Control

W W W. C O N T R O L G L O B A L .
C O M
F O R T H E P R O C E S S I N D U S T R I E S
Serving Up
Asset
Management
The asset management
pie comes in many
flavors and styles.
Do you want thin crust
or deep dish?
Wireless: Users Speak Out

What PAT Means to You
Break Away From Valve Problems
NOVEMBER/2005
CT0511_C1_Cover.indd 1 11/3/05 4:30:51 PM

CT0511_FPA.indd 2
What’s EXCLUSIVE at omega.com
pH, ORP and Conductivity Controller
and Transmitter ®
PHUCN601
$
850
Controller
PHUCN601, $850, inside control panel

shown smaller than actual size.
PHUCN601, $850, shown

larger than actual size.
For pH, ORP, Conductivity/Resistivity
1⁄4 DIN, NEMA 4X, Polycarbonate Enclosure
Reduces Chemical Consumption
with Cycle Timed Relays on Controller
11/3/05 5:26:53 PM
Two Control Relays with Third Relay
for High/Low Alarm on Controller
Two Control Relays with Third Relay
for High/Low Alarm on Controller
Ideally Suited for Heavy-Duty Applications
Such as Industrial Wastewater Neutralization,
Municipal Water and Wastewater, Pulp and
Paper, and Process Control
CT0511_FPA.indd 3
Electrodes
1 1⁄2" NPT PHE-610,
$495, shown smaller
than actual size.
PHE-620, $555,
shown smaller
than actual size.
PHUTX601, $450,
shown smaller
than actual size.
PHUTX601
$
450
Transmitter
3
⁄4" NPT
CDE-610-1, $135,
shown smaller
than actual size. PHUTX601, $450,
inside panel,
shown smaller
than actual size.
eprocesscontrol.net
Shop Online at
For Sales and Service, Call TOLL FREE
© COPYRIGHT 2005 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED
11/3/05 5:30:27 PM
Oil & Gas . Life Sciences . Chemicals . Refining . CPG . Power . Metals, Mining & Minerals . Pulp & Paper
CT0511_FPA.indd 4 11/3/05 5:32:17 PM

exponential leap
Honeywell — a force multiplier in effectiveness across your entire

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You're under incredible pressure to produce results, trim your budget, and
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And join the growing list of Honeywell customers who are making significant leaps forward every day.
To see how Honeywell can take your organization further, visit www.honeywell.com/ps/ad14
© 2005 Honeywell International Inc. All rights reserved.
CT0511_FPA.indd 5 11/3/05 5:33:14 PM

The Choice is Easy.
More than 80% of the failures in a safety application occur with the sensors and final control elements.
The DeltaV™ SIS system, at the heart of Emerson’s smart SIS solution communicates digitally with
intelligent field devices to diagnose and automatically proof test critical elements of your safety
functions. This helps ensure your process shuts down when it should—not when it shouldn’t.
And, only the TÜV-certified DeltaV SIS combined with Emerson’s certified safety services helps simplify your safety lifecycle compliance efforts in
accordance with the new international safety standard—IEC 61511.
The choice is really that easy. For more about Emerson’s smart SIS solution, visit EasyDeltaV.com/SIS .
The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2005 Emerson Electric Co.
www.EasyDeltaV.com/SIS
CT0511_FPA.indd 6 11/3/05 5:33:40 PM

A PUTMAN MEDIA PUBLICATION NOVEMBER/2005
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thin crust or deep dish?
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How model-predictive control can solve the big/little valve problem
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Worldwide and regional shipments of process level measurement, solids
process, and inventory tank gauging devices are projected to increase steadily
through 2009
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The undeniable appeal of wireless sensor networking is convincing more end-
users and system integrators to plan on implementing these technologies.
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Advancing analyzing technologies wake up pharmaceutical manufacturing
to process control benefits Q
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CONTROL (ISSN 1049-5541) is published monthly by PUTMAN Media Inc. 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 and at additional mailing offices.) 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 2004. 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
for Canada and Mexico are $112.00. Foreign subscriptions outside of Canada and Mexico accepted at $125.00 per year for surface and $210.00 for airmail. 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.
w w w.controlglobal.com NOVEMBER/2005 8
CT0511_7_9_TOC.indd 7 11/8/05 1:50:55 PM

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A PUTMAN MEDIA PUBLICATION NOVEMBER/2005
Vol. XVIII
No. 11
Departments
11 74
E D I T O R ’ S P A G E T E C H N I C A L L Y S P E A K I N G
How Safe is Your Job? Advanced Control Ready for Prime Time
Some economists are worried about overheating econo- Fuzzy logic can minimize false alerts but there
mies, while other regions are flat to recessional. is always a tradeoff.
12 75
O N T H E W E B A S K T H E E X P E R T
The World of Process Automation: Best Split Range Control Methods?
ControlGlobal.com What are the advantages/disadvantages of
Your portal to the process industries on the web the standard and alternate split range control
methods?
17
R E A D E R F E E D B A C K
Clearing Up a Few Issues
77
R O U N D U P
Chemical Tradeoffs, Middleware Misunderstood PLCs and Industrial PCs Merging
Identities
18
L E S S O N S L E A R N E D You can’t tell the players without a program—or
Engineers Can Control the Economy, Part 2 with one.
Using an artificial neural network (ANN) model on the
80
U.S. economy would decrease the federal debt. P R O D U C T I N T R O D U C T I O N S
CONTROL Editors’ Picks for the Month
23
O N T H E B U S New products from FCI, Parsec, Citect, Schneider
Training EPCs with Whip, Chair and Gun Electric and others
Instrumentation, control aren’t core components of EPCs.
83
C O N T R O L T A L K
Hoot and a Holler
24
I N P R O C E S S
AutomationDirect, AVG clash on lawsuit The (imagined) transcript of a Texas process con-
Rockwell Automation integrating real-time data; trol engineer on a daytime talk show.
Sasol Solvents wins 2005 HART Plant of the Year
85
A D I N D E X / C L A S S I F I E D
From Products to Jobs
39
C O N T R O L R E P O R T
Beware of the Sleeping Giants Find it here
They will take market share from Second Tier suppliers
86
A R O U N D T H E L O O P
PPAR-5 Convenes in San Diego
42
R E S O U R C E S
Focus on Intrinsic Safety (IS) Process understanding (PU) is the real mean-
FF Guide for IS Systems; an electrical safety encyclopedia; ing of the Process Analytical Technology (PAT)
industrial signaling and alarm solutions guidance.
CIRCULATION AUDITED DECEMBER/2003

Chemicals ........................................................................................................................19,542 Plastics ............................................................................................................................. 5,229
Food & Beverage ..............................................................................................................12,924 Stone, Clay & Glass ........................................................................................................... 2,276
Pulp & Paper ..................................................................................................................... 4,473 Textiles ..............................................................................................................................1,916
Primary Metals ................................................................................................................. 5,952 Petroleum ......................................................................................................................... 3,509
Utilities ............................................................................................................................. 3,466 Tobacco ................................................................................................................................ 227
Engineering & Consulting ................................................................................................10,536 Total circulation .............................................................................................................. 70,050
CT0511_7_9_TOC.indd 9 11/8/05 1:56:29 PM

AUTOMATIONDIRECT’s DL205 micromodular DL205 PLCs include hardware and software options
PLC series is an industry workhorse, for easy connectivity to business systems:
time-tested in some of the toughest • Ethernet modules ($299) connect to any Ethernet network in
your facility's LAN or remote WAN for fast access to critical data.
industrial settings. The D2-260, A full set of practical software tools for local data collection,
the newest CPU in the remote modem data polling, or OPC connectivity provide data to
family, gives you 30.4K keep your systems running at peak efficiency.
total memory, 16
built-in PID loops with
auto-tune and built-in
communications
capability for just
$299.
The DL205 family offers extensive serial

and Ethernet device communications:
• Connect MODBUS RTU Master/Slave devices
directly to the PLC CPU port with no additional
hardware required.
• Connect bar code readers, labelers, weigh scales,
or other ASCII devices to a DL205 system.
• Add wireless serial/Ethernet radios or a serial
dial-up modem for practical remote device
communications or for remote programming.
DL205 PLCs include one of the widest
varieties of discrete, counter, and analog
control options of any class of PLC:
• Low-cost single-channel high-speed counting or
single axis pulse output for only $79, or
multi-channel counting or multi-axis open-loop
motion control starting at $289.
• Over 40 models of discrete, analog, and temperature

modules to choose from at below-average industry
prices.
For more information on the DL205 PLC, please visit:

www.automationdirect.com/dl205
$299.00 $870.00 $830.00
*AutomationDirect prices are June 2005 prices. Allen-Bradley prices taken from Publication ACIG-PL001E-EN-P
September 2004. Technical data from SLC500 Chassis-Based Processors Product Data Publication 1747-2.39,
CompactLogix5320, Catalog Number 1769-L20 Technical Data,Publication 1769-TD003A-EN-P, November 2000.
CT0511_FPA.indd 10 11/3/05 5:42:39 PM

E d i t o r ’ s p a g e
Ep
Serving industry through the efforts of
How Safe is Your Job?

Russell L. Putman (President) 1938-1973
John M. Cappelletti, Sr. (President) 1973-1981
W
Putman Media Inc.
e’ve all watched the dislocations To measure how healthy your job is, the
555 W. Pierce Rd., Suite 301
Itasca, Illinois 60143 caused by Hurricane Katrina, and key indicator is capacity. The rule of thumb
630/467-1300 to a lesser extent by Hurricane Rita, is that when a facility reaches or exceeds
Fax: 630/467-1124 and we have to be wondering how these 80% of capacity, its owners initiate capital
www.controlglobal.com storms will affect the economy and that fa- spending, and start staffing up. As of July
NOVEMBER/2005—Vol. XVIII, No. 11 vorite part of the microeconomic world— 2005, the U.S. Commerce Department re-
Editorial team our jobs. Certainly, there will be some pro- ported that 70% of U.S. companies are at
Editor in Chief: WALT BOYES cess automation professionals who will lose that +80% level of utilization. That’s up
wboyes@putman.net
their livelihoods. Those working for small from 61% in March 2005, which is a steep
Digital Managing Editor: Rick Pedraza distributors, reps, panel shops, and similar slope and a very good sign for U.S. process
rpedraza@putman.net
enterprises will come home to automation professionals. If
Senior Technical Editor: Joe Feeley
jfeeley@putman.net find their former employment you’re in automotive, food/
EXECUTIVE EDITOR: JIM MONTAGUE simply isn’t there anymore, beverage, pharmaceuticals,
jmontague@putman.net
blown to flinders courtesy of petroleum refining, upstream
Senior Technical Editor: DAN HEBERT, PE the two storms. Others will petroleum, mining or utili-
dhebert@putman.net
find that demand for their ser- ties, you should expect ex-
Senior Technical Editor: Rich Merritt
rmerritt@putman.net vices has increased as they’re pansion, new capital projects
Columnists: Béla Lipták,Terrence K. McMahon, called on to restore and re- and hiring. If you’re in semi-
Greg McMillan, Stan WeineR build damaged process plants conductors, primary metals
Contributors: Dana Blankenhorn, Jeff Harrow, and refineries. In reality, how- and chemicals, then you’ll
Dick Morley, Bill Mostia, Ian Verhappen ever, this is all short term dis- likely wait, or even miss the
Events Director : Rick Forsgren
Editorial Assistant: Lori Goldberg
In China, Eastern Europe, some parts of the U.S.
Editorial Advisory Board and Asia Pacific, economists are worried about
Gene Giltner,
Patrick Engineering, overheating economies. In the Midwest U.S. and
Power systems and SCADA Western Europe, they’re worried about doing CPR
Jim Reizner, Procter & Gamble,
Field sensors and batch processing
on economies that are flat to recessional.
Dawn Schweitzer,
Eastman Kodak,
location. What’s the real trend for process boat in this economic cycle. Most of those
Engineering management
automation jobs? companies are investing outside the U.S.
Dan Podkulski, ExxonMobil,
Automation jobs are cyclic with the Meanwhile, only part of your job’s safety
Analyzers and sampling
economy. Global growth is slowing, but is is dependent on the economy. Much of it
Larry Wells,
Georgia Pacific,
still in the 3% range for the coming year. depends on you.
Pulp and Paper controls
Manufacturing activity continues, albeit Remember the Three Little Pigs? The
Mark Wells, Runfactory systems, INc.,
more slowly, to expand. Much of what you pig who was safe, and saved the other two,
integration, 21 CFR 11
will see depends on where you are. If you’re was the one who built the strongest house
Dan Miklovic, Gartner Research,
a Chinese automation professional, you’re with the strongest door. Working for a
Manufacturing integration, MES
seeing rampant growth. If you’re in Illinois company in a declining economic envi-
Design & Production team
or Germany, you’re seeing much smaller ronment is like building your house in the
Group Art Director: Steve Herner
sherner@putman.net growth. In China, Eastern Europe, some 9th Ward in New Orleans. You’ll survive
associate Art Director: Steve vanden heuvel parts of the U.S. and Asia Pacific, econo- just fine—until Hurricane Katrina comes
svandenheuvel@putman.net
mists are worried about overheating econ- along. Sure, you can complain that the di-
associate Art Director: DEREK CHAMBERLAIN omies. In the Midwest U.S. and Western saster relief agencies didn’t do their jobs,
dchamberlain@putman.net
Europe, they’re worried about doing CPR but you still don’t have a house.
Jesse H. Neal Award Winner on an economy that is flat to recessional,
NINe ASBPE editorial Excellence Awards
Twenty one ASBPE excellence in graphics Awards
while elsewhere in the U.S., economic Walt Boyes, Editor in Chief
FOUR ozzie awards for graphics excellence growth is significant. wboyes@putman.net
CT0511_11_EP.indd 11 11/3/05 4:36:06 PM

C o n t r o l g l o b a l . c o m
Cg
H a p p e n i n g t h i s m o n t h at t h e o n l i n e r e s o u r c e o f c o n t r o l m a g a z i n e .
W
elcome! This is the global resource for process automation. We provide
deep, actionable content and tools and news you can use to make your THINGS GET DONE on
plants work better. New features in November include the monthly Edi- ControlGlobal.com
tors’ Brief webcast, and two podcast interviews with movers, shakers, and •C ompare specifications of
troublemakers in process automation. 75 million products from more
While you’re here, sign up to receive our exclusive new e-newsletters covering the than 12,000 supplier catalogs ac-
latest development in smart field instruments (DigitalFieldInsider), process control cessible through our SpecSearch
system security (SecureSystemsInsider), and alarm management (AlarmManage- database.
mentInsider). Subscriptions are free, and if you subscribe, you’ll receive a special • Cruise 25 technology-spe-
complimentary white paper by CONTROL’s editorial staff, “10 Steps to Avoiding cific content channels with
Unnecessary Shutdowns.” articles, whitepapers, news and
new product information orga-
E x c l u s i v e t o t h e SSI : ment, and we’ll be posting the con- nized by topic.
Process Security tent archives of the last 12 years of • Sign up for weekly e-mail
Dale Peterson’s monthly WBF conferences over the next few updates on the latest develop-
Security Column months. Check back frequently for ments in process automation,
new batch content. including technology-specific
e-newsletters on developments
Sound Off in smart instrumentation (Digi-
The Intrepid Rov- talField Insider) and systems
Exclusiv e to the DFI: ing Editor blogs architecture issues (SecureSys-
The Bus is Rolling! from just about any- tems Insider).
“On the Bus” by Ian Verhappen, chair of where on almost any • Research the back-issue ar-
the Fieldbus Foundation’s Users Group, process automation chives of CONTROL magazine,
and ISA’s vice president of standards. topic. This month, search by keyword company or
Walt blogs from the full text.
Tales from the HART Chem Show in New York, Rockwell • Save a tree by signing up to
HART Communication Foundation’s Automation’s Allen-Bradley Automa- receive our full digital edition
Ed Ladd presents his continuing tuto- tion Fair in Saint Louis, and from a of CONTROL magazine—deliv
rial on all the things you can do with variety of other venues. Be sure to ered straight to your web
a HartSmart instrument. read Walt Boyes in Sound Off daily. browser each month. Access a
sample edition through the is-
ASK THE EXPERTS sue archive.
Exclusiv e to Get the straight stuff here. • Find a new job—or a new
Con t rolGloba l .com CONTROL’s Béla Lipták mod- employee—through Control-
Batch Dispatch erates, and he and his cadre of ex- Global.com’s Career Center.
A View from the Batch Processing perts answer these and readers’ other
industries questions on any process automation
World Batch Forum’s (WBF) chair- topic. Save a little money and get the
man, Maurice Wilkins, reports from best expert advice at the same time. FOR YOUR CONVENIENCE
the fountainhead of batch knowledge Ask the Experts. Links to all content referenced on
and experience. this page are at www.controlglob-
WBF and CONTROL have en- al.com/thismonth.
tered into a content sharing arrange-
12 NOVEMBER/2005 w w w.controlglobal.com
CT0511_12_WebToc.indd 12 11/3/05 4:37:22 PM

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CT0511_FPA.indd 15 11/3/05 5:46:41 PM

I ntroducing the second generation Eclipse Guided Wave
Radar level transmitter—the latest generation of loop-
powered, 24 VDC, liquid level transmitters.
For advanced set-up and troubleshooting, an optional
PACTware® DTM interface offers the leading-edge in config-
uration, diagnostics and graphic support. The Model 705 is
For an unprecedented level of applications versatility, the also available with an optional SIL 2 safety integrity rating.
new Eclipse Model 705 consolidates three previous models Yet the new Eclipse 705 maintains the same easy set-up
into a single instrument which interchanges with all Eclipse and manageability of high temperatures, high pressures,
coaxial, twin rod, and single rod probes. steam, coating, aggressive acids and changing specific
In addition, the Model 705’s improved hardware and gravities and dielectrics for which Eclipse is renowned
software expand capabilities, boost reliability, worldwide. For all the details on the new
increase performance, and extend Eclipse's Eclipse 705, call 1-800-624-8765 or visit
standard level measuring range to 75 feet. us at magnetrol.com.

