5 shades of wireless here’s how - control global · may 2015 wireless spreads into more tight...

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y

20

15

Wireless spreads into more tight places and remote locations than ever before.

Wireless control?

Here’s HoW

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5 sHades of control system sopHistication

Into theInto thewind

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MOTORSMOTORS

Variable speed drives can improve your bottom line by reducing your motors’ energy consumption. An invest-ment of as little as $59 can start paying o� immediately.

MOTORS

GS1 AC drives (1/4 to 2 hp) offer simple Volts/Hertz control for general purpose applications. Built-in I/O, Modbus communications capability and programma-ble preset speeds increase their fl exibility.

With a huge selection of high-quality industrial electric motors and the lowest prices to go with them, we have what you are looking for!

GS2 AC drives (0.5 to 10 hp) feature built-in PID control, dynamic braking and Modbus communications.

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Ironhorse DC drives can accommodate 1/50 HP @ 12VDC all the way up to 3HP @ 240VAC. These drives deliver excellent low speed control and stability and are easily confi gured for your application.

Ironhorse AC motors are available in rolled steel (1/3 to 2 hp), stainless steel (1/3 to 2 hp), cast iron (1 to 300 hp) and farm duty (2 to 5 hp) 1800 RPM models. 1200 and 3600 RPM units are also available in the most popular horsepower ratings. Our premium effi ciency models meet current NEMA standards from 1 to 150 hp, and start at $155.

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the #1 value in automationOrder Today, Ships Today!

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

with drives and motors from AutomationDirectSave Money, Save Energy Save Money, Save Energy

Research, price, and buy at:www.automationdirect.com/motors

MOTORSMOTORS

Variable speed drives can improve your bottom line by reducing your motors’ energy consumption. An invest-ment of as little as $59 can start paying o� immediately.

MOTORS

GS1 AC drives (1/4 to 2 hp) offer simple Volts/Hertz control for general purpose applications. Built-in I/O, Modbus communications capability and programma-ble preset speeds increase their fl exibility.

With a huge selection of high-quality industrial electric motors and the lowest prices to go with them, we have what you are looking for!

GS2 AC drives (0.5 to 10 hp) feature built-in PID control, dynamic braking and Modbus communications.

DuraPULSE AC drives (1 to 100 hp) add sensorless vector control, a removable keypad that stores up to four different application programs and built-in discrete and analog I/O. Communicate via built-in Modbus or an optional Ethernet connection.

Ironhorse DC drives can accommodate 1/50 HP @ 12VDC all the way up to 3HP @ 240VAC. These drives deliver excellent low speed control and stability and are easily confi gured for your application.

Ironhorse AC motors are available in rolled steel (1/3 to 2 hp), stainless steel (1/3 to 2 hp), cast iron (1 to 300 hp) and farm duty (2 to 5 hp) 1800 RPM models. 1200 and 3600 RPM units are also available in the most popular horsepower ratings. Our premium effi ciency models meet current NEMA standards from 1 to 150 hp, and start at $155.

Ironhorse DC motors are available in TENV and TEFC rolled steel enclosure styles. Their space-saving designs feature a NEMA 56C fl ange and removable mounting base.

Marathon Electric inverter-duty motors have been carefully selected to be performance

matched with our DURApulse and GS series AC drives. They are available in 1/4 to 100 hp with 1200 and 1800 RPM base speeds. Dual 230/460V and 575 VAC models are available and factory-mounted encoders are offered on select models. NEMA Premium Effi ciency XRI series from 1 to 10 hp are compliant with Energy Independence and Security Act of 2007.

STARTING AT: $275.00GP Stainless

Steel

STARTING AT: $148.00Inverter Duty

STARTING AT: $79.00

GP Rolled Steel

STARTING AT: $155.00GP Cast Iron

STARTING AT: $70.00

Research, price, and buy at:www.automationdirect.com/drives

DRIVESDRIVESDRIVES


GS2-10P2STARTING AT:

$242.00GS3-21P0

STARTING AT: $59.00

GSD3-240-2CL

DRIVESDRIVESSTARTING AT: $99.00GS1-10P2


Farm Duty

1505-Control-MotorDrives-MAG.indd 1 4/14/2015 11:10:30 AM

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a better way to view

LEVEL

viewing angle140°

+ 200 ft. (60 m)

orioninstruments .com

High-visibility level indicators and transmitters from

Orion Instruments are custom-engineered and built

tough for the most demanding applications. Contact

us to find out how personnel safety, cost of ownership,

and reliability can all be improved over traditional

sight glass gauges.

B O O T H # 1 60 4

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Many companies claim that people are their most valuable asset, but it isn’t usually reflected in their work environment. That’s why ABB and CGM have joined forces to offer three pre-packaged control room design studies to start you on a path toward building a high performance, ergonomic environment that attracts and keeps young talent.

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May 2015 • Volume XXVIII • Number 5

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

PHARMACEUTICAL MANUFACTURING, and PLANT SERVICES ), 1501 E. woodfield Rd., Ste. 400N, Schaumburg, IL 60173. (Phone 630/467-1300; Fax 630/467-1124.) Address all correspondence to Editorial and Executive Offices,

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

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

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

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

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

featuresProcess automation systems

39 / How to use wireless for controlPIDPlus is a modification of PID to accommodate slow and varying update rates, as well as lost communications. by Terry Blevins and Neil Peterson

calibration

45 / calibration’s big-time savingsToday’s calibrators more easily enable higher-resolution instrument performance, save lots of labor and reassure users about the precision of their process applications. by Jim Montague

Web eXclusiVeImproving Steam System Performance: A Sourcebook for Industry, 2nd ed. U.S. DoE Advanced Manufacturing Office. www1.eere.energy.gov/manufacturing/tech_assistance/pdfs/steamsourcebook.pdf

coVer story30 / Wireless spreads everywhere

wireless expands into more tight places and remote applica-tions than ever. Here’s how it’s deployed safely and securely. by Jim Montague

m a y / 2 0 1 5 www.controlglobal.com 5

CT1505_05_07_TOC.indd 5 5/5/15 11:04 AM

http://www.controlglobal.com

More than 100,000 customers in every industry around the globe trust Endress+Hauser to make their processes safe, efficient and repeatable. Just like a puzzle, many pieces must come together at the right time and place to manufacture a product profitably. Endress+Hauser understands there is a world of difference between a good fit and a perfect fit for your critical process measurement needs. This is proven by the sustainable value we generate for our customers through the instruments, services and solutions we deliver.

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DEPARTMENTS

May 2015 • Volume XXVIII • Number 5

9 / Editor’s PageIT and OT converge on IIoTApplications developers are starting to see how to use a whole lot more sensor data.

