Intech Isa Nov - Dec 2012

November/December 2012
Compressor control
Discrete wireless
High performance HMI
Defense in Depth
Temperature special section
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November/December 2012 | Vol 59, Issue 6
12
Setting the Standard for Automation
COVER STORY
COLUMNS AND DEPARTMENTS
The need for

enterprise control
By Peter G. Martin
Success in this accelerating global business

marketplace requires extension of real-time
plant oor closed-loop control to the entire
enterprise. Companies that cannot respond
with agility will be left behind. With proper
measures, protability can be controlled
almost as effectively as temperature, pressure,
ow, and other process variables.
PROCESS AUTOMATION
SYSTEM INTEGRATION
20 A guide to effectively
30 The high
executing compressor
performance
control retrots
HMI
By Rick McLin
By avoiding fundamental mistakes
during the design phase, engineers can
consider any retrot an opportunity
to improve compressor operation and
efciency. Major areas to make compressor control improvements include
compressor control algorithms and
control system interactions.
By Bill Hollield
Human-machine interface (HMI) software to create sophisticated graphics
has advanced rapidly over the years,
but process graphics design concepts
have not kept pace with human
interface design. There are better ways
to design process control graphics that
improve operator effectiveness.
FACTORY AUTOMATION
AUTOMATION IT
26 Discrete wireless
38 Defense in Depth
By Bill Lydon
Wireless standards to date have focused on analog sensors, but standards
are emerging for discrete wireless.
Standards groups are starting to view
general factory automation as the next
big application area for wireless.
www.isa.org
By Eric J. Byres
The cyber-attacks on industrial automation systems are increasing and can
create downtime and damage. Understanding the basic concepts of defense
in depth help in defending automation
systems.
Talk to Me
Application engineering and
product innovations
Your Letters
Security issues, career changes,
and more.
10 Automation Update
Virtual reality training, By the
Numbers, and more.
47 Executive Corner
Whats on YOUR mind?
49 Association News
In Memoriam, Certication Review
52 Automation Basics
Selecting temperature
measurement and control systems
56 Young Innovators
Innovation, education, and
experience
57 Workforce Development
Findingor developingthe
right person for the job?
58 Channel Chat
When is safe safe? The value
of a risk assessment
60 Standards
Standards update: Alarm
management
62 Products & Resources

Spotlight on temperature
66 The Final Say

Paul Galeskis ISA Excellence in
Leadership Award acceptance
speech
SPECIAL SECTION: TEMPERATURE
42 Thermal imaging detects equipment issues

By Michael Stuart
Once you enter into an automated process environment, the stakes around possible
failure become high. Fortunately, there is a tool that can help prevent that possibility
from becoming a reality: the portable thermal imager.
INTECH NOVEMBER/DECEMBER 2012
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RESOURCES
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Datales
Classied Advertising
Statement of Ownership
Index of Advertisers
ISA Jobs
InTech Online
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WEB EXCLUSIVE
Analysis of wireless industrial automation

standards: ISA100.11a and WirelessHART
Wireless communication is being adopted in
many areas, and the use of wireless networks
in industrial automation is increasing due
to the advantages of reduction of time and
cost to install new devices. ISA100.11a and
WirelessHART are two of the most important
standards available that deal with the application of wireless networks in process automation. This article compares ISA100.11a and
WirelessHART, describing the main features
and issues. Read the web exclusive at
www.isa.org/intech/201212web.
Events calendar
Find out about upcoming
events in the industry.
www.isa.org/intech/calendar
Breaking Automation News
Black and white and read all over
News is not a 9 to 5 occurrence; it breaks out all the

time. So if you want to be the rst to know about
what is happening across the industry, click here.
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White papers are a great way to learn technical detail

behind some of the latest industry advancements.
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Story Idea
Automation Industry Connection
See what company is doing what at ISA Jobs.
Find out about people and positions.
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Products 4 U
Companies are releasing new products all the time;
nd out the latest automation products hitting the
plant oor.
www.isa.org/intech/products
2012 InTech
ISSN 0192-303X
InTech is published bimonthly by ISA.

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Perspectives from the Editor | talk to me
Application engineering
and product innovations
ISA INTECH STAFF

CHIEF EDITOR
Bill Lydon
blydon@isa.org
PUBLISHER
By Bill Lydon, InTech, Chief Editor
Susan Colwell
scolwell@isa.org
PRODUCTION EDITOR
Question: Is it more important for engineers

to focus on application engineering or adding new products? The answer is both. In
either case, the knowledge, know-how,
and creativity of automation engineers is
the key to successful implementations to
improve production.
Application engineering involves using the
building blocks of technology to tailor systems to satisfy unique characteristics of specic plants, manufacturing environments,
and processes. Some of the applications are
simple, but many are complicated. My experience working with applications problems
is it requires thinking through a number of
options, variables, and constraints to design
automation solutions. I like to call the middle
of this process, balancing a basketball on
your ngertip. It always seems like there
is a big jumble of stuff to factor into your
thinking before there is clarity. When an application is implemented and running, it all
looks so simple. I do believe that there is an
artistic component to good application engineering, since it is a non-linear thought process. The solutions created by engineers look
so simple that many of their managers do
not have an appreciation of the knowledge,
know-how, creativity, and work it takes to
design simple solutions to difcult problems.
You might suggest that your manager read
the book by Mathew E. May, The Elegant
Solution, which describes Toyotas concepts
that simple solutions are valuable but take a
lot of work and know-how to achieve.
The role of automation professionals is expanding as manufacturing is being improved
with integration into business systems to
provide more exibility, responsiveness, and
productivity. The importance of automation professionals was summed up by Peter
Martin, Ph.D., vice president, business value
solutions at Invensys, in his introduction of
the ISA Automation Week 2012 Executive
RoundtableAn Open Discussion About
the Future of Automation: We [automation professionals] are the future of industry;
if we do our job industry will thrive. Martins comments punctuated the importance
of automation professionals, and the panel
discussed the need to interest new people to
join the profession. Also discussed was the
expanding role of automation professionals
to go beyond machine and process to include integration with business systems.
It is valuable for automation professionals to keep expanding their knowledge of
new automation technology, methods, and
the expanding range of products that are
building blocks to create application solutions. Certainly there are many ways to
learn about new solutions. The Internet and
industry magazines deliver information, but
I suggest that conferences also provide a
truly interactive way to improve knowledge
and skills.
A number of industry and vendor conferences took place this past year, and a
great example of a valuable non-vendor
conference was ISA Automation Week
2012, where automation professionals
from around the world beneted from a
smorgasbord of application engineering
ideas exchanged in more than 60 technical
conference sessions, networking events,
and among the 88 vendors displaying
unique new technological solutions. In
addition to the formal presentations and
sessions, the opportunity to talk with automation people from other companies
and industries provided a cross-pollination
of ideas that can stimulate new thinking
and innovations. Attending and participating in local ISA section meetings, industry
symposia (examples: water/wastewater;
safety and security), and events is another
way to gain knowledge and interact with
other automation professionals.
It is important for your career and your
company to stay ahead of industry competitors by applying technology. Ideas are
powerful and transformational and best
found by putting yourself in the right environments.
Ashley Atkins
aatkins@isa.org
ART DIRECTOR
Colleen Casper
ccasper@isa.org
GRAPHIC DESIGN SPECIALIST
Pam King
pking@isa.org
ISA PRESIDENT
Robert E. Lindeman, CAP, PMP

PUBLICATIONS VICE PRESIDENT
Eoin Riain
EDITORIAL ADVISORY BOARD
CHAIRMAN
Steve Valdez
GE Sensing
Joseph S. Alford Ph.D., P.E., CAP
Eli Lilly (retired)
Joao Miguel Bassa
Independent Consultant
Vitor S. Finkel, CAP
Finkel Engineers & Consultants
Guilherme Rocha Lovisi
BAYER MaterialScience
David W. Spitzer, P.E.
Spitzer and Boyes, LLC
James F. Tatera
Tatera & Associates Inc.
Michael Fedenyszen
R.G. Vanderweil Engineers, LLP
Dean Ford, CAP
Glenmount Global Solutions
David Hobart
Hobart Automation Engineering
Allan Kern, P.E.
Tesoro Corporation
your letters | Readers Respond
Security issues
I appreciate the article, Uninterruptible power supplies and
cybersecurity by Michael A. Stout (January/February 2012 InTech). The authors expertise and product offering are from the
UPS world, which is great. The same security issues apply to any
device located in the facilityfor example, HMIs, PCs, SCADA
system, or any operating/control device. Security by obscurity no
longer ies. Unless a serious security event occurs at a facility in
questionwater/wastewater, power generation/distributionit
is tough to get the attention of those with budget control to
implement the proper security policies and defenses.
Jeff
tiple drives, etc. that do not require modication by a system integrator. This will reduce the investment by system users in terms of
producing their software standards.
Selvan Murugan
Career change considerations

Alan Cartys article, Thinking about a job change? (May/June
2012 InTech), offered excellent insight for engineers wanting to
make the next steps in their careers; of particular interest are his
views on engineers becoming sales engineers. I agree that trying
to grow ones career with a current employer makes perfect sense,
and it cannot be argued that it takes at least three to six months
to become effective in a new role. For many reasons, however,
its not always possible for aspiring persons to grow their careers
with their companies. As a veteran recruiter in this industry, its my
ambition to reach engineers ready to make that next step and
who cannot achieve this in their present situations. Many clients
Teaching an engineer to sell, provided he

or she has the interpersonal skills necessary
to manage the circumstances that selling
demands, is indeed a valuable commodity.
are receptive to these candidates, particularly as baby boomers
retire. Teaching an engineer to sell, provided he or she has the
interpersonal skills necessary to manage the circumstances that
selling demands, is indeed a valuable commodity. Mr. Carty makes
a strong point: what happens if success isnt achieved when the
engineer takes on a new role with a new employer? Candidates
and clients must assure that objectives, business philosophies, etc.
are on par before making a commitment to one another. Success
can never be guaranteed, but risks can be minimized. I often remind clients that bringing them the best possible candidate is my
job. Keeping this employee satised and challenged is their job.
Eric C. Bergsman
Expanding on standardization
Code standardization increases throughput (May/June 2012
InTech) was an excellent article with many spin-offs, such as:
n Shorter fault-nding times by technical staff due to familiarity
with the code
n Quick new project delivery timelines due to the code library
n Ease of software modication when physical/mechanical plant
changes are made
n Ease of knowledge transfer to new technical staff.
I would also like to see PLC/DCS/SCADA system libraries come
standard with software modules for conveyors, crushers, mulSource: automation.com
8
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automation update | News from the Field
This content is courtesy of
Invensys supplies virtual reality

training to Department of Energy
nvensys Operations Management implemented an operator-training simulator for the U.S. Department of Energy
using SimSci-Esscor EYESIM virtual reality
training solution.
Designed for use within integrated
gasication combined cycle power plants
with carbon capture, and implemented at
the National Energy Technology Laboratorys Advanced Virtual Energy Simulation
Training and Research Center in Morgantown, W.Va., the EYESIM solution uses
3-D virtual reality simulation to help train
power plant control room and eld operators. Wearing a stereoscopic headset,
IGCC eld operators are immersed in a
virtual environment with the ability to
move throughout the plant, coordinating
their activities with control room operators and interacting as if they were in the
actual facility.
The EYESIM solution is also fully integrated with plant operating models, built
on Invensys operations managements
SimSci-Esscor DYNSIM dynamic simulation software, so actions taken by a eld
operator affect the plants process, and
actions performed in the control room
change the information visible to the eld
operator. Fully interactive animations respond and react to the actions of plant
personnel, illustrating how various pieces
of equipment will operate under almost
any scenario and condition. As a result,
eld and control room operators learn to
collaborate and perform as a team.
Siemens to build geared motor plant

in South Carolina
Siemens Industry announced plans to
open an assembly and manufacturing
plant as part of the companys Drives
Technologies division, Mechanical Drives
business unit. The 45,600 square-foot facility will be located in the city of Mauldin
in Greenville County. Siemens anticipates
opening the facility later this year.
The facility will assemble Siemens new
Simogear family of geared motors, featuring helical, parallel shaft, and helical bevel
gear units primarily used in modern conveyor systems often found in warehousing,
logistics and distribution, airport baggage

handling, automotive manufacturing, and
food and beverage processing.
Doug Keith, president of Siemens
Drive Technologies division in the U.S.,
said that the site combined all of the necessary elements Siemens was seeking in a
location, including proximity to transportation infrastructure, including interstates
and ports, a highly skilled workforce with
reputable educational institutions nearby,
a green-minded community, and a dedicated group of business partners.
Multiphase
owmeter market
growing fast
Multiphase owmeters are an evolving
technology and the fastest growing owmeter type, outpacing ultrasonic and other new-technology owmeters, according
to a new study from Flow Research, The
World Market for Multiphase Flowmeters. The study found that the multiphase
owmeter market totaled $240.0 million in 2011. The market is projected to
increase at a compound annual growth
rate of 14.5 percent through 2016 until
it reaches $472.2 million. While the bulk
of these revenues are from multiphase
meters, some also come from dual phase
meters manufactured by multiphase meter
suppliers.
Multiphase owmeters determine the
percent of gas, water, and oil that makes
up the uid as it comes out of an oil or
gas well. They then use other values to
determine the owrate of each uid.
This information is very valuable because
it tells the operator how much of each
type of uid is coming out of the well
before the uids are separated. Multiphase owmeters also yield valuable information about the condition of the oil
or gas well where the drilling occurs.
ISA CEO Patrick Gouhin speaks at World Manufacturing Forum

Patrick Gouhin, ISAs executive director and
CEO, spoke at the World Manufacturing Forum 2012, held the week of 15 October, an
invitation-only conference in Stuttgart, Germany, where more than 400 manufacturing
executives, experts, and policy-makers from
44 countries offered and discussed solutions
to global manufacturing challenges.
Gouhins message highlighted ISAs involvement in advancing the science of automation and development of automation
10
professionals capabilities. Gouhin said ISA is

poised to play an active and vital role in initiatives to stimulate growth, innovation, and
collaboration in worldwide manufacturing.
Amid the backdrop of a worldwide economic slowdown, conference participants
explored strategies for energizing worldwide
manufacturing activity and encouraging
cross-border collaboration and innovation.
As global value chains become increasingly linked, and competition for
WWW.ISA.ORG
limited energy resources and raw materials mount, technological innovation,

combined with a skilled workforce, is regarded as critical to fostering sustainable
economic growth around the world.
The World Manufacturing Forum focused on improving ve manufacturing
technology platforms: sustainable manufacturing and occupational safety; energy
efciency; key technologies; standards and
interoperability; and education.
News from the Field | automation update
Automation by the Numbers
$1289.9 million 1,000,000,000

The need to improve manufacturing uptime, plant protability,
and process efciency, paralleled by the rising complexity of
manufacturing processes, has underscored the demand for enhanced motor services.
Frost & Sullivan says the market earned revenues of $766.8
million in 2011, and estimates it will reach $1289.9 million
in 2018. The research covers technical consulting, motor management, installation and commissioning, maintenance and repairs, and other (training and standby motors) services.
Evolving energy regulations have highlighted the inadequacy
of in-house motor maintenance. Instead, the focus has shifted
to motor manufacturers with expertise in motor service maintenance who can facilitate energy efcient practices.
As the market makes a strong recovery from the global economic crisis, a key challenge in the short to medium term will
be for motor manufacturers to provide the right service mix
for end users. End user service requirements typically vary, with
most preferring customized solutions. The challenge, therefore,
will not only be to provide services for the product supplied, but
also to understand the functioning of the total plant and customize the service offering accordingly. It is expected, however,
that, once motor manufacturers and service providers gain sufcient expertise, the impact of this challenge will diminish.
Emerson Process Management announced that

it clocked more than 1 billion total hours
of wireless operations across 10,000 systems. Emerson Smart Wireless technology, based on the internationally
recognized IEC 62591 WirelessHART
standard approved in 2010, is now
widely implemented in reneries,
oil elds, offshore platforms, chemical plants, and other industrial facilities around the world to obtain realtime plant data to optimize operations,
improve worker and plant safety, and reduce
emissions and other environmental impacts.
Since its release ve years ago, Emerson estimates put the total installed savings resulting from Smart
Wireless eld devices at more than $350 million, and reductions
in commissioning and installation time totaling 16 man-years. The
adoption of this technology has now spread to more than 120
countries and more than 10,000 separate wireless systems.
Emerson continues to expand its wireless offerings, including
the recently introduced Mobile Worker: Voice and Video, a handsfree, high-denition voice and video solution that plant personnel
can wear in remote eld locations. Mobile Worker is designed to
help process manufacturers save time and money on plant maintenance and trouble-shooting by bringing the problem to the experts rather than bringing the experts to the problem.
78%
According to a survey from Deloitte

and The Manufacturing Institute,
the public feels that American leadership is off-course in improving
manufacturing competitiveness and that the national economy
is weak and fragile.
The survey sampled a nationally representative group of 1,000
Americans in September, nding that 84 percent strongly agree
or agree that the U.S. needs a more strategic approach to developing its manufacturing base. A vast majority (82 percent) support further investment into Americas manufacturing industry.
Despite the publics gloomy mood, however, Deloittes Craig Gif
points out that Americans do have faith in the nations technology
expertise and resources to help bolster the manufacturing industry.
For example, 78 percent of respondents cited Americas
technological prowess as one of the key contributors to the nations competitive advantage, he said. Further, 75 percent
cited Americas research and development (R&D) capabilities as
a key advantage.
11
The need for
enterprise control
Automation engineers improve business performance
By Peter G. Martin
12
he concept of delivering enterprise control on an enterprise control system

(ECS) was introduced to industry in
2006. As with any new approach in the control
and management of industrial processes and
businesses, it has taken some time for the value of enterprise control to be understood and
embraced. The forces accelerating the pace of
business are stronger than ever, however, which
increases the urgency to nd a workable realtime control solution that encompasses the entire enterprise, not just the plant oor.
WWW.ISA.ORG
The move toward real-time industrial business