5300 Belmont Road • Downers Grove, IL 60515 • 630-969-4000 • magnetrol.com
CT0511_FPA.indd 16 11/3/05 5:47:03 PM

R E A D E R F E E D B A C K
A
C
Etlrpf
R
Helping Readers Pays Off We need a shift in thinking and a

I liked Rich Merritt’s commentary new policy. I believe that for certain
in the July issue (“With a Little Help segments of the industrial market,
from My Friends,” subsidies are going to be required.
CONTROL, July 2005, The problem is how to allo-
PUTMAN MEDIA INC. p. 45). I know vendors cate our resources equitably,
555 W. PIERCE RD., SUITE 301 can often pressure and this is what needs to be
ITASCA, ILLINOIS 60143 magazines, technical analyzed.
630/467-1300
societies, etc. based Mike Geis,
FAX: 630/467-1124
WWW.CONTROLGLOBAL.COM on economic pressure business development director
that most feel. I believe Sensor Technology Division
NOVEMBER/2005—Vol. XVIII, No. 11 CONTROL has done AMETEK Automation &
a good job separating Process Technologies
PUBLISHING TEAM vendor spin from real
GROUP PUBLISHER/VP CONTENT: issues in the process control
KEITH LARSON
klarson@putman.net
industry. Keep up the good work Middleware is
Bill Wright
Siemens
Misunderstood
MIDWEST AND SOUTHEAST REGIONAL SALES MANAGER:
GREG ZAMIN I was interested to read “Do You Need
gzamin@putman.net
a Single-Source Middleware Solu-
WESTERN REGIONAL SALES MANAGER:
LAURA MARTINEZ
Chemical Industry tion?” by Dan Hebert in the July 2005
issue of CONTROL (p. 73).
218 Virginia, Suite 4, El Segundo, California 90245
310/607-0125, Fax: 310/607-0168 Tradeoffs Middleware to IT folks concerns
lmartinez@putman.net
I agree with Mr. McMahon’s analysis the layer of software that links appli-
NORTHEAST AND MID-ATLANTIC REGIONAL SALES MANAGER:
of the state of the U.S. chemical in- cations. Today, this would include
HARVEY WARREN
10 Marggraff Court dustry (“The U.S. Chemical Indus- web-services-founded environments,
Oradell, New Jersey 07649
201/261-1550, Fax: 201/261-1876 try: R.I.P.,” CONTROL, July 2005, which allow applications to commu-
hwarren@putman.net
p.86). I’ve been working with pro- nicate using Internet-standards-based
INSIDE ACCOUNTS MANAGER: cess instrumentation for more than technologies, such as SOAP, WSDL,
DORIS DEUTSCH 25 years, and can confirm the loss of XML, etc., and form the base of ser-
ddeutsch@putman.net
momentum in the U.S. chemical in- vices-oriented architectures (SOAs).
AD TRAFFIC SUPERVISOR: dustry. However, it may be too soon Vendors talk about various ver-
ANETTA GAUTHIER to give up, and too easy to suggest sions—services oriented enterprise
agauthier@putman.net
that the U.S. Environmental Protec- (SOE), enterprise services bus, ap-
SUBSCRIPTIONS/CIRCULATION:
tion Agency (EPA) is the culprit. plication integration framework, fed-
JERRY CLARK, JACK JONES
888/644-1803 The desire to have a clean environ- erated data structure, etc.—which
ment is not really the problem, but exist in the middleware ecosystem.
REPRINTS SALES MANAGER:
your example of the air-conditioned However, applications running be-
FOSTER REPRINTS
NANCY ROTHMAN ballpark is a good example of Ameri- tween the control layer and the ERP
1-800-382-0808 ext. 134
4295 Ohio Street can values. We want a clean environ- layer wouldn’t be called middleware.
Michigan City, IN 46360
nrothman@fostereprints.com ment, but we buy cars that aren’t fuel These applications include plant
efficient and use power generated by information management systems
ADMINISTR ATIVE TEAM
coal-fired plants, etc. (PIMS), manufacturing execution
PRESIDENT & CEO: JOHN M. CAPPELLETTI The problem is complex. What is systems (MES), asset management
VICE PRESIDENT: JULIE CAPPELLETTI-LANGE the average wage of a chemical plant systems (AMS), and even laboratory
VP, BUSINESS DEVELOPMENT: MARK HARLING worker or a chemical engineer? Would information management systems
VP, CIRCULATION: JERRY CLARK U.S. chemical plant workers accept a (LIMS), as well as quality manage-
50-75% cut in wages, along with more ment and human machine interface
pollution? The only way we can com- (HMI). These arguably use middle-
pete is to design new chemical plants ware to communicate with each
that are more productive and less pol- other and the outside world.
luting. Elimination or reduction of Kevyn Renner,
pollution standards will only slow the strategy and planning leader
exodus because they don’t reduce the Control & Information Systems,
costs of labor, land, insurance, etc. Global Refining, Chevron Corp.
CT0511_17_Feedback.indd 17 11/3/05 4:38:30 PM

L e s s o n s l e a r n e d
Ll
Engineers Can Control the Economy, Part 2
T
he second installment in this two-part series illustrates an DVs is described by gains applied at the nodes located in one
assumed artificial neural network (ANN) model of the or more hidden layer(s) in the model. The gains (and biases)
U.S. economy (see figure). [The first part, “Automation applied at these nodes reflect the influence a particular input
Engineers Can Control the Economy,” ran in CONTROL, has on a particular output CV. If one or more input variables
Sept. ’05, p. 47.] The model is assumed to have four manipu- are changing, their effect on a CV is a function of their weights
lated variables (MVs), five disturbance variables (DVs), and two (gains) and biases at the corresponding nodes.
controlled variables (CVs). These output CVs are assumed to The ANN model must also reflect the fact that some in-
be gross domestic product (GDP) or the LEI. They are a func- put variables will quickly influence the outputs (cost of oil,
tion of the input (manipulated and disturbance) variables. The interest rates, war, etc.), while other inputs tend to evolve
relationship between the output CVs and the input MVs and slowly (fiscal or trade policies). [continued on page 21]
Using an artificial neural network (ANN) model on the U.S.

economy would be more scientific, more accurate, less
£
influenced by political considerations, and consequently less

prone to increasing the federal debt on future generations.
THREE-LAYER, BACK PROPAGATION ARTIFICIAL NEURAL

NETWORK MODEL OF THE U.S. ECONOMY
Model Inputs
x
Manipulated Variables
1) Interest rates (cost of money)
Prime rate: 6.25%, home credit equity: 6.25%, 30-year mortgage: 5.5%;

1-year adjustable mortgage: 4.5%, 10-year treasury bill: 4.22%, federal funds: 3.25%
2) Fiscal policy (spending of money)
Federal budget: $2.5 trillion per year (t/y), including debt servicing: $1.1 t/y, military:
$0.5 t/y, 2004 deficit: $0.41 t/y, debt increase: $0.3 t/y, federal borrowing: Ó
$0.7 t/y, from China: $0.3 t/y. Debt purchase: 75% by foreigners
3) Trade (making money)
2004 imports: $1.9 t/y, exports: $1.28 t/y, worst-ever trade deficit: $0.62 t/y Î
4) Energy policy (fueling the economy)
Total energy cost: $1.5 t/y. U.S. consumption is 25% of global total.
Oil: 22 million barrels per day, electricity: 3.4 trillion KW/hr. *
{
Energy sources: 41% oil, 24% coal, 23% natural gas, 8% nuclear, 4% other.
Disurbance variables Model

5) Housing
x Outputs
Total value: $12 t, total mortgages: $10 t, total paid equity: $2 t, ratio of purchase
cost per yearly rental income (near historic high): 17 to 35
6) Securities È

Total value of all financial assets: $37 t, price to earnings ratio (P/E): 26, worst since 1927 Output
7) Debt layer
Total national debt: $30-40 t, mortgages: $10 t, federal debt: $8 t (three years budget), credit Ç (2 nodes)
cards: $3-4 t, rate of borrowing: $2 t/y
8) Savings
$0.1 t/y n
9) Long-term disturbances Hidden layer
Unemployment (not considering illegal aliens): 5%, effect of outsourcing: hard to (4 nodes)
quantify, education: good in the areas of law, finance and services, but less so in
Input layer
sciences. The best U.S. university team recently placed 17th in a global competition.
(9 nodes)
CT0511_18_20_LL.indd 18 11/3/05 4:40:27 PM

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CT0511_FPA.indd 20 11/3/05 5:52:06 PM

M F T T P O T ! M F B S O F E
A
C
Ttlsr
Ll
[continued from page 18] ables that determine the cycle period of the process. Therefore,
In process control, the time for an input variable to show to obtain the probable cycle period and amplitude of the pro-
63% of its full effect on the controlled variable is called its cess, the ANN model has to be trained on historical data.
time constant. There is also a period during which the input The main limitation in most multivariable, nonlinear pro-
has no effect at all on the controlled variable. This is called cesses is that historical data for training the ANN model don’t
its dead time. It can be short, as in the case of some political exist. In the case of the U.S. economy, however, there is detailed
event, or it can be long. data available covering the last several decades. Of course, the
model developed using that data would only reflect the econo-
5VOJOHUIFFDPOPNZ¤T"//DPOUSPMMFS my’s past dynamics. So, just as one can’t control based on feed
The gains at the figure’s nodes describe the proportional re- forward alone, one can’t fully anticipate the economy’s future
sponse of the ANN controller to an error (ef), which is the based on past performance. This is why the figure also contains
difference between the set point and the actual value of the a feedback component, where the self-correcting feedback (em)
controlled variable (LEI or GDP). The integral action of this is continuously applied to correct and update the ANN model.
controller responds to the past history of an error, such as the ef- One can only speculate how much value an ANN model
fect of accumulated budget deficits on the LEI, by integrating and its recommendations would have on the nation. What
the area under the error curve. The role of the derivative action is less debatable is the fact that it would be more scientific,
is to anticipate the future, and take corrective action based on more accurate, less influenced by political considerations,
what would happen if the correction wasn’t made. The most and consequently less prone to increase the debt on future
significant example of this is looking at the rate that we in the generations, which politicians tend to do. C
U.S. are borrowing from our children and grandchildren, and
the effect of this national debt if it’s left uncorrected. Béla Lipták, PE, process control consultant, is also editor of the In-
Most processes oscillate with a cycle period of about four strument Engineers’ Handbook and is seeking new co-authors for
dead times. Naturally, in multivariable processes, it’s the com- the forthcoming new edition of that multi-volume work. He can be
bined effect of the gains and dead times of the many input vari- reached at liptakbela@aol.com.
>ÃÊÜ
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Maintenance-Free, Industrial Air/Gas Flow Meter.

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CT0511_18_20_LL.indd 21 11/3/05 4:40:52 PM

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CT0511_FPA.indd 22 11/3/05 5:52:50 PM

o n t h e b u s
Ob
Training EPCs with Whip, Chair and Gun
O
ne of the remaining hurdles to the adoption of field- a selection of helpful, free tools is available from several
bus technologies in the automation and control suppliers, though each has its own limitations.
realm is that many of the engineering procurement Training—To gain new skills, of course, users require
construction (EPC) firms that design and install facili- training to learn and apply them. Unless a large project
ties don’t include fieldbus in their proposals. is willing to include training in its costs for using new
Part of the reason for the reluctance to make this change technology, this requires an investment in unbilled time,
is just that; it is a change with all the apprehension and which reduces profitability by increasing overhead.
baggage associated with those events. Change also comes This difficulty is compounded by the fact that, despite
with expenses for such things as: what we who have “seen the light” like to think, instrumen-
Despite what we who have “seen the light” like to think,

instrumentation and control is not a core component of most
EPCs, but rather a necessary support service needed to sell
the bread and butter of process and mechanical engineering.
Procedures—Systems in place de- tation and control is not a core component of most EPCs,
fining how something is to be done will but rather a support service needed for selling the bread and
have to be modified to reflect adding butter of process and mechanical engineering. Of course,
this new technology, depending on the the automation suppliers, for whom this is a core compe-
number of fieldbus types being considered. New ways of tency, are filling this void by becoming, not only host system
keeping track of which type of signal is doing what need to suppliers, but also complete automation suppliers responsi-
be developed. This leads to related changes in... ble for everything from the field device through to the con-
Work Processes—The amount and type of interaction trol system and the final control element.
between engineering design teams is different in fieldbus, However, not all is bad news. The good news is that
especially if you want to support field-based control. This some end users are forcing EPCs to include fieldbus as a
means that the process engineers need to sit with the auto- deliverable, and some companies are learning these new
mation engineers to confirm the interactions between field skills. In addition, some EPCs believe having fieldbus-
devices, while the electrical engineers need to discuss physi- capable staff is a competitive advantage for bidding on
cal equipment locations to minimize cable runs and in- projects, and for recruiting and retaining their staff. In
stalled costs, and the instrument engineers need to specify fact, some institutions worldwide are offering fieldbus
the actual devices. Fortunately, automation and instrumen- training, so interested organizations can obtain vendor-
tation folks often are the same person. neutral introductions to the technology.
The team also needs to determine who on the team is After this latest design hurdle is crossed, the next and
doing what task. With the field devices and associated field close to last one remaining is the installation contractors.
termination equipment now part of the control system net- That, however, is the topic for another column.
work, for example, should the design of the cable and I/O In the next column, we will talk about “industrial Eth-
be done by the electrical or instrumentation staff? ernet” and what that term really means. As always, your
Design Tools—New design tools are required to calcu- comments and suggestions on the above, as well as input
late the limitations and layout of these new networks. for future discussion topics are encouraged. Please con-
Calculations—Traditional point-to-point systems were tact me at the information below.
only concerned with having enough energy for one de-
vice. Now designers not only have to consider the en-
ergy at multiple devices, but evaluate rules and limits
on other items, such as total cable length, cable termi-
nations, communication resources, and network cycle Ian Verhappen, Contributing Editor
times necessary for the data to be collected. Fortunately, Ian.Verhappen@ICE-Pros.com
w w w.controlglobal.com NOVEMBER /2005 23
CT0511_23_OTB.indd 23 11/3/05 4:43:05 PM

i n p r o C e s s
Ip
AutomationDirect, AVG clash over, lawsuit

A simmering legal dispute between the two manufacturers recently boiled over in a public disagreement.
A
utomationDirect reported Oct. 20 that it voluntarily ne-
gotiated and agreed to an Oct. 11 court order delaying CONTROL Web Poll
the launch of its new C-more panels, and that it wasn’t
actually forced to stop selling the products by the U.S. Dis- How many vendor-sponsored user-group
trict Court for Northern Illinois, as stated by AVG at its Oct. events do you attend each year?
18 press conference.
AVG revealed that it had filed an intellectual property lawsuit
against AutomationDirect in September 2005. This litigation
reportedly claims that AutomationDirect secretly copied AVG’s
EZTouch panel during their recent joint venture partnership,
which AVG says violated AutomationDirect’s obligations to it.
AVG adds it believes that Koyo Electronics Industries was man-
ufacturing these “knock off” panels as C-more in China.
AutomationDirect responded that it believes AVG’s lawsuit
is without merit, and that it intends to prove this in court. n 44% None
In addition, AutomationDirect adds it was actually the first n 33% One
litigant in its dispute with AVG. AutomationDirect reports it n 11% Two
filed the first lawsuit in April 2005 against AVG’s EZ Automa- n 11% Three or more
tion in U.S. District Court in Atlanta for trademark and copy-
right infringement and for false and deceptive advertising. If you do attend one or more, do they
AutomationDirect says it didn’t publicize its earlier lawsuit, so meet your needs?
it could be handled in court, rather than outside.
AVG stated Oct. 18 that U.S. District Judge James Holder-
man’s order “stopped” AutomationDirect, its president and
CEO, Tim Hohmann and Koyo from soliciting or accepting
any orders for C-more products, and “restricted them” from ad-
vertising any pricing information. However, the order itself says,
“The parties agree and stipulate that…the defendants shall nei-
ther solicit nor accept any purchase order for the C-more line
of products, or discuss, advertise, or disclose the pricing of said
products with existing or potential customers from and after the
entry of this order.” The order adds that it doesn’t affect C-more
information already in circulation, that AutomationDirect can n 80% Yes, but less each year
talk about C-more with its distributors, and that the order will n 20% Yes, and I think they’re getting better
terminate when a subsequent order is issued.
Sasol Solvents wins 2005 HART Plant that are using the full capabilities of HART technology in
real-time applications to improve operations, lower costs,
of the Year award and increase availability.
Sasol’s plant uses HART Communication for full-time
T
he HART Communication Foundation (HCF, www. monitoring of 3,500 HART-enabled instruments and con-
hartcomm.org) reported Oct. 25 at ISA Expo 2005 in trol valves. Johan Claassen, Sasol’s E/I manager, says one
Chicago that Sasol Solvents and O&S SMG operations of the company’s main project objectives was to move
plant in Sasolburg, South Africa, has been selected as the from a “run-to-failure” maintenance philosophy to a pre-
2005 HART Plant of the Year. The award is given annually dictive maintenance strategy. The goal was to lower fixed
to recognize people, companies and plant sites worldwide costs and avoid or prevent unscheduled plant shutdowns
CT0511_24_32_InProcess.indd 24 11/3/05 5:02:02 PM