11 / Control OnlineSome oldies, but goodies, including control valve selection, taming override control and a GWR vs. dP transmitter smack-down.

13 / FeedbackOur readers comment on this IoT thing.

14 / Lessons LearnedControl definedFive levels of process control sophistication

19 / On the BusSituations abnormalOur operators don’t need a fighter pilot’s re-action time, but they do need clear indica-tions of when things are going badly wrong.

20/ Without WiresWireless standards and Industry 4.0How the standards committees are tack-ling the wireless component of the IoT.

22/ In ProcessIndustry 4.0 rules at Hannover Fair; Hon-eywell opens new cybersecurity lab, and more process news.

28 /ResourcesMotors and drives star in these books, tuto-rials and videos.

48 / Technically SpeakingCreating 3D models from photos3D reconstruction from imagery automates many of the steps to building 3D models.

49 / Ask the ExpertsOur experts tackle thermocouple problems and surface-mounted RTD accuracy issues.

51 / RoundupAnd so it flowsA steady stream of the latest in flow-moni-toring technology.

53 / Product ExclusiveMore safety; less gasDaisy Data releases a new enclosure purg-ing system

54 / ProductsSee the best in automation technology here

55 / Control TalkThe future is hereA talk with an up-and-coming process en-gineer about working in the business now.

57 / Ad IndexThese folks would like a word with you.

58 / Control ReportMind right for wireless?Getting your head on straight about your expectations is the first step.

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

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

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IT and OT converge on IIoT

My past month has been full of conferences and conference calls, and most have re-lated to the Industrial Internet of Things (IIoT). The common threads are an explosive increase in machine-level information (Big Data) and connectivity (on the Internet and in the cloud) that we can now profitably harness with analytics and software. So we must and we will, and we’ll need your help.

For example, for condition monitoring, we used to make rounds and enter data manually. “Sensors are more accurate than people with clipboards, and they provide real-time data,” said Bonz Hart, CEO, Meridium. “Their size and cost are going down; they’re now less than 30 cents apiece. But they can generate 63 mil-lion readings per year times a thousand—or 10,000—sensors per facility.”

Leveraging sensor data takes expertise on both the information technology (IT) and op-erations technology (OT) sides. “This is accel-erating the convergence of IT and OT, allow-ing people to use data in unprecedented ways,” .says Khris Kammer, information partner and competency manager, Rockwell Automation.

IT/OT collaboration promises to finally close the loop on plant performance. “Today we take ERP information into the plant, often manually. IT/OT integration increasingly lets us bring that information down automatically, but also back up to measure plant performance and support decisions, by telling us what’s actu-ally happening,” says Mike Brown, process ap-plication consultant, Honeywell Advanced So-lutions. “By measuring productivity and yield at the automation layer, comparing plant actu-als to ERP projections and making real-time adjustments, we can close the loop on ERP.”

Along with optimizing performance, we can truly understand how the condition of our as-sets might prevent us from achieving it. “The great increase in computing power and storage means we can take more information from in-strumentation, aggregate it and integrate it to

get a full view of risk,” says Roy Whitt, Asset Answers general manager, Meridium. “We can close the loop on maintenance.”

But that’s just the beginning. “People couldn’t imagine how the Internet would affect their lives, and we can’t imagine all the ways this will affect operations and maintenance,” Whitt says. The information we’ll be getting through the IIoT—from production data to in-ventories to individual components, parts, bolts and seals—we still can’t imagine how that will change the way we run our plants.”

With IIoT, “It’s not a killer app. It’s a com-bination of enabling technologies—software, communications—with people and a process, to get payback,” says Barry Johnson, global di-rector, information solutions and process busi-ness, Rockwell Automation. “You may not need the infrastructure without IIoT capabilities, but with them, you do. You need good, solid ways to collect, move and analyze data.”

Build the infrastructure, mind-meld IT and OT, and the applications will come. It’s revo-lutionized commerce, and it’s poised to roll through industry in ways we can’t yet imagine.

“In the Internet of Things, the Internet is not the big deal. It’s what the things can do. When we stick the IT in the thing, we get exponential improvement,” says Michael Porter, professor, Harvard Business School. “Data is becoming one of the factors of production—land, labor, capital, and now, data.” We’re moving up the continuum from monitoring to control to opti-mization and now, autonomy.

Leveraging IIoT requires folks who have an inkling of which data matters, how to analyze it and what to do with the results. “To take advan-tage, we need new skillsets,” says Porter. “We need data scientists, system engineers, develop-ers and systems integrators.”

Those skillsets may appear new to Porter, but they’re not new to you.

M a y / 2 0 1 5 www.controlglobal.com 9

Paul Studebaker EdITOr In chIEfps [email protected] t

E D I T O R ’ S P A G E

Leveraging IIoT

requires folks who

have an inkling of

which data matters,

how to analyze it

and what to do with

the results.

CT1505_09_Edit.indd 9 5/6/15 9:03 AM

mailto:[email protected]://www.controlglobal.com

800 453 6202



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

13 common causes of motor failureBoth mechanical and electrical issues

can lead to motor failure–and being

armed with the right knowledge can

mean the difference between costly

downtime and improved asset uptime.

www.controlglobal.com/whitepa-

pers/2015/detecting-the-13-common-

causes-of-motor-failure.

Extreme networkingExtreme temperatures can stop the flow

of data from remote operations, and in-

troduce significant risk. Learn how to

optimize your network for extreme con-

ditions and maximum uptime. www.

controlglobal.com/whitepapers/2015/

how-to-optimize-the-network-for-ex-

treme-conditions.

That’s $1.6 billion—with a “b”Non-malicious cyber accidents can

cost big-time too, as Pacific Gas &

Electric just learned. Read Joe Weiss’

thoughts on why pipe systems need

remote shutoff valves. www.control-

global.com/blogs/unfettered/the-cost-

of-a-non-malicious-control-system-cy-

ber-incident-more-than-1billion.

The training tableGilman Precision is part of a unique ap-

proach to developing young manufac-

turing workers. It’s covered in our sis-

ter publication, Control Design. www.

controldesign.com/industrynews/2015/

gilman-precision-finds-a-good-source-

for-new-young-employees.

ControlGlobal E-News

Multimedia Alerts

White Paper Alerts

Go to www.controlglobal.com and

follow instructions to register for our

free weekly e-newsletters.

