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 NOVEMBER 2017 • VOLUME 30 • NUMBER 11

60
COVER STORY

Secure the SIS

Understand the strength of your
last line of cyber defense

by William L. Mostia, Jr., P.E.

Features

71
FINAL CONTROL ELEMENTS
74
SOFTWARE SYSTEMS

SCADA reflects and reinvents Motors, drives deliver the force

The cloud, IIoT, virtualization and other developments bring new Rotating machinery makes new gains with variable-speed devices,
forms and functions, but can they do it securely? efficiency rules, and onboard and networked intelligence.
by Jim Montague by Jim Montague

CONTROL (ISSN 1049-5541) is published monthly by PUTMAN MEDIA COMPANY (also publishers of CONTROL DESIGN, CHEMICAL PROCESSING, FOOD PROCESSING, PHARMACEUTICAL MANUFACTURING, PLANT SERVICES and
SMART INDUSTRY), 1501 E. Woodfield Rd., Ste. 400N, Schaumburg, IL 60173. (Phone 630/467-1300; Fax 630/467-1124.) Address all correspondence to Editorial and Executive Offices, same address. Periodicals Postage
Paid at Schaumburg, IL, and at additional mailing offices. Printed in the United States. © Putman Media 2017. All rights reserved. The contents of this publication may not be reproduced in whole or part without
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accepted from Operating Management in the control industry at no charge. To apply for a free subscription, email putman@stamats.com. To non-qualified subscribers in the Unites States and its possessions, subscriptions
are $96.00 per year. Single copies are $15. International subscriptions are accepted at $200 (Airmail only.) CONTROL assumes no responsibility for validity of claims in items reported. Canada Post International Publications
Mail Product Sales Agreement No. 40028661. Canadian Mail Distributor Information: Frontier/BWI,PO Box 1051,Fort Erie,Ontario, Canada, L2A 5N8.

www.controlglobal.com NOVEMBER 2017 • 7

 113GHZ +
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 CONTENTS

Departments
39 EDITOR’S PAGE 77 ASK THE EXPERTS
Running on fumes Orifice flowmeter straight runs
Sometimes a level instrument is only Requirements vary widely and depend
as smart as its calibrator. on expectations as well as piping.

40 CONTROL ONLINE 79 ROUNDUP

Our most recent, valuable and popular I/O and terminal blocks
offerings at ControlGlobal.com Where signals and data reach up to
networks, the Internet and the cloud.
42 FEEDBACK A bull’s eye in quality.
Top 50 correction; Users must
demand open systems
Eight new products – Eight good
44 LESSONS LEARNED reasons to choose Endress+Hauser!
Can we resolve the climate debate?
Part 1: Is global warming significant? Is
it caused by CO2? 81 EXCLUSIVE
Twisted thermowell improves safety
48 ON THE BUS Emerson’s patented design prevents
Levels of inference failure due to vortex-induced vibration. $ 200.–
11–35 pcs. $ 302.–
Smart engineers can get more than 11–35 pcs.
level from level instrumentation. 82 PRODUCTS
The latest and greatest selections from
50 WITHOUT WIRES our editors’ in-boxes. PMC11 PTP31B
Merging old and new in level
Differential pressure makes great 83 CONTROL TALK $ 310.–
11–35 pcs.
strides with simple innovations. The trouble with top management
What you need to know about the
52 IN PROCESS executives who determine your fate. PMP23
Iconics conference aims for easy-to- Three of our eight new devices.
use IIoT; Bentley brings BIM to Sin- 85 CLASSIFIED/AD INDEX
gapore; Harting opens lab at North Find your favorite advertisers listed
Central College neatly in alphabetical order.
Cerabar and Ceraphant
58 RESOURCES 86 CONTROL REPORT
Reliable, flexible and easy
Deep thoughts on cybersecurity Missing Morley
• Measurement of absolute and/or
A monthly, topical guide to web-hosted The father of the PLC lives on in
gauge pressure in gases, vapors,
papers, tutorials, videos and other all the lives he touched—and will
liquids and dusts
educational materials. continue to touch.
• Customized measuring range
• Wide range of process
connections available
• High reference accuracy up to 0.3%
CIRCULATION AUDITED DECEMBER 2016

Food & Kindred Products ........................................ 10,106 Paper & Allied Products ............................................ 2,856 Explore the new pressure devices!
Chemicals & Allied Products ..................................... 8,919 Pharmaceuticals ....................................................... 3,945 www.e-direct.endress.com/pressure
Systems Integrators & Engineering Design Firms ....... 8,681 Rubber & Miscellaneous Plastic Products.................. 3,762

Primary Metal Industries ........................................... 4,657 Stone, Clay, Glass & Concrete Products ..................... 1,686

Electric, Gas & Sanitary Services ............................... 3,481 Textile Mill Products ..................................................... 802

Petroleum Refining & Related Industries ................... 4,016 Tobacco Products ........................................................ 110

Miscellaneous Manufacturers .................................... 6,982 Total Circulation ...................................................... 60,003

www.controlglobal.com NOVEMBER 2017 • 9

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AN ADVERTISING SUPPLEMENT TO NOVEMBER 2017

Worth its
weight
Registration assures performance
of HART, FOUNDATION Fieldbus
and FDI technologies
 WELCOME LE T TER

Rising value
OUR ROLE AT FieldComm Group has expanded since combining the Fieldbus
Foundation and HART Communication Foundation. With the addition of FDI
technology, our strategic importance in “simplifying the complexity” of process
automation systems grows. As the integration technology of choice for many
protocols, it is enabling users and suppliers to focus less on the underlying protocol
and more on the data.
This is not to say protocols are less relevant, in fact quite the contrary. In talking
to users, I hear one common theme, that regardless of IIoT initiatives, future archi-
tectures or newly available protocols, no one is “ripping out” field devices. These field
devices are delivering data through robust protocols trusted by users to meet their
performance, interoperability and security needs. In fact, it becomes increasingly clear Ted Masters
that the IIoT will require many protocols. President and CEO
So what does the future plant and enterprise look like at the field device level in FieldComm Group
the next 10 years? I think it is fair to say we will see a combination of HART, Foun-
dation Fieldbus, HART-IP, WirelessHART and many others. Physical layers will
include 4-20 mA, Ethernet, wireless and maybe more. The key to IIoT now becomes
how we integrate these various protocols and what we do with the data they provide.
To develop standards, we use a collaborative working model that leverages
hundreds of volunteer subject matter experts from more than 340 member com-
panies. We also partner with organizations like the OPC Foundation to create
“information models” that help extend field device information from the OT
world to IT side where many users are less familiar with the origin and meaning
of process data. FDI is one such standard that helps “simplify the complexity.”
Use cases such as asset management, analytics, monitoring and diagnostic sup-
port across enterprises all require a common model to compare like information,
regardless of protocol. The protocol is how it gets there, however, the use cases
only care about the information!
Our cover article focuses on product registration and conformance services.
As devices, hosts, and architectures become more complex, assured adherence to
standards at the protocol and information model level is a requirement for maxi-
mizing captured value. In the past year, our verification team has completed new
or updated registrations for nearly 200 products. Trust me, registration is worth FieldComm Group™,
its weight in gold! FOUNDATION™ Fieldbus,
By continuing to build on the “gold standard” of our protocols, bridging them to HART-IP™, FDI™ are
the IoT and ensuring they conform to these standards, the industry can seize this trademarks, and HART®,
data revolution to achieve improved performance in their operations and enterprises. WirelessHART®, ROM®
FieldComm Group will be there to help each unique user capture the value of this and SIF® are registered
revolution by meeting them where they are today and getting them there with many trademarks of the
solutions from our technologies and from our members. ● FieldComm Group.

Advertising Supplement to CONTROL S-3

 REGISTRATION

Registration assures value

The path to a registered checkmark is rigorous, but smooth

FƵƺƴƪƧƹƯƵƴ Fieldbus and HART provide valu-
able information and powerful communications, but
these capabilities can be incomplete and integration
may be difficult if the software and hardware are not
designed and engineered to conform with the specifi-
cations. The FieldComm Group helps users avoid
problems by offering assistance to suppliers in the
form of consultation and testing services. Products
that pass the tests conform to the specifications, are
registered and may display the “Registered” logo as-
sociated with its implemented technology, which as-
sures the specified functionality and interoperability.
“Testing and registration is very important,” says
Sean Vincent, director, technical services, FieldComm
Group. “It provides third-party verification of confor-
mance to standards, which results in better products
that perform reliably and predictably for the end user.”
This recognition is important both to suppliers and
users. “Third-party registration provides peace of mind
to the specifying engineer—the manufacturer says it’s
good, and the FieldComm Group says it meets the
certification requirements,” says Eric Wible, direc-
tor of engineering, Fluid Components International
(FCI).
“For suppliers, the customers will not spec you if
you don’t have it,” Wible says. “For the user, if there
is any issue in bringing the instrument up on startup,
you’ll get the full attention of the FieldComm Group
as well as the manufacturer.”
Device manufacturers agree that registration
benefits everyone. “Users benefit from such tests
because they know that field devices provided by
Endress+Hauser will properly work in their sys-
tem environment,” says Lukas Klausmann, senior
marketing manager, Industrial Communication,
Endress+Hauser “Furthermore, risks in plant opera-
tion, as well as during commissioning and startup, will
be reduced.”
As a field device and solutions provider,
Endress+Hauser benefits from testing because it
ensures proper integration of field devices and solu-
tions in different system environments and indus-
tries. “Based on FieldComm Group compatibility,
Endress+Hauser makes further tests with the field
device in our own test lab with all major systems to
ensure that additional device-specific benefits are
available for the users in their environment,” Klaus-
mann adds.
In short, says Scott Saunders, president and CEO,
Moore Industries, “It’s another layer we have to go
through, but if I put myself in the customers’ shoes,
and I always do, I want to know that device in service
will work with another vendor’s device.” The net result
is a user that can choose the best-in-class product for
his/her application.
Flawless FOUNDATION
Test cases are written in software, and automated testing tools
exercise the permutations. Here, a FOUNDATION Fieldbus device is un-
dergoing a physical layer review.

S-4 Advertising Supplement to CONTROL

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 REGISTRATION

TESTING IS A PROCESS, NOT AN EVENT says. “This makes sure the devices are robust.”
Before a hardware or software product is registered, it is The registration process starts long before the test
tested to ensure that it not only communicates the speci- date. “Most projects start with the specifications. The
fied parameters as expected, but that it does so in many vendor’s development team gets training and serves as
different possible scenarios and under adverse conditions the primary developers, but others may help,” Vincent
often found in industrial networking applications. says. “Questions are answered by FieldComm Group
There are required capabilities, such as read/write, and the vendors’ trained experts.”
and optional capabilities for various devices. “The As they develop the product, vendors can use quality
specifications tell you many things about possibilities, assurance (QA) test tools to be sure the performance
and the tests verify single or multiple implementations is there early in the process so they can raise issues and
of those possibilities,” says Vincent. resolve questions. “Being engaged with the tools and
Test cases are written in software, and automated tests along the way really shows at the end test,” Vin-
testing tools exercise the permutations. “Along with cent says. “Development may take months or years, so
the positive cases, where we make sure it works, we we view it as a long-term partnership. There are many
test many more negative cases using erroneous infor- options, and we expect questions along the way.
mation, and simulate mistakes and network malfunc- “We try to make everything clear so people pass
tions to make sure the device tolerates and recovers the first time. Discrepancies are caught early during
from error conditions, and keeps working,” Vincent the test process.”

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S-6 Advertising Supplement to CONTROL

 REGISTRATION

The test backlog, or queue, has been eliminated.

“All tests are done on a schedule now. We schedule
them based on clients’ start dates and plans,” Vincent
says. “We schedule up to a year in advance, but there
are generally openings within a week or two.”
The registration process and test labs are not
adversarial. “They help and support both users and
registrants, and I must mention, you don’t have to be
a member to register a product,” Vincent says. “It’s a
partnership of vendors, the FieldComm Group and
users. We help by performing audits and providing
education. When a test fails, it’s usually due to an
oversight or misunderstanding. It’s a chance for us to
work together to resolve it.”
HART monitored

COOPERATION ASSURES SUCCESS The process instrument manufacturer must fully understand the
“The process of certification testing is important WHVWSURWRFROWKHVSHFLͤFDWLRQDQGKRZLWDSSOLHVWRWKHLULQVWUX-
because suppliers can verify whether the device meets ment. Here, a HART instrument is being tested for registration.

Products, solutions, services – we put the pieces together.

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ZHFDQDOVRSURYLGHWKHH[SHUWLVHLQÀHOGQHWZRUNHQJLQHHULQJDQGDVVHWPDQDJHPHQWWKDWZLOOPDNH\RXU
LQYHVWPHQWDVXFFHVV,PSURYHGSODQWSHUIRUPDQFHOHVVKDVVOHDQGULVN²QRWKLQJSX]]OLQJDERXWWKDW
ZZZDXWRPDWLRQHQGUHVVFRPÀHOGEXV

Endress+Hauser
Instruments International AG Phone +41 61 715 81 00
Kaegenstrasse 2 Fax +41 61 715 25 00
4153 Reinach info@ii.endress.com
Switzerland www.endress.com

Advertising Supplement to CONTROL S-7

 REGISTR ATION
the specification and ensure the device is stable and
reliable,” says Huixuan Yu, senior engineer, Micro-
cyber, which produces registered products for Wire-
lessHART. “During the process of testing, suppliers
can get a better understanding of the technology for
research and development of related products in the
future.”
For example, Microcyber purchased the relevant
test equipment from the FieldComm Group and
tested its device before the official certification test.
During testing, “We and the FieldComm group ex-
changed feedback to validate the latest, upgraded test
system,” Yu says. “After the test was completed in our
facility, we submitted the device to the FieldComm
Group for official testing, and received authorized
certification.”
The process instrument manufacturer must fully
understand the test protocol, the specification, and
how it applies to their instrument. “They may fail
several times and have to go back and tweak it, but
they can apply those learnings to the next model,”
says FCI’s Wible. “Understand the test protocol, and
things will go smoothly. There’s always some frustra-
CERTIFIED TRAINING
C ompanies seeking customized training frequently
turn to Lee College Center for Workforce and
Community Development (www.lee.edu/workforce).
The center is home to several Foundation Fieldbus-
certified training programs that teach students how
to build and configure fieldbus segments and devices.
The Fieldbus Center is one of only eight certified train-
ing sites in the world, boasting a multimillion-dollar
pilot plant and several modern micro-plants outfitted
with all the technology found in today’s modern indus-
trial environments.
Registered products offer more than predictable
performance—they also can be expected to have a
common set of features. This makes it easier to learn
how to use them, and that knowledge transfers to
unfamiliar devices and brands. “Registration means
you can be confident it will operate the way you want it
to,” says Chuck Carter, retired director and now instruc-
S-8 Advertising Supplement to CONTROL
Look for the label
The “Registered” mark means the product is tested, approved, has
the specified capabilities and will function as expected, without
surprises.
tion, but you need to really know it to get certified,
and the users understand that.”
Moore Industries concurs. “FieldComm Group
supplies the toolkit, we can do all the communications
testing here, work out any kinks and bugs, then send
it to the lab,” says Saunders. “It saves us on service and
support—we don’t want to sell an $800 instrument,
then spend $5,000 getting it up and running.”
Once registered, Yu says, “Devices approved by the
FieldComm Group are quality-assured, and suppliers
can use the ‘Registered’ mark in literature, documenta-
tion and marketing materials. Users prefer to choose
registered devices.” ●
tor, Lee College. “It also means that once you learn to
work with these systems, you can take it to the bank.
They work the same way around the world, and across
brands.”
Certified training shows you all the capabilities the
instruments have in common. “Vendor-based, uncerti-
fied courses may only show you the vendors’ features,”
Carter says. “As an instructor, if a pressure transmitter
is registered, I know it will work a certain way and I can
teach it using a consistent operability and approach,
with best practices.
“At the same time, over the years we have come
across certain concepts and pieces of equipment that
are great answers. If it were not in a particular vendor’s
offerings, they wouldn’t tell you about it. I want the
users to have the best information, so I tell about it
whether the system I’m teaching on has it or not, so
users can make good business decisions.”

Information reigns
The process automation cloud relies on FieldComm Group technologies
IT SEEMS THAT everyone is talking about the fourth
industrial revolution—Industrie 4.0, the Industrial
Internet of Things (IIoT) and connecting the plant
floor to the cloud. As a result, we’re seeing a fog of
alternative technologies and standards competing for
the attention of engineers, manufacturers and vendors,
and rightfully so, as the ability to gather and analyze
information is key to driving increased value in pro-
cess manufacturing.
But regardless of where the data ends up, much of
it must come from the plant floor and at the interface
between the process and the IT networks. There, says
Scott Saunders, president and CEO, Moore Indus-
Supplier
Remote Assets
Industrial Plant
CLOUD CONNECTIVIT Y
tries, “Our job is to provide customers with data and
the capability of smart instruments to support predic-
tive modeling, asset management and reduced calibra-
tion.” This is where you find Foundation Fieldbus,
HART and FDI technologies.
SHARED DATA, LEVERAGED RESOURCES
For remote applications, “It’s very easy to add cloud
connectivity for visibility into device health, to be sure
everything is working,” says David Lincoln, digital
leader, measurement and analytics business unit, ABB.
“In the control system environment, a local cloud is
useful for data gathering, analysis and local trending.
Corporate
Business Units
Storage
Production
Delivery
Field Devices
Advertising Supplement to CONTROL S-9
 CLOUD CONNECTIVIT Y
For example, tracking how many times a valve opens
and closes is a low-cost addition. Then you can share
valve operating data with one valve expert across the
organization, or with a vendor service technician sit-
ting miles away, through the cloud.”
“We make the data available, and the customer
decides how to use it,” Saunders says. “Most use an
intranet for IIoT, not an immediate jump to the cloud
over the Internet, due to security concerns. That’s their
responsibility, they can decide that technology. Our
next two or three products will have Ethernet running
Modbus TCP, Ethernet IP or HART-IP. We make IP
available to them, they decide how high they want to
go. OPC UA? XML? It’s up to them.”
For field instruments outside a control system,
“The cloud provides the connection and a technician
can analyze the entire fleet,” says Neil Shah, product
manager, control systems technologies, ABB.
Within a control system, with no additional con-
nectivity or infrastructure, “Data may be locked into
the system. We need to convert it to get it out to the
experts for analysis,” Shah says. “For that, we can use
device management tools.” FieldComm Group’s FDI
technology is made for the job (p. S-13). Shah says,
“FDI is open, and enables us to draw on data not just
from ABB devices, not just from ones that are not
already connected, and not just from a single source.”
Capabilities found traditionally in Foundation
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They’re compliant
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S-10 Advertising Supplement to CONTROL
Fieldbus and HART portable communicators are now
connecting to the cloud to save device configurations,
share configuration data, perform automatic backups,
and make the latest data and configurations equally as
available remotely as they are locally. Saving trend data
to the cloud allows users to troubleshoot device issues
with colleagues anywhere in the world, and gives
global access to process performance data.
“Our DevCom2000 Smart Device Communica-
tor and our DevCom Apps all support HART-IP.
This allows access to all HART devices in the net-
work through an Ethernet connection to the Wire-
lessHART gateway. The user can download HART
device configurations and make parameter changes,”
says Jeff Dobos, president, ProComSol. “Now we’re
adding functionality for online use. You can view the
entire network hierarchy on one screen showing mea-
surement values, device status, and record and store
the data locally or in the cloud.”
“Our software also can save trend data—for any
period you want—to the cloud to share with colleagues
all over the world, ” Dobos says. “You can do it from the
office or home, you don’t need to go into the plant.”
OPC UA DELIVERS DATA EVERYWHERE
For a significant group of suppliers, the default solu-
tion for connecting disparate devices, packages and
systems is OPC UA. “The big thing right now is
OPC. It’s a big, open platform for Ethernet and the
Internet,” says Saunders.
As part of a continuing partnership between the
OPC Foundation and FieldComm Group, the OPC
UA information model is a part of the framework
upon which FDI is built. “This allows complex infor-
mation rendered in device package to be seamlessly
communicated to disparate applications and devices,”
says Tom Burke, president and executive director,
OPC Foundation. It allows a generic application to
connect to the corresponding device or host applica-
tion and consume data without any knowledge of the
underlying protocol of the device. Much like plug and
play in the consumer electronics business.
“End users consistently tell us that they have no in-
terest in replacing their field devices,” says Ted Masters,
CEO of FieldComm group. This is hardly surprising
given the large installed based (40 million or more
 CLOUD CONNECTIVIT Y

units) and long lifecycle of field Instead of having many pro- lows my group to simply support
instrumentation. Technologies like tocols to provide and support, OPC UA.
FDI and OPC UA allow for cre- it’s just one OPC UA interface. “At the NAMUR conference
ation of “digital twins” for the field “It takes less than a week to [in November], they’ll have a joint
instrumentation that can then be become compatible with a huge demo using OPC UA to connect
mapped into a variety of application number of devices,” Barnstedt FieldComm Group technologies
formats. Masters continues, “When says. “FieldComm Group offers to Microsoft Azure, showing how
we give management presentations, an entire ecosystem of devices you can quickly get insights into
our computers probably have three compatible with FDI technology. machine data from the cloud with
or four different ways of connecting It’s protocol independent and al- a few clicks.” ●
to a projector. Most users don’t care
if VGA, HDMI, DVI, or wireless
connections are used, as long as the
image on the computer is render-
ing properly by the projector. It’s
DĂŝŶƚĞŶĂŶĐĞ͕^ŝŵƉůŝĨŝĞĚ͘
the same in process automation.
Many, slightly different, protocols
will continue to operate in plants
D'dŽƚĂů/ŶƐŝŐŚƚ
worldwide, but the information
dŚĞŶĞǁDĂŐŶĞƚŝĐ&ůŽǁŵĞƚĞƌ^ĞƌŝĞƐĨƌŽŵzŽŬŽŐĂǁĂ
delivered by those protocols must
D'd/ĂĐĐƵƌĂƚĞůLJŵĞĂƐƵƌĞƐƉƌŽĐĞƐƐĨůŽǁǁŚŝůĞŝŶĐŽƌƉŽƌĂƚŝŶŐ
be standardized for consumption by ĞƋƵŝƉŵĞŶƚŚĞĂůƚŚĂŶĚƉƌŽĐĞƐƐĚŝĂŐŶŽƐƚŝĐƐ͕ƐƚƌĞŶŐƚŚĞŶŝŶŐŵŽŶŝƚŽƌŝŶŐ͕
all process applications. This is the ĂŶĚĐŽŶƚƌŝďƵƚŝŶŐƚŽƌĞĚƵĐƚŝŽŶŽĨŵĂŝŶƚĞŶĂŶĐĞĂŶĚŽƉĞƌĂƚŝŽŶĂůĞdžƉĞŶƐĞ͘
ultimate goal of the FDI and OPC
UA information models.”
‫ٹ‬sĞƌŝĨŝĐĂƚŝŽŶĨƵŶĐƚŝŽŶĂůŝƚLJ
CLOUD CONNECTS VIA OPC 嵣ƵŝůƚͲŝŶĐŽŵƉƌĞŚĞŶƐŝǀĞŚĞĂůƚŚ
On the cloud side, evidence that ĐŚĞĐŬ
OPC UA is the key to field-to-
‫ٹ‬DŽŶŝƚŽƌŝŶŐƉƌŽĐĞƐƐĐŽŶĚŝƚŝŽŶƐ
cloud connectivity comes from Mi- 嵣sŝƐƵĂůŝnjĞƚŚĞĞĨĨĞĐƚƐŽĨĨůŽǁŶŽŝƐĞ
crosoft. “We’ve been investing quite ŽŶƚŚĞƉƌŽĐĞƐƐ ǀŝĂƚƌĞŶĚŐƌĂƉŚŽŶ
heavily in a platform for Industrie ƚŚĞĚŝƐƉůĂLJ
4.0, Made in China 2020 and the
‫ٹ‬ZĞĚƵĐĞdŽƚĂůŽƐƚŽĨKǁŶĞƌƐŚŝƉ
IIoT,” says Erich Barnstedt, soft-
嵣ŽŶĚŝƚŝŽŶͲďĂƐĞĚŵĂŝŶƚĞŶĂŶĐĞ
ware engineering lead, Microsoft. ƌĞĚƵĐĞƐƵŶŶĞĐĞƐƐĂƌLJĚŽǁŶƚŝŵĞ
“My team owns the industrial verti- ĂŶĚĐŽƐƚ
cal for Azure IoT, and OPC UA is
the only open industrial protocol we
support to bring data to the cloud
and all its services. All the back-end
services understand OPC UA. And
OPC UA is open-source, which is a
big change. Supporting open-source
zK<K't>dZ/KZWKZd/KE
is a winning strategy.
'ůŽďĂů,ĞĂĚƋƵĂƌƚĞƌƐ
“Everything is gravitating to ϵͲϯϮ͕EĂŬĂĐŚŽ ϮͲĐŚŽŵĞ͕DƵƐĂƐŚŝŶŽͲƐŚŝ͕
OPC UA, and we want everyone dŽŬLJŽϭϴϬͲϴϳϱϬ͕:WE ǁǁǁ͘ĂĚŵĂŐƚŝ͘ĐŽŵ
to support it.”
ŽͲŝŶŶŽǀĂƚŝŶŐƚŽŵŽƌƌŽǁŝƐĂƌĞŐŝƐƚĞƌĞĚƚƌĂĚĞŵĂƌŬŽĨzŽŬŽŐĂǁĂůĞĐƚƌŝĐŽƌƉŽƌĂƚŝŽŶ͘
 CONTROL PROTOCOL SURVEY

Users Weigh In
This year’s annual protocol survey was completed by 133 members of Control’s primarily North American subscriber list
representing the process industries including Food, Chemicals, Pharmaceuticals, Primary metals, Petroleum, Utilities, etc.