CT0511_FPA.indd 25 11/8/05 2:06:39 PM
Isn't it a
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Compact 10” Coriolis Sensor

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CT0511_FPA.indd 26 11/3/05 5:56:54 PM

J O ! Q S P D F T T
AItlpuie
RP
C
by using device diagnostics to warn col, it would be ‘brilliant’. HART is

of pending problems. the next technology phase after pneu- 3PDLXFMM"VUPNBUJPO
“The biggest benefit of using the matic, electronic 4-20 mA and DCS,” JOUFHSBUJOHSFBMUJNF
HART protocol is the capability to ac- adds Claassen. “HART improves the
cess on-line device diagnostic informa- way we do maintenance. It helps me EBUBCFUXFFO
tion from our intelligent HART-enabled
devices and control valves,” explains
do my job better because I can login in
the morning and get a health status on
NBOVGBDUVSJOHBOE
Claassen. “We’ve realized more than $2 all my instruments. It frees up my time CVTJOFTTTZTUFNT
million in documented savings to date, to do things I just couldn’t do before.”
3
and will continue to enhance our use of Lonza biopharmaceutical manu- ockwell Automation reported
HART and to expand on its benefits go- facturing plant in Visp, Switzerland Oct. 24 that it’s expanding its
ing into the future.” was selected as the 2005 HART Plant plant-wide information software
Sasol’s plants produce commodity of the Year Finalist. The 100-year-old by extending its manufacturing ex-
chemicals, mainly solvents used in paints facility produces 75% of the world’s ecution system (MES) products,
and inks. The process converts propylene Niacin and is using 1,300 HART-en- deploying a service-oriented archi-
into n-butanol, iso-butanol and crude abled devices in an all-digital mode. tecture (SOA), and gathering its soft-
acrylic acid and produces derivatives The plant uses HART Communi- ware products into one, integrated
such as glacial (high purity) acrylic acid, cation to improve loop accuracy, to Rockwell Software FactoryTalk suite.
ethyl acrylate and butyl acrylate. speed up device configuration and to FactoryTalk is an integrated suite
“If I had to use one word to describe better document and validate the de- of scalable, modular, standards-based
the HART Communication Proto- vice configuration. production performance software ap-
0/5)&4)08'-003
*4"&910
Michael Kessler, Pepperl+Fuchs’

components and technology director
(right), demonstrates P+F’s upcoming
advanced diagnostics devices to Shuji
Kase, fieldbus networks consultant for
Yokogawa Corp. of America, on the
show floor Oct. 26 at ISA Expo 2005 at
McCormick Place in Chicago.

J O ! Q S P D F T T
Ip
plications that are integrated with automation software applications,” mon set of software services that in-
Rockwell’s Logix control platform adds Roach. “We’re building on this cludes security, diagnostics, auditing,
and connected to third-party and leg- foundation by creating one common data model, licensing, real-time data,
acy systems. “Many of our custom- integrated suite that embraces both historical data, configuration and
ers are familiar with FactoryTalk as a services and applications.” alarms and events. FactoryTalk builds
valuable set of integrated services that FactoryTalk’s applications will run on existing Rockwell Software, and
facilitate data sharing among multiple on FactoryTalk SOA, which is a com- provides a platform for added solu-
tions. So, as the company releases new
versions of its Rockwell Software, Pro-
pack Data and Arena products, they’ll
be incorporated into FactoryTalk.
Essentially, FactoryTalk consists
of multiple production disciplines,
which correspond with common
manufacturing activities that require
integration of plant-floor data with
business systems. Whether operating
individually or in combination with
each other, FactoryTalk’s production
disciplines use the knowledge-based
infrastructure in the FactoryTalk SOA
for more efficient data sharing, easier
integration and faster startup. These
disciplines include performance and
visibility, production management,
asset management, quality and com-
pliance, data management, and de-
sign and configuration.
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ART Communication Founda-
tion (HCF, www.hartcomm.org)
reports that its member compa-
nies have approved enhancements to
the HART Device Description Lan-
guage (DDL) specification. The en-
hanced DDL simplifies and standard-
izes the presentation of intelligent
device information for both automa-
tion suppliers and users worldwide.
HCF says enhanced DDL greatly
benefits users because it allows them
to more easily configure, diagnose,
and monitor performance of intelli-
gent instrumentation.

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#ONTACTYOURAUTHORIZED3WAGELOKSALESANDSERVICEREPRESENTATIVEFORMOREINFORMATIONORVISITWWWSWAGELOKCOMORCALL 37!'%,/+
CT0511_FPA.indd 29 11/3/05 6:00:22 PM

!J O ! Q S P D F T T
Ip
“The enhanced DDL updates the industry standard with new essentially the same on all EDD-compliant host applications
capabilities for describing advanced visualization of intelligent regardless of supplier or operating system.
device information while maintaining the proven integrity of ex- In related news, Invensys Process Systems (ips.invensys.
isting HART DDL technology,” says Ed Ladd, HCF’s technol- com) announced its own plans at ISA Expo 2005 to embed
ogy programs director. “An enhanced DD registered with HCF HCF’s SDC-625 into its process automation system. This
will work on all enhanced DD-compliant host applications.” will help users take advantage of the new EDDL being de-
DD language enhancements have been incorporated into veloped by HCF, other international fieldbus organizations
HCF’s standard DDL tools, including its Device Descrip- and automation system and device suppliers.
tion Integrated Development Environment (DD-IDE) and Invensys adds it’s deploying complementary FDT tech-
the Smart Device Configurator (SDC-625). DD-IDE sup- nology in its fieldbus solutions with EDDL and FDT/DTM
ports efficient development, testing and maintenance of en- technology working harmoniously together.
hanced DDs. SDC-625 is the HCF standard reference host
supporting cost efficient development and testing of compli-
ant enhanced DDs and DDL-enabled host applications.
HCF adds these enhancements allow manufacturers to
'JSTUBOOVBM.BUSJLPO01$
easily incorporate graphical windows, menus, images, trends $POGFSFODFESBXTXPSMEXJEFVTFST
and other advanced data visualization features into the device
.
description for an intelligent HART device. All information atrikon reports that approximately 130 visitors at-
to define the window, the presentation of data in the window tended more than 40 presentations, keynote ad-
and interaction with the device is described entirely in the en- dresses, exhibits and other events during its
hanced DD. The device information reportedly will appear three-day, inaugural MatrikonOPC Conference (www.
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CT0511_FPA.indd 31 11/3/05 6:01:46 PM

J O ! Q S P D F T T
Ip
opcusersgroup.org) in Houston, Texas. The conference

covered the vision of OPC, network cyber security, case
studies, as well as interoperability and reliability issues.
Though attendees came mostly from North America,
the conference also attracted presenters, participants, in-
tegrators and users from as far as Russia, South America,
and Europe. They represented a variety of companies, in-
cluding Microsoft, SAP, Oracle, Shell Global Solutions,
and the OPC Foundation.
“The MatrikonOPC Conference represented an impor-
tant opportunity to learn about the technology,” says Tom
Burke, OPC Foundation’s president, who delivered the first
day’s keynote. “Attendees learned a lot about the different
vendors, and learned about Matrikon’s commitment to OPC
as one of the driving companies supporting the OPC Foun-
dation and the technology.”
The three official conference days were followed by three
days of intense, hands-on workshops with more than 70 at-
tendees taking part. These computer lab-based workshops
offered Level 1, 2 and 3 OPC certification for beginner to
advanced users. “This was an excellent workshop, and its ref-
erence to real examples and exercises helped me understand
the use of OPC,” says Kenneth Arroyo of Schlumberger.
Matrikon adds that Houston will host the next Matriko-
nOPC Conference in September 2006. For more informa-
tion, visit www.opcusersgroup.org.
'%5(SPVQGPSNBMJ[FT)POFZXFMM
4DIOFJEFS 4IFMM 4BVEJ"SBNDPKPJO
5
he automation companies and end-users previously
organized as the FDT Joint Interest Group reported
Oct. 26 at ISA Expo 2005 in Chicago that they’ve co-
alesced into a formal organization known as FDT Group
AISBL (www.fdtgroup.org).
Executives from ABB, Endress+Hauser, Invensys, Metso
Automation, Omron, Rockwell Automation, Schneider
Electric and Yokogawa make up the new group’s initial
board of directors, while an executive committee and man-
aging director will run the day-to-day organization. A man-
aging director will be announced early next year, and will
serve as FDT Group’s primary contact.
Also, the group has formed an association and stan-
dards committee to help forge close relationships with
other standardization bodies.
In addition, Honeywell Process Solutions, Schneider
Electric, Saudi Aramco, and Shell Global Solutions re-
cently joined the new FDT Group. The organization
now has 39 international automation and end-user com-
panies as members. C
! w w w.controlglobal.com

CT0511_FPA.indd 33 11/3/05 6:02:11 PM

CT0511_FPA.indd 34 11/3/05 6:06:26 PM
C o n t r o l R e p o r t
Cr
Beware of the Sleeping Giants
I
t will be very interesting to see the latest version of In Europe, these three are considered leaders. Here in
CONTROL’s Top 50 Process Instrumentation and North America, it’s a different story.
Controls Suppliers in our December 2005 issue. The One of the sleeping giants used to dominate the PLC
Top Tier (Emerson, Invensys, Honeywell, ABB, Dana- market. Their share of the U.S. market is now a fraction
her, Siemens, Schneider, Rockwell and GE) probably of what it used to be. As noted above, another has process
won’t change much, except perhaps in their order. control equipment that no one knows about. So much for
Three of the companies in this Top Tier (ABB, Siemens Europe-led marketing efforts.
and Schneider) can be considered sleeping giants because The powers-that-be at all three of the giants seem to have fi-
their North American marketing experts have, until re- nally realized their errors, and are starting to turn over market-
The sleeping giants will take market share from smaller

suppliers on the Second Tier.
cently, been sleepwalking. All three ing to North Americans. One fired its long-time ad/PR agency
have lamented in public about their and hired a new one. One raided Rockwell Automation to find
poor market share for process controls an experienced, high-level marketing guru. All are hiring (or
in North America, and have expressed want to hire, they tell me) experienced marketing people. It will
a desire to increase their shares substan- be very interesting when their new ad agencies, marketing man-
tially. Yet their marketing efforts can be agers and communications people get some money to spend
described with one word: disorganized. and a directive to increase market share.
In some cases, these firms’ European corporate par- I seriously doubt if the top three—Emerson, Invensys and
ents decided they could run North American market- Honeywell—will give up their shares easily. The top three
ing operations from Europe. Others brought European companies have a bunch of savvy old pros running things,
bosses here. That often led to our getting press releases and these folks definitely know what they’re doing. Those
written in German-English, that is, barely understand- three are at the top of the heap, and they got there—and
able. It also led to burying, or at least minimizing, all the stay there—because they have great marketing machines.
well-known companies and brand names they’ve bought The sleeping giants consequently will have to take market
up: Moore, Fischer & Porter, Modicon, Taylor Instru- share from smaller suppliers on the Second Tier.
ments, Bailey and so on. In December 2005, we will cover that Second Tier.
The Europe-based companies seemed to think that just These are process control and instrumentation compa-
because they dominate Europe and the rest of the world, nies that aren’t listed in the Top Tier. We’ll look at what
North American end users would be an easy mark. Few of they have to offer for process control.
them understand how you buy products, how much you As we’ve lamented here before, many of Second Tier
value your reps and distributors, and the loyalty you have companies have superb products, but very poor marketing
toward your regular suppliers. departments. In other words, they rely on word of mouth,
We went to one of their company gatherings recently. repeat business and reps and distributors, and spend little
That’s where the firm invites its local reps and distributors or no money on advertising, public relations, direct mar-
and its local customers to hear papers and see products in keting, web pages, catalogs, etc.
an exhibit. Some of the distributors were amazed: “I didn’t The last time we covered second tier companies we
know (name withheld) had process control instrumenta- had to beg and plead before some of them would send in-
tion!” said one rep. Another attendee, a customer, didn’t re- formation. If that’s the case again this year, the sleeping
alize the company sold PLCs. giants will bury them or buy them. If so, the Top 50 for
The sleeping giants have marvelous, state-of-the-art 2006 may be very different from the Top 50 in 2005. C
products, and the companies are leaders in R&D, stan-
dards efforts and safety. The old marketing rule is, “If you Rich Merritt, SeniorTechnical Editor
want to be perceived as the leader, act like the leader.” rmerritt@putman.net
CT0511_39_CR.indd 39 11/3/05 4:45:27 PM

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S F T P V S D F T
R
'PDVTPO*OUSJOTJD4BGFUZ
/FX5PPMT:PV$BO6TFPOUIF+PC
&
very month, CONTROL’s editors take a specific you know of any tools and resources we didn’t include,
product area, collect all the latest tools we can find, send them to wboyes@putman.net, and we’ll add them
and present them here to make your job easier. If to the website.
'06/%"5*0/(6*%&'03 ments of theory and principles to pro-

*/53*/4*$"--:4"'&4:45&.4 vide a foundation for addressing ques-
The Fieldbus Foundation’s applications that arise when no standard or
tion guide, “31.25 kbit/s Intrinsically regulation exists. It also includes more
Safe Systems (AG-163 Revision 2.0),” practical examples of applying princi-
covers all aspects of intrinsically safe ples in real situations, including global
(IS) fieldbus systems and implement- operations and applications. *4" UIF
ing fieldbus control strategies in haz- *OTUSVNFOUBUJPO 4ZTUFNT BOE"VUPNBUJPO4PDJ
ardous-area applications. It includes FUZXXXJTBPSH
updates on IS fieldbus technology,
guidance on equipment certification, 4*(/"-*/(4&-&$5*0/(6*%&
sound design/installation practices, “Crystal Clear Communications for 163(&5)"58&#4*5&
Entity and FISCO models, and other Hazardous and Adverse Locations” The BebcoEPS.com website provides
variants of explosion-protected field- describes industrial signaling solu- information on purge and pressuriza-
bus systems that include IS, such as the tions, including warning beacons tion systems for hazardous locations.
IIB/IIC split architecture concept and The site offers pages of educational
the fieldbus barrier concept. 'JFMECVT resource materials, including tuto-
'PVOEBUJPOXXXªFMECVTPSH rial study guides, design guides, and
a troubleshooting section. If visitors
*/45"--*/(*/4536.&/54 are unable to find an answer about
*/)";"3%064-0$"5*0/4 purge and pressurization systems,
Electrical Instruments in Hazardous Lo- an “Ask the Expert” section prom-
cations, 4th Edition, by E.C. Magison, ises a response within one business
is an encyclopedia of electrical safety. day. 1FQQFSM'VDIT XXX
This latest edition has expanded treat- BNQFQQFSMGVDITDPN
*/53*/4*$4"'&5:."(";*/&
Process Connections offers informa-
tion on intrinsic safety and process
I/O. The magazine includes sections
on fieldbus products and applica-
and strobes, horns and sirens, buzz- tions for safe and hazardous areas, IS
ers and multiple-tone generators, interfaces for process applications,
heat and smoke detectors and steam making the most of HART capabili-
whistles. The guide provides a com- ties, taking advantage of the simplest
prehensive glossary of hazardous lo- IS barriers, how to select a display
cation definitions and terms, as well for hazardous areas, field mounting
as a helpful section on the principles remote I/O, and assessing and pro-
of sound. To receive a copy, send an tecting valuable instruments from
e-mail to: lit.request@edwards-sig- surge. To subscribe, send an email to
nals.com. (&4FDVSJUZXXX info@mtlmost.com. .5-
HFTFDVSJUZDPNTJHOBMJOH XXXNUMNPTUDPN
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CT0511_FPA.indd 43 11/3/05 6:07:53 PM

Serving Up
Asset
Management
3JDI.FSSJUU 4FOJPS5FDIOJDBM&EJUPS
CT0511_44_55_CoverStory.indd 44 11/3/05 4:49:36 PM

The
asset management pie
comes in many
flavors & styles.
Do you want thin crust or deep dish?
"
sset management (AM) is like a pizza. It can be cut into several pieces: loop tuning,
maintenance management, condition monitoring, etc. You can cook AM by assem-
bling all the ingredients yourself, or you can buy it already cooked by a full-service
supplier. AM comes in many flavors and styles too. These range from the deep-dish,
Chicago-style version, with more capabilities and ingredients than you may need or want,
to thin-crust types, with just loop tuning or computerized maintenance management soft-
ware (CMMS). Finally, AM can be delivered to your plant for local consumption, or it can
“served” to you from remote computers.
AM TASTES EFFICIENT, YUMMY! Abitibi-Consolidated continues to use asset management

Unlike some of the vaporware that plagues our process con- during operations to fine-tune its process (Figure 1). “Our
trol industry, AM software actually works, and it works well. Continuous Process Improvement Team includes engineers
Michel Gaumond, electrical maintenance coordi- and operators, who are dedicated to solving problems that
nator at the Alma Division of Abitibi-Consolidated, come up during operation, and devising ways to further op-
a paper mill in Alma, Quebec, Canada, recently in- timize and refine its process,” explains Gaumond. “This
stalled a new control system on a new paper machine, team has a dedicated set of DeltaV workstations in a separate
and used asset management to help make it all work. room, where it can analyze data from DeltaV historian, event
“System commissioning was done using the AMS as- logger and AMS, as well as OSISoft’s (www.osisoft.com) PI
set management system from Emerson Process Man- historian. The team spends 100% of its time solving prob-
agement (www.emersonprocess.com),” says Gaumond. lems and optimizing processes.”
“This simplified calibration, control configuration and Maintenance comes after startup and operations, and
verification of various field devices. With AMS, com- AM has the right ingredients there too. “We’ve trained the
missioning took less time than we expected, and made maintenance group how to use tools such as equipment diag-
it possible to document every step. It allowed us to find nostics. We now have a full year of equipment performance
and diagnose problems during testing and startup. We data, such as valve signatures, and we’re learning to perform
performed many tests on the various systems before the predictive maintenance. For example, we can compare the
actual startup, and AMS was extremely valuable when current signature of a valve to the signature when it was in-
troubleshooting.” stalled, and determine if the valve is working properly.”

