Big-Time Condition
Monitoring
Condition monitoring is more than walking around
the plant with a data logger and a clipboard.
Done big time, it can save you millions of dollars.
Advanced Process
Control at Goodyear
November 2010
What’s New in Valve Design?
CT1011_01_CVR.indd 3
Taking the Long View Keeps
Milwaukee Warm
Exclusive to
the Web
Process Automation
News from Europe
10/26/10 11:22 AM
CONT
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CT1011_full
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2010-09-21
10/22/10 13.39
3:02 PM
November 2010 • Volume XXIII • Number 11
f e at u r e s
a d v a
c o n t
nc
r o
e
l
d
p
r
o
c
e
ss
41 / Goodyear Gives Variability a
One-Two Punch
Advanced process control lets a refinery’s staff optimize
their isoprene unit’s distillation process, balance operating parameters, save energy and reduce product loss.
by Jim Montague
v a
l v
e
s
47 / Valves Turn-Around
Because they serve in the beating heart and vital junctions of every process application, valves, actuators and
positioners get plenty of attention in the form of upgraded designs, improved transmitters, enhanced diagnostics, better networking and new safety functions.
by Jim Montague
W E B
E X C L US I V ES
The European Report
Nick Denbow gives us the view from over there.
www.controlglobal.com/IAI
Cover Story
28 / Big-Time Condition Monitoring
Condition monitoring is more than walking around the
plant with a data logger and a clipboard. Done big time, it
can save you millions of dollars. by Dan Hebert, PE
CONTROL (ISSN 1049-5541) is published monthly by PUTMAN Media COMPANY (also publishers of CONTROL DESIGN, CHEMICAL PROCESSING, FOOD PROCESSING, Industrial Networking,
Pharmaceutical Manufacturing, and PLANT SERVICES ), 555 W. Pierce Rd., Ste. 301, Itasca, IL 60143. (Phone 630/467-1300; Fax 630/467-1124.) Address all correspondence to Editorial and Executive Offices, same address. Periodicals Postage Paid at Itasca, IL, and at additional mailing offices. Printed in the United States. ©Putman Media 2010. All rights reserved. The contents of this publication may not be reproduced in whole or part without
consent of the copyright owner. POSTMASTER: Send address changes to CONTROL, P.O. Box 3428, Northbrook, IL 60065-3428. SUBSCRIPTIONS: Qualified-reader subscriptions are accepted from Operating Management in the control
industry at no charge. To apply for qualified-reader subscription, fill in subscription form. To non-qualified subscribers in the U.S. and its possessions, subscriptions are $70.00 per year. Single copies are $15.00 domestic, $17.00 foreign. Subscriptions
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Post International Publications Mail Product Sales Agreement No. 40028661. Canadian Mail Distributor Information: Frontier/BWI,PO Box 1051,Fort Erie,Ontario, Canada, L2A 5N8.
N o v e m b e r / 2 0 1 0 www.controlglobal.com
CT1011_05_07_TOC.indd 5
5
10/26/10 9:52 AM
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November 2010 • Volume XXIII • Number 11
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D E PA RT M E N T S
9 / Editor’s Page
Doing it with Less—or Happy Thanksgiving. Be grateful you have a job, and work
very hard to keep it.
53 / Technically Speaking
Dan Hebert says intrinsic safety is often
your best protection option.
54 / Ask the Experts
11 / Feedback
Readers of our blogs weigh in on Stuxnet
and Automation Week 2010.
Pre-1985 SCADA systems and why fossilfuel-based economies are batch processes.
Easy online ordering!
57 / Roundup
12 / Lessons Learned
Software for Renewable Energy Processes,
Part 4.
Get your PLC and controller technology
here.
61 / Products
19 / On the Bus
Okay, we get it. Wireless works. Now, vendors, how about addressing some other process automation challenges?
The latest in process automation technology, plus Endress+Hauser’s new interface
level measurement system
63 / Control Talk
20 / In Process
Retrofit projects and getting flow right
GE Energy buys Dresser, Invensys gets it
together, and other automation news.
65 / Ad Index
Don’t miss these pages.
27 / Resources
This month’s focus is on level technology
information online.
66 / Control Report
The long view at Valley Power. Jim Montague talks about the long-term commitment of keeping Milwaukee warm.
CT1011_05_07_TOC.indd 7
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10/22/10 3:03 PM
EDITOR’S PAGE
Doing with Less or Happy Thanksgiving!
The good news is that the recession is over. The bad news is that the growth curve is
barely off zero, and it is going to be several years before we’re back to where we were
before the greedmongers brought the economy to a crashing halt. “I said ‘Greed is
good,’ but I didn’t know they were going to make it legal!” says Michael Douglas,
reprising his role as Gordon Gekko in the
movie Wall Street: Money Never Sleeps.
For all the rest of us, we need to try to get
through the next four or five years with jobs and
savings more or less intact and with retirement
plans more or less on track. Yeah. That’s going
to be easy.
Let’s break it down. If you’re in the 55 to 65
age group, as I am, you’re probably going to
have to work past 65, maybe long past. If you
like what you’re doing, that works out fine. If
you’re just hanging on until retirement, you
might want to try on that blue vest with the orange piping.
Even at our ages, there are things we can do
to make ourselves more marketable, so we don’t
get let go in a “resizing” that is actually getting
rid of the older, higher paid workers. Keep up.
Read the journals. Attend seminars and webinars. Join Facebook and LinkedIn professional
groups for automation professionals. Make an
effort to pass your knowledge along to younger
workers and be seen by your management doing so. It will make you more valuable in their
eyes, and if they do lay you off, it may get you
brought back as a $250-an-hour consultant.
If you are in the early part or the middle of
your career, much the same advice applies, just
more so. I’ve written before about the letter I
received from a recently laid-off engineer who
had spent 37 years with the same company doing basically the same job. His skills were 37
years old, and he had no resume. It’s that blue
vest again.
Your skills are yours. They belong to you and
they go with you wherever you go. Time was,
“He who dies with the most toys wins.” Now it
is, “He who has the most skills wins.”
As automation professionals, we should have
the largest skill set in all of manufacturing. You
think that’s bunk? Well, take a look at what we
know, and what we’re expected to know. ISA developed a profile of the automation worker for
the U.S. Department of Labor a few years ago,
and I reprinted it in my book, The Instrumentation Reference Book, 4th Edition. See also
www.careeronestop.org/CompetencyModel/
pyramid.aspx?AT=Y.
You work all week, and the last thing you
want to do is to study and read technical stuff
on evenings and weekends. You have a family.
You have a life. Well, make time during your
work day to expand your skills. Campaign with
your management to make that essential. If they
won’t help you, consider going where management will. Remember, there is very little loyalty
left, and you shouldn’t have any qualms about
going somewhere better.
Above all, differentiate yourself as an automation professional by knowing as much as
you can about the business of the company you
work for, or you are doomed to be in the same
job forever. Engineers’ salaries typically top out
at about 40 years old, while managers’ salaries
keep going up. Why? Because managers are
worth more to CEOs than engineers are. Yes,
I know that’s wrong. So?
If you want more respect as an engineer, you
have to get the attention of the suits on the top
floor. That means being able to talk to them
about how your job directly affects their bottom line. It might not be the job you signed
on for in engineering school, but it’s the one
you’ll need to master now if you want any job at
all. Meanwhile, be thankful for the job you do
have. Happy Thanksgiving!
Walt boyes
Editor in chief
wboyes@putman.net
Your skills are
yours. They go
where you go. Time
was, “He who dies
with the most toys
wins.” Now “He
who has the most
skills wins.”
N o v e m b e r / 2 0 1 0 www.controlglobal.com
CT1011_09_Edit.indd 9
9
10/25/10 12:51 PM
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10/22/10 3:03 PM
555 W. PIERCE RD., SUITE 301 • ITASCA, ILLINOIS 60143
G N I K A E P S YL L A C I N H C E T
FEEDBACK
administrative team
[Editor’s note: The following are posts and
comments taken from our “Unfettered” and
“The Great Kanduski” blogs at www.controlglobal.com.]
publishing team
Group Publisher/VP Content: KEITH LARSON
klarson@putman.net
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lmar tinez@putman.net
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888/64 4-1803
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Reprints Marketing Manager: JILL KALETHA
1-866-879-914 4 ex t. 121, Fax 219.561.2019
jillk@fosterprinting.com
editorial team
Editor in Chief: WALT BOYES
wboyes@putman.net
Executive Editor: JIM MONTAGUE
jmontague@putman.net
Digital Managing Editor: KATHERINE BONFANTE
kbonfante@putman.net
Managing Editor: NANCY BARTELS
nbar tels@putman.net
Senior Technical Editor: DAN HEBERT
dheber t@putman.net
Contributing Editor: JOHN REZABEK
Columnists: BÉLA LIPTÁK, GREG MCMILLAN, STAN WEINER
Editorial Assistant: LORI GOLDBERG
design & production team
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ASBPE 2009 MAGAZINE OF THE YEAR FINALIST
FOUR OZZIE AWARDS FOR GRAPHICS EXCELLENCE
Thoughts on Stuxnet
On his “Unfettered” blog, Joe Weiss
posted “Stuxnet and the Smart Grid,”
which stated:
“Stuxnet has at least two major implications for Smart Grid. The first is Smart
Grid uses key management. Stuxnet is
one of the first cyberattacks to use compromised digital keys. Since then, at least
three other cyber vulnerabilities have used
compromised digital keys. There should
be a reassessment of the key management
process for Smart Grid. The second is the
more insidious aspect of Stuxnet that attacks control system logic. Programmable
logic controllers (PLCs) and other controllers with Windows front ends are used
throughout the Smart Grid for controlling
renewable resources, and for modern automated substations and other grid systems.
These systems can be vulnerable to Stuxnet-type attacks. Control system policies
and procedures need to be developed and
implemented immediately to at least minimize these types of attacks.”
Blog reader ab3a commented:
“This [first] problem isn’t as new as
many might think. This article from
the Feb. 21, 2005, edition of eweek.com
(http://tinyurl.com/5xcm6s) is about the
lack of security in a digitally signed key.
Digital signatures are the foundation to
trusted computing. However, the more
keys one has to trust, the more likely it is
that something will sneak in through a
compromised key. Few give any thought
to that aspect of trusted computing. Now
that Stuxnet is well-known, perhaps this
attitude will change.”
Later, ab3a added:
“Stuxnet attacked the STEP 7 development environment and inserted some new
library routines. Then, when the developers or integrators downloaded a new version of the software, the rogue code was
inserted in the PLC program.
“Back to reality. There are many inte-
grated development environment (IDE)
packages for many platforms. Authenticating the code in the foundation libraries is something that I have heard of only
among the most paranoid installations. Almost nobody does it.
People authentiWorst
cate entire installafears
tion programs, but
realized
I’ve never heard of
anyone authenticating a working IDE
or an HMI. This
measure is possible,
but is it practical?
How far should our paranoia about protecting our infrastructure go?”
A scary piece of malware
named Stuxnet is in town.
Remember its name.
ExclusivE to
thE WEb
OPC and SeCurity
SimulatiOn SuCCeSS
POrtraitS
autOmatiOn newS
frOm eurOPe
Big JOB fOr COriOliS
imPrOving nerC-CiP
flOwmeterS
StandardS
OctOber 2010
President & CEO: JOHN M. CAPPELLETTI
Vice President: JULIE CAPPELLETTI-LANGE
VP, Circulation: JERRY CLARK
CT1010_01_CVR.indd 3
Automation Week 2010
Ian Verhappen, “The Great Kanduski,”
gave a positive review of the new ISA Automation Week (AW) 2010, and asked for
suggestions for improving it next year.
Jon DiPietro had a list:
“1. Free wireless will make it easier for
people to attend—they can stay in touch—
and promote AW through social media
and sharing. I hope we really promote that
as I think it’s a big deal for attendees.
2. We should think about ways to increase the interaction between exhibitors
and attendees. I’m not sure why the exhibits were closed during the sessions—there
were two occasions when I wanted to see
exhibits and couldn’t.
3. The contingent of journalists present
was pretty thin. Maybe there are accommodations we can make in order to get
more of them there to cover our event.
4. I would like to see one of the tracks
run as an “unconference.” We could create a website/page where conference attendees submit abstracts and then publicly
vote on the subjects that interest them.
The top three vote getters end up getting
a speaking slot.
5. We could borrow Emerson’s idea and
set up a social media help booth. Emerson
employees signed up hundreds of people
and showed them how to use Twitter. This
created a small army of people promoting
the Emerson event.”
N O V E M B E R / 2 0 1 0 www.controlglobal.com
CT1011_11_Feedback.indd 11
9/27/10 10:02 AM
11
10/25/10 12:52 PM
LESSONS LEARNED
Software for Renewable Energy Processes – 4
Solar technology began in 212 BCE when Archimedes concentrated the sun’s rays to ignite Roman ships. Now our space stations are powered by solar panels and lifted into
BÉL A LIPTÁK
liptakbela@aol.com
Solar is the fastest
growing powergeneration technology in the world,
increasing at an
annual rate of 60%.
12
space by hydrogen peroxide engines. It was in 1861 when Auguste Mouchout created
the fi rst steam engine powered by solar energy, and in 1883 Charles Fritz fi rst turned the
sun’s rays into electricity. It took almost a century until, in 1954, Calvin Fuller and his team
at Bell Laboratories constructed the first silicon
solar panels, which had an efficiency of 6% and
a cost of $300 per watt of electricity produced.
Today, solar cell efficiency can exceed 30%,
and the installed costs have dropped below $10/
Wp. Wp is the peak electricity produced under
“standard conditions”—equivalent to bright sun
in the tropics (25 °C and light intensity of 1 kW/
m2). On average, each Wp produces about 5
kWh/day. The key limitation of PV cells is that
any given semiconductor only responds to a certain wavelength of radiation and can therefore
convert only a portion of it to electricity. This
limitation is gradually being overcome.
The cost of conventionally generated electricity in the United States averages about 10¢/
kWh. In contrast, solar electricity costs around
15¢ to 17 ¢ per kWh. Once installed, the fuel
(solar energy) is practically free, and the useful
life of the cells range between 25 to 35 years.
The energy payback period (the number of
years it takes for the cells to generate the energy
that was needed to manufacture them) ranges
between one and four years.
As of 2010, the total global electricity generating capacity is 4800 gW, the installed solar generating capacity in only around 25 gW
or 0.5%. On the other hand, solar is the fastest growing power-generation technology in
the world, increasing at an annual rate of 60%.
Last year the First Solar Co. ranked Number
7 on Fortune’s list of the fastest growing companies, and thin-film and nano-solar technologies might even exceed that rate. Today’s market share of thin-film solar cells (copper indium
gallium selenide (CIGS) is approximately 15%.
The commercially available thin-film solar
cells have an efficiency of 11%.
The total use of renewable energy in the
United States (including hydraulic and biomass) is around 10%, and the total use of solar
energy is about 0.2%, while that of Portugal, for
example, is nearly 50% (Figure 1). On the other
hand, the trend suggests that we will be catching up in the coming years. For example, the
Westland Solar project in the San Joaquin Valley will be the world’s largest solar power plant.
It will generate 5 gW on 30,000 acres of land.
Increased use of solar energy is also motivated
by factors such as the high transportation expenses of gasoline. In Afghanistan, for example, the cost of delivering gasoline is hundreds
of dollars per gallon.
Solar Energy Storage and Transportation
In the coming articles, I will concentrate on
the software needs for control and optimization
of solar energy storage and transportation systems, giving particular emphasis to my reversible fuel cell design (http://belaliptakpe.com/
solar-hydrogen-power-plant/). Some of these
software packages might seem overly complex,
PORTUGUESE SUNSHINE
Figure 1: A solar power installation in Serpa, Portugal.