Percent of installed wired devices by protocol Major challenges to device integration

Training and education

HART
FƵƺƴƪƧƹƯƵƴ
Legacy platforms limit protocol integration
2017

2TQƒDWU2#
#PCNQI1PN[
Ethernet/IP Dealing with device drivers and revisions

HART
FƵƺƴƪƧƹƯƵƴ Cost and installation of interface devices
2016

2TQƒDWU2#
#PCNQI1PN[ 0GGFRTQƒEKGPE[KPOWNVKRNGRTQVQEQNU
Ethernet/IP
Access/availability of tools/privileges
HART
FƵƺƴƪƧƹƯƵƴ
2015

2TQƒDWU2# User interface hard or risky to use

#PCNQI1PN[
Available network options do not meet needs
HART
FƵƺƴƪƧƹƯƵƴ
2014

Other 2017
2TQƒDWU2#
2016
#PCNQI1PN[

0% 10% 20% 30% 40% 50% 60% 0% 10% 20% 30% 40% 50% 60% 70% 80%

How connected are your digital protocols?

“Which of these statements describes your HART FOUNDATION
usage. (Please check all that apply.)” 2016 2017 2016 2017

Permanently for real-time process systems 36% 44% 50% 66%

Occasional via handheld 59% 61% 39% 37%

Occasional via PC 41% 34% 33% 23%

Permanently for off-line activity 23% 17% 15% 14%

Permanently for real-time enterprise systems 10% 12% 15% 9%

S-12 Advertising Supplement to CONTROL


FDI scales new heights
)LHOG'HYLFH,QWHJUDWLRQVSHFĻFDWLRQH[SDQGVIRUJUHDWHUFDSDELOLWLHV
THE FIELD DEVICE Integration (FDI) specification
and ecosystem isn’t resting on its laurels.
“FDI packages and hosts help bring field device
information to control and upper-management
systems, so their key is providing bet-
ter interoperability, saving time and
reducing headaches for users,” says
Achim Laubenstein, integration
technology director at the Field-
Comm Group. “However, as FDI
packages and hosts from ABB, Em-
1 functions.
FDI Device Package
per protocol
Before and after
Before FDI, multiple integration products had to be implemented and
maintained by the device manufacturers, supportive documents had
to be searched and collected by the users, and several integration
standards had to be supported by the system vendors. FDI-registered
devices have one single FDI Device Package consisting of all the host
needs to optimize the capabilities of each device.
FIELD DEVICE INTEGRATION
erson, Siemens and others begin to arrive, suppliers
want to use the FDI information model and OPC
UA to connect to other communication protocols,
get data to the enterprise level via Microsoft Azure,
and participate in the Industrial Internet of Things
(IIoT) and Industrie 4.0.”
FDI was conceived to bring previously hard-to-
reach data into uniformly reported and displayed for-
mats, to help improve decisions and increase profits
for process automation companies. It merges the ad-
vantages of an FDT Device Type Manager (DTM)
and Electronic Device Description (EDD) in one,
scalable software device package to help manage the
complete lifecycles of basic and sophisticated com-
ponents, including commissioning, configuration,
diagnostics, calibration, maintenance and other
“The clear benefit of FDI is its simplified
drivers for different host systems,” says Michael
Bückel, product manager at Endress+Hauser’s
Flowtec division. “Where we used to have many
drivers for many different host systems in place,
FDI shrinks it to just one package that’s needed to
get a device up and running or for operations and
maintenance.”
In addition to simplifying the device management
process, FDI will also enable:
• Open access to cloud-based computing services via
jointly developed OPC UA information models,
• Offline configuration,
• A device package repository,
• Security, and,
• Communication servers for automation protocols.
These initiatives will enable FDI (published as the
IEC 62769 standard) to fulfill its mission statement:
ONE device – ONE package – ALL tools.
Advertising Supplement to CONTROL S-13
 FIELD DEVICE INTEGRATION
“The FDI standardization team did an excel-
lent job of writing the FDI specification—fully
supported by the FDI Package IDE [Integrated
Development Environment]—and it’s a huge
difference from the past,” says Neil Shah, global
product manager for fieldbus and asset optimization
in ABB’s Industrial Automation division. “Where
users previously had to tweak device drivers on each
system and modify EDDs to comply with each
supplier’s host, FDI makes EDDs independent of
individual supplier protocols, and allows all instru-
ments to work with any host.”
OPC UA is the key to the IIoT
An FDI Host implementing the Information Model Facet exposes a
standardized OPC UA Information Model containing the complete
device data, accessible via FDI Clients and standard OPC UA Cli-
ents/Servers. As part of the OPC UA infrastructure, the data can
be used by Asset Management Systems or published into IIoT plat-
forms and processors.
S-14 Advertising Supplement to CONTROL
Shah reports there are presently three host systems
that support FDI, including:
• Field Information Manager (FIM) from ABB;
• Instrument Inspector from Emerson Automation
Solutions, and
• Process Device Manager (PDM) from Siemens
“They all have the same purpose of integrating
field devices into systems, and also allow configura-
tion, commissioning, diagnosis and parameterization,”
explained Shah.
Despite its potential advantages, some suppliers
are concerned that FDI means they’ll have to develop
software for it in addition to the EDDs and DTMs
they already write for their field devices, which con-
tinue to be deployed in systems worldwide.
“FDI packages and hosts are at the beginning
of their implementation cycle. They will eventually
replace EDD and DTM,” adds Laubenstein. “We’ve
already held several plugfests where different suppliers
can compare and work hands-on with FDI pack-
ages and hosts, and we’re going to have more. We did
confirm at the plugfests that FDI can achieve much
better interoperability, and so our advice is to try FDI
with OPC UA server because it’s ready for IIoT and
Industrie 4.0.”
OFFLINE CONFIGURATION
One of the most sought-after capabilities in process
control has been uncoupling configuration and other
tasks from the components themselves, which allows
this programming to be done remotely and completed
before equipment is installed on plant floors.
“Offline configuration and user interface plug-ins
(UIP) are so important because they let us create
standardized configuration files, and download them
to many devices, mostly when commissioning new
plants,” says Dan Ryan, engineering program manager
for Plantweb at Emerson and chair of the FieldComm
Group Integration Working Group. “FDI lets us take
device packages and work up configurations without
the spreadsheets and manual processes we used to use.
That’s a big savings in labor and time.”
Ryan explains that UIPs are equally useful because
they enable enhanced interfaces for troubleshooting.
UIPs are an optional part of an FDI device package. For
example, Emerson’s Rosemount Radar Master Plus
UIP provides annotated, interactive graphics, added
graphical tools, and improved interoperability. “The
UIP in FDI allows Radar Master Plus to be used on
any FDI host,” says Ryan. “There’s more work to get
FDI phased in now and it is a longer-term invest-
ment, but everything’s going to be better with it.”
Mani Janardhanan, program management
director for Plantweb and IoT at Emerson, reports
that FDI is beginning to enhance the capabilities
of its products, including development plans for
AMS Device Manager and the AMS Trex device
communicator. “Our customers want a unified
technology to communicate securely with their
field devices from any platform, and FDI is that
solution,” says Janardhanan. “Emerson is already
well down the path on FDI, we introduced our
Instrument Inspector in 2016, and it’s download-
able from our website. These solutions will make
the offline configuration of plants and deployment
better, which can help users and EPCs save man-
years on commissioning.”

INTEGRATING DISPARATE NETWORKS

Today’s plants may contain a mixture of device
technologies, some based on proprietary and open
standards. FDI can access these devices using FDI
Communication Servers. The Communication
Servers integrate to the FDI Server using Commu-
nication Server Packages, allowing FDI to integrate
these different networks within a single informa-
tion model. This enables users to leverage their
installed base of devices when migrating to the
new FDI technology. FDI Communication Serv-
ers even support nested communication, where a
remote device may be tunneled through a different
protocol, supporting complete access to the embed-
ded device data. Just like devices, communication
servers are fully exposed in the FDI Server Infor-
mation model. FDI Servers communicate with
FDI Communication servers using OPC UA.
Cloud connectivity is enabled with the imple-
mentation of OPC UA on the FDI Server that
exposes the FDI Information Model. The FDI
Information model provides a consistent presenta-
 tion of the device (the “digital twin”) for enterprise
applications, cloud based services, etc. The Informa-
tion Model of each device is defined in the device’s
“FDI Device Package” using EDDL technology.
Smitha Rao, co-founder of Utthunga Technolo-
gies, adds that, “FDI enables the secure and remote
communication to the field devices using FDI Com-
YOUR FIELDCOMM INVESTMENT munication Server, which is built based on industry-
Beginner or professional – we’ve got you covered. Trine University
proven OPC UA technology.”
now offers comprehensive, hands-on, certified Foundation™
FieldComm training. DEVICE PACKAGE REPOSITORY
Learn through real-world solutions in a state-of-the-art lab. Because technicians configuring instruments don’t
Trine offers: want to download software to each one individually,
• Tailored training options.
• Innovative tools and methods.
FieldComm Group is building a cloud-focused reposi-
• Vendor-neutral training. tory of all certified, FDI packages and secure EDD
• Working labs with multiple systems. packages. This allows FDI-enabled devices to connect
• Certified professional instructor. automatically, and check if they have any updates.
Contact us today “The plan is to have an online system provide
260.665.4 or
JOOPWBUJPO!USJOFFEV FDI device packages on request, which will give
users quicker access to the latest versions,” says
Endress+Hauser’s Bückel. “Again, that one device
package can be installed in a user’s registered host
system no matter what supplier it comes from, which
makes that system simpler to maintain, and reduces
lifecycle costs.”
Stephen Mitschke, director, Foundation Fieldbus
Technology, FieldComm Group, adds that the FDI
Device Package and Repository initiative is similar
to the way Microsoft Windows downloads updates
Convert Your Mobile Device into a
HART Communicator … with our without requiring its users to go and get any software.
Advanced HART-based Products Though still being built and tested, the repository will
C ONNECT > C ONFIGURE > D OCUMENT be built on Microsoft Azure.
Complete DD-based HART Communicator for any device
- PC, Tablet, Phone. Your choice!
SUCCESSFUL SECURITY
Complete DD-based HART Communicator for any operating system
- Windows, iOS, Android. Your choice! To maintain security even as it establishes more
Full line of registered HART Modems
connections to outside users and systems, Mitschke
- USB, RS232, Bluetooth, Bluetooth Low Energy reports that the FDI specification uses multiple layers.
Your choice!
Improving its security on an ongoing basis is another
Use your own host device or one of our complete systems.
Hazardous area options available.
FieldComm Group initiative.
Significant cost savings • Mobile convenience • Satisfaction guaranteed
“All FDI packages have digital signatures, which
authenticates that software is coming from a trusted
NEW! iOS Version now available!
source, and indicates if it’s been modified,” explains
Mitschke. “The FDI environment can also be imple-
mented as a client on a server architecture, in which
case we can rely on OPC Unified Architecture (UA)
and its certificate-based security. ●

S-16 Advertising Supplement to CONTROL


Predictive and
RTQCEVKXGQPVJG2CEKƒE
6KHOO˸VKXJH3UHOXGH/1*YHVVHOLVWKḨUVWRFHDQJRLQJ3ODQWRIWKH<HDU
Source: Shell
THE LEGENDARY BOY Scout motto is “be prepared,”
but even they would need to play serious catch-up to
equal all the design, setup, configuration, commission-
ing, testing, smart instrumentation and predictive/
proactive maintenance integrated into Royal Dutch
Shell’s Prelude, the world’s largest floating liquid natu-
ral gas (FLNG) production facility. In fact, though
configuration and maintenance don’t normally get
as much glory as operational performance, Prelude’s
testing and evaluation of its processes have been so
extensive that it’s also earned the FieldComm Group’s
Plant of the Year Award for 2016.
Having recently completed its long sail from South
Korea to the Timor Sea off Australia’s northwest coast,
Prelude is presently being stationed 200-km from the
mainland. Once its connections to the local gas wells
are established and final implementation is completed,
it’s scheduled to begin regular operations in 2018. The
488- x 71-m vessel’s 14 production facilities, rising to
about eight stories above the main deck and chock-
full of FieldComm Group networking and technolo-
gies, will extract and process for transport about 3.6
million tonnes per year (Mtpa) of liquefied natural gas
(LNG), 1.3 Mtpa of condensate and 0.4 Mtpa of liq-
uefied propane gas (LPG) during its 25-year lifespan.
FIELDCOMM ON DECK
Beginning with Prelude’s initial designs and continu-
ing through to its construction and upcoming opera-
tions, Shell’s engineers report that FieldComm Group
technologies are essential in enabling the production
PL ANT OF THE YEAR
facilities to perform their advanced diagnostics, intel-
ligent operations and predictive maintenance, and
achieve their lifecycle benefits.
“FieldComm Group technologies are used exten-
sively in every phase of the Shell Prelude FLNG proj-
ect, and form the backbone of the intelligent predic-
tive maintenance system,” says Kyle Dickson, control
and automation engineer for Shell Prelude FLNG.
“The use of device templates is delivering excellent
conformity and quality assurance throughout the com-
missioning process. This has enabled a small team to
achieve impressive loop check rates whilst maintaining
exceptionally high levels of quality assurance. Once
commissioned, equipment and unit modules have used
the extensive diagnostics and alerts provided by both
HART and Foundation Fieldbus technologies to
great effect, specifically avoiding numerous plant trips
and enabling unprecedented levels of remote support
and deep-level diagnostics.”
Rong Gul, senior automation engineer and subject
matter expert (SME) for smart instrumentation and
instrument asset management with Shell Global Solu-
tions, reports that Prelude’s process applications employ:
• More than 8,000 Foundation Fieldbus devices,
including 2,500 valve positioners, located on all
control and monitoring devices, and connected
only to the DCS;
• More than 4,500 HART devices connected to the
DCS and PLCs via HART multiplexers, and used
predominantly on devices connected to safety instru-
mented systems (SIS) and fire and gas (F&G) systems;
Advertising Supplement to CONTROL S-17
 PL ANT OF THE YEAR
• ValveLink and FDT/DTM on all complex instru-
ments like guided wave radar (GWR) and valve
positioners; and
• WirelessHART on certain applications.
“In a nutshell, proactive maintenance was embed-
ded from Day 1 on this project, rather than adding it
as a work process on running facilities,” explains Gul.
“Factory acceptance test (FAT) preparation and test-
ing, training, templating, selection of smart instru-
mentation, rigid work processes, and a management
and maintenance organization firmly supporting the
technology are mandatory to make proactive mainte-
nance succeed.”
TEMPLATES ENABLE “FIX BEFORE FAIL”
One of the most important tools used to prepare
Prelude’s production facilities for consistent, optimal
operations are default, commissioning or application-
S-18 Advertising Supplement to CONTROL
specific parameters that enable diagnostic features,
device options or other functions. For example, pres-
sure, Coriolis or valve positioning devices can have
hundreds of parameters, so parameter settings can be
stored in corporate or onsite template files, depending
on individual device types or how and where they’re
applied. These parameters in templates allow users to:
• Optimize diagnostics;
• Select features and options;
• Ensure error-free downloads to devices;
• Identify application and commissioning parameters;
• Apply consistent work practices at sites to utilize
smart instrument data; and
• Eliminate error messages and unnecessary trouble-
shooting during commissioning.
Consequently, these templates streamline commis-
sioning because they can be used to apply standard
configurations to hundreds of Foundation Fieldbus
devices in a fraction of the time it used to require,
which enables more effective and proactive main-
tenance at far less cost. “Using device templates
ensures uniformity of device configuration, ef-
fectively reducing the number of commissioning
parameters required to be checked by a factor of
20,” says Dickson. “The principle of ‘do it right, do it
once” is guaranteed by correctly using FieldComm
Group technologies. The removal of regret/rework
has resulted in significant cost/schedule savings
throughout the commissioning process.
“In addition, using advanced diagnostics and
rationalized device alerts enables predictive and
targeted maintenance execution. Being in a particu-
larly remote, isolated location, Prelude depends on
having a fully realized, remote-monitoring group
of engineers, conducting surveillance and advis-
ing on device issues. Commonly, it’s been possible
to identify issues, specifically pertaining to control
valves before the fault escalates and results in a plant
upset or outage.
For instance, Prelude will draw 50 million liters of
cold water from the surrounding ocean every hour to
cool the natural gas, and help it bring it down to -162
°C. This is the temperature at which it liquefies into
LNG and shrinks in volume to 1/600 of its gaseous
state, which makes it much easier to transport. Smart
devices performing this and other tasks on Prelude
include control and safety valves; pressure, tempera-
ture and level transmitters for basic process control
system (BPCS) and safety, flowmeters for BPCS and
safety; fire and gas detection; and more.
Gul reports that implementing a proactive
maintenance schedule for Prelude’s applications
and components represents a game changer from
traditional maintenance planning, allowing proactive
maintenance to make informed, condition moni-
toring decisions, rather than relying on traditional
reactive maintenance. “Coupling predictive main-
tenance data from the asset management suite with
the criticality assessment of the field equipment
provides a rationalized report, enabling prioritized
maintenance activities.”
Gul adds the right parameter configuration of
smart instrumentation and a fully functional IAMS

Advertising Supplement to CONTROL S-19

 P L ANT OF THE YEAR

are crucial to enabling Prelude’s proactive maintenance
schedule. Templates for all devices were configured
during its FAT (Factory Acceptance Test) in Singa-
pore, and Shell Global Solutions worked with Emer-
son Automation Solutions to develop required asset
management functions. “As a result, Foundation
Fieldbus devices can be configured and loop tested six
times faster compared to traditional 4-20mA HART
devices,” says Gul, who provides training onsite to
make sure Prelude’s operators have sufficient expertise
in using the appropriate tools to diagnose and deci-
pher alerts and other information.
COMMISSIONING AND LOOP CHECK SAVINGS
At the peak of its recent commissioning efforts, Dick-
son reports that Prelude’s staff was performing more
than 500 loop checks per week, and checking multiple
streams of complex functions. The vessel’s utilities
plant was also running 24/7, which made maintenance
challenging. Thanks to using templates for its param-
eters, Prelude’s staff and contractors achieved:
• Total time savings of 80% for device commis-
sioning and loop checking across all devices that
applied user configuration via templates and test
devices using full-loop check procedure during
FAT—not just commissioning devices in the asset
management system;
• Time savings for the valve positioner loop check
procedure was more than 80% for the full loop test;
• Tested all device types able to be tested in the FAT
in less than three days, compared to previous test
using traditional methods, which took more than
two days to test just three device types; and
• Human error during FAT was identified quickly
with reporting tool allowing for correction on the
spot, whereas previously it was a tedious exercise
to find a mistake with dozens of parameters and
multiple screens.

HART and Modbus to

FOUNDATION and Profibus
Fint is a worldwide provider of fieldbus technology helping manufacturers
of instrumentation devices and system integrators to communicate on
HART, WirelessHART, FOUNDATION Fieldbus and Profibus networks.

EU office: +47 22131910, US office: +1 (512) 794 1011 Fieldbus International AS, Ullern Alle 28, N-0381, Oslo Norway, www.fint.no

S-20 Advertising Supplement to CONTROL

“All benefits as we’ve gained so far are on Foun-
dation Fieldbus only,” adds Gul. “On average, a
trained team can perform a loop check on 20 Foun-
dation Fieldbus devices per day, including a mix of
valve positioners to temperature transmitters, and
maybe three to five HART devices.

REMOTE MONITORING, COLLABORATION

$%%)LHOG,QIRUPDWLRQ
Beyond all the monitoring and control systems
onboard Prelude, Shell is also establishing a Col- 0DQDJHU
laborative Work Environment (CWE) at its local
headquarters in Perth, Australia. The facility will 6WDUWPDQDJLQJ\RXUGHYLFHVLQRQO\
seamlessly meld telepresence; live/historical process PLQXWHVXVLQJWKHƃH[LELOLW\RI)',
data; live-historical diagnostics; document shar- WHFKQRORJ\0HDVXUHPHQWPDGHHDV\
ing; and wireless personal video feeds. It will also
link Shell and its Global Vendor Support Center 7ROHDUQPRUHYLVLWZZZDEEFRPƂHOGLQIR
to support engineering to optimize production and
minimize upsets by using scenario modeling and
test runs of plant modifications.
“Perth CWE is connected using fiber-optic links
to Prelude, which will only be staffed during normal
work-hours,” explains Gul. “Hence, it’s more suited
for reliability and day-to-day work planning, rather
than ad-hoc problem identification and trouble- $FSUJöFE
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Internet of Things (IIoT) because it can:
• Improve safety by helping Prelude’s predictive
maintenance program and advanced, remote
diagnostics capabilities reduce field time for
personnel.
• Improves reliability by increasing equipment and
plant availability, which is critical for Prelude’s
single-train LNG application; and
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possible by IIoT,” says Dickson. Contact us today!
“However, our goal of fix it before it breaks will
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 YOUR PATHWAY TO THE IIOT SENSE AND UNDERSTAND VIBRATION​
Digital and optimized
for process control, the
HART PCH420V vibra-
tion monitoring sen-
sor provides users with
valuable benefits. Simple
connection to existing
plant infrastructure is a
key reason plants need to
use the PCH420V vibra-
tion sensor. Important
features include HART
7.0-compliant, three con-
figurable bands, remote
field-configurable scale
and frequency range,
hazardous location ap-
proval and multiple con-
nector choices.

FDI - THE BETTER WAY OF FIELD DEVICE Put the HART PCH420V
INTEGRATION to work in your plant and
FDI unifies device drivers, configuration tools, di- address common prob-
agnostics and documentation regardless of operat- lems including lack of un-
ing system with an independent and downloadable derstanding of vibration
software package compatible with any FDI registered in process departments.
host system. Typical users include
instrumentation engineers, system engineers, opera-
FieldComm Group is a global organization with a tions, and process automation specialists. It’s ideal for
mission to develop, manage and promote process oil & gas and chemical processing​industries. Conve-
automation standards. nient to buy online or request a quote. 

FieldComm Group, fieldcommgroup.org Meggitt Sensing Systems, www.wilcoxon.com.