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CT0511_FPA.indd 46 11/3/05 6:08:33 PM

AM: Thin Crust or Deep Dish?
Though Abitibi-Consolidated is us- Making the Crust

ing software from two of the process Pizza starts with making a good crust.
industry’s biggest AM suppliers, Em- In a process plant, the crust is real-
erson and OSISoft, similar success
is possible when using AM software
time plant floor data. Getting real-
time data into asset management is
from less famous firms. FileNet (www. getting easier all the time because
(J[\HS:PaL
filenet.com), for example, is known modern control systems can deliver __
for its enterprise content management data in a standard, usable format. As
(ECM) solutions in industries that of- Dave Ochoa, Emerson’s director of
ten drown in paperwork. strategic planning, puts it, “Many as-
Duke Energy, an integrated power sets in modern plants and mills are
and natural gas company in Char- intelligent and self-diagnosing. These
lotte, N.C., was similarly submerged assets communicate by industry stan-
in documentation and subsequently dard protocols, such as fieldbus and
aided by FileNet, according to Steve HART. System interfaces are avail-
Morgan, Duke’s electronic document able which pass information directly
integration manager. “Duke Energy through the control system, multi-
is composed of 700 subsidiaries and plexers and linking devices.”
joint ventures, with offices from Char-
lotte to London,” says Morgan. “It “We’ve been offering
faces a number of regulatory require- software deployed as EtherNet/IP
EtherNet
Net/IP
/IP w
conformance tested
ments on its three nuclear and 27 fos-
sil-fuel plants.”
a pay-per-use service
running on a central
Morgan adds Duke must maintain
records on litigation support, sales con- web server for years,
tract management, enterprise resource but there are no tak-
planning (ERP), financial account-
ing, manufacturing and engineering,
ers so far. Part of the
problem has been that
change management, engineering
document management, regulatory operating companies
submissions, process safety manage- are very protective of
ment/OSHA, health/safety/quality,
specifications/estimates and procure-
their data.”
ment, maintenance/repair/operations,
and research. Keeping track of this data The major process control vendors
may sound deadly dull—much like eat- have been on top of this trend for sev-
ing a frozen, supermarket pizza—until eral years. They saw the need for con-
you realize AM’s direct benefits. necting the plant floor to IT long ago,

“In the past, nuclear plants were so almost all of them now offer com-
down for 45 days when undergoing pletely integrated asset management
regularly scheduled shutdowns,” says software packages that acquire the
Morgan. Much of that was filling out necessary data. Even SAP, the 800-
regulatory paperwork. “Thanks to lb ERP gorilla in our industry, has
FileNet’s solution, Duke Energy has finally acknowledged that the plant
been able to bring a plant back online floor is more than just a place to get
in 21 to 30 days. Considering that such production numbers.
plants generate $1 million dollars per “Integration of plant floor informa-
day in revenue, this can add up to a tion with SAP is currently the hottest
substantial amount of extra income for area in the enterprise IT space,” says
the company.” Jindrich Liska, manufacturing intel-
Abitibi-Consolidated and Duke’s ap- ligence VP at Iconics (www.iconics.
plications and requirements show that com). “Historically, SAP and other
proven AM software from large or small ERP vendors embraced a top-down
suppliers can make your process more approach of plan-driven push manu-
efficient, productive and manageable. facturing. However, a top-down model
w w w.controlglobal.com

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CT0511_FPA.indd 48 11/3/05 6:09:42 PM

Slicing the Pie
There are eight basic pieces of the AM pie:

• C ondition monitoring—Diagnostic • Process optimization—This soft-
and status information from smart ware analyzes overall process or
instruments, fieldbus equipment unit operations, identifies prob-
and devices with embedded web lems, and recommends changes to
servers provide real-time data re- improve an entire process.
lating to equipment health. Spe- • Plant historian—Captures real-
cialty software analyzes the data time data from the entire process,
to identify problems. and makes it available to opera-
• M aintenance management— tors, process engineers and main-
CMMS takes real-time diagnostic tenance people for analysis.
information, data involving equip- • Document management—Orga-
ment usage and availability, plant nizes, updates, and makes avail-
schedules and other factors into able a host of documents, including
consideration, and determines manuals, regulations, equipment
when an “asset,” such as a con- schematics and so on.
trol valve, needs maintenance. • Supply chain management (SCM)—
• Loop tuning—Using real-time and Based on an evaluation of available
historical data, loop tuning soft- assets and incoming orders, SCM
ware can identify when a process tells the plant what to make.
loop needs to be adjusted for maxi- • ERP—Runs the enterprise’s finan-
mum efficiency. cial business.

doesn’t meet the requirements of agil- ware was because the various AM soft-
ity and responsiveness in today’s com- ware packages were completely sepa-

petitive global market. Instead, the rate and didn’t talk to each other.
new bottom-up paradigm is emerging Bruce Reierson, business develop-
as an approach to leverage plant-floor, ment manager for asset optimization

real-time information for fast and ac- at ABB (www.abb.com), explains that,
curate business decision making.” “In the past, each of the involved dis-
In other words, the ERP tail once ciplines used separate systems, spe-

wagged the process control dog. Al- cifically designed for their individual
though plant systems obediently sent needs, to achieve their respective goals.

information to ERP and other higher These closed systems made it nearly im-
level enterprise software on demand, possible to leverage their benefits enter-
results that would help plant opera- prise wide. Today, with the introduction

tions rarely came back. But now, with of open architecture environments, the
your local AM software collecting enterprise benefits by linking critical
plant floor data and using it to analyze real-time plant floor information across
process operations (Figure 2), you the enterprise in a manner that is tai-
don’t need ERP anymore. lored to the individual user.”

ERP never really worked anyway, For process control professionals,
says Dave Shook, marketing man- open integration provides two benefits:
ager at Matrikon (www.matrikon. first, linking your control system to AM

com). “The dirty little secret of ERP improves overall plant operation; sec-
software is that it’s used for financial ond, you and your control system can
functions instead of driving manu- provide the information that will help
facturing decision making,” he says. optimize an entire enterprise. In short,

“In process manufacturing, ERP has build the crust correctly, and you may
been a pretty big bust.” increase your status from being an un-
Another reason you never got any known engineer in a remote plant to
benefit from ERP and other AM soft- that of an information guru.

Ordering the Pizza

You can buy a pie from a pizzeria that just makes pizza or
from a full-service restaurant that offers pizza along with its
fish, chicken and tacos. However, you can’t get a pizza with
the same taste as a Domino’s Pizza at a sit-down restaurant.
It’s the same with AM software. All the major process con-
trol vendors offer a complete line of AM products, and all the
software works together. Alas, some of the ingredients may not
“taste” quite as good as software from a shop that specializes
in CMMS, loop tuning or document management.
There are two arguments here. The first says process
control vendors should configure their AM packages to
meet specific needs of process industry users and run with
their control systems, thus simplifying integration of the
AM process. The opposing argument is that the specialty
shops know more about their particular area of expertise
than the process control vendors, so you can get a best-of-
breed package by shopping around.
“The dirty little secret of ERP

software is that it’s used for
financial functions instead of
driving manufacturing decision
making. In process manufacturing,
ERP has been a pretty big bust.”
“Asset diagnostic applications take a variety of forms, but
• 4-20mA need to be correlated to form a comprehensive view of asset,
Control Signal unit and plant health,” says Emerson’s Ochoa. “We believe
the heart of AM is not CMMS, but rather the asset diagnostic
• HART ® Enabled
and condition/performance monitoring technologies, and the
• Field Scalable ability to access these in a holistic manner.”
Output Peter Martin, performance management VP at Invensys
Process Systems (www.invensys.com), agrees that, “The intent
• Various Probe is not just for the automation companies to provide CMMS,
Lengths rather it is to combine the worlds of automation and mainte-
• Wide Range nance in a way that will provide new levels of business value.
of Electrode Traditionally, operation and maintenance have been man-
Materials aged and automated independently. Automation suppliers are
in an ideal position to accomplish a holistic approach because
they interact with both operations and maintenance.”
George Buckbee, marketing manager at ExperTune (www.ex-
pertune.com), counters that, “Best-in-class software tools often
are orders-of-magnitude more capable than what an individual
The new standard for corrosion monitoring can be found at: DCS or PLC vendor can provide. Before high-speed open con-
nectivity, users were restricted to the tools provided with their
pfsolutions.info/corrtran DCS package. This was very limiting, because each DCS ven-
dor couldn’t keep up with the rate of innovation in each part of
the asset management field. Independent software suppliers who
focus on niche markets, are able to develop highly capable, best-
in-class applications for asset management.”
Synonymous with Safety Matrikon’s Shook, adds that, “Our asset management soft-
ware is far more sophisticated than that available from the
www.am.pepperl-fuchs.com
330.486.0002

$ !
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CT0511_FPA.indd 51 11/3/05 6:10:24 PM

AM: THIN CRUST OR DEEP DISH?
FIGURE 1. control vendors. We maintain our edge by staying ahead in
"44&5."/"(&.&/5*/$0/530- the areas that really count.”
Can the smaller companies compete with the top tier of
automation vendors? “Yes, this is nothing new,” says Heidi
Schlinsog, sales and marketing coordinator at Eagle Tech-
nology (www.eaglecmms.com). “Companies have come
out with CMMS as part of their software, and give it away
for free sometimes, which is hurting the industry because
most of their CMMSes aren’t complete.”
Matt Langie, director of product marketing for Datastream
(www.datastream.com), adds that, “The Datastream sales
team rarely sees large process control vendors in deals. If
companies are looking for best-of-breed technology, they
typically don’t consider the larger vendors.”
Langie reports that the competition is coming to an end
anyway. “The ‘end-to-end’ packaged applications are likely
to become an anachronism within five years,” he predicts.
“As service-oriented architectures (SOAs) emerge as the
standard IT infrastructure, web services will enable easy
integration between applications.”
Engineers and operators at Abitibi-Consolidated’s paper mill Roger Levin, product manager of integrated asset man-
in Alma, Quebec, use asset management to find problems agement at Rockwell Automation (www.rockwellautoma-
and fine-tune their paper machine. tion.com) agrees with this projection. “At Rockwell Auto-
Source: Emerson Process Management mation, we have the ability to manage plant assets, we have
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CT0511_FPA.indd 53 11/3/05 6:10:43 PM

FIGURE 2.
8)0/&&%4&31
Your
source for
industrial
and
process
instrumentation
Send for your

FREE catalog Asset management software on a server lets manage-
ment view plant data from all facilities worldwide. With AM
today! software, like PortalWorX from Iconics, who needs ERP?

Source: Iconics
www.mercoid.com
access to information supplied by our control systems, and
Mercoid - A Division of Dwyer Instruments, Inc. we have an extensive offering around predictive technolo-
P.O. 373 Michigan City, In 46361 gies and machine health.”
Call: 1-800-872-9141 • Fax: 219-872-9157 • e-mail: lit@dwyer-inst.com Nevertheless, he acknowledges that integration is com-
Copyright © 2005 Dwyer Instruments, Inc. and its licensors. All rights reserved.
ing. “Many of the one-stop-shopping offerings are actually
optimized for the supplier’s hardware, and therefore aren’t
usable on the open market. As open standards in the process
industry provide a way for all device manufacturers to par-
ticipate on an open playing field, the best-of-breed applica-
tions will become ubiquitous.”
It’s already happening. Some asset management ingredi-
ents offered by the process control companies actually come
from best-of-breed vendors, says Patrick Holcomb, senior
VP of business development at Intergraph (www.intergraph.
com). “Intergraph has announced integration and even re-
seller agreements with the major DCS vendors,” he says. “In
some cases, they are reselling our software, so they can rep-
resent best-in-class engineering.”
DELIVERING THE PIZZA

All eight major ingredients of AM aren’t necessarily real-
time functions. Only condition monitoring, which often is
resident in the field devices, must be in the plant. The soft-
ware to analyze condition monitoring data, plus software
for all the other AM functions, can reside in a server 6,000
miles away at your corporate headquarters, a specialty sup-
plier, or a process control vendor. If you use such a server,
then you can access AM data via networks or web browsers.
“Where the software runs is not as important as where users
can interface and gain access to critical information,” says Rock-
W.E. Anderson - A Div. of Dwyer Instruments, Inc. well’s Levin. “AM data collection, storage and analysis functions
• Phone: 1-800-872-9141 • Fax: 219-872-9057 don’t necessarily have to be at the production site. Where the ac-
• e-m a il: l i t @dw yer-i nst .com • www.dwyer-i nst .c om
tual software runs is more a function of the needs of a user.”

AM: THIN CRUST OR DEEP DISH?
Putting AM software on a cen- with web connections and a confer-
tral server is one way to approach the ence call, they solved a problem that
problem, he says. “We have a contract had plagued the plant for weeks.”
where we manage 105 sites from a
central server. This can be accessed PAYING THE DELIVERY PERSON
securely from anywhere in the world, Getting AM vendors to tell us how
and users can view data, work orders, much an entry-level AM software pack-
and machine health by facility, region age costs was fruitless. Several vendors
or machine type.” weasel-worded their answers, essentially
With a central server, you can buy saying, “How much does it cost for a
“seats” for your plant, which allow ac- user not to install asset management?”
cess to the information from licensed Only one actually answered the
terminals, or you can rent the soft- question. “An Indus AM solution can
ware. “Indus offers its asset manage- cost as little as $125,000 or as much
ment solution on a ‘hosted’ basis, as several million dollars, depend-
where the actual software resides on ing on the capabilities required, the
a server hosted and maintained by number of users, and many other
Indus,” explains Gary Frazier, direc- factors,” says Indus’ Frazier. “In the
tor corporate communications of In- long run, ‘best of breed’ AM solu-
dus International (www.indus.com). tions more than pay for themselves in
“The solution accesses data from con- a relatively short time.”
trol systems, and provides access via a For a single plant, you may not have
web server. The client pays a monthly too many options. You may have to
subscription fee for using the appli- buy the software outright. For compa-
cation. One client, Smurfit-Stone nies with multiple locations, who can
Container Corp, estimates savings set up a central server, several options
of $500,000 over five years using the exist for per-seat costs, site licenses, or
hosted model.” an enterprise license.
Prasad Raghavendra, product man- You don’t necessarily have to spend
ager at Honeywell Process Solutions a zillion dollars on AM software. “An
(www.honeywell.com), reports that, asset management system doesn’t
“Honeywell doesn’t rent any of its soft- have to be expensive to be useful,”
ware. However, there is software de- says Todd Stauffer, marketing man-
ployed as a pay-per-use service running ager at Siemens Energy & Automation
on a central web server. The package (www.siemens.com). “Inexpensive
gets its information from control sys- ‘entry level’ AM packages are useful
tems via open standards like OPC.” for plants that have limited budgets
Shook adds that, “We’ve been offer- for maintenance.”
ing this for years, with no takers so far. ABB’s Reierson confirms this assess-
Part of the problem has been that opment. “A widely held opinion is that
erating companies are very protective an asset management system must be
of their data.” installed on a grand scale to provide
Web-based delivery is a major trend measurable results,” he notes. “This is
in AM, says ExperTune’s Buckbee. a misconception. Today’s asset optimi-
“Detailed process information can zation solutions can be incrementally
be accessed by hundreds of users, di- implemented, on a physical location
rectly from their desktops via their basis or by asset type, and still provide
web browsers. When the local team immediate payback.”
needs help, they can call on experts You have plenty of options, includ-
from around the world to solve their ing purchasing AM software for your
problems. In one recent case, a con- plant, putting AM software on a central
trol engineer at a plant in North Caro- company server, leasing, purchasing
lina called in a corporate engineer and and many combinations of each. In this
an expert consultant to solve a process case, it definitely pays to shop around
oscillation problem. In just two hours, and compare all the options. C