Although many factors are driving the need
for effective real-time control and automation,
the one that executives seem to be struggling
FAST FORWARD
l
Who needs real-time enterprise

control?
The challenge: connecting the islands

of automation and information.
An exciting new role for the control

engineer.
COVER STORY
13
COVER STORY
Figure 1. Simplied real-time

protability model
with the most is the transition of their

critical business variables from transactional stability to real-time variability. Only a decade ago, the business
variables associated with industry
had been highly stable over long time
frames. Electricity pricing changed
every six months. Raw material costs
may have changed monthly. Product
costs were set for months at a time.
The business environment was highly
stable for well over a month at a time.
With this type of stability, the protability of industrial operation could be
effectively managed by simply controlling the efciency of the plants in real
time and managing nancials monthly. Increasing operational efciency
directly translated into increased profitability. Real-time control systems
could do their thing somewhat independently of business systems, and the
industrial business would be successful and protable.
Over the last decade all of this has
changed. Today, the price of electricity and natural gas changes every 15
minutes in the U.S. The price of raw
material may change multiple times
a day. And the production value of an
operation may change multiple times
each minute. Just watch a metals price
tracker on any nancial network and
you may see the market price of metals
changing every 30 seconds.
Today, not only do the production
environments require real-time control, but the business environments do
as well. Monthly nancial statements
14
are just not frequent enough to control

business variables that change multiple times a day. The solution to this
daunting industry challenge is to apply
control theory to the real-time business variables. This will require resurgence in the eld of control engineering, expanding real-time computing
domains well beyond the traditional
distributed control system (DCS) and
programmable logic controller (PLC)
boundaries.
Automation engineering talent is often reluctant to take on the real-time
business challenge. When industrial
automation engineers review annual
reports and other nancial reports
and see how complex these reports
are, their rst reaction may be shock.
Financial reporting of industrial operations is indeed quite complex, but
today not all business variables uctuate in real time. The primary industrial
business variables that may change in
real time are energy costs, raw costs,
and production value. These components of protability are typically con-
functionality must expand the realtime systems domains to encompass

the entire industrial enterprise.
Real-time control has been successfully applied to control industrial processes for many decades to maximize
the efciency of the production operations. It is so pervasive that it is sometimes perceived as basic functionality,
even though the technology of process
control has been continually evolving
and is actually quite sophisticated. The
effective application of real-time control can add order to what might initially
appear to be a chaotic situation. When
process plants were rst developed, the
operation appeared chaotic because
of the large number of variables that
changed value in real time and had
to be controlled together to produce
the desired result. Control engineers
throughout industry have learned how
to bring order out of chaos and improve
efciency on the plant oor by applying
control theory effectively.
Today, not only are plant processes
themselves more challenging; the busi-
Control engineers must expand their horizons to bring the

control of business variables into their domain of expertise.
strained by the physical process, plant
safety, and environmental concerns.
Since the physical process cannot be
altered in real time, the real-time profitability model deals with the real-time
interaction of the other ve variables
as displayed in the simplied real-time
protability model (Figure 1). Applying control theory to these real-time
components of protability is a good
starting point for bringing industrial
protability under control.
The solution: enterprise control

The real-time business environment
presents a daunting challenge to industrial executives. The solution requires expansion in both the scope
and the functionality of automation
systems. The scope must expand realtime control to encompass both plant
efciency and plant protability. The
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ness processes also present challenges,

which require real-time responses. Effective application of real-time control
of both the plant and business domains
is the only solution. Control engineers
must expand their horizons to bring
the control of business variables into
their domain of expertise. The same
basic control theory that has worked
so successfully in real-time plant operations also applies to real-time plant
protability. The key is to build protability control loops (Figure 2). This
can be accomplished by rst measuring the critical business variables in a
real timeframe. The information commonly stored in an enterprise resource
planning (ERP) system does not have
the timeliness for a protability control loop. Yet experience has shown
that these real-time business measures
can be modeled in the installed indus-
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COVER STORY
Figure 2. Prot control loop
Figure 3. Cascade control for real-time business control
trial automation system from the database comprised of the vast number
of process sensors already installed in
the plant along with some key business
variables, such as current energy cost,
raw material cost, and product value.
Operators close the loops

It would be nice if a protability controller existed with the same general
use characteristics as the traditional
PID controller used for process control, but it does not. Part of the reason
is that there are no specic natural periods for prot loops, as there are for
process loops. But the rst approach
to closing the loop may be to emulate
early process control systems and use
process operators to manually close
the loop. This can be accomplished
by providing the real-time feedback to
the operators so they can understand
how the actions they normally take,
such as setting a setpoint or putting
a control strategy in manual, impact
the protability of the operation. This
can be accomplished by supplementing them with real-time performance
scorecards or dashboards. Over time,
they will learn how to bring the protability control loop into control and to
maximize prots from their domain of
operation. As better understanding of
the dynamics and control approaches
of the prot control loops is gained,
mechanisms may be developed that
automatically close the loops.
16
It is important to realize that realtime protability control does not replace the traditional process control.
Rather, effective real-time process
control must be in place for the profitability control to work. The relationship between process control and
protability control can be thought of
as a cascade control strategy with profitability control as the primary loop
and process control as the secondary loop (Figure 3). Protability control must rst be applied across each
plant and then across the entire eet
of plants in the enterprise to realize
maximum business benet. Clearly,
protability control has broader implications and scope than process control
and a broader perspective of real-time
automation environments is required
to make enterprise control a reality.
Enterprise control systems

enabling enterprise control
One of the critical barriers to implementing enterprise control across industrial businesses is that the installed
control technologyeven within a single plantis often comprised of multiple systems and software applications
that do not work well together. There
are silos of automation and information throughout industrial operations
(Figure 4). Implementing enterprise
control requires that these silos not
only work together, but that they also
work together in real time, because the
WWW.ISA.ORG
problem is a real-time problem that

goes across traditional domains.
This is not unlike the situation at
the IT and business system levels of
industrial organizations that led to the
development of ERP systems. There
had been numerous systems and applications at the business systems level
that were not designed to interoperate.
Companies, such as SAP and Oracle,
responded to this situation by developing enterprise service-oriented architectures to pull the plethora of systems
and software together into a common
business-computing domain.
Industrial automation needs to follow suit to meet the demands of enterprise control. The development of industrial service-oriented architectures
that enable various real-time systems
and applications to work together as
a common enterprise control system
is exactly what is required to meet the
daunting challenges facing industrial
businesses. The emerging enterprise
control systems will act as the realtime counterpart to the transactional
ERP systems (Figure 5). The combination of open enterprise control systems working with ERP systems will
cover both the real-time and transactional needs of industrial enterprises
and provide the technical basis for
true enterprise control.
One key to protability for industrial companies is being able to respond
to market and business uctuations
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COVER STORY
Figure 4. The problem: silos of automation and information
Figure 5. Enterprise control systems
munity has never been in a stronger

position. Industrial automation and
real-time control are the keys to driving profitable success for industrial
companies. But capitalizing on the
traditional control and real-time automation expertise requires a shift in
perspective. The scope of where control can be effectively applied must
increase to include the control of realtime business variables. And the scope
of real-time automation must increase
to encompass entire plants and even
entire enterprises. The industrial automation industry is the key to the ongoing profitability of industrial companies. The move to enterprise control is
necessary, and the expansion of automation systems to enterprise control
systems is essential.
Although the technology underlying enterprise control systems was first
introduced to the industrial market in
2006, few industrial companies have
been in a position to take full advantage of it and develop corporate enterprise control strategies and implementations. But there have been a number
of companies that have started to capitalize on enterprise control approaches in a bounded manner. The results to
date have been promising, but the true
potential for real-time control of industrial enterprises is only beginning
to be realized.
It is a great time to be in this field. It
is time to make enterprise control a reality and demonstrate the true potential of industrial automation.
ABOUT THE AUTHOR
as they occur. Many existing process

manufacturing plants were not designed to operate with agility, and providing more comprehensive business
controls alone will not make them
agile enough for real-time operation.
Implementing a real-time enterprise
control solution across an integrated
system, however, will allow them to
manage whole fleets of assets as a
18
single business entity. This certainly

will not necessarily improve agility of
any single asset, but it will add a level
of business agility at the fleet level.
This may or may not be the complete
answer to the requirement for more
agility to match the real-time market
demands, but it is a strong step in the
right direction.
The industrial automation com-
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Peter Martin, Ph.D., (peter.g.martin@invensys.com) is vice president, business value

solutions, for Invensys Operations Management. He has spent more than three
decades in the automation industry, culminating with the development of commercially-applied dynamic performance
measurement technologies and methodologies. An established author and industry speaker, Dr. Martin received the ISA Life
Achievement Award in 2009 for his work
in performance measurement.
View the online version at www.isa.org/intech/20121201.
A guide to effectively executing

compressor control retrots
Improving existing compressor
control systems improves operations
and energy efciency
By Rick McLin
20
WWW.ISA.ORG
ompressors are major pieces of capital equipment with long, effective lifespans. Unfortunately, control system obsolescence, plant
recongurations, and changes in process requirements can all
drive the need for a control system retrot over the lifetime of the compressor, and the multivariable, nonlinear system architectures required
for compressor control can cause fear and uncertainty for the engineers
responsible for executing the project.
However, by avoiding fundamental mistakes during the design phase,
engineers can instead consider any retrot as an opportunity to improve
compressor operation and efciency. This article will explore major areas
to make compressor control improvements, including:
l Compressor control algorithms
l Control system interactions, including capacity control
PROCESS AUTOMATION
The rst area to investigate is the compressor

control algorithm itself. If the compressor installation is more than ten years old, the control
system involved is likely based on outdated antisurge techniques that may not be as efcient as
those in common use today. With current technology, it is no longer necessary to sacrice process stability to protect the compressor. Todays
control hardware capabilities allow the use of
rigorous models to optimize compressor performance, as well as tighter integration of the compressor controls into the overall process itself.
Performance maps supplied by the compressor
vendor provide the base for compressor control
algorithms. These maps typically represent ow
along the X-axis, while discharge pressure, pressure ratio, or head are located along the Y-axis.
Engineering units used on the X- and Y-axis can
be (and often are) just about anything. Indeed, the
only ow measurement not previously seen seems
to be cubic furlongs per fortnightanything else
is apparently fair game. A typical compressor performance map depicts a variable-speed machine
with performance shown as polytropic head on
the Y-axis versus ow on the X-axis, measured in
thousands of cubic feet per minute. Compressor ow and pressure follow a speed line until
they reach a surge point. The ows and pressures
change as the speed of the compressor changes.
Another set of curves denes compressor efciency at various speeds and ows. Compressor
impellers are normally designed to achieve maximum aerodynamic efciency near the center of
each speed line. If the compressor does not normally operate near its area of maximum efciency,
consider a compressor rerating.
The phenomenon of surge

Surge occurs when the kinetic energy imparted
into the gas by the impeller is less than the potential energy in the discharge. When this occurs the ow of gas will reverse direction.
When a compressor approaches the surge
point along a speed-line ow, the compressor
will reverse direction. This ow reversal happens at the speed of sound, far too fast for instrumentation to detect, and, once started, cannot
be stopped. A surge cycle will repeat unless the
surge control system intervenes. Repeated surge
cycles can seriously damage or even destroy a
compressor, so predicting the onset of surge is
essential in modern surge-control algorithms.
What happens during a surge event

Figure 2 is a representation of a surge event.
FAST FORWARD
l
Compressor control can cause fear and uncertainty for engineers.

Avoiding fundamental mistakes during the design phase, engineers
can consider any retrot as an opportunity to improve compressor
operation and efciency.
Current technology allows the use of rigorous models to optimize

compressor performance, as well as tighter integration of the
compressor controls into the overall process.
Compressor control system retrots can be intimidating, but by

following basic design principles they can achieve positive results.
Only a single-speed line

is shown for clarity. AsSurge line
sume that initially the
compressor is operat3
ing at point (1) in the
2
diagram.
Speed line
The compressor is operating at its maximum
ow capabilities at point
4
1
(1). As the discharge
pressure increases, the
work the compressor
must accomplish also
increases. This pushes
Flow
the compressor operatFigure 1. What happens
ing point along the speed line to point (2). If the
during compressor surge
discharge pressure continues to increase, the
compressor operating point will move to point
(3). If the control system cannot reduce the discharge pressure, the operating point will cross
the surge line and ow will reverse through the
compressor. When the ow reverses through the
compressor, the compressor operating point will
rapidly move to point (4). The surge event reduces
the discharge pressure and increases the suction
pressure of the compressor. The compressor will
then re-establish forward ow and the operating
point will move from point (4) back to point (2).
Total time for a surge cycle is one to three seconds,
but the ow reverses through the compressor in
under a millisecond. This cycle will repeat until
the compressor controls can intervene to change
the operating conditions and stabilize compressor
operation.
Discharge pressure
Improving compressor control algorithms
Common compressor control algorithms

Minimum ow recycle
There are several control approaches to prevent
surge in compressors. The oldest and least efcient method is minimum ow recycling. This
approach simply picks a ow rate that guarantees the compressor will not surge. If the ow
drops below the set ow rate, the recycle or
blow-off valve opens and maintains a redened
minimum ow through the compressor.
21
PROCESS AUTOMATION
higher, the compressor

can produce a higher
discharge pressure beMinimum flow control setpoint
fore a surge occurs. In
Surge line
the summer, when the
Speed lines
air density is lower, the
compressor
cannot
Pd/Ps
produce the same high
discharge
pressure.
As a result, control
is very simple; with
a discharge pressure
proportional integral
derivative (PID) feaFlow
turing an adjustable
While this approach can be effective,
variable pressure setpoint for ambient
it is not efcient. When the compressor
temperature.
operates at lower speeds, it requires a
Because variations in manufacturing
large ow to protect the equipment. This
require a conservative approach, many
approach also does not take into account
companies use discharge pressure
changes in gas properties, which may alcontrol for packaged air compressors
ter the compressor surge line.
where the surge data is generic, rather
However, while inefcient, this apthan specic to a particular machine.
proach can be useful as a fallback alUnfortunately, this approach often
gorithm in an advanced surge-control
wastes energy and does not provide adapplication. Fallback algorithms are
equate equipment protection. In addiused when eld instrumentation faults
tion, as the compressor impellers wear
prevent an accurate calculation of the
out or intercoolers become fouled, the
compressor operating point. In fact,
maximum discharge pressure the comwith degraded eld instrumentation,
pressor can achieve decreases. This reminimum-ow fallback may be the
quires a lower pressure setpoint to proonly practicable control algorithm.
tect the compressor, which if ignored
will cause compressor damage.
Maximum discharge pressure
Similarly, for older packaged compresThis approach to surge control relies
sors using pneumatic controls, mainteon the relationship between the maxinance personnel often ignore outdated
mum achievable discharge pressure a
pneumatic temperature measurement
compressor produces at various tembecause it is difcult to calibrate. This reperatures. Discharge pressure control
sults in a pressure setpoint that does not
is commonly used on constant-speed,
change with temperature, which also can
packaged-air compressors (typically incause damage to the compressor.
tegrally geared machines) where suction
More modern controls, even if igpressure does not vary. The advantage of
nored by maintenance personnel, allow
this approach is that it is extremely infor automatic adjustment of the surge
expensive (read: cheap) to implement
line. Once a surge occurs, the margin
because minimal instrumentation is recan be adjusted to limit the number of
quired: just a discharge pressure transsurge cycles a compressor would expemitter and an ambient temperature.
rience. Multiple surge cycles also can
There is not even a need to measure
be set to trip the compressor to help
ow through the compressor.
prevent damage.
There are several compressor maps
supplied by the manufacturer to relate
Delta P vs. h
the maximum pressure the compressor
The Delta P vs. h algorithm, also known
can produce in both summer and winas Pressure Rise, was originally develter conditions. During the winter, when
oped in the 1970s. It was developed
air is colder and therefore air density is
based on observations that the presFigure 2. Minimum ow recycle
22
WWW.ISA.ORG
sure ratio across the compressor closely followed the measured differential
pressure across a ow measurement
device. Delta P vs. h is still widely in use
today, due to its relative operational
simplicity and low cost. In fact, this
control method requires only a ow
and a differential pressure measurement across the compressor to function successfully.
Unfortunately, while Delta P vs. h is a
major improvement on minimum ow
recycle, it still has signicant problems. The method does not account for
changes in gas properties and requires
a suction pressure that does not signicantly change during operation.
As control systems have become more
advanced, it has become possible to implement more elaborate thermodynamic models for compressor control. As a
result, some form of a compressor head
model has largely replaced Delta P vs. h.
Compressor head vs. ow
The compressor head vs. ow algorithm
calculates the head generated by the
compressor and plots it versus the temperature- and pressure-compensated
ow produced. Regardless of whether
the algorithm is based on polytropic or
adiabatic head, this approach can accurately predict the compressor operating
point at various temperatures and pressures. In addition, it is not affected by
changes in the molecular weight of the
gas. The basic equations for this algorithm are shown below.
The basic equation for polytropic
head is dened as:
Figure 3. Polytropic head equation
Where
Hp =
Pd =
Ps =
Td =
Ts =
n
=
Polytropic head
Discharge pressure
Suction pressure
Discharge temperature
Suction temperature
Number of moles of gas in a
given pressure/volume
PROCESS AUTOMATION
Z
= Gas compressibility
R
= Universal gas law constant
MW = Molecular weight of the gas
The difculty with using this equation
for surge control is that not all the variables can be measured directly. Gas compressibility and molecular weight cannot
be determined except by ofine analysis.
To eliminate these variables from
the equation, it is necessary to utilize
the ow relationships of differential
pressure-ow measurement devices.
Orice, venturi, annubar, and other
head-type measurement devices have
ow equations that include terms for
molecular weight and compressibility.
For example, the classic orice equation:
Figure 4. Head-type ow measurement

equation
Where
Q = Flow, in appropriate units
H = Differential pressure across
ow measurement device
(head)
K
= Orice coefcient, dependent
on ow units and geometry
The
term is present in both
the head and ow equations. These
equations are used to generate the plotting coordinates used on the polytropic
head versus ow compressor control
map. Changes in molecular weight,
suction temperature, and compressibility affect the X and Y coordinates by
the same amount, allowing the generation of compressor maps that are valid
for variable composition gas streams.
This approach generates a compressor control map often referred to as a
Universal Surge Curve. This approach is
valid for all temperatures and pressures
as dened by the manufacturers compressor map and accounts for changes
in molecular weight. Accommodate
changes in gas properties, such as the
heat capacity ratio, by incorporating
the thermodynamic relationships derived from Charles and Boyles law.
Control system interactions

