. Operational screens are used to provide situational awareness of the process.
Poor HMI design, higher risk
usability studies, users are given a minimal amount of training, usually commensurate with the minimal job skills, and then asked to perform specific tasks using the user interface. All user interactions are recorded, including mistakes and repeats to discover the good and bad aspects of the interface. All recordings are then analyzed to reduce user confusion, changes are made to the interface, and tests are rerun. This may sound like a lot of work, but it is actually only a small percentage of the total effort required in designing HMIs. Usability studies are often short, involving only a few hours of testing, and typically involve only one or two usability experts.
HMI design standards
Safety Board
estimated the total loss due to operator error as $10 billion per year, and poor performing HMIs are a major cause.
HMI screens are used to manage the operation and supervise the process. Unfortunately, poor performance of the HMI system has been cited numerous times as a significant contributing factor to major industrial accidents. The U.S. Chemical Safety Board (CSB) has estimated the total loss due to operator error as $10 billion per year, and poor performing HMIs are a major cause. If your HMI was designed over five years ago, then you may now be running a multimillion-dollar operation from HMIs created when there was little knowledge of proper HMI practices and principles. Newly designed interfaces follow the principle of high-performance HMIs. A high-performance HMI is one that is designed with a consideration of user and functional requirements, with good human factor engineering, and that supports all normal, abnormal, startup, shutdown, and switchover modes of operation. Designing a high-performance HMI (HPHMI) is one case where it is important to follow good software engineering practices used in user interface design, and not just copy existing designs. Good software engineering practices involve usability labs and usability studies. In
Go Online
At www.controleng.com/ archive, find more under this headline. At www.controleng.com search related topics.
14
Usable and safe, not pretty
Fortunately, there is help in designing highperformance HMIs, both in formal standards and in general rules. Formal standards include: ISA 101 Human Machine Interfaces for Process Automation Systems (draft), NUREG-0700 Rev. 2-2002 Human-System Interface Design Review Guidelines, ISO 11064 Ergonomic design of control centers, and ASM Consortium Guidelines: Effective Operator Display Design. Despite these guidelines, there is no standard recipe for designing a good display. There are too many variables to define a prescriptive set of rules that apply in all cases, but the design must accurately depict the process, work in both normal and abnormal situations, and differentiate between safety system and operational requirements. Designing high-performance HMIs is an acquired skill, which requires frequent feedback from usability labs and usability studies. If your HMIs are being designed without usability studies, then you may have interfaces that would be more appropriate for programmers than operators. Train your development staff in the rules of high-performance HMIs and you will be improving operator performance, reducing operational errors, and potentially saving millions per year due to missed critical information. ce - Dennis Brandl is president of BR&L Consulting in Cary, N.C., www.brlconsulting.com. His firm focuses on manufacturing IT. Contact him at dbrandl@brlconsulting.com.
More than Just a Pretty Face for Your HMI Solution.
HMIs with fully embedded communications and maintenance functions.
Put the power of a Mitsubishi Electric Graphic Operator Terminal (GOT) right at your ngertips. With the push of a single button, enjoy multimedia and tightly integrated communications, maintenance and diagnostics. Features like ladder monitor, logic monitor and ow chart monitor for sequence and motion control are time-saving, built-in functions that simplify maintenance and reduce costs. Time is more than just money. Its having the condence your HMI solution will work as awlessly on the rst startup as it did on your last project. Need more than pretty pictures and ashing lights from your HMI? Go with the Mitsubishi Electric GOT1000 Series.
GOT1000 Series of HMIs
integration
ROUNDTABLE
Engineering systems in manufacturing, industrial buildings
Manufacturing and industrial facilities have some engineering requirements that often require integration of plant floor, air handling, power, and fire/life safety systems. Control Engineerings sister publication, Consulting-Specifying Engineer, provided this roundable discussion. See more in June www.csemag.com/archives.
CSE: Please describe a manufacturing or industrial facility youve worked onshare details about the project, including building location, size, etc. Jonathan Eisenberg: We are currently working on a large industrial/chemical facility in South America that includes manufacturing space, bulk chemical storage and dispensing rooms, and a central utilities plant. Our role on the project includes building and fire code consulting, as well as detailed fire suppression design. Peter Zak: American Orthodontics is a world leader in the production of braces and other hardware used by the dental profession. A renovation included three new electrical services and new rooftop equipment. The entire production process was relocated to the new facility, which required the design of multiple voltage equipment connections and an overhead process/utilities delivery system for plumbing, exhaust, compressed air, and specialized gases to all machines. The transition to the new facility was carefully coordinated between the architect and facilities staff, which produced a utility installation series of plans. CSE: How have the characteristics of manufacturing or industrial facilities changed in recent years, and what should engineers expect to see soon? Zak: As part of a brazing process, the manufacturer used dissociated anhydrous ammonia, which created a hydrogen by-product. The product moved through a series of chambers on a belt. There was a zero tolerance for draft or airflow that could compromise the brazing process. As the product moved through the chambers, the challenge was to collect the spent hydrogen gas
Jonathan Eisenberg, PE, Associate Manager Rolf Jensen & Associates Inc. Boston
Brian P. Martin, PE PDX Electrical Discipline Manager CH2M Hill Portland, Ore.
and remove the radiated heat (1800 F) from the surrounding area without creating a draft. This was accomplished with the design of a low-velocity hood system and space pressure controlled ventilation system.
Eisenberg: In our industrial/chemical project work, we see a trend toward more complex processes that often have a need for materials that are both more hazardous and are required in larger quantities. This is driven by significant advancements in chemical process technologies. For example, as semiconductor device sizes continue to get smaller and need advanced capability, the processing involved in their manufacture becomes more involved. Zak: In the past, the sole purpose of operations was to support facilities production. Maintenance by failure was common, and the primary job of the facilities engineer was to keep things glued together to get the product out. As operating costs began to increase due to age and inefficiencies, it became increasingly difficult to remain competitive and the costs associated with upgrades were prohibitive. There appears to be a tendency for more planning or forward-thinking by industrial clients that includes not only short- and long-term needs, but serviceability, flexibility, efficiency, and sustainability when appropriate. As with anything, cost is always an issue, but there is a concentrated effort to not be short-sighted. Brian P . Martin: The biggest change that has taken place, and will continue to evolve, is the use of advanced modeling from the initial concept, throughout the design, during commissioning, and throughout the lifecycle of the facility. Different modeling software packages are being used to develop initial costs, to model the airflow throughout the facility, to provide 3-D models for
Peter Pobjoy, PE, LEED AP Chief Design Officer Southland Industries Los Angeles
Peter Zak, PE Principal GRAEF USA Milwaukee
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construction, and to provide a 4-D model of the construction sequence and as a part of the measurement and verification strategy for U.S. Green Building Council LEED and energy code compliance. In many cases, these software packages are allowing facilities to meet other long-term strategic goals, such as greater energy efficiency, sustainability, a higher level of facility flexibility for process changes, increased power density, and better integration into the community. All of these have become or are becoming baseline requirements for industrial facilities.
CSE: What unique engineering issues do you encounter with these facilities, and how do you overcome them?
The issues are best addressed during the planning and schematic design phases if possible. There has to be continuous dialogue with the owner/end user from the beginning of the design to the end of construction. Pobjoy: In critical systems that require a high level of reliability, systems must be designed with redundancy to maintain operation in the event of a component failure. Major pieces of equipment with very specific requirements for structural support and vibration isolation require close collaboration with the equipment manufacturers in order to coordinate the details. This includes multiple shop drawing reviews, modeling, and templates in the field.
CSE: When designing building monitoring and control systems, what factors do you consider? Eisenberg: We often recommend fire protection features, such as explosion control, that include gas/vapor detection and monitoring. Design and location of these systems depends on the properties of the liquids and gases that are present. Important questions like high or low placement of the detectors need to be answered. For an outdoor process installation, a flame detection system has to see all angles of the equipment to perform correctly. Zak: Several things we evaluate when designing a control system are: Owner operating level of expertise What is the complexity of the system, and to what level should it be monitored? Does the owner want the ability to change control points? Is energy consumption being tracked? Pobjoy: These include: Keeping the level of complexity to a minimum and understanding how the facility will be operated and by whom Infrastructure approachdistributed versus centralized Digital versus hardwired Commercial level or industrial level con trollers (such as programmable logic control lers, PLCs) Redundancyare the controls required to be backed up in certain areas or on certain systems? Calibrationdo the control devices need to be calibrated in the field? Accuracydo the processes require tight tolerances for temperature and humidity? Quality of valve and damper actuators. ce
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most large industrial projects have typically not been announced to the public or to public agencies. Many owners want to know their cost with certainty at a very early stage of the design, but without engaging the authority having jurisdiction (AHJ), this can be very difficult. This is typically overcome by making assumptions early based on the design teams experience with the local jurisdiction. Once the development has been announced, then these assumptions are validated with the AHJ. Utility and master site planning is also a challenge when you are not able to engage the local jurisdiction and utilities. Owners want to know how long it will take the utilities to ramp capacity to support their plant, but may not be ready to discuss the ramp with the utilities. You can get stuck in a chicken-and-egg scenario, which is typically identified as a risk until the conversation can take place. Eisenberg: We analyze and recommend solutions for issues such as site separation distance from exposures, bulk chemical storage and transfer, fire protection water supply requirements, and local fire suppression needs for specific chemical process equipment. The key to reaching solutions for these issues that are workable for the facility is to perform a thorough hazard analysis at the start of the project. From this study, we get a clear picture of how the facility operates, and what effective fire protection measures are the most practical. Zak: Several challenges we encounter are: What is the impact of the process equipment on the mechanical, electrical, and plumbing (MEP) systems? Which codes are in force? Current and future needs of the facility or process Planning.
Martin: During the initial planning stages,
Manufacturing and industrial structures frequently include a significant level of computer and server equipment, adding to the complexity. Courtesy: CH2M Hill
The presence of sensitive and volatile chemicals can add to the challenge of working on manufacturing and industrial facilities. Courtesy: RJA
INTERNATIONAL
Industry prepares for the next industrial revolution