CT0511_FPA.indd 56 11/3/05 6:11:08 PM
A FINE TIME TO BREAK AWAY
FROM OLD VALVE PROBLEMS
How model-predictive control can solve the big/little valve problem
By Greg McMillan, CONTROL columnist
I
n the old days, we used small and large valves with the put. A split range point other than 50% was readily imple-
idea that the small valve would extend the rangeability mented, and the actual valve positions were displayed for
of the manipulated flow for low loads. The valves were the operator. The split range point was set to compensate
split ranged with the split range point set at the classic for the different valve sizes and gains. For example, if the
value of 50%. The split range was typically done in the po- big valve was about 10 times larger than the small valve,
sitioner. Of course, the big valve tended to get stuck in the the small and big valves stroked from 0 to 10% and 10 to
seat where the friction was highest, especially if the valve 100% controller output, respectively. Signal characteriza-
was designed for tight shutoff or the plug stayed in the seat tion blocks were added to linearize the installed character-
for long periods of time. istic of each control valve. Tricky configuration engineers
As a result, some ingenious engineers devised a scheme devised and implemented valve-switching strategies that
in which a pressure switch tripped and energized solenoid better addressed the transition at the split range point.
valves. This froze or closed the small figurE 1.
valve, and preloaded a pressure to the
big valve to get it off of its seat, so it SIMULTANEOUS THROTTLING OF FINE AND COARSE CONTROL VALVES
could take over throttling the flow for
high loads. These valves looked like
Christmas trees with the extra sole-
noids, switch and tubing, but the in-
strument technician wasn’t in the
holiday spirit when maintenance was
required. Getting everything right in
the middle of the night, when a valve
needed to be replaced to keep the plant
running, was difficult. The failure rate
was higher than a simple valve, which
was not so bad, considering the pneu-
matic positioner and pressure switch
were out of calibration anyway af-
ter about six months operating in the
plant. Since there was no “readback”
of actual valve position in the control
room, various creative explanations
were offered for the increasingly pesky
oscillations as the calibration and set-
tings shifted. Then there were the per- The MPC can solve the problem without split ranging, valve position control,
sistent entertaining questions of split or custom solutions.
ranged gap and overlap.
Early improvements Next, adaptive controllers came along that identified

In the last decade, users got smarter, and installed digi- the different gain and dynamics of the installed behavior
tal positioners that would hold their calibrations. The split of each valve, and stored them in regions to schedule tun-
ranging in the field was now accurate, but configuration ing settings based on controller output. This adaptation
engineers preferred the maintainability, visibility, and flex- was beneficial because big valves had a larger valve gain
ibility of the standard “splitter” block on the controller out- and a slower response due to their bigger actuators. Also,
CT0511_57_59_FT.indd 57 11/3/05 4:55:31 PM

the valves might have been on streams with FIGURE 2. .1$TSFªOFWBMWFSFTPMVUJPO
different transportation delays and process If you could always use the small valve
f luids. The big valves also tended to have
#*(7"-7&4 -*55-&7"-7&4 for a fine adjustment, you could solve
more stick-slip because of the incentive to the real problem, which is controlling
use less expensive types for bigger sizes, valve resolution. Those innovative con-
which affected process gain and dead time. figuration engineers devised a valve
Even if the percentage of stick-slip was the position controlling strategy, in which
same as for the small valve, the variability an integral-only controller was added
introduced into the process by the big valve that manipulated the big valve to keep
was greater because of the larger f low co- the small valve at 50% open. The split
efficient, and so the need to manage then range was eliminated and the process
correctly was more urgent. controller just manipulated the small
Consequently, some control engineers valve. Unfortunately, the valve posi-
realized that valves tended to limit cycle tion controller could not have propor-
across the split range point because of the MPCs control the process tional or derivative action, and the in-
severe discontinuity and increased fric- variable by simultaneously tegral time setting needed to be five
tion at this point, and that the rangeabil- manipulating the small and big times larger than the product of the
ity problem was really a subset of the valve valves. process controller gain and reset time
resolution problem. This insight was hard to prevent interaction between the
to identify because the official definition of valve range- two loops. As a result, the valve position controller was too
ability didn’t account for valve stick-slip; valve specifi- slow for big upsets or set point changes. Feed-forward ac-
cations did not quote stick-slip; and test results from a tion could be added, but unmeasured disturbances were still
valve supplier were generally at a mid throttle position— a problem and it was a challenge to explain the difference
i.e. not riding the seat. between a valve position controller and a valve positioner.
CT0511_57_59_FT.indd 58 11/3/05 4:55:54 PM

'6563&#"4&%7"-7&$0/530-
The explanation that a valve positioner and offered the opportunity to elimi- There are many opportunities to use
is the box on the valve didn’t work any- nate it by freezing the big valve at its fine adjustment valves to reduce process
more when fieldbus allowed valve posi- last position, which was when the pro- variability without the +60-year-old
tions controllers to be in the field. cess variable was within a band around headaches of split ranged or valve posi-
In addition, there was a creative the set point. The width of the band tion control. It is a fine time to break
modification to the PID algorithm to was the product of the big valve’s reso- away from old valve problems and break
move the big valve to share the load lution and the big valve’s process gain. into model-predictive control. C
with the small valve, but it was a cus-
tom implementation that didn’t ad-
dress differences in valve dynamics or
large dead times.
Finally, engineers found that a small
model predictive controller (MPC)
could inherently solve these traditional
valve problems without relying on split
ranging, valve position control or cus-
tom solutions. In essence, an MPC is
set up to control the process variable
by simultaneously manipulating the
small and big valves.
For some MPC software, this is all
that is required. For MPC software
that requires controlled variables to
equal the number of manipulated
variables, the small valve is wired back
as an additional controlled variable
for optimization.
Figure 1 shows how small (trim)
and big (coarse) valves are simultane-
ously moved to compensate for load
upsets and to meet set point changes.
The default MPC tuning was used,
except that the penalty on error for
keeping the small (trim) valve at 50%
was reduced by a factor of 10. This ad-
justment was made so optimization of
this valve position was a lot less im-
portant than the control of the process
variable. Even with this reduced pen-
alty, the small valve still returned to
50% relatively quickly to be ready for
the next adjustment.
In addition, the MPC incorporated
the knowledge of the difference in
valve gains and dynamics in its process
models, and eliminated interaction
associated with simultaneous throt- !CCURACYMEETSVERSATILITY-#-ULTIFUNCTION#ALIBRATOR
tling. The MPC also facilitated feed- 9OUWONTlNDTHISCALIBRATORCOLLECTINGDUSTONTHESHELFINYOURWORKSHOP
ITISALWAYSONTHEGO4HATSBECAUSE-#ISADOCUMENTINGMULTIFUNCTION
0ORTABLECALIBRATORS
forward control with proper dynamics CALIBRATORWITHEXCELLENTACCURACYANDAMAZINGVERSATILITY)TISTHE 7ORKSTATIONS
by adding disturbance variables, and ALL IN ONETOOLFORlELDCALIBRATION #ALIBRATIONSOFTWARE
0ROFESSIONALSERVICES
s0RESSURETEMPERATUREELECTRICALANDFREQUENCYSIGNALS )NDUSTRYSOLUTIONS
was better able to deal with dead-time
s#OMMUNICATESWITHCALIBRATIONSOFTWARE
dominant processes. The MPC further s)NTRINSICALLY3AFEVERSIONALSOAVAILABLE-# )3 WWWBEAMEXCOM
reduced the limit cycle from the reso- s2OBUSTCASING INFO BEAMEXCOM
lution limit (stick-slip) of the big valve
w w w.controlglobal.com NOVEMBER/2005 6:
CT0511_57_59_FT.indd 59 11/3/05 4:56:12 PM

PULS
LS
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CT0511_FPA.indd 60 11/3/05 6:11:36 PM

Rising Levels of Process
Level Measurement Devices
Worldwide and regional shipments of process level measurement, solids process, and inventory tank gauging devices are
projected to increase steadily through 2009 By Jim Montague, executive editor
S
imilar to the often slowly fill- figurE 1.
ing tanks and containers they PROCESS LEVEL MEASUREMENT SENSOR MARKETS
monitor, combined shipments
600
of process level measurement 600 (Present and projected shipments
systems and inventory tank gauging in millions of $ to major geographic
(ITG) devices are expected to increase 500 regions in 2004-09)
500
at a steady 4.4% compound annual
growth rate (CAGR) to almost $1.64
billion in 2009 from $1.32 billion in 400
400
2004, according to recent worldwide
and regional studies by Venture Devel-
300 2004
opment Corp. (www.vdc-corp.com). 300 2004
2005
2005
Regional shares in 2004 were 2006
2006
2007
roughly comparable for Europe, 200
2007
2008
200 2008
Asia-Pacific and North America (Fig- 2009
2009
ure 1), though divisions between pro-
cess level sensors and ITGs report- 100
100
edly varied sharply among regions.
For example, ITG shipments in 2004
0
totaled $147.5 million in Asia-Pacific, 0 Europe North America Asia/Pacific Latin America Middle East/Africa
Europe North America Asia/Pacific Latin America Middle East/Africa
$82.2 million in Europe, $58.7 mil-
lion in North America, $21.4 million
figurE 2.
in Middle East/Africa, and $17.2 mil-
lion in Latin America. PROCESS LEVEL MEASUREMENT SENSOR TECHNOLOGIES
From a technological perspective,
hydrostatic and sonic/ultrasonic
level sensing accounted for the larg-
est portion of worldwide process
level shipments in 2004, and their 2004
2004
(Present and projected % shares of
dominance is expected to continue ($1.32
worldwide shipments by technology)
though 2009. However, their market ($1.32
billion
billion
shares also are projected to decrease total)
total)
slightly in the next four years, while
capacitance, vibration, displacer,
f loat and other technologies are all
projected to make slight gains in this
period (Figure 2). 2009 Hydrostatic
2009 Microwave radar/non-contact 6.1
The largest relative gains in con- Hydrostatic Microwave radar/non-contact 6.1
Sonic/ultrasonic Load cell
($1.64 Sonic/ultrasonic Load cell
tinuous measurement technologies ($1.64 Capacitance Microwave/radar contact/guided
billion Capacitance Microwave/radar contact/guided
billion Vibration Nuclear
are expected for microwave/radar total) Vibration
Displacer Nuclear
Magnetostrictive
total) Displacer Magnetostrictive
contact/guided (10.6%) and non- Float Others
Float Others
contact sensors (8.4%). While there
likely will be a barely perceptible
0% 5% 10% 15% 20% 25% 30% 35%
shift from mechanical to electronic 0% 5% 10% 15% 20% 25% 30% 35%
CT0511_61_63_LevelMarket.indd 61 11/3/05 4:57:29 PM

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SOLUTIONS.
You know how important uptime is for your process control

applications. Weidmuller can help you to design more
reliable process control panels with our electronic fuses,
power supplies, and diode modules. They’re all part of our
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CT0511_FPA.indd 62 11/8/05 2:18:14 PM

-&7&-.&"463&.&/53*4*/(
sensing technologies in continuous CAGR to $272.6 million in 2009 microwave/radar contact/guided

measurement, VDC’s worldwide re- from $211.5 million in 2004. Sonic/ (15.9% to $38.9 million in 2009)
port projects that shipments of me- ultrasonic technology made up the and tilt switch (11% to $2.7 million
chanical point measuring/sensing largest share ($65.4 million) of these in 2009) in solids measurement. Re-
devices will outstrip electronic types. shipments in 2004, and it’s expected gionally, shipments for solids-level
The global study, “Worldwide Pro- to reach even higher ($74.4 million) sensing in North America are ex-
cess Level Measurement and Inven- by 2009. Though growing by smaller pected to increase at a 3.1% CAGR
tory Tank Gauging Markets, Octo- dollar amounts, double-digit per- to $78.7 million in 2009 from $67.5
ber 2005,” anticipates above average centage increases are expected for million in 2004. C
growth for float switch (6.7%), vibra-
tion (6.4%), and paddlewheel (6.1%)
measurement devices.
Does Your Process Data
FIGURE 3.
/035)".&3*$"/130$&44
Leave You Puzzled?
-&7&-%&7*$&4)*1.&/54 1 2
[by category in millions of $, with % of
market share, and compound annual
growth rate (CAGR) through 2009] 3
4 5
2004
shipments
%
share
Projected
CAGR
M A N U F A C T U R I N G
Gas and 89.0 20.8 2.4 N
petroleum
A
Chemical 87.0 20.3 3.2
L
Water/waste 47.4 11.1 1.4
water Y
6
Food and 43.1 10.1 2.8 T
beverage
Electric power 28.0 6.5 4.6 I
7
Pharmaceutical 21.9 5.1 3.0 C
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Others 78.8 18.4 1.4
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CT0511_FPA.indd 64 11/3/05 6:12:49 PM

Wireless Winning Wider
Acceptance in Automation
The undeniable appeal of wireless sensor networking is apparently convincing more end-users and system integrators to plan
on implementing these technologies. By Jim Montague, executive editor
I
n summer, a young process control engineer’s fancy figure 1.
turns to thoughts of…wireless? You bet. And a lot more
of them apparently are thinking that way too. WIRELESS RESEARCH, DEPLOYMENT PLANS
Close to 20% more automation end-users and sys-
tem integrators (SIs) in August 2005 considered deploying a
wireless sensor network than those who considered doing so Have you researched wireless
at the beginning of the year, according to recent research by 80% sensors for industrial
B&B Electronics and Sensicast Systems. Their online sur- monitoring applications?
70%
vey found more than half (53%) of 200 respondents this past
summer thought about adding a wireless sensor network in 60%
the next 12 months, while only 45% in January 2005 mulled
50%
adding wireless during 2005 (Figure 1). These data also are
significant because most of the increase in respondents who January 2005
40%
August 2005
plan to adopt wireless apparently come from among those
30%
who were previously undecided.
20%
18% more respondents considered 10%

deploying wireless sensors networks 0
N/A
in August than in January, 2005, Yes No No answer
and 53% are considering deployment 60%

Are you considering deploying
in the next six months a wireless sensor network in
the next 12 months?
50%
The two companies released results of their latest survey

40%
in mid-October, and found strong and growing interest from
respondents in wireless sensor networking. The August and
30%
January surveys formed a two-part series that B&B (www. January 2005
August 2005
bb-elec.cm) and Sensicast (www.sensicast.com) designed to 20%
track industry attitudes about wireless technologies.
There are many reasons why wireless sensor networking 10%
is gaining momentum among users and SIs, but it’s most
likely that its appeal and advantages are finally beginning to 0
N/A N/A N/A N/A N/A
outweigh traditional fears and actual drawbacks related to Yes No Not Yet Never Don’t know No answer
it. In short, cost savings, ease of implementation, safety and
security levels of wireless are replacing concerns and criti-
cism as users learn more about wireless and how to use it. Don Wiencek, B&B’s president, says, “Our field experi-
Wireless manufacturers also are offering site surveys to de- ence has proven the robustness of the technology. Now, the
80%
termine what wireless solutions are most appropriate for in- survey results show that our customers are increasingly ea-
dividual applications, and are helping users experiment and ger70%
to use wireless sensing in their projects.”
try out wireless in smaller, representative sections of their
60%
facilities. More than two-thirds of January’s respondents and Research breeds familiarity
three-quarters of August’s plan to install 50 wireless sensors Not50%
only are implementation plans increasing, but they seem to
or less in their applications (Figure 2). be fueled by a growing interest in wireless sensor networks for
40%
January 2005
August 2005
w w w.controlglobal.com 30% NOVEMBER/2005 65
20%
10%
CT0511_65_67_Wireless.indd 65 11/3/05 4:58:47 PM
FIGURE 2.
&91&$5&%8*3&-&444&/40364&
80%
How many wireless sensors
70%
would you deploy in your
60% typical application?
50%
40%
January 2005
August 2005
30%
20%
10%
0%
Less than 50 51 to 100 101 to 250 More than 250
FIGURE 3.
13*."3:4&/403*/5&3'"$&4611035
80%
What primary interfaces do your
70%
sensors presently support?
60%
50%
January 2005
40% August 2005
30%
20%
10%
0%
4-20mA RS 232/ 0-10 V Discrete Ethernet UART 12C HART analog
RS 485 inputs
industrial monitoring. The survey found and machine (53%) monitoring/predic-

that 73% of respondents in August are re- tive maintenance, which were followed
searching wireless sensors for use in more by process control (38%) and industrial
rugged environments, compared to 64% safety monitoring (23%).
who were interested in January. In addition, the respondents re-
The researchers add that reliability of ported that 2.4 GHz remains their fa-
wireless sensor networking was the main vored wireless operating frequency.
reason respondents say they’re delaying More than twice as many respondents
deployment. Thirty-three percent report selected 2.4 GHz (35%) in August,
that reliability is their greatest concern compared to 900 MHz (16%), which
about adopting wireless technologies. parallels results in January.
Despite these persistent worries, how- Also, in the January survey, 69% of
ever, the survey also revealed that re- respondents confirmed that they plan
spondents had a strong understanding to use their wireless sensors in harsh,
of which applications were appropriate radio frequency (RF) environments,
for wireless sensor networks. The appli- while 46% added that battery-oper-
cations chosen as most appropriate were ated wireless sensors were important in
process (66%), environmental (61%) their applications.