SIL 3-CAPABLE SSX AND SST SAFETY ETHERNET HART MULTIPLEXER

ISOLATORS

Moore Industries’ SSX and SST Safety Isolators and

Splitters provide reliable isolation and pass valuable
HART® data in Safety Instrumented Systems (SIS) and
process control settings. Part of the Moore Industries
FS FUNCTIONAL SAFETY SERIES, these exida-
approved, SIL 3-capable isolators have been de-
signed and built from the ground up to the strict IEC
61508:2010 standards for safety-related applications.
The SSX and SST protect safety systems by isolating
an SIS from basic process control systems so that
disconnections or other failures don’t impact the
safety system. While most isolators “strip off” HART
data, the SSX and SST pass along HART data to asset
management systems, programming devices or host
systems.
Phoenix Contact’s new Ethernet HART multiplexer pro-
vides a simple way to parameterize and monitor up to 40
HART devices on an Ethernet network. The GW PL ETH
series features a modular design and is an up-to-date re-
placement for the widely used RS-485 HART multiplexer
solution. It offers integration via HART-IP, Modbus TCP, or
PROFINET. Additionally, using the included CommDTM,
the multiplexer and connected HART devices can be
integrated into an FDT Frame application.
Designed for applications like partial-stroke testing,
valve diagnostics, and batch-data transfers, the mul-
tiplexer features a HART master on each channel for
the fastest possible updates and execution times.
For more information, visit www.phoenixcontact.
com and enter #1567 in the “Search” bar.

Moore Industries, www.miinet.com/ssxsst Phoenix Contact, www.phoenixcontact.com

 NEW REGISTRATIONS

Recently Registered Technology

These products have been registered since July 30, 2016. View an additional 44 Foundation Fieldbus and 38 HART devices
that have recently received updated certifications by visiting go.fieldcommgroup.org/registration-all.

New Registered Host Systems

Protocol Manufacturer Type Model / Host Name
HART Honeywell Process Solutions Host FDM
New Registered Devices
Protocol Manufacturer Type Model / Device Name
HART ABB Flow Transmitter FCXxxx
HART ABB Automation Products GmbH Mass Flow FCXxxx
HART ABB Ltd Analytical Water Transmitter AWT210
HART Anderson Level Transmitter L3
HART Anderson Instrument Co. Inc. Level Transmitter L3
HART AUMA Actuators, Inc Actuator DREHMO i-matic
HART Badger Meter Inc. Flow Transmitter RCTX
HART Balluff Automation Level Transmitter BMD_1H,1L
HART Balluff GmbH Level Transmitter BMD_1H,1L_SIL
HART Beijing Huakong Technology Co Ltd Temperature Transmitter HK-H600T
HART Cameron Flow Transmitter G3-LEFM
HART Cameron Flow Transmitter CamCor
HART Chengdu Action Gas Detector AEC2232bX
HART Chengdu Action Gas Detector GQ-AEC2232bX
HART Crowcon Detection Instruments Ltd. Gas Detector XgardIQ
HART Crowcon Detection Instruments Ltd. Gas Detector Xgard Bright
HART Draeger Safety AG & Co. KGaA Gas Detector PIR 7x00
FOUNDATION Fieldbus Eaton Electric Ltd. MTL IS Megablock F2xx-IS
HART ELMETRO GROUP Mass Flow Flomac
HART Emerson Process Management Pressure Transmitter WPG Wireless Pressure Gauge
HART Emerson Process Management Flow Transmitter 8800D
HART Emerson Process Management Temperature Transmitter 3051S Diag
HART Emerson Process Management UGL Detector Incus Ultrasonic Gas Leak Detector
FOUNDATION Fieldbus Endress+Hauser 4-wire Coriolis Flowmeter Promass 300/500
FOUNDATION Fieldbus Endress+Hauser 4-wire Magnetic Flowmeter Promag 300/500
HART Endress+Hauser Flow Transmitter Promag 400
HART Endress+Hauser Process Solutions Level Transmitter Micropilot FMR6x
HART Endress+Hauser Process Solutions Analytical Liquiline Compact CM82
HART Fisher Controls Level Transmitter DLC3100
HART Fisher Controls Level Transmitter DLC3100
HART Flowline Level Transmitter ECHOPRO LRxx
HART Fluid Components International Flow Transmitter ST50 product family
HART Fluid Components International Flow Transmitter MT100 Series
HART Foxboro by Schneider Electric Level Transmitter 244LD
HART Fuji Electric Co., Ltd. Ultrasonic Flowmeter FST
HART Fuji Electric Co.,Ltd. Flow Transmitter FST
HART Gasensor Technology Pte Ltd Analytical GQ-CE8900
FOUNDATION Fieldbus General Electric Ultrasonic Flowmeter XMT1000
HART General Electric Ultrasonic Flowmeter XMT1000 UFM
HART GODA Instrument Level Transmitter GDRDXY
HART Heinrichs Messtechnik Flow Transmitter UMF3
HART Hoerbiger Automatisierungstechnik Holding GmbH Actuator TriVAX
HART Honeywell Temperature Transmitter STT 700 Smartline Temperature Transmitter
HART Honeywell Temperature Transmitter STT 700 Smartline Temperature Transmitter

Advertising Supplement to CONTROL S-23

 NEW REGISTRATIONS

New Registered Devices

HART Honeywell Process Solutions Level Transmitter SLG700
HART Isoil Industria S.p.A. Flow Transmitter MV110-MV210
HART Isoil-Hemina Flow Transmitter MV110-MV210
HART KOSO Valve Positioner KGP5000
HART KOSO Valve KGP5000
HART Koso Engineering Co. Ltd. Actuator KOSO_5400LA
FOUNDATION Fieldbus Krohne Messtechnik Differential Pressure Transmitter OPTIBAR 7060
HART Krohne Messtechnik GmbH Coriolis Mass Flowmeter MFC400S
HART Krohne Messtechnik GmbH Level Transmitter OPTIWAVE x400/x500
HART LIMACO Level Transmitter ULM
FOUNDATION Fieldbus Magnetrol Non-Contact Radar Level Transmitter Model R86
HART Magnetrol Level Transmitter Model R86 Pulsar® Pulse Burst Radar Level Transmitter
HART Mettler-Toledo AG Analytical M400 2XH Cond Ind
HART Mettler-Toledo AG Analytical M400 4-wire
WirelessHART Microcyber Corporation Wireless Development Tool M1100S DEV-WH-X
HART MTS Systems Corp. Level Transmitter LP-Series
HART MTS Systems Corp. Level Transmitter LP-Series
HART Nivo Controls Pvt. Ltd. Flow Transmitter MFI 860 NivoMag
HART Oval Corporation Flow Transmitter ALTImass2
HART Pentair Valves & Controls Valve Positioner AVID-T
FOUNDATION Fieldbus Pepperl+Fuchs GmbH Multi-Input / Output Device D0-MIO-Ex12.FF
FOUNDATION Fieldbus Phoenix Contact Modbus to Foundation Fieldbus Gateway GW PL FF/MODBUS
FOUNDATION Fieldbus Phoenix Contact Zone 1 Isolated Block Couplers FB-8SP ISO / FB-12SP ISO
HART Power-Genex Ltd. Valve Positioner SS235
HART Private JSC Manometr-Kharkiv Gas Detector Safir
HART RIKEN KEIKI Analytical GD-88
HART rittmeyer instrumentation Analytical MGAH.360.x
HART Rosemount Magnetic Flowmeter 8712EM/8732EM HR7
HART Samson Electropneumatic Positioner TROVIS SAFE 3793
HART Samson AG Temperature Transmitter TROVIS 3793
HART Schneider Electric/Eckardt Valve Positioner SRD998
HART Schneider Electric/Foxboro Temperature Transmitter RTT15
HART Schneider Electric/Foxboro Temperature Transmitter RTT15S
HART Schneider Electric/Foxboro Flow Transmitter CFT51
HART Schneider Electric/Foxboro Pressure Transmitter I/A Pressure S
HART Shanghai Yinuo Mass Flow Mass flowmeter
HART Siemens AG Actuator SIPART PS2
HART Sierra Monitor Corporation Gas Detector IT Series
FOUNDATION Fieldbus Softing AG Linking Device FG-200 HSE/FF Modbus
HART SWAN Analytical Instruments ph/Redox Transmitter AMI pH/Redox
HART Texas Instruments Simulated Sensor DAC8730
FOUNDATION Fieldbus V.Automat & Instruments Pvt. Ltd. Level Transmitter 401E-1
HART Val Controls A/S Intelligent Diagnostic Controller IDC24
FOUNDATION Fieldbus VEGA Grieshaber KG Differential Pressure Transmitter VEGADIF 85
HART WIKA Alexander Wiegand SE & Co. KG Pressure Transmitter LF-/LW-1
HART WISE Sensing Inc. Gas Detector GT(X)-1100
HART WISE Sensing Inc. Analytical GT(X)-1100
FOUNDATION Fieldbus Yokogawa Electric Corporation Temperature Transmitter YTA610
HART Yokogawa Electric Corporation Temperature Transmitter YTA610
HART Young Tech Co. Ltd. Valve Positioner YT-3300
HART Young Tech Co. Ltd. Valve Positioner YT-3400
HART Young Tech Co. Ltd. Level Transmitter SPTM

S-24 Advertising Supplement to CONTROL

 PRODUCT SOLUTIONS

ENDRESS+HAUSER’S NEW TABLET FOR INDUSTRY’S FIRST WIRELESSHART®

UNIVERSAL DEVICE CONFIGURATION
PRESSURE GAUGE
Field Xpert SMT70 is
Reduce pressure measure-
a high-performance,
ment maintenance challenges,
ruggedized, indus-
improve personnel safety and
trial tablet. Equipped
access field data continuously
with touch-optimized
with Emerson’s Wireless Pres-
configuration software
sure Gauge. Proven sensor
and preinstalled device
technology provides over-
driver libraries, it sup-
pressure protection. Informa-
ports many industrial
tion viewed locally via a dial
communication proto-
and LED diagnostic indica-
cols. It offers one-click connectivity, 20 languages,
tors. Pressure readings and
NAMUR NE 107 device diagnostics and Heartbeat
diagnostics are transmitted as
verification. An update service ensures the latest
frequently as once per minute.
functionality and maximum security.
Emerson Automation Solutions
Endress+Hauser
www.Emerson.com/
www.endress.com/SMT70
Rosemount-Wireless-Pressure-Gauge

CONVERT PROTOCOLS WITH EASE NEXT-GENERATION MASS FLOWMETER

WITH FIELDCOMM PROTOCOLS
The next-gen ST100
Series Flowmeter for
air/gas flow measure-
ment and plant com-
munication from Fluid
Components Interna-
tional (FCI) features the
A new, unique series of protocol converters FieldComm protocols
can take you from Modbus RTU or HART to including both
Foundation Fieldbus, Profibus DP, Profibus PA, Foundation Fieldbus and HART. It is the first triple-
HART and WirelessHART. Simple configuration. variable instrument that measures mass flow, temper-
Temperature range: -40 C to + 85 C. Each converter ature and pressure. In addition to flow rate, totalized
handles 4 devices. Minimum investment. Short time flow and temperature, pressure measurement up to
to market. Delivery within 2 weeks. 1,000 psi (70 bar) is available. An on-board data log-
ger stores 21 million readings on a removable card.
Fieldbus International
www.fint.no, +47 22131910 Fluid Components Intl. www.fluidcomponents.com

YOKOGAWA YTA710 TEMPERATURE ENABLE YOUR DEVICE WIRELESS

TRANSMITTER Microcyber’s A1110 adapt-
YTA710 temperature trans- ers connect 4~20 mA,
mitter is highly accurate. HART and Modbus devices
The sensor input can be to WirelessHART, sup-
choice of single or dual in- porting loop, external
puts. This input can accept power and battery. Using
thermocouple, RTD, ohms Microcyber
or DC millivolt inputs and WirelessHART technol-
converts it to 4-20 mA DC ogy to transmit additional
with HART 7 or Founda- HART information such as
tion Fieldbus signal for process and diagnostics
transmission. HART type is data to host system is reli-
certified as complying with SIL 2 for safety require- able, secure, flexible and
ments. smart.

Yokogawa Electric Corporation Microcyber Corp.

www.yokogawa.com/solutions/products-platforms/ www.microcyber.cn/
field-instruments/ industrialwireles1/

Advertising Supplement to CONTROL S-25

Calendar
For up-to-date information, see “Events” on
www.fieldcommgroup.org
Rockwell Automation
Process Solutions
User Group
Houston, TX, USA
November 13-14,
2017
ARC Industry
Forum
Orlando, FL, USA
February 12-15, 2018
HART Fundamentals
Bangalore, India
February 12-13, 2018
Device Integration
(EDD and FDI)
Bangalore, India
February 14-16, 2018
FieldComm Group
Working Group
Meeting
Bangalore, India
February 19-23, 2018
S-26 Advertising Supplement to CONTROL
FIELDCOMM GROUP
CURRENT COURSE OFFERINGS
Introduction to HART Protocol
Available Q1 2018, this self-paced, e-learning
workshop covers the basics of HART communica-
HART Fundamentals
tion protocol, as well as an overview of the HART
Germany
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April 9-10, 2018
Device Integration HART Fundamentals and QA Testing Workshop
(EDD and FDI) This workshop is an intensive two-day course
Germany covering all aspects of HART communication
April 11-13, 2018 protocol. You will gain the information needed
HART Fundamentals to develop new HART-enabled products, support
Austin, TX, USA existing products and design systems that utilize
April 23-24, 2018 HART technology.
Device Integration
(EDD and FDI) Device Integration - Writing EDD and FDI
Austin, TX, USA Package Workshop
An intensive three-day course where develop-
April 25-27, 2018
ers learn the step-by-step process for building
Advanced principles of
a Device Description for a HART- or FOUNDATION
FƵƺƴƪƧƹƯƵƴ Fieldbus
Fieldbus-enabled device based on Electronic
Germany
Device Description Language (IEC 61804-3, EDDL)
May 15-17, 2018
for use across all DD-enabled host platforms.
Advanced principles of
FƵƺƴƪƧƹƯƵƴ Fieldbus Introduction to FOUNDATION Fieldbus
Austin, TX, USA Available Q1 2018, this self-paced, e-learning
June 5-7, 2018 course for developers, end users, marketing pro-
fessionals and applications engineers assumes
little or no prior knowledge of FOUNDATION Field-
bus, but students should be familiar with process
control. Students will learn the basic concepts and
terminology related to the FOUNDATION Fieldbus
integrated architecture and gain a working knowl-
edge of the technical foundation upon which the
technology is built.
Advanced Principles of FOUNDATION Fieldbus
This workshop is an intensive three-day course
covering all aspects of the FOUNDATION Fieldbus
protocol. Students will learn the skills required
to develop new FOUNDATION Fieldbus products,
support existing products and design systems
utilizing FOUNDATION Fieldbus technology.
9LEUDWLRQPRQLWRULQJ
+$57HQDEOHGÀHOGFRQÀJXUDEOHYLEUDWLRQVHQVRU

Digital & optimized for

process control

Three user
FRQÀJXUDEOHEDQGV

Integrates with
exisiting controllers

1-800-WILCOXON www.wilcoxon.com
info@wilcoxon.com EX\ZLOFR[RQFRP
 Your Pathway to the IIoT

FDI - THE BETTER WAY OF FIELD DEVICE INTEGRATION

(&+WPKƒGUFGXKEGFTKXGTUEQPƒIWTCVKQPVQQNUFKCIPQUVKEUCPFFQEWOGPVCVKQP
regardless of operating system with an independent and downloadable software
package compatible with any FDI registered host system.

INDUSTRY WIDE SUPPORT AND INTEGRATION

Endorsed by leading end user groups like NAMUR and supported by all major
automation system technologies including FOUNDATION Fieldbus, HART,
PROFIBUS and OPC, FDI is making it easier for automation suppliers to
develop and integrate intelligent devices.

FUTURE-PROOF INSTRUMENTATION INTEGRATION

Jointly developed over 5 years by the world's largest Distributed Control
Systems suppliers – ABB, Endress+Hauser, Emerson, Honeywell, Invensys,
5KGOGPUCPF;QMQICYCŤ(&+KUTGXQNWVKQPK\KPIƒGNFFGXKEGKPVGITCVKQP
technology and best practices.

FieldComm Group is a global organization

with a mission to develop, manage and
promote process automation standards
Learn more at ƒGNFEQOOITQWRQTI

Running on fumes
Sometimes a level instrument is only as smart as the guy doing the calibration.
THE first time I ran out of gas was in my 1953
Studebaker coupe. When I was 13 years old,
my father bought me the car for $50. Having
sat abandoned for years, it had bad and missing
paint, no transmission, and an interior ravaged by
vermin, but it was a ’53 Loewy coupe, and it was
mine. He put it in our suburban backyard, and I
went to work. By the time I got my driver’s license,
it was completely apart, cleaned and painted, and
back together. It took first place, modified division,
at the seventh annual Studebaker Drivers Club
national meet.
That car and I were very close, and with all I
had done for it, I took it personally when it refused
to run just because I was in a hurry and couldn’t
get gas just then. It was a life lesson, so I was
less surprised the only other time it let me down,
which was during a high-speed pass of multiple
cars on a two-lane highway in Arkansas.
An oncoming car was getting too close, so I
went to pull in behind one of my slow-moving pas-
sees and discovered that even those big finned
drums I had retrofitted from a 1964 Gran Turismo
Hawk almost couldn’t haul us down from 90 mph
in time to prevent a rear-ending. As I write this, I
can smell the burning linings.
Nowadays, despite widespread digitalization,
to my knowledge, all cars with gas tanks still have
float-actuated rheostatic level sensors, and the
dashboard indicators are essentially voltmeters.
New ones have low-fuel warning lights and some
can even count down the miles to empty. The one
in my wife's car is highly accurate—the other day,
with an indicated 8 miles left to empty, I put 17.9
gallons in the “18.5 gallon” tank. I call that close
enough.
Many people I know won’t let their cars go
below half a tank, but I want to stop for gas as sel-
dom as possible, preferably at my favorite station
near my home. So, I often push my luck and learn
exactly how far down the gauge I can go. As a
consequence, I’ve run out of gas every few years,
all my life. That's one reason I carry a AAA card,
and I know how to use it.
www.controlglobal.com NOVEMBER 2017 • 39
EDITOR’S PAGE
The latest time was just last week, and it also
involved a Studebaker—this time, a 1963 Avanti.
I recently had the sensor out of the car, and had
calibrated it carefully, making sure the gauge read
full with the float arm raised to the top, and empty
with it just above the floor of the gas tank.
But I stupidly did it with the engine off, at per-
haps 12.2 battery volts. With the engine running,
the charging system regulates at 14.2 volts, so it
reads about 1/8 high. I knew this, but I thought,
surely, reading 3/16 of its 20-gallon tank, it would
get me to the next service area.
However, with only a few miles to go, the car
lost power and we coasted across three lanes of PAUL STUDEBAKER
traffic to the right shoulder. Perfectly safe, remem- Editor in Chief
ber, I have a lot of practice at this. pstudebaker@putman.net
I noted the mile marker, pulled out my smart
phone and called AAA, but for some reason, with
the highway number, direction and mile marker,
With a few miles to go,
they couldn’t figure out where I was. After a
the car lost power and
few minutes of back-and-forth and questions I
we coasted across three
couldn’t answer (Visible landmarks? None, it’s
lanes of traffic to the
dark. Municipality? Don’t know. Last highway I
right shoulder. Perfectly
crossed? I don't recall), I told them I could see
safe, remember, I have
an exit up ahead but couldn’t quite make out the
a lot of practice at this.
sign, so I would just walk up the shoulder a ways
and read it. By the time I did that and walked
back, a tollway rescue truck had pulled up behind
my car, so I told AAA to forget it.
The rescue worker put two gallons in the tank,
gave me a form to send back with $10 in a post-
paid envelope, and waited while I cranked the
engine for too long to refill the float bowls with its
mechanical pump. Eventually, the beast fired up,
and I was on my way. Total lost time was less than
45 minutes.
When I told this story to my millennial son, he
asked, “Why didn’t you look up your location with
the phone GPS?” It had never occurred to me
because all those times in the past, I didn’t have a
smart phone. Hey, I know what I’m doing.
 CONTROL ONLINE
NEWS & BLOGS
Common mistakes not
commonly understood
Often due to work overload and time
crunch, some mistakes are repeated
over and over, even though engineers
are attentive and experienced, and
have the best intentions. Here’s Greg
McMillan’s take.
www.controlglobal.com/blogs/con-
troltalkblog/common-mistakes-
not-commonly-understood-part-1
Expro unveils an industry first
The international oilfield services
company has accomplished the first
proven wireless transmission of res-
ervoir pressure data to surface from a
recently abandoned subsea appraisal
well that incorporated a rock-to-rock
cement plug.
www.controlglobal.com/industry
news/2017/expro-unveils-first-proven-
electromagnetic-transmission-of-
reservoir-pressure-data-to-surface-
across-an-open-hole-well-section-
without-casing
Pentair unveils new electrical
company
Beth Wozniak will lead nVent as CEO
and Stacy McMahan will take on the
role of CFO. Pentair’s separation into
two independent companies is sched-
uled to be completed by Q2 of 2018.
www.controlglobal.com/
2017 State of Technology:
Oil & Gas Applications
SPECIAL REPORT
In our latest State of Technology report, panelists from Cono-
coPhillips, Chevron and Rice University chart past and present
forces enabling their industry’s future, and propose a range of 2017 STATE OF TECHNOLOGY:
possibilities for improving productivity and cutting costs in new OIL & GAS APPLICATIONS
and existing plants. Among the other topics explored in this ebook
are “ExxonMobil makes strides to simplify, standardize its designs
and solutions,” “A digital foundation for the chemical, oil and gas in-
dustry,” “UOP pioneering ‘optimization-as-a-service’,” and “Human
factors engineering delivers ROI.” It’s available as a free download.
https://info.controlglobal.com/sot-2017-oilgas
Webinar – IIoT: Fundamentals for open and secure design and deployment
IIoT is the convergence of sensing, actuation, networks and computation, en-
abled by the evolution of many different technologies. The resulting flat auto- 2017
mation architectures, also defined by terms like Edge Networks and Industrie
4.0, are filled with opportunity and risk, including improved performance,
reliability and lifecycle costs, weighed against complexity, cybersecurity and
ROI. Join Albert Rooyakkers, CEO of Bedrock Automation on Dec. 13, when
he shares the innovative designs, technologies and standards that ensure WEBINAR SERIES
open and secure automation extends to the IIoT.
https://info.controlglobal.com/the-industrial-internet-of-things-iiot-fundamentals-for-open-and-secure-design-
and-deployment
Whitepaper – Frequency and antenna selection effects on accuracy of free-space radar
In addition to the importance of frequency, antenna design, smart algorithms and Frequency and Antenna Selection Effects on
Accuracy of Free Space Radar
location play a big role in successfully measuring levels in tanks or silos. The more Accuracy of free space radar depends on frequency, beam angle, antenna
configuration and installation.
By: Bill Sholette, Level Product Manager, Northeast, and Gene Henry, Level Product
difficult the application and higher the accuracy requirement, the more critical it is
Business Manager, Endress+Hauser, Inc.
Free-space radar transmitters for level measurement
typically use 6, 26 and 80 GHz frequencies. Recently,
there has been a lot of hype concerning high frequency
radar transmitters, where some manufacturers claim: the
to have optimal frequency and antenna design. This whitepaper explores the im-
higher the frequency the better the performance. This is
not necessarily true. Instead, accuracy is dependent upon
a combination of frequency, beam angle, antenna
FRQÀJXUDWLRQDQGLQVWDOODWLRQEXWPRVWLPSRUWDQWO\WKH
dielectric constant of the product itself.
Free Space Radars
There are two major operating principles for free space
portance of reviewing application details and working with experienced profession- radar transmitters: Time of Flight (TOF) and Frequency
Modulated Continuous Wave (FMCW). Both have “time”
as the base for a distance measurement…. But calculate
´WLPHµLQDGL̟HUHQWZD\
Figure 2: Frequency modulated continuous wave radar measures level
based on the difference in frequency sent vs frequency being received.
TOF radar uses a microwave pulse launched from the
transmitter. When the microwave energy reaches the
material being measured, there is a change of impedance
als to determine the best result for your requirement.
due to the dielectric constant (gas phase to liquid or solid