C o N T r o l o N l i N E

Digging around in the attic

This month, we’re featuring some of the best items from our archives. If you haven’t spent time exploring our back issues, you should. Scroll down on the home page to the bottom and look for the link to Issue Archives. There, arranged by date, are issues of Control going all the way back to 2003. While part of our mission is to keep up with the newest technology, it’s also true that some of those older articles are evergreen—some of the basics never change.

How to select control valvesThis is a three-fer from our resident process automation Yoda, Béla Lipták. “How to select control valves, parts I, II and III” appeared in the July, September and November 2006 is-sues, respectively. Everything you need to know about getting the right valve for the right job, including a handy, printable chart to guide you through some of the nuances of the process. Part 1 is at www.controlglobal.com/issues/2006/008. Part II is found at www.con-trolglobal.com/articles/2006/167. Part III appears at www.controlglobal.com/arti-cles/2006/215.

Under the hood of override controlAll the techniques for preventing reset windup of non-selected controllers will perform comparably to reset feedback if the dynamics of the various loops aren’t too dissimilar, says Process Automa-tion Hall of Fame member Harold Wade in this article from December 2005. He goes on to ex-plain that override control refers to applications where one process variable controls the process in normal operation, but during abnormal opera-tion another variable assumes control to prevent encroachment on safety, process or equipment limits, and discusses ways to accomplish this. Go to www.control-global.com/articles/2005/551. As a bonus, Part II appears in the January 2006 issue at www.controlglobal.com/articles/2006/011/.

GWr vs dP transmitter smack downThis whitepaper from Magnetrol does a comparison between the tried-and-true method of liquid level measurement, the differential pressure transmitter, and the newer technology of guided wave radar measurement. Go here for the link: www.controlglobal.com/whitepapers/2010/032.

P

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Tube LimitTemperature Controller

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ResetFeedback

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CT1505_11_WebTOC.indd 11 5/5/15 11:08 AM

http://www.controlglobal.comhttp://www.controlglobal.comhttp://www.controlglobal.com/whitepa-pers/2015/detecting-the-13-common-causes-of-motor-failurehttp://www.controlglobal.com/whitepa-pers/2015/detecting-the-13-common-causes-of-motor-failurehttp://www.controlglobal.com/whitepa-pers/2015/detecting-the-13-common-causes-of-motor-failurehttp://www.controlglobal.com/whitepa-pers/2015/detecting-the-13-common-causes-of-motor-failurehttp://www.controlglobal.com/whitepa-pers/2015/detecting-the-13-common-causes-of-motor-failurehttp://www.controlglobal.com/whitepapers/2015/http://www.controlglobal.com/whitepapers/2015/http://www.control-global.com/blogs/unfettered/the-cost-of-a-non-malicious-control-system-cy-ber-incident-more-than-1billionhttp://www.control-global.com/blogs/unfettered/the-cost-of-a-non-malicious-control-system-cy-ber-incident-more-than-1billionhttp://www.control-global.com/blogs/unfettered/the-cost-of-a-non-malicious-control-system-cy-ber-incident-more-than-1billionhttp://www.control-global.com/blogs/unfettered/the-cost-of-a-non-malicious-control-system-cy-ber-incident-more-than-1billionhttp://www.control-global.com/blogs/unfettered/the-cost-of-a-non-malicious-control-system-cy-ber-incident-more-than-1billionhttp://www.control-global.com/blogs/unfettered/the-cost-of-a-non-malicious-control-system-cy-ber-incident-more-than-1billionhttp://www.control-global.com/blogs/unfettered/the-cost-of-a-non-malicious-control-system-cy-ber-incident-more-than-1billionhttp://www.controldesign.com/industrynews/2015/http://www.controldesign.com/industrynews/2015/http://www.controlglobal.comhttp://www.controlglobal.com/http://www.con-trolglobal.%http://www.con-trolglobal.%http://www.con-trolglobal.%http://www.controlglobal.com/arti-cles/2006/215http://www.controlglobal.com/arti-cles/2006/215http://www.controlglobal.com/arti-cles/2006/215http://www.control-global.com/articles/2005/551http://www.control-global.com/articles/2005/551http://www.control-global.com/articles/2005/551http://www.controlglobal.com/articles/2006/011/http://www.controlglobal.com/whitepapers/2010/032http://www.controlglobal.com/whitepapers/2010/032

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mailto:[email protected]

This IoT thing[See “Out of Control” blog post at www.controlglobal.com/blogs/in-and-out-of-control/this-internet-of-things-thing-not-as-simple-as-it-looks.]

Hi, Nancy—Thanks for your thoughts. While you’re correct there are many possible variations of connec-tivity and attendant standards, [let’s] step back and look at real examples and what M2M (or IoT) offers that indus-trial settings lack today. For example, consider a large commercial building HVAC system. Such a system already has an integrated building automation system (BAS). It’s likely that system is wired into everything it’s supposed to monitor and control. The communica-tion protocols are probably industrial, such as HART or proprietary.

Now let’s say the existing system doesn’t have any direct sensors for motor health. It almost surely keeps track of on-hours, maybe starts and stops, maybe other data. But we now have these sensors that monitor vibra-tion signatures and can give predictive health information for blower motors. We could go to the BAS vendor and re-quest they integrate these things, and they would, and it would cost a lot.

Alternatively, we could connect these sensors to the existing WLAN and use a browser-based system to track all of our motors. Such a system could be set up in perhaps an hour per mo-tor and begin providing baseline data in days. Keeping in mind these are sense-only nodes—no control—the se-curity risk is low. Assuming the WLAN is properly secured, or could be, we could at least have a demonstration sys-tem running very quickly to prove the value of adding these monitors.

This is a simple example, and more remote sensing gets into the realm of WWAN, the domain of the telecoms. That does get somewhat more compli-cated, but can still be done today with off-the-shelf hardware and software.

BLAINE BATEMANeafpres@eaf-l lc .com

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

VICE PRESIDENT 1984-2012

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editorial teamEditor in Chief: PAUL STUDEBAKER

[email protected] t

Executive Editor: JIM [email protected] t

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

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CT1505_13_Feedback.indd 13 5/5/15 11:09 AM

http://www.controlglobal.com/blogs/in-and-out-of-control/this-internet-of-things-thing-not-as-simple-as-it-looks.]http://www.controlglobal.com/blogs/in-and-out-of-control/this-internet-of-things-thing-not-as-simple-as-it-looks.]http://www.controlglobal.com/blogs/in-and-out-of-control/this-internet-of-things-thing-not-as-simple-as-it-looks.]http://www.controlglobal.com/blogs/in-and-out-of-control/this-internet-of-things-thing-not-as-simple-as-it-looks.]http://www.controlglobal.com/blogs/in-and-out-of-control/this-internet-of-things-thing-not-as-simple-as-it-looks.]http://www.controlglobal.com/blogs/in-and-out-of-control/this-internet-of-things-thing-not-as-simple-as-it-looks.]mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]

14 www.controlglobal.com M A Y / 2 0 1 5

BÉLA LIPTÁKl ip takbela@aol .com

Feedback control

can’t prevent

errors because

it can initiate

corrective action

only after an error

has developed.