Automation companies share views on the fourth industrial revolution, Industry 4.0, according to Control Engineering Europe.
Suzanne Gill
Speaking at Hannover Messe, Siegfried Russwurm, CEO of Siemens Industry Sector, said: Never before has the world of manufacturing and production technology been changing as rapidly and fundamentally as today. Courtesy: Control Engineering Europe
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Control Engineering Europe www.controlengeurope.com
18
ndustry 4.0 was high on the agenda of many Hannover Messe exhibitors, according to Control Engineering Europe. Referred to by many as the fourth industrial revolution, the concept of Industry 4.0 is to merge the virtual world with the real world, bringing IT and production closer together. Horizontal integration, from product to production, is one of its major ambitions. Industry 4.0 now also forms the cornerstone of the German governments high-tech strategy to secure the competitiveness of German industry. Siemens showcased how it, and its customers, will meet todays challenges and shape the new production age. Speaking at Hannover Fair, Siegfried Russwurm, CEO of Siemens Industry Sector, said: Never before has the world of manufacturing and production technology been changing as rapidly and fundamentally as today. Although Russwurm believes that there is some way to go before Industry 4.0 becomes reality, Siemens is already laying the essential foundations for its implementation. A decisive role will be played by industrial software that allows the integration of product development and production, and consequently paves the way for the holistic optimization of product development and production processes. Before the Hannover event CEE spoke with Eckard Eberle, CEO of Industrial Automation Systems, Siemens Industry Sector, to find out more about fast-changing industry needs. Industry is getting more complex, he said. Products need to get to market in ever-shorter time frames, which requires the whole development and production phases to be shorter too. The product and production design processes will need to more closely collaborate. The information created in the design phase needs to be used to a greater degree throughout the production process. Originally it took more than one week, from conclusion of a product design change, to create a Rolls Royce work plan for the shop floor at a U.K. plant. Siemens helped the company to more closely integrate its system with the companys MES. They now can make changes in two or three hours.
We have many examples where such integration is taking place. However, we expect that, within the next 10 to 20 years, the entire data flow will be seamless.
Safety challenges
As the automation landscape continues to develop, companies also face new safety challenges. New safety objectives include, for example, the protection of production data, product and plagiarism protection, know-how protection, access protection integrity protection, and remote maintenance. Pilz is playing its part in ensuring that safety is recognized as a critical success factor in Industry 4.0, said Susanne Kunschert, director at Pilz GmbH & Co. We are advocating a holistic approach to protection in both its forms, safety and security. We want to use our experience from the machinery safety and automation sectors to drive this important work forward. On the product side, Pilz is pursuing a modular, distributable approach to enable the benefits of a decentralized control structure without the increased complexity that would normally result when programs are distributed on different control systems. Pilz predicts that intelligent sensors and actuators in distributed systems will increasingly assume the functions of control systems. Improved interaction between machine modules, as well as between human and machine is the aim. Safe motion controllers (interconnected synchronously and safely via real-time Ethernet) already support local control and evaluation functions. Pilz is moving in this direction with its intelligent camera systems for safe, threedimensional zone monitoring and camera-based protection and measuring systems. ce - Suzanne Gill is editor of Control Engineering Europe; this article appeared on www.controlengeurope.com on June 12, 2013, and was edited for Control Engineering. See more in this article online from Beckhoff Automation, Belden, Control Techniques (Emerson Industrial Automation), and Eaton, at www. controleng.com/archive, June.
MONTH JULY 2012 2013 CONTROL CONTROL ENGINEERING ENGINEERING www.controleng.com www.controleng.com
UPDATE
Wireless network: Field testing benefits
technology
Carefully field test industrial wireless equipment for smoother installation, operation.
efore installing industrial wireless equipment, careful testing can prevent potential problems and reduce troubleshooting time following an installation. Proof of concept helps ensure correct radio selection for the job. In most cases, the first step is to conduct a software path loss study. Distances under 305 m (1,000 ft) usually do not require such a study. A simple test can be done with a functional radio set to the desired wireless mode, transmit data rate, and transmit power setting. The first step in performing a path study is to plan where the remote sites will be constructed. This can be done by traveling to each site with a handheld GPS unit and collecting the GPS coordinates or by using maps and other tools, such as Google Earth. A path simulation uses topographic maps to plan the network virtually. It can show which objects might obstruct communications. This helps determine the ideal height of the antenna mast and the necessary distance between radio links. With todays advanced software, it is possible to ensure proper Fresnel zone clearance in line-of-sight wireless systems. Fresnel zone is the area around the direct line connecting the transmitting and receiving antennas. Obstacles in this area can disturb the wireless connection. Figure 1 shows an ideal installation with undisturbed connection. Figure 2 shows a zone obstructed by terrain. The transmission frequency and the distance between the transmitting and receiving antennas help to determine the radius of the Fresnel zone. For a reliable path, at least 60% of the Fresnel zone should be unobstructed (also known as the 0.6 Fresnel zone). Increasing antenna heights is generally the only way to keep the 0.6 Fresnel zone clear of obstructions. The longer the distance the radios need to communicate, the clearer the Fresnel zone must be. Path studies are not flawless. They might not be able to account for human obstructions or foliage growth. An on-site field test using temporary equipment can prevent such issues. If the installation is more than 1,000 ft, a field test is the best way to ensure that the correct components have been selected. Recommended
Field test
equipment for an effective field test includes a voltmeter, coaxial cable, portable antenna masts with tripods, antennas, filter, GPS, laptop, spectrum analyzer, radios under test, watt meter, and power supply/battery. At each remote site, you will need to test communications back to the master site using a variety of antennas. This will help locate the optimal signal strength. Radio performance is directly related to how the antenna is mounted, raised, and polarized. Most omnidirectional antennas are vertically polarized. All directional Yagi antennas should match the vertical polarization with elements perpendicular to the ground. Using the site map and software path study created earlier, locate each remote site to be constructed and measured under test. It is best to set up the master location first, and then work outward, from the relative closest site out to the farthest. To determine the height of the master antenna, again refer to the software study. Usually the farthest slave is the weakest link, so you will set the master antenna to the height that is required by that slave. Next, move to the nearest remote site. Use the mast and tripod to raise the antenna to the predicted height where it achieves a 20 dB fade margin. Using a voltmeter or the radios software measurement tool, record the received signal strength to the master and compare the reading to the software simulations prediction. If the radio did not achieve a 20 dB fade margin above the receive sensitivity, raise the remote antenna height until it reaches that level. Make note of this height for final installation. Also, ensure that the Yagi antenna azimuth points directly to the master, and that it is polarized correctly. If a 20 dB fade margin cannot be achieved, a higher gain antenna may be needed. Once the radio has received an acceptable signal, you need to verify how the RF link will transport the data it must carry. A typical test consists of pushing data through the same (or comparable) link that will be used in the final installation. ce - David Burrell is wireless product specialist, Phoenix Contact. Edited by Mark T. Hoske, Control Engineering, mhoske@cfemedia.com.
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Figure 1: Clear Fresnel zone is shown in red. Figures courtesy: Phoenix Contact
Figure 2: Interference in the Fresnel zone is shown in red.
Figure 3: Waveforms present in the coaxial cable and transmitted from the antenna display what happens when VSWR is present. Vertical red line represents impedance of cable or other components on the line.
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See more on troubleshooting with this article online at www.controleng.com/ archive, June www.phoenixcontact.com www.controleng.com/wireless
VIC
w machine
SAFETY
From Individual Control Panels, To Complete Systems Integration
Farming out functional safety?

What are the consequences of farming out the designing in of functional safety component requirements? See four factors to consider and one caution.
System-wide communication, process control and monitoring Powerful solutions for product and process integration
Let us Be Y- OEMs ur Pane and Systeo ms InteglraBuilder tor!
From construction to custom programming panels and systems integration d esigned for your specific needs
re automation You probably think, suppliers truly Great stuff! Right? considering Caution: Dont be too farming out the quick to run to the bank. As design and safety certificaan end user, just because tion effort of integrating your favorite automation functional safety features supplier quickly brought you into existing components? a safety certified component This functional safety topic doesnt necessarily mean its J.B. Titus, CFSE, is receiving significant chatcapable of full service to Certified Functional ter on the Internet and in the you as its customer. FarmSafety Expert (CFSE) media. ing out the design and cerWell, it seems that there tification effort is only one are some engineering firms that spe- spoke in the wheel of resources required cialize in this capability and offer these by automation suppliers to support services to various automation suppli- their safety automation products. They ers. This strategy appears to be based on will also need pre-sales support, postvarious factors: sale service support, and training sup1. Market demand has increased for port, to name a few. You wouldnt want automation products with functional safe- to phone your automation suppliers ty features. For example, drive systems 24-hour hotline only to be transferred to can have a safe stop, safe torque off, etc., its engineering firm subcontractor (for with safety functionality built in. functional safety) and then to the sub2. Time to market can be shortened contractors voicemail. After all, reducby using experienced, qualified engi- ing unplanned machine downtime was neering firms to provide these services. supposed to be part of your return-on3. Automation companies typically investment decision. incur incremental costs to grow speSo, you might want to ask your favorcialized internal safety certified orga- ite automation supplier a few questions nizational know-how to perform these related to the topics above before decidservices. ing. ce 4. Increased market demand comes - J.B. Titus, Certified Functional from an increasing awareness of reduced lifecycle costs of ownership through Safety Expert (CFSE), writes the Control safety automation versus hardwired Engineering Machine Safety Blog. Reach him at jb@jbtitus.com. safety applications.
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Engineering interaction: Go to this blog at www.controleng.com/blogs, see related articles: Inside Machines: Does adopting ISO 13849-1:2006 change the U.S. model for compliance and enforcement? Machine safety: Incorporating functional safety as part of your machine safety plan, Part 4 Machine safety and functional safety: Which type? Machine safety: Functional safety and the steps to be compliant in the U.S.
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Phone: (336) 793-2658 viccontrols.com input #11 at www.controleng.com/information
LEGALITIES
automation
21legal takeaways
A
pologies to the International Society of Automation, but you may not need to buy the concise little guidebook that I authored and the ISA just publishedthe book with the anything-but-concise title, The Automation Legal Reference, a Guide to Legal Risk in the Automation, Robotics and Process Industries. The reason buying may be optional is that for the past two months I have been giving away for free the essential takeaways from each of that books 21 chapters. I have parceled these out via social media and speeches [including at the Control System Integrator (CSIA) 2013 Executive Conference]. Below all 21 are listed. Control Engineering magazine is the place where many of these takeaways originated. In the electronic version of this article, you can find links to a number of these initial articles. Here are the 21 actionable insights that I believe are essential to minimizing risk in industrial engineering projects:
1. Automation projects are a type of construction project. This is my central insight. An automation project is not the sale of equipment. Its not a software deliverable. Its the construction of a system. Well-worn construction law principles apply, but a gap needs to be bridged between lawyers and engineers. Each needs to speak the others dialect.
for the automation industry

Yes, its a construction project, but the standard AIA and other trade association forms fall short. Among other things, the warranties are not appropriate for software, the concepts of testing and commissioning are not even mentioned, and dont even get me started on intellectual property.
4. Both systems and contracts need integration. Integration in the contract sense means the scope of work is nailed down and boxed up. Without it, the goalposts are on rails. 5. Limitation of liability is the king of all key contract terms. If you give attention to no other contract term, pay attention to this one. The rest of the Dirty Dozen provisions of contracts are also important, but they pale in comparison to the king. 6. The beauty of a contract clause is in the eye of the beholder. Of course, whether something rises to the level of the Dirty Dozen or the Other Ugly Eight potentially troublesome contract clauses is a matter of perspective. For instance, free from defects, while empowering the end user, should not be endured by those that deliver software. 7. Risk should be placed on the party in the best position to control it. Its the most compelling argument that can be made while negotiating an automation agreementand, whats more, its in the best interest of all. 8. Lack of clarity in specs usually serves no oneexcept the lawyers. 9. Not valuing IP is leaving money on the table. Because most automation projects involve creatively solving a physical problem, the solutions can have great value. Its not an all-or-nothing proposition; ownership can be shared. Give attention to the possiwww.controleng.com
Automation projects are like construction projects, know your project delivery method, and standard contracts dont work are the first three of 21 points of advice.
3. Standard contract forms dont work.
Mark Voigtmann, Faegre Baker Daniels
You cant find a tree if you cant find the forest. Knowing the delivery method definesmost importantlywhich company owns which part of the design. Most automation projects fall under the method called design-build, but that comes with consequences. Those consequences need to be considered (and the important exceptions identified).
2. Know your project delivery method.
automation
LEGALITIES
contract exactly. Using the phrase among other things to keep the door open to additional points.
14. Asserting a claim is an investment (that should be
bilities and opportunities involved.

