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 COMMENT
Specify performance, manage risk
P
roduct specifications have been cen-
tral to the decision-making process of
purchasing equipment since the dawn
of equipment procurement. How many
times have end users been locked into using
systems from a single source because the
spec called for specific hardware and/or soft-
ware from that vendor? The author of the cover
Jack Smith story in this issue of AppliedAutomation dis-
Edit or cusses the concept of specifying performance
instead of parts or equipment. The author
writes, “Many plants and facilities purchase
machines and process skids from OEM sup-
pliers. The temptation often is to specify parts
and vendors down to a very detailed level,
but this can result in higher costs, longer lead
times and no performance guarantees from the
OEM. A better approach in many instances is
to specify performance, while giving the OEM
as much leeway as possible in terms of parts
and vendors. This is particularly true for plants
and facilities with limited onsite staff, and a
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corresponding heavy reliance on OEM suppli-
ers, often including support contracts.”
The author of the second article in this issue
connects the concepts of alarm management
and process safety management. “‘Alarm man-
agement’ is the application of human factors to
design and maintain an alarm system to maxi-
mize its effectiveness. ‘Process safety manage-
ment (PSM)’ is a disciplined framework for man-
aging the integrity of systems and processes
that handle hazardous substances. It relies on
good design principles, well-implemented auto-
mation systems and engineering, operating and
maintenance practices,” he writes.
Alarm management and process safety man-
agement are about managing risk. The author
writes, “There are many interactions between
alarm management and process safety man-
agement. Each discipline requires a rigorous
methodology to properly implement, yet under-
standing how they interact is equally important
to ensure a safe and productive process.”
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Contents
A6 Specifying performance
instead of parts
Specifying performance instead of parts when purchasing
machines and process skids will cut costs, reduce lead
time and guarantee operation.

A10 Connecting alarm management

and process safety
Making the connection between alarm management
and process safety management can ensure a safe
and productive process. A6
ON THE COVER: OEMs have invested time and effort
to design, build and test their control system to meet the
performance requirements of their machine or process.
Courtesy: AutomationDirect

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Content Manager Media and is mailed as a supplement with Control Stuart Smith
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Applied Automation June 2019 • A5

 C o v e r s t o ry
Specifying performance
instead of parts
specifying performance instead of parts when purchasing machines and process
skids will cut costs, reduce lead time and guarantee operation.
By Bill Dehner
M
AutomationDirect
any plants and facilities purchase
machines and process skids from OEM
suppliers. The temptation often is to
specify parts and vendors down to a very
detailed level, but this can result in higher
costs, longer lead times and no perfor-
mance guarantees from the OEM.
A better approach in many instances is to specify per-
formance, while giving the OEM as much leeway as pos-
sible in terms of parts and vendors. This is particularly
true for plants and facilities with limited onsite staff, and
a corresponding heavy reliance on OEM suppliers, often
including support contracts.
Figure 1: Innovative Treatment Products selected AutomationDirect
products for the control system on this water treatment skid,
allowing the company to provide performance guarantees to its
customers. Courtesy: Innovative Treatment Products
A6 • June 2019 Applied Automation
Issues with specifying vendors
Specifying preferred parts and vendors can make it dif-
ficult to create a bid specification because excessive detail
is required, very little of which directly influences the most
important attribute: performance of the machine or pro-
cess skid (see Figure 1). It may stop OEMs in their tracks,
resulting in fewer bidders, or sometimes only one.
Boxing in the brands that can be used will often push an
OEM out of its comfort zone (see Figure 2). For example,
if the OEM can’t use its preferred controller or human-
machine interface (HMI), the design and schematics will
need to be changed, which will cause higher costs and
delays in other areas. The learning curve will remain in
effect throughout the project, adding even more delays,
along with longer lead times for parts.
Focusing on parts and vendors instead of performance
in the bid spec may require a new programmable logic
controller (PLC) program to be written, one never tested in
use before. This required software development time may
or may not extend the project schedule, but either way
someone must be paid to write it. The OEM often must
outsource programming for unfamiliar controllers, adding
another layer of risk and complexity. Regardless of who
writes the software, it likely will need extensive debugging
as it hasn’t been proven in use, which will extend the time
needed for startup and commissioning.
Limiting vendor and OEM options is like requiring the
wheel to be reinvented. What the OEM knows and has
proven in use for years turns into a custom control sys-
tem, which may result in less reliable operation. All the
tuning, tweaks and optimization performed on the OEM’s
preferred control system must now be repeated. Some of
this can be done during design, test and startup—but other
issues will inevitably crop up later.
Combining detailed part and vendor specifications with
the changes needed to an OEM’s control system also may
lead to delays in support, and/or a much more expensive
support contract. Most of the OEM’s technical personnel
will not be able to support the unfamiliar control system,
in the worst case leading to reliance on a single person
within the OEM’s organization, or within one of its subcon-
tractors.
Specifying performance
It’s much simpler to specify performance instead of parts
and vendors, for instance a certain number of parts pro-
duced per hour with 98% uptime. While specifying parts
and vendors doesn’t guarantee performance, specifying
performance can. Most OEMs will be quite reluctant to
guarantee performance if they can’t use their preferred
vendors. Allowing them to do so will make performance
guarantees much more likely, and also can result in
improved assurances. In the preceding example, the OEM
might be able to guarantee 99% uptime if it uses its pre-
ferred vendors, which could result in substantial savings.
But just how does a company go about specifying per-
formance, while assuring the machine or process skid can
fit into its general plant operating parameters? The follow-
ing list gives an example of some of the most important
electrical performance requirements to include in a control
design specification, which should be included along with
required performance in terms of the machine or process
skids output, uptime, maintenance costs, etc.:

‡$VLQJOHSRLQWSODQWFRQQHFWLRQVKDOOEHSURYLGHG
for a 3-phase, 480 V ac, 60 Hz supply.

‡$PDLQGLVFRQQHFWZLWKHOHFWULFDOORFNRXWIHDWXUH
shall be provided.

‡&RQWUROZLULQJVKDOOEH9GFRUOHVV

‡3URJUDPPDEOHORJLFFRQWUROOHUVKDOOKDYHDPLQLPXP
H[SDQVLRQRILQSXWRXWSXW,2SRLQWV
‡6XSSOLHUPXVWSURYLGHSURJUDPPLQJVRIWZDUHIRU
all programmed devices.
‡'LVFUHWHLQSXWVVKDOOEH9GFVLQNLQJSRLQW
modules.
‡'LVFUHWHRXWSXWVVKDOOVRXUFH9GFWRDVLQNLQJ
output device, 16-point modules.
‡6HQVRUVVKDOOEH313W\SHZLWKLQGLFDWRUOLJKWV
Figure 2: OEMs have invested time and effort to design, build and test
their control system to meet the performance requirements of their
machine or process. Courtesy: AutomationDirect
The electrical performance requirements in the preced-
ing list should be self-explanatory, with each requirement
simple to verify. These electrical requirements, along with
other performance specifications, are usable throughout an
DQGPLFUR0TXLFNGLVFRQQHFWFDEOHV
‡&RQWUROHQFORVXUHVKDOOPDLQWDLQDPLQLPXPRI
1(0$HQYLURQPHQWDOSURWHFWLRQ
‡$OOZLULQJDQGKRVHVVKDOOKDYHODEHOVWKDWPDWFK
the electrical schematic.
‡2SHUDWLQJWHPSHUDWXUHVKDOOEH)WR)RUEHWWHU
‡7KHRSHUDWRULQWHUIDFHVKDOOEHDFRORUWRXFKVFUHHQ
with a minimum 6-inch diagonal display.
automation project from the bid stage to site acceptance
testing, where each requirement and specification must be
checked to assure it is met.
Beyond cycle time, parts per hour, productivity availabil-
ity and quality requirements, additional system or machine
performance might include critical process performance
such as crimping a cap in a housing or other item required
to make a good part. This would include, for example,
press-to-depth crimp performance of 3-5 tons of force with
LQFKSUHVVVWURNHGHSWKUHSHDWDELOLW\2WKHUSHU-
IRUPDQFHUHTXLUHPHQWVPLJKWEHDSURGXFWLRQUDWHRI
parts per hour with 98% uptime.
Applied Automation June 2019 • A7
 C o v e r s t o ry