industrynews/2017/pentair-unveils-
new-electrical-company-nvent
E-NEWSLETTERS
ControlGlobal E-News
Multimedia Alerts
White Paper Alerts
Go to www.controlglobal.com and
follow instructions to register for our
free weekly e-newsletters.
40 • NOVEMBER 2017
VXUIDFHWKDWFDXVHVWKHHQHUJ\WREHUHÁHFWHG7KH
DPRXQWRIHQHUJ\UHÁHFWHGLVGHSHQGHQWRQWKHGLHOHFWULF
of the material being measured. High dielectric materials,
VXFKDVZDWHUUHÁHFWDOORUPRVWRIWKHHQHUJ\HPLWWHG
/RZGLHOHFWULFPDWHULDOVVXFKDVK\GURFDUERQVUHÁHFW
smaller amounts of energy.
The radar times how long it takes for the microwave
https://info.controlglobal.com/white-paper-2017-frequency-antenna-selection- Figure 1: Time-of-flight radar calculates level based on the time it takes
for a microwave pulse to travel to and return from the surface of the
material being measured.
pulse, moving at the speed of light, to reach the surface
and return. This time divided by two provides the distance
to the surface being measured. The transmitter then
subtracts the distance from the span of measurement
resulting in the level of product inside a tank or silo.
accuracy-free-space-radar
Infrared thermography part of effective preventive maintenance
Learn how the maintenance manager at a saw mill found that adding thermog-
raphy to its maintenance program not only improved reliability and efficiency, Infrared thermography:
part of an effective preventive
maintenance strategy
at Weyerhaeuser Application Note
but also saved more than the price of the camera in a single timely repair. If you can use a digital camera,
you can learn to operate a Fluke
thermal imager. While the images
from your thermal imager may
not make it into the family photo
album, they could very well save
While the images from your thermal imager may not make it into the fam-
your business thousands of dollars
when integrated into your overall
preventive maintenance strategy.
Just ask Dave Feniak at the
Drayton Valley, Alberta, location
of Weyerhaeuser Co., one of the
world’s largest integrated forest
products companies.
ily photo album, they could very well save your business thousands of dollars Preventive maintenance applications for Fluke thermal imaging are plentiful in an industrial
environment such as this Weyerhaeuser location in Drayton Valley, Alberta.
Feniak, the sawmill’s electrical noticed a very hot spot in the far (194 °F),” he says. “We did amp
maintenance supervisor pur- distance,” Feniak recounts. checks and found a severe
when integrated into your overall preventive maintenance strategy. Read more chased the imager and, after
some basic training on its use,
went into the plant and found a
problem. A big problem.
“We have been doing IR (infra-
red) scans routinely on a six- to
The Fluke thermal imager
Feniak used has a built in laser
pointer, and once Feniak turned
it on he found that heat was
being generated about 150 feet
away from the sawmill trim-saw
imbalance between phases. This
was on a Thursday, so we got
our spare motor out and installed
it the next morning on the
maintenance shift, with no
downtime. If the motor had failed
nine-month basis since 1992 motor.
or so, and we usually find very “Taking the camera right
few problems. I was looking at over to the motor we saw the
in this case study. bearings in the planer mill and motor windings were at 90 °C
If you are interested in starting
up a similar program visit
www.fluke.com
https://info.controlglobal.com/infrared-thermography-preventive-maintenance-
From the Fluke Digital Library @ www.fluke.com/library
weyerhaeuser
www.controlglobal.com
—
ABB Ability™ Smart Sensor
motors that let you know when
it’s time for a service.
ABB’s new condition monitoring solution revolutionizes maintenance for low voltage
motors. ABB Ability™ Smart Sensor monitors key parameters and sends the data
to a secure server for analysis. Users can access detailed status reports from their
smartphone or PC. The solution enables proper maintenance planning for longer
motor lifetimes, lower energy consumption and big reductions in downtime.
www.abb.com/motors&generators
FEEDBACK
Top 50 correction
Each year I enjoy your "Top 50" (Octo-
ber ’17, p. 38, www.controlglobal.com/
articles/2017/patience-has-rewards-top-
50-automation-companies-of-2016). But,
I noticed that ifm had a significant jump in
the global rankings, and checked into their
background. The Top 50 survey indicates
revenue of $1,827.1 million, yet the ifm
website indicates total 2016 revenues of
around €775 million or $860 million (and
some revenue may not qualify under the
survey guidelines). Your thoughts?
TOM KNAUER
knauert89@yahoo.com
[ARC’s Allen Avery replies: $860 million is
correct, which would put them well down
the list from where they are now, around
27 or 28.]
Users must demand open systems
Today, ExxonMobil has 100 or more con-
trol systems installed and working since
the 1980s. They are obsolete and repair
parts can't be ordered from the original
manufacturer, but are available from third-
party suppliers. New software is out of the
question, but they can keep them running
for a few more years. It's easy to replace
these systems with a new system from the
same vendor, but they have declared that
they will not do this again. They do not
want to have their vendor dictate the con-
trol system renewal path. This is their drive
to Open Systems for Process Automation
that's now a project of the Open Group’s
Open Process Automation Forum (OPAF.)
Every end-user company should have
the same expectations of its suppliers to
build open systems for process automa-
tion. However, many user companies view
endorsement of the products of one sup-
plier as adequate to meet their needs, and
it does—for now. What will they feel like in
20-30 years when all of those systems are
obsolete and perhaps their chosen vendor
is no longer in business?
Vendors are in control of the process auto-
mation business, and prepare their product
lines to prevent open competition. ExxonMo-
bil is leading the way to open systems, but
42 • NOVEMBER 2017
1501 E. Woodfield Road, Suite 400N
Schaumburg, Illinois 60173
In Memory of Julie Cappelletti-Lange,
Vice President 1984-2012
EDITORIAL TEAM
Editor in Chief
GREG SHINSKEY TRIBUTE
Paul Studebaker, pstudebaker@putman.net
IIOT AND ASSET MANAGEMENT
EXPERTISE INSIDE FLOW INSTRUMENTS
RATE-PREDICTIVE CONTROL Executive Editor
Jim Montague, jmontague@putman.net
Digital Managing Editor
Kyle Shamorian, kshamorian@putman.net
has
Contributing Editor
John Rezabek
The Top 50 process automation
suppliers are making slow,
consistent gains Columnists
Béla Lipták, Greg McMillan, Ian Verhappen,
Stan Weiner
Editorial Assistant
Lori Goldberg
DESIGN & PRODUCTION TEAM
VP, Creative & Production
Steve Herner, sherner@putman.net
Art Director
vendors are packing the OPAF effort to slow Jennifer Dakas, jdakas@putman.net
down the work or at least to help keep their Senior Production Manager
Anetta Gauthier, agauthier@putman.net
ability to build closed/proprietary systems.
How do I know? They have been doing this PUBLISHING TEAM
successfully since 2001 when Foundation Group Publisher/VP Content
Keith Larson, klarson@putman.net
Fieldbus HSE became an international stan-
dard and the (then) Fieldbus Foundation pre- Midwest/Southeast Regional Sales Manager
Greg Zamin, gzamin@putman.net
pared its Host Interoperability Support Test 704/256-5433, Fax: 704/256-5434
Specification. The architecture of Foundation Northeast/Mid-Atlantic Regional Sales Manager
Fieldbus offers a completely open process Dave Fisher, dfisher@putman.net
508/543-5172, Fax 508/543-3061
automation system, but most process con-
West Coast/Mountain Regional Sales Manager
trol DCS suppliers do not support HSE, and Jeff Mylin, jmylin@putman.net
847/516-5879, Fax: 630/625-1124
prefer to use their own proprietary version of
Ethernet. In other words, an open process Classifieds Manager
Lori Goldberg, lgoldberg@putman.net
automation architecture has existed since
Subscriptions/Circulation:
2001, except for support by vendors. Jerry Clark, Jack Jones, 888/644-1803
Today we know that Foundation Field-
EXECUTIVE TEAM
bus HSE is an adequate basis for the Open
President & CEO
Process Automation architecture, but work John M. Cappelletti
needs to be done to bring all of Foundation
VP, Circulation
Fieldbus up to 21st-century standards by Jerry Clark
adding security, wireless, HART integra- VP, CFO
tion, IEC 61131-3 programming and many Rick Kasper
other items. However, we can't count on Foster Reprints
Corporate Account Executive
DCS/control system suppliers to actually Jill Kaletha, jillk@fosterprinting.com
219-878-6094
build interoperable systems, even if this
work is completed by the OPAF. Not until Finalist Jesse H. Neal Award, 2013 and 2016
end users actually demand these open in- Jesse H. Neal Award Winner
teroperable systems, and refuse to accept Eleven ASBPE Editorial Excellence Awards
Twenty-five ASBPE Excellence in Graphics Awards
proprietary control systems. Not only are
ASBPE Magazine of the Year Finalist, 2009 and 2016
end user companies part of the problem, Four Ozzie awards for graphics excellence
by not participating in the OPAF they're not
part of the solution either.
RICHARD H. CARO, CEO, CMC ASSOCIATES
Rcaro@CMC.us
 break through
the

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 LESSONS LEARNED
Can we resolve the climate debate?
Part 1: Is global warming significant? Is it caused by CO2?
RESOLVE is probably too strong a word, but
we can certainly analyze the climate change
process the same way process control profes-
sionals evaluate any process before attempt-
ing to control it, because we know that in order
to control a process, one must understand it!
So the goal of this article is to prove whether
climate change is a "Chinese hoax" or is in fact
occurring; has parameters like gain, inertia,
time constants, capacity and dynamics that
can be determined; and determine the size and
the speed of change of this variable, both if it's
is left uncontrolled and when it is controlled.
BÉLA LIPTÁK This knowledge is important because it tells us
liptakbela@aol.com how much total change is needed and the time
frame in it must be achieved.
Is present global warming significant?
Most scientists believe For the past million years, the incoming and
that if this process is outgoing energies of our planet were in balance,
allowed to remain and as a consequence, the average tempera-
uncontrolled and the ture of the earth's surface stayed at 15 °C. At
temperature rise reaches the same time, the surface temperature of the
4.4 °C (8.0 °F), Earth moon, which receives the same amount of solar
could no longer support energy (340 W/m2) as we do, stayed at -18 °C.
a large human The earth was 33 °C warmer than the moon
population. because it has an atmosphere, while the moon
does not.
For the past million years, the earth's atmo-
sphere contained a fairly constant amount of
"naturally present" greenhouse gases, which
acted like a mirror, reflecting more than half
of the infrared energy that the earth radiated
to the cold space that surrounds it, while the
moon radiated all the energy it received back
into space.
Our global energy imbalance started at the
beginning of the Industrial Revolution in 1880,
when global record-keeping began and when
the greenhouse gas concentration of our at-
mosphere started to increase. At that time, the
rate of temperature rise was less than 0.01 °C
per decade. By today, this rate has increased
to about 0.12 °C per decade, and the average
44 • NOVEMBER 2017
global temperature has reached 16.1 °C. This
is 1.1°C (2.0 °F) above the average in 1880,
and for this reason, in April 2016, 195 nations
signed the Paris Agreement, which sets a maxi-
mum allowable limit for this warming to 2 °C
(preferably 1.5 °C). Most scientists believe that
if this process is allowed to remain uncontrolled
and the temperature rise reaches 4.4 °C (8.0
°F), Earth could no longer support a large hu-
man population.
Some might think that the present 1.1 °C
temperature rise is insignificant, but from a
process control perspective it is not, because
considering the immense mass of our planet,
it represents the accumulation of gigantic
amounts of heat. Therefore, this rise from 15
°C to 16.1 °C is a temendous upset to this heat
balance process.
How do we know if CO2 is the cause?
Before reaching any conclusions, a good pro-
cess control engineer will check the reliability of
the measurements. In case of the atmospheric
concentration of CO 2, the data for the past half-
century is highly reliable, as the measurem-
nents were made by instrumental means. The
rest of the data, which goes back to when the
earliest Neanderthals evolved about 200,000
years ago, was obtained by ice core drilling.
This involves drilling down to some 3,000-
4,000 feet, crushing the drilled ice samples un-
der vacuum, and expanding the gas into a pre-
evacuated sampling loop, where it is analyzed
by gas chromatography. As this drilling process
was repeated many times and in many loca-
tions, with little variation in the results, this data
can also be considered reliable.
In my analysis, I am not considering earlier
data, because I do not have enough confidence
in their accuracy. Those measurements, going
back to millions of years, are usually based on
detecting the composition of gases trapped in
crushed stone samples. While in my conclu-
sions I do not depend on them, I should men-
www.controlglobal.com
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 500

LESSONS460LEARNED
440

400
Current level
500
CO2 level (ppmv)
460 360
In view of the above, I would con-
440
320 For centuries, atmospheric CO2 had never been above this line 1950 level
clude that although many other vari-
400
Current level
ables contribute to global warming,
280
CO2 level (ppmv)

360
the existance of a direct relationship
For
240centuries, atmospheric CO2 had never been above this line 1950 level
320 between global temperature and atmo-
280
200 spheric CO2 concentration is unques-
240 tionable (Figure 1).
160
200 During the past 50 years, both the
400,000 350,000 300,000 250,000 200,000 150,000 100,000
160 rate of rise of50,000 0
CO2 concentration and
400,000 350,000 300,000 250,000 200,000 150,000
Years100,000
before today (0 = 1950)
50,000 0
the rate of temperature rise increased
Years before today (0 = 1950)
drastically faster than in previous cen-
4 4 turies (Figure 2). Based on this data,
2
2 process control professionals would
0
0 conclude that, because of the capacity
-2
∆T, °C

-4 -2 and inertia of this process, the tem-

∆T, °C

-6 perature will continue to rise even after

-4
-8 the CO2 concentration is reduced. In
-10 -6
400,000 350,000 300,000 250,000 200,000 150,000 100,000 50,000 0 addition, the rate of reduction in this
-8 Years before today (0 = 1950) concentration will be slow, because the
-10 residence time of the CO2 in the atmo-
400,000 350,000 300,000 250,000 200,000 150,000 100,000 50,000 0
TEMPERATURE AND CO2 IN LOCKSTEP Years before today (0 = 1950) sphere exceeds a decade or more.
Figure 1: During the past 400,000 years, CO2 concentration in the atmosphere (top) never On the other hand we would also
exceeded
390 295 ppmv, while today it is at 407 ppmv. The temperature
58.1
of the Earth's surface conclude that if a global temperature
CO2 in ice cores
(below),
380 followed the changes in CO2 concentration with a delay.
57.9
rise of, say, 2 °C is reached, this will
Global average temperature, °F

370 Direct CO2 measurements

57.7
also increase the amount of heat radi-
360
CO2 level (ppmv)

350 57.5
ated back into space by an immense
340
57.3
amount (0.5 to 0.75 W/m2). Therefore,
330
390 58.1
CO2 in ice cores 57.1 eventually the energy balance would
320 380
57.9 be reestablished, but at an even higher
Global average temperature, °F

310
370 Direct CO2 measurements 56.9
300
56.7 temperature.
290 360 57.7
The various scientific models sug-
CO2 level (ppmv)

56.5
280 350 57.5 gest that if the CO2 concentration is
340
1880 1900 1920 1940 1960 1980 2000
reduced to about 345 ppmv, this can
57.3
330 limit the global temperature rise to
320 57.1
2 °C. This I disagree with! It seems
310 56.9 to me that this conclusion does not
300 sufficiently consider the tremendous
56.7
290 inertia and "dead time" of this pro-
56.5
280 cess, and therefore our target should
be 295 ppmv and not 345 ppmv. The
1880 1900 1920 1940 1960 1980 2000 295 ppmv concentration was not ex-
ceeded during the past million years,
RECENT RAPID RISING and therefore, the energy balance of
Figure 2: Since 1880, the rate of rise of both CO2 concentration and surface temperature the planet will not be reached until we
drastically increased. (National Climatic Data Center) reach it again. I also doubt the accept-
ability of the continued use of fossil
fuels even for only a few decades be-
tion that all these studies agree that mosphere). Therefore, I can say with cause my crude calculations suggest
today's CO2 concentration of 400 ppmv reasonable confidence, that the CO2 that even if we stopped using them to-
(parts per million by volume) has never concentration in our atmosphere has day, it is already inevitable that the sea
been reached (https://en.wikipedia.org/ not exceeded 280-295 ppmv during levels will already rise some 4.5 - 6.0 m
wiki/Carbon_dioxide_in_Earth%27s_at- the past couple of million years. (15-20 feet).

46 • NOVEMBER 2017 www.controlglobal.com

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 ON THE BUS
JOHN REZABEK
Contributing Editor
JRezabek@ashland.com
Koppelman has been
deploying very modest
innovations, using
inexpensive Arduino
chips to connect a few
level instruments to an
Amazon cloud service.
48 • NOVEMBER 2017 www.controlglobal.com
Levels of inference
Smart engineers can get more than level from level instrumentation.
IT was cold for the midwestern United States,
and when the frigid January morning got down to
-15° F, the house operators were discussing which
of two level indications they should believe. The
“continuous” level, an analog (4-20 mA) DP trans-
mitter, was trending high, and high level could
result in liquid carryover to the steam system—a
bad thing for all the steam users on this cold day.
But the other level instrument—an Eye-Hye multi-
point device that used conductivity “spark plugs”
to detect level—indicated that the level was get-
ting perilously low. Since the level control was
based on the 4-20 mA instrument, it was reduc-
ing boiler feed water (BFW) flow. Should they take
the BFW in manual to catch what one instrument
showed to be a low level, or believe the other
measurement? The debate was settled moments
later when the boiler tripped on low level, as two
independent level switches provided the “votes”
to trip the burner management system (BMS).
While our hardy neighbors to the north might
be getting out the sunscreen when the ther-
mometer reads above 0° F (-18° C), tempera-
tures below -10° F put all the winterization and
presumed specifications of equipment to the test.
In midwestern latitudes, waste heat boilers and
their ilk in process plants are rarely indoors, so all
the boiler trim, e.g. gauge glasses, level switches
and transmitters, must have thorough and intact
insulation. Over many years of wear and tear, with
insulation removed and reapplied for shutdowns
and other routine maintenance, it can be far from
certain that all critical equipment and instrumen-
tation will endure the harshest weather. Without
adding more redundancy, is there more informa-
tion available that might have helped operators
determine which level to believe?
I was fortunate to stumble upon an interest-
ing talk by Minneapolis-area craft brewer Michael
Koppelman last month at the Emerson Global Us-
ers Exchange. In his 20-barrel Badger Hill Brew-
ery, Koppelman has been deploying very modest
innovations, using inexpensive (less than $20)
Arduino chips to connect a few level instruments
to an Amazon cloud service. He was delighted to
find how much he could infer about activities at
the brewery from a single trend. Noise in the cold
liquor (brewing water) tank meant the hot liquor
tank was boiling, i.e. too hot and wasting energy.
Changes in a single tank level could also be reli-
able indications of various steps in a batch, such
as mash-in, sparging and so forth. “With access
to this information, my head brewer can better
plan his day, maybe sleep in a bit if he sees he
can’t start a batch until later,” mused Koppelman.
The frugal entrepreneur of small-batch brewing
was cleverly using his limited instrumentation bud-
get for multiple inferred measurements. The same
principle can be applied at the large process plant
that has a more lucrative payout for reliability. For
years, HART and fieldbus instruments have been
available with a statistical process monitoring fea-
ture that can be configured to monitor the noise in
the raw process signal. Changes in the noise can
be used to make inferences about the validity of
the measurement. If the high-side impulse line of
a differential pressure (DP) level transmitter starts
to plug up or freeze, one might be able to see
the signal change from the actively boiling liquid
interface to the more or less flat-line state of the
plugged line. It might take some attention, time
and tuning to make the inference of a suspect
measurement reliable, but the information would
have been invaluable to the puzzled operators on
that cold January morning.
Rather than simply repeat a 4-20 mA signal
from the emergency shutdown system to the DCS,
today one can install SIL-rated signal splitters, like
the Safety Series isolator and splitter from Moore
Industries. The signal passed on to the DCS can
have the full HART capability, so if you’ve config-
ured it for some manner of plugged line detec-
tion, you may be able to inform the operator in
near-real time of a measurement that shouldn’t be
believed. The cost is a little more than an Arduino
chip and space on Amazon’s cloud service, but so
is the payout for a plant that dare not go cold on a
frigid morning.
A perfect view – even
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 WITHOUT WIRES
IAN VERHAPPEN
Senior Project Manager,
Automation, CIMA+
Ian.Verhappen@cima.ca
Extended flanged
diaphragm seals ‘fill’
the nozzle with the
diaphragm itself, thus
preventing plugging
or bridging of the
measurement ports.
50 • NOVEMBER 2017 www.controlglobal.com
Merging old and new in level
Differential pressure makes great strides with simple innovations.
WIRELESS is often a good application for level
measurement because in many cases, the re-
sponse time is somewhat slower, the distances
tend to be quite long between sensors, and there
is little interference from things like pipe racks
and closely packed equipment.
Despite advances in level sensing and com-
munications technology, a significant percentage
of level measurements still rely on plain, old dif-
ferential pressure measurement and the equation
∆P=ρg∆h directly correlating the differential pres-
sure to the associated height of the column of liq-
uid above the lower pressure tap. Many intelligent
transmitters can output level directly by simply
dividing the differential pressure by the density.
We also know that every pressure transmitter
measures differential pressure—in many cases,
one side is open to atmosphere and hence the
psig output. This means that for an open tank
or non-pressurized vessel, there's no need for
the low-pressure leg to be connected to a sec-
ond nozzle in the vapor space. To ensure that it
remains in liquid all the time, the lower nozzle is
located just below the lowest liquid level. Using
a capillary and diaphragm seal system has the
advantage of being isolated, and therefore less
susceptible to contamination by the process. As
a result, a capillary is usually used to connect the
second (top) nozzle with its flush, flanged dia-
phragm seal, while the high-pressure (lower) side
is directly mounted to the vessel/nozzle by another
flush, flanged diaphragm seal.
Care must be taken with capillary seals, not
only in selecting the fill fluid, but also during in-
stallation. Mechanical protection provides support
and protection from kinks or restrictions in the
capillary that will cause errors in measurement
and premature capillary failure.
Intelligent devices, however, can replace the
capillary system to the top transmitter with a
second transmitter, or with an “electronic remote
sensor” and cable. Because it's not possible to
have two transmitters perfectly calibrated, the
two-transmitter option introduces some error.
However, if the level (differential pressure) is large
enough to mask this error and digital communi-
cations are used, then the two-transmitter option
may be less expensive in the long run than a long
capillary. In addition, using two wireless transmit-
ters offers the option of not needing to install a
power conduit.
For applications in solids or where material
builds up in the nozzle, extended flanged dia-
phragm seals ‘fill’ the nozzle with the diaphragm
itself, thus preventing plugging or bridging of the
measurement ports. There are, however, a few
cautionary items to consider. The diaphragms are
designed to have a close tolerance to the pipe's
internal diameter—always be sure the full pipe
diameter is available, so you don't damage the
diaphragm during installation. Another consider-
ation is to keep the diaphragm approximately 0.5
in. behind the surface of the inner vessel wall, as
this will reduce erosive wear on the diaphragm,
while also ensuring any solids buildup on the re-
sulting ledge can't build up to a level where it will
adversely affect measurement.
All of us know that assuming can come back to
bite us—so why assume the density when, by us-
ing a second set of nozzles a fixed distance apart,
the above equation can be solved for density?
Placing these nozzles below the lowest liquid level
will provide a calculated density representing the
actual liquid in the vessel. For example, I normally
place the nozzles 1 m or 3 ft apart with the lower
tap on the same centerline as the level measuring
transmitter(s). This provides enough distance to
get a reasonable measurement, but manufactur-
ers may allow smaller gaps. If space is an issue,
then the top density measurement nozzle may
sometimes be located above the low liquid level,
while the lower nozzle is always below the low-low
liquid level.
Advances such as intelligent devices and digital
communications make it possible to use tradi-
tional measurement technologies in new ways.
Though applied in innovative ways, they continue
to rely on basic principles.
Action Packed

At first glance, the Sigma-7Siec is likely to fool you.