Nearly 50% of Portugal’s energy is derived from solar
power.
www.controlglobal.com N O V E M B E R / 2 0 1 0
CT1011_12_16_Lessons.indd 12
10/26/10 10:15 AM
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CT1011_full page ads.indd 13
10/22/10 3:04 PM
Lessons Learned
but at a time of unmanned drones and
Google’s unmanned cars, they should
be feasible. I will start the discussion
with small units serving individual
homes and smaller industrial plants.
The optimization software needed
for PV systems with both storage and
grid connections has to 1) provide total
automation, including record-keeping,
2) provide capability to reconfigure the
system to automatically maximize profitability and 3) provide self-diagnostics.
In developing the software package,
the primary goal must be simplicity, so
its operation does not require more understanding from the homeowner than
what’s needed for operating a thermostat. To provide this requires total automation, so that the system will safely
operate on its own, without the need
for the homeowner to take any action
at all. On the other hand, the software
must allow the homeowner (or preferably the electric company) to update
any data or setpoint, such as changes in
the price of electricity (during normal,
night or peak periods, if they differ). If
the home has electric car(s) charging
during the night, the software package must be provided with the target
amount of electricity needed to be in
battery storage in the morning.
Grid Connected PV System
with Net-Billing Meter
The main components of a simple installation are the solar collectors and
the intelligent, bi-directional electric meter, which is furnished by the
electric utility company. Such a sys-
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tem has no electricity storage capability. Therefore, when solar electricity
is insufficient or unavailable (at night
or on cloudy days), it obtains some or
all of the electricity needed from the
grid (red direction of electricity flow in
Figure 2). Inversely, when excess solar
energy is available (beyond the needs
of the household) it is sent to the grid
(green direction in Figure 2).
Billing is done on the basis of net
electricity used (or generated) during
the month. This net amount is a function of the size of the solar collectors,
the insolation in the area, the weather
conditions and other factors (dirt buildup or collector maintenance, etc.)
The economics of the operation
is a function of the contract with the
electric utility and is also affected by
government support. The utility either
charges (or pays) a flat rate for the electricity or a rate that changes with the
time of the day. If the second is the
case, it’s likely that the night rate is the
lowest, and the “peak rate” is the highest. Peak rate is usually applied when
the power plant is operating at nearly
full capacity (usually because of high
air conditioning loads on hot summer
days). Under these conditions, receiving the excess solar energy is advantageous to the utility because it does not
need to start up its emergency generators. Sending “peak electricity” to the
utility is also advantageous to the homeowners if the rate paid is higher.
It is the utility company that takes
government subsidies and regulations
into consideration, so that the homeowner just receives a monthly statement without requiring any additional
paperwork. Besides direct subsidies,
the government in some countries
guarantees a fixed rate for the solar energy sent to the grid. This rate is often
higher than its “market value.” In such
cases the utility is required to distribute that extra cost among the “non-solar” households.
As shown in Figure 2, the electric
meter is an intelligent one that auto-
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Lessons Learned
matically considers the electricity flows in both directions
and displays the net total (cost or payment) at any time during the month. The software provided by the utility is automatically adjusted for times of day variations in cost rate or
times of “peak periods,” so the homeowner is not burdened
with adjusting them.
The software in the intelligent electric meter should also
be able to perform other control tasks, such as to automatically charge the batteries of the electric car(s) when the electricity is inexpensive (“night time”), and to maximize the
amount of electricity sent to the grid (by temporarily turning
off optional users) during periods when peak electricity rates
apply on hot summer days.
None of this software, nor the intelligent net-billing utility
meters themselves exist today, but as energy costs increase,
they will. The purpose of this series of articles is not only to
describe software that is available, but also to describe the
control software needs of the future as renewable energy systems become more complex and sophisticated.
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CT1011_12_16_Lessons.indd 16
12-Oct-10 10:45:30 AM
10/26/10 3:24 PM
Import your Modicon 984™ ladder logic
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CT1011_full page ads.indd 17
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CT1011_full page ads.indd 18
10/22/10 3:06 PM
10-10
ON THE BUS
We Get It – Wireless Works
A few months back, I received a quote from my instrument salesman that was shockingly
devoid of the previously ubiquitous WirelessHART attachment. Every prior quote—in
my case almost exclusively for wired devices—contained an added attachment extolling the virtues of wireless. So when I opened the one with no such addendum, I wrote
him back about the missing attachment. “You
must have lost it,” I joked. Can anyone remember an instrument technology that was marketed with such persistence and zeal?
Perhaps that’s because WirelessHART
emerged in products well before the completion of the ISA 100.11 wireless specification.
Consensus standards are messy and difficult
for suppliers. It’s much easier to create the standard and then just dish it up. Isn’t this how we
ended up with multiple fieldbus standards?
Well now we have multiple wireless standards. The “freedom to choose” that was so
fundamental to the mission of ISA SP50 and
later Foundation fieldbus is not particularly
strong in the wireless arena. If you have the
wrong system, you may not be free to choose
your favorite field device—unless you’re happy
with two wireless backhauls, one for ISA 100.11
devices and one for WirelessHART.
There’s some talk of convergence, but what
convergence can avoid stranding hundreds of
existing WirelessHART users? The Fieldbus
Foundation is working on a specification for
a backhaul to serve both, but host suppliers
would need to push forward support of Foundation High-Speed Ethernet, instead of preempting an open solution with proprietary ones.
I worked for one of the companies that installed early betas of WirelessHART before
2005. The effort at a fairly modern refinery on
the West Coast included measurements of rotating equipment bearing temperatures, which
turned out to be of extraordinary value, allowing the plant to predict failures before they
caused an unplanned outage. But, to this day,
I’ve never understood why such valuable measurements—claimed to have saved tens of thousands or even hundreds of thousands of dollars—couldn’t justify running wires.
And, none of us sitting around at that 2004
Technology Information Exchange (TIE) had
applications that were aching for a wireless solution. We already had wireless solutions that
were rarely used because they were rarely
needed. We had a lot of aging legacy systems
that needed a path to modern digital integration, and most of the legacy systems had wires
connecting the DCS to field devices. We had
scores of new safety interlock applications requiring SIL-rated safety instrumented functions—no one saw wireless helping us with that.
Even tank farms, where we always dreamed of
using wireless, required SIL-capable systems.
No one could imagine wireless measuring up
in that area. The mountain of measurements
stranded due to the expense and/or complexity
of running wire—that could be solved with a
Zigbee or Dust radio mesh—were off the radar,
as it were, of many process industry users.
WirelessHART products have been available since at least 2007, and today one can
obtain compatible products from ABB,
Endress+Hauser, Siemens, Pepperl+Fuchs,
Emerson and others. Given the numerous installations already in the field at diverse end users, and the prestige of the excellent suppliers
who support it, I’m happy to say I’m sold. WirelessHART works and delivers as advertised.
Is there anyone remaining out there who
thinks otherwise? I haven’t installed any personally, but I have plenty of neighbors and
friends who have, and none of them are ripping
it out.
Wireless is not a hard sell—most managers
are ready to approve it if the expense seems justifiable. They are typically already big users of
wireless, from their laptops to their iPhones and
Blackberries. Maybe it is our overly conservative process culture, but I think it’s really “fitness for purpose” that causes most users to just
keep yanking in their copper twisted pairs.
john Rez abek
contributing Editor
jrezabek@ispcorp.com
Wireless is not a
hard sell—most
managers are ready
to approve it if the
expense seems
justifiable.
N o v e m b e r / 2 0 1 0 www.controlglobal.com
CT1011_19_OTB.indd 19
19
10/25/10 12:54 PM
IN PROCESS
GE Energy Acquires Dresser Inc.
$3-billion deal brings Dresser’s valve business into GE fold.
GE has announced that it has signed
a contract to acquire Dresser Inc., a
global energy infrastructure technology and service provider. The $3 billion deal is the latest in a series of acquisitions over the last 10 years that has
helped grow GE’s energy business and
deliver record profitability.
Dresser’s portfolio, which includes
technologies for gas engines, control
and relief valves, measurement, regulation and control solutions for gas and
fuel distribution, will expand GE’s core
energy offerings, and extend its reach
into adjacent offerings for its energy and
industrial customers. The deal is subject to customary closing conditions,
and is expected to close promptly after
receiving regulatory approval.
“Dresser is a great fit for the GE business model,” said John Krenicki, vice
chairman of GE and president and
CEO of GE Energy. “Dresser’s technology complements our existing gas
engine portfolio, and adds offerings
complementary to those of GE in the
$45-billion flow technology industry, including product offerings in the highly
engineered valve segment. Eighty-five
percent of Dresser’s revenue is from energy customers, and it has developed
a large installed base of equipment,
which is a big reason why 40% of its total revenue is derived from aftermarket
service offerings, and there is a lot of
room for future expansion.”
David Clayton, senior analyst at
ARC Advisory Group, commented on
the acquisition: “With its acquisition of
Dresser, GE immediately becomes one
of the world’s leading control valve suppliers. With 2009 revenues exceeding
$500 million, Dresser is the second largest global control valve supplier. Dresser’s portfolio includes final control elements for general service, engineered
solutions for severe service applications,
20
“GE now has the potential to
address the full scope of process
automation, from field
instrumentation to process
automation systems and software.
Only a handful of companies in the
industry can do all this.”
– Larry O’Brien, ARC.
and digital solutions that can communicate with nearly any control system.
Dresser’s Valscope Pro and ValVue
OVD diagnostic tools enable Dresser to
evaluate and diagnose nearly the entire
spectrum of installed control valves still
in service—intelligent or conventional.
As the world’s demand for both energy
and predictive maintenance solutions
continues to grow, gaining access to a
key automation component in the energy markets and the ability to properly
assess their health should enhance GE’s
position in the global energy markets.”
Larry O’Brien, ARC’s research director for automation, added, “Between
the combined automation-related businesses of GE Energy and GE Intelligent Platforms, the company now has
the potential to address the full scope of
process automation, from field instrumentation and control valves to rotating
equipment diagnostics, process automation systems and related software. Only
a handful of companies in the industry
can do all this.”
Headquartered in Addison, Texas,
Dresser operates in more than 100
countries, delivering compression, flow
technology, measurement and distribution infrastructure and services to
customers in more than 150 countries.
Dresser had revenues of $2 billion and
earnings of $318 million in 2009.
This deal is the latest in a series of
moves by GE Energy to expand its business. On Sept. 27, it announced a joint
venture in China to expand further into
the world’s largest wind market. On Oct.
1, it closed on its purchase of the assets
of Calnetix Power Solutions, which expands GE’s capabilities to recover waste
heat from industrial processes for electricity generation, and will also complement GE’s gas engine business. On
Oct. 4, the company also signed a $700
million contract with Saudi Electricity
Co. for a new, high-efficiency power
plant in Riyadh, Saudi Arabia.
IOM Gets It Together
This year’s Invensys Operations Management (IOM) user group meeting
held in October in Orlando, Fla., demonstrated that the latest reinvention of
Invensys has finally achieved what the
company has been working on since the
original British-owned Invensys kludged
together several disparate companies to
compete in the automation space in the
1980s and 1990s. It has been a struggle,
but now it appears that the venerable
brands of Foxboro, Eurotherm, Sim-Sci
Esscor, Avantis and Wonderware have
been brought together in such a way as
to leverage their strengths and diminish
their weaknesses.
In a year, IOM has completed the
reorganization, finalized branding,
and is working on leveraging the
strengths of its varied distribution
channels, from direct sales to manufacturers’ reps to stocking distributors
to control system integrators. Steve
Blair, president of IOM-USA, said,
“Our objective is to not mess up, and
if we can do that, we’ll come out of
www.controlglobal.com N o v e m b e r / 2 0 1 0
CT1011_20_25_InPro.indd 20
10/26/10 10:19 AM
e
10-10-23 Control ad_DXAdvanced_ADB1002.indd 1
CT1011_full page ads.indd 21
10/15/10 2:48 PM
10/22/10 3:07 PM
IN PROCESS
this with an immensely stronger distribution organization. We’re working
on the ‘who does what’ right now.”
Sudipta Bhattacharya, IOM’s CEO
and president, presented a roadmap
that indicates that InFusion, ArchestrA and InTouch are the future for the
software part of I/A, and the 100 Series controllers will be upgraded and
improved. IOM also introduced a new
programmable automation controller
(PAC) bearing the Foxboro name.
The Foxboro PAC and I/O subsystems
are integrated with Wonderware’s
software. He also noted that the Eurotherm control system that has mostly
been treated as a red-headed stepchild by the true Foxboro believers
will be going forward as the smaller
control system it was intended to be.
The marketing term for Invensys
going forward is “Enterprise Control
System (ECS).” Invensys’ Neil Cooper describes it as “a meta-integration
of control, production control and
business control with a real-time feedback system.” In the case of Invensys,
that’s InFusion based on the ArchestrA software platform backbone.
An ECS component is any Invensys offering or any third-party offering
that communicates with the ArchestrA
backbone software. On the plant floor,
that would be the DCS, SCADA, PAC,
historian, HMI and safety systems from
Foxboro, Triconex, Wonderware, Eurotherm or from third parties.
At the site-wide or multi-site level,
the term ECS incompasses production
and performance applications, such as
quality, performance, batch, mobile
worker management, MES, asset man-
agement, optimization, simulation and
workflow, business process management and collaboration, EMI/intelligence, enterprise integration and visualization, with solutions available from
Avantis, IMserv, Sim-Sci Esscor, Skelta
and Wonderware.
Trade Shows Rebound
The death of the old mega-trade
shows, which attracted thousands of
exhibitors and even more thousands
of attendees, may have been exaggerated. These week-long extravaganzas
fell on hard times thanks to the double
whammy of the Internet and economic
hard times. But some of the venerable
giants are stirring again.
For
instance,
SPS/IPC/Drives
2010—Electric Automation, Systems
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CT1011_20_25_InPro.indd 22
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communication gap between serial only, fieldbus, and Ethernet devices—unlocking untold information from PLCs,
drives, motion controllers, and more. Red Lion’s free, robust Crimson® software enables drag-and-drop register
mapping that lets a Siemens ® PLC to talk to an Allen Bradley ® drive in just seconds. The built-in Ethernet gateway
lets you network-enable serial or fieldbus machines onto a common communications backbone in minutes, and
convert your old PLC’s and drive’s proprietary protocol into a single modern and open standard.
But that’s just the beginning. Use the integrated web server to quickly set up secure,
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PDA or phone. Easily create a web based HMI depiction of your machine or process with the included
5000+ image graphics package. Receive alarms or event notification remotely via e-mail or SMS text.
Collect performance data, display it, store it for evaluation, or trigger PLC functions—live or remotely.
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The no-risk asset and data management solution.
Data Station Plus is the evolutionary, non-invasive device and software platform that expands and unifies the
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CT1011_full page ads.indd 23
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10/22/10 3:08 PM
MODERNIZING
Level Measurement
Solids Handling with VEGAPULS 68
Liquids Handling with VEGAFLEX 66
With Ohmart/VEGA pulse radar technology, level
With no moving parts, guided microwave radar eliminates
measurement of solids is unaffected by difficult
many measurement and maintenance issues associated
process conditions such as dust, making radar the
with mechanical float systems. The sensor is available in
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CT1011_full page ads.indd 24
10/22/10 3:08 PM
IN PROCESS
and Components, the yearly gathering
of European process automation vendors, is reporting exhibitor space bookings matching its pre-economic blowup
numbers in 2008—a whopping 90,000
square meters. Conference organizers
report that approximately 1300 exhibitors will present products and services
at this year’s event in Nuremberg, Germany, on Nov. 23-25.