(capacity control)
An operating compressor is an integral
part of the process in which it is installed. Control of the volume of gas delivered by the compressor is necessary
to match process requirements. As a result, capacity control, while often handled by other controllers or a plantwide
distributed control system (DCS), is best
handled by the compressor controller.
Modern compressor controllers have
the capability to incorporate capacity
control, which allows compressor surge
conditions to factor into the capacity
control. By decoupling, the plantwide

DCS then sends a setpoint for the capacity controller, which provides compressor protection while still meeting plant
requirements. Decoupling (described in
more detail later) prevents a process or
capacity controller from pushing a compressor into surge by forcing it out of its
operating envelope.
Methods of compressor capacity
control
Variable speed
The ow rate and discharge pressure that a compressor can produce
relates directly to the speed at which
the compressor is being driven. The
gure below illustrates the movement
of the operating point when the speed
is reduced. Reducing the compressor
driver speed from point (1) to point
(2) reduces the ow produced by the
compressor. In this example, the pressure ratio across the compressor does
not change, allowing the compressor
to supply a lower ow rate at a reduced
speed. Speed control also allows the
compressor to stay in its most efcient
operating range.
If the speed lowered rapidly, it is possible the compressor would pass the
surge line and surge would occur. Instead, having the speed controlled by
the compressor controller allows implementation of decoupling to protect
the compressor from surge.
Compressor performance map

Max speed
Speed lines
Pressure ratio
Guide vane angles
Surge line
Surge line
Pd/Ps
Speed 2
Pd/Ps
Speed 1
5 deg
0 deg
-5 deg
-15 deg
-30 deg
Q2
Flow
Figure 5. Variable speed control
Q2
Q1
Q1
Flow
Figure 6. Inlet guide vane compressor map

23
PROCESS AUTOMATION

Max speed
Surge line
Speed lines
Pressure ratio
Pd/Ps 2
Speed 1
Pd/Ps 1
Figure 7. Changing pressure ratio

using throttling
Q2
Flow
Inlet guide vanes

Inlet guide vanes are stationary blades
with variable pitch that provide a mechanism to alter the swirl pattern on the
inlet ow to a compressor. Commonly
used on xed-speed compressors, they
increase the operating range of the
equipment. Inlet guide vanes connect
together with a mechanical linkage to
allow all guide vanes to move together.
Inlet guide vanes can signicantly increase the efciency of the compressor
and improve the turndown ratio of the
machine. Figure 7 shows a compressor
performance map for a constant speed
compressor with inlet guide vanes.
While this map looks similar to a variable speed map, there are signicant
differences in the control methodology
used. For example, the slope of each
guide vane angle line is usually much
steeper than a speed line.
Guide vanes dramatically alter a
compressor performance, and special
control techniques can take guide vane
position into account. Guide vane position feedback is critical, as maximum
compressor discharge-pressure capabilities vary greatly with guide vane position. If the guide vane position is not
accurately reported to the surge controller due to mechanical problems or
incorrect calibration, severe damage to
the compressor can result.
24
Speed 2
Min speed
Q1
Suction or discharge throttling

The least efcient method of compressor capacity control is throttling. Throttling to lower compressor ow increases
the pressure ratio that the compressor
has to achieve. This causes the compressor to work harder than necessary.
However, because the gas has not
been compressed rst, suction throttling is more efcient than discharge
throttling for lowering ow across a
compressor. Suction throttling reduces
suction pressure, which increases the
pressure ratio and thereby reduces ow
through the compressor. Discharge
throttling increases discharge pressure,
which also increases the pressure ratio.
If the compressor installation has a
suction throttle valve to decrease suction
pressure, rapid changes in the valve position can push the compressor into surge
by increasing the pressure ratio above the
surge line of the compressor. Similarly, if
the compressor has a discharge throttle
valve to increase discharge pressure,
changes in valve position can increase
the pressure ratio above the surge line of
the compressor, causing surge.
Decoupling
In the instances above: reducing speed,
changing inlet guide vane angle, or increasing pressure ratio by throttling,
capacity controllers respond to a pro-
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cess demand. As mentioned previously,

decoupling is a technique utilized to
protect the compressor against being
forced into surge by capacity controllers. It temporarily suspends the control
action driving the compressor towards
an unstable operating area while it establishes recycle ow to stabilize the
compressor. Once stabilized, the capacity control action is once again allowed
to satisfy the process demand.
Effective implementation of decoupling is only possible in the surge
controller, as it is responsible for determining the compressor operating
point, including when and how quickly
a compressor is approaching the surge
line. A DCS accomplishes capacity demand from a remote setpoint to the
compressor controller, which can
implement decoupling to protect the
compressor from surge.
Managing a successful compressor

retrot
Compressor control system retrots
can be intimidating, but by following
the basic design principles outlined
here, they are not impossible to accomplish. Multivariable, nonlinear applications will never be easy, but systems
can be designed that improve operations and energy efciency. In fact, the
current generation of programmable
logic controllers offers amazing performance, including algorithm execution
speeds that are better than made-forpurpose black box controllers, at a very
effective price point.
ABOUT THE AUTHOR
Rick McLin, development manager, Turbomachinery ControlsRockwell Automation, has more than 25 years of experience
in turbomachinery controls (TMC) as an end
user and leader of development teams in
the U.S. and abroad. Rick spent 16 years
at one of the largest oil companies in the
world, developing surge control algorithms
and implementing distributed control systems in oil and gas production facilities.
Rick also led the development of the subsea compressor control and safety systems
developed for Statoil in the North Sea.
The OSIsoft PI System
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Discrete wireless
Wireless discrete monitoring and controls standards emerging
By Bill Lydon
26
ndustrial wireless is proving valuable for automation professionals in many areas of industrial automation with products and standards
emerging. People are comfortable with wireless
since they use it in their daily lives with cell phones,
personal computers, security monitoring, and other devices. Wireless standards to date have focused
on analog sensors, but there is growing interest and
adoption of wireless for discrete monitoring and
for controlling digital output points. Discrete monitoring and control points signicantly outnumber
analog input and outputs in automation systems
and are the largest installation cost on most projects. Discrete points monitor contact closures from
a wide range of sensors and use contact outputs to
control a wide range of devices, including motors,
two position valves, and solenoids. If wireless cost
and reliability improve to compete with hardwiring, this would be a real improvement in automation systems. Today, wireless sensors are being applied to select applications that have a high return
on investment as a low-cost means for monitoring
hard-to-reach locations and deploying new innovative applications. Examples include connecting
far distant sensors that are too expensive to wire,
such as tank monitoring/control, and as an alternate to electromechanical slip rings on rotating
machines connecting electrical signals from a stationary to rotating structure.
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Discrete considerations
One of the challenges for wireless is the majority of discrete points (contacts in/out; digital in/
out) in factory automation require high-speed
response since they are typically part of interlocking control logic that synchronizes machine
and assembly line operations. In addition, the
point density is much higher than analog points
in process applications. There are a wide range
of devices, including limit switches, proximity
sensors, relays, push buttons, stack lights, machine stops, and motor starters. Applications
that do not require high response speed are
the rst candidates for wireless. Interestingly,
there are approved safety applications in operation using wireless 802.11, but it is important
to remember that wireless becomes part of the
safety loop. If there is a communications breakdown, this causes a safety fault.
Proprietary wireless
Early adopter users have been ahead of wireless standards using various proprietary wireless
devices primarily to monitor and control hardto-reach discrete points. There are a number of
proprietary industrial wireless offerings in the
U.S. and Canada and other countries, and many
operate in the 900-MHz band or lower frequency,
providing a strong signal that allows communi-
FACTORY AUTOMATION
cation through walls and other structures. Legal

frequencies for these applications vary by geography. Common ISM (industrial, scientic, and
medical) bands for industrial and commercial
applications are:
l 220-MHz band in China
l 433-MHz band in Europe and some other
countries
l 869-MHz band in Europe
l 900-MHz band in North America and some
other countries
l 2.4-GHz and 5.7-GHz bands, allowed in most
parts of the world
As radio waves travel, the radio signals gradually
lose energy. The higher the frequency of transmission, the quicker the radio wave will lose energy
down to a point where it cannot be detected by a
receiver. Higher frequency waves also lose energy
more quickly when trying to penetrate walls, trees,
or other obstructions. If both a 900-MHz radio
and a 2.4-GHz radio had the same output power
and receiver sensitivity and were compared side
by side, the 900-MHz radio would get almost twice
the range of the 2.4-GHz radio.
Building automation industry

The building automation industry is signicantly less demanding in communications response
requirements than industrial automation with
more rapid adoption of wireless. The BACnet
building automation protocol standard for
building automation hardwired networks dened by ASHRAE (American Society of Heating,
Refrigerating, and Air Conditioning Engineers)
has agreements with ZigBee and EnOcean wireless standards organizations that have dened
interfaces and protocol mapping to BACnet.
ZigBee is an 802.14.4 mesh-based standard that
has been implemented in the 2.4-GHz, 915-MHz
(Americas), and 868-MHz (Europe) frequency
bands.
EnOcean technology is based on ultra-low power
electronics and radio technology that allows it to be
powered using energy harvesting to transmit wireless signals over a distance of up to 300 meters using 868- or 315-MHz frequencies with 125-kbps
data rate. EnOcean invented and patented energy
harvesting wireless sensors in the 1990s. A good EnOcean example is a light switch that, when pushed,
generates power for an EnOcean radio to transmit
to a receiver to turn on a light. EnOcean contributed key technology to the ISO/IEC 14543-3-10:2012
standard, titled Information technologyHome
Electronic Systems (HES)Part 3-10: Wireless
Short-Packet (WSP) protocol optimized for energy
harvestingArchitecture and lower layer protocols.
WirelessHART
activity
FAST FORWARD
l
Discrete points signicantly outnumber
The HART Foundation

analog input and outputs in automation
reports that many end
systems and are the largest installation cost
that may be ready for wireless communicausers have requested
tions.
that HART technology
l
Early
adopter users have been ahead of
support discrete apwireless standards using various proprietary
plications, and they
wireless devices for discrete manufacturing,
now have a discrete
but this may change.
applications
specil Wireless standards are starting to be
cation. Wally Pratt,
developed for discrete applications.
HART Communication
Foundation chief engineer commented, Where WirelessHART adopted
orphaned process instruments and applications,
this new specication adopts orphaned discrete
applications. HART has dened a discrete variable for on/off or state-related values that may be
inputs from, or outputs to, plant equipment. The
discrete variable may also contain a copy of the
register values from a connected programmable
logic controller (PLC). Inputs receive a plant signal
and status and convert those signals into a digital
value. The conversion process may include signal
conditioning, termination, isolation, and/or indication for that signals state. The input may be
a simple Boolean value, push-button inputs, or
binary coded data (BCD). If the input is an on/
off or open/close type, such as with a push button or limit switch, the signal can be represented
in a single bit. If, on the other hand, the state of
the input varies, such as with a blocking valve,
where the valve is open, closed, opening, or closing, the state requires a full word. Output modules
transmit single bit or state signals to activate various devices, such as actuators, blocking valves,
on-off valves, solenoids, and motor starters. The
output maintains a target value and may include
the actual value as well for a discrete output. Often the output module maintains the status of the
output, too (i.e., whether the output is functioning correctly). A host application modies discrete
outputs by writing the target value of the output,
and then monitors the transitions to intermediate and/or nal states by reading the actual value.
All HART discrete products must include core
mandatory capabilities that allow equivalent device types to be exchanged without compromising system operation. HART discrete features are
backward compatible to HART core technology,
such as the device description language.
ISA 100.11a
The ISA 100.11a Working Group 16 has been considering discrete factory automation and published a technical report, ISA-TR100.00.03-2011
27
FACTORY AUTOMATION
Wireless User Requirements for Factory

Automation. ISA100 WG16 is chartered
to investigate applications for wireless
technology in the factory automation and
discrete manufacturing industries, such
as automotive manufacturing, packaging machinery, machining, and robotics.
The technical report presents descriptive
user and market-related requirements of
wireless communication in factory automation applications and explores use
cases, factory automation topologies,
and recommendations for attributes and
values for existing, emerging, and conceptual solutions for wireless communications as applied to factory automation
applications. The report highlights factory
automation functional and technical requirements that place unique demands
on wireless, including the high transaction response speeds. For example, one of
the most demanding applications cited is
very high-speed processing requirements
for sensor feedback of a motion control
loop to actuate a servo drive to achieve
precise positioning in microseconds.
The report noted that data from a single
node should be represented as a register,
or set of registers, in a way that is similar
to, and modeled after, data read from a
remote I/O unit of a PLC. If all the data
are discrete, then all inputs and outputs
are to be represented as binary bits of a
single data element. For example, one 16bit word = 16 inputs or outputs. It recommends that a single data model similar to
that of the PLC be dened. Model use cases cited include discrete inputs, intelligent
limit switch tuning parameters, proximity
switch sensitivity value, discrete outputs,
opening or closing time delay, and pulse
output parameters.
This technical report presents classes of needs dened as use cases:
Wire substitution
Simple substitution of wires on stationary equipment (e.g., automation
controller to I/O, controller to controller, controller to enterprise system) describes a general case for wireless.
Robot end effector
A robot end effector is the working end
of a robot that interacts with tooling to
perform specic functions.
28
Track-mounted equipment
Track-mounted equipment includes
overhead cranes, hoists, gantries, and
rail cars that are used to move material
and personnel.
Rotary equipment
Rotary equipment (e.g., packaging llers) typically spins around a single xed
axis.
Torque and gauge tools
Torque tools are used on automated
assembly lines to tighten fasteners
(e.g., bolts) to a prescribed tightness.
Gauge tools are used in manufacturing
operations to measure specic attributes
of a unit of work against a prescribed
tolerance.
Mobile material containers
Mobile material containers (also called
intermediate bulk containers or IBCs) are
used to transport raw materials, workin-process (WIP), and nished goods to
various locations within a manufacturing operation. Examples include totes,
super sacks, barrels, and similar vessels.
Mobile high-value assets
Mobile high-value assets include removable or replaceable tooling (e.g., molds,
dies), storage (e.g., movable racks), maintenance tools (e.g., powered hand tools),
and other transportable assets that are
used in the manufacture of product or
maintenance of machines.
Mobile test and calibration xtures
Mobile test and calibration xtures
refer to combinations of sensors and
recorders that capture data related to
units under test.
Wireless Ethernet (802.11)

Standard 802.11 wireless Ethernet has become commonplace throughout industry and provides a transparent transport
for many industrial Ethernet protocols,
including Modbus TCP, EtherNet/IP, and
PROFINET. Users are simply connecting
Ethernet PLCs or Ethernet remote I/O
devices to a wireless Ethernet (802.11)
adapter to communicate. Wireless Ethernet modules are also available for many
controllers and remote I/O products that
plug directly into them in place of hardwired network interface modules. In ad-
WWW.ISA.ORG
dition to controllers, there are many devices using industrial Ethernet, including
sensors, motor drives, and robots that
can easily be connected to an 802.11
wireless Ethernet network. Key considerations in these applications include total
number of 802.11 access points required
to adequately cover desired area, existing
wireless Ethernet networks operating in
the same area, wireless range, installation environment (indoor or outdoor),
and security. Since these applications are
running over standard wireless Ethernet,
there can be a lot of other communications trafc with the potential to create
problems. Some companies are communicating with safety devices over 802.11,
and these are approved safety applications. These safety applications are interesting but if there is a communications
fault, the machine process must go to the
specied safe state stopping production.
PI activity
The PI organization responsible for
PROFIBUS and PROFINET has a wireless working group focused on wireless.
Since PROFINET is Ethernet-based, it
is already being applied running over
802.11 and Bluetooth. In addition, the
PROFISAFE safety protocol is being applied over 802.11 wireless using PROFINET as the transport mechanism. The
wireless working group is also developing the FA WSAN (factory automation
wireless sensor actuator network) specication. The technology is based on the
ABB WISA technology and uses the IOLink standard as the protocol. The IOLink standard denes a point-to-point
connection for discrete I/O that provides information from smart discrete
devices. In a hardwired application, this
is accomplished with a three-conductor
sensor/actuator cable and an IO-Link
Master. Only one IO-Link device can
be connected to a single port. A unique
characteristic of the WISA/WSAN technology is that the radio and sensors can
be powered from the radio waves.
User concerns
Users are learning that industrial plant
wireless requires a systems approach. For
example, wireless has been growing at a
fast rate, which has the potential to create
FACTORY AUTOMATION
performance issues at a plant site without

proper system level management. If you
have ever been in an Internet caf and
frustrated because you cannot get e-mail
with too many people using the Wi-Fi,
you have experienced what can happen
in an unmanaged wireless network. While
this is frustrating, an unmanaged network
with the potential for the loss of data communications in a wireless industrial plant
application could become catastrophic.
I have spoken with users who experienced wireless problems caused by several sources, including microwave ovens,
walkie-talkies, and IT adding wireless devices without notifying plant personnel.
It is easy to think of wireless communication as limitless, but it has limitations similar to wired industrial networks.
Wired industrial networks have a nite
bandwidth available for communications, and overloading the network will
create performance problems. Wired industrial networks are in a closed system,
making them inherently more deterministic than unmanaged wireless communications. Wireless networks also have limitations on communications bandwidth
and response issues if not managed.
ABOUT THE AUTHOR
of total points on a project will be wireless in the near future is anyones guess.
The number of wireless points deployed today is a small fraction relative
to the number of hardwired points. In the
future, the number of points that will be
connected wirelessly is likely to increase,
assuming wireless for discrete applications becomes more responsive, reliable,
and cost-effective. It is hard to compete
with the reliability and availability of hardwiring to an I/O card for discrete points.
Bill Lydon (bill@intecheditor.org) has a wide

range of control and automation experience,
including design engineering, application
engineering, and business. He is currently
the editor of InTech magazine and Automation.com. Bill is an automation industry
consultant as well as a North American representative of PLCopen and a member of
industry committees including OMAC.
its guaranteed to
singe your electronics.
Sorting it all out