You wouldn’t guess from its trim size that Yaskawa has packed a single-axis motion
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normal servo amps take up. That means less crowding in control cabinets, plus the easy
familiarity of IEC61131-3 programming.

Ready for more capability in less space? Take action by contacting a Yaskawa
representative about Sigma-7Siec.

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IN PROCESS
Iconics conference aims for easy-to-use IIoT
Software, security, augmented reality, wearable systems and other solutions help suppliers, integrators,
partners and users plunge into the IIoT.
SEVERAL hundred visitors focused on
"connected intelligence" at the Iconics Con-
nected Intelligence Customer Summit 2017
on Oct. 30-Nov. 2 in Providence, R.I. They
took in dozens of presentations and exhib-
its, and learned, not just to understand the
Industrial Internet of Things (IIoT), but how
to take the greatest advantage of it for their
applications and organizations.
“Connected intelligence is our theme
at this year’s summit, and it has a dual
meaning for us,” said Russ Agrusa,
president and CEO of Iconics (www.icon-
ics.com), which was recently named the
2017 Microsoft Application Development
Partner of the Year and is a five-time win-
ner of the Microsoft Partner of the Year
award. “First, it refers to our extensive
suite of automation software, and how it
provides out-of-the-box solutions for visu-
alization, mobility, historical data collec-
tion, analytics and IIoT. The second point
is that over the past 30 years, Iconics has
built a community of partners and cus-
tomers who have the opportunity to meet
our software designers and other employ-
ees, and have one-on-one discussions
about IIoT, Industrie 4.0, cloud comput-
LIVING ON THE EDGE
Jotham Kildea, business development manager, Iconics, shows how its IoTWorX software works
with affordable IoT devices to create cloud-ready solutions and serve in edge applications at
the Iconics Connected Intelligence Customer Summit 2017 on Oct. 30-Nov. 2 in Providence, R.I.
52 • NOVEMBER 2017 www.controlglobal.com
ing, artificial intelligence (AI) and the lat-
est advances in automation software."
Attendees explored and tried out mul-
tiple Iconics advances first-hand, including
its new IoTWorX software suite designed
for IIoT and Industrie 4.0 applications. IoT-
WorX combines software technology with
affordable IoT hardware devices to create
cloud-ready solutions for energy, building
automation, manufacturing and industrial
applications. Iconics maintains that data is
the "new currency," and that its long-time
mission of "making the invisible visible" is
further enhanced by IIoT and wearable,
hands-free devices. Iconics provides in-
tegrated support for Microsoft’s HoloLens
holographic computing headset, Real-
Wear's (https://realwear.com) HMT-1 head-
mounted Android computer and other new
virtual-reality (VR) devices.
"We want to make the IIoT and its de-
vices more natural to use—and hands-
free, too," explained Agrusa. "Connected
intelligence means linking to the real
world, and then historizing, analyzing and
mobilizing data."
Other demonstrations and releases
during the conference included:
IIOT BEACON
"We want to make using the IIoT and its devices
more natural to use—and hands-free, too," said
Russ Agrusa, president and CEO of Iconics.
• Genesis64, Version 10.95, HMI/
SCADA and building automation
software suite that includes what's
reported to be the world’s first 3D,
holographic machine interface
(HMI), which can be used with the
HoloLens self-contained holographic
computing device. This combination
of Iconics software with Microsoft
hardware allows users to visualize
real-time data and analytics KPIs in
both 2D and 3D holograms.
• Smart Energy AnalytiX software-as-a-
service (SaaS) combines Iconics' exper-
tise with energy management software,
FDDWorX fault detection/diagnostics
and KPIWorX self-service dashboarding
tool technologies into a cloud portal-
based subscription solution.
• Hyper Historian data historian with Mi-
crosoft Azure data lake for more data
storage, archiving and retrieval. Iconics
reports that, when real-time “hot” data
is collected at the edge by IoT devices
and other remote collectors, it can be
securely transmitted to “warm” data
historians for mid-term archiving and
replay, and archived to “cold” long-
term data storage systems such as data
lakes, Hadoop or Azure HD Insight.
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IN PROCESS
Bentley brings BIM to Singapore
Journeying to Asia for the first time, Bent-
ley Systems' Year in Infrastructure Con-
ference 2017 was staged Oct. 10-12 in
54 • NOVEMBER 2017 www.controlglobal.com
Singapore. The event was highlighted by
more than 50 Be Inspired Awards final-
ists, who presented their projects using
Bentley's building information manage-
ment (BIM) software to design, simulate
and run applications in six categories.
"There's a lot of desire to invest in
infrastructure, but it's usually limited by
concerns about the variability of the out-
come," said Greg Bentley, CEO of Bentley
Systems (www.bentley.com). "Digitaliza-
tion can reduce that variability and en-
able more projects to go forward. As a
BIG WHEEL IN BIM
"Digitalization can reduce variability and
enable more projects to go forward. That's
why we're committed to going digital," said
Greg Bentley, CEO of Bentley Systems, at its
Year in Infrastructure Conference 2017.
result, we're committed to going digital,
but our advantage is our skill set."
Major releases at the event included:
• Select Connectservices, a Micro-
soft Azure-based service that
provides learning, mobility and
collaboration to Bentley's applica-
tion subscribers.
• Connect Edition application portfolio
for design, analytical, construction
and asset performance modeling of
infrastructure.
• ProjectWise Connect Edition cloud
services, also powered by Azure,
complements and extends Bent-
ley's ProjectWise Design Integration
service.
Advantech EtherCAT Solutions
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 IN PROCESS

Harting opens lab at North Central College

Several dozen visitors "went back to school" to attend Harting's
annual media day on Oct. 25 at North Central College in Na-
perville, Ill. The connector firm's U.S. and European leadership
cut the ribbon to officially open the college's Harting Electronics
Laboratory that the company is supporting to nurture the next
generation of control engineers and technicians.
To assist these data transfer efforts, Harting has traditionally
used a networking strategy of combining multiple circular con-
nectors in one larger rectangular connector. However, to par-
ticipate in the Industrial Internet of Things (IIoT), it's launching
Smart Han connectors that integrate more intelligent electronics,
include Ethernet switches, surge protection, and even an on-
board microprocessor for energy measurement.
"This is a very happy partnership because encouraging engi- LEADERS IN THE LAB
neering is the source of our future, and enables us to reach future Troy Hammond, president of North Central College (left), shows the
potential employees," said Phillip Harting, chairman of the board at new Harting Electronics Lab on Oct. 25 to the firm's leaders, includ-
Harting. "As a global company, we try to respond to the needs of our ing (l. to r.) Jon DeSouza, president and CEO of Harting Americas;
users, and this is about responding by developing the students and Frank Brode, senior VP of new technologies; Uwe Graff, managing
graduates that will be needed in engineering and the sciences." director; and Philip Harting, chairman of the board.

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56 • NOVEMBER 2017 www.controlglobal.com


SIGNALS AND INDICATORS
• Opto 22 (www.opto22.com) announced Oct. 24 a new version of
its groov edge appliance that directly embeds key IIoT technolo-
gies, including MQTT and OPC-UA drivers. Added to the groov View
software for web and mobile visualization, and its open-source
Node-RED development environment, the new release offers engi-
neers, technicians and developers a comprehensive set of tools for
edge deployment in industrial environments. These new embedded
capabilities were made possible by forging close partnerships with
technology providers Inductive Automation (https://inductiveau-
tomation.com) and Cirrus Link Solutions (www.cirrus-link.com)
and are part of Inductive's Ignition Edge Onboard program.
• Advantech (wwwadvantech.com) reported Nov. 6 that it's part-
nered with Mitsubishi Electric, Omron, NEC, IBM Japan and
Oracle Japan to establish the Edgecross Consortium on Nov. 29 to
overcome boundaries between companies and industries to real-
ize collaboration between factory automation and IT. The group
reports that it allows easy realization of factory automation and IT
collaboration through its open Edgecross software platform that's
Globally Certified HMI Systems and Components for Hazardous Areas
 ATEX, IECEx Zone 1/21, Zone 2/22, and NEC Class I & II, Div. 1/2 HMIs
 Workstations and panel components designed specifically for adverse conditions in the oil & gas industry
 Operator workstations and thin clients manufactured to meet the stringent demands of cleanroom and hygienic
applications in the life science industry
www.pepperl-fuchs.com/hmi
www.controlglobal.com
IN PROCESS
based on edge computing. By residing on the edge layer, this plat-
form facilitates connectivity between factory shop floors and value
chains, while enabling the rapid acquisition, analysis, and utiliza-
tion of data essential to smart manufacturing.
• Endress+Hauser (www.endress.com) reported Nov. 8 that it's
expanding its portfolio of products, solutions and services in the
field of process analytical measurement by acquiring Blue Ocean
Nova AG (www.blueoceannova.com/en), a manufacturer of innova-
tive inline spectrometers for monitoring quality-relevant process
parameters. The company will operate under the umbrella of
Endress+Hauser’s center of competence for liquid analysis.
• Emerson (www.emerson.com) and exida (www.exida.com)
released Oct. 31 the DeltaV safety instrumented system (SIS)
configurator, which is an exida exSILentia tool that automatically
generates DeltaV SIS configurations. By pairing built-in DeltaV
functionality with exida’s comprehensive software tools for func-
tional safety, users can develop safety logic configurations much
faster and in fewer steps.
Ensuring process
availability.
Providing flexibility.
Challenging expectations.
VisuNet HMI Systems
NOVEMBER 2017 • 57
RESOURCES
Serious cybersecurity sources
A monthly topical guide to web-hosted papers, tutorials, videos and other educational materials.
ICEWEB CYBER COMPILATION
The now-legendary ICEweb site takes
on cybersecurity, and has compiled a
treasure trove of articles and links at its
"Control System Security" sub-website.
The collection covers SCADA security,
malware, expenses of attacks, Stuxnet,
oil and gas facility security, standards,
videos and links to U.S. government and
many other resources. They're all located
at www.iceweb.com.au/Security/secu-
rity.htm
ICEWEB
www.iceweb.com.au
NIST CYBER BLOG AND DOCS
The official site of the "NIST Cybersecu-
rity Framework" consists of basic docu-
ments and a blog with the latest updates
on what's going on with cybersecurity
from the unique perspective of the Na-
tional Institute of Standards and Technol-
ogy. The site also includes FAQs, news,
events, workshops and even a couple of
short and informative videos. It's at www.
nist.gov/cyberframework
NIST
www.nist.gov
EXIDA VIDEO INTRODUCTION
This 44-minute video, "Introduction to
Process Control Cyber Security," is de-
rived from a webinar by cybersecurity
consultant exida. It reports that it pro-
vides an introduction to control system
cybersecurity and the security lifecycle.
While the course follows the security level
lifecycle from ANSI/ISA-99.01.01 and
ANSI/ISA-99.02.01, it also references
other industry standards and best prac-
tices. It's located at www.youtube.com/
watch?v=ZcQLg9ary1Q e
EXIDA
www.exida.com
If you know of any tools and resources we didn’t include, send them to ControlMagazine@Putman.net with
“Resource” in the subject line, and we’ll add them to the website.
58 • NOVEMBER 2017 www.controlglobal.com
'UNFETTERED' IS 10 YEARS OLD
The great "Unfettered" blog written by
Joe Weiss and hosted by Controlglobal.
com just celebrated its 10th birth-
day a few weeks ago, which means it's
achieved more than a decade of thor-
ough and unrelenting coverage of cyber-
security issues and threats—and what's
too often not being done about them. As
his bio says, "Weiss is an international
authority on cybersecurity, control sys-
tems and system security, and he weighs
in on cybersecurity, science and tech-
nology, security emerging threats and
more." Find it at www.controlglobal.com/
blogs/unfettered
CONTROL
www.controlglobal.com
ICS-CERT SITE DELIVERS
The U.S. Dept. of Homeland Security's
Industrial Control Systems Cyber Emer-
gency Response Team (ICS-CERT) site
has been improving with more timely
threat updates and recommendations for
users about protecting themselves, their
applications and their organizations from
probes, intrusions and cyber attacks. In
fact, notices and alerts are now delivered
right to those who sign up. It's at https://
ics-cert.us-cert.gov
ICS-CERT
https://ics-cert.us-cert.gov
SECURITY FOR NORTH AMERICA
AND EUROPE
The ISA99 standards development com-
mittee brings together industrial cyber-
security experts from across the globe
to develop the ISA-62443 (IEC 62443)
security standards These two 90-min-
ute webinar videos, "Cybersecurity for
Control Systems in Process Automa-
tion—North American Session" and
"Cybersecurity for Control Systems in
Process Automation—European Ses-
sion," are offered by the ISA and Sie-
mens. ISA99 Committee Co-Chair Eric
Cosman and Siemens Plant Security
Services PSSO Robert Thompson pres-
ent the current threat landscape and
key steps you can take to protect your
critical assets in the production environ-
ment. They're at www.youtube.com/
watch?v=V7gVX7pbVjk and at www.you-
tube.com/watch?v=l5mDPtxW-8Y
ISA
www.isa.org
PROTECTION AND PREVENTION
WHITEPAPER
The 17-page whitepaper, "Cybersecurity
for Industrial Automation & Control
Environments," is authored by Schneider
Electic and Frost & Sullivan, and cov-
ers all the basic scenarios and stragies
for minimizing risk, improving postures
and partnering with the right helpers. It's
at www2.schneider-electric.com/docu-
ments/support/white-papers/white-pa-
per-cybersecurity-for-industrial-automa-
tion-control.pdf
FROST & SULLIVAN
https://ww2.frost.com
ISA99 SECURITY MODELS
This 50-minute video, "Industrial Cyber
System Security, the ISA 99 Security
Models," is presented by Dennis Brandl
of BR&L Consulting Inc., who addresses
control system security, and how the ISA
99 Security Models can be a solution.
He originally delivered this presentation
at the 2015 NovaTech Users Conference
in New Orleans, La. It's at www.youtube.
com/watch?v=apD651mYp6A e
NOVATECH
www.novatechweb.com
CYBERSECURITY
Understand the strength
of your last line of defense
by William L. Mostia, Jr., P.E.
CYBERSECURITY is a complex issue, made more complicated by
having four technical domains (IT, enterprise, process control and
safety systems) with different purposes, goals and potential hazards
and risks, and often with different personnel involved. Here are
some of the considerations in performing the security assessment
required in Clause 8.2.4 of the new Second Edition of IEC 61511-
1: 2016 standard for safety instrumented systems (SIS). Some of
the considerations also apply to non-SIS safety systems and to the
broader industrial control and automation systems (ICAS).
The purpose of the SIS is to ensure that we make product
safely. For the most part, it's not involved in how the process is
controlled or how process and production information is nor-
mally collected or manipulated outside of the SIS, only if the
process exceeds safe limits. We have some secondary concerns
that the safety system doesn't affect production through exces-
sive spurious trips or through high maintenance rates.
The broad cyber domains are conceptually illustrated in Fig-
ure 1, where it can be seen that the SIS is essentially embed-
ded in the ICAS system and generally is considered part of it.
It's important to understand the role the SIS plays in the ICAS to
understand how a cyber attack might occur in a SIS, and what
cyber consequences could be physically realized and lead to a
hazardous condition.
60 • NOVEMBER 2017
CYBERSECURITY
Introduction to IEC 61511 First Edition A key difference in today’s security threats and what was in
When the First Edition of IEC 61511-1 came out some 14 years the 61511-1 1st Edition is that we've moved from a small arena Cyber domain
(not to scale)
ago (and ANSI/ISA S84: 1996 before it), cybersecurity concerns (your company) that included mostly internal, physical threats
and threats weren't well recognized in the process industries. to a much larger threat arena (the world) that can include both Government-
The 61511-1 2003 1st Edition standard did recognize potential internal physical threats and external, largely invisible cybersecu- and
state-supported
security threats to SIS. They primarily revolved around inadver- rity threats, potentially from all over the world. Hackers
Cyb
er
tent or unauthorized access and changes affecting the safety
thr
eat
Company
integrity of the SIS. Unauthorized or mismanaged changes have Second Edition security assessment requirements IT/
vec
Public
tor
long been recognized as a safety hazard (e.g. Flixborough, IEC 61511-1 2nd Edition recognized the increasing threat of cyber Enterprise Internal
threats
1974), which led to management of change (MOC) rules. attacks to SIS, and added additional requirements to help reduce Process control
Security concerns at that time (and they're still concerns to- the risk. Compliance with the new IEC 61511-1 Second Edition Terrorists
Process safety
BPCS
& SCAI ICAS
day) were primarily unauthorized physical access (e.g. locked 2016 will require that the SIS have a security assessment (Clause
cabinets, building access control, etc.), programming access 8.2.4) and that its design shall provides the necessary resilience tor SIS
t vec
er t hrea
(e.g. keylocks, programming panels and computers, dongles, against identified security risks (Clause 11.2.12). Clause 8.2.4 Unknown Cyb
etc.), and password controls. Most threats were considered details a general outline of what's to be accomplished in a secu- threats
internal, e.g. inadvertent, unauthorized and/or undocumented rity assessment, but not much on the nitty gritty of performing
changes, problems caused by disgruntled employees, etc. the assessment. The basic methodology is one of reductionism: Unknown unknown area
Recent rapid advances of digital control technology, advances breaking down the SIS domain into smaller equipment pieces;
in computing power and interconnection of the world via the analyzing the equipment’s vulnerabilities; evaluating the existing THE CYBER DOMAINS
Internet, intranets, wireless and now the Internet of Things (IoT) protections that limit exposure of the vulnerabilities to a physical Figure 1: The safety instrumented system (SIS) is embedded in the
and Industrial IoT (IIoT) have opened a Pandora’s box of op- security breach or cyber attack; providing additional protections to industrial control and automation system (ICAS) along with the basic
portunities, but also unleashed the big, bad wolf in the form of reduce the risk to an acceptable level based on the corporate risk process control system (BPCS) system, where it is subject to the same
increasing cybersecurity threats. criteria; and documenting the risk assessment. In addition, when variety of cyber threats.
www.controlglobal.com www.controlglobal.com NOVEMBER 2017 • 61
CYBERSECURITY
BPCS
Cyber threat Vulnerability
access point
Cyber initiating
cause(s) in BPCS Enabling Alarm layer of
conditions protection #1
Non-cyber
initiating cause
Cyber attack
defeats IPL
Access
Cyber threat point Vulnerability
A CYBER THREAT VECTOR
Figure 2: A cyber attack on the basic process control system (BPCS) that looks like a normal equipment failure or human error could defeat the
alarm independent protection layer (IPL). If the attack is also directed at the SIS, defeat of the safety instrument function (SIF) could also defeat
the IPLs for that hazard, leaving protection to the mechanical IPLs.
using a reductionism methodology, care must be taken to not miss
system-level threats.
The overall risk assessment process is similar to a process haz-
ards and risk assessment (H&RA). In some cases, a cyber attack in
the ICAS could initiate a cause similar to an equipment failure or hu-
man error in a process H&RA, where other layers of protection (as-
suming some of those have not been defeated by the cyber attack)
will come into play to bring the process to a safe state. A standard
layer of protection analysis (LOPA) would prevent the physical real-
ization of this cyber threat into a hazard. In this case, the ability of
the SIS to resist defeat of the SIS safety function can be paramount
to achieving a safe state of the plant.
SIS cyber domain
Philosophically, the SIS is best understood in the context of lay-
ers of protection, where the SIS is equivalent to one to three in-
dependent protection layers (IPL) that protect against identified
hazards determined by a process risk analysis. Figure 2 illus-
trates a situation where a cyber attack on the basic process con-
trol system (BPCS) could initiate a cause equivalent to a normal
equipment failure or human error. This same attack could lead to
defeat of the alarm IPL, if it's in the BPCS and the attacker has
sufficient skill in manipulating the BPCS.
If the SIS is designed to protect against that particular initiat-
ing cause, it should serve its purpose as an IPL, and bring the
process to a safe state. However, if the attack is also directed at
the SIS, defeat of the safety instrument function (SIF) protecting
against the BPCS initiating cause could also defeat the IPLs for
that hazard, leaving protection to the mechanical IPLs.
If the initial cyber attack was directed strictly at the SIS and
62 • NOVEMBER 2017 www.controlglobal.com
Generation of
Cyber Physical Cyber initiating
out-of-range
consequence consequence cause(s) in BPCS process condition
SIS cyber
domain
SIS layer of PSV layer of
Hazard
protection #2 protection #3
Cyber attack Cyber attack
defeats SIS IPL defeats IPL
Spurious
trips
Cyber
consequence
not the BPCS, then the SIS safety function could be defeated,
leaving a latent dangerous failure in the SIS. A cyber attack on
the SIS might also initiate a spurious trip (one or many), causing
a safety incident or disrupting production. If software resets are
used in the SIS (versus field resets), then the cyber attack might
also auto-reset the SIF and trip again later, leading to a hazard-
ous condition.
These SIS cyber attacks can be overt, such as in conjunc-
tion with a simultaneous cyber attack on the BPCS, or covert
by defeating the safety function of the SIS and waiting for a
normal safety demand or a later cyber attack on the BPCS. It's
important to realize that the SIS typically isn't the only IPL, which
should be considered in any risk assessment, and that the pri-
mary risk we are concerned with is a physical realization of a
hazard.
It's also important to understand how a SIS can be defeated
in order to provide protection against those events. For example,
some of the ways a SIS/SIF can be defeated are placing the
safety functions in bypass without the operator being aware;
placing the logic solver in an infinite loop; changing the trip and
alarm setpoints; disconnecting the output from the logic, spoof-
ing the inputs; forcing the outputs, etc. This understanding can
lead to SIS designs that, in addition to the zones/conduits protec-
tion scheme, can help to protect against specific failure modes
resulting from a cyber attack.
IEC 61511-1 security assessment steps
To perform a security assessment under the new IEC 61511-1
standard, one of the first things is to establish the outer boundary
of the SIS under assessment. Where the zones/conduits in ISA/
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CYBERSECURITY
IEC 62443:2010 and ISA TR84.00.09
protection concept are used (Figures 3
and 4), the zone boundaries of the SIS are
the boundaries for the security assess-
ment. This is somewhat similar in concept
64 • NOVEMBER 2017
to nodes in a HAZOP. An alternative to the
HAZOP top-down approach, would be
to use a failure mode and effect analysis
(FMEA) bottom-up approach, and look at
how the system could fail to accomplish its
purpose given a security event. Or use a
combination of both methods to cover all
your bases.
The security assessment requires a de-
scription of all the covered devices. These
device descriptions should include a list
of all the hardware and software versions,
including device sub-modules, for change
management.
Security-critical information (e.g. alarm
and trip setpoint, field device parameters,
communication parameters, etc.) in the
devices and system should be identified to
allow detection of unauthorized changes
in the parameters critical to safety. The
description should include all connec-
tions to other devices within the SIS, to
devices outside the SIS boundary, and to
all devices used for non-operational pur-
poses (programming terminals, update
connections, field device communicators,
calibration equipment, asset management
systems (AMS), any connection to the out-
side world whether they're active or not,
etc.). Include hardwired connections that
can be influenced by a cyber attack and
any connections that help provide protec-
tion against cyber attacks (e.g. hardwired,
keyed, bypass-enabled switch).
Known cyber vulnerabilities for each
device should be listed. As part of gen-
erating this list, known cyber vulnerabili-
ties should be discussed with the device
manufacturer, and researched in the
industry. Physical security vulnerabili-
ties for each device and for the system
as a whole should also be listed. There is
commercial software becoming available
to make this inventory effort easier, and
to help automate monitoring of unauthor-
ized changes and potential security is-
sues. An example of this type of software
is Cyber Integrity by PAS (www.pas.com).
Also, develop a description of identified
security threats that could exploit listed
equipment vulnerabilities and result in se-
curity events (including intentional attacks
on the hardware, application programs
and related operating system software, as
well as unintended events resulting from
human error). It's important in this type of
risk assessment to understand the security
www.controlglobal.com
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 CYBERSECURITY