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

Control de� ned

In process control, there are at least � ve levels of sophistication that the automation engineer can apply. The advantage of the higher levels is better control, but applying them also requires better understanding of the process. In the ana-log age, using higher levels of sophistication also involved substantially higher costs, but now, this consideration has become less signi� cant. To il-lustrate the � ve levels, I will use the example of controlling the outlet temperature from a steam-powered liquid heat exchanger.

Manual Control (Figure 1): Manual feed-back control is performed by the operator by watching the hot water temperature and manu-ally throttling the steam � ow to keep this outlet temperature constant. Manual feedforward con-

trol is performed when the steam � ow is throt-tled on the basis of the temperature and � ow of the incoming cold water.

Feedback Control (green components in Fig-ure 2) is similar to manual control, except that the operator is replaced by an automatic con-troller, which is more accurate and does not get tired or distracted, and the dynamics (gain, time constant, dead time) of the process are tuned to match that of the controlled process.

Figure 2 illustrates the case when the control valve is on the steam side of the heater. If it is on the condensate side, a smaller valve can be used, but the dynamics of the process will be slower and non-symmetrical because lowering the condensate level is much faster than build-ing it up. On the other hand, this con� guration eliminates the minimum condensing pressure problems that can interfere with the steam trap operation at low loads.

Figure 2: More advanced systems replace the

operating person with an automatic controller ca-

pable of handling the personality of the process.

Ws = (W) (T2 – T1) = KW(T2 – T1)

Ws (t)W(t)

CpHS

W and T1 are measured variables T2 is the controlled variable Ws is the manipulated variable

Steam

Ws

Ws

FT

SP

FC FIC

T2

T2*

T1W

Hot �uid

TIT

TIC

T2Cold �uid

Condensate

Lead/lagOutput

Input

K(T2* – T1)Minor loadsHeat lossesXmtr errorsSteam enthalpy changes

Lead/lag K

+Σ

x

W

TITTIT

T2

LET THE CONTROLLER DO ITFigure 1: Manual feedforward and feedback

control depend on the operator to control the

process.

Feedback control Feedforward control

Desired temperature = To

Temperature indicator


Hot water

Hot water

Steam

Cool water

Steam

Cool water

Waterheater

Waterheater

Steamvalve

Steamvalve

Feedback control Feedforward control

Desired temperature = To



Hot water

Hot water

Steam

Cool water

Steam

Cool water

Waterheater

Waterheater

Steamvalve

Steamvalve

HANDS ON

CT1505_14_16_Lessons.indd 14 5/5/15 11:11 AM

mailto:[email protected]://www.controlglobal.com

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While feedback control is the most commonly used, it has serious limitations. The main one is that it can’t anticipate and, therefore, can’t prevent errors because it can initiate cor-rective action only after an error has developed. Therefore, in the case of the liquid heater process, if either the properties of the manipulated variable (for example, steam pressure) or the load (cold � uid � ow or temperature) change, feedback control will wait until these changes upset the outlet temperature be-fore initiating corrective action.

Cascade Control (red components in Figure 2) can cor-rect for manipulated variable upsets, such as steam pressure changes, before they could upset the controlled variable (tem-perature). As shown in Figure 2, the cascade loop consists of two controllers in series, but has only a single setpoint—that of the primary (master) controller (TIC). The main value of having a secondary (slave) controller (the FIC) is that it will act as the � rst line of defense against steam quality distur-bances, preventing these upsets from entering and upsetting the primary controlled variable (temperature).

For the cascade slave loop (FIC) to be effective, it should be more responsive (faster) than the master. Some rules of thumb suggest that the slave time constant should be less than ¼ to 1/10 that of the master loop, and the slave’s period of oscillation should be less than ½ to 1/3 of the master loop. In case of the steam heater process, this requirement is usu-ally satis� ed.

One should also be careful to prevent “reset wind-up” in the TIC. This can occur because the TIC is usually provided with an integral mode, which keeps integrating the error as long as it exists and, therefore, if the FIC setpoint is blocked, such as when it is switched to manual, it keeps integrating until its output reaches maximum, and when the FIC is re-turned to automatic control, a large upset occurs.

To guarantee bumpless transfer, provide external reset, which is an internal logic component in the TIC algorithm that deactivates the integral mode if the TIC output does not equal the FIC measurement, and reactivates it only when it does.

So cascade takes care of correcting for disturbances caused by changes in the manipulated variable, but what about load changes?

Feedforward Control (blue components in Figure 2) can correct for load changes, which in the case of a heater, can be variations in the � ow rate or in the temperature of the en-

tering cold � uid. The required total steam � ow (Ws) is the product of the required temperature rise (T2-T1), the � ow rate of the cold � uid (W), and the ratio (K = Cp/Hs), which is the ratio of the speci� c heat of the � uid (Cp) and the latent heat of the steam (Hs). Because this calculation is never completely accurate due to heat losses in the system and measurement er-rors, it has to be corrected by the feedback TIC’s output signal (T2*) in the feedforward calculation. This way, because the feedforward correction is on the outlet of the cascade master, the TIC does not even know if the incoming � ow or tempera-ture has changed.

Feedforward provides a more direct solution than does feedback alone. On the other hand, the feedforward system consists of several devices if implemented in hardware, or sev-eral blocks of software if implemented digitally. The function of these blocks is to implement the mathematical model of the process. Unfortunately, the use of feedforward control is limited to the better understood processes because when the process is more complex than a heat or mass transfer process, the feedforward calculation (or the required measurements), become complicated or even impossible.

Another limitation of feedforward is that a load change can temporarily change the load itself, for which feedforward can’t correct.

Lead/Lag Control (yellow component in Figure 2) is needed if load changes cause a temporary increase or de-crease in the load. In case of the liquid heater, for example, if the load (� ow W) increases, initially an additional load will appear because, in order for the heat exchanger to transfer more heat (through its � xed heat transfer area), its own tem-peraure must also increase. This need to heat the metal body represents a temporary additional load, which will drop to zero when the required higher temperature is reached. We re-fer to this phenomenon as “lead” action. Similarly, when the load drops, the heat exchanger itself can be cooler, and while cooling, this heat also serves to heat the cold � uid, so the load will appear to be temporarily reduced (“lag” action).