The WirelessHART group has the rst
and only specication out for discrete
wireless, and some members have products with other organizations developing
standards. New wireless points will continue to be added to systems to access
difcult-to-reach sensor/actuator locations for new functions. What percentage
RESOURCES
IO-Link Organization; www.io-link.com

PI Organization; www.probus.com
BACnet; www.bacnet.org
ZigBee Alliance; www.zigbee.org
EnOcean Alliance;
www.enocean-alliance.org/en/home
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HART Foundation;
http://www.hartcomm.org
ISA100, Wireless Systems for
Automation | ISA;
25
www.isa.org/isa100
ISA100 Wireless Compliance Institute;
http://www.isa100wci.org
29
Unit 2
Overview
05-31-10
13:22:07
Total
Alarms
1
PULV
5000
5000
15
7500
1250
5
1200
1200
3000
Steam
KLBH
4750
Air
KLBH
7400
Steam
F
990
Fd Wtr
KLBH
4580
Coal
KLBH
1000
Reheat
F
1005
Drum
Lvl in.
-0.5
Furn
Pres
-0.5
1 Hr
0
0
-15
1 Hr
0
0
-5
Steam
psig
2400
Status
A-ON E -ON A
B -ON F -ON
C-ON G-OFF E
D-ON H-ON
Turbine Generator
Gross MW Net MW
Alarms
C
MVAR
HZ
PUMPS
AND
FANS
LPT -A
in.hg
LPT -B
in.hg
Pump Status / Alarms

C2 HWP
A2BFPT
ON
ON
SUBFP
B2BFPT
ON
ON
A2 HWP
ON
B2 HWP
OFF
A2 CWP
ON
B2 CWP
ON
Hydrogen
psig
1 Hr
600
600
0
Hydrogen
F
Turb Oil
F
Stator
GPM
A2 ECW
ON
B2 ECW
ON
Fan Status / Alarms

B2 FD
A2 PA
ON
ON
B2 ID
B2 PA
ON
ON
A2 FD
ON
A2 ID
ON
Condenser Feed Wtr

A2 BPFT B2 BPFT
C-SBAC
ON
D-SBAC
ON
Drum Lvl
in.H2O
HW Lvl
in.H2O
DA Lvl
in.H2O
DA Wide
FT.H2O
Cond Hdr
psig
-0.5
20.1
0.0
AUTO
9.0
SO2
#/MMBTU
Stack CO
ppm
Inst Air
psig
200
90
702.1
Boiler
A/F Ratio
640.1
BBD
pH
- 5.2
Econ
pH
60.00
Econ Gas
Out F
0.2
Aux Stm
psig
0.2
Fans
Furn in.H2O
49.1
104
AUTO
115
AUTO
351
3.1
3.1
A2 ID
Stall
A2 FD
Stall
B2 ID
Stall
B2 FD
Stall
Econ
% O2
Sec Air
in.H2O
CEMS/MISC
NOX
% Opac
#/MMBTU
400
AUTO
7.1
9.4
9.4
775
300
- 0.5
25
25
25
25
6.0
7.0
21.0
0.45
0.9
A Level 1 Overview display
The high performance HMI

Process graphics to maximize operator effectiveness
By Bill Hollield
30
lmost three decades ago, we control engineers were given a new task for which
we were ill-prepared. We installed control systems with the capability to display realtime process control graphics for the operator.
But the screens were blank, and we were responsible to ll them up.
We had no available guidelines as to what
constituted a good graphic. So, we did the best
we could with what we knewwhich wasnt
much! As a result, we set in place a low-performance paradigm of what a control system
human-machine interface (HMI) should look
like, and inertia has done the rest. Mostly for
convenience, we chose to depict the process as
a P&ID view covered in live numbers. We stuck
with that paradigm even as graphic capabili-
WWW.ISA.ORG
ties of DCS/SCADA systems improved, mostly

migrating rather than redesigning the displays.
Now, tens of thousands of operators throughout the world are controlling multi-billion dollar processes by looking at primitive cartoons
designed at a time when we really did not know
what we were doing.
Poorly performing HMIs have been cited as
signicant contributing factors to major accidents. The principles for designing proper process
graphics are now available. A high performance
HMI (HPHMI) has many advantages, including
improved operator situation awareness and process surveillance, better abnormal situation detection and response, and reduced training time
for new operators. Many industrial companies
have graphic improvement efforts underway.
SYSTEM INTEGRATION
FAST FORWARD
l
HMI improvement is justied by giving

operators the tools to successfully run the
plant.
Information needs to be displayed in meaningful and actionable ways rather than as

raw data.
Learn new concepts to improve HMI design.
High performance displays depict information. Information is data, in context, made useful. HPHMI graphics show not only the process
value, but where it is relative to whats good.
Abnormal conditions are designed to stand out
clearly. Color is used consistently, effectively,
and sparingly. Graphics are designed with a
proper hierarchy.
Displaying information
In Figure 1, much money has been spent on the
instrumentation. But can you answer the simple
question, Is this process running at peak efciency, or very poorly? To know that, one must have
specic training and months of experience in normal and abnormal situations. The operator must
compare each number to a memorized mental
map acquired through experience and upsets. This
is a difcult cognitive process. Most operators have
well over a thousand such numbers and status indications spread out over dozens of graphics. Detecting abnormal conditions is difcult.
In the Figure 2 depiction, a compressors instruments are displayed in a different fashion. The
normal or desired range of each value is clearly
depicted using the light blue range. The values
proximity to alarm ranges and automated interlock thresholds is shown. (We normally expect operators to also memorize which sensors are interlock initiators). Values in alarm are depicted with a
redundantly-coded alarm priority indicator.
With a single two-second glance at this bank
of properly designed analog indicators, the operators can tell if any values are outside of the
normal range, by how much, and the proximity of the measurement to both alarms and interlock activation. Humans intuitively understand analog depictions. The abnormally high
discharge temperature shown is easy to detect
even though it is not yet in alarm. Alarm condi-
Figure 1: A typical 1990s graphic screen based on a P&ID
tions stand out.

By coding information into the display, the
operator can effectively scan dozens of values in
a few seconds. This supports surveillance of the
process and early detection of abnormalities.
We do not wait for an alarm to indicate a problem. The best knowledge of desirable operating
conditions is coded into the display and in view
all the time, not buried in written procedures.
Variability in the prociency and knowledge of
individual operators is reduced.
Operator training time is also signicantly
reduced, since important knowledge is not acquired hit-or-miss through experience. This is
important because most companies will lose
well over half of their experienced operators and
engineers in the next 10 years.
Use and abuse of color

It is important to eliminate the common overuse and misuse of color. One important princiINTECH NOVEMBER/DECEMBER 2012
31
SYSTEM INTEGRATION
RECYCLE COMPRESSOR K43

Cool
gpm
Suct
psig
Inter
psig
Dsch
psig
Suct
degF
Dsch
degF
Inter
degF
E. Vib
mil
N. Vib
mil
W. Vib Motor
mil
Amps
Oil
psig
Oil
degF
Alarm
Indicator
Interlock
Threshold
Alarm
Range
Desirable
Operating
Range
42.7
38.7
93.1
185
95
120
170
12
170
80
290
Alarm
Range
Figure 2: Analog depiction of information
ple is that color alone is not used as the

sole discriminator of an important status condition. The same colors designated for alarms must not also be used
for other trivial purposes, minimizing
their signicance.
The most common and worst color
principle violation is the red (off)green
(on) equipment paradigm. The power
industry reverses this, with red meaning
energized. Who is right? Neither! Figure

3 indicates poor color-coding vs. proper
practice.
The red-green coloring shown is (improperly) the only difference depicting
equipment status. Since red is usually
used as an alarm color, it should not
be used for something as trivial as depicting an off condition. Being off is
usually a normal and appropriate sta-
Wrong
Graphic hierarchy
Better
Pump Not
Running
STOPPED
(Shape is Filled
Darker)
Pump
Running
Better
Wrong
RUNNING
(Shape is Filled
Brighter)
Poor But Typical Alarm Depiction

480.1 psi
Priority 1
480.1 psi
480.1 psi
Priority 2
Priority 3
480.1 psi
Diagnostic
Priority
Proper Alarm Depiction with Redundantly Coded Elements

1
480.1 psi
Priority 1
480.1 psi
Priority 2
4
480.1 psi
480.1 psi
Priority 3
Diagnostic Priority
Figure 3: Depicting status and alarms with redundant coding and proper color usage
32
WWW.ISA.ORG
tus; a process running normally should

not be showing red. Brightness coding
is a better practiceimagine that a
light bulb is inside the pump. A status
word is placed next to the equipment
to ensure clarity. This paradigm can be
usefully extended into tables and other
depictions.
Alarms are commonly indicated by
simply changing the color of a process
value or its background, a poor practice. Alarm conditions should be shown
by a redundantly coded (shape, color,
text) element indicating the alarms
presence and priority. A click on the
alarm indicator can call up its rationalization information. Alarm colors are
not used for non-alarm purposes.
Bright colors are used to draw attention to abnormal situations, not show
normal ones. A gray background and
muted colors minimize screen glare and
reection, facilitating a brightly lit control room. A color palette and the proper
uses of each color are determined in advance. HPHMI is not either eliminating color or just converting graphics to
grayscale.
Displays should be designed in a hierarchy providing progressive exposure

of detail. Displays designed from a
stack of P&IDs will not have this; they
will be atlike a computer hard disk
with one folder for all the les.
Hierarchy begins with a Level 1 Process Area Overview. This is a big picture
display showing the operators entire
span of control. It is an overall indicator of how the process is running. It depicts the most important information
and the key performance indicators.
The Overview is a good use of a largeformat wall screen. Control interactions are not made from this display.
A Level 1 Overview display of a large,
coal-red power plant is shown on page
30. At a glance the operator can detect if
the various parts of the process are running well. We sometimes hear, But it
doesnt look like a power plant! Should
your auto instrument panel look like
your engine?
Every process consists of smaller, sep-
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SYSTEM INTEGRATION
Feed Composition
%A %B %C
Coolant:
GPM C
Cat. Purge Conv.

Act% MCFH Eff. %
Feed
MPH
ADTV-1 ADTV-2
MPH
MPH
Temp
C
Pres
psig
Product: Thionite
State: Mid-Run
RTAM: ON-OK
Reserved
Faceplate Zone
Traditional Operator Graphics Versus High-Performance

Interlock Actions:
When any item
I I-5A
I I-5B
I I-5C
Stop Feed
OFF
on
the
screen
is
Graphics in a Coal-Fired Power
Stop ADTV-1 OFF
Stop ADTV-2 OFF
selected, the
I I-5D
I I-5E
I I-5F
Max Cooling OFF
faceplate
for
Plant Simulator, ID 1017637.
Max Vent
OFF
that item
appears in this
SHUT
The power plant chosen had
77.5
11.9
4.0
45.0
97.2
80.5 15.5 4.0 80.5 15.5
80.5 15.5 4.0
ISOLATE
reserved area.
VENT
FREEZE
DOWN
AUTO
AUTO
AUTO
AUTO
AUTO
M5
M5
M5
76.0
12.0
4.0
45.0
95.0
M5
All
control
used a plant-training simuFeed MPH
33.1%
22.3%
44.3%
54.1%
44.3%
manipulation is
80.0
accomplished
lator for more than a dozen
Material Balance
through the
standardized
OP
VENT SYS
years. In the test, several opReset
faceplates.
To Coils
erators detected and resolved
Lvl
72.0
Prod
Agitator
2 Hrs
-90
-30
-60
Reactor M5
%
4
MPH
ON
Additive 1 MPH
various abnormal scenarios
+10%
14.0
Analysis: Purity %
40.0
using both their familiar existMain Menu
OP
0%
ing graphics and new, HPHMI
L2 M5 Startup
L2 M5 Scram
10.0
graphics. The HPHMI provided
-90
-30
2 Hrs
-60
-10%
32.0
Additive 2 MPH
L2 Feed System
-90
-30
2 Hrs
-60
75.9
92.0
signicantly-improved opera6.0
AUTO
75.0
L2 Prod Recovery
Analysis: Inhibitor Concentration %
IN OUT %DIFF
54.3%
tor performance in several ar6.0
Tot. In: 19707
L2 Compression
OP
Tot Out: 19301
eas. The operators reaction to
Calc Diff: 2.1 %
L2 RX Summary
Hours: 238.1
---- Level 3 ---2.0
2 Hrs
-90
-30
-60
the overall test is best summed
5.0 %
Daystrom Pumps
Temperature C
M5 Circ
4.0
48.0
-90
-30
2 Hrs
-60
up in this quote: Once you
M5 Interlocks
PRODUCT
74.3 %
M5 Cooling Sys
got used to these new graphOP
Pump A RUNNING OK
M5 Vent Sys
ics, going back to the old ones
Pumps
Pump B STOPPED FAULT 3
40.0
M5 Agitator
Needed 1
-90
-30
2 Hrs
-60
would be hell.
Figure 4: Example Level 2 display of a reactor
As an example of the power
of inertia, many plant scenarios
arate unit operations. A few examples
often desirable for Level 3 displays.
require an immediate half-rate
might include a compressor, reactor,
Most of the existing graphics in the
reduction, or runback. Done incorpipeline segment, distillation train, furworld can be considered as improvable
rectly, the plant can drop to an undenace, generator, or feed system. A Level
Level 3 graphics.
sirable zero output. To accomplish this
2 Process Unit display (Figure 4) is the
Level 4 Process Diagnostic displays
stressful and difcult task, operators
primary graphic for detailed surveillance
provide the most detail of subsystems, inwere trained for a decade in using their
and control manipulations. It contains
dividual sensors, or components. Screens,
normal graphics for runback. This inall the information and controls required
such as Point Detail, are Level 4.
volved using a dozen different screens,
to perform most operator tasks associDeveloping a hierarchy does not
some to adjust only a single item. Prior
ated with that process part. This cannot
have to be a complex and expensive efto this test, it had not occurred to the
be accomplished by simply replicating
fort. For existing systems, most of the
plant to design any special-purpose
a P&ID. A typical operator might have
benets of HPHMI can be obtained by
screens for use during the runback,
about a dozen Level 2 graphics.
creating about 20 new displaystypicontaining all the controls and trends
Clicking on any value or element
cally a Level 1, a dozen or so Level 2s,
needed for that task. For the test, a pair
brings up the detailed faceplate for that
and a few new Abnormal Situation disof HPHMI runback screens were creparticular element, through which adplays. The existing graphics are desigated, used, and evaluated as far superior
justments are made. In this example, the
nated Level 3. This will be somewhat
for runback accomplishment.
faceplate is an element appearing in the
inconsistent, but most existing graphupper-right reserved area. Faceplates
ics are already inconsistent. Over time,
The HPHMI work process
should not obscure the primary portion
the Level 3s can be improved.
There is a proven seven-step methodof the graphic. Two alarms are in effect
There are dozens of additional deology for the development of a high
on this reactor.
piction improvements and HMI topics
performance HMI:
Embedded trends with indications
addressed in detail in The High PerStep 1: Adopt a high performance
of the desirable range are used in all
formance HMI Handbook, available
HMI philosophy and style guide with
HPHMI graphics. Control system trend
through ISA Publishing.
proper principles.
on demand capability works poorly in
Step 2: Assess and benchmark existing
actual practice.
Proving these concepts
graphics against the HMI philosophy.
Level 3 Process Unit Detail graphics
In 2009, the Electric Power Research InstiStep 3: Determine specic perforaddress a single piece of equipment
tute (EPRI) conducted a major test of these
mance and goal objectives/targets for
or control scheme. These are used for
HMI concepts. A report was produced,
process control, such as safety parama detailed diagnosis of problems. An
Operator Human Machine Interface
eters, production rate, efciency, cost,
augmented P&ID type of depiction is
Case Study: The Evaluation of Existing
and quality.
Run Plan:
Actual:
36
WWW.ISA.ORG
Feed
ADTV-1
ADTV-2
Temp
Pres
Level
SYSTEM INTEGRATION
Step 4: Task analysis identies which

controls must be monitored and manipulated to achieve the performance
and goal objectives, determining the
content of each Level 2 and 3 graphic.
Step 5: Design high performance
graphics, following the HMI philosophy, addressing the identied tasks.
Step 6: Install, commission, and provide training on the new HMI.
Step 7: Control, maintain, and periodically reassess the HMI performance.
Justication for HMI change

Inertia, not cost, is the primary force preventing HMI improvement. Operators
are usually on board immediately when
shown examples of HPHMI concepts.
They see the value compared to their
existing screens covered in raw numbers. Surprisingly, the engineers tend to
be the most resistant to change. Based
on actual incident histories, HPHMI can
produce signicant cost savings.
ABOUT THE AUTHOR
HMI Consultant, is a 37-year industry veteran with international experience in all

aspects of alarm management and HMI
development for the petrochemical, power
generation, pipeline, and mining industries.
Bill is co-author of The Alarm Management Handbook, The High Performance
HMI Handbook, and The Electric Power
Research Institute (EPRI) guideline on
Alarm Management. He is a member of
the American Petroleum Institutes API
RP-1167 Alarm Management Recommended Practice committee, the ISA18
Alarm Management committee, the
ISA101 HMI committee, and the Engineering Equipment and Materials Users
Association (EEMUA) Industry Review
Group. Bill is a regular presenter on
these topics in such venues as API, ISA,
and Electric Power symposiums. He has a
BSME from Louisiana Tech University and
an MBA from the University of Houston.
Bill R. Hollield (bhollield@pas.com),

PAS Principal Alarm Management and
The HMI is the primary tool for the

operator to successfully run the process. The operator must succeed for the
plant to succeed. Alarm systems are receiving considerable attention but are
only a small part of the operators HMI.
Rather than justify creating a good
HMI, we would ask, Was there a justication for installing a poor HMI in the
rst place? Lets x what is broken.
Conclusion
Our sophisticated control systems are
currently operated via ineffective and
problematic HMIs, designed without
adequate knowledge. Operator performance can be greatly enhanced by
HMIs reecting proper principles. A
high performance HMI is practical,
achievable, and affordable.
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37
Defense
in Depth
A single cyber defense is the weakest form of cyber protection