Meanwhile, Deutsche Messe, organizers of Hannover Fair, the world’s
largest industrial technology trade fair,
is adding Industrial Automation North
America to its international expansion
plans. For the last few years, Hannover
Fair has included the Interkama Exhibition, which attracted 150,000 visitors
this year.
This new show will be held Sept. 1215, 2012, alongside the International
Manufacturing Technology Show
(IMTS) at McCormick Place in Chicago. It will showcase products and
solutions for production automation,
complementing the IMTS focus on machine tools, metalworking and precision
manufacturing. The move stems from
a strategic alliance with AMT—The Association for Manufacturing Technology, which organizes of IMTS.
ISA Announces the
2011 Testing Window
Application Deadlines
ISA has announced the three testing
dates and application deadlines in 2011
for its Certified Automation Professional
(CAP) and Certified Control Systems
Technician (CCST) certification awards.
To take the certification exam in the
preferred testing window, applications
must be postmarked or submitted online by that testing window’s application
deadline:
Window 1: To take the exam between March 1–April 30, 2011, the application postmark/online submission
deadline is Friday, Jan. 14, 2011
Window 2: To take the exam between July 1– Aug. 31, 2011, the application postmark/online submission deadline is Friday, May 13, 2011
Window 3: To take the exam between Nov. 1–Dec. 31, 2011, the application Postmark/Online Submission
Deadline is Thursday, Sept. 15, 2011
More information about the certifications and preparation for the tests can
be found at www.isa.org.
Electronics and moisture don’t mix.
©2010 Pentair Technical Products
The Hoffman brand H2OMIT® Dehumidification System
quickly removes moisture from the air inside your enclosure–up to
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condensation. Installs easily, equalizes air pressure and maintains the
UL Type rating* of virtually any enclosure brand. hoffmanonline.com
*maintains UL Type rating
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CT1011_20_25_InPro.indd 25
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If reliable, maintenance-free and accurate level measurement is required, consider the
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transmitter in the world to acquire the coveted SIL2 certification. Used as a stand-alone
level transmitter with “donut” style float or in conjunction with a magnetic level gauge, the
AT series provides over 20 years of reliable and repeatable performance in the field. The
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CT1011_full page ads.indd 26
10/22/10 3:10 PM
swa4
RESOURCES
On the Level about Level Measurement
Control’s Monthly Resource Guide
Every month, Control’s editors take a specific product area, collect all the latest, significant tools we can find,
and present them here to make your job easier. If you know of any tools and resources we didn’t include, send
them to wboyes@putman.net, and we’ll add them to the website.
LEVEL MEASUREMENT BASICS
LEVEL BASICS—THE MOVIE
Omega Engineering
888/826-6342 www.omega.com
Transactions in Measurement & Control, Vol. 4, Flow and Level Measurement, from Omega Engineering, is
a 113-page, free, downloadable PDF
covering the basics of level measure-
ControlGlobal
www.controlglobal.com
In this video, Control’s editor in
chief, Walt Boyes, talks about the basics of measuring level and how to
select the correct level technology
for your applications. Topics include
wireless standards, hydrostatic level
measurement, level measurement
basics and more. Watch the video
at www.controlglobal.com/multimedia/2008/024.html.
LEVEL LIMIT SWITCHES
888/363-7377
ment. Beginning on p.age 72, level
topics include level sensor selection,
pressure/density,
RF/capacitance
and radiation-based instrumentation, and speciality level switches.
The direct link is www.omega.com/
l iter at u re / t r a n s ac t ion s / Tr a n s ac tions_Vol_IV.pdf.
STEAMY TUTORIAL
800/575-0394
Spirax Sarco
www.SpiraxSarco.com/us/
“Methods of Detecting Water Level
in Steam Boilers” is an online tutorial from Spirax Sarco that discusses
the application of level controls and
alarms, plus an overview of different level-detection methods, including f loat-type controls, conductivity probes and capacitance devices.
The direct link is at http://preview.
tinyurl.com/3al6ow9.
ging. A customer has a horizontally
mounted tank that is 144 in. long
and 64 in. in diameter. The ends
are f lat. The customer would like to
know the daily usage of the liquid in
the tank via a measurement in the
morning and another at the end of
the day. The customer wants accuracy of up to 1 gallon changes in this
tank measurement. Some say this is
impossible, given it is a horizontally
mounted tank and that the sensor
cannot detect those extreme small
changes. Follow the discussion and
possible solutions at http://tinyurl.
com/2fmlsju.
Endress+Hauser
www.us.endress.com
This article discusses in detail the
characteristics of a universal limit
switch for liquids using a vibronic
limit switch as an example. Starting with the general requirements of
such an instrument, this switch may
be used in approximately 80% of all
applications occurring in practice.
It demonstrates both the physical
measurement principle and the electronic units for frequency evaluation
and signal transmission. The focus is
on using a limit switch for overspill
protection to guarantee safe operation, even under extreme conditions.
The direct link is http://preview.tinyurl.com/35yqvv8
LEVEL ADVICE
PLCS.net
www.plcs.net
This is an online discussion that begins with a problem about horizontal-tank level measurement and log-
SOLIDS LEVEL MEASUREMENT
Blue Level Technologies
888/615-3835
www.blueleveltechnologies.com
Continuous level measurement is
about one thing, which is answering the question, “How much stuff
do I have?” Usually the desired engineering unit is expressed in terms
of volume or weight. “Measuring”
volume or weight is not always the
most practical approach. Sometimes
it isn’t even viable. This is where
continuous level measurement sensors and systems come into play and
offer a viable and cost-effective approach. “Application Considerations
for Continuous Level and Inventory
Monitoring of Powder and Bulk Solids” is a white paper from Blue Level
Technologies that discusses the challenges of powder and bulk solid level
measurement. The downloadable
PDF is found at www.controlglobal.
com/whitepapers/2010/046.html.
N o v e m b e r / 2 0 1 0 www.controlglobal.com
CT1011_27_Resources.indd 27
27
10/25/10 12:56 PM
Condition monitoring
Big-Time Condition
Monitoring
Condition monitoring is more than walking around
the plant with a data logger and a clipboard.
Done big time, it can save you millions of dollars.
by Dan Hebert, PE
To some, condition monitoring (CM) means installing vibration sensors on a few critical motors, and then having a
maintenance technician with a handheld data logger check
sensor readings on a more or less regular basis.
To others, such as Romel Bhullar, senior technical fellow/director at the engineering and construction giant Fluor
(www.fluor.com), CM is a very big deal, requiring a systems
approach. “At Fluor, working as systems integrators on mega
projects, we routinely incorporate conditioning monitoring
solutions to control and manage capital assets,” says Bhullar. (Figure 1)
“Besides huge upfront capital layouts of several hundred
million dollars or more, these assets are directly responsible
for delivering very valuable products like several hundred
thousands barrels per day of petroleum or billions of cubic
feet of natural gas. Unplanned interruptions can shut down
operations and cost companies millions,” adds Bhullar.
Condition monitoring to keep modern process plants up and
running are necessarily complex. “A conditioning monitoring
project typically involves integrating and marrying diverse and
competing commercial technologies, systems and parameters,”
explains Bhullar. “It also requires very high-speed, real-time input monitoring, signal conditioning and processing. We have
to deal with different sensor suppliers, vibration systems and
28
system integration problems—using a variety of networks,
communication protocols, media, servers, and application
hardware and software.”
However, it pays off, especially in process industry applications, where plant shutdowns due to equipment failure can cost millions of dollars per day. The dollars and
the challenges may seem daunting, but the rewards can be
significant, and there are ways to cut the project down to a
manageable size.
Getting Started
While a plant-wide CM and asset management system isn’t
a simple project, the approach to it can be fairly straightforward, according to Michael Gurney, co-CEO of Concept
Systems (conceptsystemsinc.com), a systems integrator in
Albany, Ore.
“When it comes to the actual implementation of a CM solution, there are two options,” he advises. “The first is using
control hardware already in place, and the second is equipping assets with new instrumentation and controls.”
Much hardware installed in a plant already has diagnostic
capabilities. “In virtually all cases we’ve looked at, there are
capabilities already on the plant floor for capturing data on
an asset, but most go underutilized,” says Gurney.
www.controlglobal.com N o v e m b e r / 2 0 1 0
CT1011_28_38_CoverStory.indd 28
10/26/10 11:22 AM
Sometimes, you don’t even have to install sensors, as everything you need may already be there. InduSoft (www.indusoft.com), for example, installed a SCADA system at the
University of Texas in Austin. “The system monitors more
than 1200 meters from more than 100 buildings on the campus,” explains Fabio Terezinho, InduSoft’s VP of Consulting Services. “The InduSoft system combines real-time data
acquired from an OPC server with historical data retrieved
from the historian, and displays information from electrical,
chilled water, domestic water and steam on dashboards—
and makes the information available to remote users anywhere via a web browser.”
The system also generates reports with a log of events,
such as calibration/verification of the meters, which is used
to schedule preventive maintenance and check the integrity
of the data. Alarm and remote notification allows the university to detect and fix defects in a timely manner. According to InduSoft, installation went smoothly. “Integration of
the open architecture InduSoft Web Studio with third-party
systems previously installed at the site was straightforward,”
says Terezinho.
Another example of a relatively easy condition monitoring implementation occurred at Centro Energia Teverola
Photo courtesy of Fluor
Condition monitoring
keeping things humming is part of the deal.
Figure 1: When Fluor designs and builds huge process plants for its
clients, the condition-monitoring system is a key deliverable.
(www.centroenergia.it), a 150-MW combined-cycle cogeneration power plant in Teverola, Italy, about 20 miles
north of Naples. The plant already had CM sensors installed on instruments and valves, all wired into the ex-
Condition Monitoring Tells All
Fluor designs and builds huge process facilities such as chemical plants, refineries
and power plants. Romel Bhullar, senior
technical fellow/director at Fluor, says, “In
almost every project we do—refineries, energy, petrochemical, biochemical, pharmaceutical or power—asset condition monitoring (CM) is an integral part.”
One such project at Potomac Electric
Power Co. (Pepco) involved a plant supplying power to the city of Washington, D.C.
“It’s critical that the power generation turbines, generators and auxiliary systems
have a CM system that monitors impending failures and identifies reasons to do
preventive maintenance.”
Putting together such a system isn’t
easy. “Standard commercial off-the-shelf
solutions weren’t flexible and functional
enough to match our needs,” he says.
“There were mountains of challenges:
technical, people, commercial, multiple
company cultures and organizations,” he
adds. “In these days of tough economic
times, all vendors are protecting their
markets and providing proprietary and
expensive solutions. It makes integration
very difficult.”
Things are improving, but problems
still exist when tying together different
communication protocols. “There have
been significant developments in networking technologies and communications equipment, but major issues in the
bottom two layers of the OSI model still
need lot of work,” he notes. “Management may have different objectives than
the people in operations, IT and control
systems—not to mention suppliers. It’s a
maze out there.” Bhullar says the cost to
install the CM system at Potomac Power
“…was several million dollars.”
The data being gathered is extremely
important to more than just the power
company. EPRI (www.epri.org), a power
industry consortium in Palo Alto, Calif.,
contributed to the project, so it could see
the data.
“The conditioning monitoring system
provides data in real time to all the EPRI
stakeholders across the U.S.,” Bhullar
explains. “GE is looking at their new gas
turbine/generator and collecting performance parameters to improve their design. Westinghouse/Mitsubishi is collecting data on their newest gas turbines/
generators. Potomac Power’s operations
and maintenance staff are looking at impending failures. And Fluor is collecting
data for validating our methods for predicting failures.”
The system works, too. “The cooling
system on one of the turbine blades had
failed due to plugging of the passages,”
he says. “The system identified the problem, and Potomac was able to replace the
blade in off peak hours without any loss in
power.”
It works for EPRI too. The information
is being used by member utilities to make
decisions relating to equipment selection,
design configurations, maintenance and
replacement policies. The data is also being used by these same utilities to validate supplier sales claims and promises
of newer technologies before making the
huge required capital outlays for a comprehensive CM system.
N o v e m b e r / 2 0 1 0 www.controlglobal.com
CT1011_28_38_CoverStory.indd 29
29
10/26/10 11:19 AM
Photo courtesy of Emerson Process Management
Condition Monitoring
isting legacy control system. But it was experiencing unexpected performance degradation because of clogged
filters on the gas turbines, and the legacy system wasn’t
helping.
To obtain the advanced analysis needed to identify the
problems, Centro Energia installed Emerson Process Management’s (www.emersonprocess.com) AMS Performance
Monitor. Emerson wrote a macro to acquire the necessary
data from the legacy control system’s historian. (Figure 2)
Data is sent to Emerson’s centralized service site in Teesside in northeastern England, where Emerson analyzes the
data and provides Centro Energia with actionable information. Vincenzo Piscitelli, general manager at Centro Energia,
reports, “The return on investment was very fast. A single filter change has already paid for this service for two years.”
Improving Existing CM Systems
Some plants may already have a conditioning monitoring
system that isn’t doing the job. Vectren (www.vectren.
com), a power company in southwest Indiana, wanted to
monitor more than 500 existing assets. Vectren’s engineers were using a combination of software and spreadsheets to analyze more than 15000 equipment readings.
The trend analysis software checked for problems and reported instances when assets were broken or not running
efficiently. Alarms indicated problems that needed im-
teverola, this is england calling
Figure 2: Centro Energia’s 150-MW, combined-cycle
cogeneration power plant in Teverola, Italy, is monitored
remotely by Emerson Process Management in the U.K.
Attacking the Problem
Systems integrator Concept Systems
in Albany, Ore., has implemented many
high-level asset condition monitoring
(CM) solutions. Michael Gurney, coCEO, says that a CM project takes a twolevel approach: First, use control hardware already in place; next, equip assets
with new instrumentation and controls.
Much of the equipment in a plant already
has diagnostic capabilities. “A typical automation system will control the equipment,
but stop short of pulling data off the controller or motor drives. With some simple programming, a system can collect key data
such as motor start/stops, cylinder cycles,
fault counts, drive current, downtime, cycle
time/flow rates, valve position, pressure
readings and more,” says Gurney.
“Collecting and correlating this data
finds problems,” he explains. “For example, monitoring the flow rate at known valve
positions will point to issues with the valve
prior to catastrophic failure. All this informa30
tion can be used to make better sense of
the data and better manage that asset.”
Some equipment may not have the
sensors needed for CM. In this case,
the asset has to be equipped with sensors and tied into the control system.
“The possibilities are really endless and
depend on the type of asset being monitored,” points out Gurney. “Because of
this, a crucial step is evaluating what
assets really need to be monitored and
how. The question is what assets put my
processing line at greatest risk. In many
cases this may not be known, and that is
where data gathered from existing control hardware can help.”
Critical areas where a CM solution
could be usefully employed include: mechanical systems for vibration and current monitoring; pneumatic systems for
temperature, pressure, condensation, air
flow and filter monitoring; hydraulic systems for oil pressure, temperature, level,
flow, accumulator and filter monitoring;
and electrical systems for power quality
and temperature monitoring.
Gurney says several options exist for
analyzing data. “In many cases, data can
be fed directly into a computerized maintenance management software system,
and the data never needs to be directly
presented to maintenance personnel,” he
says. “Companies will also offer to take
on this function for customers—where
they analyze the data directly and work
with the maintenance staff or with thirdparty mechanical, pneumatic, hydraulic
or electrical specialists.”