In addition to the listed control techniques, the toolbox of the automation engineer contains many other, more sophis-ticated techniques to control more complex or multivariable processes (see Optimization of Industrial Unit Processes at www.amazon.com/Optimization-Industrial-Processes-Sec-ond-Edition/dp/0849398738), but the most often used tech-niques are the � ve I’ve discussed.


Feedforward provides a more direct solution than does feedback alone, but its use is limited to the better

understood processes because when the process is more complex than a heat or mass transfer process, the

feedforward calculation (or the required measurements) become complicated or even impossible.

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

CT1505_14_16_Lessons.indd 16 5/5/15 11:12 AM

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O N T H E B U S

The “best” indica-

tion needs bullet-

proof reliability if

we expect it to alert

an operator who

has hundreds or

thousands of vari-

ables to monitor.

john Rezabek contribut ing [email protected]


Situations abnormal

consultants focusing on operator effective-ness sometimess draw inspiration from military aircraft designs, which incorpo-rate a lot of graphical depictions of flight and combat variables on their cockpit “heads-up” displays. The present generation of operator graphics uses some of these elements, often hiding or eliminating numerical values, and incorporating retro panelboard faceplates, ani-mated bar graphs and dials.

But when I pitch these ideas to the boss, he asks: do we expect our operators to be fighter pi-lots? That’s a succinct way of saying, jazzy new graphics aside, we don’t rely on operators for life-or-death, split-second judgments like one would from a pilot in combat. Most HAZOPs, layer of protection analyses (LOPAs) and alarm philosophies specify allowing 10 minutes for an operator to respond to take credit for an opera-tor intervention.

While operators aren’t supposed to be ready to unleash a Sidewinder missile in a fraction of a second, they still benefit from a keen aware-ness of the state of the process. Most process phenomena are taking place inside opaque pip-ing, vessels and machinery; instrumentation is the only way anyone has a notion of what’s happening. In the view of ISA 18.2-2009/IEC 62682, the “situational awareness” we provide is supposed to be optimized for clarity, accuracy and consistency to ensure that operators can in-tervene and prevent the process from entering the upset state. But what the tidy concentric diagram in section 5.3 (http://bit.ly/1aXqlZH) doesn’t depict is that the target or optimal op-erating regime is frequently at the edges of the capacities and ratings of equipment.

When we ask what the best indication of an abnormal situation is, alarm philosophies might suggest we consider suppressing or eliminating redundancies. For example, a flow alarm, a mo-tor status and pressure indication may all have alarms configured that indicate a pump has tripped. In this simple example, the rational-

ization team might not want the operator to get three alarms for the same malfunction. But tak-ing away alarms (and redundancy) means that the remaining “best” indication needs bullet-proof reliability if we expect it to alert an opera-tor who has hundreds or thousands of variables to monitor.

In the days of pneumatics, a measurement came to the control house panel as a pressure (3-15 PSI) in a single tube. If you wanted to alarm on that measurement, you got a pressure switch, calibrated it to actuate at the desired alarm set-ting, and wired the switch to an annunciator. This was an uncomplicated and direct linkage between the process variable and the alarm sys-tem that engendered the single-loop integrity we’d like our modern systems to replicate.

Autonomous devices on a fieldbus segment solving function blocks have built-in alarming capability, and can be configured to publish their measured variable and any alarm status re-lentlessly on a precisely synchronized, determin-istic network. If my alarm philosophy compels me to configure only the “best” indications for a single malfunction, it would be ideal if I could obtain the alarms in this manner with as few in-tervening complications as possible. Even if I’m creatively implementing state-based or first-out suppression, I want to invoke these measures if and only if the measurements are timely and validated.

But in many implementations of fieldbus, the DCS alarm system isn’t listening directly to the devices on the bus. Systems may employ a grafted-on approach, where all the fieldbus data is funneled into the legacy controller infrastruc-ture. A measurement used in a PID controller relies on the PID block to generate alarms, so all the intervening code and communication is necessary to ensure the alarm is annunciated. As systems move toward architectures where the I/O isn’t closely wired to the controllers, au-tonomous and deterministic delivery of alarms would be a measurable benefit.

CT1505_19_OTB.indd 19 5/5/15 11:13 AM

mailto:[email protected]://www.controlglobal.comhttp://bit.ly/1aXqlZH

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

20 www.controlglobal.com M a y / 2 0 1 5

Though not well-

known in North

America, China

has developed two

industrial wireless

standards as well.

ian verhappenDirector,

inDus trial automation ne t [email protected]

wireless standards meet industry 4.0

anumber of documents in the IEC fam-ily of standards and whitepapers discuss wireless as an important component of Industry 4.0. Like the fieldbus standards, each wireless standard is targeted to a particular in-dustry. Most protocols, including fieldbus and wireless standards, follow the Open System In-terconnect (OSI), ISO/IEC 7498-1, seven-layer model. Below is a summary of each of the doc-uments developed or in progress.

IEC 62591:2010 is the WirelessHART doc-ument that specifies the following key com-ponents necessary for this and the majority of fieldbus/digital field network communication standards: Physical layer service definition and protocol specification (Layer 1); data-link layer service and protocol (Layer 2); application layer service and protocol (Layer 7), with network management, security and communication pro-files incorporated in the intervening layers as a common stack that also includes the associated wireless procedures. The standard also defines a gateway to connect the field-level network to the balance of the plant.

IEC 62734/Ed1, aka ISA 100.11a, is a protocol suite including system management, gateway considerations and security specifications for low-data-rate wireless connectivity with fixed, portable and slowly moving devices. Though it is intended to support all applications, the target niche is similar to WirelessHART’s—process au-tomation monitoring and control where end-to-end communication latencies on the order of at least 100 milliseconds can be tolerated.

Though not well-known in North America, China has developed two industrial wireless standards. IEC 62061:2011—WIA-PA, Wireless Networks for Industrial Automation—Process Automation, specifies the communication net-work, communication profile and system archi-tecture built on IEEE STD 802.15.4,ISA100.11a. IEC PAS 62948/Ed.1. WIA-FA, is the sister stan-dard to IEC 62061 targeted to the factory auto-mation environment.

Two other documents of interest address how to manage wireless networks in an environment where they are competing for limited resources because they share the license-free industry/sci-entific/medical (ISM) bands with a wide range of devices. The first is a technical specification (TS), IEC TS 62657-1:2014 Part 1—Wireless Communication Requirements and Spectrum Considerations. It addresses how to provide the wireless communication requirements for appli-cations within the broader ISM environment, while remaining independent of the wireless technology being used.