By Eric J. Byres
38
he past two years have been a real wakeup call for the industrial automation industry. For the rst time ever, it has been
the target of sophisticated cyber-attacks like
Stuxnet, Night Dragon, and Duqu.
The most destructive post-Stuxnet threat is
the malicious malware known as Shamoon. As
with Stuxnet, Duqu, and Flame, it targeted organizations in the Middle East, in this case Saudi
Aramco, Qatars RasGas, and likely other oil and
gas concerns in the region. It is a new species,
however, because it did not disrupt an industrial process as Stuxnet did, nor did it stealthily
steal information as Flame and Duqu did.
Instead it removed and overwrote the information on the hard drives of 30,000 to 55,000
(yes, those numbers are correct!) workstations
of Saudi Aramco (and who knows how many
more at other rms). It is believed to have been
launched by a single disgruntled employee
working inside the corporate rewall.
What Shamoon and the others teach us is
that relying on a single defensive solution (like
a single Internet rewall) exposes a system to
a single point of failure. No matter how well-
WWW.ISA.ORG
designed or strong that single defense is, either

resourceful adversaries or Murphys Law eventually results in the defense malfunctioning or
being bypassed. When that happens, the entire
system is wide open to attack. A far more effective strategy for reliable security is called Defense in Depth.
Back to the basics

The Defense in Depth strategy is not something
unique to ICS/SCADA security. In fact, it is not
even unique to cyber security. It is a military strategy that has been around since days of the Romans. If you search the Internet, the rst denition you will nd is the military one on Wikipedia:
Defense in Depth (also known as deep or
elastic defense) is a military strategy; it
seeks to delay rather than prevent the advance of an attacker, buying time and causing additional casualties by yielding space.
Rather than defeating an attacker with a
single, strong defensive line, defense in
depth relies on the tendency of an attack
to lose momentum over a period of time or
as it covers a larger area.
AUTOMATION IT
Defense in Depth for banking security

Unfortunately, if you want to secure your control system, the above denition does not help
you much. So let us look at security in a bank
and see what we can learn.
Ever wonder what it is that makes a typical bank so much more secure than a home or
convenience store? It is not because banks have
stronger steel doors or armed guards. Those
help a bit, but are quickly offset by the fact that
a banks adversaries (i.e., professional bank robbers) are also better armed and more determined than the typical house burglar.
The rst answer is that a bank employs multiple security measures to maximize its security.
For example, just to name a few defenses, a typical bank has steel doors, bulletproof windows,
security guards, room-sized safes, security
boxes, alarm systems, cameras, and securitytrained tellers. Even more important, not only
are there more defensive layers at a bank, but
each layer is designed to address a specic type
of threat at the point where it is employed.
For example, bank doors are effective, but
simple, security devices. They are either locked or
unlocked. They either grant or deny access to customers on an all-or-nothing basisregardless of
what a visitor looks like or how the visitor behaves.
One layer up is the security guardsthey perform access control to clean the general ow
of people into the bank. They ensure that access
to the bank is for people who have a legitimate
need to be there and will behave within expected norms. They regard each visitor based
on specic criteria, such as wearing a mask, suspicious behavior, acting erratically, etc.
At yet another level, the tellers, security box
keys, passwords, etc. keep these pre-screened
customers from accessing other accounts or
information. Rather than worrying if a visitor
should or should not be in the bank, the tellers
and passwords present a different layer of security: account security. These measures lter
what account access individual customers are
allowed, based on who they are.
Multiple differentiated layers

The bank analogy points out three important
aspects of Defense in Depth:
n Multiple layers of defense. Do not rely completely on a single point of security, no matter
how good.
n Differentiated layers of defense. Make sure
that each of the security layers is slightly different. This ensures that just because an attacker nds a way past the rst layer, they do
not have the magic key for getting past all the
subsequent defenses.
n Context- and threat-specic layers of defense.
Each of the defenses should be designed to be
context- and threat-specic.
This last point is the most subtle and perhaps
the most important. Going back to the bank example, note that banks do not simply have additional security guards at every level. Banks understand that threats come in different avors,
ranging from the desperate drug addict with a
gun to the sophisticated fraud artist. Thus for the
banks, each defensive layer is optimized to deal
with a specic class of threats.
Designing for the threat

So what does this have to do with security on
the plant oor? Like the bank, the SCADA/ICS
system can be exposed to a variety of different
security threats, ranging from disgruntled employees, to computer malware, denial of service
attacks, and information theft. Each needs
FAST FORWARD
l New species of cyber threats are being deto be considered and
ployed.
defended against.
l
Relying
on a single defensive solution exFor example, a
poses a system to a single point of failure.
boundary
rewall
l Defense in Depth improves protection.
can act like the bank
guard, so that network messages using specied protocols are
either permitted or denied access into the control network. This is ideal for keeping the bulk
attacks out, particularly the average IT worm or
the common denial of service attack.
Deeper into the control system, more sophisticated SCADA-aware rewalls can observe the
trafc beyond the obvious protocol types. This
allows defenses based on the behavior and context of the systems using these protocols on the
control network. For example, if an operator station computer suddenly starts trying to program
a PLC, then perhaps a worm like Stuxnet or a disgruntled employee is at work. These attacks need
to be immediately blocked and alarms raised to
prevent serious risk to the system.
Finally, servers and controllers with a robust security implementation can act like a well-trained
bank teller. After a user successfully connects to
a server or controller, the security conguration
ensures they only get access to the specic applications and data they are supposed to have access to. Attempts to access other services or data
should be blocked and logged.
As with the steel doors, the bank guard, and
the teller example, the perimeter rewall providing the boundary security, the SCADA/ICS
39
AUTOMATION IT
rewall providing the internal security,

and the server providing the application security are an essential team. For
example, a rewall can block millions
of randomly malformed messages directed at a control system as part of a
Denial of Service (DoS) attack. At the
same time, deep packet inspection and
user authentication checks can prevent
an attacker or worm inside the rewall
making changes that might risk property
or lives.
ABOUT THE AUTHOR
Eric Byres (eric.byres@belden.com), CTO

and VP Engineering of Tono Security
(part of Hirschmann, a Belden Brand), is
a well-known industry expert in the eld
of industrial cyber security and is chair of
the ISA99 Security Technologies Working
Group, Chair of the ISA99 Cyber Threat
Gap Analysis Task Group, and Canadian
representative for IEC TC65/WG13, a stan-
Shamoon Malware and SCADA Security What are the Impacts?,
Depending upon a single defense, such

as perimeter rewall, is building a security solution based on a single point
of failure. Make sure that your facility
has a proper Defense in Depth design
where the network, control devices,
and systems are collectively hardenedthereby providing reliable security for the plant oor.
Tonosecurity.com/blog, Oct 2012

Securing SCADA systems from APTs like Flame and Stuxnet,
Tonosecurity.com/blog, June 2012

How to Use ANSI/ISA-99 Standards to Improve Control System Security,
InTech magazine, January 2011

Making Cyber Security Work in the Renery,
InTech magazine, October 2007
Process Measurement
like you've
never seen it
before
Scan.Learn
Toll Free: (800) 722-7556

www.anton-paar.com/process-solutions.us
RESOURCES
Providing reliable security

for the plant oor
40
dards effort focusing on an international

framework for the protection of process
facilities from cyber-attack. Eric was recognized for his contributions to the automation industry when honored by the International Society of Automation (ISA) as
an ISA Fellow for his outstanding achievements in science and engineering.
WWW.ISA.ORG
WebPort & WebPort Connects :
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Imagine receiving notifications and alarms so you
can get a jump on troubleshooting controller issues.
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WebPort is a next-generation industrial gateway,
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Thermal imaging
detects equipment issues
Annealing furnace circulation

fan motors
BC09 basement-living-room
Belt and sheave inspection
Hot roller bearing
Portable thermography in automated process environments

By Michael Stuart
utomation often provides signicant

advantages in todays competitive environment; in some industries, it is practically a requirement to stay in business. Unfortunately, human beings have yet to create a
machine or system that operates perfectly at all
times. All automated systems will need maintenance at one time or another. The saying the
weakest link can break even the strongest chain
is nowhere more true than in highly-complex,
highly-engineered automation systems. Every
system has an Achilles heel, and it could be a
part of the operation perceived to be so minor
that it has no xed monitoring sensor.
FAST FORWARD
l
Portable thermography is a powerful tool for maintenance and

problem diagnosis.
Portable thermography allows users to see heat patterns.
Portable thermography helps nd problems quickly.
Murphys Law dictates that anything that can

go wrong will go wrong. With all of the components that go into an automated system, this
can certainly seem to be the case. And once you
enter into an automated process environment,
the stakes around possible failure become even
42
WWW.ISA.ORG
higher. Fortunately, there is a tool that can help

prevent Murphys Law from actually becoming
a reality: the portable thermal imager.
Portable thermography can help you and
your team to maintain your automated systems
and proactively keep your motors, controls,
conveyors, bearings, chain drives, and other
electro-mechanical automation equipment in
top operating condition. For automated process environments in particular, handheld thermal images can also be used to identify leaks,
blockages, and settling in sealed vessels, pipes,
steam systems, or heat exchangers, and to capture process temperature readings. And the
price point for this technology is just a fraction
of what it was even a few years ago. The newest portable thermal imagers are more rugged,
more reliable, and easier to use than ever. These
tools have enormous potentialmaintenance
of automated systems and equipment is just the
tip of the iceberg.
Motors and thermal imaging

Motors have a few key inspection points: bearings, belts, couplings, electrical connections,
movement of heat, overall temperature, and
how the equipment functions and fails.
Bearings under equal load should display
Blocked process line
Overheating conveyor belt drive motor
Roller bearing problem

on conveyor belt system
Images: Michael Stuart, Thermographer
equal temperatures. A hotter bearing on the

sheave side of a motor could indicate overtightened belts. Sheaves that are hotter around
the circumference could indicate slipping belts.
Slipping belts can also be indicated when belts
do not cool between the motor and blower
sheaves. And belts with unequal thermal patterns can indicate misalignment.
Pay attention to overall temperature, especially if there are any indications of poor cooling. Understand the roles that conduction and
convection play in moving heat through the
equipment. Also learn the manufacturers operating specications for precisely how the equipment is supposed to function and what failure
might look like.
Taking a baseline image of all motors gives
you the chance to make comparisons over time
and to pick out any abnormal hot spots that
may crop up, such as under-full load.
Spotting potential problems

using thermal imagery
Thermal signatures are often associated with
machine health. Normal machine operation
has a veriable signature, and problems often show up as outside of this norm. Identifying these problems requires an understanding
of the machine and how it is to fail. A portable

thermal imager makes it simple to quickly check
the motors overall temperature at regular intervalsespecially for smaller motors, which may
sometimes get overlooked when it comes to
maintenance.
When determining whether a motor is overheating, use the motor temperature rating on
the nameplate as a guide. Exterior motor temperatures are typically about 36F cooler than
interior temperatures.
The ideal routine or preventive maintenance
program starts with newly commissioned and
freshly lubricated motors and takes snapshots
of all key inspection points with the motors running. These images are then used as baselines.
Maintenance with new motors

With new motors, watch the initial start-up
through a thermal imager. Any wiring, alignment, or lubrication problems will show up
thermally, before any permanent damage occurs. As the motor ages, components become
worn and heat-producing friction develops.
This will cause the housing to heat up. Taking
thermal images at regular intervals will allow
for comparison to the baseline to analyze the
motors condition. Generate a maintenance
43
PIP IR autoblend color alarm
PIP IR ironbow motor inspection
order when any thermal images indicate overheating.

When looking at small bearings,
compare thermal patterns of one bearing to similar bearings in the same operation. The inspection can even be
done while the equipment is operating. Small bearing failures can result in
re, mechanical stress, belt wear, and
increased electrical loads. The inspection of small bearings is an area where
infrared shines as a maintenance technology.
When looking at belts and sheaves,
be aware that guards may restrict your
view. And be sure to re-inspect belts
and sheaves after corrective actions
are taken. When inspecting pumps and
fans, focus on the couplinglook for irregularities. A healthy coupling should
have a consistent thermal signature.
Component wear will cause abnormal
heating. Alignment issues will show up
as excess heat before causing bearing
problems or any subsequent irreversible damage.
Inspecting tanks
In automated process environments,
thermal imaging can also be used to
inspect tanks. Scan the outside surface
for variances in temperature at different points. Inspect gaskets, seals, and
valves at their openings. Monitor tank
levels; locate uid, solid, oater levels, and sludge. While large process
tanks typically have built-in visual or
electronic indicators for tracking prod-
44
Roller bearing problem on conveyor belt
uct levels, these are not always reliable.

Thermal inspections can reveal the interface between the liquid and the gas
(usually air) in a vessel, indicating how
full it is and whether the contents have
settled or separated inappropriately.
Knowing what the correct levels are
prevents overlling and ensures reliable inventory gures for raw materials
and/or nished products.
When a tank or silo changes temperature, it is often possible to see thermal patterns associated with the levels
inside. For instance, it is invaluable to
know the sludge level when operating
a continuous process or preparing to
clean out a tank.
Thermography can also reveal oating materials as well as layers of liquids,
gases, and solidssuch as the layer of
parafn that sometimes forms between
the oil and water layers in separators,
which can hinder their operation.
Identifying leaks and other issues

Leaks typically develop in or around
gaskets or seals. Less frequently, corrosion will cause a weakness to develop
and rupture a vessel. To nd leaky gaskets or seals, scan a thermal imager
along the seal looking for abnormalities. A large change in temperature
along the seal or gasket indicates the
loss of either heat or cold, which is the
signature of a failure.
Thermal imagers can also monitor
process control valves for leakage, stiction (sticking), or excess friction. The
WWW.ISA.ORG
Tank inspection
excitation coil of a valve may overheat

if it works too hard, indicating a problem such as current leakage or a valve
size mismatch. Technicians can follow
up by calibrating the valve or the valves
positioner.
A damaged refractory or liner will,
under certain conditions, show up
as hot or cool spots. Most leaks occur
when a seal or gasket fails, or when corrosion leads to a leak in a vessels wall.
No matter its origin, a leak will usually
manifest itself as a temperature anomaly. When inspecting refractory insulation, hot areas are associated with refractory thinning or failure. Cool areas
are associated with internal product
build-up.
Steam traps, lines, radiators,

and convectors
Thermal imagers can quickly spot trap
and line temperatures into and out
of steam traps. Check each transmission line and follow pipe temperatures
to the source of any problems. If the
temperature is low in steam pipe, low
in trap, and low in condensate return,
then the trap may be stuck closed. If
the temperature is too high in steam
pipe, high in trap, and high in condensate return, then the trap may be
stuck open. If temperature is high in
steam pipe, high in trap, and slightly
lower in condensate return, the trap
is likely operating properly. Correctly
operating steam traps should show a
temperature differential from one side
Motor and pump inspection
Specialized process equipment inspection
Air handler main fan bearing
to the other.
A trap that is failed open can go undetected for long stretches of time
weeks or even monthsand be very
costly once it is detected. A thermal imager will display these traps as warm on
both sides. If you nd a trap that looks
like that, make sure it has not just cycled. If it has, and remains hot on both
sides after more than a few minutes, it
likely is not working properly.
A thermal image of a tank that is either completely empty or completely

full, or that has a shiny reective surface, will appear uniform. No product
level will be visible. Otherwise, the
product level will be seen as a thermal
Heat exchangers and steam radiators

Thermal inspection of heat exchangers can quickly and safely identify
Measurement best practices:

n
Substances within tanks

Thermal imagers can detect the level
of substance inside a tank, provided
that there is a temperature difference
between the substance inside, the air
inside, and the air outside, and provided that the tank is not composed
of a shiny material, such as stainless
steel.
Gases have higher heat capacity than liquids, meaning that liquid
temperatures change more slowly
than gas in the headspace. Because
tanks are most often located outside,
their contents change temperature
throughout the day because of solar loading. The temperature difference between the product and the
headspace can typically be observed
through the tank walls. At times,
though, the air and substance within
a tank will be the same temperature,
effectively rendering the level invisible. The level will once again be visible when the air gains or loses thermal energy.
separation between the headspace and

the product.
Verify that electro-mechanical equipment targets are operating at a minimum of 40% of load. Lighter loads do
not produce as much heat, making it
harder to detect problems.
Within the safe zone, get as close to
the target as you can. (While thermal
imaging is non-contact, if you measure
live electricity with enclosure doors removed, NFAP 70E safety standards still
apply. Wear appropriate PPE, try to
Specialized process
stay four feet away from the target, equipment inspection
and minimize time spent in the arcash zone.)
Do not try to shoot through doors; thermal gradients within an electrical cabinet make it impossible to understand the thermal impact inside the cabinet.
Infrared does not penetrate glass or plastic safety shields, so you will need to
work around those.
If inspecting outside, take wind and air currents into considerationas they
could cool any abnormal hot spotsaccount for ambient temperatures, and
watch out for thermal loading (heat from the sun).
Remember that not all problems are indicated by excessive heat. Restricted ow
in a cooling system could be indicated by a cooler-than-normal reading.
When working with low-emissivity assets, consider sources of reective infrared
radiation.
When trending assets, it is important to have consistent loads for capturing accurate temperature data over time.
45
Bluered modern chiller
Air handler fan pillow block

bearing
Motor pump and valves
Ironbow motor with hot

bearing
areas of corrosion, mineral deposits,

and sludge build-up, as well as a lack
of heat transfer caused by external
damage such as hail, abuse, or lack of
maintenance. But it is important to remember that mechanical heat transfer
is one area where sharp lines of temperature difference rarely exist. Heat
exchangers do not offer up the clear
The more time you spend

using a thermal imager, the
better you will become at
identifying anomalies.
hot spots that you can see in other
overheating or malfunctioning equipment. Instead, heat exchangers are
constructed to facilitate a temperature
exchange. Higher resolution thermal
imagers and on-camera adjustments
can help capture lower thermal dif-
ferences (called Delta T), which are

often exhibited by blocked passages
or clogged strainers with plate-type
exchangers.
Shell-type heat exchangers, on the
other hand, often show denite areas
of blockage caused by solid build-up of
materials. Steam radiators are another
type of heat exchanging device. They
are commonly found in schools, commercial buildings, and homes. Infrared
inspection of these will reveal blocked
passages, cracks, and internal damage caused by corrosion. In all cases,
infrared inspection allows for specic
trouble areas to be diagnosed.
Conclusion
By its very nature, troubleshooting is
scenario-specic. Personal experience
goes a long way in determining just
how useful thermal imagers can be.
The more time you spend using a thermal imager, the better you will become
Infrared theory
Thermal imagers create pictures by measuring infrared energy or heat. The thermal imager reads the surface temperature of objects and then assigns different
colors to the different temperatures, resulting in a picture of sorts. But not all materials emit thermal energy equally. Emissivity is the property that describes how
efciently an object radiates or emits heat. It is expressed as a value from 0 to 1.0.
Shiny materials have low emissivity; painted or heavily oxidized metals, and nonmetals, have higher emissivity.
at identifying anomalies. As your thermal knowledge and skill build up, they
can be combined with existing knowledge of line and equipment functionality, adding up to formidable troubleshooting power and, thus, improved
long-term maintenance.
ABOUT THE AUTHOR
Michael Stuart (michael.stuart@uke.

com) is a practicing T/IRT Level III thermographer (certied in compliance with
ASNT standards) and has signicant
experience in the use of thermography
for electrical, mechanical, and building
inspection applications and analysis.
He is the senior product manager for
thermal imaging products with Fluke
Corporation. Michael conducts training for customers and Fluke personnel
in the fundamentals of thermal imaging
for troubleshooting, preventive maintenance, predictive maintenance, building
inspection, weatherization, and energy
auditing. He has actively taught various
subjects related to electrical test & measurement and predictive maintenance at
NTI and has presented hands-on courses
for various regional training events sponsored by the NJATC, IUOE, and others,
and has co-authored a book, Introduction to Thermography Principles, with
well-respected fellow thermographer
John Snell of the Snell Group.
46
WWW.ISA.ORG
Tips and Strategies for Managers | executive corner
Whats on YOUR mind?