Figure 3: Specifying HMI opera-

tional parameters instead of a
vendor allows OEMs to select
HMIs with the best price-
performance ratio. Courtesy:
AutomationDirect

HMI specifications also

can be performance-
based using operational
parameters. For example,
requiring an overview
screen with mode, cycle,
product and fault informa-
tion. Product selection via
recipes, teach robot points
and help and fault mes-
sage screens are other
examples of operational performance requirements for an
HMI (see Figure 3).
Basic requirements for data collection are another
example of a performance-based specification. This
might include storage of fault message data, display of
the number of good and reject parts by part number, cur-
rent cycle time, last 10 cycle times data, etc.
These performance requirements lead the way to a
quicker installation and startup. The end goal is a reliable
and efficient machine or process skid that fits into ongo-
ing operations.
Supporting the system
Many OEMS are willing and able to maintain their
machines and process skids remotely for a low monthly
cost after the warranty expires, but often only if they can
use their preferred vendors. This approach also fits well
with many end users due to a shortage of technical staff.
The need for after-warranty support should be well-
defined in the performance-based specification at the
start of the project, with costs specified. The provision of
remote and onsite support services should be defined.
Using these support options in performance-based
specifications helps ensure machines and process skids
will be supported at the level required and lets the OEM
use their standard design.
With the OEM equipment tested, accepted and paid
for, quick resolution of any operational problems is a
must. To speed this process, remote access is critical.
Whether it’s during the first-year warranty period, for
example, or after the warranty expires, remote access
keeps support costs low for both the end user and the
OEM. Troubleshooting via remote access should there-
fore be a performance requirement. That means that
remote access is not an add-on feature, but instead a
requirement designed into the control system from the
start.
The end goal is a reliable and
efficient machine or process skid that
fits into ongoing operations.
OEMs and their customers look to the future
At least some OEMs are now supplying machines and
process skids through lease arrangements instead of
requiring a purchase. These lease arrangements often are
very performance-oriented, with the OEM not being paid if
performance guarantees are not met.
Another wrinkle is for the OEM to be paid based on pro-
duction of the machine or process skid, for example, a cer-
tain amount per pound of product produced, with any set
monthly payment. This type of arrangement most closely
aligns the purchaser’s needs for maximum production with
the OEMs financial goals, and is therefore gaining favor.
Both of these types of agreements, leasing and paying
only for production, strongly favor specifying performance
instead of parts and vendors, and are a requirement of
many of these types of contracts. Even if the OEM con-
sents to enter into one of these types of agreements using
parts and vendors specified by the purchaser, costs are
sure to be higher.
Therefore, current and future trends may favor specify-
ing performance instead of parts and vendors in many
instances, and often may lead to more favorable outcomes
for both parties.
Bill Dehner is a technical marketing engineer at
AutomationDirect. He has spent the majority of his 14-year
engineering career designing and installing industrial con-
trol systems for the oil & gas, power and package handling
industries.