10. Identify, then classify relevant automation standards. There are standards, and then there are standards. Some are binding, some not. Knowing which is which ishow can I put thishelpful.
being licensed is not getting paid. Each country, state, and province has unique means of regulatingor notthose who work in the automation profession. Even if you are in one of those places that do, the odds of your company being challenged by a state agency may be small. Customers, on the other hand, may use it as an excuse not to pay.
11. The number one risk in not
Good e-mail hygiene means sticking to the story and quoting the contract exactly, among other things.
ance is mitigation.
analyzed like any other investment). You would not buy a stock where the transaction cost is greater than the potential gain. The same goes for litigation. Litigating rarely makes sense, and even when it does, there are important matters to monitor.
contracts, and insurance. Process is prevention. Contracts are avoidance. Insur-
15. Avoiding negligence liability means giving attention to process,
12. Speak green to win more business (and to avoid liability). The upside of knowing about LEED and Green Globes is getting in the door when a competitor cannot. The downside can be suffering performance specs based on attaining LEED criteria. 13. Good e-mail hygiene wins the case. This means company-wide discipline. Sticking to the story. Quoting the
16. No business mess is insured, and every business mess is insured. What your insurance company tells you in the face of a significant loss frequently is not the last word. 17. Liens and bonds are backup pots of money. If the company that owes money does not have it, these represent Plan B. 18. The most important parts of a service agreement are the exclusions. Being on call is a part of every maintenance and service agreement. But when does a service call turn into a new project? Your exclusions provide the answer. 19. Beware the solvency of the middleman. Did I mention that liens and bonds are backup pots of money? 20. Conduct an audit of your legal health. Smart documentation for projects is only the external piece of the company versus legal risk continuum. The internal piece also needs attention. 21. Your lawyer and you should work from the same playbook. It is the difference between your lawyer being a part of the problem or the solution. ce
- Mark Voigtmann leads the automation practice at Faegre Baker Daniels, a law firm with offices in the U.S., the U.K., and China. The Automation Legal Reference can be purchased at the ISA bookstore at www.isa.org/books. Edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com.
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www.controleng.com/archive July 2013 has links to more Voigtmann advice with this article online. www.faegrebd.com www.controlsys.org (CSIA) input #12 at www.controleng.com/information
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Beckhoff Automation expands
Virtual Machines
Training vs. mentoring
See July at
industry
www.controleng.com/archive
See June 25
Real World Engineering blog
System Integration
www.controleng.com/blogs
NEWS
grounds, have the most expertise in operations, then in strategy and vision, followed by leadership and motivation, with often little knowledge of finance. He discovered during time as a turn-around consultant that ultimately, only two things are relevant: Cash flow and people. Looking at related metrics before a company gets to the brink of bankruptcy can help companies run more effectively. Balancing time spent in four areas provides a good start. 1. Strategize daily. Most leaders have 20 undone things from yesterday and 80 more from today. Strategy and vision can get pushed aside. 2. Motivate those around you. 3. Understand operations (be good at what you do). Companies rarely underperform because you dont have good operational skills. 4. Understand finance.
Will your automation business survive, thrive?

Beyond engineering, system integrators and other automation and controls companies, like other businesses, rely on non-operational skills, like finance, to stay afloat. Because accounting can be obtuse, a mid-market business can sinkunseeninto insolvency, without attention to key metrics, said Nick Setchell, CEO, Practice Strategies, at the CSIA 2013 Executive Conference. Setchell talked about the RealTime CEO Maximizing Real Business Value, at the meeting. The consultant, from Adelaide, SA, Australia, explained to system integrators that company leaders need a balanced understanding and application of 1) strategy and vision, 2) leadership and motivation, 3) finance, and 4) operations. Many leaders, especially those in mid-market companies (MMCs) with engineering back-
Many engineering leaders in mid-market companies have the most expertise in operations, then in strategy and vision, followed by leadership and motivation, with often little knowledge of finance, according to Nick Setchell, CEO of Practice Strategies.
At www.controleng.com, search Setchell to see video and online article with more automation management advice. www.RealTimeCEO.com www.controlsys.org
5 proactive CNC maintenance tips

lost data or lost machine positioning Avoid costly equipment repairs on com3. Inspect cooling fans and heat sinks to puter numerical control (CNC) equipment. ensure proper operating temperatures and Perform these five simple, proactive maindecrease the risk of component failure tenance steps during planned shutdown 4. Perform a full memory backup periods, advised Mitsubishi Electric Auto5. Seek advice via email or phone to mation Inc. perform proactive maintenance checks or Preventing failures should always be a schedule on-site maintenance, if needed. priority. One of the best times to be proacBeyond preventive or proactive maintetive is prior to an extended shutdown, Avoid costly CNC equipnance, predictive maintenance is possible said Russell Pobutkiewicz, technical serment repairs with five simwith advanced CNC controls that use senvice and support project manager, Mitsubiple, proactive maintenance sor input and usage information to advise shi Electric Automation Inc. He offered five steps during the holiday when maintenance is needed, further tips for CNC maintenance. shutdown, advises Mitsubireducing staff time and unscheduled down1. Use scheduled downtime for proacshi Electric Automation. time risk. tive CNC maintenance to increase equipCourtesy: Mitsubishi Electric See other information about machine ment uptime and productivity, improve Automation control. machine performance and save on costly www.controleng.com/machinecontrol repairs www.meau.com 2. Check all batteries, since weak batteries can result in
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industry
NEWS
old levels vary depending on the application. For example, in temperature switch applications, the on/off operating points should be as close as possible, requiring sensitive differential travel as low as 0.0001 in. However, in liquid-level pump applications, for example, too tight of a differential may cause the fill pump to cycle more often, shortening the pumps lifetime.
STEP 3: Environmental conditions
5 steps to select a basic switch

A precision snap-action switch, commonly used to detect temperature, position, and liquid levels, is typically available in three models. It can consist of a basic switch alone, a basic switch with an actuator(s), or a basic switch with an actuator and an enclosure. The snap-action comes from the plunger and spring design. Snap-action basic switches have existed since the 1930s, and this small-form-factor electromechanical switch has evolved over the years to meet the requirements of a variety of applications to detect temperature, position, and liquid levels. Engineers need to consider five key switch specifications.
STEP 1: Physical size impacts other characteristics
Environmental requirements can play a big role in the selection of snapaction switches, particularly in highreliability and critical applications, such as industrial controls, medical devices, and military equipment. Understand the environmental conditions of the application, including contaminants in the air that could potentially get into the switch, fluids the switch will be subjected to, and operating temperature requirements. For harsh environment applications, look for switches that offer a wide operating temperature range and are environmentally sealed. Switch reliability is critical. How many cycles of electrical and mechanical operations will an application need? Because these switches can be designed with various contact materials, casings, and terminals, they can meet the electrical and mechanical requirements of a wide range of applications. A highreliability snap-action switch can operate up to 10 to 20 million cycles before mechanical failure and up to 50,000 to 100,000 electrical cycles under maximum load before electrical failure. Price difference between a high and low quality switch can be pennies. In many cases, a more reliable switch will pay for itself in terms of decreased warranty costs over the life of the assembly.
STEP 4: Operational lifetime
Size matters when selecting snapaction switches. Switch dimensions directly relate to other device characteristics including current range, travel, and operating force. For example, one of the smallest snap-action switches available in the market measures .50 in. x .236 in. x .197 in. (LxWxH). While this tiny switch may be a good choice for a compact circuit breaker to detect the status of the circuit, it typically handles only between .1 to 3 amps (A) and features a short travel. Applications requiring higher amps could require a larger switch. As an example, in oil tank applications where the snap-action switch is used to detect the level of liquid, the switch needs to offer a longer travel and higher current. TIP: The smaller the switch, the shorter the travel and the less current the switch can handle. The physical size of the switch also impacts operating force. In an ideal world, engineers look for switches with a low operating force and high current capacity. But, there is a trade-off between these two specifications. To provide a high current range and still maintain good contact, the snap-action switch needs more robust springs, which translates into a higher operating force and a larger switch. Engineers also need to pay attention to differential travelthe distance between the switchs trip and reset position. Thresh
Honeywell Micro Switch snap-action switches are available in many configurations to meet an engineers specific requirements. Courtesy: Honeywell
STEP 2: Electrical requirements
Snap-action switches can typically handle from 5 mA at 5 V dc up to 25 A at 250 V ac. A snap-action switch line that offers many options from low energy to power-duty electrical ratings allows these switches to be used in more applications. Engineers must know the rated current and voltage (ac or dc) of the application to select the right switch for the job. Because there is a big push to lower energy consumption of a variety of equipment across all industries, snap-action switches should be capable of operating at low currents (logic level loads) and dc voltages. However, there will always be a need for switches that can handle high current and high voltage, such as industrial-grade pump applications. In addition to load requirements, circuitry must be selected. Switch contacts are either normally open (NO) or normally closed (NC). With NO contacts there is no current flow between the contacts. When the switch is activated, the contacts are closed and the circuit is completed. With NC contacts, there is current flow between the contacts. When the switch is activated, the contacts are open and the circuit is broken.
STEP 5: Check for agency approval requirements
Choose switches that meet a variety of global electrical requirements, which helps simplify product design for multiple regions. Key standards include UL in the U.S., cUL or CSA in Canada, ENEC in Europe, and CQC in China. - Tom Werner is senior product marketing manager for basic switches, Honeywell Sensing and Control. Edited by Mark T. Hoske, Control Engineering, mhoske@cfemedia.com.
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Manufacturers seek benefits from increased connectivity

Commercial communication technologies are quickly migrating onto plant floors, creating opportunities, and potential risks, for manufacturers. During its 2013 RSTechED event, Rockwell Automation offers approaches to help manufacturers securely integrate disruptive technologies (such as mobile devices, cloud computing, and virtualization), to help build a Connected Enterprise, the theme of this years computing, mobility of production data, and network security are among topics. Labs include networking security best practices for securing data. Several customer-led sessions from manufacturers covered process automation, manufacturing intelligence, visualization, machine safety, industrial networking, Internet of Things, and security, among other topics. The event had more than 150 sessions, labs, and workshops from Cisco Systems, Microsoft, Kraft Foods Group, Enbridge, Ball Corp., Livzon Pharmaceuticals, and others. www.rockwellautomation.com www.RSTechED.com
Frank Kulaszewicz is senior vice president, architecture and software, at Rockwell Automation.
conference, in San Diego, June 9 to 14. Disruptive technologies can enable collaboration across all levels in manufacturing organizations, explained Sujeet Chand, senior vice president and chief technology officer at Rockwell Automation and one of the scheduled keynote speakers at event. By connecting the entire enterprise, manufacturers can fully harness the information they need to optimize their operations. In the keynote address, Chand and Frank Kulaszewicz, senior vice president, architecture and software, Rockwell Automation, explored how the adoption of disruptive technologies is
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Sujeet Chand is senior vice president and chief technology officer at Rockwell Automation. Images courtesy: CFE Media, Mark T. Hoske
transforming industrial automation. Manufacturing needs to be more smart, productive, secure, and sustainable. Collaboration sparks innovation to improve overall productivity and sustainability, said Kulaszewicz. The connected enterprise allows true collaboration among plant personnel, but production subsystems, the plant floor, and enterprise IT systems. But first, manufacturers need a smart and secure infrastructure. Tracks and sessions examine the disruptive technologies driving the connected enterprise. Case studies, new technologies, system integration, cloud
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cover story
The HMI of the future will look very familiar