By John Nesi
hrough a series of special events and forums over the past month, I have had
a chance to engage in some in-depth,
highly insightful conversations with process engineering, control engineering, and IT executives
across a range of industries. From oil and gas to
ne chemical to water/wastewater to food and
beverage, these professionals shared some common priorities and goals as they look forward to
2013. It might be interesting to see if they align
with your own.
Information security as
a strategic imperative
There is no doubt that safety and security of people and processes have long been top-of-mind,
but in todays information-enabled enterprise, the
stakes have gotten higher. While nobody will go
on the record (and why would they?), it is fair
to say that the great majority of companies we
talk to are under constant threatboth malicious
and accidentalfrom hackers, viruses, uneducated employees, and well-meaning contractors,
among others. The wrong breach at the wrong
time could have drastic consequences, and nobody wants it to happen on their watch.
Devices playing on open networks, such as
EtherNet/IP, is pervasive, and we have moved, as
Cisco describes it, from an Internet of People
to an Internet of Things. We also have new opportunities for remote access for monitoring, diagnostics, and maintenance, but companies are
struggling with how to do it safely, securely, and
consistently.
This means that we need to stop thinking of
security as something to implement after the
system is installed. We need to design security
in from the beginning, and we need to manage
it at all layersdevice, controller, process, and
enterprise. And since it is highly likely that the
devices in the future will be walking around the
plant in someones pocket or clipped to their
belt, we need to move to a model where we secure the data and not the device. The data HAS
to go somewhere or it is not particularly valuable, so validating the data and managing who
has access to it is much more productive than
only worrying about which devices it sits on and
who has access to those devices.
Strange bedfellows are

not so strange anymore
Successful security strategies require closer collaboration between process automation, operations,
and IT, but it is not the only place where crossfunctional collaboration is critical.
The forward-looking customers we are talking to have truly broken down the walls between
these historically siloed functionsmixing staffs,
cross-training, creating hybrid job titles, establishing rotating tours-of-dutyall in the name of better collaboration for business benet.
There seems to be a new unity of purpose in
manufacturingwhere IT, operations, process automation, and control engineering are going beyond
installing this server, managing that process, or controlling those machines to put laser-like focus on
improving operations, managing costs and margins,
and reducing risk and assuring compliance.
More and more companies are establishing operations teams that rally around common busi-
We need to design security in from the beginning,

and we need to manage it at all layersdevice,
controller, process, and enterprise.
ness purpose, whether it be energy efciency, supply chain throughput, risk mitigation, or any other
pressing business priority. One major opportunity
we see is collaboration around the governance
of data. The expenditures that companies made
around enterprise resource planning (ERP) systems
heightened the awareness of the value of more
visibility into the supply chain, but ERP never really fullled its promise in truly bridging the gaps
between operations, manufacturing, and IT. Now,
cross-functional teams have the opportunity to take
it to the next step by dening how data is secured,
accessed, and distributed for better traceability, lot
management, quality, energy consumption, and
overall productivity. Those companies that embrace
this collaboration will realize gains that give them a
competitive advantage and make their jobs easier.
Re-thinking roles and technologies
Todays engineers are more operationally focused.
Maintenance is becoming more networked. Oper-
47
executive corner | Tips and Strategies for Managers
ators are more open to modern technology, and executives are recognizing the
treasure trove of information from production. All of this is happening while we
Despite all the competitive,

economic, and regulatory
pressures we face, it is an
exciting time to be in this
industry.
usher in a new generation of engineers,
IT professionals, and business managers
who have different attitudes and expectations.
This calls for a departure from legacy
process control systems and legacy thinking. The people we are talking with are
less interested in philosophy and more
interested in seizing opportunities for
48
real business improvement. They are embracing newer, more contemporary process control platforms. They are adopting open, standards-based architectures.
They are installing wireless. They are integrating mobile devices. They are using
multi-channel
communicationsdata,
voice, videoand they are creating collaborative ecosystems with their equipment OEMs, their integrators, and their
automation suppliers.
One last observation on the conversations of the past monthand that is the
high degree of optimism that people have
for what the future holds. Despite all the
competitive, economic, and regulatory
pressures we face, it is an exciting time
to be in this industry, and better security,
more collaboration, and re-thinking roles
and technologies will help the forwardthinking companies in this eld achieve
success.
WWW.ISA.ORG
ABOUT THE AUTHOR
John Nesi (janesi@ra.rockwell.com) is the

vice president of market development
for the global sales and marketing segment of Rockwell Automation. John has
more than 32 years of experience in sales,
marketing, systems, services, operations,
and engineering across various businesses
with Rockwell Automation. He is responsible for the strategic and commercial
development for Rockwell Automations
growth initiatives, including sustainability, power and energy, working with customer segments in the industrial sector to
promote energy efciencies, process optimization, and production intelligence to
improve demand-driven production in a
safe, sustainable environment. John holds
a bachelor degree in Electrical Engineering from Cleveland State University and is
an executive scholar of Kellogg School of
Management.
Highlights and Updates | association news
In memoriam
Leslie R. Driskell
Leslie
R.
(Les)
Driskell of Mt.
Lebanon, Penn.,
died on 5 November. Born in 1916
to a family of very
modest means in
Louisville, Ky., he
achieved international prominence as an instrument engineer, consultant, author, and teacher specializing in control valves and industrial
process control systems.
Dropping out of the University of Louisville after one year for nancial reasons,
Driskell worked at various clerical jobs
during the Depression and eventually
became a technician at Seagram-Calvert
Distilleries while also taking correspondence courses in what was then a new
eld, industrial process control.
During the war, Driskell worked for
DuPont and was deferred from military service because he was supervising
all instrumentation at the corporations
$45-million plant manufacturing synthetic rubber, which was vital for the war
effort. He also taught night courses in
industrial instrumentation for Purdue University, sponsored by the U.S. War Training Program.
After the war, Driskell moved his family
to Pittsburgh. After answering a blind ad in
the ISA Journal, he began working for BlawKnox Construction. This eventually became
the Chem Plants division of Dravo Corporation. While at Dravo, he began writing
articles for engineering magazines. These
led to offers to teach and consult, as well
as work on standards and practices committees of what was then the Instrument
Society of America (ISA). Driskell served
as chair, ISA Standards & Practices Committee, from 1967-88; chair, Final Control Elements Committee, from 1957-66;
president, ISA Pittsburgh Section, from
1954-55; and director, ISA Louisville Section, in 1947. In 1968, he received the
Instrumentation Technology Award and
was named ISA Fellow. Driskell received
the Chet Beard Final Control Elements

Award in 1983 and the ISA Pittsburgh
Section Award in 1992. By the 70s, he
was heading Dravos 100-man instrument-electrical engineering department.
Driskell authored four textbooks and
co-authored four others, all on control
valves, wrote over 40 published articles,
lectured extensively and taught more
than 100 short courses in the U.S. and
internationallyincluding Canada, Kuwait, Venezuela, Mexico, Norway, the
Netherlands, and Japanand developed
an equation for the ow of compressible
uids through valves that became an international standard.
Driskell retired from Dravo to begin a
20-year career as a consulting engineer.
Clients included nearly two-dozen engineering corporations in the U.S. and
abroad. He frequently served as an expert
witness in court cases involving critical
control equipment at mills, power plants,
and chemical plants.
E. Ross Forman
Edgar Ross Forman of Erdenheim, Penn.,
died on 29 October. Born in Camden in
1923, he was a mechanical professional
engineer and a pioneer in automated systems and control engineering.
Forman was active for many years in
MathCounts, an outreach program of
the National Society of Professional Engineers. He was also a former president of
the NSPE Valley Forge Chapter. He authored numerous papers,
trade journal articles, and chapters in major books for the industry on Chemical Engineering Control Systems.
Forman was the only president of the ISA Philadelphia Section
who served a year-and-a-half term, due to the change in their

scal year, and served as District 2 vice president, as well as vice
president of the Industries and Science Department. As chairman of the Education Committee of what was then the Instrument Society of America (ISA), he initiated the Philadelphia Plan
of coordinating courses leading to certication. Forman served
as a member of the industrial visitation team to China. He developed the Old Shoe Award to honor salesmen in the industry,
as well as founding the Outstanding Tech Award. A Fellow of the
Society, Forman received the following awards: District 2 Service,
Donald P. Eckman for education, Golden Achievement, and Outstanding Service.
49
association news | Certication Review
ISA Certied Automation Professional (CAP) program

Certied Automation Professionals (CAPs)
are responsible for the direction, design,
and deployment of systems and equipment
for manufacturing and control systems.
CAP question
Using forward decoupling, the objective
is to:
A. accumulate the interaction between
two process variables and their outputs
B. cancel out the interaction between
two process variables and their outputs
C. use feedback to eliminate the gain of
one process variable and its output
D. use a decoupling algorithm to eliminate all gain between outputs
CAP answer
The correct answer is B, Cancel out the
interaction between two process variables and their outputs. In MIMO (multiple input, multiple output) systems, often
the process variables and outputs interact
with one another, which makes control of
the independent variables difcult. A forward decoupling algorithm can be used
to cancel out these interactions, making
more traditional control methods applicable to these complex systems.
Answer A is not correct; accumulation
of the interactions would be counterproductive to the loop performance, and
would simply magnify the coupling between inputs and outputs.
Answer C is not correct. Simple feedback can be used to make adjustments

to the output based on a measured or
calculated quantity, but simple feedback
cannot be used to eliminate the process
gain between a process variable and its
own output.
Answer D is not correct. Similar to Answer C, a decoupling algorithm does not
eliminate all gains between outputs,
but rather, when used in a forward decoupling method, can be used to cancel
the interactions between multiple inputs
and their outputs.
Reference: McMillan, Gregory, et al.,
Models UnleashedVirtual Plant and Model
Predictive Control ApplicationsA Pocket
Guide, ISA, 2004.
ISA Certied Control Systems Technician (CCST) program

Certied Control System Technicians (CCSTs) calibrate, document, troubleshoot,
and repair/replace instrumentation for
systems that measure and control level,
temperature, pressure, ow, and other
process variables.
CCST question
How can a transmitters current output
signal be converted to a voltage-input
signal, as required by an electronic controller?
A. a resistor is placed across the input terminals of the controller
B. all wiring in the loop is tied positive-tonegative
C. a forward bias diode is placed between
the transmitter and controller
D. capacitor is placed across the output
terminals of the transmitter
50
CCST answer
The correct answer is A, A resistor is
placed across the input terminals of the
controller. A 250 resistor in a 420mA
DC current loop will produce a 15VDC
signal, as indicated in Ohms law: E = I
R, where E is voltage, in volts; I is current,
in amps; and R is resistance, in ohms. At
4mA (0.004A), E = 250 x 0.004A = 1V.
At 20mA (0.020A), E = 250 x 0.020A
= 5V.
Answer B is a true statement for a current loop, but is not the way that a current signal is converted to a voltage signal
that is required by the controller. This answer indicates the driving force for direction of current ow.
WWW.ISA.ORG
Answers C and D would electrically modify the behavior of the circuit, but would
not convert current signals to voltage signals. A diode across the controller could be
used to prevent current ow in the reverse
direction, or could be used with an LED in
an optical isolation circuit. A capacitor in
a current loop could be used to suppress
surges at the transmitter terminals.
Reference: Goettsche, L.D. (Editor),
Maintenance of Instruments Systems, 2nd
Edition (2005), ISA Publishing
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Selecting temperature
measurement and
control systems
How to get accurate data and perform reliable control from

systems designed for the rigors of industrial applications
By Steve Byrom
52
easuring and controlling temperature is undoubtedly the most common measured parameter because it
is critical to so many operations and tasks. Accurate temperature measurement and control is
vital to the quality of manufactured goods, such
as nished metal components, and to the efcient and safe operation of a process or system.
In todays market, there are myriad devices for
monitoring and controlling temperature, ranging from simple temperature controllers to complex distributed control systems. Most temperature measurement and data acquisition products
are well-suited for the job for which they are intended, but care must be taken when applying
them in harsh industrial environments.
Many low-cost monitoring and control devices and systems perform well in applications
where they are not exposed to environmental stress. While these lower-cost devices and
WWW.ISA.ORG
systems may be well-made for their intended

purposes, they often will not perform well in
environments with excessive electrical noise or
when exposed to over-voltage input conditions.
Therefore, selecting the right equipment for the
environment in which it will operate is critical
for accurate and reliable performance.
The objective when selecting these temperature measurement and control systems is to nd
a product that provides very stable and reliable
performance. The systems should also provide
data in the form required by the application,
such as for compliance reporting or mandatory
plant data archiving. Depending on the application, these systems should be able to act as
the data source for real-time operations, with
their data serving as the front end of the plant
control system. Finally, the systems should be
cost-effective as well as rugged, with very long
life spans.
AUTOMATION BASICS
Ensuring performance in tough conditions

Finding the right type of device among the wide
variety of temperature measurement and control systems can be daunting. Equipment selection begins with the ability to measure the
required temperature sensor. Inputs that can
measure thermocouples, resistance temperature detectors (RTDs), and DC voltage or mA
outputs from temperature sensors or transmitters are a standard requirement.
Thermocouple sensors are commonly used
and available in a variety of types and congurations to handle almost any application. Proven
through decades of industrial service, thermocouple sensors are economical and physically
rugged devices that provide accurate measurements for wide temperature sensing ranges.
RTDs can provide even greater accuracy, but operate over more narrow temperature ranges and
are more costly. Both sensor types can typically
operate continuously in conditions of excessive
temperature and vibration.
Temperature transmitters measure thermocouple or RTD sensors in the eld close to
the process, are usually hardened to operate
outdoors and in combustible environments,
and output temperature data in a variety of
formats, ranging from 4- to 20-mA to various
digital data protocols such as HART. Smart
transmitters can provide a wide variety of information in addition to the process variable
sensor reading, including diagnostic and calibration data.
Selecting the right solution

A large process or test application may require
hundreds of points or more of temperature sensor measurements. Operators will need to view
this data, and a control system will need to act
on many of these data points. The data commonly requires archiving for future review and
reporting.
Modern plants and industrial sites have many
methods for handling this sensor data, including direct inputs to an existing control system
such as a distributed control system (DCS), a
PID controller, a programmable logic controller
(PLC), or a data acquisition system (DAS).
Determining the best solution is dependent
on many factors including existing control
system capacity, overall cost, and the ability to
achieve the project goals. Adding direct inputs
to the control system can be a viable option if
the control system has available capacity and
the ability to measure the required sensors. It
should also be able to meet the planned require-
ments for operator

FAST FORWARD
display, control, and
l Temperature measurement devices must be
data archiving, and
capable of providing reliable and accurate
reporting of the new
measurement in often-hostile industrial
environments
measurement points.
l Solutions should be scalable and integrate
Single-loop PID
easily with existing plant-wide control and
controllers can be the
monitoring systems
best choice for monil A data acquisition system (DAS) is the
toring and controlling
preferred option in many applications
a limited number of
temperature loops.
These controllers provide local operator interface, excellent control performance, and the
ability to output the process value to plant information systems via analog retransmission or
in a digital data format.
DASs and PLCs can be the best option when a
large number of temperature points need to be
measured and controlled. A DAS is well-suited
for applications that require low-cost data display, storage, and access to users via an economical interface, such as a web browser or very
inexpensive or free PC-based software.
Extensive control needs are best achieved
with a PLC system, but measurement-only
and recording applications are best served by
a DAS, which is available for a lower cost and
optimized for temperature monitoring. In some
cases, a DAS and PLC working together provide
an extensive array of functions and can be the
best choice at an attractive cost.
A modern DAS can also expand the capacity ofand integrate withan existing plantwide control system, such as a DCS, by measuring many temperature sensor inputs and
retransmitting the data to the DCS. In this
manner, the DAS can act as a multiplexer, and
be the data source for existing control and
monitoring systems, often at a lower cost per
channel than the existing system. Common
serial and Ethernet protocols like Modbus
RTU, Modbus TCP, and EtherNet/IP provide
built-in connectivity from the DAS to the control and monitoring system.
DAS or PLC?
PLCs, with their inherent and almost limitless
exibility and wide-ranging application capabilities, are the clear choice for complex control applications. PLCs have similar temperature measurement performance to most DAS
equipment, but they may not support certain
types of thermocouple or RTD sensors. In addition, PLCs sometimes deliver inferior measurement of electrically noisy sensor inputs.
Furthermore, most PLCs do not have local data
53
AUTOMATION BASICS
recording capability.
If PLC limitations are a hindrance
for the particular application, a modern data acquisition/data logging
system is a logical choice. Oftentimes
a DAS can work with a PLC, by doing what the PLC may not be able to
dosuch as measuring unusual input sensors, providing more accurate
measurements, and providing backup
data recording along with quick access
to historical data.
Since there is a lot of overlap in the
measurement capability of a PLC versus DAS, choosing one over the other
will be based on many other factors.
This may include the presence of
and preference in usingan existing
vendors PLC system. If the plant can
cost-effectively plan a new system that
meets all objectives using their preferred PLC vendor, that can be the best
choice.
A DAS, however, can be the best
choice when control is not the main
requirement, and when the plant does
not have established PLC expertise and
support. The combination of excellent
measurement performance, easy to use
and inexpensive software, web browser
access and readily available connectivity to other plant systems via common
protocols makes a DAS an attractive solution for many applications.
Data acquisition system (DAS)
Advanced DAS features
In general, DASs are used for two distinct purposes: testing/laboratory applications and industrial applications.
A lower-end, less robust DAS will often
work well in a clean lab environment,
but that same DAS will not be able to
perform in a harsh industrial environment, such as a petrochemical plant.
DASs for test laboratory and industrial process environments both have
their own performance challenges.
Some test applications require temperature measurements of energized
components or circuits where the
thermocouple sensor is in direct contact with high AC voltage. Successful
measurement under these conditions
requires differential inputs with high
common mode voltage and noise rejection specications, as well as robust
channel-to-channel and channel-to-
A basic DAS is typically connected to a