The other critical element of a CM solution is measuring the results. “Overall equipment effectiveness determines
gains recognized by a CM solution,” he
explains. “Having this data prior to the
CM implementation will deliver quantifiable data on the improvements when
viewed before and after the project.”
www.controlglobal.com N o v e m b e r / 2 0 1 0
CT1011_28_38_CoverStory.indd 30
10/26/10 11:20 AM
© 2009 Swagelok Company
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CT1011_full page ads.indd 31
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7/9/09 10:58:39 AM
10/22/10 3:11 PM
Condition Monitoring
mediate attention, but the existing (www.invensys.com) “The monitoring
procedures were time-consuming, and
approach had several drawbacks.
“Dangerous conditions could evolve the cause of problems couldn’t always
quickly and undetected, increasing the be determined immediately. Alarms
likelihood of costly unplanned outages,” were also repetitive and didn’t reflect
notes Isauro Martinez-Cairo, director problems that a combination of condiEthernetio_Half_CM.ai
3:53:29 PM
tions might have triggered.”
at
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Management
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Better I/O means more uptime and productivity.
Higher-density means a lower cost per channel.
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CT1011_28_38_CoverStory.indd 32
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Invensys helped Vectren achieve a
better solution by implementing Avantis Condition Manager, an automated
CM software solution. It tracks the performance of assets to determine exactly
when maintenance should be performed, generating alerts as conditions
are triggered. Staff receive warnings
when conditions begin to degrade, enabling them to perform maintenance
as needed, rather than as dictated by
an arbitrary schedule. This reduces
unplanned downtime, and enables a
highly effective predictive and proactive maintenance strategy.
“The preventive maintenance functionality alone provides enough savings
to pay for the entire implementation,”
reports Scott Brown, a reliability engineer at Vectren. “Instead of wasting an
engineer’s time reviewing charts, that
engineer is freed to do other tasks.”
Marathon Oil (www.marathon.com)
had a similar problem. Marathon operates the East Brae gas platform in the
North Sea, 165 miles northeast of Aberdeen, Scotland, and it had an aging vibration monitoring system that monitored and reported on the condition of
the equipment. The former system was
rapidly becoming obsolete, so Marathon
turned to Rockwell Automation (www.
rockwellautomation.com) for an upgrade.
The first phase of the work was replacing the vibration systems on the
three gas export compressors, and installing Allen-Bradley XM Series intelligent I/O modules (Figure 3). These
modules process, in real-time, critical
parameters used to assess the health
of the rotating machinery on the platform. The condition monitoring system predicts the future health of the
machines, providing machinery protection where needed. Results of the
upgrade included more reliable vibration monitoring and improved reliability and availability of the compressors.
Advanced Monitoring
We’ve discussed a few examples of
companies replacing older CM and
10/26/10 11:20 AM
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CT1011_full page ads.indd 34
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10/22/10 3:13 PM
Condition Monitoring
Under Pressure To
Calibrate Faster?
Powerful Condition Monitoring
The installation at Centro Energia Teverola’s 150-MW
combined cycle cogeneration power plant in Teverola,
Italy, near Naples, illustrates two key aspects of modern condition monitoring (CM) and asset management
systems.
First, it may not matter what kind of new or legacy
control system is installed at your plant because modern CM software packages can work with almost any
system. Second, you don’t have to develop specific
knowledge about CM because outside services exist that will analyze the data and recommend best
courses of action.
Centro Energia had a legacy Bailey Infi-90 control
system with 5000 I/O, and it wanted to monitor clogging problems with inlet filters on its gas turbines as
well as other operations. The data Centro Energia
needed to analyze was already being collected by the
control system, so all the company had to do was install Emerson Process Management’s AMS Performance Monitor software and contract for Emerson’s
remote analysis services.
It’s necessary to monitor the gradual deterioration
in filter performance and calculate the cost of the resulting reduction in turbine performance. By comparing this with the cost of the maintenance required, the
most appropriate point to replace the blocked filter can
be determined.
But Centro Energia doesn’t make the determination:
Filter and other data from Teverola is transmitted to
Emerson’s performance monitoring center of expertise in Teesside, in northeastern England, where experienced engineers analyze the data and produce
reports showing performance. These reports can
be accessed via any standard web browser, and are
based on thermodynamic models developed for each
machine.
In addition to the online information, Emerson also
provides advice about the operational efficiency of
machinery. Existing or potential problems are highlighted, as well as new opportunities to improve overall efficiency.
Vincenzo Piscitelli, general manager, Centro Energia Teverola, says, “We can assess the effectiveness
and economic return of our maintenance activities,
which allows us to determine what maintenance work
is required to improve equipment performance.”
This improved planning has also enabled Centro
Energia Teverola to reduce average repair times from
seven hours to two hours.
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CT1011_28_38_CoverStory.indd 35
7/30/10 2:36 PM
10/26/10 11:20 AM
Condition Monitoring
articles/2010/WorkersUnchained1004.
html), we discussed how wireless technology makes it easy to add assets to a
CM system and eliminates the need
for operators to walk around the plant
with a data logger.
Most of the major process control
Photo courtesy of Rockwell Automation
manual systems, and the rush may
be on. As asset management and CM
hardware and software become less expensive and easier to use, it pays companies to invest in the technology.
For example, in our April 2010
cover story (www.controlglobal.com/
CM goes to sea
Figure 3: Marathon Oil gathers data with
Rockwell Automation’s intelligent I/O modules to monitor the operation of gas compressors on this platform in the North Sea.
Beamex® MC5 Fieldbus Calibrator
Fieldbus transmitters must
also be calibrated.
The Beamex® MC5 Fieldbus Calibrator is a combination of a
Multifunction Calibrator and a Fieldbus Configurator. The MC5 is
a compact, easy-to-use and field compatible calibration solution
that offers a lot of functionality. The MC5 can be used for various
other calibrations as well.
Portable calibrators
Workstations
Calibration software
Professional services
Industry solutions
CT1011_28_38_CoverStory.indd 36
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info@beamex.com
system vendors understand the need
for CM and offer packages that work
with their control systems. Or, as we
saw in the Centro Energia case, their
software works with other vendors’ new
and legacy systems as well.
Some exotic technology is available to solve tough problems. Tony
Amato, president of Swantech (www.
swantech.cwfc.com), Falls Church,
Va., a systems integrator and supplier
of CM technology, explains how one
company diagnosed problems with a
stress wave energy (SWE) analyzer.
“The company detected increased
stress wave energy on a bottoms
pump for a distillation column. The
system had been in place for more
than a year, and the SWE had been
trending low and consistent during
that time. By correlating increases
in SWE to historical process data,
the customer found the increases in
SWE coincided with decreased and/
or erratic pump f low. Further analyzing the differential pressure and
10/26/10 11:21 AM
OCT10-CAT (CM).qxd:CONTROL DESIGN
9/13/10
3:40 PM
Page 1
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© Allied Electronics, Inc 2010. ‘Allied Electronics’ and the Allied Electronics logo are trademarks of Allied Electronics, Inc.
CT1011_full page ads.indd 37
An Electrocomponents Company.
10/22/10 3:15 PM
Condition Monitoring
Keep
Your
Process
Flowing
with our proven solutions
KING-GAGE
ES2 Liquid Level Transmitter
new slimline design embodies robust protection
against a full range of environmental challenges
such as extreme washdown practices, aggressive
cleaning agents, and extreme humidity.
• Flush mount slimline
design
• Loop powered
(4-20 mA output)
• Suitable for washdown
(IP68 rated connections)
KING-GAGE
LP3 Tank Level System
simplifies process control integration, inventory
monitoring, and even shares data plant wide via
Ethernet. Now with data logging for reporting and
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• Monitor up to 32 tanks
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To learn more call or visit our website.
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Advantages of
Condition Monitoring
Challenges of
Condition Monitoring
1.Reduces downtime
2.Improves performance
3.Allows proactive instead
of reactive maintenance
4.Identifies problems before they occur
5.Uncovers difficult to discover issues
6.Pays for itself quickly
1. Finding time and personnel
to implement and operate
2.Integrating different hardware systems
3.Integrating different software systems
4.Coordinating efforts across
operations and maintenance departments
5.Obtaining initial and ongoing funding
the column level indicated the problem was fouling in
the column packing or trays, leading to increased stress
on the bottoms pump. The column was inspected and
fouling was present. Following cleaning, SWE returned
to normal levels,” explains Amato.
Gurney of Concept Systems says companies should
consider two underused technologies: statistical process
control (SPC) and digital video recorders (DVRs). “SPC
tools offer better data analysis and earlier, more accurate
detection of problems,” he explains. “Small variances,
oftentimes operating within normal high/low limits, reveal equipment issues well before catastrophic failure.”
As for DVRs, Gurney says they offer the ultimate
troubleshooting device by giving personnel the ability to
record processing lines when upset conditions or downtime are detected. “This way, plant personnel can go
back and look at the video captured during these events
and determine the root cause of the problem,” he says.
As CM capabilities increase and costs come down,
the challenge for many will be finding the time to install and operate these systems. Despite proven payback,
plant personnel often are so burdened with day-to-day
operation that they can’t find the time to use proven
CM tools.
Lack of skilled personnel to analyze and interpret
condition monitoring data is another continuing challenge. A solution may be off-site analysis of CM data
by third-party suppliers, with actionable data provided
to plant personnel on an exception basis as is the case
with Centro Energia’s use of Emerson’s off-site analysis
services.
State-of-the-art CM is still not easy or inexpensive,
but it’s also not an insurmountable challenge, and the
expense and effort are well-spent when weighed against
the cost of downtime for critical assets.
Dan Heber t is Control’s senior technical editor
CT1008
www.king-gage.com
CT1011_28_38_CoverStory.indd 38
10/26/10 11:21 AM
INTRODUCING THE
Vantage
Combination Measurement System
The VEGAMAG Vantage utilizes VEGAPULS through-air
radar to report level by tracking the float, which is also
coupled to the magnetic level indicator. An optional full
port ball valve provides isolation in order to take the
gauge out of service without interrupting the process.
Constructed in a 2” schedule 40 pipe as standard, the
Vantage’s small profile fits into nearly any mounting
arrangement. The Vantage is ideal for processes with low
dielectric constant values, flashing, foaming, or in light
hydrocarbons.
Key Specifications
•
-328 to 842°F (-200 to 450°C)
operating temperature
•
Up to 2,320 psi (160 bar)
operating pressure
•
Visual indication from up to 200 ft
•
SIL2 Qualified (IEC 61508/61511 Standards)
•
Compliant with ASME B31.1/31.3 Standards
877.411.VIZE | info@vizellc.com | www.vizellc.com
CT1011_full page ads.indd 39
10/22/10 3:16 PM
Isn’t it time to evolve?
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CT1011_full page ads.indd 40
10/22/10 3:41 PM
AdVANCED PROCESS CONTROL
Goodyear Gives Variability a
One-Two Punch
Advanced process control lets a refinery’s staff optimize their isoprene
unit’s distillation process, balance operating parameters, save energy and
reduce product loss.
It takes plenty of raw materials and energy to make
rubber for tires but managing all those feedstocks
and handling all that energy can be changeable
and difficult. For example, Goodyear Tire & Rubber Co.’s largest U.S. chemical plant in Beaumont,
Texas, produces huge amounts of rubber and C5
high-purity isoprene, but it had been facing ongoing hurdles in its high-purity monomer recovery
unit, according to Kaylynn Johnston, Goodyear
Chemical’s senior engineer.
“We have fluctuations in feed composition, and
this leads to variability in our operations, which
means we may need to compensate with changes
in temperature or other setpoints,” says Johnston.
“The Beaumont plant also is Goodyear’s largest
energy consumer, and our C5 refinery and its distillation columns are the plant’s largest energy
consumer, mainly due to the all the steam they
use. Because of these challenges, we thought advanced process control (APC) could help.”
Johnston and Jon Cimino, of Emerson sales
representative Scallon Controls, presented “Sustaining and Extending Advanced Control Value
in an Operating Plant” at Emerson Process Management’s recent Global Users Exchange 2010.
Johnston reports that the C5 refinery’s main operating challenges include:
• A product purification unit that involves multiple distillation trains with 11 columns, both
conventional and extractive;
• Ultra-high purity product specifications that
require very tight quality controls;
• Multiple large, 200+ tray columns that result
in extremely long time constants;
• Different feedstock suppliers with different
qualities;.
• Large energy demands and complex production
requirements; and
• Safety margins required to compensate for
disturbances in feed quality.
by Jim Montague
As part of a DeltaV migration project at the Beaumont plant, Goodyear also implemented Emerson’s
SmartProcess distillation optimizer, which uses embedded DeltaV APC, and has on-line key performance indicator (KPI) calculations. SmartProcess
includes reusable applications that can be pre-engineered and used multiple times. They include a combination of DeltaV composite blocks, modules and templates, APC
tools like PredictPro and Neural, DeltaV
graphics, documentation tools, sample
configurations, and a simple dynamic
simulator. The project also included Emerson’s APC Consulting Services, functional designs, control performance audits and implementation assistance.
First Project:
Balancing Distillation
The initial phase only covered the
first column in the series, to gradually
give the plant’s staff experience with
APC technology, nurture operator
acceptance, and show APC’s value
to Goodyear’s management. APC
will be added in later phases and
other C5 columns by Goodyear’s
engineers themselves with support
from Emerson’s APC consultants.
“At first, the C5 refinery’s operators were uncomfortable with APC,
but the engineers explained its strategic
value to them, and this helped their comfort level,” says Cimino. “It also helped as the
operators got more run-time experience with the
APC tools. The dynamic simulator in SmartProcess was helpful, too. For example, we wanted to
know ahead of time about controller loading issues, and the simulation showed us that controller
loading wouldn’t be a problem.”
N o v e m b e r / 2 0 1 0 www.controlglobal.com
CT1011_41_45_Feature2.indd 41
41
10/26/10 10:25 AM
Orion - Harsh Conditions:Control3
10/18/10
3:40 PM
Page 1
LIQUID LEVEL MEASUREMENT
When the going gets tough,
the tough get an Orion.
Orion level gauges take on the
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in the world’s harshest conditions.
O
rion level controls are built tough. Our Aurora
Magnetic Level Indicator (MLI) combines floatoperated and leading-edge electronic measurement in a
single, redundant indicator. Orion MLIs not only serve
industry’s most demanding applications and environments,
they’re built to thrive in these extremes.
Learn more about new or replacement solutions in
liquid level indication at orioninstruments.com.
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CT1011_full page ads.indd 42
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10/22/10 3:44 PM
AdVANCED PROCESS CONTROL
Goodyear also used SmartProcess’
Distillation Control Module, which
includes standard distillation calculations, module library, predict block
and pre-configured neural blocks.
“The first column in the C5 refinery
separates chemical components based
on different boiling points. Tray temperatures reflect composition on that
tray, but they need to be compensated
for pressure. As a result, control strategies are based on ‘what comes in must
go out,’ and so we need material balance of overhead and feed ratio and an
energy balance of reflux and feed ratio,” explains Johnston. (Figure 1)
To optimize the distillation column, Johnston and her colleagues use
SmartProcess’ function blocks to set
objectives for manipulated variables
(MVs), controlled variables (CVs) and
constraints for overall objective functions, and then view them all in the
software’s optimizer window. “We were
able to set minimums or maximums
for critical variable, and also prioritize
those variables,” adds Johnston. “We
also could establish target setpoints for
the column, and calculate setpoint for
multiple variables.”