HMI/SCADA applications enable companies to benefit from commercial off-the-shelf technologies adapted for industrial automation to lower costs and improve operations.
Fabio Terezinho
ver since PC-based software was introduced to industrial automation, the once very separate worlds of commercial off-the-shelf (COTS) and industrial technologies have become more aligned. Many readers will remember when PC-based software was first introduced for HMI/ SCADA systems in the mid-1980s. At the time, there were concerns with reliability and speed of response, but PC-based software is now the de facto standard when it comes to HMI packages, both for operator interface and SCADA applications. HMI applications now routinely run on both
Table 1:
SCADA for COTS technologies improves operations: n SCADA systems accessed by smart phones and tablets provide faster and less expensive remote access. n SCADA systems for multi-touch screens are intuitive for both younger and mature workers. n Multi-touch commands can be executed three times faster than keystrokes and mouse clicks. n Multi-touch screens are better suited to harsh environments. n Cloud-based HMI/SCADA drastically reduces costs associated with purchasing and maintaining hardware and software for data storage and access. n Cloud providers are expert at implementing the latest security measures. n Multiple Internet providers and diverse server locations protect access to data in cloud-based HMI/SCADA.
office-grade and industrial PCs, and the software used to program these applications is also PC-based. At the same time, SCADA technologies are advancing to enable manufacturers to reduce costs through the use of COTS applications (see Table 1). The word influence is important because industrial automation devices are not and will not be duplicates of COTS devices. An industrial PC may have the look and feel as well as some of the underlying technology of a COTS PC, but its also designed to withstand the demands of harsh environments, and often also includes other features to increase reliability such as solid-state data storage. Just as desktops were replaced with laptops in many instances, laptops are now being replaced by tablets and smartphones with multi-touch technologies. This trend is also moving into industrial settings. In addition to the way we access HMI systems, the way data is manipulated and stored is being transformed by SCADA technologies for devices first developed for personal use. Corporations are recognizing and reacting to these trends. A recent study by the Gartner research firm predicts that about half of the
Figure 1: Todays SCADA packages enable workers to monitor and control remote areas on tablets and smartphones. All photos courtesy: InduSoft
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Figure 2: Cloud-based HMI moves the expense of IT hardware, software, and management to cloud providers, while providing easier data access and better security.
worlds companies will enact BYOD (bring your own device) programs by 2017 and will no longer provide computing devices to employees. The implication is clear: employees will be expected to use their own smartphones and tablets to access corporate computing systems, a move driven by both cost-saving potential for companies, and greater ease-of-use and mobility for their employees.
Faster, less expensive ways to access data
Smartphones and tablets are great products for todays more mobile workforce as many employees are being asked to monitor and control multiple local and remote sites, often from home offices or while on the road. These workers need quick and easy remote access to HMI systems in order to make more informed decisions away from the control room, and what better way than to utilize devices that they are already intimately familiar with through everyday use. One of the factors powering this movement is SCADA software that enables users to access automation systems as easily on their smartphones in the field as they do in the plant. Authorized users needing remote real-time access can be supplied with either read-only or two-way access, depending on their specific duties and responsibilities. From handheld devices, users typically access web-based HMI systems via a secure browser or an app. The server-browser option almost always comes standard with a web-based HMI package. Many HMI/SCADA software packages also provide a type of server-mobile phone app for free or at a very low cost. As with SCADA server-browser platforms, remote users benefit from full-featured two-way communication. As compared to a browser, these SCADA apps connect more quickly to remote systems, load screens faster, and provide more rapid response times (see Figure 1).
Both browser and app access are much less expensive than providing access via a thin client or a PC connected to the corporate network, particularly if the company has adopted a BYOD policy. In addition, browser-based access doesnt require any software to be loaded onto the mobile device, and app access only requires the user to load a simple app. This frees corporate IT from the task of supporting these devices, and further reductions in required support can be realized by adopting another COTS technology: cloud-based computing.
More affordable data storage
Key concepts
Consumer electronics conventions are driving industrial users to adopt new approaches. Changing demographics of operators are driving companies to explore more modern HMI technologies. Older technologies require additional training costs for younger operators.
Once the domain of storing photos and music files, the cloud is now being employed as a repository for corporate data and software. But what exactly is the cloud? Cloud computing provides 24/7 network access to a shared pool of configurable computing resources: networks, servers, applications, services, and storage. These resources can be quickly deployed and accessed with minimal effort on the part of the user. Most current cloud-based SCADA systems are configured with a local SCADA application running on a PC installed at the site, and with this PC connected to the controllers. The local PC is then connected to the cloud, sending data to the cloud where its stored and distributed, and receiving commands from the cloud as required (see Figure 2). HMI/SCADA systems inherently generate tremendous amounts of data, and this data must be available for access by many users located in disparate and often widely distributed locations. Many of these users also need to be able to issue commands to HMI systems. This requirement for reliable and high-speed two-way wire and wireless access is an area where the cloud shines, as it has been applied to commercial applications with these requirements for many years. Moving to a cloud-based HMI can significantly lower costs and enhance functionality.
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cover story
Figure 3: SCADA systems that can be accessed via multitouch screens are better designed for use in harsh areas than the alternative operator interface methods such as keyboards and pointing devices.
Users can easily view data via smartphones and tablet computers. They also receive alerts via SMS text messages and e-mail. Cloud computing also basically eliminates the high cost and problems of the hardware layer of IT infrastructure. This new paradigm offers dynamic and affordable scalability, with potentially huge savings. Companies dont need to spend money on software licenses, redundant hardware, and disaster recovery sites that may never be used. The cloud also lets companies quickly add new resources on demand only when they are needed, instead of designing systems upfront with excess capacity. Until recently, data storage was a large required corporate expense as data often needed to be saved on separate servers housed in different geographical locations to provide secure backup, and IT staff were required to maintain and help provide access to the data. By contrast, cloud-based computing provides easy data archiving on a pay-as-you-go model by which users usually only pay for the amount of storage needed, with the cloud company providing all required backups and maintenance.
Is the cloud safe?
In many companies, shrinking budgets have dramatically reduced IT staff and resources, and remaining IT personnel often dont have the time or the expertise to keep current with constantly evolving potential threats. On the other hand, cloud providers specialize in providing secure access to applications along with carefully protected data storage. Their people are trained continually on how to protect their systems from internal and external security threats, and cloud providers can afford the required IT staff because they spread their costs among many customers. Many companies rely on a single Internet provider, but this means that if Internet service goes down, then access to control and monitoring functions is lost. The cloud instead uses multiple providers to ensure uptime, with data stored on more servers in diverse locations to ensure secure backup in the event of a catastrophe. The latest SCADA applications are changing the way automation systems are deployed and accessed in industrial settings. Along with being able to access systems using COTS devices such as smartphones, tablets, and cloud-based computing, SCADA packages also provide users with the choice to use another popular COTS technology known as multi-touch.
Benefits of multi-touch
When the Internet is mentioned in the context of an industrial automation application such as HMI/SCADA, one of the first concerns involves security. As with any system, theres always some chance of a security breach, but cloudbased SCADA often provides better protection than similar systems managed internally.
When COTS technologies migrate to industrial automation such as cloud computing, its typical to feel some skepticism. Will the new technology be secure and reliable enough for industrial applications? Can it withstand the rigors of a dirty, noisy industrial manufacturing or distribution site? Will the cost-benefit ratio result in a positive ROI? Combining SCADA for multi-touch applications along with the industrial hardware designed for harsh environments, users are now benefitting from these technical advances. Multi-touch HMI works through a system of touches and finger movements called gestures, very similar to the zoom, pan, and pinch gestures used to navigate smartphone and tablet screens (see Figure 3). Gestures are very intuitive and enable much faster execution times. On average, a multi-touch command can be executed three times faster than the same command performed by keystrokes and mouse clicks. This allows operators to respond much faster to alarms and changes, and also frees up time to analyze and improve operations. Another advantage of multi-touch HMI is enhanced safety as advanced touchscreens enable operation by gloved hands. Multi-touch HMI can also be programmed so that critical safety-related actions require two-handed operation. Multi-touch technology is usually a better choice for harsh environments than keyboards
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and pointing devices. No moving parts are exposed to dust, water, and other contaminates, prolonging the equipments life span. Protecting keyboards and pointing devices in hazardous areas, such as Zone 1 or 2, is possible, but typically very expensive. Multi-touch HMI screens can also be supplied with a protective overlay of glass or polycarbonate to safeguard them from splashes, dirt, and extreme temperatures.
Helping to fill a gap
One of the biggest issues for todays manufacturers is the need to hire and train new automation professionals and operators as baby-boomer employees retire. Inevitably, most of these new workers will be from generations very familiar with smartphones, tablets, and multi-touch. In fact, asking these workers to use keyboards and pointing devices instead of multi-touch would be akin to asking them to operate a TV without a remote. Multi-touch techniques for SCADA applications reduce the amount of training required to get these new automation professionals and operators up to speed. Moreover, since the method for accessing the system is so similar to the way they use their smartphones and tablets, more instruction can be focused on understanding and analyzing data, rather than how to access it. Soon it will be difficult to train new operators who have only used multi-touch screens to use older keystrokes and pointing methods, resulting in increased training time and expense. In speaking with end users and system integrators, an interesting phenomenon is also occurring: mature workers in larger than expected numbers also prefer multi-touch technologies. The same is often true for cloud-based access to HMI/SCADA systems through smartphones and tablets. Waiting for IT to load an application onto a desktop PC, and depending on IT to keep the network up and running, isnt an attractive option for many. Much preferred is browserbased access via their own device or, better yet, app access which provides many advantages in both consumer and industrial applications. Most employees of manufacturing firms use their smartphones and tablets to access e-mail, the web, and key data sources such as their bank accounts from virtually anywhere via a few simple touch commands. Consequently, they will expect this type of functionality in their work lives. Companies that dont update their systems with the software required for this type of access run the risk of looking antiquated to their employees, incurring high costs and foregoing
The future is already here
important benefits. The latest SCADA technologies dont just satisfy employees desires; they also provide faster access to more data, which improves overall operations. For example, data mining has become very important in this information age, and cloud-based HMI systems are built to effectively manage large amounts of data. The ability to access and respond to data in more intuitive ways is already improving the safety and efficiency of manufacturing operations. Graphical interfaces have made it easier to view and analyze data, and multi-touch SCADA technologies and access via handheld devices are increasing those capabilities. Multi-touch and cloud computing for SCADA are the newest developments that enable COTS technologies to be used in industrial settings, but they wont be the last. Computer, smartphone, and other consumer electronics manufacturers are continually developing more intuitive ways to use their products. Many are working on using eye movements and other revolutionary methods for navigation, as well as adding new functionalities such as wearable 3D viewing devices. HMI/SCADA applications will inevitably be at the forefront for allowing new technologies to be adapted for industrial environments. While most manufacturers wont immediately adopt all these new technologiestablets, smartphones, multi-touch screens, and cloud computingmost are already using some, with more being adopted on a continuing basis. Now that SCADA packages offer an affordable and reliable way for industrial companies to use these devices for accessing automation systems, they will eventually become as common as desktops once were. Laggards will run the risk of being overshadowed by competitors who are increasing profits through efficiency gains and cost cutting provided by these technologies. ce Fabio Terezinho is vice president of consulting services for InduSoft.
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Read this story online at www.controleng.com to see a video demonstration of a multitouch HMI application from Honeywell Process Solutions.
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n For more information, visit: n www.indusoft.com n Read this article online to see a video demonstration of multi-touch for industrial use n Subscribe to Information Control eNewsletter at www. controleng.com/newsletters
energy management
Reducing peak demand as electrical consumption patterns change