PROTECT PUMPS
$2925..).'s#!6)4!4)/.s"%!2).'&!),52%s/6%2,/!$

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s"EST3ENSITIVITY threat vectors. These include how the threat gets into the system (access
s$IGITAL$ISPLAY
points); how the point is accessed; nature of the attack; any enabling
TWO ADJUSTABLE SET POINTS conditions that facilitate the threat vector; devices or path the threat vec-
s2ELAY/UTPUTS
s!DJUSTABLE$ELAY4IMERS tor takes to propagate through the system to reach a point for a physical
4-20 MILLIAMP ANALOG OUTPUT
realization into a hazardous or undesirable condition; and what is neces-
sary to happen to result in a safety incident.
COMPACT EASY MOUNTING
The methods to prevent the threat vector from reaching the de-
/NLYvXvXv
s3TARTER$OOR s0ANEL vice’s vulnerability and methods to mitigate the cyber attack, or in the
s2ACEWAY s7ALL worst case to recover from the attack, should be listed. It'is also im-
UNIQUE RANGE FINDER SENSOR portant to note how such cyber intrusions/threats could be detected
s7ORKSON7IDE RANGEOF-OTORS
s3IMPLIlES)NSTALLATION in the system, even if the system successfully repelled the attack, be-
cause they may be probes of your system.
Successful cyber attacks that lead to a safety consequence should be
investigated just as an accident would be. Unsuccessful cyber attacks or
intrusions should be treated as a near misses and investigated appropri-
ately to ensure that the system's cyber protection worked properly, and
that the attack's failure was by design rather than good fortune.
A description of the potential consequences of security events and
their likelihood should be determined. Note that IEC 61511-1 doesn't
define what a “security event” is, so the definition of the consequence
is a bit nebulous. A successful cyber attack could be seen as a conse-
#!,,./7&/29/52&2%% quence by cybersecurity personnel. However, to create a safety hazard,
WWW.LOADCONTROLS.COM  $!942)!,888-600-3247 there must be a physical realization of the security event that leads to a
propagation of the effect into an incident.
A successful cyber attack on a device or system is an intermediate
consequence (an initiating cause or the defeat of a safety system) in
a risk chain that may include other IPLs that could protect against the
developing process hazard. This perspective connects many of the ef-
fects of a cyber attack on our process control and safety systems into
our normal process risk assessment methodology (Figure 2).
A determination of the likelihood of the security event is required,
which leads us potentially into the same morass that we have with the
Convert Your Mobile Device into a HAZOP/LOPA initiating cause frequencies and SIS equipment failure
HART Communicator … with our rates. We don't have sufficient information to determine the likelihood
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C ONNECT > C ONFIGURE > D OCUMENT (systematic error) occurring in a particular system; or the failure rates
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Complete DD-based HART Communicator for any operating system tainty in determining the likelihood will be high, leading to conserva-
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Full line of registered HART Modems such a probability calculation. ISA TR84.00.09:2017 Appendix D
- USB, RS232, Bluetooth, Bluetooth Low Energy
Your choice! provides some example calculations.
Various lifecycle phases, such as design, implementation, commis-
Use your own host device or one of our complete systems.
Hazardous area options available. sioning, operation and maintenance, are required to be considered in
Significant cost savings • Mobile convenience • Satisfaction guaranteed the security assessment. Similar to their process safety counterpart,
HAZOP/LOPA, a SIS security assessment should occur during the
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various phases of the safety lifecycle based on an overall risk manage-
ment plan to mitigate potential security risks.
Once the risks have been the determined, the requirements for ad-
ditional risk reduction measures should be identified to reduce the risk
below the corporate risk criteria. A description of how the risk reduction
will be accomplished should be included in the security assessment.

66 • NOVEMBER 2017 www.controlglobal.com

 CYBERSECURITY

Your Global Automation Partner

Conduit
Corporate Enterprise zone Level 4
servers
Internet

Zones
Plant DMZ Level 3
Site network

Domain Data
Workstation Workstation Workstation controller historian
Remote
access Back door
Data Advanced
Control layer historian control
module
Level 2
Process control network
(PCN)

SIS DCS PLC DCS

controller controller
PLC gateway controller Operator
interface
(HMI)
Engineering
workstations BPCS Control room WARNING
Control equipment room Not suitable for repairing
Field instruments
crummy sensors
BPCS (or your reputation).
Level 1 (typical)

SIS ZONE

DEFINE THE BOUNDARIES

Figure 3: A first step in a security assessment under the new IEC 61511-1 standard is to establish Rugged, reliable industrial
the outer boundary of the safety instrumented system (SIS) under assessment. Where the zones/
conduits in ISA/IEC 62443:2010 and ISA TR84.00.09 protection concept are used, the zone bound-
automation products from
aries of the SIS are the boundaries for the security assessment. Turck are built to perform in
the toughest conditions, and
There are several important notes in potentially mitigate the attack or to continue
Clause 8.2.4. Note 1 points to SIS security to function in part or until the system can be our engineered solutions
guidance provided in the technical report safely shut down. are customized to meet
and standards ISA TR84.00.09, ISO/IEC Dividing the ICAS into logical zones also
27001:2001 and IEC 62443:2010. ISO/IEC provides a basis for select SIS security as-
your application challenges.
27001:2001 is a general-purpose IT cyber- sessment boundaries (Figure 3). Note that Cheap knock-offs can’t
security standard, while IEC 62443:2010 the control system and SIS can be broken
compare. Turck works!
is a standard that covers cybersecurity for down into multiple zones for larger systems.
industrial control and automation systems. Clause 8.2.4, Note 2, says information
ISA technical report TR84.00.09 covers and control of boundary conditions needed
cybersecurity and the functional safety for the security risk assessment typically re-
Uprox®3 Inductive
lifecycle. Note that this technical report is sides with the facility owner/operating com-
Proximity Sensors
substantially longer than the IEC 61511-1 pany, not the supplier. Like all risk assess-
Developed to combine compact
standard itself. ments, the burden is on the owner/operator sensor design with the longest
The security guidance provided in ISA/ to perform and implement the results of the switching distance to all metals
IEC 62443:2010 and TR84.00.09 advo- assessment. This doesn't relieve the supplier of all inductive proximity
sensors on
cates dividing the ICAS into logical hardware from an obligation to provide a secure cyber-
the market.
groupings called zones, and the communi- security environment for their equipment,
cation paths or interfaces between zones, nor to promptly notify the owner/operator
called conduits, to control the interaction when a cybersecurity vulnerability has been
between the various zones. This has the identified or cyber breach of their equipment
Now available with IO-Link!
benefit of controlling the paths that a cyber has been detected. The owner/operator has
threat vector can propagate through a sys- the reverse obligation.
tem, and logically isolates the system should Note 3 states that the SIS assessment
it come under attack, allowing the system to can be included in an overall process auto- Call 1-800-544-7769
or visit info.turck.us/sensors
www.controlglobal.com NOVEMBER 2017 • 67
CYBERSECURITY

mation security risk assessment. This is reasonable, but there are
philosophical differences in the purposes of the systems, their vul-
nerabilities and their access points. The control system purpose is
to keep the process within safe operating boundaries while making
quality product efficiently. The SIS purpose is to not allow the pro-
cess to exceed the safe operating limit, with a minimum of spurious
trips and maintenance. There's certainly an overlap that needs to be
addressed in the overall risk plan.
Note 4 is important because it states that the SIS security risk
assessment can range in focus from an individual SIF to all SIFs
in SISs or within a company. A company should have a risk as-
sessment plan that covers SIS cyber threats, and how it fits into
the process safety risk assessment plan. Obviously, an initial SIS
security assessment must be performed to comply with IEC 61511
2nd Edition. However, while not required, performing a security
assessment on existing IEC 61511 1st Edition SISs would be con-
sidered good engineering practice.
Once the initial security assessment has been accomplished and
SIS security has been brought up to date, subsequent assessments
should be done under MOC for new installations, for SIF additions
to existing equipment, and for SIS design or configuration changes.
The assessment should also be revisited when new security vulner-
abilities are identified; after a security audit if deficiencies are found;
or when the security assessment is revalidated (nominally every
three years or less).
SIS security documentation
Additional documentation types will have to be developed to allow
the security assessment team to perform a thorough security as-
sessment, document the current security state of the system, main-
tain the security-critical information database, and perform continu-
ous and periodic audits against unauthorized changes.
Many companies have high-level system architecture drawings
of their control and safety systems that could be adapted into zones
and conduits drawings. It's likely that the higher-level drawing will
have to be broken down into middle- and lower-level drawings, such
as individual zones and equipment drawings, to show all the access
points, equipment and protective measures, and have room for the
necessary information for a security risk assessment (Figure 4).
A further drilldown will typically have to be done for equipment

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68 • NOVEMBER 2017 www.controlglobal.com

 CYBERSECURITY

Your Global Automation Partner

BPCS
Communication
Digital Analog/discrete
Conduits
(typical)

SIS Remote access

Remote access Zone
Safe operating
SIS parameters
Windows controller
Run/off/program database
vulnerabilities remote switch
Original, patch
Original, patch and Engineering and update
update software station software

Removable media
Unauthorized Unknown threat vector
SIS
access field (typical)
Physical
access Unknown
gap

WARNING
Windows vulnerabilities Windows vulnerabilities
Original, patch and Original, patch and update
update software software
Calibration AMS
Remote access Remote access Not suitable for repairing
Unauthorized access Unauthorized access crummy sensors
(or your reputation).
BREAK DOWN THE THREATS
Figure 4: Breaking the high-level control system zone/conduit drawing (Figure 3) into just a SIS
system-level zone drawing illustrates secondary access points such as calibration trip point
databases, asset management system (AMS), Windows, etc. at the SIS system level.
Rugged, reliable industrial
security drawings, which would illustrate an management system (AMS) database, PSV automation products from
individual piece or logical grouping of SIS database, etc. There even has to be con-
Turck are built to perform in
equipment. These are broken down into in- cern for paper information (we generate a lot
dividual modules if modular in design and of uncontrolled paper about the process for the toughest conditions, and
documenting model numbers; hardware our HAZOPs and LOPAs). our engineered solutions
and software serial and version numbers;
are customized to meet
equipment access points; identified protec- Develop expertise
tions; and other information to perform a Most major SIS consultants, such as your application challenges.
security assessment and to help maintain Kenexis, aeSolutions, exida, etc., offer Cheap knock-offs can’t
the security information database. Much of competent cybersecurity services, but the
compare. Turck works!
this effort should be done at the engineer- owner/operator should have the in-house
ing level by people who are familiar with expertise to do this assessment, or to at
the individual pieces of equipment and least be fully involved to understand what
their security concerns, and then reviewed SIS system components are at risk; what the
by the security assessment team. security threat vectors are; what the system
Successful cyber attacks depend on vulnerabilities are; how to limit system ac- QR24 Rotary Inductive Sensors
An expanded line of noncontact inductive
knowledge of the system to be attacked, cess, internal pathway flows, and system
rotary position sensors with optional
its protections, and the process under and component vulnerabilities to threat vec- stainless steel housing.
control. This typically requires reconnais- tors; how to minimize the security threats; Wide variety of
sance of the system, maybe more than and how to recover safely. The better your outputs includes

one, and may be signified by minor suc- understanding of your SIS and ICAS from HTL Incremental,
SSI, CANopen and
cessful, weak and/or failed attacks. a security perspective, the better chance
analog in voltage
Cyber reconnaissance may also be made that you'll be prepared to repel any security and current.
on the plant’s potentially less secure com- attack.
puter systems, such as drawing databases,
process descriptions, process narratives, Frequent contributor William (Bill) Mostia,
standard operating procedures, HAZOP/ Jr., P.E, principal, WLM Engineering, can be
LOPA databases, calibration database, asset reached at wlmostia@msn.com. Call 1-800-544-7769
or visit info.turck.us/sensors
www.controlglobal.com NOVEMBER 2017 • 69
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 MOTORS & DRIVES

MOTORS, DRIVES
DELIVER FORCE
BEHIND THE SCENES
Hardworking rotating equipment is getting help from
variable-speed devices, efficiency rules, and onboard and
networked intelligence to aid process applications worldwide.
by Jim Montague

BECAUSE fluids are universally heavy and process applications
are usually in harsh, remote and/or weather-beaten settings, the
motors and drives that serve them have a tougher time than their
counterparts elsewhere—requiring them to be stronger, more
durable and more reliable. And yet, they don't seem to get much
credit. A lot of rotating equipment in process applications seems
to be treated as an afterthought by their users and organiza-
tions—only coming to mind when they halt production.
"The process industries continue to be ruled by automation
equipment such as PLCs and DCSs, so I think motors and drives
are still viewed like I/O points," says Richard Kirkpatrick, project
manager for variable speed (VS) AC motors at Baldor Electric Co.
(www.baldor.com), an ABB Group member.
In recent years, most advances in motors and drives con-
centrated on increasing efficiency, adopting variable speed/fre-
quency drives (VSD/VFD), using permanent magnets to increase
power density, integrating regenerative functions to save power,
and adding intelligence onboard or nearby to achieve further
operational gains. But, as Hollywood producers say, "What have
you done for me lately?" Well, if motors and drives were more vis-
ible, their answer would be "plenty."
"The process control industry traditionally focuses on op-
erational improvements that drive out variability and push
constraints to make money. However, you can still make prod-
uct when a PID loop is underperforming by putting the loop in
manual. You can't make product when your rotating equip-
ment goes down," says Tim Shope, industry and process con-
sulting manager for North America at Rockwell Automation
(www.rockwellautomation.com).
Skip trucks in the desert
At their most basic, motors and drives have made much of the
modern world possible in the close to 200 years following the
first Industrial Revolution, but their labor-saving capabilities are
still taking over for manual and other inefficient forms of work in
remote and developing regions.
For instance, the Kapurdi lignite mine in northwest India was
established in 2010 to deliver brown coal to the Jallipa Kapurdi
coal-fired power plant, which are both owned by the Barmer
Lignite Mining Co., Ltd. (http://blmcl.in). The lignite was initially
transported 4.5 km in trucks, but after two years, BLMCL de-
cided a conveyor would be more efficient, according to senior VP
Anil Sood. "Transporting the lignite on a conveyor is more envi-
ronmentally friendly with minimal pollution and dust,” says Sood.
“A conveyor was also a more cost-effective, all-weather solution.”
"The process industries continue to be ruled
by automation equipment such as PLCs and
DCSs, so I think motors and drives are still
viewed like I/O points."
Because the lignite conveyor would be the power plant's life-
line and one of India's longest, it was vital for it to have reliable
motors, drives and controls. BLMCL eventually decided to use
three Dodge controlled start transmission (CST) units from ABB
(www.abb.com). "The CST design combines a planetary gear
reducer with an integral wet clutch system to provide efficient
transmission of motor power and torque,” says Prabal Bose,
ABB’s regional sales manager for Dodge MPT in India. “This al-
lows consistent, smooth startup and shutdown of long conveyor
belts, which minimizes peak loads and stresses. Its double-lip
taconite sealing system with added excluder seal prevents con-
tamination from entering the CST.”
Sood reports that BLMCL thought CST might be the best option
for its desert location with high temperatures and dust, and that
it's delivered several years of trouble-free performance. "We've
operated the mine at 100% capacity for more than two and a half

www.controlglobal.com NOVEMBER 2017 • 71

MOTORS & DRIVES
years,” explains Sood. “The CST drives delivered 99% availability
with no breakdowns, and only required oil replacement."
Speed control still saves
Though many innovations in motors and drives are newer and
may be more attractive, nothing has delivered more efficiency
gains than the continuing expansion of VSDs and VFDs in pro-
cess control applications and in manufacturing in general.
"It's generally agreed that we can expect power consumption
to increase 42% over the next 20 years due to growing popula-
tions and increasing use of motors and drives for pumps, fans
and other uses," says Rockwell's Shope. "However, it's impor-
tant to remember that the total ownership cost (TOC) for rotating
assets typically consists of just 10% for the initial cost of buying
the motor, VSD, starter, pump, etc. and another 15% for mainte-
nance, while the remaining 70-80% is energy costs. That's the
big one that VSDs can help with."
Harvey Eure, VFD and power quality product manager, Delta
Products Corp. (www.delta-americas.com/ia), adds that, "Low-
voltage VFDs operate AC motors that are typically 5 hp and
above to reduce electricity costs, control process speed, and
reduce wear and tear of mechanical systems such as conveyors
or pumps linked to the AC motor. However, there's been a trend
of using VFDs more frequently in smaller motor applications with
fractional horsepower—about 0.25 hp and up—for AC induction
and permanent magnet motors. In addition, VFD costs have de-
clined in recent years, making them more affordable for smaller
AC motor applications such as factory automation equipment
and small conveyors. Compared to traditional gearboxes, VFDs
provide more precise control of motor speed and process speed.
"For larger AC motors, the trend is using VFDs with active
front-end sections to lower harmonics and regenerate electricity.
In applications with high inductive loads, such as water pump
motors, users monitor the facility's electrical system harmon-
BALL MILL POSITIONING
Figure 1: To control a medium-voltage AC motor with a low-voltage
AC drive, Ash Grove Cement's plant in Chanute, Kan., replaced
generators powering its ball mill spotter with preconfigured, 480-V,
450-hp Allen-Bradley AC VFDs, which power three 4,000-V, 2,300-hp
AC motors to rotate the mill efficiently and bring it to controlled starts
and stops. Source: Ash Grove Cement and Rockwell Automation
72 • NOVEMBER 2017
ics that's generated back to the power utility from nonlinear load
sources such as VFDs. The diode rectifier, along with capacitors
charging and discharging, create non-sinusoidal voltage and cur-
rent waveforms back to the power utility grid. Because utilities
can charge penalties to facilities with poor power quality, and to
prevent this in the future, facilities with large motors will begin
buying VFDs with active front ends for lower harmonics."
Eure adds that Delta has developed a VFD panel for oil and
gas pumps, which employs a VFD with a reciprocating piston
pump for an oil well. "The pump mechanically lifts liquid from an
oil well, while the panel increases production time by varying the
speed according to the fluid level with a user-defined stroke-per-
minute command," he explains. "The control scheme has been
adapted to a variety of oil and gas pump systems to optimize
pumping speed and save on energy.
"The VFD provides four-quadrant control with regenerative
energy fed to the active front-end device. Electrical energy is re-
generated back to the utility during the pumpdown stroke, which
accounts for 50% of pump rod motion. The regenerative VFD
minimizes wear on components, such as the rod strings, gear-
boxes and v-belts, due to reduced pump starting and stopping."
Standards assist as well
Because of the operational and financial benefits they deliver,
variable-speed and other efficiency-boosting technologies have
also been supported and advocated by many standards organi-
zations and regulatory bodies in recent years.
"Standards keep evolving, and energy-efficiency laws, like
the Energy Policy Act (EPAct) in 1999 and the Energy Indepen-
dence and Security Act in 2007, have been followed by the U.S.
Dept. of Energy's more recent U.S. Integral HP Motor Rule in
2016," says Baldor's Kirkpatrick. "Meanwhile, the process indus-
tries have always made significant use of VS motors, and until
now they've been exempt from most efficiency rules because
they can achieve some percentage gains just by decreasing their
speeds. But now, there's talk that the EU's European Commis-
sion may soon draft efficiency rules for systems that include VS
motors and drives, and those requirements will likely hit us, too."
Smart design expands flexibility
Just as with most other process control devices, motors and
drives have also added onboard data processing and intelligence
for more flexible performance across voltage levels and more
proactive maintenance.
While it may once have seemed impossible to control a
medium-voltage AC motor with a low-voltage AC drive, 100-year-
old Ash Grove Cement (www.ashgrove.com) in Chanute, Kan.,
recently implemented a low-voltage, AC VFD with its existing,
2,300-hp, medium-voltage AC motors to solve problems with
its old motor controls (Figure 1). To maximize production, the
Chanute plant continuously manufactures cement, using almost
1,000 motors that generate a combined 45,000 hp to produce
www.controlglobal.com