When Goodyear turned its newly
optimized controllers on, it immediately gained positive results. “Because
the column consumes so much energy,
Goodyear’s engineers wanted to minimize steam use and reduce the amount
of product going out of the overhead,”
adds Johnson. “Once it was optimized,
the controller immediately started reducing distillate rate and overhead
(OH) concentration. Average product
loss via OH was approximately 22%.
Product impurities were within specifications, and there were new opportunities to reduce safety margin. And, we
reduced overall steam use by 7%.”
Second Project: Optimizing Extraction
The second project’s challenge was to
optimize the C5 column’s extractive
distillation system for isoprene, which
involves four variables. “The tempera-
CT1011_41_45_Feature2.indd 43
ture setpoint needs to be such that the
sidedraw contains most of the impurities, but not too much product,” says
Johnston. “We first need good information for our manipulated variables,
and then we can run tests in manual or
automatic.” (Figure 2)
These process variables include
MVs, CVs, disturbance variables (DVs)
and constraints:
• M Vs consist of controller setpoints
written to by the model-predictive
controller (MPC). For example,
they can include first-column,
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a removable firmware/parameter memory module (which means
that, if the power unit or control unit is replaced, the drive can be
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10/26/10 10:25 AM
DRE-26 Control
6/15/10
3:00 PM
Page 1
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CT1011_full page ads.indd 44
10/22/10 3:46 PM
Bottoms Main Product
ADVANCED PROCESS CONTROL
Complicated
OH condenser
system
TI
Temperature SP
needs to be such
that the sidedraw
contains most of
the impurities
but not too
much product
LC
Lt Ends
Impurities
This flow sets the
material balance (D/F)
Feed 2
Feed 1
At constant OH rate,
this temp sets the
energy balance (R/F).
TC
MV
Product
Before APC
Impurities
Feed
TC
Steam
After APC
FC
Solvent
Bottoms Main Product
FIRST PROJECT PROCESS OVERVIEW
Rolling AVG Product Loss
CV
Solvent
Btms product
returned to
previous column
SECOND PROJECT PROCESS OVERVIEW
0
20
40
60
80
100
120
140
Days
BIG SAVINGS
Figure 1: The first distillation column in the C5 Figure 2: This process involves a very active, two-col-
Figure 3: Among the two projects’ multiple
refinery/isoprene unit at Goodyear’s plant
umn extractive distillation system, which was opti-
gains, the second’s advanced process
separates components based on different
mized using manipulated variables (MVs), controlled
control (APC) greatly reduced product loss
boiling points.
variables (CVs) disturbance variables (DVs) and
in the C5 refinery/isoprene unit’s distillation
constraints.
process.
Temperature SP
needs to be such
that the sidedraw
contains most of
the impurities
but not too
much product
CV
Feed
MV
TC
FC
Steam
Solvent
side-draw temperature setpoints.
concentration in the purge stream. Overhead product qualRolling AVG Product Loss
• CVs include
process
variables
to
be
maintained
at
a
speity was not negatively impacted. We reduced product losses
Product
Impurities
cific value or set point, such
as column OH pressure.
by 7,000 pounds per day. And we reduced energy consump• DVs are measured variables that may also affect the
tion a moderate amount,” adds Johnston. (Figure 3)
Before APC
value of controlled variables, such as solvent concentraTo maintain its new APC tools and system in the future,
tion, feed flowrate, reflux remperatures and first-column Goodyear may need to change the limit ranges of its manipOH pressure.
ulated,
controlled or constraint variables if feed rate or comAfter APC
Solvent
• Constraints
(LV) are variables that must be kept within position change significantly. “We may also need to tweak or
Btms product
returned to
an operating
range, such as product stream impurity rebuild our models at some point, and we might need to reprevious
column
0
20
40
60
80
100
120
140
level and percent of product in the impurity stream.
generate the controller to adjust performance versus robustDays
Models were developed for the four process variables, and ness, such as in ‘penalty on move’ versus ‘penalty on error’
Goodyear’s engineers used their own knowledge to adjust situations,” she concludes.
the models’ parameters. Actual process data were then used
Goodyear plans to install SmartProcess Distillation modto validate the models.
ule and APC models on its additional distillation columns
Johnston said the modeling and tuning resulted in im- in the C5 refinery process unit, and explore the potential for
proved temperature control, further reduced product loss, using APC in other units on non-distillation applications.
and improved impurity levels. “The new control scheme in
Jim Montague is Control’s executive editor
our second project also reduced the rate and the product
Rolling AVG Product Loss
Before APC
After APC
0
20
40
60
80
100
120
140
Days
CT1011_41_45_Feature2.indd
45
VibIO_Con_Nov10
o.indd 1
10/26/10
10:26
AM AM
10/18/10
10:52
When Precision Means Everything.
At Badger Meter, we’re continually focused on enhancing our
product offerings to be even more accurate, more precise and
more effective for your most critical and demanding applications.
From chemical and food and beverage processing to research,
Badger Meter can provide a standard or custom-designed
control valve to help improve every application. Every time.
800-656-3837 | www.badgermeter.com/valvefam23.aspx
© 2010 Badger Meter, Inc.
CT1011_full page ads.indd 46
High Performance Solutions
10/22/10 3:48 PM
Valves
TurnAround
Because they serve in the vital junctions of every process application,
valves get plenty of attention in the form
of upgraded designs, improved transmitters, enhanced diagnostics, better networking
and new safety functions.
Everyone must love valves because they’re always trying to of steam per hour for two nearby soda-ash (sodium carbonhelp them out. As a result, for a basic and traditional piece ate) production plants. (Figure 1). The feedwater is obtained
of hardware, valves get more attention than your average from the River Dane, cooled and pre-treated to remove any
algae or silt, then passed through one of the six
starlet. Some fans bring technical fixes to the
valves and actuators themselves, but more often by Jim Montague filters before being sent to a holding tank.
Consequently, E.ON installed an 8-in. Fisher
than not, lately this parade of assistance includes
more capable and wireless transmitters, improved diagnos- Control-Disk rotary valve from Emerson Process Management (www.emersonproces.com) to replace its original buttics components and software and many other accessories.
Truth to tell, however, valves get so much affection be- terfly valve. Control-Disk’s thicker disk profile and true
cause their users’ applications and continued employment equal-percentage characteristics enable it to adapt to changdepend on them and because they also wear down, hinder ing process conditions and provide control over a wide range.
performance and even break with startling regularity. Even The valve provides 15% to 70% travel without compromising
valves that are less in the spotlight, such as those in safety or capacity, which is a big improvement compared to standard
emergency-shutdown settings, usually get regular check-ups butterfly valve designs that offer 25% to 50% of travel.
E.ON adds its new rotary valves dramatically improved
and updates for obvious reasons.
its backwash flow control without compromising capacity at
peak demand. Since it was installed, the plant hasn’t lost
Butterfly to Rotary
Sometimes true devotion to valves is expressed in a sim- any filter media or experienced any downtime due to waple redesign or shift to a new method that better serves a ter filter problems. “The Fisher Control-Disk valve not only
given application. For instance, E.ON’s combined heat and controls the backwash flow rate more accurately, but when
power (CHP) plant in Northwich, Cheshire, U.K., used to 100% open, it delivers a flow rate adequate to meet the water
have problems with backwash flows when air scouring and plant’s demands without restrictions. Its performance and
backwashing the six filters used to pre-treat feedwater for its reliability led to savings of £3500 a year and enabled us to
make-up boiler. The original butterfly valve used in this pro- improve our customer service,” says Neil Price, E.ON’s imcess couldn’t provide a steady flow rate, causing media to be provement and performance coordinator.
Though necessary to maintain production, profitabillost through the filters. As a result, the filter media had to be
ity and safety, valve redesigns and technical shifts still can
replaced or refilled at an average cost of £3500 a year.
E.ON’s CHP facility in Northwich is one of the largest of be jarring to plant-floor staff, so they understandably avoid
its type in the U.K. It generates 130 megawatts of electricity them as long as possible. To ease these transitions, K-Tork
for local residents and can supply approximately 500 tons Actuators and Controls (www.ktork.com) reports that trainN O V E M B E R / 2 0 1 0 www.controlglobal.com
CT1011_47_50_Feature3.indd 47
47
10/26/10 10:29 AM
VA LV E S
ing remains vital to making sure users are comfortable with,
believe in and can see improvements from their new valves.
“The best way is to ship a new product and send a qualified technician to demonstrate it in the user’s own pipeline,”
says Jeff Butler, K-Tork’s field services technician and project
manager. “Three or four years ago, I was at Pacificorp’s coalfired power station in Huntington, Utah, where they were
changing out 88 actuators and drives on their combustion air
control process, and the training impressed their staff with
how easy the replacements were to set up. In fact, they were
able to do it on their own from the first day. Traditional positions take about 15 minutes to calibrate, but the new smart
positioners took about 5 minutes each.”
Smarter Means Safer
One of the most significant evolutions in valve technology
lately has been its growing links to more sophisticated diagnostics and supporting software via fieldbuses, Ethernet
and now wireless networking. And, despite some initial reluctance, these ties are proving they can help valves function
better and at least as safely as their traditional counterparts.
BATTLING BACKWASH
Figure 1: To better clean filters that pre-treat water from
the River Dane, E.ON’s combined heat and power (CHP)
plant in Northwich, Cheshire, U.K., switched from butterfly
to rotary valves in its air scouring and backwash process.
“ We Deliver
ToTal QualiTy.”
Failure is not an option in a Cashco valve or
regulator application. Your business and
our reputation depend on total quality
and reliability.
That’s why every Cashco employee is
involved in our ISO 9001:2000 Quality
Assurance Program. It’s why we test every
unit to ensure 100 percent product
functionality before it leaves the
factory. And it’s the reason the
return rate on Cashco warranted
products is less than one percent.
Holly Fries, Inside Sales Engineer
4 Years Industry Experience
www.cashco com
Innovative Solutions
CAS-181A.indd 1
CT1011_47_50_Feature3.indd 48
Cashco, Inc., P.O. Box 6, Ellsworth, KS 67439-0006, Ph. (785) 472-4461, Fax: (785) 472-3539
11/25/08 11:43:32 AM
10/26/10 10:30 AM
CT1011_full page ads.indd 49
10/22/10 3:52 PM
Va lv e s
Historically speaking, Eric van Gemeren, vice president of
R&D for Flowserve’s (www.flowserve.com) valve division, says
valve actuators and positioners are at an evolutionary inflection point because users are waking up to three major changes
in their applications and businesses. “First, many petrochemical and power facilities are losing older technicians, so a lot
of diagnostic competency and knowledge is walking out the
door,” says van Gemeren. “Second, there’s more heightened
awareness of the need for safety and security in process applications because of recent incidents. And, third, the technology and costs of valve technologies are changing dramatically,
so that now it’s possible to add awareness affordably to even
the simple devices that move valves up and down. This allows
more actuators and positioners to be placed in more critical
points and then give users more useful information than before. As a result, many actuators and positioners are taking on
roles that some operators and technicians used to do.”
Likewise, when an automation upgrade project at La
Vertiente gas plant in the Villamontes tropical zone in Bolivia required implementation of motorized valve equipment with Safety Integrity Level 2 (SIL 2) certification, the
CT1011_47_50_Feature3.indd 50
plant’s engineers researched and settled on using 31 of Rotork Fluid Systems’ (www.rotork.com) spring-return failsafe,
quarter-turn, Scotch-yoke, pneumatic actuator packages
with mechanical, partial-stroke test capabilities. Owned
by BG Bolivia, La Vertiente processes gas from the remote
Escondido, Los Suris, Palo Marcado and La Vertiente gas
fields, and supplies natural gas and stabilized condensate to
YPFB, the country’s national hydrocarbon company.
The new actuators are installed on emergency shutdown
(ESD) valves in La Vertiente’s most critical processing areas.
Their applications consist of hydrocarbon condensates and
water, leaving the raw gas separators, glycol and hot oil in
the regenerator, and natural gas throughout many of these
processes, including the gas inlet manifold and the power
gas for the compressors. Besides providing La Vertiente with
its new, more capable actuators, Rotork also supplied 28 CPrange and three GP-range, SIL 2, actuated-ball-valve packages. These were delivered by Prosertec, Rotork’s representative in Bolivia, which also provided on-site support with
installation, commissioning and start-up.
Jim Montague is Control’s executive editor.
10/26/10 10:31 AM
CntrlProdMigration_Ad.qxd:CntrlProdMigration_Ad
10/17/08
9:19 AM
Page 1
GE
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The migration embeds our most advanced Mark VIe technology
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for future enhancements and life cycle support. Improved
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For faster migration with less downtime, call your local controls
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CT1011_full page ads.indd 51
10/22/10 3:53 PM
What are the best choices for the
future of my APACS+ system?
You have the choice, we have the options. Let Siemens show you
how to fully protect the investment in your current APACS+ system.
By supporting you through 2020, Siemens provides a range of modernization options to keep your plant productive
and up-to-date with the fast-paced changes in the marketplace today. Learn more about available products and
solutions for your APACS+ and QUADLOG systems by visiting us online at www.usa.siemens.com/apacs2020.
Answers for industry.
APACS_Ad_1_Control_Nov_2010.indd 1
CT1011_full page ads.indd 52
9/21/2010 1:12:14 PM
10/22/10 3:55 PM
T E C H N I C A L LY S P E A K I N G
Intrinsic Safety Often the Best Option
Installing electrical and automation panels in hazardous areas requires use of one of
three protection methods: explosion-proofing (Exd), purge and pressurization (Exp)
or intrinsic safety (IS).
Exd contains the pressure of the explosion, and then cools it
through a critical flame path to a level that will not ignite the surrounding environment.
Exp protects the environment by segregating
hazardous material from the ignition source
before equipment is powered. First, explosive
mixtures are purged from the enclosure; then
a positive pressure is maintained inside the enclosure to insure hazardous gasses do not propagate back in during operation.
IS protection limits the energy entering the
hazardous area to a level incapable of igniting
the easiest ignitable concentrations of gas/air
mixtures under fault conditions.
“None of the protection methods can provide
absolute certainty of preventing an explosion,”
observes Robert Schosker, product manager for
intrinsic safety and HART at Pepperl+Fuchs
(www.pepperl-fuchs.com). “However, statistically, the probabilities are so low that not even
one incident of an explosion has been verified
when a standardized protection method has
been properly installed and maintained.”
Joe Zullo, IS business unit manager for
the Americas at Cooper Crouse-Hinds MTL
(www.cooperindustries.com), adds that, “The
common methods of IS are Exia (safe under
two faults) and Exib (safe under one fault).
Though the United States and Canada do have
zone classifications on the books, most installations fall under the division concept, which
requires Exia equipment.”
IS is feasible only when total power requirements are relatively low. Electrical distribution
panels aren’t candidates for IS, nor are most
analyzers and some instruments, all because of
their relatively high power requirements. But, if
the components in the panels have low powerneeds, then IS is often the best solution.
“IS is the only method permissible in all
classes, divisions and zones—and the only
method accepted for Zone 0. No special wire,
cable, enclosures, conduits, seal-offs or alarms
are required. Hot maintenance is allowed. The
flexibility and ease of installation and maintenance make it very effective for process control
and measurement,” explains Zullo.
Despite its advantages, IS isn’t widely used
in some parts of the world. “IS is very popular
in Europe and Asia, but not so much in the
United States or the Middle East,” notes Rob
Stockham, general manager of Moore Industries-Europe (www.miinet.com).
Many observers chalk up the relatively low
use of IS to nothing more than greater familiarity with other protection methods. If so, this
prevents an opportunity for money saving in
these areas by thinking outside the explosionproof and purged-enclosure boxes.