TSs describe requirements in detail using less technical language than a full specification. They’re often published when the subject under question is still under development or when in-sufficient consensus for approval of an interna-tional standard is likely to be achieved.

Part 2 of this series, IEC 62657-2:2013 on co-existence, started as a TS, but then in 2013, it was accepted as IEC 62657-2:2013 Wireless Communication Networks—Part 2, Coexis-tence Management. It specifies the fundamen-tal assumptions, concepts, parameters and pro-cedure for wireless communication coexistence by providing guidelines, requirements and best practices for wireless communication’s availabil-ity and performance in an industrial automation plant.

Integration of the field level through busi-ness systems, including the wireless standards above, are a key part of Industry 4.0. The IEC has prepared a series of whitepapers on Indus-try 4.0 and the Internet of Things (IoT), and the sixth paper in that series, “Internet of Things: Wireless Sensor Networks (WSNs)” (www.iec.ch/whitepaper/pdf/iecWP-internetofthings-LR-en.pdf) discusses the use and evolution of WSNs within the wider context of IoT, and pro-vides a review of WSN applications, while also focusing the attention on infrastructure tech-nologies, applications and standards featured in WSN designs.

CT1505_20_Wireless.indd 20 5/5/15 11:14 AM

mailto:[email protected]://www.controlglobal.comhttp://www.iec.ch/whitepaper/pdf/iecWP-internetofthings-LR-en.pdfhttp://www.iec.ch/whitepaper/pdf/iecWP-internetofthings-LR-en.pdfhttp://www.iec.ch/whitepaper/pdf/iecWP-internetofthings-LR-en.pdf

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Microprocessor-aided technolo-gies are taking over manufac-turing worldwide, and meld-ing formerly separate operations for greater optimization and savings. This is the integrated, networked and digital heart of the Industrial Internet of Things (IIoT) or Industry 4.0, and it was visible everywhere at Hannover Fair 2015 on April 13-17.

“Hannover Messe 2015 has made it clear—Industry 4.0 has arrived, and is sweeping every sector of industry,” says Jochen Köckler, member of fair organizer Deutsche Messe’s manag-ing board. “Digital integration is be-coming a key aspect of modern man-ufacturing,“ he added.

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HYB-AD-01599-EN-01 (May 2015)

Verify performance. Monitor your system performance on the fly

with the Dynasonics® DXN portable clamp-on

hybrid meter. This powerful, easy to use, and

highly accurate meter allows you to obtain flow

measurements virtually anywhere. Utilizing

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verification and testing, the DXN helps to increase

operational efficiency in your liquid process.

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operational efficiency in your liquid process.

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Automating functions. Simplifying operations.Modernizing protection.

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

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for research, hands-on training, and for the development, testing and certifica-tion of cybersecurity solutions.

“Solutions development and test-ing leverages commercial cyberse-curity technologies, but they need development before they can be ap-plied to control systems,” says Mike Spear, global operations manager for industrial cybersecurity at Honeywell Lifecycle Solutions & Services. “You can’t simulate attacks on a running plant without risking shutdowns. Here, we can test a customer’s system in a controlled environment.”

Downs accepts Hall of Fame awardJames Downs, PE, engineering fel-

low and manager of the Advanced Controls Technology group at East-man Chemical Co. (www.eastman.com), has received the award repre-senting his induction as a 2015 mem-ber of the Process Automation Hall of Fame from Control editor-in-chief Paul Studebaker. Studebaker presented it at a meeting of the Advanced Control Group at Eastman on March 18 in Kingsport, Tennessee.

Along with designing advanced control systems for reaction systems, distillation processes, polymer pro-cesses, extraction and other separa-tions processes, Downs developed regulatory and plantwide operations strategies for numerous capital ex-pansion projects combining plant and control system design techniques.

[For more, see the Process Automa-tion Hall of Fame cover story in the February 2015 issue of Control.]

James Downs, PE, engineering fellow

and Advanced Controls manager at East-

man Chemical, accepts his 2015 Process

Automation Hall of Fame award from

Control editor-in-chief Paul Studebaker

on March 18 in Kingsport, Tennessee.

HALL OF FAMER

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visibly. better.2435 Experion Orion SmartLine NPI PAS - Print Ad Trim: 200mm x 265mm Bleed: 206.4mm x 270mm

Discover Smart Operations with Seamless Visibility Across Your Entire Enterprise. Like Experion®’s superior HMI and collaboration solutions, Honeywell’s

new SmartLine™ level, pressure and temperature transmitters leverage

more meaningful data from across your operations. Seamless integration

with Honeywell’s Experion PKS Orion enables advantages such as Extended Diagnostics

to assess the health of critical fi eld assets, Maintenance Status Display ensuring the transmitters

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Driving ForcesControl’s Monthly Resource Guide

R E S O U R C E S

GROWN-UP MOTOR DRIVESMotors and drives have been moving up to variable-speed control for better accuracy, but now they’re also increas-ing power density and efficiency, and even coordinating more closely with PLCs and intelligent systems, accord-ing to Control executive editor Jim Montague. Learn how process opera-tions as diverse a cement suppliers,

iron ore mines, refineries and natural gas producers are using the latest drive technology in increase efficiency, re-duce power usage and improve reli-ability. Go to www.controlglobal.com/articles/2013/montague-motors-drives-grow-up.

Controlw w w.controlglobal .com

A THREE-STEP PROGRAMThis three-minute video from ABB explains the basics of motor and drive sizing. Learn the three steps around application requirements, sizing the motor and then selecting the drive. Why is torque so important? What is the difference between variable and constant? Find out here. www.control-global.com/multimedia/2014/three-steps-to-sizing-your-motor-and-drive/required by regulations.

ABB

w w w.ABB.Com

TCO OF VFDSLearn what factors contribute to the total cost of ownership of a drive; how to calculate the net present value; all about the inverse relationship between reliability and TCO; and how longev-ity of product and customer service and support affect TCO. Medium-voltage, variable-frequency drives have many benefits, such as energy efficiency and process control, however, quantifying them challenges engineers to identify which solution is the most affordable and reaps the greatest rewards. It’s vi-tal to your success and your company’s profitability that you know your TCO. Find out more at www.controlglobal.com/whitepapers/2013/know-your-tco-a-look-at-medium-voltage-vfds.

siemensw w w.siemens.com

MEET MOTORS AND MOTOR CONTROLSThis series of videos from Texas Instru-ments introduces the different types of motors used in the industry—DC, brushless DC, stepper, permanent magnet synchronous and AC induc-tion. To gather a better understand-ing of motors, differences in these mo-tors with advantages and disadvantages of each are shown. Basic motor drive circuits from full H-Bridge drive to half-bridge for three-phase motors are covered. Other drive concepts such as six-step commutation along with drive issues such as current recirculation are included. Field-oriented control and how it’s progressed with improving technology is also discussed. The di-rect link to the series is found at https://training.ti.com/introduction-motors-motor-control-series.

te x As ins trumentsw w w.t i .com

DRIVES AND MOTORS BASICSSelecting the right motor and drive combination saves energy and im-proves performance. This tutorial cov-ers the basics of AC induction motors, torque and horsepower, motors and loss-reduction techniques, motor eco-nomics and adjustable-speed drive sys-tems. The site also contains links to other motor and drive subject tutori-als and lectures. Go to www.pacontrol.com/Motor1.html.