Proliferation of electric vehicles and other rechargeable devices can create new peak demand patterns. Planning and renewable sources can mitigate the effects.
Ray Strods
t seems with all the emphasis placed on energy efficiency these days, most of the attention is given to reducing energy usage and little mindshare seems to be given to managing and reducing power demand, which can be just as costly. Believe it or not, a recent study by the EV Project shows that for commercial and industrial facilities, the aver-
Adding new electrical demands that are time-specific can change demand patterns. All diagrams courtesy: Siemens
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age cost of peak power is roughly $10 per kW per month. This may not seem like a lot, but for a commercial or industrial facility, this can easily add up to charges in the tens of thousands of dollars a year, and in some areas can be up to 70% of the total electric utility bill. The reason this cost is so high is that utilities need to ensure there is enough distribution and generation capacity to meet this need. If there is not enough distribution infrastructure, the utility has to build new power lines and install new transformers, all of which have large capital costs. If there is not enough generation capacity, the utility needs to bring online less efficient power generation equipmentusually simple cycle natural gas peaker plantsthat are more expensive to operate. One emerging technology that is already having a large effect on peak demand is electric vehicles. An average electric passenger vehicle has an onboard charger around 6.6 kW while certain specialty cars can have upwards of 10 and 20 kW chargers. If you have a fleet of these cars, the peak demand from charging these can add up quickly. A facility for a shipping and logistics company recently found that trying to add 50 electric vehicles would cause the peak demand of
the building to rise from 100 kW to over 430 kW if all the cars were charging at once! The drastic increase in peak demand would not only cause the facilitys utility bill to rise, but the utility was also going to charge the facility to upgrade the transformer that was servicing its building at a price of over $100,000. This problem doesnt apply only to passenger vehicles. Many facilities are also exploring the conversion of fork truck equipment from propane to electric, and this can have a similar impact. There are solutions to this problem, or any peak demand problem for that matter, that range from using old approaches like timers to more advanced technologies like PLCs (programmable logic controllers) that shift the load to other locations or control how many devices can be on at one time. Other approaches increase the energy available by adding renewable capacity such as a solar photovoltaic system.
Spreading out demand
If the charging setup is not too complicated, adding a timer to delay starting the charger(s) can be an effective solution.
Load control and shifting approaches for vehicle chargers can follow several basic strategies: 1. Charging stations with integrated delay featuresA common utility billing pattern is to have a time-of-use rate that favors using electricity in the evening. Most businesses tend to have the highest demand peak in the middle of the day. Unfortunately, most businesses and factories are closed during the evenings and cars are plugged in as soon as people head home for the day around 5:00 p.m., before the lower rates take effect. This can create a peak around this time that eventually can end up costing those paying the bills extra money. If the extent of the situation isnt too large, a simple solution can be adding a delay feature to the charging stations. This allows users to delay the charger going on until the time that lower rates come into effect. 2. Set up a time-based cycling program using a PLCWhile charging stations with integrated delay features are usually an inexpensive solution, there is room for error in any situation where human intervention is required. If a user has to know to set a start time, it will be necessary to educate all those EV users on how to work around those demand charges, and unfortunately this information doesnt always stick. Also, if everyone delays at one time for the same duration, we still create the peak, its just shifted to a better time. This is where automation can come to the rescue. By using a simple discrete automation controller we can cycle the charging stations so that only a set number of chargers are operating at once. 3. Integrate a power meter with demand capabilities into the PLCEven after integrating a cycling program, we might still not be able verify that our peak demand is indeed lowered or by how much. What if our buildings demand fluc-
Adding some intelligence to the system in the form of a PLC can control when individual chargers operate, reducing total demand.
tuates frequently and we want to better match the charging process to fill in the valleys, so to speak? This is where we take it to the next level and integrate some inexpensive power monitoring equipment. Now we can automate the charging process so that peak demand never crosses a certain threshold. We can also maximize the amount of time the vehicles are actually charging by making sure charging stations are not unnecessarily turned off like the previous model.
Using renewable sources
Individual controllers on each charger can monitor consumption for each device, and help optimize use and charging patterns.
While the solutions discussed so far spread out consumption, they dont do anything to
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energy management
increase available power. As alternative generating technologies evolve, such as photovoltaic (PV) cells, they have become more practical and cost effective for smaller deployments. Solar PV installations convert sunlight energy directly into electricity. Such an installation can provide two
benefits to a facility. First, it can generate electricity that translates into lower energy usage from the utility and a lower energy bill. The second and less discussed benefit is the ability to reduce peak demand. Solar PV systems are usually rated at peak power output with a common small commercial or
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industrial system in the 100 kW range. Since power output is determined by sunlight strength, the system cannot normally be depended on to put out that rated power at all hours of the day, but it can put out power consistently. Even when solar systems are shaded by clouds, many systems still put out some power, albeit at a much a lower level. So if we take our hypothetical 100 kW solar system and assume 25% of it will be effective in reducing peak demand, we have a reduction in demand of 25 kW, which can equate to $3,000 per year. In certain situations, you need much higher than 25% certainty that the PV system will be able to offset the peak demand. If that is the case, you should consider looking into PV systems that combine some form of storage, often battery based, with a traditional solar inverter. In this situation, the solar inverter can pull power from the battery bank whenever the sun isnt shining and still keep your overall building demand low. While storage can pose an added cost, you will probably not need the capacity to go completely off grid, so the cost might not be as large as you think. This requires a control system that is a bit more complex but if your peak demand situation is difficult to overcome by other means, this can be a useful tool to minimize the most expensive peaks. Hopefully this introduction gave you some insight into the cost of peak demand and just how easy it can be to use some old technologies to limit peak demand of new technologies, and how to use new technologies to solve this very old problem. ce Ray Strods is product manager, renewable energy products, for Siemens infrastructure & cities low and medium voltage division. Reach him at microsolar.industry@siemens.com
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2 014 S Y S T E M I N T EG R ATO R O F T H E Y E A R C A L L F O R E N T R I E S
ARE DUE AUGUST 1,
ENTRIES
2013
System Integrator of the Year Awards

Who should enter?
If youre part of a contract engineering rm or an engineering division of a larger company that can design and implement computerized control systems for industrial machinery, manufacturing lines, or other automated facilities that produce either a commodity or a nished product, Control Engineering urges you to enter its 2014 System Integrator of the Year competition. The chosen System Integrator of the Year winner will receive worldwide recognition from Control Engineering. The winner also will be featured as the cover story of the 2014 Automation Integrator Guide, distributed in December 2013.
Control Engineerings annual
Dont miss your chance to enter. Entries must be received by Aug. 1, 2013. Questions? Contact Vance VanDoren, System Integration contributing content specialist for Control Engineering : controleng@msn.com (765) 296-7600
Whats in it for the winner?
How will the competition be judged?

Control Engineerings panel of judges will conscientiously evaluate all entries. Three general criteria will be considered for the selection of Control Engineerings System Integrator of the Year:
Business skills Technical competence Customer satisfaction
Tell us how you measure up in these three areas. Get the application at www.controleng.com/SIY
automation distributors
Service offerings expand from automation distributors

Todays distributors offer more than warehouses full of the latest gadgets, providing a diversity of services to ease buying, installation, start-up, and more.
Vance VanDoren, PhD, PE
D
W
istributors in the industrial automation industry have traditionally stocked their warehouses with all the latest technology from the vendors they represent so as to facilitate sales to local clients. With exclusive territories delineated by their vendor partners, distributors have prospered by charging a markup on every product sold nearby. This business model, born in the last century, still helps clients obtain hardware, software, and replacement parts on short notice.
Critics argue that the advent of Internet storefronts and improvements in shipping and logistics make the local-warehouse function obsolete. A distributor that adds no other value to a clients automation projects simply drives up the cost. So in recent years, some automation distributors have been making an effort to earn their keep in other ways that enhance the products they sell or improve their clients purchasing experience. See the Distributor evolution graphic. The Association for High Technology
Automation distributor types: Logistics vs. projects

Frank Hurtte hat we have observed is an evolutionary
split in distributor services. One type of distributor became an expert in the logistics of the moving parts and providing just what the customer wants without heavy investment in technical services. These distributors provide the same products but work to make the transaction side of buying easier. They have invested in websites, automated part number selection schemes, and industrial vending machines (over 21,000 installed in 2012). Examples include Grainger, MSC, Fastenal, and AutomationDirect. They have no local level expertise (except phone support) and depend on customers knowing precisely what they want and offering a lower price point for the product. The other branch of the distributor evolution contains distributors who have opted for a more hands-on selling approach. They are serving customers by assisting in selection of products,
maintaining the products, and pushing forward things like drive start-ups, programming assistance, architecture layout, troubleshooting, and in some instances, project work. These distributors have developed services like training, control architecture design, and communications layouts, which often exceed others in the market. Why? They are forced to learn about new technologies ahead of engineering firms and systems integrators because they play the role of trainers to that group as well. Further, distributors often find themselves on the front lines of proving things work. A customer calls and says, the DeviceNet connection doesnt work like you promised. The distributor then goes out and troubleshoots to prove the system works, often discovering undocumented issues along the way. - Frank Hurtte is the founder of distributor River Heights Consulting. www.riverheightsconsulting.com
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Distribution (AHTD) now recognizes a class of members known as Automation Solution Providers (ASP) that sell technology-based industrial automation products, and Knowledge Design and application engineering Support services Integrated solutions Value-added services. These services include programming, customer training, demonstration rooms and equipment, post-order product service and warranty support, and start-up assistance.
Not just product sales
Brian Fisher, president and CEO of Pacific Technical Products, sees his ASP firm as something of a cross between a traditional distributor and a system integrator, though we actually put in a lot more up-front time during the design phase of the project to help select the right product for the application, and then we end up reviewing everything with the customer once the detailed product list is complete. Doing so reduces the chance of a mismatch between the capabilities of the products purchased and the requirements of the project at
hand. Products typically fail where theyre misapplied, said Fisher, and it is an ASPs job to prevent those failures much the same way a pharmacist prevents medical failures that could result from the misapplication of a prescription drug. Rick Gehring, president and CEO of ASP Applied Controls, elaborated: We help manufacturers and machine builders design and implement technology solutions to reduce costs throughout their processes and protect their automation investments for the long run. He cited some of the challenges that an ASP can help clients address: Maintenance demands from complex control schemes and constantly changing software Difficulty lowering lifecycle costs and generating expected returns Complying with changing regulatory and safety concerns Rising costs due to rapidly evolving technologies Reducing and managing energy consumption. Some ASPs and ASP-like distributors have moved even further into the design and installation fields that traditionally have been the pur-
Key concepts
Distributors can go beyond offering the latest technologies to provide buying, installation, startup, and other services. Automation distributor services build on each other Integrators and distributors can work together
Distributor Evolution
Logistics provider
Vending machines
Automation expertise
Services provided
Internet supplier Integrated supply Supply Contracts JIT shipping Credit Inventory Amalgamate orders Product selling Value add selling
Automation solution provider
Technical specialist
1954
1984
1994
2004
Some distributors specialize in making the transaction easier; others have a more hands-on approach to selling. Courtesy: River Heights Consulting, Control Engineering
www.controleng.com
automation distributors
view of automation system integratorslevel five of the Automation distributor hierarchy. For example, Zeller Technologies is one of the few distributors in the nation that provides a full range of services as well as parts, said Zellers automation controls manager, Tom Rudloff. We do high-level automation system engineering, installation, and start-up, along with field service troubleshooting on any system in industry. Our techs have been in almost every type of manufacturing process out there, Rudloff explained.
Conflict with system integrators
Automation distributor services