five tons of cement per minute, but its former control system was
unreliable and required constant maintenance.
“The success or failure of our plant depends on our motors.
We need reliable equipment and ongoing maintenance to protect
our motors, control production and operate efficiently,” says Bob
Wright, electric operations manager at Ash Grove. "Not long ago,
manufacturers had a run-until-it-breaks mentality, but now we
have the tools to protect capital investments.”
In addition, staff at the Chanute plant were having trouble
using a 60-hp generator motor to manually rotate and position
their three ball mills for monthly servicing, which further limited
production and revenue. “Each hour that we stop operations to
perform maintenance or resolve a fault translates to 300 tons
of cement that could have been produced,” Wright explained.
"Usually, this situation called for a new spotting controller and
gear motor or a medium-voltage drive.”
Instead, Ash Grove replaced generators powering the mill's spot-
ter with preconfigured, 480-V, 450-hp Allen-Bradley AC VFDs from
Rockwell Automation. These drives power three 4,000-V, 2,300-hp
AC motors during spotting to rotate the ball mill efficiently, and bring
it to controlled starts and stops. Also, the low-voltage AC drive has
the torque control to operate at the 6 Hz the ball mill requires for
spotting. The drive separates and independently controls motor flux
and torque-producing current, allowing it to deliver full torque down
to zero speed. These capabilities, coupled with precise motor speed
control, allow the AC drive to handle demanding motor control appli-
cations, including those typically reserved for DC motors.
By networking its new drive to an existing Allen-Bradley Con-
trolLogix PAC, Ash Grove improved operational performance, re-
ceives real-time access to crucial production data, and protects
assets with advanced diagnostic and protection capabilities.
Unlike the previous generator, smooth VFD technology reduces
equipment wear, as well as time and money previously spent on
maintaining the motor. Instead of needing annual motor main-
tenance, the new AC drive also requires less upkeep and motor
rewinding. As a result, Ash Grove not only updated its drives,
it modernized its approach to maintaining capital investments,
saved an initial $250,000, and achieved 90% uptime.
“Besides costing less than half as much as a medium-voltage
drive, using a low-voltage AC drive in this application saves on
maintenance and energy,” Wright said.
Baldor's Kirkpatrick adds, "We're also beginning to see direct-
drive solutions without gearboxes because if users can get the
added torque they need with permanent magnets or other more
power-dense designs, then they can eliminate gearboxes, which
have relatively higher maintenance, more reliability failure points,
and efficiency that degrades sooner over time. Similarly, lami-
nated-frame designs—with laminated steel plates in the stator
serving as the motor frame—used to be only in servomotors, but
they've been making their way into larger motors in recent years.
This design provides better heat dissipation and increases power
density at the same time."
www.controlglobal.com NOVEMBER 2017 • 73
MOTORS & DRIVES
VARIABLE SPEED SPANS THE GLOBE
It's been awhile since they were an innovative novelty, and
variable-speed drives (VSD) are so mainstream now that they
can be found in process applications worldwide. A sampling of
applications by Emerson Automation Solutions (www.emerson.
com) reveals at least five examples, including:
• Thailand-based Mitr Phol Sugar Corp. (www.mitrphol.com) re-
placed the drive on variable-speed conveyors between process
stations at its Phulaung plant, and implemented Emerson's
Control Techniques Unidrive M600 VSD with SI-Encoder. Mitr
Phol's electrical and automation staff report that M600's
closed-loop control, low harmonics, and task-based commis-
sioning, diagnostics and maintenance minimize downtime.
• Zanardi Fonderie S.p.A. (http://zanardifonderie.com) in
Verona, Italy, produces spheroidal graphite castings, and
worked with supplier G.B.M. of Milan and Emerson to reduce
power consumption in its central flume aspiration system by
replacing its motor with an upgraded Leroy Somer AC motor
controlled by a Powerdrive MD2 VSD. The drive was inter-
faced to regulate the ventilator's outflow with a PLC and a
synoptic display on a PC to communicate with the drive via
Profibus, and adapted the flow reference to phases set by
the PLC. As a result, the ventilator uses less than 1,200 kWh
per day on average compared to prior daily consumption of
2,000 kWh, which adds up to a 40% savings.
• Denmark-based plastic extrusion specialist Stål & Plast (http://
uk.staal-plast.dk) improved its operating reliability and reduced
maintenance costs by replacing three worn DC electric motors
(one 175 kW and two 71 kW) with Leroy Somer's higher-torque
Dyneo PM motors and an Emerson Control Techniques Unidrive
M700 VSD at its plant, which uses a fully automated, vacuum-
forming process to make three-layer bench tray systems for
greenhouses and nurseries, and is expected to save 90,000 kWh
per year for annual energy savings of about 9%.
• To recapture some of the energy its conveyors consume at its five
limestone mines, Greer Industries (www.greerindustries.com) in
Morgantown, W.V., recently installed Powerdrive FX VSDs with dy-
namic braking from Leroy Somer, which serves as a regenerative
drive on a downhill conveyor at one mine. "It proved to be a straight-
forward swap when it came to fitting the Powerdrive FX," says Jim
Phillips, electrical operations manager at Greer. "In fact, it provided
a cleaner connection to our PLC than our previous drive."
• Mostafa Paper Complex Ltd. (MPCL, www.mostafagroup.com)
in Chittagong, Bangladesh, recently added Control Techniques
Unidrive M700 AC VSDs and encoders to run suction rolls, paper
guide rolls and dryers on its latest paper machine. Because of
the module/software configuration from Control Techniques,
complete machine logic and sequence for MPCL could be imple-
mented inside the drive, removing the requirement for an exter-
nal PLC, panel and related accessories.
SCADA/HMI
The cloud, IIoT, virtualization and other forces are reshaping supervisory control and
data acquisition (SCADA) into new forms and functions, but can they do it securely?
IF it had a face—and it sort of does—would you recognize super-
visory control and data acquisition (SCADA) if you saw it on the
street? Would SCADA even recognize itself in a mirror these days?
Chance are, probably not. This is because all the earth-shaking
shifts due to data digitalization and the Internet are also turning
SCADA on its head, and taking it in entirely new directions. Granted,
its conceptual borders were always pretty porous—some water/
wastewater users think it's their entire control system, while oth-
ers consider it limited to just their human-machine interface (HMI),
However, even as it continues to display collected information in
many applications, the accelerating influence of cloud and virtual-
ized computing services and the Industrial Internet of Things (IIoT)
are pulling SCADA into strange shapes to perform unfamiliar tasks
beyond its traditional jurisdiction.
"Where utilities used to have second and third redundant control
and SCADA systems for comprehensive disaster recovery, they're
now synching with duplicate systems in the cloud," says Michael
Chmielewski, offer management VP, process safety and SCADA,
Schneider Electric (www.schneider-electric.us). "We have one large,
U.K.-based gas utility that's talking about moving its whole SCADA
system to the cloud. SCADA isn't going to dissolve, but it's going to
become more of a secure service deployed out of the cloud."
Seeking definitions
"Even as a broad term, SCADA is not a distinct thing anymore. Now
it's all about the data, and how what used to be SCADA is converg-
ing with and incorporating a whole bunch of new technologies,"
says Chuck Tommey, P.E., business development manager at A&E
Engineering (www.aeengineer.com) in Greer, S.C., a member of the
Control System Integrators Association (CSIA, www.controlsys.org).
"On-premise SCADA with servers in racks, Ethernet to PLCs and
HMIs are still perfectly valid and will continue for a long time, but
we're on the brink of a big mindset change.
"We've all heard about the cloud, IoT and data analytics for
10 years, especially from the information technology (IT) side,
but now they're converging with operations technology (OT) on
the plant floor. Virtualization, IIoT, cloud computing and data
analytics are all part of SCADA, or they can be used to enhance
or manage it. This means the most successful end users and
74 • NOVEMBER 2017
by Jim Montague
companies will be those with well-integrated IT/OT teams or IT
departments with significant understanding of OT."
New sandboxes, new shovels
Logically, because the cloud, virtualization and IIoT multiply the
connections a SCADA system can have with other systems, they
also increase the number of different functions it can take on—
along with the tools to perform them.
To monitor and control more than 200 megawatts (MW)
of utility-level, solar generating capacity at five plants built by
Depcom Power (www.depcompower.com) in Scottsdale, Ariz.,
Vertech (http://vertech.com), a CSIA-member system integra-
tor in Phoenix, Ariz., developed an innovative SCADA system
that could handle each facility's thousands of connected devices
from many vendors. They include 15,000 tags, 30 screens, 10
"SCADA isn't going to dissolve, but it is going
to become more of a secure service deployed
out of the cloud."
clients, 10,000 alarms, one local Microsoft SQL database, one
offsite database and 2,000 historized tags. Besides coping with
the volume of tags, Josh McGuigan, Vertech senior control sys-
tems integrator, reports that Depcom's new SCADA system also
needed to be robust to cope with new plant rollouts and data
levels that can quickly become overwhelming.
"For the solar power plant SCADA system at Depcom's plants,
we used Inductive Automation's (https://inductiveautomation.
com) standard Ignition software architecture, including one lo-
cal historian and one connection to a database in the cloud,"
explains McGuigan. "On a typical site, an Ignition gateway will
be directly connected to nearly 100 devices. However, some of
those devices act as gateways themselves, so the total system
is used to monitor and control around 3,000 devices, which
amounts to more than 15,000 I/O tags per site."
McGuigan adds that intelligent reporting, which does more
than provide the top 1,000 rows of a database table in a tabular
format, is essential for large solar arrays. Using advanced script-
ing in the Ignition Reporting module, Vertech designed a report
www.controlglobal.com

that analyzes data from hundreds or thousands of strings of solar
panels to highlight low-performing equipment and prioritize op-
erations and maintenance team activities.
"Ignition lets us provide a SCADA system for Depcom that
improves on the industry's status quo," adds McGuigan. "Users
now have more data available and their interface is easier to use,
allowing operations and maintenance teams to be more effec-
tive in identifying and troubleshooting issues. The analysis of site
performance data, which used to be a manual task, is now auto-
mated, so any site performance issues are quickly brought to the
appropriate people."
Dealing with (big) data
So, what can cloud-enhanced SCADA do with its new powers?
Probably the most important job is make sense of the buckets of
data coming in from all its new connections.
For instance, the water supply system in Hamilton, New Zea-
land, consists of one treatment plant that sources water from
the Waikato River, and delivers it through more than 1,000 km
of pipes to eight reservoirs and more than 150,000 residents
(Figure 1). The city also runs the Pukete Wastewater Treatment
Plant (WWTP). To comply with drinking water standards that
New Zealand revised in 2008, including retaining operating re-
cords for 10 years, the city had implemented Rockwell Automa-
tion's (www.rockwellautomation.com) RSView 32 SCADA system
10 years ago, but its manual data recording to Microsoft Exel
spreadsheets recently needed upgrading.
“Our previous system was outdated and we required an up-
grade to help simplify the process of complying with current wa-
ter regulations in New Zealand," says Gary Pitcaithly, automation
and electrical manager at Hamilton City Council. "Not only that,
but we identified the potential for improving operational efficien-
cies at the plant by implementing an integrated system that aims
to increase productivity and reduce downtime.”
As a result, Hamilton implemented Rockwell Automation's lat-
est FactoryTalk software, including its FT View SE, FT Historian,
FT Vantage Point, FT Asset Centre and FT ViewPoint, which pro-
vides real-time exchange of information throughout applications
and organizations for improved business decisions, responsive-
ness and productivity; reduced costs, and easier regulatory com-
pliance with long-term data storage and automatically generated
reports. Staff can also externally manage the system via tablet
PCs or smart phones.
“The upgrade has delivered greater ease of use of our system
throughout the WWTP," adds Pitcaithly.
Affordability aids adoption
Another of the unglamorous—but still crucial—advantages that
cloud and virtualized computing add to SCADA systems is the
fact that they can quickly help reduce operating costs after a
relatively small investment at the beginning.
For example, to help smaller and rural water/wastewater utili-
www.controlglobal.com NOVEMBER 2017 • 75
SCADA/HMI
ties perform data acquisition, alarming, reporting and other
SCADA functions on a budget, system integrator Perceptive Con-
trols (www.perceptivecontrols.com) in Plainwell, Mich., devel-
oped its Perceptive Polaris cellular, cloud-based SCADA system
and software, which employs SNAP PAC controls from Opto 22
(www.opto22.com), and avoids using costly servers and hard-
ware. One of the key development challenges Perceptive's engi-
neers faced was how to reduce data sent between lift stations on
the SCADA network.
“We knew that using cellular modems meant one of the most
important requirements of this project would be the ability to
transmit the smallest data packets possible, with as much data
in each packet as possible,” says Kevin Finkler, software engi-
neer at Perceptive Controls. “We had to stay under the data caps
of the cellular provider we planned to use.”
The system integrator first tried posting data from a controller
to a cloud-based server, but testing showed this method was too
slow, and couldn't send configuration changes back to control-
lers. While considering alternate options for transferring data,
Perceptive's developers investigated SNAP PAC's Representa-
tional state transfer (RESTful) application programming interface
(API) capabilities, which include a built-in, secure HTTP/S server
with an open, documented API that creates a RESTful architec-
ture. RESTful and its technologies, like HTTP/S and JavaScript
Object Notation (JSON) are intrinsic to IoT and essential for web,
data and mobile-based application development.
KIWI WATER COMPLIANCE
Figure 1: The municipal water/wastewater treatment and distribution
system in Hamilton, New Zealand, recently upgraded its SCADA sys-
tem to Rockwell Automation FactoryTalk Historian ME and Vantage-
Point software to improve reporting, system stability and compliance
with drinking water standards requiring it to retain operating records
for 10 years and generate monthly reports. Source: Hamilton City
Council and Rockwell Automation
SCADA/HMI
"Plant management that previously had to migrate SCADA equipment
every three to five years can now extend their lifecycles to 10 to 15 years."
“After switching to the new RESTful API
method, we now have a cloud-based soft-
ware application running on a dedicated
server that uses SNAP PAC’s RESTful API
to request data directly from the controller,"
explains Finkler. “Requests are made over
a private cellular network to avoid cyberse-
curity concerns, and avoid opening ports in
firewalls. We store data in float tables on the
PAC (about 44 indexes per table), and the
software can grab up to 100 tables per re-
quest without slowing performance.”
Perceptive's cloud application then uses
the RESTful API to write back how many
tables were retrieved, so the controller can
delete the old data, and move everything up
in the table with new data again at the top.
This ensures that all data is received into
the cloud application. “It’s more efficient to
make the cloud application process large
amounts of data, instead of making the con-
troller do the work in addition to its normal
operations,” adds Finkler. “This method
saved an average of 5.8 kb per data set
transmitted, which ended up saving us
about 250 MB per day, adding up to signifi-
cant savings in cellular data charges.”
A&E's Tommey adds, "We see a lot of
lower-cost SCADA solutions at shows, but
when you get down to it, their initial cost is
still high for users. However, when OT and
IT converge in the cloud, they can reduce
SCADA and other costs, and turn many
capital expenses into operating costs. Plus,
today's subscriber-based fee structures can
reduce costs even more, especially at the
front end, where these expenses can be
hard for users to swallow."
For instance, Tommey reports that a typi-
cal SCADA project with three servers, wired
and wireless networking, field devices and
software licensing can add up fast to an
average of $100,000, while an equivalent,
subscriber-based version on the cloud may
only cost $10,000 upfront with added sub-
scription fees on a monthly or annual basis.
"This is a lot more approachable for users in
their local budgets," says Tommey.
Despite this tenfold cost reduction, Tom-
76 • NOVEMBER 2017
mey adds that many potential users remain
reluctant to do SCADA in the cloud due
to security concerns, worries that Internet
links will go down, and anxiety that their
data won't always be available to them. "As
connectivity gets more reliable, more users
will make the switch," he says.
To help users handle the transition from
traditional SCADA to the cloud, Tommey
adds that A&E is designing hybrid systems
with local, secure, second-by-second data
storage using traditional HMI and histo-
rian software (such as Ignition, Wonder-
ware, WinCC, OSI Pi or FactoryTalk), and
then sends only certain pieces of data to
the cloud for analysis. The cloud allows
this data and analytical results to be more
available via tablet PCs and smart phones.
"This enables some remote data access,
distributed alerting, machine learning and
prescriptive maintenance without putting
everything in the cloud," Tommey adds.
Security underpins everything
While the many benefits of cloud-enabled
and IIoT-aided SCADA are terrific, these
added connections to higher-level networks
and the Internet come with increased risk
of probes, intrusions and attacks, which de-
mand updated cybersecurity and constant
vigilance by staff.
"The big bugaboo impacting all these
new technologies is cybersecurity, espe-
cially in the OT space," explains A&E's Tom-
mey. "Cybersecurity must be addressed as
a continuous cycle, but a lot of companies
on the OT side don't understand this yet.
They all did 20-30 years of work on lean
process improvement, and that continu-
ous improvement thought process must be
extended to cybersecurity. The problem is
this security monitoring piece doesn't exist
in 95% of manufacturing facilities because
they just have traditional air-gapped equip-
ment or firewalls. There's more security
monitoring on the IT side, but there's very
little on the plant-floor side, and many small
startups and larger suppliers are seeking to
fill these gaps."
www.controlglobal.com
 ASK THE EXPERTS

Orifice flowmeter straight run

Requirements vary and depend on expectations as well as piping configurations.

Q: have a question about orifice flowmeters: Why
do we put it before the control valve (CV) and not
after it (upstream of the CV, not downstream)?
This seems to be the case in the refineries around
98% of the time. I need to know if there are stan-
dards that require designers to put the orifice in
this position or could we put them after the CV if
there is enough length of pipe? If there is enough
straight run, does it matter? Thanks for your help.
are not concerned with accuracy (the measurement This column is moderated
is not for accounting purposes), the length of the by Béla Lipták
straight runs can be less than in Figure 1. Otherwise (http://belaliptakpe.com/),
the longer the run, the better the accuracy. With automation and safety
flange taps, the downstream straight line require- consultant and editor of the
ments (6-8) are unaffected by the upsream distur- Instrument and Automation
bances, but if pipe taps are used, they require twice Engineers’ Handbook
that length (12-16). Flange taps are used above 2-in. (IAEH). If you have an
pipe size and corner taps are used below. automation-related question

SADEEM AL-BAGHDADI
sadeemhazim1976@yahoo.com
A: If you must, you can place a valve before an
orifice flowmeter (for example, after a subheader
on-off ball or gate shutoff valve). But there are
many reasons to prefer upstream placement.
The flow path is tortuous through a control
valve, causing the Reynolds number (Re) to vary.
Therefore, the fluid will need to pass through a long
straight line before stabilizing. The throttling also
causes variation of the pressure of the flowing fluid,
which changes the orifice coefficient. Also, in liquid
applications, if the vena contracta pressure drops
below the flash point of the liquid, flashing occurs
There are really no such things as standards. for this column, write to
There are recommendations, and they tend to dis- liptakbela@aol.com.
agree. Probably the best is ISO5167, Parts 1 and
2, which gives similar advice to the recommenda-
tion in my handbook (Figure 1).
The American standards AGA and API tend to
be a little more conservative than ASTM. Of the
standards of other nations, the German and the
French are probably the most conservative. I also
found over the years that vendors’ recomenda-
tions can be highly unreliable.
Naturally, there is more to installation than
50
A: Throttled valve or regulator A
45 upstream to orifice
Minimum number of pipe diameters required to be straight

that makes the measurement meaningless.

B: Two elbows in different planes
We want the velocity profile (the flow regime) at 40 upstream to orifice
C: Two elbows in same plane or B
the orifice plate to be stable and the same as it was
35 fully open ball/gate valve
during testing of the plate. The orifice coefficients upstream to orifice
are determined using long, straight pipe runs during 30 D: A single elbow upstream to
orifice (twice for expander)
testing, and therefore, if we want to keep the orifice F: Straight run downstream
25
of orifice C
coefficient correct, we should reproduce the tes-
ing conditions, both in terms of straight runs and in 20 D
A
terms of Re. The Re must exceed 20,000 even at B
15 E
minimum flow to guarantee turbulent conditions. Lorem ipsum
Control valves are usually one size smaller than 10 C
the pipe and therefore, the expander after the CV D&E
5 F
adds to the straight run requirement. By the way, F

over the years I did not find much value in flow 0

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
straighteners. Orifice (d) to pipe (D) diameter ratio β = d/D
The straight run recommendations vary widely.
When the orifice-to-pipe-diameter ratio β is 0.8, I STRAIGHT RUN REQUIREMENTS
use 50 for reducers and throttling valves, and 40 for Figure 1: Minimum straight run requirements
elbows in two planes, but Spink, for example, reco- upstream and downstream of orifice plates, as deter-
mends 60 to 100. If all you need is repeatability and mined by Béla Lipták.

www.controlglobal.com NOVEMBER 2017 • 77

ASK THE EXPERTS
straight runs, and there is more to orifices than installation. For
a full treatment of selection, sizing, etc. see Chapter 2.6 in my
handbook.
BÉLA LIPTÁK
liptakbela@aol.com
A: If you don’t have access to a copy of the relevant volume of
Liptak’s Instrument Engineers’ Handbook, "Process Measure-
ment and Analysis," see the international standard ISO5167 Part
1 and 2 . Note that this is not necessarily conservative.
The API standard (API MPMS 14.3 ) allows the use of 19-
tube flow straighteners ahead of the orifice, but these have been
demonstrated to be a cause of error rather than an improvment.
IAN H. GIBSON
Process, control and safety engineering consultant
gibs0108@optusnet.com.au
A: Yes, indeed, you can make a case to place the orifice down-
stream of the control valve for liquid service where there are suf-
ficient straight-run lengths. However, this is more complicated
for gas service, where you will have a variable pressure/density
downstream of the CV. You can use a multivariable DP transmit-
ter to compensate.
Straight run rules are meant to be applied in the majority
of cases without doing analysis (rules for everyone). One can
always break the rules if you know the basis and what further
analysis is required.
In the case of orifice placement, it is not just about straight
run lengths.
SIMON LUCCHINI, CFSE, MIEAUST CPENG (AUSTRALIA)
Chief controls specialist, Fluor
Simon.Lucchini@Fluor.com
A: Yes, you can put the orifice plate downstream of the control
valve, provided you have the upstream and downstream lengths
available to give you a stable flow regime, where the turbulence
caused by the tortuous flow thorough the control valve stabilizes
into stable flow. The ASME standard assumes a stable flow, and
flow regime in a range of Reynolds number, on which the flow
coefficients are based. Therefore, for flow computation to be
valid, you have to be in that flow regime.
You can send me the sketches/iso-meteric drawings and I can
review it for you, at no cost.
ROMEL S. BHULLAR, P.E. ISA FELLOW
Senior technical fellow/director, control systems, Fluor
Romel.Bhullar@Fluor.com
A: The orifice coefficient research is done with long, straight,
run of pipe because this is the only arrangement that can be du-
plicated. Anything less than that is likely to have a nonstandard
flow pattern, and it will affect that coefficient. See the standards
or a good flow handbook to see what is required for good accu-
78 • NOVEMBER 2017 www.controlglobal.com
racy. A partly open control valve will certainly create a compli-
cated flow pattern.
CULLEN LANGFORD P.E.
Member, ASME Main Flow Committee
CullenL@aol.com
A: The reason you should not place an orifice plate downstream
of a control valve is simple: The pressure downstream of a con-
trol valve will vary as the valve opens and closes. If the orifice
plate is upstream of a control valve, the pressure is always con-
stant, which allows for correct measurement.
So, as indicated before, no matter how many downstream
straight runs you have, the pressure will constantly be modified if
the control valve is upstream, causing measurement errors.
ALEX (ALEJANDRO) VARGA
vargaalex@yahoo.com
A: I suggest that you read the ISO5167 Part 1 and 2 standards,
which may answer most of your questions about how to install the
orifice flow meters (www.iso.org/obp/ui/#iso:std:iso:5167:-1:ed-
2:v1:en). Another good reference is the 2013 Chemical Processing
article, "Think straight about orifice plates” (www.chemicalprocess-
ing.com/articles/2013/think-straight-about-orifice-plates).
Regarding the second part of your question, control valves are
generally one size smaller than the pipe size. To minimize pres-
sure losses, pipes are restored to their normal size downstream
of the control vale. If you install the orifice plate downstream of
the control valve, then the reduced pipe size will remain in place
for ~ 50 pipe diameters. That is a long run of reduced pipe size,
which will increase your pressure loss in pipe. This pressure loss
has to be compensated using hydraulic analysis. So why would
you spend extra money, when you can achieve the same effect
by placing the flowmeter upstream of the valve?
RAJ BINNEY
binney4family@internode.on.
A: Measurement of liquid flow with an orifice flowmeter depends
on the liquid remaining totally as a liquid and not as a vapor. At
the vena contracta following the sharp-edged orifice, the pres-
sure drop will be a maximum (minimum pressure.) We care-
fully evaluate the temperature and pressure of the flowing liquid
stream and size the orifice so the pressure at that vena contracta
will not be close to the liquid boiling point. If boiling occurs, we
call that flashing; therefore Bernoulli’s law no longer applies and
the relationship between pressure drop and volumetric flow rate
becomes unknown—you can’t use orifice flowmeters to measure
the flow of flashing liquids. By locating the orifice plate/flowme-
ter before the CV, any pressures close to the vapor pressure are
shifted downstream of the control valve, rather than downstream
of the orifice.
RICHARD H. CARO, CEO, CMC ASSOCIATES
RCaro@CMC.us
 ROUNDUP

I/O and terminal blocks are the crossroads

These humble components form the nexus where real-world signals and data reach up to networks, data
processing, Internet and the cloud—and all those systems and software would be helpless without them.