“Relative to maintenance costs, intrinsic
safety is the most advantageous because it allows live maintenance with no need for plant
shutdown. Intrinsic safety is also more reliable
because of the use of de-rated components as
prescribed by the standards,” says Schosker.
“Comparing the three most widely used protection methods, intrinsic safety is preferred for
safety and reliability reasons. Intrinsic safety is
also the most economical for installation and
maintenance. The use of intrinsic safety provides the best mix of an affordable system and
safety requirements.”
Stockham seconds Schosker’s opinion, but
adds some caveats. “With IS, there is never
enough energy to initiate an explosion, so conventional panels, wiring and glands can be
used. The costs of devices and installations can
be less, and the devices can be accessed and
worked on live,” explains Stockham. “However,
IS systems have to be planned and designed using certified components matched to meet safe
electrical system parameters. Not all devices
can be made IS, and some site policies may
prohibit mixing of protection methods to avoid
confusion.”
DAN Hebert
Senior Technical Editor
dheber t@putman.net
Not one incident of
an explosion has
been verified when
a standardized
protection method
has been properly
installed and
maintained.
N o v e m b e r / 2 0 1 0 www.controlglobal.com
CT1011_53_TechSpeak.indd 53
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10/25/10 12:57 PM
ask the expertS
Microprocessor Control of Remote Pipeline Sites
“Ask the Experts” is moderated by Béla Lipták (http://belaliptakpe.com/), process control consultant and editor of the 3-volume
Instrument Engineer’s Handbook (IEH). He is recruiting co-authors for the 5th edition now and welcomes contribution offers
from qualified colleagues. Also, if you have questions for our team of experts, please send them to liptakbela@aol.com.
Q
I am working on a fun historical project and am
trying to find information on the SCADA systems
used on gas pipelines in the late 1970s and early
1980s. I have found a few articles, but because it is preInternet, information is sparse. In particular, I am looking for information on the RTU, MTU and compressor
automation technologies used on projects that were installed on projects such as the Alaskan Pipeline:
• Who manufactured these systems? In those days,
the players seem to be companies like AGTL/NOVA,
Baker and DATAP, not the ones we see today.
• How was SCADA deployed and what were the design
strategies? How active was the control at the MTU? How
were critical systems like compressor control managed
on the SCADA system?
• What were the underlying processors and operating systems? This was pre-PC, so I guess VAX and 8080,
but there were also HP projects from around then. Were
most of the RTUs “home-grown” or did companies like
Siemens have their early S-Series processors in this market?
• What was considered leading-edge technology and
who was working on it? Calgary had a very vibrant community of SCADA inventors. Does anyone know any of
the people involved in those early projects?
• Does anyone have ideas where else to ask?
I was a very young engineer in those days and never
really got involved in the SCADA technology from that
period. After 1986, I have enough information, but by
then the systems had started evolving to the PC-based
systems we see today.
Eric Byres P.Eng
eric@byressecurit y.com
A
In the late 1970s and early 1980s, Modcomp computer
systems were widely used in SCADA and pipeline systems. They are still in business, but no longer make
computers. They competed against the Data General and
Digital Equipment Co. (DEC). (Two more names that have
not lasted.)
I did software support on the Modcomp II computers running the Max 2 operating systems on the Alaskan pipeline.
54
The Modcomp systems were designed for real-time applications, including steel mills, nuclear power plants, refineries,
chemical plants and pipelines. I had heard, but can’t confirm, that Modcomp received the business because Digital
did not want to take the liabilities for running in these risky
applications.
In the SCADA system, the MTUs were PLCs that performed local control. They used radio transmitters and receivers connected to modems to send periodic updates (I
seem to remember about 5 minutes or more) to the Modcomp II SCADA system. The SCADA system was implemented in Fortran (remember that language?), and was
custom-built for the pipeline. The system provided pipeline
operators with real-time visibility into the operation of the
pumping stations and material flows and pressures. They
could send commands to the MTUs and pumping stations
using the same method for control. The Modcomp SCADA
system sent its data to a corporate system that provided overall (across the U.S.) visibility of the status. I think this system was also custom-built for the company. Here is a link
to information about Modcomp: www.cs.uiowa.edu/~jones/
modcomp/
Dennis Br andl
DnBrandl@BRLConsulting.com
A
I worked for ModComp in the late 1970s. That was
before the PLC era really started. I don’t know what
equipment ModComp used for the RTUs then, but
later they developed the Modex, a small ModComp CPU
with integrated I/O. Before that, most of the RTUs were
built from Computer Products I/O boards.
One of the largest SCADA projects that I worked on
was for the Tennessee Valley Authority (TVA). They had
RTUs with PDP-11 computers at every dam site. Each was
equipped with a local control center, but connected by
leased telephone lines to SCADA remote master stations.
As I remember, this system with more than 100 remote and
master nodes was supplied by a Swiss or German supplier
with a proprietary communications protocol.
The other SCADA system I remember was made by
EMC, and was based on the DEC PDP-11 at first and the
VAX later. Eventually, the RTU for this SCADA system was
www.controlglobal.com N o v e m b e r / 2 0 1 0
CT1011_54_55_ATE.indd 54
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ask the expertS
built with the TI-550 PLC, but later was
switched to use one of the Siemens Simatic series after Siemens purchased the
PLC division of Texas Instruments.
Solar Energy
CO2
CO2
Richard H. Caro, CAP
E-mail: RCaro@CMC.us
Q
You wrote about the suitability of
the process control principles to
control the economy, the weather,
the protection of our rivers, the stabilizing of global warming, etc. You also
mentioned that the delayed conversion
from exhaustible to inexhaustible energy
sources can change the process of human evolution from a “continuous to a
batch” one. What did you mean by that?
Solar Energy
Oxygen
CO2
CO2
Food (Energy)
Mammals
Solar Energy
Rain
Evaporation
Vegetation
Oxygen
Solar Energy
Rain
Organic Wastes
Food (Energy)
Evaporation
Solar Energy
Mostly
Mammals
Vegetation
Oceans
CO2
CO2
Untouched
Organic
Wastes
Energy
Deposits
Oxygen
Mostly
Solar Energy
Oceans
Rain
Fossil/U
235
Untouched
Food (Energy)
Evaporation
Energy
Rivers
&
Ground
Water
(H
0)
2
Mammals
Vegetation
Deposits
Fossil/U
Organic
Wastes
235
Rivers & Ground
Water (H20)
Mostly
Oceans
Pre-industrial age until about 1700
AD this process was “continuous”
Untouched
CO2
CO2
Energy
Deposits
Fossil/U235
Solar Energy
CO2
Oxygen Water (H20) Solar Energy
CO2 Rivers & Ground
Solar Energy
Rain
CO2
Food (Energy)
Evaporation
Mammals
Vegetation
Oxygen
Solar Energy
Rain
Organic Wastes
Food (Energy)
Evaporation
Solar
Energy
CO2
Exhausting
Mammals
Vegetation
Oceans
CO2
CO2
The Planet’s
Organic
Wastes
Energy
Deposits
Oxygen
Exhausting
Solar Energy
Oceans
Rain
Fossil/U235
The
Planet’s
Food
(Energy)
Evaporation
Energy
Rivers & Ground Water (H20) Vegetation
Mammals
Deposits
Fossil/U
Organic
Wastes
235
CO2
Nichol as Wagoner
nickwagoner@rogersa.com
A
As you know, a batch process is
one that has a beginning and an
end. The figure on the right illustrates the “process of life” as it operated prior to the industrial age, during
it, and how it should operate during
the coming post-industrial age.
During the pre-industrial age, the
food energy from the vegetation plus
water and oxygen were sufficient to
maintain the continuous process of
life on the planet indefinitely.
In the present industrial age, more
and more exhaustible energy is obtained
from the diminishing fossil and uranium deposits (shown in red). This cannot continue forever, and therefore I call
the present operation a batch process.
In the future, when the exhaustible
deposits are gone, hopefully we will
have converted to a solar-hydrogen
based energy economy that depends
on the free, clean and inexhaustible
energy supply from the sun. You can
find a detailed description of such a
power plant and reversible fuel cell
(RFC) at http://belaliptakpe.com/solar-hydrogen-power-plant/.
Bél a Lipták
liptakbela@aol.com
Rivers & Ground
Water (H20)
Exhausting
Oceans
The Planet’s
Energy
Solar Energy
Deposits
Fossil/U
During
about
1700 - Solar
2200Energy
this process became
235
Oxygenthe industrial age between
CO
CO
an unsustainable 2“batch”
process
asWater
mankind
Rivers
& Ground
(H20) 2started to depend on
Solar Energy
exhaustible fuel deposits.
Solar Energy
Oxygen
Oxygen
Solar Energy
Rain
CO
Inexhaustible H2 Energy
2
CO2
Food (Energy)
Energy From
Evaporation
Solar-H2
RFC
Mammals
Vegetation
Oxygen
Power
Solar Energy
Rain
Organic Wastes
Solar
Energy H2 Energy
Inexhaustible
Plants
Food (Energy)
Energy From
Evaporation
Solar Energy
Solar-H2Oxygen
Mostly
RFC
Mammals
Vegetation
Oceans
CO2
CO2
Power
Exhausted
Organic
Wastes
Plants
Energy
Deposits
Oxygen
Mostly
Solar Energy
Oceans
Rain
Fossil/U
Inexhaustible H2 Energy
235
Exhausted
Food (Energy)
Energy From
Evaporation
Energy
Rivers
&
Ground
Water
(H
0)
Solar-H2
2
RFC
Mammals
Vegetation
Deposits
Power
Fossil/U
Organic
Wastes
235
Plants
Rivers & Ground
Water (H20)
Mostly
Exhausted
Energy
Deposits
Fossil/U235
Oceans
Rivers & Ground Water (H20)
In the post-industrial age after about 2200 this process can again become
“continuous” if mankind converts to using inexhaustible solar energy
to generate the hydrogen.
Figure 1. The pre-industrial, the industrial and the post-industrial cycle of energy generation and consumption shown as batch and continuous processes.
N o v e m b e r / 2 0 1 0 www.controlglobal.com
CT1011_54_55_ATE.indd 55
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10/26/10 10:36 AM
Setting the Standard
in Process Measurement Applications
Integral or
Remote-Mounted
Transmitter
Compatible with
all Ronan
Detectors
Ideal for
Continuous Level,
Density, Mass
Flow and Weight
Applications
Rigid Crystal
Flexible
Detector
Density
Introducing the NEW X96SI/R
The Only Radiometric Transmitter With Full Ethernet Capability!
Ronan pioneered the use of low-level sources
to improve efficiency and safety.
Only Ronan manufactures the RLL low-level source, which
does not require the stringent documentation, training or
handling procedures of other gauges.
THE STANDARD IN NUCLEAR MEASUREMENT TECHNOLOGY
Ronan Engineering is dedicated to manufacturing radiometric measurement systems
that are tailored to your specific needs and requirements. We provide customized
solutions to solve your toughest process measurement challenges.
859.342.8500
sales@ronanmeasure.com
www.ronanmeasure.com
CT1011_full page ads.indd 56
10/26/10 10:33 AM
ROUNDUP
PLCs and Industrial Computers
The latest PLCs, PACs, embedded units and other computing goodies.
PLC/PC HYBRID
FANLESS EMBEDDED COMPUTER
The 758 Series IPCs pair
CoDeSys V2 software, Linux
OS, IEC programming languages and multiple onboard
fieldbus protocols for realtime control applications.
Independent Ethernet ports
provide fieldbus connectivity and support Profibus and CANopen protocols. Direct
connection to the 400+ modules in the Wago-I/O-System
is possible.
Wago
800/DIN-RAIL; www.wago.us
The Uno-3084 fanless embedded automation computer with front-accessible
I/O design features an Intel
Core 2 Duo L7500 1.6 GHz
processor, 2GB DDRII RAM
(expandable to 4GB), dual
DVI-I ports with support for
up to three displays, two RS-232/422/485 ports with automatic flow control, and two 10/100/1000 Base-T RJ-45 ports
and five USB 2.0 (one internal) ports.
Advantech Industrial Automation
800/205-7940; www.advantech.com/ea
CPU FOR HIGH-END CONTROL APPLICATIONS
SMART PAC
The RX3i CPU315 is ideal
for applications where large
amounts of data and application optimization are needed.
The 1-Ghz processor enables
applications to reduce machine cycle times. It has 20
Mbytes of battery-backed
user memory and 20 Mbytes of flash user memory, configurable data and program memory, programming in Ladder
diagram, structured text, function block diagram and C.
GE Intelligent Platforms
800/433-2682; www.ge-ip.com.
Smart SoftPLC includes a
four-port managed Ethernet
switch/router with PoE and
fiber connection options, five
serial ports and an option for
an RS-485 or phone modem.
It combines I/O control and
logic, rich communications,
an embedded firewall/VPN and an embedded web server in
a small, value-priced package that can handle applications
ranging from simple and small to large and challenging.
SoftPLC
512/264-8390; http://softplc.com
ePC LITE FANLESS PC
PRODUCTIVITY IN PAC FORM
The ePC Lite is a low-cost,
fanless version of the ePCSeries industrial computers.
It has an Intel-based, fanless
Atom N270 CPU board and
solid-state drive. Its 1.6 GHz
processor provides processing
power to HMI and SCADA
applications. Windows XP Pro, SATA 40-GB solid-state
drive, 15-in. XGA LCD, 1-GB DRAM, analog resistive fivewire touchscreen, and a NEMA 4 front panel are standard.
Nematron
734/214-2000; www.nematron.com
The Productivity3000 PAC
combines features and capabilities of a PC-based control
system with that of a typical
PLC. It is a modular, rackbased system of up to 116,000
I/O points with local, expansion and remote I/O bases
and a full lineup of discrete, analog and specialty I/O modules. The high-performance CPU has 50Mb memory, fast
scan times and seven communication ports.
Automation Direct
800/633-0405; www.automationdirect.com
N o v e m b e r / 2 0 1 0 www.controlglobal.com
CT1011_57_60_RoundUp.indd 57
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10/26/10 10:38 AM
ROUNDUP
COMPACT, BATTERY-LESS PLCS
Simple, intuitive and exceptionally powerful, Modicon
M340 PAC provides numerous cost and performance
advantages over comparably priced PLCs. It requires no
battery and is a compact 4 in. high and 3.7 in. deep with
high-density, 64-point I/O cards, and is only 1.25 in.
wide. It uses CANopen networks and USB cables. The
PAC has 4 Mb of memory upgradeable to 16 Mb and a
70K instructions/ms execution speed.
Schneider Electric
847/397-2600: www.us.schneider-electric.com/PLC
WIRELESS PAC
Snap-PAC-R1-W is a rack-mounted PAC with IEEE
802.11a/b/g Wi-Fi networking, two independent 10/100Mbps wired interfaces for standard Ethernet networking, and one RS-232 serial port for PPP communication.
It provides control, communication, I/O processing, remote monitoring and data acquisition, and is fully integrated with Opto 22’s PAC Project software and all
Snap-PAC brains and I/O modules.
Opto 22
951/695-3000; www.opto22.com
GENERATE IEC CODE AUTOMATICALLY
Simulink PLC Coder extends model-based design for
the industrial automation segment by helping create
source code in structured text (IEC 61131-3 ST) using
Simulink models that can be easily integrated in B&R
Automation Studio. It complements the Automation
Studio Target for Simulink. Users can generate ANSI-C
or structured text code alternatively, and automatically
integrate it into the automation project.