PC, with the PC being used for operator
display and data logging. A more capable system may incorporate built-in
data logging functions that allow it to
record data. This provides redundancy
and the convenience of stand-alone
operation. With universal inputs, users
can assign any channel to measure any
input signal type, and fully congurable recording and display functions
in the PC software or the unit itself allow it to be tailored for each application requirement.
High-speed DASs can capture many
thousands of data samples per second per channel, but temperature is
generally a slow-changing parameter
that does not require this level of performance. Depending on the manu54
Data acquisition systems can combine monitoring, control, display, and data handling in
a single unit.
facturer, a wide array of DASs may be

offered, ranging in size from portable
hand-held devices to large standalone
systems that can easily handle hundreds or even thousands of inputs.
DASs, with their multiple capabilities, can handle a wide range of monitoring, control, and data logging functions. Some of the newest DASs include
embedded control functions that can
provide up to 500 lines of logic. This lets
them perform many of the same control functions as a separate temperature or process controller.
Considerations when
choosing a DAS solution
WWW.ISA.ORG
ground isolation. A low-cost, singleended measurement circuit will fail

under these conditions in the worst
case and often provide noisy and unusable data.
Industrial settings can present other
challenges with the added demands of
coping with ambient temperature extremes, dirt, vibration, and moisture.
A well-engineered system must survive
and provide stable and accurate measurements in these applications and
environments.
Products built for industrial environments should have dust- and splashproof front panels, preferably compliant with IEC529-IP65 and NEMA4
standards, and the ability to retain data
during power failures of any duration
in non-volatile memory not requiring a
battery protection circuit.
Measured and calculated data should
be continuously saved to a secure, nonvolatile ash memory. At scheduled in-
Considerations for
choosing the right DAS
n
n
n
n
Built to withstand harsh environmental conditions, such as high

voltage, temperature extremes,
etc.
Ability to reject signal noise and
perform stable measurements
Scalability to protect investment
User-friendly operator displays
Networking capabilities
AUTOMATION BASICS
tervals, the les in the memory can be automatically copied to another ash memory, and these les can be copied
and archived to an FTP server. These features enable three
copies of the same data le to be stored at the same time in
different locations, providing redundant and highly secure
data storage.
A DAS should also be highly scalable to expand as needed.
This can be done by adding input modules or by connecting
to expansion hardware via a serial or Ethernet connection
using a protocol such as Modbus, which can enable users to
add hundreds of input channels to the base unit.
Data display and manipulation

Operators need a method to observe data and interact with
the DAS. This can be a PC display showing the DAS software screens, a web browser, or a built-in color LCD at the
DAS. Typical displays include trend, digital, and bar graph
screenswith the ability to build custom displays that suit
the needs of the user. Users should be able to review historical data with date and time calendar search functions. The
DAS should also contain reporting templates, such as an Excel report template that enables reports to be created easily
and automatically.
ABOUT THE AUTHOR
Steve Byrom (steven.byrom@us.yokogawa.com) has been with

Yokogawa for 16 years and has 30 years of experience in industrial automation. He is a graduate of Lincoln Technical Institute,
in Allentown, Penn.
View the online version at www.isa.org/intech/201212basics.
REFERENCES:
Fundamentals of Test Measurement
http://www.isa.org/InTechTemplate.cfm?Section=Communities&tem
plate=Ecommerce/FileDisplay.cfm&ProductID=7926&le=ACFE8EB.
pdf
High Winds Tester
http://www.isa.org/InTechTemplate.
cfm?Section=Archives4&template=/ContentManagement/ContentDisplay.cfm&ContentID=71521
Protection or Degradation
http://www.isa.org/InTechTemplate.
cfm?Section=Archives4&template=/ContentManagement/ContentDisplay.cfm&ContentID=63839
OPC
www.opcfoundation.org
A modern DAS can serve multiple functions:

monitoring and control, local operator display, redundant data recording, and multiplexed data source to a plant-wide control
and monitoring system.
Network connectivity ties everything together. The goal
of any DAS is to deliver sensor data for reporting and analysis. The ubiquitous Ethernet interface is a DAS requirement, connecting the DAS to the plant network and into
the PC world. Multiple protocols are typically available,
such as FTP for le transfer, Modbus TCP and EtherNet/
IP, web browsing, email messaging, and OPC server support. When standard industry protocols are supported by
the data acquisition equipment, data can be seamlessly
exchanged with virtually any other control or computing
system in the enterprise.
Touchscreen interfaces are the next step in streamlining
DASs. Newer systems offer improved ergonomics and operator interface, going from the buttons and panel key navigation to only one or two buttons and a touchscreen operation
interface that has many of the characteristics of a modern
smartphone or tablet interface.
A modern DAS can serve multiple functions: monitoring
and control, local operator display, redundant data recording, and multiplexed data source to a plant-wide control
and monitoring system. When an application demands all
or most of these functions, a DAS can be the best t, offering
a highly reliable and economical solution.
55
young innovators | Talking Shop with the Next Generation
Innovation, education, and experience prepare

leaders for automation industry future
By Prabhu Soundarrajan
Innovation distinguishes between a leader and a follower. Steve Jobs
n this rapidly changing world, it is very important to think different in order to stay ahead
of global competition. I would like to share my
life experiences with automation professionals
who aspire to grow and make a difference in this
world.
I have worked hard since my early years. I grew
up in India in a humble, middle-class family and
was motivated by science and math. I fell in love
with chemistry during my undergraduate years and
I found a small nanotechnology rm in Austin, Tex.

that gave me an opportunity to commercialize nano
sensor technologies. After four years and several
million dollars worth of government contracts, the
risk was totally worth it for my career.
chose a material science (polymers) major so that
I might pursue a career in the U.S. All my friends
said that I was making a mistake because I did not
choose to become a computer programmer. I did
not care; I stayed with my conviction and dream to
create a difference in this world.
I ended up at the University of Akron, a premier graduate program in polymer science and
engineering, with a scholarship in early 2000.
The University of Akron had just started a new
nanotechnology initiative that attracted my
attention. I took a huge step to be the first
research graduate student under a foreign professor to take up the new area of research.
The gamble paid offI graduated with flying
colors and even won a university-level business
plan competition for nanotechnology-enabled
sensors.
As I began looking around in the industry,
there were very few organizations where I could
use my innovative edge in the commercial world
to create value. I did not get discouraged, and
instead found a small nanotechnology rm in
Austin, Texas, that gave me an opportunity to
commercialize nano sensor technologies. After
four years and several million dollars worth of
56
WWW.ISA.ORG
government contracts, the risk was totally worth

it for my career.
I moved to California to pursue my entrepreneurial ambitions (again, this was a risk and
change from the presumed status quo of engineering researchers). I took up a position with a
company that just had licensed a sensor technology from a U.S. government lab. I combined my
education and innovative edge to develop and
commercialize the technology in collaboration
with global conglomerates. It was during this time
that I realized that I needed formal business training. I spent my personal funds to pursue business
education in some of the top universities for that
eld. Once again, my gamble paid off, as I was
promoted to a vice president role in recognition
of my commitment for the company to succeed.
More recently, I have been fortunate to work
with global leaders and innovators around the
world and run businesses that are $100M and
more. The reason I am here is because I was not
afraid to experiment and take risks in my career.
It is very important for young innovators to
keep learning. It is not about how much one
knows, but it is about how much one can learn
from others on a daily basis. Keep innovating,
keep dreaming and working hard. The success is
on its way.
ISA is a great technical and professional development resource to help achieve your dream, network, and nd your next job and grow with us.
ABOUT THE AUTHOR
Prabhu Soundarrajan is the director of ISAs chemical and petroleum division. He is also the global
director at RAE systems, a leading innovator of
wireless safety sensors for industrial markets, and
has held executive positions as vice president of
sales and business development, global business
unit manager, and has served on the board of directors of international organizations. Prabhu has
authored several papers and patents and also has
won the best paper award at ISA. He is a young
innovator and is willing to mentor aspiring young
ISA members.
Professional Growth | workforce development
Findingor developingthe right person for the job?

By Terri Helmlinger Ratcliff
n the same way that the factory environment is much different today than
it was ve, ten, or twenty years ago
especially in terms of automationthe
workforce environment has also changed.
That should not surprise us, but we seem
to be taking a long time to adapt to the
new situation.
What has not changed is that all
companies, sooner or later, need people to fill positions. With increased reliance on automation, we may need less
unskilled labor, but in truth we often
need highly skilled people for critical
positions. Companies need fewer op-
pany. This may be driven by strict emphasis on the bottom-line and the quarterly
dividend. After all, it is hard to show training as a prot center.
To some degree I can understand
this, since a companys mission is to
make a product or deliver a service,
not specifically to train people. They
may minimize in-house training if they
see little value added from it, and in
hard times they may decide training is
an easy thing to cut. But often the specialized offerings that outside agencies developed go under-utilized, since
jobseekers may not pursue training if
Rather than taking responsibility or committing internal

resources to develop their employees, these companies look
to community colleges and other institutions for specialized
training, then express dismay when their hiring pipelines
empty out.
erators, perhaps, but still need designers, engineers, and maintainers to keep
the line tuned up and running smooth.
Many companies are having trouble
finding people with the right skills. At
the Industrial Extension Service, we frequently hear that companies have positions open for specific skill sets but are
not filling them.
Unfortunately, some of these companies do not seem prepared to develop the right skills in people. On-the-job
training opportunities have declined as
companies have passed the buck on
training. Rather than taking responsibility or committing internal resources
to develop their employees, these companies look to community colleges and
other institutions for specialized training, then express dismay when their
hiring pipelines empty out.
I wonder if this is because companies
treat training as a sunk cost, rather than
an investment with a payoff to the com-
they are not sure it will land them a

job. As these specialized programs fail
to thrive, the institutions that started
them are less likely to develop new
ones, and taxpayers may feel their
money has not been well spent.
I see problems mounting when companies find it difficult to fill job openings but cannotor will nottrain
willing candidates. If this continues,
companies may lose the in-house skills
to perform high-value tasks, and end
up forced to outsource them.
This will not be solved quickly or
easily. To get started, I would ask companies and industry groups like ISA to
begin answering some questions:
n Can we afford NOT to invest in internal
training?
n Can we agree on common training
needs, topics, strategies, etc.?
n If we can agree on some common elements, can we combine resources and/
or develop partnerships to improve
training offerings and trainee success?

On my side of the fencegovernment and academiawe need to answer some questions, too:
n Can we determine what factors may
predict a persons success in company/
industry training programs?
n If so, can we help companies and industry to identify and recruit people
who are likely to succeed?
n Can we discover economic principles
about (or develop recommendations
about) the payoff companies can expect from training?
n If so, can we help companies decide
when in-house training is better than
outsourced training, and possibly help
develop cooperative approaches to lling critical needs?
With training, as with any investment, we must put something in and
accept some amount of risk before
we get the payoff. Currently, companies put as little as possible into training (usually through taxes, sometimes
through grants or equipment gifts or
tuition), and accept the risk of not having the trained, skilled workforce they
need. It would be far better if companies found the optimal level to invest
in in-house or cooperative training,
and thereby reduce the risk that their
production lines and businesses will be
interrupted by skill shortages.
Unfortunately, it seems the situation
is likely to get worse before it gets better. The environment today is different
from what it used to be, and a few
years from now it will be different still.
We need to get started, to figure out
how to stave off a future with too few
skilled workers.
ABOUT THE AUTHOR
Terri Helmlinger Ratcliff is the Executive Director of the Industrial Extension

Service and the Interim Vice Provost for
Outreach and Engagement at North
Carolina State University.
57
channel chat | Tips and Strategies for Systems Integrators
When is safe safe? The value of a risk assessment

By Rick Carpenter
n late August, Hurricane Isaac drove

water over the top of a levee on the
outskirts of New Orleans, triggering
life-threatening ooding seven years to
the day after Hurricane Katrina.
Emergency management ofcials in
low-lying areas reported the overtopping
of this 8- or 9-foot high levee of southeast New Orleans. About 2,000 residents
of the area had been ordered to evacuate, but only about half were conrmed
to have gotten out before Isaac brought
driving winds and rain.
Not only did Isaac deliver more of a
punch than people thought possible, it was
the rst test for multibillion-dollar ood
defenses built after levees failed under Katrinas storm surge, leaving large parts of
New Orleans swamped, killing 1,800 people, and costing an estimated $81 billion,
the costliest natural disaster in U.S. history.
and
components.
Both OSHA and ANSI
are important agencies in North America. They provide
guidelines on how
machinery can operate safely in order to
prevent a dangerous
situation. However,
neither organization
creates standards on
how or when a safety component is con- Lakeview of levee in New Orleans
Source: fotolia.com
sidered safe. Both
OSHA and ANSI rely
on standards, such as ISO/EN 13849 and
the harm or damage could be. It is usually
IEC 62061, to dene what makes safety
a combination of the likelihood of occurdevices safe, as well as how the safety derence and the consequences: How likely is
vices should be used on machinery in order
this to happen? How serious could it be?
to achieve a safe state of operation.
Risk is usually expressed as high, moderate, or low (qualitative), or as a number,
Does the equipment meet with current safety standards so
with the higher number indicating the
greater the risk (quantitative).
as to comply with adopted OSHA and/or ANSI standards?
Risk assessment is the process of identifying hazards related to environment, health,
Natural levees serve as barriers by conToo often, many manufacturing faciliand safety that are intrinsic properties of
ning rivers during periods of ordinary
ties believe that they are safe simply bework-related activities, assessing both the
ow. They may even protect low-lying
cause there is already some sort of safety
likelihood that the hazard will lead to a loss
areas from ooding if the level of a river
device or devices in place, and no one
and the severity of that potential loss. The
is not too high. For this reason, articial
has been hurt on the existing equipment.
results of likelihood and severity are comlevees designed to contain a river during
However, the question needs to be asked
bined according to an agreed-upon rule to
ood stages are often built, but these aragain, when is safe safe?
give a single measure of potential risk.
ticial levees can themselves create probHow can you evaluate existing machinSimply put, a risk assessment is a carelems by conning the river to a narrow
ery already in place? Does the machinery
ful examination of what, in your workchannel, or conning sediment, which in
already provide proper functional safety?
place, could cause harm or damage to
turn raises the river bed higher and highAnd does the equipment meet with curpeople, property, or the environment. You
er. These same levees can provide a false
rent safety standards so as to comply with
can then decide if you have taken enough
sense of security as we just witnessed
adopted OSHA and/or ANSI standards?
precautions or should do more to prevent
with Hurricane Isaac.
The wrong approach is to simply ignore
any harm or damage from happening.
these issues and hope nothing will ever
Safety measures do not obviate risk
happen. The correct approach is to conABOUT THE AUTHOR
Functional safety standards exist to ensure
duct a functional safety risk analysis and
Rick Carpenter (rick.carpenter@lomancsi.
the safety of processes and to help prevent
see where any safety issues may be.
com) is functional safety and life sciencaccidents from happening on the induses manager at Loman Control Systems,
trial plant oor. These standards provide
Assess likelihood and severity
Inc., a Control System Integrator Assoa formulized method to determine the
Risk is, by denition, the chance or likeliciation (CSIA) Certied member based in
risk associated with industrial machinery.
hood that someone or something could
Lititz, Penn. To learn more about CSIA,
Functional safety standards also provide
be harmed or damaged by the hazard, tovisit the associations web site at www.
guidelines to prevent unsafe conditions
gether with an indication of how serious
controlsys.org.
58
WWW.ISA.ORG
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standards | New Benchmarks & Metrics
Standards update: Alarm management
larm management was a topic

of great interest as automation
standards experts from across
the globe convened in Orlando, Fla. during ISA Automation Week 2012 for the
IEC Technical Committee (TC) 65 plenary
meeting. IEC TC65, Industrial Process
Measurement, Control, and Automation,
is the worlds principal body for international standards used in industrial automation and control.
ISA has had a long and successful collaborative relationship with IEC TC65,
through which several widely-used IEC
standards have been based on original ISA
standards in areas including batch control,
functional safety, cyber security, and enterprise-control system integration.
ing technical reports this year, the most

recent of which is ISA-TR18.2.5-2012,
Alarm System Monitoring, Assessment,
and Auditing. This technical report provides guidance and information supplementing ISA-18.2-2009 on the use of
alarm system analysis for both ongoing
monitoring and periodic performance
assessment. Monitoring, assessment,
and audit are essential to achieving and
maintaining the performance objectives
of the alarm system. These activities can
identify improvement opportunities in the
other lifecycle stages, such as philosophy,
rationalization, detailed design, implementation, operation, maintenance, and
management of change.
Alarm system performance analysis can
The standard denes the terminology and models to