The services provided by modern automation distributors can be arranged in a hierarchy where each level builds on the levels below. Higher levels also involve more technical skills and greater involvement with a clients automation projects. 1. No fee-based services. Customer technical needs other than manuals and front line questions are pushed to manufacturers. 2. Limited fee-based services, typically centered on classroom training and custom modifications of product 3. Classroom training, one-on-one engineering assistance, drive start-up, system wide layouts 4. Training, troubleshooting, start-up, and product specific programming; piecemeal project integration 5. Training, troubleshooting, start-ups, complete project integration
These expanded service offerings can be a mixed blessing, especially when a distributor counts both end users and system integrators as clients. End users no doubt appreciate the additional technical services that a distributor can bring to bear on their automation projects, but system integrators often see those services as a competitive threat. Unfortunately, system integrators must still buy products from their designated distributor to incorporate into their own automation projects, leaving them in the awkward position of patronizing their competition. One conflicted integrator voiced his concerns rhetorically in a post to the discussion list of the Control System Integrators Association (CSIA): For the distributors that have internal SI capability:
Automation Solution Providers also sell knowledge, design and application engineering, support services, integrated solutions, and value-added services.
How do you attempt to manage the inherent conflict when bidding against your SI customer for SI services? How do you handle hardware and software pricing on projects that are bid against SI customers? Why do you maintain an SI capability that competes with your SI customers? Why should I buy anything whatsoever from a competitor? Judging from the number of distributors getting into the system integration business, these competitive conflicts are likely to become even more common. See the Distributors offering system integration services chart.
Cooperation, support
Integrated services Solutions provider Knowledge-based
Advanced value-add
Traditional/logistics
Distributors can offer a range of assistance from traditional logistics through integrated services. Courtesy: River Heights Consulting, Control Engineering
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On the other hand, many system integrators and distributors enjoy a mutually beneficial relationship. See the sidebar, Integrators and distributors can work together. And according to Viktor Tadjer, general manager of Kibernetika & Co. OOD, distributors today really cant afford to stay out of the system integration business entirely. I find it very rare when we have sold a PLC or some HMI device without any addi-
tional engineering. My opinion is that distributors of control systems equipment should have at least average skills for integrating and/or commissioning the equipment they sell. Otherwise, many problems arise because of expensive errors in specifications and the resulting deliveries, Tadjer said. Some distributors recognize this need and still find ways to cooperate with their system integrator clients. With our overlapping role as a products distributor and small integration service provider, said Brenden Fritz, president of Automated Drive Systems, we focus on distribution and integration of small machine level systems that typically are smaller than a large integration companys focus. Laurie Hall, president of Martindale Associates, takes a similar approach. We can help with the installation for clients if the project is small, but for a project over $5K thats very custom, or one that will take several weeks or months, we typically call in a large integrator, said Hall. Cooperative competition also affects the relationships that system integrators have with the vendors that their distributors represent. See System integrators partner with automation suppliers, Control Engineering, December 2012. ce - Vance VanDoren, PhD, PE, is contributing content specialist for Control Engineering. Reach him at ControlEng@msn.com. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.
Integrators and distributors can work together

Todd Carswell
aintaining a good relationship with our main distributor has been an integral part of our success. Twenty years ago we
looked to our distributors to carry a parts inventory and that was all. Because of this attitude, a lot of big distributors (and even some smaller ones) in the 1990s moved to centralized warehouses with very little local inventory. Some closed down their supply house and opened a sales office only. Others cut back on their technical staff as well, relying on the manufacturers to supply technical support. Today, some of the distributors still have this mind-set. Ours has gone the other direction, and because of this, they receive the bulk of our electrical purchases. On the inventory side, theyve raised supply house inventory to meet our demands and manage and run our inventory here. This saves us a tremendous amount of time. We also look to them for our technical needs. The local branch has specialists for variable frequency drives (VFDs), programmable logic controllers (PLCs), human-machine interfaces (HMIs), and other areas. These people help with design questions and service questions and set up training sessions, at their shops and at ours. - Todd Carswell is vice president of technical services at system integrator Vecoplan LLC. www.vecoplanllc.com
Distributors offering system integration services

As a percentage of all integrators founded in the same period excluding integrators less than 2 years old
20% 18%
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www.ahtd.org www.appliedc.com www.automateddrives.com www.controlsys.org www.kibernetika-bg.com www.martindaleassoc.com www.ptpcorp.com www.zellertechnologies.com At www.controleng.com/archive, December 2012, read: System integrators partner with automation suppliers. July 2013, get an automation vendors perspective: Customer demands push distributors past products.
16% 14% 12% 10% 8% 6% 4% 2% 0% 19771981 19821986 19871991 19921996 19972001 20022006 20072011
Year founded
Courtesy: Control Engineering Automation Integrator Guide
Consider this...
Are you getting what you need from your distributors? If not, why not?
The number of distributors getting into the system integration business has been on the rise in recent years, as indicated by the percentage of system integrators that also offer distribution services. Courtesy: Control Engineering Automation Integrator Guide
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inside process
Make the right choice, RTD vs.TC

When you need a temperature measurement, one of the most basic decisions is choosing which kind of sensor to deploy. The application should guide your decision.
Ashleigh Hayes
Temperature sensors:
Key concepts
Measuring temperature is a basic requirement in virtually any process manufacturing environment. Two sensor technologies support the majority of installations. Selecting between the two main approaches depends on specific process requirements and conditions.
emperature variances in process industries can have significant impact on profits, safety, and quality. A variety of industries and applications are affected, including oil and gas, power, refining, petrochemical, pharmaceutical, and more. Monitoring temperature accurately is dependent upon several factors, including selecting the right sensor for the specific application and process. Two of the most common temperature measurement devices are resistance temperature detectors (RTDs) and thermocouples (TCs). The technology behind them is different, each having its own benefits that drive appropriate selection. An RTD uses the principle that the electrical resistance of a metal increases as temperature increasesa phenomenon known as thermal resistivity.
In comparison, a TC is a closed-circuit thermoelectric temperature sensing device consisting of two wires of dissimilar metals joined at both ends. A voltage is created when the temperature at one end of a wire or junction differs from the temperature at the other end. This phenomenon is known as the Seebeck effect. That voltage depends on the particular metal as well as the temperature difference. Comparing the different voltages created by the different metals is the basis for TC temperature measurements.
Comparing the differences
RTDs are constructed of a resistive material with leads attached and usually placed into a protective sheath. The resistive material may be platinum, copper, or nickel; the most common is platinum because of its high accuracy, excellent repeatability, and exceptional linearity over
There is no single answer that works in every situation. There are tradeoffs in performance characteristics that need to be considered carefully when making a selection. Diagrams courtesy: Emerson Process Management.
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a wide range. It exhibits a large resistance change per degree of temperature change. The two most common RTD sensor styles are wire-wound and thin-film. Wire-wound RTDs are manufactured either by winding resistive wire around a ceramic mandrel or by winding it in a helical shape supported in a ceramic sheathhence the name wire-wound. For thin-film RTDs, a thin resistive coating is deposited on a flat (usually rectangular) ceramic substrate. Thin-film RTDs are typically less expensive than wire-wound RTDs because fewer materials are needed for their construction. Normally, RTDs are much more repeatable and have better sensitivity than TCs. Long-term drift of an RTD is predictable, while a TC drift is often erratic. This provides the benefit of less frequent calibration and therefore lower cost of ownership. Finally, RTDs provide excellent linearity. When coupled with the linearization performed in a quality transmitter, a precision of about 0.1 C is possible, which is much better than what is possible with a TC. In comparison, a TC is a closed-circuit thermoelectric temperature sensing device consisting of two wires of dissimilar metals joined at both ends. Various combinations of metals are classified as types and have specific characteristics. The most common types are J (which uses iron and Constantan) and K (which uses Chromel and Alumel). TCs have faster response times and higher temperature ranges than RTDs, but are also less accurate. TCs have heavy gauge wire construction for durability and therefore can withstand high vibration (see Figure 1). Chart A compares key sensor characteristics.
Choosing the right sensor technology
1. What temperature range you are trying to measure? When selecting a sensor, it is important to determine the correct temperature range. If the temperature is above 850 C, you must use a TC. If it is below 850 C, you can select either an RTD or a TC. Also, keep in mind that wire-wound RTDs have a wider temperature range than thin-film RTDs (see Chart B). 2. What is your required sensor accuracy? Determining the level of accuracy needed is also an important factor in the selection process. In general, RTDs are more accurate than TCs, and wire-wound RTDs are more accurate than thin-film RTDs. Assuming there are no other factors driving the selection of one technology over the other, this guideline will help you find the most accurate sensor technology. 3. Is process vibration a concern? The amount of process vibration also needs to be considered when selecting a sensor. TCs have the highest vibration resistance of all of the sen-
The stainless steel probe of a temperature sensor can look the same, so you have to know whats inside..
When choosing the right sensor for your process and application, there are a few basic questions that you should ask. The answers will provide valuable insight for selecting the appropriate sensor.
Thermcouples come in a variety of types determined by the combination of wire types. Most types have a higher temperature limit than an RTD.
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inside process
sor technologies. If you have a known high vibration, TCs will give you the highest reliability. Thin-film RTDs are also resistant to vibration; however, they are not as robust. Wire-wound RTDs should not be used in high-vibration environments.
The right choice brings the right results
The overall key to success is asking basic questions and matching up the information with the right sensor for your applications and process. An example would be adding a tempera-
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ture measurement to a pipeline where the measurement is under varying conditions with constant vibration and a process temperature variance of 200 to 300 C. The goal is to have the best possible accuracy despite these challenges. To determine what type of sensor to use, first consider the differences between TCs and RTDs. The temperature range makes both sensor technologies feasible for this application. TCs are known for their higher vibration tolerance, so at a first glance TCs would appear to be a good option. However, in this specific instance the measurement requires the best possi-
L L VE EVE LE CE L A F R INTE DENSITY TEM PER ATU VO RE LU ME
The overall key to success is asking basic questions and matching up the information with the right sensor for your applications and process.
ble accuracy. The right choice for this application would be a thin-film RTD. Thin-film RTDs are known for their higher tolerance to vibration than wirewound RTDs, and will provide a higher accuracy than a TC. A second example would be the temperature in a reactor that ranges between 550 and 900 C with little vibration. The goal is to gain accuracy within 5 C. RTDs provide consistent accurate measurements, especially in environments with little vibration. However, dont forget the temperature range. RTDs typically should not be used above 850 C. Since the process temperature can range up to 900 C, a TC would be selected. Sensors are more susceptible to failure and inaccurate measurements when used in improper temperature ranges. That is why it is critical to select the correct sensor. ce Ashley Hayes is a marketing engineer for Emerson Process Management.
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inside process
Diagnosing faults in engineering models