B & R Automation
770/772-0400; www.br-automation.com
MICRO PLC WITH RS485 CAPABILITY
MicroSmart Pentra is now available with optional
RS485 communications. It is the only micro PLC on the
market that allows control systems to seamlessly communicate with up to seven serial devices via RS232C or
RS485. Now, with the new RS485 communication module, it can talk multiple communication protocols on
the same system. For fast transmission speed, this unit
also supports communication baud rates up to 115Kbps.
IDEC
800/262-4332; www.IDEC.com/usa.
CT1011_57_60_RoundUp.indd 58
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ROUNDUP
PACS FOR EXTREME APPLICATIONS
NI cRIO-9023 and NI cRIO-9025 real-time controllers
are ideal for high-performance measurement and control applications operating at extended temperatures.
They operate in a range from -40 °C to 70 °C and are
available with conformal coating for additional protection in harsh conditions. The 9023 has a 533 MHz PowerPC processor. The 9025 has an 800 MHz PowerPC
processor and dual Ethernet ports.
National Instruments
800/258-7022; www.ni.com/compactrio
BetaProbe™ TI
Precision
Thermometer
FLAT-PANEL MONITORS FOR DUSTY SPACES
VisuNet Series industrial flat-panel LCD monitors have
Class II Division 2 certification for use in dusty environments. They’re also available as general-purpose displays, as UL-listed Class I/Div 2 devices, and can be
combined with a Bebco EPS purge system for Class I/
Div. 1 hazardous environment mounting. Touchscreen
options are available. They come in 10-, 12- 15-, 18-, 19and 20-in. sizes, and are rated for use from -10 °C to 55 °C.
Pepperl+Fuchs
330/486-0002; www.pepperl-fuchs.us
MASTERLOGIC PLC
MasterLogic PLCs bring power and robustness to highspeed logic, interlock and sequencing applications.
They can be deployed in a standalone mode or used
with the Experion Process Knowledge System architecture, and are compatible with Honeywell’s portfolio of
process control systems, including the recently released
Experion LS. MasterLogic CPUs, power supplies, rack
sizes and I/O selection are suited to many applications.
Honeywell
800/343-0228; www.honeywell.com/ps/hfs
INDUSTRIAL-STRENGTH MONITOR
NX Series enclosed industrial display system is a
NEMA-sealed, commercial-grade, large monitor built
in a rugged-steel 14-gauge enclosure. It can operate
as a standalone monitor, or it can be integrated with a
Modpak modular computer system, which allows easy
serviceability, service removal and upgrading. It has a
Lexan protective lens window and sealed connectors for
power, Ethernet and USB ports.
Dynix
734/677-6100; www.dynics.com.
CT1011_57_60_RoundUp.indd 59
.
..
.
..
..
.
.
.
.
..
High performance model with
wire wound RTD probe
Accuracy: ±0.04°C
Range: -90 to 300°C
Standard model with thin film
RTD sensor
Accuracy: ±0.06°C
Range: -50 to 160°C
Integral adjustable angle probe
Intrinsically safe (IEC Ex
and ATEX)
Replace multiple L-I-G
thermometers
User adjustable stability
indicator
Data logging with optional
BetaLOG-TI™ software
Large, bright display with
backlight
Min/Max capture
Easy field recalibration
10/26/10 10:40 AM
ROUNDUP
60
EXTREME-ENVIRONMENT PANEL PC
ENERGY-SAVING EMBEDDED PC
The Allen-Bradley Extreme
Environment Panel PC combines intrinsic safety with
the capacity to withstand extreme temperatures. With
U.S. NEC Class 1, Division 2
hazardous location certification, it can be used in areas
where explosive materials are present. It is rated to withstand
temperatures from -20 °C to 70 °C inside the computer cabinet, and display side temperatures of -20 °C to 55 °C.
Rockwell Automation
www.ab.com/industrialcomputers/
The new CX5000 has Intel
Atom technology and up to
1.6 GHz of processing power.
It has a magnesium housing,
making it lightweight, and
improves its mechanical stability and resistance to EMC.
The DIN rail-mountable
PAC has a fanless design with a maximum power loss of 12.5
Watts. Just 3.9 x 3.9 x 3.6 in. (100 x 100 x 91mm), CX5000
also is exceptionally compact.
Beckhoff Automation
952/890-0000; www.beckhoffautomation.com
UPGRADED CONTROLLER BASE STATION
INDUSTRIAL PCS WITH HIGH-SPEED PROCESSOR
The upgraded base station
for the Nanoline controller, nLC-055, is designed for
small to mid-sized machines
with limited I/O points. It
can add, subtract, multiply
and divide, as well as perform
modulo (percentage) operations. Other new features include two analog inputs with 12bit resolution, eight digital inputs, two high-speed counters,
a built-in real-time clock and four relay outputs.
Phoenix Contact
800/322-3225; www.phoenixcontact.com/usa_home.htm
Siemens introduces four industrial PCs built with the
Intel Core i7 (i series) processor. The Simatic IPC627C
box PC and the HMI
IPC677C panel PC are suitable for high-speed measurement, open- and closed-loop
control tasks, and their HMI functions directly at machine
level. The 19-in. IPC847C rack and compact IPC647C rack
PCs are designed for continuous, 24-hour service.
Siemens Industry, Inc.
www.sea.siemens.com
TWO-NETWORK HMI
SENSOR DATA VIA THE INTERNET
G3 Series HMI is available
with the new Ethernet expansion card, G3Enet. Now
users can add a second Ethernet port to increase bandwidth and separate networks.
G3 Series HMIs with the
G3Enet card provide communication with devices on two distinct Ethernet networks
simultaneously—without an industrial router. The expansion card can be easily fitted to any G3 series HMI.
Red Lion Controls
717/767-6511; www.redlion.net
RST-5001 network and webenabled 4-20 mA input controller is compatible with any
4-20 mA device, and sends
email and text message alerts
when user-defined limits are
reached. It can be powered
via either a standard 24 VDC
supply or PoE. Conversion options include volume, level,
distance, weight or user-defined units. No special programming software is required.
Automation Products Group
888-525-7300; www.apgsensors.com
www.controlglobal.com N o v e m b e r / 2 0 1 0
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Product introductions
MANUAL VALVES WITH LIMIT SWITCHES
UNIVERAL TRANSMITTER FOR VIBRATION MONITORING
Online Configurator allows
customers to build, view and
price manual valve assemblies. Choices include twoway full-port valves, threeway diverter ball valves,
flanged ball valves and resilient seated butterfly valves.
Limit switch selection includes inductive proximity sensors,
weatherproof and explosion-proof switches. Once virtual assembly is completed, users can view a color image of the
final product, model number, product description and cost.
Assured Automation
800/899-0553; www.assuredautomation.com.
Model 682A16 universal
transmitter for 24/7 vibration monitoring is designed
to protect machinery by providing crucial information
that avoids costly downtime.
It’s ideal for vibration monitoring applications with IMI’s
4-20 mA sensors or its ICP accelerometers. It can be used
with existing PLC, DCS and SCADA systems, leading to
alarm, control or shutdown. It’s DIN rail-mounted and has
an optional detachable front panel LCD display.
IMI Sensors
800/959-4464; www.imi-sensors.com
SUPER-FAST PROCESS TRANSMITTERS
STRAIN GAGE SIGNAL CONDITIONER
JH5000 Series DIN-rail transmitters have been redesigned
to allow a fast response option, while maintaining their
full accuracy specifications.
Option HS (high speed) provides 1 millisecond response
(95% complete). Faster response (or slower) is readily available on special order. Input styles include DC, thermocouple, RTD, strain gauge/
load cell and potentiometer/resistance. Also, math functions
such as add/subtract, multiply/divide and square root are
available.
JH Technology
800/808-0300; www.jhtechnology.com
Model 163MK strain gage
signal conditioner accommodates ¼-, ½- and full-bridge
strain gage applications. The
unit offers 1/4-bridge completion and calibration for applications such as materials and
structural testing. It has two
built-in precision 1/2-bridge completion resistors for 1/2-bridge
applications, and can also handle full-bridge applications. It
has a high-gain differential amplifier, two-pole Butterworth
filter and built-in excitation supply.
Calex Mfg. Co.
800/-542-3355; www.calex.com
ON YOUR RADAR
LIGHT-WEIGHT MODULAR CABINETS
The Optiwave 6300 C Radar
instrument is ideal for solid
measurement of uneven silo
contents. It measures powder, granulates and bulk solids in buffer silos, hoppers,
bulk storage containers and
on conveyor belts. Choose a
3-in. diameter (DN 80) antenna made of polypropylene (PP)
or Teflon (PTFE) or a 6-in. (DN150) PP antenna. Stainlesssteel horn antennas up to 6 in. with a built-in horn purging
feature are also available.
Krohne
800/FLOWING; www.krohne.com/northamerica
Perfect for corrosion resistant
applications and made from
PVC or polycarbonate, this
line of modular cabinets is
available in sizes up to 72 in.
Doors feature stainless-steel,
lift-off hinges with a quarterturn locking provision with
single or double doors. The cabinets include wall- or floormount features. When the product is shipped flat, assembly
at the job site is simplified with exploded view drawings and
factory-supplied hardware. Factory assembly is available.
Midwest Plastic Fabricators
330/995/0992; www.midwestplasticfabricators.com
N o v e m b e r / 2 0 1 0 www.controlglobal.com
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Control Exclusive
Interface Level: Two Technologies are Better than One!
Interface level is hard to do at all, and it is very hard to do well. This is because of the nature of interfaces and
the physics and technology of the measurement of them.
Roughly, an interface occurs when two fluids (or a
gas and a fluid) meet that have dissimilar dielectric constants (Dk). Seldom is it this easy. There are gradients,
rag layers, emulsions and other issues that make it difficult to measure interfaces. In fact, one vendor provides
a camera-based system that looks through a thick Pyrex window to optically detect an interface.
Interfaces where the top level changes or where the dielectric constant of one of the interface layers
changes (adding water to the bottom layer for a
diluent, for example) are even more problematic
than when the interface is two liquids of static
composition and the top level is constant.
There are three basic technologies (other
than the camera) that are used commonly to
measure interface level in liquids. The first
is capacitance or RF admittance, the second
is TDR (guided wave radar), and the third is
gamma nuclear gauging.
Gamma gauges require licensing, and usually, for interface detection, they require an insertion source or inserted detector. Most vessels
aren’t designed to permit this. Gamma gauges
are also significantly expensive, costing approximately $1000
per foot of measured level. In addition, gamma gauges have
other issues that make them prohibitive for all but the most
difficult applications.
Capacitance (or RF admittance) probes, while they must
be inserted in the vessel, are designed to penetrate a standard ¾-in opening in the top of the vessel. Most vessels have
at least one extra tank nozzle that can be used. The overall
or “top” level must remain constant, so that any change in
the capacitance/admittance reading reflects only a change
in the interface level. Capacitance technology is not affected
by emulsion or rag layers in the application.
TDR radar provides the advantage of being able to measure both top level and interface level. But the technology
requires the dielectric of the upper layer to be less than 10
Dk or not enough energy will get through the fluid to reflect
off the interface itself. The one drawback of this technology
is that it does not work well if the application has a rag or
emulsion layer, as the signal gets lost and is not returned to
the transmitter.
Realizing that no one technology provides optimum measurement, Endress+Hauser has introduced the Levelflex
FMP55 Multiparameter Transmitter. This transmitter fuses
62
the two technologies of capacitance and guided wave radar
on the same rod or cable sensor, and provides the benefit of
both technologies. The FMP55 is the first of a new series of
instrumentation that Endress+Hauser is calling
its Evolution Series.
The capacitance part of the transmitter is
responsible for making the interface measurement, while the TDR radar section measures the
overall level. This means rag or emulsion layers
no longer affect the ability to read the interface,
and the use of the radar device allows the overall
level to vary if required.
The FMP55 features a multi-echo tracking algorithm that can track up to 20 tank echoes simultaneously as the tank level rises or lowers. This
makes sure that the transmitter will not make a
“jump” to an echo that is not the true level, such
as a tank internal or a vapor blanket gradient.
The FMP55, like many Endress+Hauser transmitters, is
equipped with a HistoROM built into the main housing of
the transmitter. All of the setup parameters are stored on
the HistoROM and, in the event of an electronics changeout, all of the information can be fed directly into the new
electronics package. In the case of multiple units being set
up at the same time for the same measurement parameters,
the same HistoROM information can be transferred into a
removable display that can be removed and installed in the
next transmitter, greatly reducing setup time during field
commissioning.
Endress+Hauser offers three different setup methods for
the FMP55. The first method is the use of the removable
display. Second, the device can be fully commissioned via
the three buttons on the display itself, using a menu-guided
six-step quick setup. Endress+Hauser’s free FTD/DTMbased FieldCare software program allows for a very flexible
method for setup, and the software can be integrated into a
complete lifecycle management system. HART and Profibus
PA outputs are available.
For more information, contact Endress+Hauser at www.
us.endress.com, or by calling 1-888-ENDRESS.
www.controlglobal.com N o v e m b e r / 2 0 1 0
CT1011_62_Exclusive.indd 62
10/26/10 10:43 AM
C O N T R O L TA L K
Retrofit Projects – Getting Flows Right
Greg McMillan and Stan Weiner bring their wits and more than 66 years of process control experience to bear on your questions, comments, and problems. Write to them at
controltalk@putman.net.
Greg: In the 1970s and 1980s, we suspected
valves and instruments were not delivering
the performance listed in the catalogs. We got
imaginative on how to shift loop setpoints and
add biases to close material and energy balances. There was little published information
on installation effects and drift. A few articles
detailed the effects for a differential head orifice flow meter. One article in 1983 disclosed
that total error for a 0.2% catalog accuracy DP
was 2.1% due to zero and span shifts from process temperature and static pressure. The error
introduced by changes in the tolerance of internal diameter and roughness of pipe and the
wear on orifice edge can be 4%. If you consider
changes in the fluid density and the deterioration in signal-to-noise ratio at low flows, the installed accuracy of these installations could be
5% to 10% even if the upstream piping run had
enough straight lengths. Check out my November entry, “Secret Installation Effects,” at http://
modelingandcontrol.com/ for a list of vintage
articles disclosing the real installed accuracy.
New technologies such as radar level are independent of pressure, temperature, density and
composition, and require no field calibration.
The drift of these new sensor and transmitters
technologies have often been reduced by a factor of five. Periodic calibration checks are not
required for five years or more. If you have old
technology, now is the time to upgrade.
Greg Mcmill an
Stan weiner, pe
controltalk@putman.net
Stan To help understand what is important in
an instrument upgrade project, we continue
our interview of Hunter Vegas, a senior project
leader for Avid Solutions Inc., a system integrator in Winston Salem, N.C.
Greg: What are the biggest problems with getting the right control valves?
Hunter: Probably the hardest thing about control valves is getting the right information for
sizing. The range of densities, flows, inlet and
Stan One of my main objectives on projects
was to use magnetic flowmeters and Coriolis mass flowmeters wherever feasible because
they were largely unaffected by installation and
operating conditions. Except for design and
application mistakes, the calibration was not
questioned whenever there was a problem in
the control room. They also cost less to install
and maintain.
Greg: Modern measurements are either inherently less affected by installation or operating
conditions or have intelligence to compensate
for these conditions. Coriolis meters are much
less sensitive to pipe vibrations. DP transmitters
are corrected for static pressure and temperature. DP flowmeters are corrected for changes
in fluid density for a constant composition.