PAControl.Comw w w.pacontrol .com

ALL ABOUT DC MOTORSThis link takes you to two tutorials on DC motor subjects. “DC Motor Cal-culations” details the steps needed to calculate mechanical power require-ments, torque-speed curves, numeri-cal calculations and calculation sam-ples. “How to Select a DC Motor” covers the necessary available voltage, output required torque and speed, the required physical envelope, and oper-ating temperatures. Go to www.mi-cromo.com/dc-motor-tutorials.

miCromow w w.micromo.com

EFFICIENT MOTORSThis 39-page PDF, “Motor Efficiency, Selection and Management: A Guide-book for Industrial Efficiency Pro-grams” is for those that need a basic, non-engineering overview of general-purpose motors, motor efficiency and motor management fundamen-tals, particularly in the context of op-timizing motor system performance. It’s at www.motorsmatter.org/tools/CEEMotorGuidebook.pdf.

Consort ium For energy eFFiCienCyw w w.cee1.org


If you know of any tools and resources we didn’t include, send them to [email protected] with “Resource” in the subject line, and we’ll add them to the website.

CT1505_28_Resources.indd 28 5/5/15 11:18 AM

http://www.controlglobal.com/http://www.controlglobal.comhttp://www.control-global.com/multimedia/2014/three-steps-to-sizing-your-motor-and-drive/http://www.control-global.com/multimedia/2014/three-steps-to-sizing-your-motor-and-drive/http://www.control-global.com/multimedia/2014/three-steps-to-sizing-your-motor-and-drive/http://www.control-global.com/multimedia/2014/three-steps-to-sizing-your-motor-and-drive/http://www.control-global.com/multimedia/2014/three-steps-to-sizing-your-motor-and-drive/http://www.ABB.Comhttp://www.controlglobalhttp://www.siemens.comhttps://training.ti.com/introduction-motors-motor-control-serieshttps://training.ti.com/introduction-motors-motor-control-serieshttps://training.ti.com/introduction-motors-motor-control-serieshttps://training.ti.com/introduction-motors-motor-control-serieshttp://www.ti.comhttp://www.pacontrolhttp://www.pacontrol.comhttp://www.mi-cromo.com/dc-motor-tutorialshttp://www.mi-cromo.com/dc-motor-tutorialshttp://www.mi-cromo.com/dc-motor-tutorialshttp://www.micromo.comhttp://www.motorsmatter.org/tools/http://www.cee1.orgmailto:[email protected]://www.controlglobal.com

YA S K AWA A M E R I C A , I N C .D R I V E S & M O T I O N D I V I S I O N

1 - 8 0 0 -YA S K AWA YA S K AWA . C O M

View Video:http://Ez.com/yai750

©2015 Yaskawa America Inc.

EXPERIENCETODAY

1990

We recently came across a two decades old photo of some young up and coming engineers that were part of our drive engineering team at the time.

Guess what? All those people are still with us. In fact, they are among our company leaders today. Imagine. Twenty years of experience from each of them going to work for you every day. Incredible knowledge. Penetrating insights. Real results.

Yaskawa puts all of that to work for you every day. Think of what you can do with a partner like that.

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W I R E L E S S

WIRELESS IS EXPANDING INTO MORE TIGHT PLACES AND REMOTE PROCESS APPLICATIONS THAN EVER BEFORE. HERE’S HOW IT’S DEPLOYED SAFELY AND SECURELY.by Jim Montague


Reducing wires was just the beginning. Today’s wireless is all about covering bigger areas and going places to secure signals and data that could never be reached be-fore. And what’s another word for going where you want and doing what you want? Freedom.

Of course, there are always a few rules to obey and guide-lines to follow. Even though it can deliver the same informa-tion as a hardwired system, wireless still has some unique design and operating requirements.

Wider Circles, Bigger UmbrellasFor instance, 20-year-old system integrator Croft Automa-tion (www.croftautomation.com) in Waco, Texas, has a client running an oil well production � eld with a 20-mile radius, so it must closely monitor tank levels at many remote pro-duction sites, multiple compression sites and central delivery points, as well as comply with U.S. Environmental Protection Agency (EPA) regulations and prevent other problems. So, if a high tank level occurs at the central delivery point, Croft’s customer needs to shut down production automatically to avoid spills and minimize environmental impacts. The � eld, tanks and other facilities had an alarm system, but it wasn’t reliable. Its original noti� cation system also was too slow and sometimes failed to deliver messages.

To acquire more noti� cations more reliably, Croft se-lected Radioline wireless devices from Phoenix Contact

spreads everywherespreads everywhereWireless

CT1505_30_37_CS.indd 30 5/5/15 11:21 AM

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W I R E L E S S

(www.phoenixcontact.com), which extend the reach of I/O and serial communications to as many as 250 devices, easily set up using a thumbwheel and I/O mapping instead of com-plex programming software, and can monitor via I/O-to-I/O, I/O-to-Modbus and serial-to-serial networking. Radioline is available in 2.4-GHz or 900-MHz frequency ranges, but Croft opted for 900 MHz, which can be used in long-range applications up to 20 miles and for short-range, non-line-of-sight installations. As for alarms, even if the user doesn’t get a noti� cation, Radioline can still help suspend production when required.

“Some of these sites can be nasty, hot and extremely dusty, but Radioline gives our users � eld � exibility with Modbus and even more � exibility with wire replacement,” says Johnny Jones, automated systems manager at Croft. “It was easy to set up one radio as the master, and then com-municate to multiple remote sites. The low power draw was another distinct advantage for the remote sites, so engineers don’t have to replace batteries very often.”

So far, Croft has installed Radioline in 83 locations at the production � eld, including master and � eld sites. Jones plans to add 20 to 30 more nodes within the next year, and reports that Radioline also reduces maintenance visits, hours and costs. “This solution gives us a cleaner � nished product that our customers are happier with,” says Jones.