A8 • June 2019 Applied Automation

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 A l A r m , p r o c e s s sA f e t y mAnA g e m e n t
Connecting alarm management
and process safety
making the connection between alarm management and process safety
management can ensure a safe and productive process.
By Lee Swindler
M a v e r i c k Te c h n o l o g i e s
T
wo highly specialized areas of expertise in the
process automation industry are alarm manage-
ment and process safety management. While
you might think these are separate topics, they
actually go hand-in-hand. Let’s examine the
relationship. To get us all on the same page,
here is a definition of each:
Alarm management is the application of human factors
(ergonomics) to design and maintain an alarm system to
maximize its effectiveness. A common problem is hav-
ing too many alarms annunciated during a plant upset,
commonly referred to as an “alarm flood.” However,
other problems can exist with an alarm system, such as
poor prioritization, improperly set alarm points, ineffec-
tive annunciation, unclear alarm meanings and so on.
Improper alarm management is one of the leading causes
of unplanned downtime, contributing to more than $20 bil-
lion in lost production every year, and to major industrial
incidents, such as the 2005 Texas City refinery explosion.
Process safety management (PSM) is a disciplined
framework for managing the integrity of systems and pro-
cesses that handle hazardous substances. It relies on good
design principles, well-implemented automation systems
and engineering, operating and maintenance practices. It
deals with the prevention and control of events that have
the potential to release hazardous materials and energy.
For the process industry, emphasis is placed on process
safety to prevent unplanned releases that could result in a
major incident, which typically is initiated by a hazardous
release. It also may result from a structural failure or loss of
stability that potentially escalates into a major incident.
It’s about risk
How does alarm management impact process safety?
In addition to keeping a facility operating better, it comes
into play when determining the risk, or more precisely the
residual risk, in a given process. PSM risk analysis can be
broken down into three steps:
A10 • June 2019 Applied Automation
Step 1: First, you must systematically evaluate the
hazards (inherent risks) in operating a given process
unit. This is typically done in a team setting performing
a process hazard analysis (PHA) with the most common
method being a hazard and operability (HAZOP) study.
Hazards are identified and individually evaluated to deter-
mine the probability of occurrence along with the severity
of consequences if the hazard is realized. In most com-
panies, the overall risk is defined as the probability times
the severity.
Step 2: For each identified hazard, the team must
then evaluate any safeguards that mitigate those hazards
(e.g., the alarm system) to determine how much residual
risk remains after taking credit for the safeguards. The
safeguards are called independent protection layers
(IPLs). Independence is important because if one safe-
guard fails, it should not affect any other safeguard’s abil-
ity to mitigate risk. Several methods are used to evaluate
the safeguards with the most common being a layer of
protection analysis (LOPA).
Step 3: After taking credit for the IPLs, the team will
compare the residual risk to the company-defined toler-
able risk level to determine if action needs to be taken.
If residual risk is greater than tolerable, either the pro-
cess needs to be redesigned or additional safeguards
installed. A common safeguard is to install a safety
instrumented system (SIS) to reduce the residual risk
to acceptable levels. The size of the gap between the
residual risk and the tolerable risk determines the safety
integrity level (SIL), which is a measure of how “safe” the
SIS needs to be (see Figure 1).
In the case shown in Figure 1, the residual risk level
exceeds the tolerable risk level even after taking credit
for IPLs, such as the basic process control system
(BPCS) and mechanical protection (e.g., relief valves
or rupture disks). To fill this gap in protection, a SIS
can be implemented to reduce the residual risk to a
tolerable level.
Note the BPCS IPL is usually a credit for a safety
alarm that triggers an operator response preventing the
hazardous event, or some type of automated control,
which keeps the process from reaching the hazardous
Figure 1: Residual risk exceeds the
tolerable risk level in this drawing. The
size of the gap between the residual
risk and the tolerable risk determines
the safety integrity level (SIL). Courtesy:
Maverick Technologies

condition. However, you only can

count on the BPCS to provide
credit for one IPL, because the
alarm and automated control func-
tions are not truly independent.
Certain BPCS failures could dis-
able both functions.