Method of minimal evidence techniques help identify invalid modeling assumption variables.
Richard J. Fickelscherer, PhD, PE, Daniel L. Chester, PhD
ffective model-based control strategy depends on creating an accurate model of the process. Without this most basic capability, the process will not run properly. So when faults arise, it is important to determine if they are actual operational problems or an incorrect modeling assumption. This overview describes a general methodology for creating optimal model-based process fault analyzers. It is called MOME (method of minimal evidence). MOME is a diagnostic strategy based upon the evaluation of engineering models describing normal operation of the target process system with sensor data. This methodology uses the minimum amount of diagnostic evidence necessary to discriminate uniquely between an invalid modeling assumption variable (e.g., an assumption which assumes the absence of a particular process fault situation) and all other valid modeling assumption variables. Moreover, it ensures that the resulting fault analyzer will always perform competently and optimizes the diagnostic sensitivity and resolution of its diagnoses. Diagnostic knowledge bases created with this methodology are also conducive for diagnosing many multiple fault situations, for determining the strategic placement of process sensors to facilitate fault analysis, and for determining the shrewd distribution of fault analyzers within large processing plants. It has been demonstrated to be competent in both an adipic acid plant formerly owned and operated by DuPont in Victoria, Texas, and an electrolytic persulfate plant owned and operated by FMC in Tonawanda, New York. A simplified schematic of the two FMC processes (ESP - sodium persulfate and LAP - ammonium persulfate) is illustrated in Figure 1. Effective operation of these persulfate processes requires extremely strict control of the solution chemistry. Maintaining tight windows
of the strengths and pH across all the various cation and anion species throughout is thus critical. This in turn requires highly accurate and reliable measurements of these variables and methods for verifying those accuracies. Consequently, automated model-based process fault analysis provides a useful tool for guaranteeing which of these measurements are currently correct and immediately flagging those which are not. This automated detection and alerting capability allows FMC to operate its DCSs in full auto-pilot mode more frequently. While MOME can be set up using a homegrown system, it has been converted into a patented fuzzy logic reasoning algorithm and is now fully automated in a program called FALCONEER IV. Once this platform became available, FMC found that converting its original hand-compiled FMC ESP fault analyzer into the format necessary for automatically generating the diagnostic logic required only coding the existing 30 primary models and performance equations describing that process. Creating, coding, and analyzing more than 30 primary models and five performance equations for the FMC LAP process required approximately two personweeks of effort in order to derive a fully functional and validated process fault analyzer. FMC has independently documented some of the benefits derived from these two applications. All FALCONEER IV applications can diagnose all single fault situations at all possible levels of diagnostic resolution and all non-interactive and also almost all possible pairs of interactive multiple fault situations.
MOME diagnostic strategy
Key concepts
An effective model-based process control strategy depends on having an effective process model. Analyzing faults to the root cause is using this analysis strategy can yield a more reliable result with less information required. Additional information on this technique is available online.
Model-based reasoning is a highly systematic and powerful means for deriving plausible hypotheses as to the causes of abnormal process behavior. The first step in developing competent model-based fault analyzers is to derive a set of as many linearly independent models of normal process operation as possible. These should accurately describe the behavior of the target process
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inside process
Learn more on the basics of model-based control
odel-based control is one of the main approaches for a larger advanced process control (APC) strategy. Plant operators turn to this in situations where conventional regulatory control might not run a process optimally. For example, where a process runs erratically, its difficult to run close to the upper limit in an effort to maximize production without breaking through the limit. When the line is more stable, its possible to run closer to the edge. Building a process model begins with understanding and quantifying what is actually happening to the feedstocks as they are turned into final products. This includes chemical reactions, energy balance, reaction times, and so on. As this story discusses, if there are problems keeping the process under control while running model-based control, it is important to determine if there is a problem with the process itself, or if one of the assumptions of the model is incorrect. If you want to know more about APC in general, here are articles you can find at www. controleng.com/archives that can help you understand the concepts better:
Do-it-yourself model-based control, March 2013 Advanced process control in electric utilities: How model-based control can optimize overall steam cycle and burner management, March 2012 Controlling Diesel hydrotreaters: How APC solved a chronic and burdensome operating problem on a Diesel hydrotreater, January 2010 Driving plant optimization with APC, November 2009
system during its malfunction-free (i.e., normal) operation. These models include the normal operating characteristics of the process system components, the functional relationships between those components, the process control strategy, and the underlying fundamental conservation, thermodynamic, and physio-chemical principles. The set of modeling assumptions required to derive these models defines the domain in which they predict normal process behavior. The diagnostic evidence generated by evaluating these models with actual process data is then compared with the expected patterns of the model behavior during various possible fault situations, i.e., the SV&PFA (sensor validation and proactive fault analysis) diagnostic rules, which can logically discriminate between the various possible process operating events within the fault analyzers intended scope. The specific patterns of diagnostic evidence used for this discrimination depend entirely upon the specific model-based diagnostic strategy actually employed. Model-based fault analyzers in a nutshell are thus computer programs that determine which of their SV&PFA diagnostic rules most closely match currently observed process behavior.
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inside process
Trading lower diagnostic resolution for higher diagnostic sensitivity allows the fault analyzer to narrow down the potential process faults that could be occurring currently into a reasonable number of plausible explanations.
Their understanding of process fault situations is thus completely determined by their underlying models of normal operation and the consequent SV&PFA diagnostic rules for identifying those fault situations. However, the SV&PFA diagnostic rules we utilize are automatically generated by our MOME fuzzy logic algorithm compiler and are thus always logically correct. Consequently, since the diagnostic evidence used by those diagnostic rules is determined directly from evaluating its underlying process models, the fault analyzers performance is inherently circumscribed completely by understanding normal process behavior represented within those models.
The main advantage
The MOME diagnostic strategys chief advantage for developing optimal diagnostic rules arises from its choice of patterns of possible satisfied and violated process model residuals used to identify plausible fault hypotheses. Only those models considered relevant for each potential process fault are contained in the associated diagnostic rules. MOME consequently identifies all possible assumption variable deviations
consistent with the current pattern of diagnostic evidence generated by the most recently sampled process sensor data. Perfect resolution between different process fault hypotheses is thus not always possible or is possible only at larger magnitudes of the specified fault (i.e., at a magnitude sufficient enough to violate all so affected relevant model residuals). This is the classic trade-off between timely fault detection and correctly identifying the underlying fault(s). Trading lower diagnostic resolution for higher diagnostic sensitivity allows the fault analyzer to narrow down the potential process faults that could be occurring currently into a reasonable number of plausible explanations for the current process state that can then be further checked out by the process operator to determine the actual fault present. This directly flags potential incipient fault situations sooner rather than waiting until the faults magnitude is severe enough to allow unique classification. This is why the methodology is called the method of minimal evidence: all plausible fault situations are diagnosed whenever even just one of the linearly independent sets model residuals indicates abnormal process operation.
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Logical deductions
MOME employs model-based reasoning to deduce the cause or causes of abnormal process behavior. It does so with the least amount of diagnostic evidence necessary to diagnose the various possible fault situations uniquely. Moreover, the resulting fault analyzer always makes competent diagnoses at the best resolution and highest sensitivity possible for the given magnitude of the fault(s) occurring. A key feature of this method is in the way in which the various patterns of diagnostic evidence are selected. This selection fully utilizes all of the information contained within the available diagnostic evidence, especially the estimates of the fault magnitudes of linear assumption variable deviations inherent in the violated model residuals. The strategy followed in this selection relies upon default reasoning: all but one of the fault hypotheses (if perfect resolution is possible) being supported by some of the diagnostic evidence contained within a given pattern of diagnostic evidence is systematically shown to be implausible by some of the other evidence also contained within that pattern.
Thus, by default, the remaining fault hypothesis is the only plausible explanation of the full pattern of relevant diagnostic evidence. Using default reasoning in this manner allows this diagnostic strategy to base each fault diagnosis upon the least amount of diagnostic evidence necessary for that proper diagnosis. This directly allows many other potential multiple fault situations to be properly diagnosed. The various issues described throughout this treatment and its companion online article are discussed in much greater detail and in Optimal Automated Process Fault Analysis, Richard J. Fickelscherer and Daniel L. Chester, John Wiley & Sons, Inc., 2013. This material is reproduced with permission of John Wiley & Sons, Inc. http://www.wiley.com/WileyCDA/ ce Dr. Richard J. Fickelscherer, PE, is a partner at Falconeer Technologies, LLC, Williamsville, N.Y. Reach him at falconeertech@verizon.com. Dr. Daniel L. Chester is currently the associate chair of the department of computer and information sciences at the University of Delaware. He is also a co-founder of Falconeer Technologies, LLC. Reach him at chester@cis.udel.edu.
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n The online version of this story contains a link to a more detailed discussion including more detail on the supporting techniques and equations. Read it at www. controleng.com n http://falconeertech.com/ n www.wiley.com
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inside process
NASA becomes service provider for private space ventures