REMOTE I/O IN PLC FOR WIFI AND IIoT FIELD I/O ADDS ETHERNET/IP
EZRack PLC automation con- Protos X "Xpansion" field I/O
troller and remote I/O device system has added EtherNet/IP
is a low-cost, advanced PLC protocol communications. This
that's IIoT and Wifi ready; has modular system consists of a
USB data logging up to 64 GB; bus coupler and associated I/O
free programming software; terminals, as well as a slim de-
and a simulator package. EZ- sign and I/O configurations that
Rack uses message queuing telemetry transport (MQTT) proto- allow the exact points needed in the smallest possible footprint.
col for direct connectivity to external devices, and for easy setup Two- to 16-point discrete I/O terminals and two- to 8-channel
of secure communications. These ties let EZRack serve as a analog I/O terminals are available. Up to 64 terminals per assem-
PLC and as a low-cost, edge-gateway computer/controller. bly and 255 I/O terminals total are possible.
EZ AUTOMATION AUTOMATIONDIRECT
http://store.ezautomation.net/rack-plc-starter-kit-s/1179.htm www.automationdirect.com/protos-x

SPECIALTY, HIGH-CURRENT I/O DISTRIBUTION WITH THREE CONFIGURATIONS

750-494 three-phase, power- DBL distribution blocks
measurement I/O specializes have three configurations
in high currents, measures DC in one device—single-
and AC currents up to 20,000 pole splitter, multi-pole
A with external shunts, and splitter and grouping
reports many values including functionality. They're
voltages, currents, active, reac- modular and touch-proof, which eliminates the need for bus
tive and apparent power, power factors, phase shift angles and bars, isolators and fasteners. The compact size saves up to 50%
harmonics. 750-494 measures energy consumption; detects on rail space compared to conventional distribution bars. They're
and processes measured variables; analyzes network perfor- available in five sizes, ranging from 80-400 A, and can be easily
mance; and detects current via its external shunts. ganged together for multi-pole applications.
WAGO ABB
800-DIN-RAIL (346-7245); www.wago.us www.abb.com

I/O ON EXTERNAL, IP67 CONTROLLER MIX HAZARDOUS, NON-HAZARDOUS SIGNALS

TBEN-PLC Codesys 3 compact LB/FB remote I/O systems
IP67 PLC has a robust housing connect input and output sig-
and environmental protection nals onto fieldbus networks,
that lets it run directly on-ma- and support general-purpose
chine without a control cabinet. or intrinsically safe (IS) appli-
When used as a master/scan- cations with modules that can
ner, it supports Profinet, Ether- be mixed and matched on the
Net/IP, Modbus TCP, Modbus RTU, CANopen and SAE J1939. same backplane. LB systems are rated for Div. 2 mounting with
However, TBEN-PLC can also be used as a remote I/O device for inputs and/or outputs mounted in a Div. 1/Zone 0 area, while FB
Profinet, EtherNet/IP, Modbus TCP, Modbus RTU and CANopen, systems are rated for Zone 1 mounting with inputs and/or out-
enabling it to be used as a protocol converter or gateway. puts mounted in a Zone 0 area.
TURCK PEPPERL+FUCHS
800-544-7769; www.turck.us www.pepperl-fuchs.us.com

www.controlglobal.com NOVEMBER 2017 • 79

ROUNDUP

HIGH-DENSITY FUSE BLOCKS FOR CLASS I, DIV. 2 I/O CONNECTS IS FIELD TO ENTERPRISE
UT 4-PE/L/HESI double-level, Allen-Bradley Bulletin 1719 Ex
fuse terminal blocks are certi- I/O platform brings in data from
fied UL Class I, Div. 2 and devices in hazardous areas via
incorporate reliable screw con- EtherNet/IP and HART 7, and
nections in a 6.2-mm pitch. uses a common platform for
They also have fusing, feed- easy monitoring and control.
through and shielding in one Bulletin 1719's distributed I/O
package, so they require 66% less DIN-rail space than single- platform is certified for Class I, Division 2 (North America) and
level blocks that would need three blocks for the same tasks. Zone 2 (global) hazardous areas. As an intrinsically safe (IS) I/O,
They're also rated for multi-conductors, maintain CID2 certifica- it connects to field devices in Class I, Division 1 (North America)
tion, and are approved for Class I, Zone 2, EX, IEC EX UL, cUL, and Zone 1 (Global) hazardous areas. Three chassis models are
and AEX nA II Gc with current ratings of 20 A and 300 V UL. available with scalability for eight to 45 I/O on one adapter.
PHOENIX CONTACT ROCKWELL AUTOMATION
www.phoenixcontact.com/processblocks www.rockwellautomation.com

ETHERNET, MODBUS CONCENTRATOR COMPACT, COST-EFFECTIVE MARKING

NET Concentrator System TopJob S sensor/actuator termi-
(NCS) has added an EMM nal blocks offer a convenient,
Interface Module, and its cost-effective marking system.
I/O network comes stan- They're also compact, saving
dard with a Modbus/TCP 72% of rail space compared
Ethernet port and dual, to standard feed-through ter-
independent Modbus RTU RS-485 ports. Either of the Modbus minals. In addition, TopJob's
RTU ports can be configured as a Modbus master port, allow- LEDs, jumpers and marking are in plain view of users for quick
ing NCS to poll other Modbus RTU slaves as a typical Modbus status and overview. They also feature Cage Clamp connection
master; provide simultaneous Ethernet and dual Modbus RTU technology, which is reported to offer the greatest degree of pro-
master/slave communications; and provide a real-time signal tection against shock and vibration, even under extreme environ-
gateway between field/factory floor and controls. mental conditions.
MOORE INDUSTRIES INTERNATIONAL NEWARK ELEMENT 14
818-894-7111; www.miinet.com 800-463-9275; www.newark.com

DIRECT CONNECT TO EX ZONE 0 REMOTE I/O FOR DISTRIBUTED CONTROL

ELX series EtherCAT terminals AMAX-4800 series industrial
with intrinsically safe (IS) I/O EtherCAT slave modules are
and compact design, enable di- compact, protected by an iso-
rect connection of field devices lation circuit, and include an
in hazardous areas, including integrated DIN-rail mount kit
classified Zones 0, 1 and 2. for easy installation, as well as
With upcoming certification of Euro-style, front-panel-accessi-
compliance with ATEX and IECEx, ELX series meets all guide- ble, pluggable terminal blocks with LED indicator to ease startup
lines for explosion protection. They have either 12-mm housings and maintenance. AMAX-4800 features high-density channel
with up to four IS inputs or 24-mm housings with up to eight design, and supports I/O formats, such as isolated digital input,
similar inputs. These slim terminals reduce space requirements isolated digital output, photoMOS relay output and relay contact.
in control cabinets by up to 50%. It also supports EtherCAT distributed clocks.
BECKHOFF AUTOMATION ADVANTECH CORP.
952-890-0000; www.beckhoffautomation.com 888-576-9668; http://buy.advantech.com

80 • NOVEMBER 2017 www.controlglobal.com

 CONTROL EXCLUSIVE

Twisted thermowell improves safety

Patented design prevents failure due to vortex-induced vibration.

THERMOWELLS subjected to flow experience dynamic

stresses imposed by oscillating vortex pressures. These dy-
namic stresses can result in vortex-induced vibration (VIV),
the leading cause of thermowell stress failures. Emerson is
now offering a patented “twisted square” thermowell that sup-
presses VIV, eliminating the concern of dynamic stress failure.
The new design was inspired by the difficulties of specify-
ing conventional thermowells to avoid issues with VIV. Most
often, stress failures occur on conventional thermowells that
have not undergone recommended calculations per ASME
PTC 19.3 TW to ensure the thermowell will withstand fluid
forces and process pressures.
The wake frequency limit is generally the most challenging
calculation to pass, especially for long thermowells or high-
velocity flows. The limit must be verified to ensure that the
natural frequency of the thermowell is safely away from the
Strouhal (vortex-shedding) frequency. As these frequencies
converge, the thermowell can “lock in” to resonant conditions,
greatly magnifying dynamic stresses caused by the VIV.
“A conventional thermowell experiences lock-in frequen-
cies that multiply stress 1,000 times or more,” says Timchan
Bonkat, product manager, temperature, Emerson Automa-
tion Solutions. “Every material has its own fatigue limit. After
enough reps, it will fail.”
The traditional solution to avoid these lock-in regions is to
shorten the thermowell and/or increase the outer diameter.
These changes can result in decreased accuracy or increased
response time of the temperature measurement.
“Customers try to standardize on a thermowell, so to ac-
commodate the worst application, they choose one that’s
short and fat,” Bonkat says. “They may have to use a larger
nozzle size and retrofit existing applications. In some of their
applications, the short, fat thermowell may not reach far
enough into the flow for a representative reading.”
These situations are becoming more frequent because
process velocities are increasing due to more frequent use of
smaller pipe sizes to save cost on projects.
Instead of stiffening the thermowell, the Twisted Square
Thermowell desynchronizes the vortices in its wake so they
are not uniformly defined or alternating at a consistent phase
along the length of the thermowell. This dampens the dy-
namic stresses from the vortices and suppresses VIV excita-
tion to a safe level.
The design reduces resonance stresses by more than 90%,
ONE WELL, MULTIPLE APPLICATIONS
Emerson Automation Solutions’ Rosemount Twisted Square
Thermowell allows the same thermowell to be used in multiple
applications and changing process conditions without risk of
vortex-induced failure.
so static stresses dominate. “With a twisted square thermo-
well, the static stresses will always be the limiting factor. With-
out resonance lock-in, the dynamic stresses don’t generate
enough energy to be damaging,” Bonkat says.
“The twisted square simplifies thermowell calculations, and
it works in applications where conventional thermowells don’t
pass ASME PTC 19.3 TW,” Bonkat says. “It allows optimum
penetration using existing nozzles, and is available in all nor-
mal configurations and materials. It allows for growth because
plants can change flow rates and other operating conditions
without resonant frequencies concerns, and it also reduces
stocking requirements because one design can be used in a
wide variety of applications.
“Above all, it provides an accurate and reliable temperature
measurement while preventing thermowell failures that can
cause expensive shutdowns, or at worst result in leaks and
explosions.”
For more information, including a link to an eye-opening
video comparing deflections of a conventional thermowell
and a Twisted Square Thermowell under a wide range of flow
velocities, see www.emerson.com/en-us/catalog/rosemount-
twisted-square-thermowell.

www.controlglobal.com NOVEMBER 2017 • 81

PRODUCT INTRODUCTIONS

MONITOR PERFORMANCE IN THE CLOUD CONNECT FASTER AND BETTER

Insight Performance KEPServerEX v. 6.3 indus-
module provides OEE trial connectivity platform
monitoring, asset uti- has proved Create, Read,
lization analysis and Update and Delete (CRUD)
downtime tracking functionality for the Con-
in the cloud. Cloud figuration API, new time-
deployment leverages sync functionality for driv-
conventional or IoT ers with Electronic Flow
edge devices to collect Measurement (EFM) ca-
data, sending it directly to a hosted online environment, bypass- pabilities, a new Keyence
ing the usual layers while remaining secure. Built-in analysis KV Ethernet driver, and remote project loading via the ThingWorx IoT
enables cross-plant benchmarking that delivers actionable intel- Platform. The focus is on saving users time, streamlining processes
ligence to increase performance and operating efficiency. and enhancing project customization capabilities.
SCHNEIDER ELECTRIC KEPWARE
online.wonderware.com https://info.kepware.com/kepserverex-version-6-3-release

STREAMLINE AGA FLOW MEASUREMENTS REMOTE POSITION INDICATION FOR MANUAL VALVES
Y-Flow family includes the SPI Smart Position Indicator
low-power Y-Flow YFFC orifice provides reliable and accurate
flow computer and Y-Flow open/close position indica-
YRTU remote terminal unit. tion for multi-turn valves. Limit
Y-Flow YFFC measures AGA 3 switches or sensors for remote
orifice gas flow using DPharp indication are located and
technology to obtain differen- terminated internally so no ex-
tial and static pressure from ternal junction box is required.
one sensor. Y-Flow YRTU al- Position is mechanically shown
lows addition of an external locally via a large display dial.
turbine meter, ultrasonic meter, multivariable transmitters and/or It is impossible for the SPI to impede valve operation, and the
Coriolis meter to perform complex AGA gas flow calculations as maintenance-free unit is housed in an IP-67-rated anodized alu-
well as remote control applications. minum enclosure.
YOKOGAWA ROTORK
www.yokogawa.com www.rotork.com/en/media/view-article/newsID/2613

MODERNIZE THAT CONTROL ROOM MODBUS ETHERNET/SERIAL I/O MODULES

Experion Local Control Low-cost S-Series I/O
Network (LCN) enables modules can be used with
incremental upgrade of the any controller or computer
TotalPlant Solution (TPS) that has the capability to
control system for secure, be a ModbusTCP or Mod-
seamless integration with bus RTU master. They
Experion PKS. Using Ex- comprise a complete fam-
perion Fault Tolerant Ether- ily that support a variety of
net (FTE), the LCN bridge connects Experion to Classic Coax LCN. signals and combinations of digital and analog I/O per module.
Once this is established, the LCN coax connection can be removed Most modules support both Ethernet ModbusTCP and serial
one LCN node at a time. Instead of a hardware connection for every Modbus RTU protocols. Removable terminal blocks, universal
Experion TPS node, only one redundant Experion LCN bridge pair inputs, surge protection and signal isolation, DIN-rail or panel
is needed to enable virtualization. mounting are among the common features of every module.
HONEYWELL PROCESS SOLUTIONS SOFTPLC CORP.
www.honeywellprocess.com http://softplc.com/products/io

82 • NOVEMBER 2017 www.controlglobal.com


The trouble with top management
What you need to know about the executives who determine your fate.
GREG: I have had a long-term, productive and
enjoyable relationship with Walt Boyes, a former
editor in chief of Control. Walt encouraged me to
be innovative and to start my Control Talk blog.
Walt is the voice of the Insider (www.spitzerand-
boyes.com/insider), published with his longtime
friend and associate David Spitzer as part of
Spitzer and Boyes LLC, which provides services
and seminars.
My wife, Carol, and I had the pleasure of a din-
ner meeting with Walt and his wife, Joy Ward, who
is director of research at Spitzer and Boyes. Joy
is a journalist and a well-known consumer market
researcher and technical writer. Joy has inter-
viewed many executives. I thought, what a combi-
nation of talents sitting with me, whose insights I
should gain and share. I am realizing an increas-
ingly important topic is what we need to know
about the managers and executives making deci-
sions that affect our profession. I mostly just had
to listen to develop this column—I didn’t get past
the first question due to the wealth of information.
Do the people making the decisions on what
plants must do have an understanding of automa-
tion and process control?
WALT: In industry, many of the people making de-
cisions about plant operation, projects and goals
are not engineers or chemists, let alone process
control engineers. They typically spent their whole
education in business schools, ending with a MBA.
They consequently tend to believe manufacturing
enterprise is a black box and out comes a product.
If you set the right inputs and schedule the outputs
per business analysis, you don’t need to know what
is going on in the box. One of the many problems,
like pulling teeth, is getting executives to do some-
thing meaningful about cybersecurity. Computer
systems experts say privately that it's going to take
a major incident, like shutting off the grid for a year,
to get the attention this threat deserves.
JOY: MBAs without any engineering degree may
think the business principles are the same no mat-
www.controlglobal.com
CONTROL TALK
ter what industry you're in. As long as the plant
does not adversely affect this quarter’s business
results, everything is OK. It's really difficult for in-
dustry to have a long-term view, and make large in-
vestments in equipment, or even small investments
in better automation and process control. The main
route easily visualized to improving the bottom line
is to cut people and services.
WALT: While this is perhaps seen more in terms of
people doing the day-to-day work, particularly in-
strumentation and process control engineers, it's
now occurring throughout a company. For exam-
ple, an ultimatum was given to 12 vice presidents
(VP) that if business goals for the 4th quarter were GREG MCMILLAN
not made by Christmas by laying off 1,500 peo- STAN WEINER, PE
ple, there would be no bonuses. One VP said this
was wrong and resigned. The other 11 VPs did Greg McMillan and Stan Weiner
whatever was necessary to get their bonuses. bring their wits and more than 66
years of process control experience
GREG: A production unit I once worked in was to bear on your questions, com-
quickly sold for an absurdly low price to meet ments and problems.
quarterly business goals.
Write to them at
WALT: People are not rewarded for integrity. It's controltalk@putman.net.
hard to tell your spouse you quit for moral rea-
sons. Executives are locked into seeking bonuses.
GREG: I've heard the philosophy is to cut people
until something goes wrong. Of course, this may
be too late. I know one plant that had to shut down
because there was no one left who understood the
process and its unique problems. Most people who
were given incentives and/or ultimatums to leave
were not given time to document even a tad of their
essential knowledge, often gained the hard way
over decades of plant experience.
WALT: At the plant level, people have to act de-
fensively with no control over what to do. Funda-
mentally, to get control at the plant level, you need
control at the enterprise level. Say a plant engineer
asks for $750,000 to increase process perfor-
mance from advanced process control (APC) with
NOVEMBER 2017 • 83
CONTROL TALK
an additional $50,000 per year in ex-
penses to cover technical support. What
determines its fate is independently set
enterprise numbers. The numbers are
not coming up from the bottom, but down
from the top. If you do better by 15%, you
better see the result soon, and next year
you need to do 20% better. The enterprise
numbers can also be shifting a problem
from plant A to plant B, so you'd better
hope you aren't plant B.
GREG: We see this within plants, where
reducing variability and improving per-
formance in one part of the plant hurts
another part by the transfer of variability
or the reduction in utilities or feeds. Each
unit operation has an operating point of
maximum efficiency and capacity, and is
upset by changes in utilities or feeds.
WALT: A company in Greece that is a col-
lective of people who were running the
plant took over a plant that was going to
be shut down. The plant is doing well. As
engineers and technicians, what we need
to realize is that the plant is no longer our
plant. What is ours is the knowledge, and
we should use that to our advantage.
For the other Top 10 things you don’t want to hear from an executive, visit www.controlglobal.
com/articles/2017/the-trouble-with-top-management.
84 • NOVEMBER 2017 www.controlglobal.com
JOY: Automation leaders are self-driven,
and want teams and are into the group
thing. They don't want to be the dictator.
They're very sharing people with a real-
istic bottom-line emphasis and motiva-
tion to advance knowledge. I saw this in
the Insider interviews with Peter Martin,
Peter Zornio, Chris Lydon, Andy Chatha,
Eddie Habibi, Peggy Koon and Charlotte
Hill, to name a few. It's very hard to make
sure the enterprise level attracts people
like these, with both business and engi-
neering expertise.
GREG: There are many executives in the
refining, petrochemical and pharma-
ceutical industries, and with suppliers
of automation systems, who are very
enthusiastic and appreciative of technical
opportunities and achievements. I expect
most of these have a degree in engineer-
ing or science.
Nearly all of the industrial chemical
plants at Monsanto were built during the
first half of my career, when the CEO was
an engineer.
JOY: Engineering changes lives. Engi-
neering changes the world for the better.
This is what drives engineers. You don’t
have to have a PhD to accomplish all
that you need and want to do. PhD just
means you were able to withstand the
baloney piled higher and deeper. Un-
less you are going to teach, a PhD isn't
needed.
GREG: Engineers need to be more out-
spoken about their contributions, build
their teams, and teach what's learned
and achieved.
WALT: It’s difficult for executives with no
technical training to know what’s hap-
pening on the front line. This lack of un-
derstanding makes artificial intelligence
(AI) attractive. They think all activities are
repetitive, and like in parts manufactur-
ing, can be replaced by robots. They also
fail to realize that AI results are correla-
tions, rather than cause and effect, and
that input data can't just be dumped into
the system, but must be screened. The
results must also be analyzed based on
process knowledge and first principles.
GREG: The “lights out” plant forecast in
the 1970s has not materialized.
JOY: The bottom line is that engineers
are fundamentally altruistic and want
to make a difference in the future. The
question is how they can do this when
they're told to do as told. What are we go-
ing to do with the engineers in their 20s,
30s, and 40s, who don’t have the men-
tors due to continual retirement and the
hiring freeze in the 1980s? How do we
enable engineers to do what they really
want to do? If the executives don't un-
derstand process control or automation,
what can we really do?
GREG: Our December column will de-
scribe what we think is the solution. In
the meantime, check out the August
2017 Control Talk blog, “Motivating man-
agement and millennials (M&Ms)” (www.
controlglobal.com/blogs/controltalkblog/
how-to-motivate-management-and-mil-
lennials-m-and-ms).
 United States Postal Service
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(4) Copies Distributed Outside the Mail (Include
Pickup stands, Trade shows, Showrooms and 25 100
Other Sources) ABB������������������������������������������������������6 Massa Products ���������������������������������76
e. Total Non-requested Distribution 1,120 1,220 ABB Measurement Products�������70, S21 Microcyber��������������������������������S19, S25
f. Total Distribution 45,134 45,490 Advantech Automation�����������������������55 Moore ���������������������������������������� S5, S22
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g. Copies Not Distributed 1,123 381
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h. Total 46,257 45,871 AutomationDirect���������������������������������2 Orion Instruments��������������������������������3
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i. Percent Paid and/or Requested Circulation 97.52 % 97.32 %
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16. Electronic Copy Circulation months single issue Development����������������� 63, 65, S2, S22
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(Line 16a) 59,784 59,822 Endress+Hauser����������������8, 9, S7, S25
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divided by 16c i 100) 98.16% 98.00% Vega Americas������������������������������������49
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 CONTROL REPORT
JIM MONTAGUE
Executive Editor
jmontague@putman.net
"To me, Dick's openness
to possibility, character-
ized by a seemingly
endless stream of big
ideas, and his person-
able humility make
him stand apart from
other innovators across
all industries."—Rick
Caldwell
86 • NOVEMBER 2017 www.controlglobal.com
Missing Morley
The father of the PLC lives on in all the lives he touched—and will continue to touch.
I'M always slavishly grateful to people who can ex-
plain to me how things really work because I usu-
ally can't figure them out on my own. A few years
ago, I was trying to research "industrial comput-
ers," but it was devilishly difficult because they'd
begun to morph and take on almost any form.
How could I cover them if I couldn't define them?
Luckily, it was at about the same time that I met
briefly with the legendary Dick Morley at one of
the many tradeshows we all attend, and I asked,
"Isn't the PLC really just a computer, too?"
And, without missing a beat and with no hint
of ego or psychological investment—which might
easily be expected from someone at the root of
that device's invention—he told me, "Well, yes, it
is a computer, but we had to put it in an enclosure
and make it look industrial so engineers and other
people on the plant floor would use it."
Perfect. For me, this was a rare and completely
unselfconscious answer, which led me to focus on
where the calculations are actually occurring as
my definition of "industrial computer," and not re-
main tangled up in the increasingly shifting forms
they take. As you might guess, this perspective
has been helpful in approaching and framing
many stories since then, and I've continued to ap-
preciate Dick and the little Ninja star of insight he
provided way back when.
As a result, like so many other folks, I was
deeply saddened to hear about Dick's death on
Oct. 17 at the age of 84 after a long illness. I really
only interacted with him for a few minutes, but of
course, he profoundly impacted the lives of thou-
sands of family members, friends and associates
over his long life and career. Not surprisingly, most
have been consoling each other with a deluge of
stories since his passing.
Dr. Peter Martin delivered a great tribute, "Loss
of a Legend—And a Friend," in one of the blogs
on Schneider Electric's website (https://blog.
schneider-electric.com/machine-and-process-
management/2017/10/19/loss-legend-friend).
Likewise, the Go Fund Me site set up in his mem-
ory (www.gofundme.com/lv6bho) contains many
tributes and reminiscences, too.
Even one of his best-known locations on the
web, The Barn Website (www.barn.org), is still up
and running with its usual content. I'm told that
"Geek Pride Days," motorcycles, skiing, fostering
and adopting children, and apparently chasing
interns with remote-controlled backhoes were just
a few of Dick's many pastimes, but those are ru-
mors that others will have to confirm.
In fact, it can hard to find someone who doesn't
have something kind, funny or interesting to say
about him. "Dick’s legacy as a mentor, innovator,
and inspiration extends well beyond his many pro-
fessional accomplishments," says Rick Caldwell,
president of system integrator SCADAware. "To
me, his openness to possibility—characterized by
a seemingly endless stream of “big ideas”—and
his personable humility make him stand apart
from other innovators across all industries. He was
a friend to me for 25 years, and had a profound
effect on me, in the way I think and how I look at
things. I will miss him greatly."
Sam Hoff, CEO of system integrator Patti Engi-
neering, added, "Dick was an optimist, innova-
tor, and visionary. Every time I met Dick, it was a
memorable experience, and he gave me several
nuggets to use in business and life. He and his
wife, Shirley, were very giving as they took in many
foster kids over the years. He is now reunited with
the love of his life. In conclusion, the best thing to
say about Dick is 'Life Well Lived.'"
More recently, the International Society of Au-
tomation (www.isa.org) announced Nov. 7 that it's
created the Richard E. “Dick” Morley Innovation
Scholarship to honor him (https://isaautomation.
isa.org/morleyscholarship). ISA endowed the fund
with an initial $50,000, and has pledged to match
the next $50,000 in donations.
I believe it's good to be reminded of all these
close contacts and stories about Dick because
they're items his family and friends get to keep
with them always. And, if little pieces of us like-
wise get to stay close to the spirits of the de-
parted, then Dick must have lot of company.
 Profit Engineer

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