N o v e m b e r / 2 0 1 0 www.controlglobal.com
CT1011_63_64_ControlTalk.indd 63
63
10/26/10 10:45 AM
C O N T R O L TA L K
Stan: When do you use vortex flowmeters?
through tube designs are are less likely
to plug and have reduced pressure
drop; however, the tube length must
be long, or the meter’s sensitivity can
be reduced. U-tube or other curved
meters have high sensitivity, but often have higher pressure drops and are
easier to plug. Liquids with entrained
gas or foam can create high inaccuracies, but manufacturers are promising
improved performance for these conditions in some higher-end product lines.
The biggest deterrent against using
Coriolis meters is their cost, especially
in larger line sizes.
Hunter: Unlike most other flow me-
Stan What are the problems with
ters, a vortex meter’s flow reading will
fall to zero when the flow falls below
the turbulent flow regime. Therefore,
one has to be certain a vortex meter
will never have to operate below the
point where the reading will drop out.
(This is the low-flow cutoff value cited
in the meter specifications.)
I have also had problems with the
plugging of the pressure sensor ports
with some designs, and the meter is
sensitive to the velocity profile and
varying kinematic viscosity. Despite
that, the vortex meter offers many cost
advantages over head type meters, and
is an excellent choice in the right application. One item worth noting is
that any flowmeter will be worthless
if it is installed incorrectly. Upstream
and downstream meter runs, proper
line bracing and line fill are critical for
proper operation.
magnetic flowmeters?
outlet pressures, and vapor pressures
are usually provided for “normal operating conditions.” However it is the
abnormal conditions (very high/low
flow rates at high/low pressure drops)
that dictate the sizing limitations of the
valve. If it’s in batch service, the range
of operating conditions can be very
wide. I make certain to ask enough
questions of operations and process engineering to make sure I understand
the true requirements of the valve.
Greg: I think Coriolis meters offer
the possibility of a live process flow
diagram (PFD) in specialty chemical,
food and pharmaceutical production.
What is important in Coriolis meter
selection?
Hunter: Coriolis meters are one of the
few meters that measure mass directly,
and provide a temperature and density
signal as well as flow. However, there
are some issues to consider. Straight64
Hunter: In some cases, large line sizes
or process conditions dictate the use
of differential head meters. Their installed costs can be very high, but if
installed correctly, they are extremely
accurate and are often used for custody
transfer.
You can use a pair of DP transmitters across a single orifice to get very
high turndowns, and the addition of
an RTD temperature and integral
pressure measurement enables density compensation for a broad range of
process conditions. A honed meter run
can also eliminate the errors from differences in internal diameter and surface roughness.
Greg: I can relate to this Top 10 list
Hunter: Magmeters are an excellent
meter with minimal pressure drop, but
the liquid must have some conductivity for the meter to work. It is important to understand all of the conditions
that the meter may experience to avoid
problems. I had a magmeter measuring the blowdown on an ammonia
vaporizer that worked well—provided
there were trace amounts of water in
the ammonia. When all of the water
was blown down, the meter saw pure
ammonia, and the very low conductivity made the meter stop working.
Another source of problems can
be the possibility of steam-out on the
lines. Some plants will steam out a
line and then block it, creating a very
strong vacuum as the steam condenses.
Some magmeters employ a sleeve-like
Teflon liner, and when heated by the
steam and subjected to vacuum, the
liner will collapse and ruin the meter.
A liner reinforced with a metal backing
can handle these conditions.
The last area of concern is using a
magmeter in lined pipe. In this situation you must use ground rings to provide an electrical path for the meter to
function.
Greg: When do you use differential
head meters?
from Randy Reiss, who moved from
Austin to NYC for a graduate degree
in math, because I live in Austin but
visit NYC to see my daughter perform
at the Metropolitan Opera.
Top 10 Reasons Why NYC is Friendlier
than Austin
10. The subway rats tip their hats and
say hello (where did they get the hats?)
9. Hell’s Kitchen now rivals Austin in
rainbow banners.
8. The Hudson River is a prettier shade
of gray than Brushy Creek (but smells
the same).
7. The Chrysler Building is like a big
University of Texas tower.
6. Its easier to drive into Manhattan
than downtown Austin—really it is!
(Duh, the benefits of light rail!)
5. The graffiti on the buildings in NYC
rivals most art I saw in galleries on
South Congress (SoCo).
4. “Houseton” street only has one
name.
3. The Brooklyn-Queens Expressway (BQE) moves faster than Loop 1
(Mopac).
2. We never needed the phrase “excuse
me” anyway.
1. In-route subway stop schedule
changes give your day that added extra
variety that makes you smile!
www.controlglobal.com N o v e m b e r / 2 0 1 0
CT1011_63_64_ControlTalk.indd 64
10/26/10 10:47 AM
Contact: Polly Dickson, pdickson@putman.net, 630-467-1300 ext.396
C L A SSI F IEDS
A D I N DE X
Advertiser��������������������������������������������� Page No.
equipment & materials
ABB Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
LOOKING to
ABB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ADVERTISE?
Acromag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Adalet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ABB and Siemens Specialists
Allied Electronics . . . . . . . . . . . . . . . . . . . . . . 37
ABB Advant, MOD 300
ABB Bailey Infi 90
Siemens Moore APACS
Siemens Simatic S5
Large Parts Inventory
Phone: 585 241-6010, Fax: 585 241-6014
www.classicautomation.com
customerservice@classicautomation.com
Ametek Drexelbrook . . . . . . . . . . . . . . . . . . . . 44
AutomationDirect . . . . . . . . . . . . . . . . . . . . 8, 33
AVG Automation . . . . . . . . . . . . . . . . . . . . . . 49
Badger Meter . . . . . . . . . . . . . . . . . . . . . . . . . 46
Beamex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Cashco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
United States Postal Service
Statement of Ownership, Management, and Circulation (Requester Publications Only)
Emerson Process Mgt/Systems . . . . . . . . . . . 68
Emerson Process Mgt/Saab . . . . . . . . . . . . . . 13
Endress + Hauser . . . . . . . . . . . . . . . . . . . . . 6, 7
FasTest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
GE Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Inline Industries . . . . . . . . . . . . . . . . . . . . . . . 58
Keller America . . . . . . . . . . . . . . . . . . . . . . . . 14
King Engineering . . . . . . . . . . . . . . . . . . . . . . 38
K-Tek . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Load Controls . . . . . . . . . . . . . . . . . . . . . . . . . 16
Contact: Polly Dickson
pdickson@putman.net
630-467-1300 ext.396
1.
2.
3.
4.
5.
6.
7.
8.
9.
Publication Title: CONTROL
Publication Number: 1049-5541
Filing Date: 9/30/2010
Issue Frequency: Monthly
Number of Issues Published Annually: 12
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Complete Mailing Address of Known Office of Publication:
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Contact Person: Keith Larson
Telephone: 630-467-1300
Complete Mailing Address of Headquarters or General Business
Office of Publisher: 555 West Pierce Road, Itasca IL 60143
Full Name and Complete Mailing Address of Publisher, Editor,
and Managing Editor
Publisher: Keith Larson, 555 West Pierce Road, Itasca IL 60143
Editor: Walt Boyes, 555 West Pierce Road, Itasca, IL 60143
Managing Editor: Jim Montague, 555 West Pierce Road, Itasca IL
60143
10.Owner:
Putman Media, Inc.
555 West Pierce Road, Itasca, IL 60143
John M. Cappelletti
555 West Pierce Road, Itasca, IL 60143
Julie A. Cappelletti - Lange 555 West Pierce Road, Itasca, IL 60143
Jenny G. Cappelletti
555 West Pierce Road, Itasca, IL 60143
Nicholas G. Cappelletti
555 West Pierce Road, Itasca, IL 60143
Melody L. Cappelletti
555 West Pierce Road, Itasca, IL 60143
11.Known Bondholders, Mortagees, and Other Security Holders Owning
or Holding 1 Percent or More of Total Amount of Bonds, Mortgagees, or
Other Securities. If none, check box: • None
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mail at nonprofit rates( (Check one)
The purpose, function, and nonprofit status of this organization and the
exempt status for federal income tax purposes:
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13.Publication Title: Control
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LOOKING to
ADVERTISE?
Lumenite Control Technology . . . . . . . . . . . 50
Magnetrol International . . . . . . . . . . . . . . . . . 10
Magnetrol/Orion . . . . . . . . . . . . . . . . . . . . . . 42
Martel Electronics . . . . . . . . . . . . . . . . . . . . . 59
Average No. Copies Each Issue
No. Copies of Single Issue
Contact: Polly
Dickson, pdickson@putman.net,
630-467-1300 e
During Preceding 12 Months
Published Nearest to Filing Data
15. Extent and Nature of Circulation
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52,028
54,280
b. Legitimate Paid and/or Requested Distribution (By Mail and Outside the Mail)
(1) Outside County Paid /Requested Mail Subscriptions Stated on PS Form 3541. (Include direct written request from recipient, telemarketing and Internet requests from recipient, paid subscriptions including nominal rate subscriptions, employer requests, advertiser’s proof and exchange copies).
48,772
48,038
. 24
(2) In-County Paid /Requested Mail Subscriptions Stated on PS Form 3541. (Include direct written request from recipient, telemarketing and Internet
requests from recipient, paid subscriptions including nominal rate subscriptions, employer requests, advertiser’s proof and exchange copies).
2,3
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73
73
. 25
(4)Requested Copies Distributed by Other Mail Classes through the USPS
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48,845
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. 18
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(1) Outside-County Non-requested Copies Stated on Form 3541 (include Sample copies, Requests Over 3 years old, Requests induced by a Premium,
. 23
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1,740
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(2) In-County Non-requested Copies Stated on Form 3541 (include Sample copies, Requests Over 3 years old, Requests induced by a Premium, Bulk
07_Looking_House.indd 1
Sales and Requests including Association Requests, Names obtained from Business Directories, Lists, and other sources
. 17
(3) Non-requested Copies distributed Through the USPS by Other classes of Mail (e.g. First-Class Mail, Non-requestor Copies mailed in excess of 10%
Limit mailed at Standard Mail or Package Services Rates)
. 52
(4) Non-Requested Copies Distributed Outside the Mail (Include Pickup Stands, Trade Shows, Showrooms and Other Sources)
152
500
. 31
e. Total Non-requested Distribution (Sum of 15d (1), (2), and (3))
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50,737
53,478
. 40
g. Copies Not Distributed
1,291
802
h. Total (Sum of 15f and g)
52,028
54,280
. 22
i. Percent Paid and/or Requested Circulation (15c divided by f times 100)
96.27%
89.96%
16. Publication of Statement of Ownership for a Requester Publication is required and will be printed in the November 2010 issue of this publication.
. 45
17. Signature and Title of Editor, Publisher, Business Manager, or Owner
Jeremy L. Clark, VP of Circulation
Date: 09/30/2010
. 67
I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes false or misleading information on this
. 39
form or who omits material or information requested on the form may be subject to criminal sanctions (including fines and imprisonment) and/or civil
sanctions(including civil penalties).
Moore Industries . . . . . . . . . . . . . . . . . . . 15, 16
Ohmart Vega . . . . . . . . . . . . . . . . . . . . . . . .
Omega Engineering . . . . . . . . . . . . . . . . . . .
Pentair Technical Products . . . . . . . . . . . . .
Pepperl+Fuchs . . . . . . . . . . . . . . . . . . . . . . .
Red Lion Controls . . . . . . . . . . . . . . . . . . . .
Ronan Measurements . . . . . . . . . . . . . . . . .
Schneider Electric . . . . . . . . . . . . . . . . . . . .
Siemens Process Automation . . . . . . . . . . . .
Swagelok . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ClassicAutomation.indd 1
Tatsoft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wago . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yaskawa Electric . . . . . . . . . . . . . . . . . . . . . .
Vize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yokogawa . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CT1011_65_Class.indd 65
10/26/10 10:48 AM
CONTROL REPORT
The Long View and Valley Power
Time speeds up as we get older, but 10 years is still a big chunk of chronology. And in
this stressed-out era of 24/7 news, showbiz fads, financial scandals and other distracJim Montague
e xecutive Editor
jmontague@putman.net
“Technology is
only as good as
the people that use
it and interpret its
data, so it takes
a commitment to
training, setup and
implementation.”
66
tions, it can be difficult to focus on unglamorous commitments—good marriages, raising families, consistent professionalism— or staying warm next to Lake Michigan.
Sure, global warming may one day turn Milwaukee into a tropical hotspot, but, for now,
most of its downtown area by the lake needs
the steam heat it gets from We Energies’ Valley
Power Plant. This venerable plant is the largest utility-owned, co-generation facility in the
United States. It haa two 280-megawatt units,
and its four coal-fired boilers produce 1.25 million pounds per hour (MLb/hr) of steam.
In the most recent decade of its continuing
mission to provide and improve its service, Valley Power has steadily transitioned from using
stand-alone laptop PCs and multiplexers and
moved to using Emerson Process Management’s online AMS Device Manager and its
Ovation interface. This journey was described
by Todd Gordon, We’s instrument technician
leader at Valley Power, at the recent Emerson
Global Users Exchange in San Antonio, Texas.
“Now, we all have to love technology, but
we know it can create an overload unless training and implementation are coordinated,” says
Gordon. “We’ve also learned that technology
such as AMS can’t solve every problem. If your
hardware and mechanics aren’t set up properly,
then your overall system isn’t going to work.
Technology is only as good as the people that
maintain, use it and interpret the data, so it also
takes a time commitment for training, proper
setup and implementation.”
Built in the 1960s, Valley Power initially
used local, pneumatic controllers for pressure,
temperature and level and an I/P converter,
which was upgraded from E/P in 1993. Gordon
reports the plant’s journey to AMS really began
when it installed its first “smart,” non-HART
transmitter in 1988. Then, in 1993-94, DCS
controls were installed at Valley Power. Likewise, in 1993, the plant gained its first “smart,”
non-HART positioner, which used DOS-based
software that required a Windows 98 laptop.
“The main question is can the newer, smart
instrument do its job better than the older technology? We’ve usually found that the answer
is yes,” says Gordon. “Fisher DVC positioners
also provided an input to DCS for valve position from the HART signal. These were on our
two most critical valves. So when the positioners told us the valves were getting sticky, we decided to replace them, and this saved us from
tripping out units three times.”
Later, Valley Power added Base Station with
Multiplexers in 2004. These enabled online,
continuous monitoring when hardwired to
HART devices. “The base station communication from the handhelds and laptops are very
useful, but we still like to go and see the valves
move,” added Gordon. “There are still some
things you can only see when you’re there.”
Even newer devices at Valley Power include
its HART diagnostic transmitters, and it plans
to add wireless devices soon. Most recently, the
plant replaced its multiplexers with Emerson’s
Ovation interface and spent part of this year
working on a new DCS controls upgrade, in
which the base station will be integrated into
the DCS controls.
“In general, our performance monitoring
has given us better tuning of controls, improved
heat rates for reduced fuel consumption, faster
ramp rates for changing load demands, centralized performance monitoring and predictive
maintenance,” added Gordon. “All of this has
been a journey, not a destination. We found
that online capabilities increase effectiveness
of smart instrumentation and supporting software. However, you can’t maximize a plant’s efficiency if you can’t accurately control and effectively manage the final drive elements.”
Pretty cool, that is, if you can wake up from
present-day distractions, become aware of some
important history and take that longer view.
www.controlglobal.com N o v e m b e r / 2 0 1 0
CT1011_66_ControlReport.indd 66
10/25/10 1:01 PM
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woodworking, pumping, refrigeration, and printing.
Get the fool-proof protection and performance you need in your drives. Call Yaskawa today.
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CT1011_full page ads.indd 67
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