8*3&-&448*//*/("$$&15"/$&
“Our latest survey clearly reveals

FIGURE 5.

the industrial sector’s growing inter-
est in wireless sensor networks and
8*3&-&444&/403
'6/$5*0/4/&&%&%
monitoring capabilities that work What types of functionality are
well within challenging RF [radio you looking for in a wireless
frequency] environments,” says Paul sensor system?
(August 2005)
Sereiko, Sensicast’s CEO.
Despite their wireless aspirations, 76% Interface to
both January and August’s respon- existing system(s)
dents report their present sensors are
64% Data logging
firmly grounded in traditional inter-
50% Data display
faces, including 4-20 mA, RS 232, RS
485, 0-10 V, discrete inputs, Ethernet, 49% Event logging
and HART analog (Figure 3). 27% Alert messages via e-mail
26% Alert messages to
4UBOEBSETBOETBWJOHT mobile phones
End-users and SIs answering the Jan- 19% System control via PDAs
uary 2005 survey further indicated 14% Custom messaging for mul-
their awareness of the IEEE 802.15.4 tiple recipients
(37%) and ZigBee (41%) wireless stan- 12% Alert messages to pagers
FIGURE 4. 11% Alert messages via instant

message
7% System control via
4&/40345:1&4*/ instant message
8*3&-&44/&5803,4 2% Dedicated controller
What types of sensors would you 1% Initiate video
use in your wireless network? . /(
0%(
1% Long life
(January 2005) % ())

1% Motor control
!
!

51% Voltage %12'

dards. In addition, 24% added it was $ !(
49% Pressure very important to support 802.15.4 in
!"#$(
%3
48% Electric current their products, while 12% said it was
4 !

46% Flow very important to support ZigBee in
('(
(
41% Humidity/moisture/ their products. They added that Zig-
condensation Bee was needed to encourage interop- 4 % 5.'

erability (61%), standards (50%), mul- ' (
38% Presence/proximity
tiple vendors (42%), mesh networking 4 & '%

35% Level
(39%), and to lower costs (18%). %
26% Motion
These standards are expected to
25% Position (angular, linear) further enhance the savings that im-
19% Gas plementing wireless can generate. By
18% Displacement deploying wireless sensors in their ap-

19% Weight plications, the January respondents an-

ticipate saving various amounts per sen-
17% Light (UV, VIS, NIR, IR)
sor. For example, 15% expect to save less

16% Acceleration than $50; 27% expect to save $51-100;
13% Velocity 25% expect to save $100-250; 13% ex-
12% Sound pect to save $250-500; and 20% expect
12% Force to save more than $500 per sensor. C
11% Strain
For more information and results from
10% Magnetic
B&B and Sensicast’s survey, visit

4% Particle www.bb-elec.com/wirelesssurvey. !"#$
%
&'

% % (
& '%%
)*+),*,),,)-

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CT0511_FPA.indd 68 11/3/05 6:13:20 PM

PAT SLAPS DRUGMAKERS WITH
CONTROL SYSTEM AFTERSHAVE
Advancing analyzing technologies wake up pharmaceutical manufacturing to process control benefits
By Velumani (Lou) A. Pillai and Martin Warman, Pfizer Corp.
H
ey, hey! The control system train has pulled into the products. Designing quality into products requires a
pharmaceutical station! All aboard! Though users in comprehensive understanding of the process, including
other process industries have seen it coming or been the impact of product components on process variability,
riding it for years, Process Analytical Technology (PAT) along with mechanisms to manage the process.
is now bringing similar improvements and benefits to many Continuous improvement is a critical element in a sound
pharmaceutical applications. And, though PAT most directly quality system. The FDA expects pharmaceutical manu-
applies to pharmaceuticals, its effects will be felt in other in- facturers to implement continuous improvement through
dustries regulated by the U.S. Food and Drug Administration the PAT framework. In addition to continuous improve-
(FDA), such as food and beverage, as the government tightens ment, the PAT framework also encompasses risk assessment,
its regulatory grip to include all ingestible products. knowledge management, and on-line analysis.
Specific GMP regulations have not yet changed. De-
Quality has to be designed in, and spite this delay, the FDA is providing science and risk-
based guidance related to GMPs.
not tested into, products. Consequently, PAT will help pharmaceutical manu-
facturers design, monitor, control, and predict process
PAT’s benefits included reduced production cycle times, performance. Many of these functions are now imple-
improved manufacturing efficiency, reduced rejects, and in- mented separately, but PAT promotes an integrated envi-
creased production uptime. PAT can also speed time to mar- ronment that combines modeling tools for design/analy-
ket for new products, improve operator safety, and improve sis, process analyzers, and process control/optimization.
relationships with regulatory agencies Knowledge of all these functions is required to effi-
Encouraged by the FDA, the pharmaceutical industry ciently apply these technological innovations to phar-
is seeking to accelerate its manufacturing innovations. maceutical manufacturing.
While it continues to spend on research and
figurE 1.
marketing, the pharmaceutical industry lags
behind other automated process industries in PAT SYSTEM BLOCK DIAGRAM
manufacturing productivity.
To improve productivity, there is growing en-
thusiasm in pharmaceuticals for PAT, an FDA ini-
Data
tiative to improve manufacturing efficiency and Method Analysis
product quality, while also harmonizing regula-
tory expectations. PAT provides a framework for
designing, analyzing, and controlling manufactur-
ing. The PAT initiative focuses on the principles of System
PAS Functions
building quality into products and processes, as Hist
well as continuous process improvement.
Spectrometer
Configuration
New century, new hope
With the subsequent launch of its good man- PC AT
DB
ufacturing practices (GMPs) for 21st Cen-
Detector
tury initiative, the FDA began calling for
innovative approaches for process develop- Data Tank
ment, manufacturing, and quality assurance Modeling Process
Configuration
(QA). This was a paradigm shift that required
quality to be designed in and not tested into
CT0511_69_73_PAT.indd 69 11/3/05 5:07:23 PM

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CT0511_FPA.indd 70 11/3/05 6:16:36 PM

PAT + FDA = Quality
SCADAPack
PAT monitors, controls, optimizes application optimization; and Release, delivers
The most basic implementation of PAT during PAT application execution.
is process monitoring. This involves One of the main problems is that each
monitoring critical-to-quality assur- instrument vendor offers its own propri-
ance (CQAs) variables to build process etary software, but in future PAT applica-
knowledge, establish process variance, tions this proprietary model won’t work.
and set the design space in which the As PAT applications proliferate, im-
product is robust. plementations with custom interfaces,
The next level up in PAT implemen- point-to-point interfaces, custom mod-
tation adds control to the basic process elers, and PAT data islands will be un-
monitoring functions. CQAs are now
monitored and controlled to limit or
wieldy. To aid multi-factorial analysis,
it’s imperative that PAT applications in-
Innovation
in SCADA System Control
manage process variance in the de- teroperate in the control and modeling
sign space to ensure product quality. space, so we propose that a PAT soft- Introducing SCADAPackES,
PAT software must be interfaced to a ware standard be established, which a Programmable Automation Controller
process control system (PCS) that per- should include a standard user inter- that brings a new level of innovation to
forms real-time control. face to setup and run instruments, a SCADA systems. Meeting industry
The highest level PAT implemen- common modeling environment, and demands for high-speed distributed
tation adds optimization to the moni- one environment to build and config- control and automation, the
toring and control functions. Optimi- ure analyzers. It should also include bi- SCADAPackES raises the standard for
zation reduces process variance and directional communications with PAT
both functionality and cost
optimizes process capability by run- data storage systems.
effectiveness.
ning controlled “Design of Experi- Availability of a PAT software stan- It is the ideal solution for a variety of
ments” on the CQAs. dard could help end-users develop and water and wastewater applications
CQAs can be predicted based on deploy new measurements by: including plant-wide distributed control
history and the performance of the • Reducing validation costs for PAT over Ethernet, front-end
process by using a set of relationships devices; processing/data concentration, and
that have been created with mathe- • Minimizing deployment time for compressor or pump/lift station
matical models. These predictions PAT technology; control.
can be made available to the PCS • Improving PAT system robustness; Features include:
for timely control. • Reducing custom interface code;
� Industry-Standard Protocol Support
• Providing flexibility to repurpose PAT
� IEC 61131-3 Programming Tools
PAT standardization fights complexity devices based on evolving needs; and
A typical PAT System incorporating • Improving scalability and extensibility � Time Stamping with Millisecond
monitoring, control and optimization Resolution for first fault analysis
(Figure 1) needs to acquire data, con- Common PAT software architecture � Seamless Integration with
trol the process, run prediction models, A functional map implementing a PAT ClearSCADA Software
and display results. This implementa- software standard (Figure 2) shows the � Dual 10/100BaseT Ethernet Ports
tion is easy to handle with one instru- Instrument and Sensor Interface has a � Removable Compact Flash Card
ment, but grows exponentially more common interface for all process sensors,
The SCADAPackES effortlessly
complex in typical applications with analyzers, and instruments. The control, integrates with ClearSCADA, providing a
hundreds or even thousands of sensors operation, analysis, retrieval and predic- powerful configuration tool for the
and analyzers. Each instrument has its tion functions all use the PAT Common commissioning and maintenance
own process and instrument configu- User Interface. During on-line operation, phases of the overall SCADA system.
ration, data modeling, method builder, the user interface provides access to se- SCADAPack products are backed by a
and data analysis capability. lect appropriate methods, and generates three-year warranty and an exceptional
Most pharmaceutical processes re- results from predictions versus time. customer support program.
quire multiple process measurements The interface also reports status
to characterize a process, adding yet of prediction alarms and instrument CONTROL
more inputs to the quality system. alarms with appropriate alarm man- MICROSYSTEMS
The system also needs to function at agement functions. In off-line mode,
w w w. c o n t r o l m i c r o s y s te m s . com
different levels of compliance: Devel- the interface provides access to the
Ottawa � Calgary � Houston
opment, during PAT application de- method builder, PCS configuration, Los Angeles � Birmingham � Melbourne
velopment; Information, during PAT and Design of Experiments setup.
Sales: (888) 267-2232
International Sales: (613) 591-1943
CT0511_69_73_PAT.indd 71 11/3/05 5:07:37 PM

Tank Liquid Level
FIGURE 2.
Inventory Monitoring
Design of
Experiment
Process Integration 1"540'58"3&'6/$5*0/"-."1
PAT Common User Interface

E-8w
®
KING-GAGE ES2i Transmitter Process On-line Prediction Off-line Off-line
Control
• Hydrostatic Level Gauging System & Monitoring Method Builder Retrieval Analysis
• Two Wire Loop Powered
• Sanitary Flush Mount
PAT Instrument Common Data
Control Access Storage
Instrument and Sensor Interface
Protocol Adapter Protocol Adapter Protocol Adapter Protocol Adapter Protocol Adapter Future
Sensors/ Prop. Inst. Software
Inst
Control Instrument Sensor Unit
® Devices Operation
KING-GAGE TeleSensor Instrument Transient
• Maintenance Free Operation PAT Data
• Tank Top Mounting Options
• Better Than ± 0.2% Accuracy
PROCESS
The user interface manages the PAT and qualitative and trend models are
hardware configuration, and performs now widespread, inspiring the term
analyzer calibration functions. Any “process signature.”
data retrieval from data storage takes All data should be stored in a way
place through the interface. that’s easy to access for analysis.
Raw data files should be converted
#VJMEJOH1"5NFUIPET to a standard format such as Analyti-
To acquire, process, and execute cal Information Mark-Up (AniML,
real-time predictions, a PAT method ASTM E13.15).
needs to be created. This is usually Events and context-based process
created off-line and executed on-line data from other sources also should
in real-time. The method builder be available. Data storage must handle
controls active modules, and adjusts structured and unstructured informa-
integration time, exposure time, and tion. Implementations can include ex-
KING-GAGE LevelPRO ®
signal gain or amplification. It also isting data storage mechanisms, but
• 8 Tank Monitor/Controller handles summations or averages of these may need to be scaled and ex-
• Preconfigured via iButton (Flash) each data acquisition to generate a tended to new types of information.
• RS485/Modbus/ASCII output spectrum. This data storage can be integral to the
Once the analytical information PAT software or it can be a part of a
www.king-gage.com is generated, the method acts on this common data repository.
information via various mathemati-
Transmitters cal pre-treatments and prediction )PXEPXFHFUUIFSFGSPNIFSF
engines. The traditional approach Creating a PAT software standard will
Indicators
uses quantitative models. Single or require committed suppliers and end-
See Us in Chicago Controls multivariate models generate cali- users working together. We anticipate
BOOTH 1632
bration models, real-time analytical that common functions will be identi-
data, and predictions. fied first, and that products will then
KING-GAGE
®
However, the need to generate emerge. We also propose that end-us-

these values is driven more by percep- ers take advantage of standard PAT
tion than necessity. This is changing software when it’s available.
Productivity Matters. It's About Time.
CT0511_69_73_PAT.indd 72 11/3/05 5:08:11 PM

PAT + FDA = Quality
SCADAPack
The first step is to standardize com- when creating PAT software stan- delivers
plex measurements. Spectroscopy dards. We’ll have to exchange data
methods are routinely adapted for PAT. with existing systems for process con-
Examples are near infrared (NIR), Ra- trol, enterprise resource planning,
man, UV-visible, fluorescence, and laboratory information management,
acoustic. Measurement technologies and manufacturing execution. A uni-
suitable for pharmaceutical needs fied schema is critical to facilitate data
must be identified. This will help sup- exchange among these platforms.
pliers meet implementation challenges Several organizations have devel-
and simplify deployment. oped schemas focusing on standard
Presently, we spend a lot of time data related to functions of relevance. The next generation of
specifying a measurement for a pro- These include Analytical information SCADAPack controllers
cess application. We would like to see Markup Language (AniML), Batch
Introducing SCADAPack2, the first
standards created that will reduce re- Manufacturing Language (BatchML),
quired time, and make time commit- and Business to Manufacturing entry in the next generation of
ments more predictable. Markup Language (B2MML). While SCADAPack controllers. Combining
In the most advanced implementa- these schemas have been around for high performance communications
tions, PAT systems are used for moni- awhile, corporate schemas must be and 32-bit processing with flexible
toring, control, and prediction. In these developed to use them effectively. I/O, USB connectivity and advanced
cases, data needs to be exchanged with Schema validation services for the en- power saving features, the
systems that perform analysis, con- tire pharmaceutical industry also will SCADAPack2 is the new gold
trol, decision making, and reporting. be required to support new PAT soft- standard from Control Microsystems.
A good first step for data exchange in ware standards.
advanced implementations is to create To facilitate pharmaceutical manu- Features include:
standard ways of trading data across ex- facturing process improvement and � 32-bit microcontroller
isting systems. innovation, application architectures � 16MB Flash Memory
now geared to corrective action must
Control system architecture impacts instead focus on continuous improve-
� Three Serial Ports
We’ve heard about several efforts to build ment. Current application architecture (RS-232, RS-485)
master plans for deploying innovative domain models must evolve to address � 10/100BaseT Ethernet
measurement technologies. Most are continuous improvement. � Dual USB 2.0 Compliant Ports
done in isolation without considering For risk analysis and mitigation, the � Multiple AGA Gas Flow runs
effects on control system architecture, root cause of all deviations must be as- (API 21.1)
existing applications and infrastructure certained, so all deviations aren’t treated
needs. However, any master planning ef- equally. For process design, it’s neces-
� Configurable Power-Saving Modes
fort has to consider these impacts. sary to use measurements to determine In addition to PLC features, the
The master planning effort must what’s critical to quality using design of SCADAPack2 provides full RTU
align strategies and derive specific experiments and correlations.
functionality with flexible
objectives for infrastructure, appli- Process understanding requires that
programming options using
cations, integration, and PAT sys- knowledge about the process be available
tems. To do this effectively, all func- for easier analysis. These considerations
TelePACE Relay Ladder Logic or the
tions must be mapped to domains. require revisiting accepted application ar- IEC 61131-3 family of languages. All
New functions, such as process opti- chitectures that support only procedural SCADAPack products are backed by
mization and process improvement, compliance. C a three year warranty and the best
should be considered. customer support program in the
For each of these functions, impacts Velumani (Lou) A. Pillai is senior manager/ industry.
on level and approach to automation team leader for Drug Product Integrated Au-
must be considered. This master plan- tomation Solutions with Pfizer Global Manu-
ning exercise will help end users un- facturing-IT. CONTROL
derstand their business’ readiness to MICROSYSTEMS
embrace continuous improvement out- Martin Warman is senior manager/team w w w. c o n t r o l m i c r o s y s te m s . com
lined in the PAT framework. leader with Pfizer Global Manufacturing’s
Ottawa � Calgary � Houston
We all have to deal with exist- Process Analytical Support Group, Global Los Angeles � Birmingham � Melbourne
ing systems and infrastructure, even Technology.
Sales: (888) 267-2232
International Sales: (613) 591-1943
w w w . c o n t r o l g l o b a l . c o m
CT0511_69_73_PAT.indd 73 11/3/05 5:08:27 PM

t e c h n i c a l l y s p e a k i n g
Ts
Advanced Control Ready for Prime Time
T
here are many advanced process control (APC) and “Fuzzy logic early event detection reduces the fre-
artificial intelligence (AI) solutions for process ap- quency and scale of process upsets, and it also reduces
plications, which can provide process optimization, costs associated with process upsets. Fuzzy logic can
predict failures, and simulate process variables that are minimize false alerts without compromising detection
difficult or impossible to measure. and notification of actual events, but there is always a
Solutions not only are available, they’re also field- tradeoff between sensitivity and increasing likelihood of
proven. That’s the good news. The bad news is that APC false notification,” adds Wagler.
and AI won’t work unless applied and maintained by Invensys provides a multivariable, model-predictive
automation professionals that know the process, under- control software package with a full array of tools, in-
“Fuzzy logic can minimize false alerts without compromising