Gaining independence
As mentioned, the BPCS only
can be counted on for one IPL
credit for reasons of indepen-
dence. But what if you are already taking credit for auto-
mated control and also would like to have credit for a
safety IPL alarm? Is there a way of implementing alarms
that need to be kept separate from the BPCS? Well, yes,
there is. Here are two common approaches:
1. You can directly wire a field instrument to a lightbox
annunciator. This was the traditional approach for alarming
in the “old days” of panel board control systems and still
is used today. Because the signal and annunciation are
kept separate from the BPCS, you can take IPL credit for
operator action from the alarm in addition to the automated
control in the BPCS.
2. To avoid the limitations of using a lightbox annuncia-
tor, a field instrument instead can be routed to an indepen-
dent monitoring system with a human-machine interface
(HMI) separate from the BPCS. The SIS or a dedicated
programmable logic controller (PLC) can feed the indepen-
dent HMI. Note the overall availability for this independent
system needs to have probability of failure on demand
(PFD) of 0.1 or less.
The key is to have the safety IPL alarm function com-
pletely separate from the BPCS such that no single failure,
including cybersecurity attack, could jeopardize the func-
tion of both systems. This independence includes the field
instrument, which cannot be shared with the BPCS.
Requirements for safety IPL alarms
Several requirements need to be met to use an alarm as
a safety IPL:
1. Specific. The alarm must be designed to work for a
specific initiating event that leads to the hazard you
are trying to prevent.
2. Auditable. You need to test the alarm, including asso-
ciated instrumentation, at an appropriate frequency to
verify that the alarm will work.
3. Independent. The alarm must be independent from
other IPLs and not disabled by the initiating event for
the hazard.
4. Dependable. The likelihood that the alarm will annun-
ciate, and the operator will respond properly meets
the requirements to be counted as an IPL. The
overall alarm function (sensor + logic solver + HMI +
operator response) needs to have a PFD of less than
or equal to 0.1. This subject is addressed in detail in
various Center for Chemical Process Safety (CCPS)
books, such as “Guidelines for Safe Automation
of Chemical Processes and Layer of Protection
Analysis.”
PHA team responsibilities
When performing the PHA, it is essential that the team
properly evaluates and documents every alarm that has
been designated for IPL credit. This includes the following
responsibilities:
• Does the alarm meet the four requirements defined
above for safety IPL alarms?
• Will the operator have adequate time to recognize the
alarm and take necessary action before the hazard is
realized?
• What should the alarm setpoint be?

Applied Automation June 2019 • A11

 AlArm, proce ss sAfety mAnAgement

• What does the test frequency need to be?
• What is the proper operator action required to
mitigate the hazard?
All this information needs to be entered into the alarm
management system with a designated class for safety IPL
alarms to ensure they are not modified unless a PHA is
conducted. Regardless of what sort of alarm management
system is used, the IPL alarms need to be clearly desig-
nated because they require special handling.
Impact on alarm management
Using alarms as safeguards for process safety hazards
increases their importance and adds another dimension of
importance for performing proper alarm management. Proper
alarm management becomes more imperative than ever.
Maintaining the performance of the alarm system is criti-
cal to ensure that operator response is timely and accurate.
Alarm floods, chattering or an excessive number of active
alarms will reduce the chance that the safety IPL alarm will
receive the attention needed. Alarm response procedures
should be clear and easily accessible (ideally in the HMI) so
operators can respond quickly and effectively.
Auditing is an ANSI/ISA-18.2 lifecycle requirement
that requires a comprehensive assessment of the alarm
system, including evaluation of the alarm system perfor-
mance and work practices used to administer the alarm
system. Periodic reviews of how frequently safety IPL
alarms have been triggered along with the timing and
accuracy of the associated operator response will reveal
gaps not apparent from routine monitoring and will allow
identification of necessary improvements.
Safer processes
As you can see, there are many interactions between
alarm management and process safety management.
Each discipline requires a rigorous methodology to
properly implement, yet understanding how they interact
is equally important to ensure a safe and productive
process.
Lee Swindler is an industry manager with Maverick
Technologies. He has 31 years of automation industry
experience, including 21 years in manufacturing and 10
years on the engineering services side. He has a PMP
certification along with being a TÜV certified functional
safety engineer.

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headquarters is located just north of Atlanta, Georgia.