Justin Shade, wireless product marketing specialist at Phoenix Contact, adds that, “Wireless networking contin-ues gain acceptance in industrial applications. With the cost of copper continuing to rise, and wireless manufactur-ers creating newer products that are reliable and easy to im-plement, the use of wireless devices is continually growing.

“Simplicity is always most important when implementing a wireless system. The biggest drivers of wireless are the ease of installation, reduced maintenance costs and the ability to quickly program the network. If it can’t be installed cor-rectly and quickly, then it’s no longer a cost-effective alterna-tive to running wire. To make adoption easy, wireless manu-facturers are adding ways to easily install and program their devices. These include solutions as simple as external LEDs to show signal strength or con� guring modules via thumb-wheels, pushbuttons or SD cards. Being able to con� gure or maintain a module without using a computer allows install-ers to be quick and ef� cient.”

Many Tight SpotsIronically, besides spanning large areas, wireless is probably most useful and adept at handling small places and numerous locations where it’s too cramped or costly to use hardwiring.

For example, BP’s chemical production center (www.bp.com/en/bp-geel.html) in Geel, Belgium, needed a re-liable, affordable way to gather data from its many hydro-carbon sensors that continuously monitor its tanks, valves

and pipelines, and deliver it to the control system to notify operators of any leaks. Leak detection on large sites can be dif� cult and costly, and BP’s operators were already mak-ing twice-daily inspection rounds using portable leak detec-tors, but new and stricter government regulations for storing and handling � ammable liquids required continuous moni-toring. However, a traditional, online monitoring solution would require extensive cabling, associated I/O, signal con-verters and installation costs.

As a result, BP integrated its hydrocarbon sensors with Smart Wireless components from Emerson Process Man-agement (www.emersonprocess.com), which enabled cost-effective leak detection, even from remote locations at the plant. Based on the IEC 62591 WirelessHART protocol, the new wireless devices were easier for BP’s maintenance team to install because they didn’t need new instrument cabling, trenches and ducting, which saved an estimated 50% on the material cost and 90% of the time needed to install a con-ventional hardwired system.

The plant’s new leak detection system uses Emerson’s Rosemount 702 wireless discrete transmitters in combina-tion with Pentair’s (www.pentair.com) Fast Fuel sensors and TraceTek sensor cables. When one of the sensors detects xy-lene or benzene, their associated Rosemount 702 wirelessly transmits an alarm signal to a Smart Wireless gateway that relays it to the control room, where operators monitor and record the status for accurate incident reporting and time stamping in the host control system.

The TraceTek cables are attached to the concrete base surrounding BP’s tanks, so leaks from the tank wall can be detected (Figure 1). They’re also laid underneath, connect-ing piping, and draped around the tank � anges and man-holes, which allows the Fast Fuel sensors to detect hydrocar-bons in sump wells and pump skids.

“By combining Emerson’s wireless technology with hy-drocarbon sensors, BP has expanded its operators’ view and enhanced its existing leak detection practices, and helped improve site safety,” says Bob Karschnia, Emerson’s wireless vice president. “This is another example of how users are taking advantage of wireless to gain business bene� ts, in-cluding enhanced safety and regulatory compliance.”

Moazzam Shamsi, director of global solutions architects at Emerson, adds that, “Wireless is achieving a high level of con� dence among design/plant engineers, and this has resulted in its increased deployment plantwide for multiple applications. In brown� eld projects, the objective is using wireless to deploy solutions to meet operational excellence initiatives through pervasive deployment. In green� eld proj-ects, contractors and users see wireless as a mitigation strat-egy in managing cost, schedule, space and weight.”

Shamsi adds that standards such as WirelessHART are further aiding acceptance of wireless, and even lessening

M A Y / 2 0 1 5 www.controlglobal.com 31

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http://www.phoenixcontact.comhttp://www.bp.com/en/bp-geel.htmlhttp://www.bp.com/en/bp-geel.htmlhttp://www.emersonprocess.comhttp://www.pentair.comhttp://www.controlglobal.com

W I R E L E S S

the need for site assessments. “The most widely used protocol is Wire-lessHART, and it’s been rati� ed as an international standard for some years as IEC 62591. Features in the protocol help it coexist with other networks by optimizing bandwidth and radio time,” explains Shamsi. “Also, no site survey is required for sensor networks like WirlessHART. Using a simple rule set, it can be easily implemented. Wireless green� eld projects are planned with a few simple steps: locate instruments based on segmentation criteria, such as plant area per unit; check coverage via scaled site drawing; locate repeaters to increase network resilience; and verify network with a planning tool.”

Experience and EaseOne dividend of so many wireless ap-plications deploying in recent years

is the experience and advice that vet-eran users can relay to their less-experi-enced counterparts, along with techni-cal innovations that make wireless a lot easier to install and run.

For instance, Valero Energy Corp.’s (www.valero.com) re� nery in Wilming-ton, Calif., processes California/foreign crude oil blend and un� nished feedstock from local and foreign sources, and it’s undertaken several multiyear projects to adopt and update wireless across its facili-ties. The re� nery’s staff uses an ISA100-compliant OneWireless R200 mesh net-work from Honeywell Process Solutions (www.honeywellprocess.com), including its wireless device managers (WDMs), � eld device access points (FDAPs) and XYR6000 wireless transmitters.

The � nished, active network consists of 30 wireless transmitters, 11 FDAPs, two FDAPs wired to the DCSs and


Interface Level

Product Level

Temperature

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The Measureable Difference

MTS Systems Corporation, Sensors Division • 3001 Sheldon Drive Cary, NC • Tel. 800-633-7609 • www.mtssensors.com • [email protected]

Level Plus®Liquid Level Transmitters

Figure 1: BP’s chemical production center

in Geel, Belgium, combines Emerson

Process Management’s Rosemount 702

wireless transmitters with Pentair’s Fast Fuel

sensors to detect xylene or benzene leaks

in its tank walls, valves and pipelines.

EASIER LEAK SEEKING

Eme

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Extend your Ethernet network where you need it most

Eaton’s ELPRO wireless and wired Ethernet products can solve the most challenging communications issues in your plant.

Our broad range of licensed and unlicensed high-speed, long-range wireless modems support 2.4/5.8 GHZ, 900 MHz and 150–450MHz, for an integrated and complete industrial Ethernet infrastructure solution.

Our line of robust, fast managed and unmanaged Ethernet switches in copper and fiber configurations deliver a compre-hensive solution for device and control network connectivity.

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5 shades of wireless here’s how - control global · may 2015 wireless spreads into more tight...

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