detection and notification of actual events, but there is
always a tradeoff between sensitivity and increasing
likelihood of false notification.”
stand the basic principles of APC/AI, cluding support for neural networks and fuzzy logic. In-
and possess computer skills. vensys reports that APC/AI’s bottom-line benefits come
“While the software tools are rel- much more from optimization than from control. “Con-
atively easy to work with, applying trol only addresses response to upsets, which occur in
them to the right objectives and operating and maintain- only a small fraction of operational time, while optimi-
ing them effectively is challenging,” says Paul Kesseler, zation works all the time,” says Lew Gordon, a principal
the manager for North America APC Solutions at In- application engineer with Invensys.
vensys Process Systems (www.invensys.com). “We work National Instruments (NI, www.ni.com) provides a
closely with customers to target APC solutions, config- range of APC and AI solutions, including Model Free
ure the software, and train control engineers. But, no Adaptive control from partner Cybosoft (www.cybosoft.
matter how well defined the application or well trained com), fuzzy logic capabilities, and toolkits that support
the operator, making the most of APC requires thinking other types of advanced control such as linear quadradic
about processes in an entirely different way.” control. “These solutions are used to tackle tricky con-
Vendors typically and habitually understate the dif- trol problems with multiple inputs and outputs and noisy
ficulty of implementation, so their warnings should be disturbances, or to deal with systems in which not all
heeded. APC solutions require highly skilled personnel, of the process variables can be measured,” according to
and there are three ways for end users to secure and use Brian MacCleery, NI’s industrial product manager.
these experts. Yokogawa Corp. of America (www.yokogawa.com/us/) has
The first is to staff up at the plant level. This is impractical taken a slightly different approach to APC. Rather than devel-
for all but the very largest plants. The second is to provide oping solutions in-house and refining these solutions in client
a central engineering staff that can service multiple plants. applications, it instead uses technology originally developed and
This makes more sense for most. The third alternative is to proven by Shell Global Solutions. Yokogawa’s multivariable op-
rely on vendor or independent system integrators’ services. timizing controller is a linear multivariable controller that has
This solution can be effective for plants and organizations undergone continuous improvement since it was originally de-
with limited internal resources. veloped by Shell in the early 1980s. The controller periodically
If the right people are in place, many benefits can be de- adjusts the level of several manipulated variables to bring and
rived from APC and AI implementations. “In terms of arti- keep controlled variables on given targets, taking into account
ficial intelligence, we use fuzzy logic to assimilate and eval- steady-state dynamic interactions between variables. C
uate outputs from various early event detection models,”
reports Randy Wagler, the profit suite product manager at Dan Hebert, PE, SeniorTechnical Editor
Honeywell Process Solutions (www.honeywell.com). dhebert@putman.net
CT0511_74_TechSpeak.indd 74 11/3/05 5:10:14 PM

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Best Split Range Control Methods?

“Ask the Expert,” on ControlGlobal.com, is moderated by noted process control authority Béla Lipták. Béla and his cadre
of leading experts in process automation, recruited from among the co-authors of the Instrument Engineer’s Handbook 4th
Edition, are “in the box” all month answering process control questions from all comers. The best will be published here.
Question:
W
e have a tempered water system supplying cooling the diagram below work? It seems that because there is a
and heating to an exothermic reactor. We’re using difference between the heating and cooling gains that we
a cascade-split range control method. The master could have each valve have it’s own PID controller. That
controller is for the reactor temperature; the slave is for way we can tune each valve for its own gain. The add and
the tempered water temperature. The slave outputs goes subtraction of 5 degrees is to make sure each PID is not
to a splitter, which then controls the steam valve and wa- seeing the same setpoint (to give them a ‘dead-band’) and
ter valve for the tempered water. aren’t constantly fighting each other.
My question is in regard to the split range control. Is this an acceptable method of control? What is wrong
The diagram below (Figure 1.) is a typical split range with it? I hope you can explain the advantages/disadvan-
control for: a tempered water system. The water tempera- tages of the standard and alternate split range control meth-
ture is the PV for the PID. A typical splitter would be ods. Thank you in advance for your time.
0-49% for cooling, and 51-100% David Rolfe
for heating (with steam). In some figure 1.
applications, another option is to TYPICAL SPLIT RANGE CONTROL
shift the split point if the heating
process gain is higher than that of Slave PID
Master
cooling (different ‘strengths’ in the Out SPLITTER
SP Steam Valve
valves). For example a 0-32% for Out In Out
cooling, 34-100% for heating split.
PV
My question is in regards to the Water
difference in ‘strength’ between Temp
the heating valve and cooling valve Water Valve
(different process gains). Would
Answers:
Use = % Valve
The normal configuration is to use an equal-percentage not such large one as ±5 oF), because the dead band can
(=%), fail-closed steam valve with a positioner that oper- be provided by setting the positioner ranges for 0-49%
ates it between 50-100% of the output signal from the re- and 51-100%.
verse acting slave PID, which has a 10-20% proportional Because the gain, time constant and deadtime of the
band and a little integral. The water valve is also =%, it process is different during cooling from that which ex-
fails open, and it operates between 0-50% of the output ist during heating, it is reasonable to modify the tuning
signal from the reverse acting slave PID. To prevent re- constants when switching from cooling to Steam
PID Heat heating. But
Valve
Subtract
set windup in the master, we also provide the master TIC keep in
5 deg F mind, that 1)
CAS_INmost of the integral
Out and
In derivative
with external reset from the slave transmitter output. changes have to be done in the master, and 2) I would
In your existing configuration, I don’t see the need not adjust
Waterthe gain
PVin two separate slave PIDs, but in the
Master fulfill that func-
for the splitter because the positioners same one.
TempThis is because if you have integral in the po-
Out
tion. In the configuration I would recommend, I see the sitional algorithm of the slave controller, the internal ref-
need for inserting dead band at the PID (particularly erence
Add would be lost at theCool
PID Water Valve
time of switching.
5 deg F CAS_IN In
Out
PV
CT0511_75_76__ATE.indd 75 11/8/05 2:26:34 PM

A s k t h e e x p e r t
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figure 2.
EQUAL-PERCENTAGE, FAIL-CLOSED STEAM VALVE CONFIGURATION

PID Heat Steam Valve However, if the positioner is
Subtract
5 deg F CAS_IN Out In digital, smart, and has its calibra-
tion accessible from the control
Water PV room, the accuracy and main-
Master Temp tainability of split ranging in the
Out
field is no longer as much an is-
Add PID Cool Water Valve sue. It’s especially important that
5 deg F CAS_IN In the valves do not have a deadband
Out
or stick-slip as the trim goes in
PV and out of the seat that is greater
than half of the split range gap.
I have also asked some of my colleagues about your ques- The deadband and stick-slip cited for many valves is at the
tion and their answers are given below. ideal throttle position of 50% and does not show the effect of
Béla Lipták the extra friction from seats and seals at shutoff.
CONTROL columnist It’s also important that each control valve not be oversized
and that the master controller not get the slave controller
Tune Cascade for Cooling unnecessarily traversing the split range point. For set point
I agree with your assessment of the proposed system. The changes to the master controller and startup, I favor a feed-
dead zone inserted between the two slave controllers will forward signal of the set point change added to the master
cause cycling in the primary loop. Also, the bias intro- controller output and a head start initialization of the slave
duced into the set points will cause offset if external reset controller output to preposition the proper valve.
feedback is applied. Greg McMillan
The cascade system should be tuned for cooling, and this CONTROL columnist, Washington University professor
usually gives acceptable results for heating.
Where this is not the case, separate PID settings can be Split Block Common in DCSs
scheduled into the slave controller, depending on which Of course, it’s not normal practice to put in two PID con-
valve is open. This is easy to do with digital controllers, and trollers. As such, there is freedom to have both heating and
is a standard feature in some. cooling occurring at the same time, which is energy ineffi-
Greg Shinskey cient and does not improve control.
Process Automation Hall of Fame member The split block implementation is common in most
DCS systems. That way, the output of the PID and the
Put Splitter in DCS positioners can be set separately. The valve setup can set
I have seen dual PID controllers used for pH control to fail open or fail close and be set to 0-100% as in any
where there was an acid and base reagent. Unfortunately, other application. This makes it easy for maintenance
the difference between the set points needed to keep the and reinstallation if necessary. The split allows conver-
controllers from fighting and insuring both valves aren’t sion of the 0-50% of the PID to be converted to 0-100%
open at the same time is highly dependent on the dynam- for the one valve and 50-100% of the PID to 100-0% for
ics and tuning of each PID. I prefer a single split ranged the other valve, or vice versa. It also allows users to gap
controller with its tuning scheduled per the valve throt- or overlap the valve outputs if desired. Again, overlap is
tled as you mentioned. So far as the split-range point, op- wasteful and gap doesn’t often help, but insets some ad-
erators expect 50%, but a different point may help com- ditional dead time. But certainly, logic to change tun-
pensate for the difference in process and valve gains if ing constants is needed because of the different process
the controller gain can’t be scheduled. Since the process characteristic between the zone.
dead time and time constant are also different for heating The biggest problem in exothermic reactors is the large
and cooling, the integral time will also be different. How- amount of heat needed to initiate the exotherm, and then
ever, if mostly proportional action is used for the slave to immediately remove the heat when the reaction starts
controller, it may not need to be scheduled. to take place. Most PIDs can’t keep up with the results of
I favor using the splitter in the DCS configuration instead bad temp control.
of split ranged analog positioners because it eliminates spe- Bruce Jensen
cial positioner calibrations. Yokogawa Corp. of America
CT0511_75_76__ATE.indd 76 11/3/05 5:12:05 PM

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PLCs and Industrial PCs Merging Identities

These days, you can’t tell the players without a program—or with one.
M
arket predictions for PLCs and industrial computers • Mixed-up controllers: It’s getting very difficult to tell the dif-
say that sales will continue to increase at about 5% per ference between some PLCs and some industrial comput-
year in the face of worldwide economic slowdowns. ers. PLCs have process control-like functions, such as PID
ARC Advisory Group (www.arcweb.com) reports the control, historians and built-in web servers. Some of the
worldwide market for PLCs will grow at 5.9% and the computers are impossible to define because, although they
China market for PLCs will grow 14.1%. Venture Devel- are based on a PC chip architecture, they employ PLC-like
opment Corp. (www.vdc-corp.com) says the growth rate IEC 61131 languages and support many common industrial
for ruggedized industrial computer systems is 4.4%. IMS and PLC networks, such as Profibus, Modbus, Ethernet IP,
Research (www.imsresearch.com) pegs the world growth DeviceNet and so on. Is it a PC or a PLC? The only way you
of PLCs at 3.3% and growth in the Asia-Pacific region at can really tell anymore is if the vendor calls its device a PLC
6-7%. Disagreeing market researchers aren’t unusual. In or an industrial computer. We may simply have to start call-
fact, since their purpose is to sell $3,500 reports, it helps ing this category “Industrial Controls.”
their sales to disagree loudly and publicly. • O pen controllers: Proprietary systems continue to
Alas, none of these researchers directly addresses the use dwindle. More and more PLCs and industrial PCs
of PCs and PLCs in process control, so we’ll just have to have open WinTel (Windows-Intel) architectures, sup-
wing it. Based on what we’ve observed, and as indicated by port all device and network interfaces, and come with
the products you’ll see in the roundup below, some of the software that allows the device to communicate up and
apparent trends are: down the enterprise with ease.
• L ogical controllers: PLC-like logic is beginning to be These trends and limited print space make it very diffi-
embedded into otherwise normal PID controllers, tem- cult to describe some of these complex devices. If you see
perature controllers and similar devices. Motor drives “more info at controlglobal.com” in the device descrip-
are beginning to either embed PLCs, or the drive man- tion below, it means we have more information about the
ufacturers are abandoning their proprietary systems in product on our web site. Go to controlglobal.com, scroll
favor of off-the-shelf PLCs. Paper machine builders down to “Site Highlights,” and click on the roundup sec-
also appear to have abandoned their proprietary con- tion. Then, select the PLC/PC roundup from the list of
trol systems in favor of PLCs. product roundups you’ll find there.
TOUCHY COMPUTER puter has a 1.3-GHz Celeron CPU,

Optima Touch industrial computer has 512 MB RAM, and a S3 ProSavage4
an integral LCD touchscreen monitor, 4xAGP 3D/2D video controller. More
comes standard with the Windows XP info at controlglobal.com. Eurotherm;
operating system, and can be config- 703-669-1329; www.eurotherm.com
ured with several HMI software pack-
ages. It is available with a 15 or 10.4-in. SPEEDY PLC HISTORIAN
TFT flat-panel LCD and a continuous In-rack PC56-Historian provides high-
analog resistive touchscreen. The com- speed, real-time data collection, stores
and accesses data locally in a mod-
ule for ControlLogix controllers, and
communicates with the ControlLogix
controller directly via the ControlBus
backplane. It can be added to new or
existing ControlLogix PLCs with-
out changing the control application.
More info at controlglobal.com. ProSoft
Technology; 661/716-5100; www.prosoft-tech-
nology.com
CT0511_77_80_Roundup.indd 77 11/3/05 5:16:43 PM

S P V O E . V Q
Ru
."/:10354*/"4503. "/"-0(*00/580#0"3%4
4115T flat-panel industrial computer Elite-2000 offers up to 16 analog
has a 2.0-GHz Intel Pentium 4 proces- inputs and outputs built onto two
sor with 533-MHz system bus and 512- boards. Each analog expansion board
KB cache, 15-in. flat panel LCD, and an incorporates its own processor, and
analog resistive touchscreen. Its 4xAGP can be manufactured for up to eight
analog inputs and eight analog out-
puts in various configurations. The
analog cards are factory configured
to accommodate requirements with msec. It can also be used with Profi-
bus, DeviceNet, CANopen, Lightbus
and SERCOS interfaces. More info at
controlglobal.com. #FDLIPGG "VUPNBUJPO
XXXCFDLIPGGBVUPNBUJPODPN
1$%*41-":0'"''&$5*0/
graphics controller has up to 64-MB Panel PC combines an industrial PC
video RAM for handling 3-D graphics. and display in one unit. Options in-
The PC has on-board 10/100 Base-T clude processors ranging from a Cel-
Ethernet, two USB 2.0 ports, parallel eron 400 MHz to a Pentium M 1.6
port, two RS-232 serial ports, one con- no wasted I/O. More info at control- GHz, and touch devices with 10.4-in.
figurable RS-422/232/485 serial port, global.com. &OUFSUSPO*OEVTUSJFT VGA, 12.1-in. SVGA and 15-in. XGA
PS/2 keyboard and mouse ports, and an XXXFOUFSUSPODPN
additional video port. More info at con-
trolglobal.com. 9ZDPN"VUPNBUJPO '6/$5*0/#-0$,$0/530--&3
FYUXXXYZDPNDPN HoloCON controllers are compliant
with the IEC 61499 standard for dis-
.6-5*-001:$0/530--&3 tributed function block controls. The
PPC-2000 multi-loop PID controller standard lets users design a distrib-
has built-in programmable logic func- uted control system, logically, physi-
tions, allowing various analog and dig- cally distribute the controls and I/O,
ital I/O plus control loops to be cen- and coordinate the control process-
ing using event-driven software. Each
controller has Internet-ready Ethernet
networking; up to three I/O cards in- TFT displays. More info at control-
cluding discrete, analog, and two-axis global.com. #3 *OEVTUSJBM "VUPNBUJPO
servo-positioning; real-time clock; and XXXCSBVUPNBUJPODPN
a graphical function block program-
ming environment with 500 function -0"%&%8*5)-*/69
blocks. 8FTUFSO 3FTFSWF $POUSPMT Micro-VersaTrak μIPm is pre-loaded
XXXXSDBLSPODPN with open-source Linux, and the com-
tralized into one compact unit and pany’s industrial IPm firmware and
programmed as an integrated system. 3*%*/(#64&40/5)&%*/3"*- Sixnet I/O Tool Kit. It has a built-
It handles up to 48 PID loops with 80 CX1020 provides PC performance at in mix of 14 discrete and analog I/O,
analog inputs and 46 digital I/O avail- the modular I/O level. It mounts on four serial ports, and a 10/100 Ether-
able for logic programming or moni- a DIN rail, has a 600 MHz Intel Cel- net interface. Programming can be
toring. Inputs include thermocouples, eron M CPU, and uses Compact Flash done using any mix of the ISaGRAF
RTDs, linear dc voltage or current in- memory. When EtherCAT is used as IEC61131 languages or high-level C/
puts and counters. 8BUMPX the fieldbus, the PC reportedly can C++. More info at controlglobal.com.
XXXXBUMPXDPN achieve response times of less than 1 4JYOFUXXXTJYOFUJPDPN