After the Space Shuttle program closes, launching systems get a new life with new customers, with new requirements for monitoring services. The tricky side of measuring helium and nitrogen use calls for sophisticated flowmeters.
Jack Sine
ver since the Space Shuttle program was cancelled, NASA and the Kennedy Space Center have been rebranding themselves. While they will continue to build and launch spacecraft for exploration and other government projects, the earlier single-minded focus on the shuttle program has broadened. NASA has now taken its sprawling complex and is essentially leasing space and capabilities to tenants. While those tenants consist mostly of subsets of NASA working in different areas of aerospace, two are private companies: SpaceX and United Launch Alliance. SpaceX designs, manufactures, and launches
advanced rockets and spacecraft. The company was founded in 2002 by Elon Musk of Pay Pal fame to revolutionize space transportation, with the ultimate goal of enabling people to live on other planets. Today, SpaceX is focused on space technology through its Falcon launch vehicles and Dragon spacecraft. SpaceX is the only private company to launch and return spacecraft successfully from low earth orbit. Recently, its Dragon spacecraft attached to the ISS (International Space Station), exchanged cargo payloads, and returned safely to Earth. This technically challenging feat led to a $1.6 billion contract with NASA to fly at least 11 more cargo supply missions to the ISS. In the near future, SpaceX plans to carry crew as well. United Launch Alliance (ULA) is a 50-50 joint venture owned by Lockheed Martin and Boeing. ULA brings together two of the launch industrys most experienced teams from the Atlas and Delta rocket programs. They provide space launch services for the U.S. government, including the Department of Defense, NASA, the National Reconnaissance Office, and others. Atlas and Delta expendable launch vehicles have supported Americas presence in space for more than 50 years, carrying a variety of payloads including weather, telecommunications, and national security satellites that protect and improve life on Earth, as well as deep space and interplanetary exploration missions that further our knowledge of the universe.
The need for metering
Metering stations, like this one for Pad A, are located at strategic points around the facility near to the areas where nitrogen and helium are used for the spacecraft. Courtesy: Flexim
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It used to be that the only customer we had was the shuttle program, says Dan Tierney, sustaining systems engineer for URS Corporation, a contractor working with NASA at the Kenne-
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Kennedy Space Center is on Floridas coast near Cape Canaveral, east of Orlando. The shuttle launch pad was used for Apollo launches. Courtesy: Flexim
dy Space Center. Since we must try to conserve it. Key that was the sole user of Most recently it cost $120 everything that was supper 1,000 cubic feet. We concepts plied, there was no need to want to encourage our cus Repurposing the Space monitor usage. Now that tomers to not overuse it, Shuttle launch facilities has the shuttle program has so everyone is now doing pushed NASA to engage ended and NASA has varaccountability for how with a new group of cusious customers, we need much theyre using. They tomers. to bill each one separately must transfer funds for Products and services for everything we supply commodity use, and they that were not monitored them. For liquids and gasmust rethink how much previously now need to ses that meant that we had theyre using for conservabe measured precisely for to install metering. tion reasons. commercial purposes. For a variety of rea Measuring gas flows at Selecting the right sons, the two most diffihigh pressures presents meter cult flows to measure are challenges found in other areas of process manufacNASA is noted for its gaseous nitrogen and helituring. meticulous attention to um, Tierney adds. Both detail, so when it was time are vital in rocket and spacecraft use. Nitrogen is a propellant to determine what flow metering it needand helium has three uses. The first is ed for its helium and nitrogen piping, removing atmospheric moisture from it teamed Tierney with Michael Katz, clean room facilities. Second, because a mechanical design engineer for URS helium is an extremely small molecule Corporation, and assigned them the job and can find its way through the tiniest of identifying the ideal flowmeter for opening, it is valuable as a leak detec- the job. It had to be capable of measurtor on spacecraft. Third, it is used in high ing the flow of liquid and gaseous helivolumes in launch support. Since helium and nitrogen at extreme pressures um does not freeze upon expansion as through extra-thick XXS pipe. And it most gasses do, it is used as a purge gas had to measure gas flow through piping to sweep out combustible vapors from less than an inch in diameter. First they established the goals of the rocket engines and engine compartments study: in a process called safing. Define primary requirements and The need for metering was also a means to encourage conservation, determine industry manufacturers capaTierny explains. Helium is very expen- bility to meet NASA standards through a sive 10 times the cost of nitrogen. market survey Determine technology types and/or Helium is also a finite commodity, so
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methodologies for flow measurement n Perform technical literature survey to verify applicability and reliability of technology types n Assess through comparative analyses the differences of various technology types n Provide a rough order of magnitude (ROM) cost study of candidate flowmeters under consideration, and n Recommend a flowmeter selection as a fixed-installation for both pipeline transit to launch pads and for the fixed processing facilities. The challenges were considerable. Flowmeters tested would have to provide accurate measurements on a variety of tube and pipe sizes at a wide range of pressures and flow rates. The three sites to be used for testing were the old shuttle launch pad, the helium facility, and the nitrogen facility. All of them had different requirements and provided a range of challenges.
Testing requirements
allowable operating pressure (MAWP) n Measurement accuracy of 1.0% or better n Self-ranging scale for a flow range of 10 - 20,000 standard cubic feet per minute (SCFM) n Capable of measuring high-purity compressed GN2 (2.5 in. pipe) and GHe (1.5 in. pipe) n External meter, clamp-on types must be capable of reading through heavy-wall pipe, schedule XXS n Must support in-place calibration. The study investigated the feasibility of all potential flowmeters, either as pipe insertable or non-intrusive types, based on the ability to meet those criteria.
Selecting the meter
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At LC-39 (the old shuttle launch pad) the meters would be tested on pipelines of gaseous nitrogen (GN2) and gaseous helium (GHe). While the specific conditions around the larger facility differed somewhat, most were outside of typical industrial ranges: n Rated for 6,000 psig maximum
We started our research on the Internet, Katz recalls. Some meters we already had knowledge of, but there are a lot of flowmeters out there. One thing that disqualified many of them was that they couldnt measure flow through thick pipe. And because we move nitrogen and helium at some very high pressures, we use thick pipe. When their research was done, Tierney and Katz invited those that seemed most qualified to perform the measurements described above. The velocity flowmeters assessed by the team included electromagnetic, vortex, swirl, tur-
P11
bine, and ultrasonic. tance on the part of NASA management While many of the meters provid- because of the previous experience with ed acceptable accuracies, operating and ultrasonics. John did presentations for a maintenance costs played a big fac- variety of groups at NASA, mostly mantor, says Tierney. All but one of the agement, engineering, and particularmeter types was intrusive and had to be ly the fluid management department, exposed directly to the flow. That meant says Tierney. They included demonstraan expensive installation. And then there tions with a portable meter that gave his was maintenance. Because the meters claims credibility. were exposed directly to the flow, they NASA then purchased two portable would experience wear. That meant ultrasonic flowmeters and went around that down the road, we would have to testing them on every line that needed shut down, remove the meter, clean or a permanent meter. By taking this extra replace parts, and start step, the team overup again. That added came any remaining While many greatly to the long-term doubt about the ability of the meters cost. The one type of of clamp-on ultrasonic meter left was ultrasonmeters to measure the provided ic, and NASA had some full range of NASAs acceptable bad experience with applications. ultrasonics in the past, accuracies, How ultrasonic so there was a negative metering works mind-set with NASA operating and The technique most management. maintenance ultrasonic flowmeKatz adds, We did ters use is called trana lot of research on all costs played a sit-time difference. It the meters we reviewed. big factor. That exploits the fact that For ultrasonics we only invited one manufacadded greatly to the transmission speed of an ultrasonic signal turer because it was the long-term cost. depends on the flow only one that said on velocity of the carrier its website that it produced accurate measurements on thick- medium, kind of like a fish swimming with or against the current. The signal wall pipe. John Van Norstrand, southeast region- moves more slowly against the flow than al manager for Flexim Americas, knew with it. When taking a measurement, the of the situation. The problem NASA had in its previous encounter with ultra- meter sends ultrasonic pulses through the sonic flowmeters was that they failed medium, one in the flow direction and to accurately measure flow on thick one against it. (The transducers alterwall pipes, he says. Flexim uses both nate as emitters and receivers.) The tranLamb-wave and shear-wave transduc- sit time of the signal going with the flow er technology. Lamb-wave transducers is shorter than the one going against. The create a wide beam of sound by vibrat- meter measures transit-time difference ing at the harmonic of the pipe wall. This and determines the average flow veloccreates a very efficient signal which is ity of the medium. Since ultrasonic signeeded for gas measurement at lower nals propagate through solids, the meter pressures. For gas measurement at very can be mounted directly on the pipe and high pressure where the pipe wall is very measure flow without a penetration, thick, a shear-wave narrow-beam trans- eliminating any need to cut the pipe. ducer is more effective. It is important to offer different transducer designs to Ultrasonic metering installed After we got the approval from cover the variety of flow applications we encounter. Having both transducer types NASA, Flexim worked very well, Tierin our demonstration kit allowed us to ney says. We started with two fixed operate well on all the pipes we encoun- installations: the helium pipeline and nitrogen pipeline at the old shuttle pad tered at NASA. Nonetheless, there was still reluc- known as Launch Complex 39A. It
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inside process
The center is located on an island of more than 200 square miles, so the launch facilities are well spread out. Courtesy: Flexim
on small tubing. It became the main focus. Even though they are big laboratories, clean rooms, and processing bays, they dont use the quantities of a launch pad, so we had to prove success with small tubing. Flexims solution was just the opposite of the high-pressure, thick-walled pipe. They switched to the lamb wave transducers and that solved the problem. is reserved for NASAs next rocket. Since the meters did not come in contact with the gasses, the installation was fast and easy with no need to shut the system down during installation. There was only one problem early on with measuring flow in the small-diameter stainless tubing with the portable meters. We were testing smaller piping going into the leased buildings where we use a pressure vessel outside the leased facilities and run tubing into the building. Since these measurements are what we bill our clients by, the ultrasonic had to be successful
Future metering needs
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The accuracy of the ultrasonic meters was as good as or better than any of the other meters we tested, and installation and maintenance costs are almost nil, Katz adds. NASA management and engineering are all on board. So in coming months we will be installing an additional 22 permanent ultrasonic flowmeters at the Kennedy Space Center and using the resulting data to bill our lease clients on gas usage. ce Jack Sine specializes in green building and IAQ issues. Reach him at jack.sine@verizon.net.
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Balluffs ultrasonic sensors are designed for distance measurement or position detection of granules, uids, and powders. They measure ll levels, heights, and sag without making contact as well as count and monitor the presence of objects. They operate independently of color and surface nish and are not affected by transparent objects that generate strong reections, making them useful for critical applications. Each series is available as a switching or analog version with voltage or current output (0-10 V or 4-20 mA). The M30 version includes variants with two switching outputs (one switching and one analog output, or two switching outputs and one analog output) so that one sensor can adopt the functions of two. Balluff, www.balluff.com
Hybrid motor starter can help reduce maintenance demands and extend motor life
Siemens Sirius 3RM1 hybrid motor starter is designed as both a direct-on-line starter and a reversing starter with integrated overload protection for motors up to three horsepower used for fans, pumps, lifting gear, and machine tools. At just 22.5 mm wide, the unit reduces space requirements in control cabinets by up to 82%. Hybrid technology combines the benets of semiconductor and relay systems in one device: The low-wear semiconductor components are responsible for connection and disconnection operations while an energy-efcient relay system is used during operation. This extends the motor starters service life and reduces maintenance demands. It also uses an infeed system for the motor starter. Siemens, http://www.usa.siemens.com
Heavy-duty electric actuator uses recirculating ball bearing guides for multi-axis positioning
The EGC-HD electric actuator features recirculating ball bearing guides that helps absorb lateral forces and torques. With a toothed belt or ball screw drive and two parallel guides, the unit is ideal for cantilevered systems. The toothed belt model offers exible motor connections on all four sides. The EGC-HD offers a multi axis and modular positioning system which can include inductive proximity sensors, and standardized interfaces for all drives and motor packages. Flush mounting of up to two sensors effectively eliminates protruding edges outside of the drives cross section. An LED status display is visible regardless of approach direction. Festo, www.festo.com
52
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Level switch for liquids designed for process vessels in sanitary applications
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Emerson Process Managements 475 Field Communication Silver Edition represents 25 years of industry expertise in handheld communicator technology. The Silver Edition uses version 3.8 software, which enables it to use both both HART and Foundation Fieldbus digital valve controllers with its ValveLink Mobile application. This allows it to set up and calibrate valves and run diagnostics such as stroke valve, step response, and valve signature on the entire valve assembly in the eld. The communicator is intrinsically safe and enables conguration, calibration, and troubleshooting of more than 1,500 HART and Foundation Fieldbus devices from all suppliers. www.emersonprocess.com
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BASICS
Basic cost accounting for process manufacturing

As business aspects of running a process plant become more important to operators, it helps to understand some simple accounting concepts.
Peter Welander
Even though you probably dont control indirect costs directly, any time you can increase production, the indirect cost gets divided by more units of output, so the indirect cost per ton goes down.
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56
he article last month on how process engineers and operators are getting more involved in the business elements of running a plant suggested that operators need to learn some basic concepts of accounting. Accountants like to match costs with the activities that create products and income. The income a plant generates is easy enough to understand because the output is sold at a specific price per ton. To figure out if youre profitable, you have to compare income against cost. Costs are a bit more complicated, and there are two main components. The first part is the direct cost (aka variable cost), which includes tangible things directly connected to production of your output. If your plant typically produces 100,000 tons of product per month, that requires a corresponding amount of feedstock, gas to fire boilers, operators to watch the process, electricity to run pumps, scrubbers, etc. What are the costs incurred to create that amount of product, or, reversed, what costs would not be there if we had not run production at all? Direct costs should vary directly with the level of output. Lets say for the sake of argument, at normal production levels, direct costs for your plant add up to $600/ ton, so total direct cost for a month is $60 million. (These numbers are all made up, so dont read too much into them.) Direct costs are the most obvious, and sometimes casual observers believe their plant is far more profitable than it is because they assume that is the only cost element. The other side of the accounting coin is indirect costs, and thats where things get more complicated. Every plant has many kinds of costs that arent directly related to production: Rent or property costs for the facility Maintenance (equipment and people) Infrastructure (keeping the lights and air conditioning on) Security services Loading dock Plant office building, equipment, and staff Non-production utilities, and Assorted ancillary things.
Since indirect costs do not change with production levels, they tend to be relatively stable and so are sometimes called fixed costs. (Capital equipment is usually handled differently, so buying a new reactor comes from a capital account.) Accountants like to add up indirect costs for the month. Then they divide the total by the number of units produced for the month. So, continuing our model, lets say indirect costs are $2,000,000 per month. We divide that according to our output of 100,000 tons, so the indirect cost per ton is $20. That means the total cost per ton is $620. Anything beyond that will be handled farther up the food chain. Others will deal with the gross margin, etc. Ultimately, you can make things better or worse by making your cost lower or higher. So, how can you improve things? Raw materialsYou might not have any influence on what you pay for feedstock, but you should be able to help improve efficiency and reduce the amount lost in production. EnergyAgain, maybe you cant control pricing, but you can help control consumption. OutputEven though you probably dont control indirect costs directly, any time you can increase production, the indirect cost gets divided by more units of output, so the indirect cost per ton goes down. Your accountants establish standard costs for your products based on experience. When the actual cost deviates from the standard, its called a variance, which can be favorable or unfavorable. Unfavorable is when production goes down because of an outage, and now you have fewer units of output and the indirect cost goes up per ton. Or, your energy efficiency goes down because a heat exchanger is fouling and it drives up your direct cost. Thats a bad thing. Favorable is when you find opportunities to increase output, improve efficiency, or do something else to come in under the standard cost. That draws the kind of attention you want. ce Peter Welander is a content manager for Control Engineering, and got an A in his cost accounting class. pwelander@cfemedia.com
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Industry prepares for the next industrial revolution