develop an alarm system, and the work processes
recommended to effectively maintain the alarm system
throughout the lifecycle.
Alarm management is expected to join
that list in 2013, as Nick Sands of DuPont,
co-chair of ISA18, updated attendees at
the plenary meeting on the ongoing IEC
development of ANSI/ISA-18.2-2009,
Management of Alarm Systems for the
Process Industries, into standard IEC
62682. He also briefed attendees on
work by ISA18 to develop a series of ISA
technical reports to provide rationale, usage guidelines, and examples to support
the application and use of the standard.
ISA-18.2-2009 addresses the development, design, installation, and management of alarm systems in the process
industries. Alarm system management includes multiple work processes throughout the alarm system lifecycle. The standard denes the terminology and models
to develop an alarm system, and the work
processes recommended to effectively
maintain the alarm system throughout
the lifecycle.
ISA18 has completed three support60
also play a part in overall plant performance metrics and can be used as an input to process improvement efforts. This
is typically in conjunction with process
historian data and control loop effectiveness data. The focus of the assessment
process is to apply engineering judgment
and review to determine whether the
alarm system is performing properly.
Earlier this year, the ISA18 committee
completed two additional ISA technical
reports:
ISA-TR18.2.4-2012, Enhanced and
Advanced Alarm Methods, is intended
to help people evaluate when to use
enhanced and advanced alarming methods, what benets they can achieve, and
what challenges and costs to expect. Per
ISA-18.2-2009, enhanced and advanced
alarm methods typically go beyond the
basic methods and techniques that are
usually, or at least initially, applied. While
signicant improvement in alarm system
function and performance can usually
WWW.ISA.ORG
be made by following the basic alarming

methods and principles, in some cases
they may not be sufcient to achieve
the goals for performance and operator
guidance stated in the alarm philosophy.
For example, due to changing process or
equipment state, the alarms may not always trigger at the appropriate times for
operator action, or may trigger at times
when no action is needed.
ISA-TR18.2.6-2012, Alarm Systems for
Batch and Discrete Processes, covers the
application of alarm management principles in the standard to batch and discrete processes. The general principles
and techniques described are intended
for use in the lifecycle management of
an alarm system based on programmable
electronic controller and computer-based
human-machine interface (HMI) technology. Use of the technical report should
consider batch and discrete process
alarms from all systems presented to the
operator, which may include basic process control systems, annunciator panels, safety instrumented systems, re and
gas systems, and emergency response
systems. Following the recommended
guidance will help to identify and address
alarm specication, design, implementation, and management opportunities
that are important to batch and discrete
processes. It can also help minimize the
generation of nuisance alarms that could
complicate and frustrate an operators
awareness, understanding, and response
to abnormal situations.
Additional supporting technical reports
being developed by ISA18 will cover alarm
philosophy, alarm identication and rationalization, and basic alarm design.
For information about viewing or
obtaining the ISA-18.2-2009 standard
and the supporting technical reports,
visit www.isa.org/ndstandards, select 18 from the rst drop-down list,
and scroll down.
For information on ISA Standards,
visit www.isa.org/standards or contact
Charley Robinson, crobinson@isa.org.
ISA salutes
our partners.
Through the ISA Corporate Partnerships Program,
leading companies have joined together to invest
in the future and work together to solve the
problems our industries face. Automation
professionals around the world will benefit
from their support of ISA, and were
proud to recognize their contributions.
We accomplish more together than we
ever could alone. So, on behalf of ISA
members, leaders, and customers
everywhere, let us humbly say...
Thank you.
ISA Corporate Partners:
ISA Automation Week Partners:
Learn more about our partners at www.isa.org/partners

Learn more about becoming a partner at: www.isa.org/partnershipsoverview
product spotlight | Temperature
Focus on temperature
This content is courtesy of
Precision process calibrator

Fluke Calibrations 7526A Precision Process Calibrator combines versatility, precision, and value into a single benchtop
process calibrator. The 7526A simplies
calibration of temperature and pressure
process instrumentation by incorporating an isolated measurement channel,
allowing users to source and measure
simultaneously. Easily calibrate RTD and
thermocouple readouts, pressure gauges,
temperature and pressure transmitters,
digital process simulators, data loggers,
multimeters, and more.
Non-contact temperature sensor
Omegas OS212 compact non-contact temperature sensor is a

high-quality, low-cost sensor that measures temperature of inaccessible or moving objects and materials. It features a fast response with high stability, two-wire 4- to 20-mA output proportional to target temperature, optional manual emissivity adjuster
with display and stainless steel housing, sealed to IP65. This
product is ideal for research, industrial applications, HVAC, oil,
automotive, and beverage industry. Applications include noncontact temperature monitoring associated with liquids, motors,
plumbing, food, refrigerated rooms, manufacturing, chemical
plants, and oil reneries.
Omega
www.omega.com
62
WWW.ISA.ORG
The calibrator simulates and measures

nine RTD and 13 thermocouple types,
accurately measures pressure to within
0.008 percent of reading when combined
with Fluke 525A-P Series Pressure Modules, sources and measures dc voltage
from 0 to 100 V to within 0.004 percent
of reading, sources dc current from 0 mA
to 100 mA, accurately measures dc current to within 0.01 percent from 0 mA to
50 mA, and supplies 24 V dc loop power.
Fluke Calibration
www.ukecal.com
PID controller
Red Lion Controls released the PAX2C PID controller, which is
designed specically for the process and temperature control
markets. Applications include food and beverage, plastics, packaging, energy, gas, heat treating, and glass processing.
The PAX2Cs features include eld installable plug-in option
cards, which simplify conguration by enabling customers to use
different cards to build their own controllers. This type of exibility eliminates the need to order additional products to meet
changing application requirements. A dual-line tri-color display
provides at-a-glance visual representation of up to 16 changing
alarm conditions with seven programmable color zones; customizable to allow users full access to bar graphs, annunciators, color
zones and display mnemonics.
The PAX2C also features universal input, a universal power
supply, and easy programming, rmware, and software upgradesusing a standard built-in USB connector and Red Lions
Crimson software to support both current
needs and future requirements.
Red Lion Controls
www.redlion.net
Temperature | product spotlight
Non-intrusive pipe clamp sensor

Emerson Process Management announces the release of its Rosemount 0085 non-intrusive Pipe
Clamp Sensor. This temperature
measurement solution allows efcient data capture in applications
where intrusive measurements are
not possible due to excessive stress
placed on sensors with thermowells.
The Rosemount 0085 is optimized
for ideal sensor-pipe contact and
heat
transfer,
with a spring-loaded
sensor and a highly conductive at nickel or silver sensor tip. Its
robust design was built to hold a transmitter in its assembly, and when paired
with the Rosemount 648 wireless transmitter, the sensor gives operators immediate access to reliable temperature
measurements with no process intrusion.
Process manufacturers with the 0085
non-intrusive Pipe Clamp Sensor will
have enhanced visibility across their operation and be better positioned to resolve issues proactively, improve operations, and meet quality and production
targets while lowering costs. The Pipe
Clamp Sensor is easy to congure and
maintain, and its simple two-bolt design
makes it easy to install.
Emerson Process Management
www.rosemount.com
ture, and transmits the relevant data to the bridge where it is

evaluated. Due to its diagnostic capabilities, VIBCONNECT RF
monitors the condition of roller bearings and other rotating
components and also detects damage caused by cavitation.
The VIBCONNECT bridge acts as the central receiver. It processes
the data from the sensor units and transmits it through the operators network for visualization and archiving. For the evaluation
of received data, the system includes a range of comprehensive
analytical functions that enable the operator to assess the machine vibration, temperature, and bearing condition.
Ludeca
www.ludeca.com
Wireless condition monitoring

system
Ludeca announces VIBCONNECT RF

Wireless Condition Monitoring System for machine components. The
sensor unit monitors machine vibration, bearing condition, and tempera-
63
classieds
datales
Datales list useful literature on products and services that

are available from manufacturers in the instrumentation and
process-control industry. To receive free copies of this literature,
please contact each manufacturer via their provided contact
information.
Maintenance Management
Software/ CMMS
ADVANCED TEMPERATURE/
PROCESS CONTROLLER
Omegas new CN2300 series DIN
Ramp/Soak Advanced Temperature/Process
Controller with USB interface features a
graphic/text LCD display and datalogging
options. This affordable controller has 64
independent programs, 255 segments per
program, universal inputs, autotune, modular isolated control outputs, alarm functions and has 5 language
options: English, French, German, Italian and Spanish. Ideal for
food, automotive, manufacturing and chemical industries.
FastMaint CMMS
Your FAST TRACK to maintenance management
For Utilities, Manufacturing Plants,

Industrial & Commercial Facilities
Fast to setup. Easy to use. From US$ 995
Download 30-Day Trial/ Web Demo
www.smglobal.com (919) 647-9440

SMGlobal Inc, 5448 Apex Peakway #308
Apex, NC 27502 USA
Plus Maintenance Books,

Tips & Training
http://www.omega.com/pptst/CN2300.html
Omega Engineering, Inc.
Phone: 1-800-TC-OMEGA or 203-359-1660
STATEMENT OF OWNERSHIP
MANAGEMENT AND CIRCULATION
(Required by 39 U.S.C. 3685)
Custom REPRINts
Title of Publication: InTech

Publication Number: 0192-303X
Filing Date: 09/26/12
Frequency: Bimonthly
Number of Issues Published Annually: 6
Annual Subscription Price: $8.65 (member)
Mailing Address and Business Headquarters:
ISA, 67 Alexander Drive, Research Triangle Park, NC 27709
Publishing: Susan Colwell Editor: Bill Lydon
Average # of copies
each issue during
preceding 12 months
Actual # of copies
of single issues published
nearest to ling date
Paid and/or requested circulation through:

-Dealers:
6,737
6,401
-Mail subscriptions:
41,143
34,133
Total paid and/or

requested circulation:
47,880
40,534
Free distribution by mail:
1,714
1,422
Free distribution outside the mail:
281
267
Total free distribution:
1,995
1,689
Total distribution:
49,875
42,223
Copies not distributed:
568
567
Returns from news agents:
none
none
Total:
Percent paid and/or requested circulation:
50,443
96%
42,790
96%
I certify that these statements are correct and complete:

Susan Colwell, Publishing Manager
64
WWW.ISA.ORG
ad index
InTech advertisers are pleased to provide additional information about their products and services. To obtain further information,
please contact the advertiser using the contact information contained in their ads or the web address shown here.
Advertiser
Page #
ABB..............................................................9
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Anton Paar................................................40
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ARC Advisory Group ................................63
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Arjay Engineering Ltd. .............................55
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CSA Group ......................................Cover 3
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Emerson Process Management ......Cover 4
www.emersonprocess.com
Advertiser
Page #
Rosemount, Emerson Process

Management ...................................Cover 2
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EtherWAN .................................................48
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Honeywell ................................................33
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OSIsoft ......................................................25
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Schweitzer Engineering Laboratories ....37
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Sample of Jobs Available at ISAJobs.org

See more at ISAJobs.org, where you can search for available jobs or advertise positions available within your
company. ISA Members post resumes at no charge.
Senior Field Service Engineer
Thermo Fisher Scientic: The Field
Technician will independently perform
scheduled maintenance and execute installations, troubleshoot, provide product/technical training to customers in
industrial locations with physically demanding environments often outside,
in varying weather conditions and harsh
environments. Extensive travel required,
including some international. Locations
include Colorado, Oregon, Washington,
and Massachusetts. Ability to read wiring diagrams, troubleshoot pneumatics, program PLCs is a plus. Seeking
motivated, self-starting individuals. Full
training will be provided to the successful candidate who has the core skills required for the position. see more at
ISAJobs.org.
Process Controls System Engineer

Alcoa: The Controls Engineer will provide technical and engineering support for PCS at the Warrick Smelter
near Newburgh, Ind. The focus will be
on automation. Primary areas will include: Programmable Logic Controllers
(PLC) hardware and software, Human
Machine Interfaces (HMI), Variable Frequency Drives (VFD), Instrumentation,
and Device Communication. The ideal
candidate is an ambitious self-starter
who wants to learn the various areas of
the plant operation and later advance
into other technical or managerial positions. BS in Electrical Engineering, Electrical Engineering Technology, or related
degree required. Minimum two years
experience in automation and control
systems. see more at ISAJobs.org.
Thermal Systems Control

Technical Associate
AURA: The National Solar Observatory
(NSO) Advanced Technology Solar Telescope (ATST) Project has an immediate
opening for a Thermal Systems Control
Technical Associate to provide support in
the design and development of the ATST
Project and thermal systems. Initial development work will be done in Tucson,
Ariz., with eventual relocation to Maui,
Hawaii. Perform technical support activities at an experienced level, including PLC/
PAC/DCS programming and process controls installation. Excellent compensation/
benet package. Minimum Associates
degree or military school in engineering
technology or related technical eld and
at least ve years of technical experience.
see more at ISAJobs.org.
65
the nal say | Views from Automation Leaders
Paul Galeskis ISA Excellence in Leadership Award

acceptance speech
Paul Galeski
Editors Note
The Final Say this month is Paul Galeskis acceptance
speech when he received the Excellence in Leadership Award during the 50th Annual ISA Honors and
Awards Gala, 24 September 2012, at the Rosen
Centre Hotel in Orlando, Fla. Galeski founded Maverick Technologies in 1999 with the intent of becoming a global resource dedicated to helping manufacturing businesses reach new levels of success.
Over the past decade, Maverick has worked with
hundreds of world-class clients to devise unique approaches, enhance productivity, reduce costs, and
improve safety through the innovative application
of industrial automation, enterprise integration, and
operational consulting.
Ladies and Gentlemen,
I am excited to be here, and I am pleased and humbled to receive this award. I am also deeply honored
that the award is presented by the International Society of Automation, an organization of which I have
been a proud member for more than 25 years, and
which I believe remains on course to set the highest standards for our industry and to produce leaders
and companies who can meet those standards.
I also want to thank all the superb people at Maverick Technologies who have allowed me to lead
them and who daily reect the high ideals of this Association. Those people are the real award winners!
While I sincerely appreciate this honor, I feel
compelled to use this forum to discuss a serious
threat to our nations, customer requirements, and
a role for each of you.
You are all educated, involved leaders so you must
know that our networks are under signicant attack
every day by various hostile elements. By networks,
I mean every system that uses IP addresses, whether
in chemical plants, gas pipelines, the electrical power grid, and more. By hostile elements, I mean everything from disgruntled employees to enemy nation
states. The point is that our automated systems in
those networks are more vulnerable today than perhaps any other time in their development.
In July, Gregory C. Wilshusen, director of information security issues with the Government Accountability Ofce (GAO), noted that threats to systems
supporting critical infrastructure (which includes the
electricity industry and its transmission and distribution systems) are evolving and growing. He pointed
out that the increased reliance on IT systems and
66
WWW.ISA.ORG
networks expose the electric grid to potential and

known cyber security vulnerabilities.
What impact might a grid failure have? Well, recently blackouts left half of Indias population without electricity, demonstrating both vulnerability and
impact. A series of failures and excessive demand on
the Indian national grid knocked out power for 640
million people in northern and central India on 31
July, a day after a separate blackout left 360 million
in seven states without power. In May, the French
press reported that Joe Weiss, managing partner for
the security rm Applied Control Solutions, said the
latest (cyber) attacks highlight the vulnerability of
so-called critical infrastructure systems.
He said control systems vulnerabilities can be
found in the electrical grid, water utilities, and others, as well as pipeline operators.
Once you get to those systems, really bad
things happen, Mr. Weiss said. Thats where
people die.
So if I have your attention now
This is where all of you and this great Association come in: Together we need to demonstrate
industry leadership to:
n Learn more about the cyber threat to automated systems, including the ISAs very signicant
efforts to deal with the cyber threat through the
emerging ISA-99 standard.
n Inform, advise, and help automation end users
to develop appropriate requirements to mitigate the threats and make our manufacturers,
utilities, and other critical infrastructure secure,
safer, and more competitive.
n Design affordable and easily-deployed solution
sets for our manufacturers and our nation.
n Only when this threat is mitigated, can we recognize the rightful place of our professionautomationas the engine of modern, globally
competitive manufacturing.
In closing, cybersecurity is a real issue facing the
automation industry and is a topic that we all need
to address now. I welcome the opportunity to engage with ISA and its members, starting with this
Conference, to talk about this important matter.
Most importantly, I want to express my gratitude
to my family, who has supported me in all my undertakings, all the great people at Maverick Technologies, and all of you who make this organization
so successful.
Thank you very much!
Together, we are the worlds

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November/December 2012

With rising costs and tighter budgets, I

You CAN Do THAT

DIN Ramp/Soak Advanced

PP3, PP6, and

November/December 2012 | Vol 59, Issue 6

Setting the Standard for Automation

COLUMNS AND DEPARTMENTS

The need for

Success in this accelerating global business

62 Products & Resources

66 The Final Say

SPECIAL SECTION: TEMPERATURE

42 Thermal imaging detects equipment issues

INTECH NOVEMBER/DECEMBER 2012

Analysis of wireless industrial automation

Breaking Automation News

Black and white and read all over

News is not a 9 to 5 occurrence; it breaks out all the

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ISA INTECH STAFF

By Bill Lydon, InTech, Chief Editor

Question: Is it more important for engineers

Robert E. Lindeman, CAP, PMP

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your letters | Readers Respond

Career change considerations

Teaching an engineer to sell, provided he

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PGC5000A. Latest process gas chromatograph

ABB Analytical Measurements

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ISA CEO Patrick Gouhin speaks at World Manufacturing Forum

INTECH NOVEMBER/DECEMBER 2012

professionals capabilities. Gouhin said ISA is

limited energy resources and raw materials mount, technological innovation,

News from the Field | automation update

Automation by the Numbers

$1289.9 million 1,000,000,000

Emerson Process Management announced that

According to a survey from Deloitte

The need for

he concept of delivering enterprise control on an enterprise control system

INTECH NOVEMBER/DECEMBER 2012

The move toward real-time industrial business

Who needs real-time enterprise

The challenge: connecting the islands

An exciting new role for the control

INTECH NOVEMBER/DECEMBER 2012

Figure 1. Simplied real-time

with the most is the transition of their

INTECH NOVEMBER/DECEMBER 2012

are just not frequent enough to control