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#0550."$$&44*#-&1$ one connection point. Users can con- analog control and discrete logic,
IPC-7143 PC has bottom access, nect the programmer anywhere on the and can be expanded to handle up to
which reportedly allows its cables to I/O network, and monitor, configure, 8,192 points. :PLPHBXB $PSQ PG "NFSJDB
be organized and maintained more or troubleshoot any ENIU or the mas- XXXZPLPHBXBDPNVT
ter controller, reducing downtime and
machine commissioning. More info at '06/5"*/0':065)'030-%1-$4
controlglobal.com. (& 'BOVD Modicon Advance Program offers
XXXHFGBOVDDPN three levels of upgrading for aging au-
tomation systems based on a facility’s
130'*#64."45&3"/%$0.."/%&3
758 Series programmable controller
can be a Profibus master, and it has on-
board Ethernet ports for connectivity
easily than previous models. When to the enterprise. It has a 266-MHz,
mounted on the wall, there’s no need multitasking, battery-backed CPU,
for a rear maintenance area, and there built-in web server, 32-MB RAM/32-
are no rear access cables to manage. It
supports a CD-ROM, two SATA HDD maintenance schedule and budget.
trays, and two IDE disk drive bays. The program offers simple, phased or
"EWBOUFDI FYU XXXF"VUP complete migration to Modicon PLCs
NBUJPO1SPDPN and software. The results are increased
production and efficiency, reduced
1-$&%*5"#-&8)*-&0/-*/& downtime and repair costs, better com-
Allen Bradley MicroLogix 1100 con- ponent reliability and enhanced con-
troller lets users adjust programs, in- nectivity through access to multiple
cluding PID loops, while still online. MB flash memory, and a real-time networking options. More info at con-
It has an embedded EtherNet/IP com- clock. The CAA programming tool trolglobal.com. 4DIOFJEFS&MFDUSJD
munications port and an embedded supports all five IEC 61131-3 program- XXXUFMFNFDBOJRVFDPN
Ethernet web server, which give us- ming languages, and has built-in visu-
ers remote access to control informa- alization, OPC server, and a fieldbus 1$501-$$0..6/*$"5*0/.0%6-&
tion. More info at controlglobal.com. configuration tool. 8BHP D0-DCM Communications mod-
3PDLXFMM"VUPNBUJPO FYU FYUXXXXBHPVT ule adds two serial ports to any DL05
XXXSPDLXFMMBVUPNBUJPODPN or DL06 PLC. It supports PC-to-PLC
-0(*$"- /&5803,&%5&.1$0/530-
&5)&3/&55",&41-$"/:8)&3& FA-M3 multi-controller provides
Series 90-30 programmable logic con- PID temperature control and cal-
troller has an Ethernet Network Inter-
face Unit (ENIU) that enables users
to connect Series 90-30 I/O over Eth-
ernet to a master controller through
communications for programming and

data collection, PLC to HMI interface,
PLC to PLC data exchange, RS232 or
RS422/485, Modbus RTU, DirectNET,
and K-Sequence slave network proto-
culates up to 20,000 logic functions cols, and operates as a DirectNET or
in 1 msec. It supports Ethernet, De- Modbus master. More info at control-
viceNet, Profibus and Modbus, has global.com. "VUPNBUJPO%JSFDU
built-in software to accommodate XXXBVUPNBUJPOEJSFDUDPN
w w w.controlglobal.com NOVEMBER/2005 8:

p r o d u c t i n t r o d u c t i o n s
Pi
BIG CORIOLIS RAISES THE BAR optional 10-point calibration that can AC DRIVE HELPS TORQUE,
Many process applications that could achieve 0.05% accuracy. High temper- SPEED REGULATION
be improved or save money with high- ature and high accuracy density mea- Telemecanique Altivar 71 variable
accuracy Coriolis flow measurement surement are available options. Stan- speed AC drive has dual micropro-
are ignored because typical Coriolis dard outputs include dual 4-20 mA, cessors, motor control algorithms
flowmeters are limited to serving in 6 one standard with HART, a frequency/ for better torque performance and
in. or smaller line sizes and/or with be- pulse output of total flow, and a binary speed regulation, and Modbus and
nign fluids compatible with stainless output of instrument status. Output CanOpen protocols. The drive is
steel. However, FCI reports its new CM options include Profibus-PA and a tam-
Series Flowmeters expand available ap- per-proof, custody transfer configura-
plications for Coriolis technology. tion that is sealed and certified, and
prevents resetting of the internal total-
izer. Fluid Components International; 800/854-
1993; www.fluidcomponents.com
SIMPLE BUSINESS INTELLIGENCE

SOFTWARE
TrakSys 4.0 performance manage-
ment software reportedly allows man-
ufacturers to leverage their existing
automation, IT and business systems
“Large line sizes, high flow rates infrastructure. TrakSys 4.0 uses real-
and wetted materials that have been time analytics and visualization to de-
impossible, unavailable, or required liver personalized and collaborative
extremely expensive, special products business intelligence in the form of
are now all achievable with standard key performance indicators across the
products in FCI’s CM Series,” says value chain. The software operates by
Sam Kresch, FCI’s product line man- collecting data from diverse sources, 15% smaller than previous models. It
ager. CM Series has a wide range of converting it into useful performance has a large, easy-to-read, customiz-
standard wetted parts, including 316 information, and distributing it to the able LCD display that uses plain text
stainless steel and Hastelloy, Tantalum, right users at the right time, without words and has a navigation wheel
Monel, nickel, titanium, carbon steel, special programming. TrakSYS is com- that allows users to scroll through
zirconium and others, adds Kresch. pliant with ISA95, the business process menus. More info at controlglobal.
For example, CM flow sensor’s standard, and is built on Microsoft’s com. Schneider Electric; 847/397-2600;
thick, pipe-wall construction is suit- .NET architecture. Parsec Automation www.us.schneider-electric.com
able for high-pressure applications up Corp.; 714/996-5302; www.parsec-corp.com
to 13,000 psig (900 bar). In applications STAINLESS-STEEL MOTOR FOR
where there is a danger of the fluid so- SCADA CONVERSION TOOL AIDS WASHDOWNS
lidifying into a no-flow state or where UPGRADES Allen Bradley MPS stainless-steel
heat is needed to maintain flow, CM Switch2Citect automated conversion motor for washdown applications
series employs an internal heat tubing tool helps SCADA users upgrade to Ci- meets government regulations that
array, which improves efficiency and tectSCADA version 6 from legacy sys- specify “safe” materials that can be
saves space compared to the typical, tems including InTouch, Fix32, iFix used in manufacturing applications,
bulky external heat blanket technique and FactoryLink. The tool automati- such as food, beverage and life sci-
commonly used by other devices. cally converts most graphics and tag ences. The motor has a cleanable
CM Series is designed for mass databases, reportedly reducing configu- design, which is in accordance with
flow measurement service in liquids ration time by 80%. It has a web client best practices for food safety require-
and gases in line sizes from 1/8 to 12 and process analyst, and an integrated ments. More info at controlglobal.
in. (3 to 300 mm) with standard accu- alarm and trend viewer on one screen. com. Rockwell Automation; 800/223-5354,
racy of ±0.1% to ±0.15% of rate and an Citect; 770/521-7511 ext. 208; www.citect.com ext. 1842; www.rockwellautomation.com
CT0511_80_81_Products.indd 80 11/3/05 5:19:11 PM

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NEEDLE VALVES ISOLATE AND VENT carbon steel, straight and angle pat-
GU series needle valves isolate and terns, and choice of end connections
vent system media in instrument air, in sizes from 1/4 to 1 in. Valves work
nitrogen headers, lube oil and gen- in operating pressures up to 6,000
eral utility service applications in the psig at 200 °F. Swagelok; 440/349-5934;
oil and gas, chemical, petrochemi- www.swagelok.com
cal and other general industrial mar-
kets. Options include stainless and THERMAL MASS FLOWMETERS ADD
SECURITY
Enhancements to SRG thermal mass
flow meters for air and gas include a re-
mote electronics enclosure, a touch dis-
play screen keypad, and an explosion-
proof junction box. The enclosure is
constructed of fiberglass and is NEMA
4X rated. The keypad is password pro-
tected to prevent unauthorized tam- probe support/sensor assembly. More
pering with the flowmeter. The junc- info at controlglobal.com. Sage Metering;
tion box is mounted at the end of the 866/677-7243; www.sagemetering.com
STATEMENT OF OWNERSHIP, MANAGEMENT,

AND CIRCULATION
(Required by U.S.C. 3685)
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CT0511_80_81_Products.indd 81 11/3/05 5:19:54 PM

CT0511_FPA.indd 82 11/3/05 6:18:51 PM
D P O U S P M ! U B M L
A
Ctlt
)PPUBOEB)PMMFS
and instruments successfully used at (SFH Now for something completely
other locations will not work in his different. We are lucky enough to
plant. Since we ruled out dropping a have the transcript of the guest ap-
control valve on his head, we are left pearance of a process control engi-
with an answer from Henree Pernash neer from Texas on a prominent day-
Locknester PhD, DD, MS, GED, a time talk show. Needless to say the
certifiable automation engineer. audience went wild with applause at
the long-awaited chance to find out
)FOSFF The answer all depends on more about what is under the covers
Greg McMillan (gkmcmi@msn.com) and where the new plant is located. If it is in this mystifying profession.
Stan Weiner, PE (sweiner@swfla.rr.com) in Southern Texas, you need to take
bring their wits and more than 66 years of the plant’s instrument engineer and )PTU Woo haa! Woo hoo! Sit down
process control experience to bear on your maintenance supervisor out for some big boy and tell us if everything is
questions, comments, and problems. steaks and Lone Star beer. If the plant bigger in Texas.
is located in the St. Louis area, take
them out for some steaks and Bud- 5FLTVO Ah’m uh big fayun and haly
UBO The September puzzler asked weiser beer. If the plant is located in ’preciate being on TayVay. Did yew
4 why the plant instrument engineer

tells you that the control schemes
New England, take them out for some
steaks and...well, you get the idea.
know thet thuh pipelines are bigger
in Teksus, which makes thuh valves
CT0511_83_84_CT.indd 83 11/3/05 5:21:20 PM

D P O U S P M ! U B M L
Ct
bigger, which makes thuh stick-slip 5PQ3FBTPOT8IZB1SBDUJDBM#PPLPO

bigger, which makes thuh limit cycle $POUSPM8PO¤UCFB$PMMFHF5FYU
bigger and control more difakult? 10. Costs less than $50.
9. None of the authors have PhDs
)PTU Tell us about your sensitive side. 8. Contains Top 10 lists
7. Shows flow sensors upstream instead
5FLTVO Ah am fixin tuh git fine valves of downstream of the control valve
for my rilly important loops and use 6. Discusses stick-slip and backlash
model-predictive control tuh do uh 5. Shows unmeasured load upsets as
rilly good job of simultan’usly throt- inputs to the process
tling “Big Hoss” and “Little Jo” tuh 4. Includes field implementation con-
cover uh rilly big f low range without siderations
split range. 3. Estimates tuning settings to just one
decimal place
)PTU How does this make you feel? 2. Doesn’t use tensor analysis for flow
loops
5FLTVO It jes make me feyul az fine az 1. Depicts signal lines in figures as
frog’s hair. electronic instead of the pneumatic
academic standard
)PTU How do you get in touch with
yourself? (SFH Since the response to our puzzlers
has been puzzling, we’re going to end
5FLTVO Ah levus thet tuh ma wife. each column with a trend chart of the
month and simply ask, “What is wrong?”
)PTU Control Talk—The Early Years is The only clue will be in the grand ac-
our book of month. All that talk about ademic tradition of giving the dynam-
model-based control, decoupling, and ics of the process and ignoring the ef-
invcrse response made our readers hot. fect of the valve, sensor and transmitter.
Is it going to end up in a classroom? In other words, the process gain, delay
(dead time), and lag (time constant) in
5FLTVO Thet’s uh hoot and uh hollar. Ah the heading of the trend chart are exclu-
kinduh doubt professors will want it for sive of non-ideal instrumentation and
theez 10 raysuns. implementation of the loop. C
5IJT.POUI¤T1V[[MFS
8BJUJOHGPSBO*OWJUBUJPO
8
hat is a cause of the hesitation and slowness in the approach of
the process variable to its new set point in the following trend:
Process Gain = 1, Delay = 10 sec, and Lag = 5 sec?
4FOEBOFNBJMXJUIZPVSBOTXFSUPUIF1V[[MFS $0/530-
RVFTUJPOT PSDPNNFOUTUPDPOUSPMUBML!QVUNBOOFU
CT0511_83_84_CT.indd 84 11/3/05 5:21:50 PM

CT0511_Classified.indd 85 11/3/05 5:30:26 PM
a r o u n d t h e l o o p
Atl
PPAR-5 Convenes in San Diego
T
he fifth meeting of the Pharmaceuticals Process Analyt- details will be posted at www.patroundtable.org.
ics Roundtable (PPAR-5) was held in late September at Meanwhile, the annual PPAR benchmarking survey
Pfizer’s R&D campus in La Jolla, Calif. About 25 indi- included responses from 12 pharmaceuticals manufac-
viduals attended, representing 13 manufacturers and three turers. The full results of this questionnaire, with more
supporting organizations. The supporting organizations were than 40 questions and responses to three earlier bench-
the National Institute for Science and Technology (NIST), marking surveys, also can be viewed at www.patroundta-
the University of Washington’s Center for Process Analytical ble.org. One question concerned analytical technologies
Chemistry (CPAC), and the University of Tennessee’s Mea- now used in commercial manufacturing, as well as those
surement and Control Engineering Center (MCEC). used for direct closed-loop control:
“While process understanding (PU) is the real meaning of the

Process Analytical Technology (PAT) guidance, ‘PU Initiative’
just didn’t have the proper ring to it.”
John Loran, science and technology Analyzer Used in Closed

VP at Pfizer’s La Jolla-based R&D Cen- technology manufacturing loop
ter for Pharmaceutical Sciences, opened
pH 9 7
the meeting, remarking on Pfizer’s early
use of NIR for process development. Conductivity 9 4
With federal regulators demanding sharply increased levels NIR 6 5
of process understanding and process robustness, now is the Mid IR 4-
time to link key business drivers, such as Pfizer’s Right the
UV-Vis 9 5
First Time (RFT), with technological initiatives in pursuit
of FDA’s Process Analytical Technology (PAT) guidance. Raman 4-
Collaboration between FDA’s Center for Drug Evalua- Mass spectrometry 7
tion and Research (CDER) and pharmaceutical manufac- GC 4 1
turers to achieve a deeper scientific understanding of drug
LC 5 1
manufacturing processes is the PAT Initiative’s objective.
The name, Process Analytical Technology, has been A roughly two-hour teleconference was held with
badly misconstrued in some quarters by limiting it to on- CDER’s Afnan to review 12 questions that had been for-
stream analyzers. CDER’s Ali Afnan remarked that, while mulated by PPAR’s conferees. This level of interaction
process understanding (PU) is the real meaning of the guid- between the FDA and pharmaceuticals industry was
ance, “PU Initiative” just didn’t have the proper ring to it. inconceivable five years ago. The transformation is al-
The current PAT guidance is the final one to be authored most entirely due to Ajaz Hussain and his Patriot Team,
by CDER. Future developments and enhancements will de- a group in CDER charged with overseeing the imple-
rive from ASTM’s E55 Committee. mentation of the PAT Guidance document. The extent
Afnan was co-chair of IFPAC/2005. His colleague, Chris to which the PAT Initiative and the collaborative spirit
Watts, is co-chair of IFPAC/2006. Scheduled for Feb. 20-23, takes firm root in the culture of FDA will depend on
2006, in Washington, D.C., conference details are at www. both the industry’s response in funding the necessary
ifpac06.org. Pharmaceutical professionals were a growing investments and the agency’s follow up in pursuing sci-
fraction of IFPAC’s attendees in 2003-05. ence-based regulatory policies. C
Anyone seeking to gain a clearer appreciation of the PAT
Initiative and related technical activities needs to consider
three important venues: ASTM E55 Committee, PPAR Terry K. McMahon,
and IFPAC. Amgen/CPAC, Merck and Talecris have of- McMahon Technology Associates
fered to host the 2006 gathering. Location, date and other Mcmahontec135@aol.com
CT0511_86_ATL.indd 86 11/3/05 5:24:47 PM

CT0511_FPA.indd 87 11/3/05 6:19:29 PM
GE Fanuc Automation
Feel like you’ve outgrown

your control system?
Grow beyond with PACSystems®.
For years, PLCs have provided rugged, reliable control for the
most demanding plant environments. Unfortunately, when it
comes time to expand or upgrade their system, most PLC users
find themselves feeling… trapped.
PACSystems® from GE Fanuc Automation gives you access

to an endless sea of possibilities. By combining the steady per-
formance of a PLC with the speed and flexibility of PC control,
PACSystems enables you to grow easier, bigger, and farther
than with any other control technology.
Grow easier. Program, commission and maintain all of your

equipment from a single, user-friendly development environ-
ment. Maximize your engineering productivity and reduce costs
and training time for your team.
Grow bigger. Use a single, integrated control system for all

of your process, discrete and motion domains. Increase your
production processing and overall quality throughput as
needed – to grow as big as you want to be.
Grow farther. Expand the technology across multiple plat-

forms, with a migration path that accommodates both new
and existing investments. No matter where you want to go,
PACSystems can help you get there.
If you’ve outgrown your control system, see where PACSystems

and our full suite of compatible Proficy™ software applications
can take you.
Download our whitepaper at www.gefanuc.com/grow2

for more information.
©2005 GE Fanuc Automation. All rights reserved.
CT0511_FPA.indd 88 11/3/05 6:20:17 PM

CD0403_Full_Ads.qxd 2/24/04 9:35 AM Page 16
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