For over 20 years we’ve been saving our customers

time and money on industrial automation products.
We have a huge inventory that is constantly growing
in order to provide you with the quality components
needed to keep your projects on schedule. We’ve heavily Orders ship quickly from our state-of-the-art warehouse
invested in new infrastructure that will allow us to
continue offering the service and support you deserve.

We make ordering easy and our service For more information,

is exceptional. Shop online with our contact us at 800-633-0405
exhaustive product listings or browse or visit us online at
our online catalog; fax or phone us – www.automationdirect.com.
you’ll get friendly, efficient service
from the most helpful sales team in the
business. Independent surveys completed
by readers of industrial trade magazines
for their Readers’ Choice Awards have placed
us at the top of the list for service 15+ years in a row.

1-800-633-0405 | AutomationDirect.com
 A DV E R T I S E M E N T
Technology Updates and Automation Expertise
from SEW-EURODRIVE
SEW-EURODRIVE —
Much More Than Gearmotors
Our team of (MAXOLUTIONS) automation engineers
provides the expertise, project planning, software,
commissioning, and worldwide support for your most
challenging motion control projects. They can serve
as a valuable extension of your engineering team,
reducing the stress and demanding workload.
Our experts provide a solution of perfectly matched
SEW components that work together seamlessly —
because we designed them that way!
Complete Drive Maintenance and Management
SEW-EURODRIVE now offers a full complement of
drive maintenance and management services. Our
CDM® Maintenance Management service provides a
24/7 online portal as well as a complete overview of
your drive components, the condition of your units,
drive usage, and service details. Plus, our new on-site
Pick-Up Box Service will free up your maintenance
team for other tasks. Just place your drives that need
repair in the supplied box and we’ll handle the pick-up
and return of your units.
MOVIGEAR® and MOVI-C®
for Decentralized Installations
MOVIGEAR is the mechatronic drive system that
combines the gear unit, IE4 motor, and electronics
in one compact unit. Recent updates include fully
integrated Ethernet/IP communications and digital
motor integration. This advanced single-cable
technology carries power, feedback information, and
control signals along a single hybrid cable between
decentralized devices. MOVI-C modular automation
system is a one-software, one-hardware, automation
platform that combines fully integrated components,
control electronics and software.
About SEW-EURODRIVE
Engineering excellence and customer responsiveness
distinguish SEW-EURODRIVE, a leading manufacturer
of integrated power transmission and motion control
systems. SEW-EURODRIVE sets the global standard
for high performance and rugged reliability in the
toughest operating conditions. With global headquar-
ters in Germany, its U.S. operations include a state-
of-the-art manufacturing center, five regional assembly
plants, more than 63 technical sales offices and
hundreds of distributors and support specialists.
This enables SEW-EURODRIVE to provide local
manufacturing, service and support, coast-to-coast
and around the world.
P: 864-439-7537
F: 864-439-7830
www.seweurodrive.com
POWER HAS
COME FULL
CIRCLE
NEW!
Introducing the
GA800 AC Drive
Your time is valuable. The new, easy-to-use GA800 AC
Drive from Yaskawa gives you the power to make all of your
operations better.

• Rest easy with legendary Yaskawa quality and embedded

functional safety.
• Experience ultimate ease-of-use with DriveWizard® Mobile
and optional Bluetooth ® connectivity.
• Enjoy incredible torque production and network connectivity.

Your days are complicated enough. Let us help

simplify them. To learn more, visit or call Yaskawa
today at 800-YASKAWA.

Yaskawa America, Inc. Drives & Motion Division 1-800-YASKAWA yaskawa.com For more info: http://go.yaskawa-america.com/yai1293
Less means more!

Focused on the essentials: the new i500

Slim design, scalable functionality, and extremely user-friendly.
The groundbreaking i500 is size-optimized and allows for zero-
clearance mounting, saving valuable cabinet space. And thanks
to the innovative interface options, it’s easy to commission in
minimal time. The best thing of all is that the modular structure
adapts to different production configurations in no time at all.
Less does mean more!
Learn more about our solutions at www.lenze.com. As easy as that.