CNT 2016 11 01

november 2016
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November 2016 Volume XXIX Number 11
Cover Story
30 / Harness big data
How to manage new information streams,

identify correlations, and achieve gains.
by Jim Montague
features
Support & protect
measure & manipulate
38 / Cybersecurity in the SIS world
43 / Motors & drives make magic
Find and slay the dragons lurking in typical

safety instrumented systems.
by William L. Mostia, Jr., P.E.
Innovation, intelligence and networking bring motion

to life in unusual applications and environments.
by Jim Montague
CONTROL (ISSN 1049-5541) is published monthly by PUTMAN Media COMPANY (also publishers of CONTROL DESIGN, CHEMICAL PROCESSING, FOOD PROCESSING, THE JOURNAL, Pharmaceutical
Manufacturing, PLANT SERVICES and SMART INDUSTRY), 1501 E. Woodfield Rd., Ste. 400N, Schaumburg, IL 60173. (Phone 630/467-1300; Fax 630/467-1124.) Address all correspondence to Editorial and Executive Offices,
same address. Periodicals Postage Paid at Schaumburg, IL, and at additional mailing offices. Printed in the United States. Putman Media 2016. All rights reserved. The contents of this publication may not be reproduced in whole or part
without consent of the copyright owner. POSTMASTER: Send address changes to CONTROL, P.O. Box 3428, Northbrook, IL 60065-3428. SUBSCRIPTIONS: Qualified-reader subscriptions are accepted from Operating Management in the
control industry at no charge. To apply for qualified-reader subscription, fill in subscription form. To non-qualified subscribers in the Unites States and its possessions, subscriptions are $96.00 per year. Single copies are $15. International subscriptions
are accepted at $200 (Airmail only.) CONTROL assumes no responsibility for validity of claims in items reported. Canada Post International Publications Mail Product Sales Agreement No. 40028661. Canadian Mail Distributor Information:
Frontier/BWI,PO Box 1051,Fort Erie,Ontario, Canada, L2A 5N8.
N o v e m b e r / 2 0 1 6 www.controlglobal.com
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November 2016 Volume XXIX Number 11
On-site
On-line
Hands-on
or in the
Classroom
Departments
11 / Editors page
Cubs win
The Chicago baseball team isnt the
only group of loveable losers ending a
drought.
12 / Control online
Our most recent, valuable and popular

offerings at ControlGlobal.com
15 / Feedback
You can do intrinsically safe wireless,

human factors and Deepwater Horizon
16 / Lessons learned
Controlling the smart cars, part 2

Theyll be safer if engineers draw on the
experience of other industries.
20 / On the bus
Control at the edge, revisited

A new flame comes into our long love/
hate relationship with distributed control.
22 / Without wires
Redefining determinism
Today, even Ethernet and wireless are
almost always fast enough.
24 / In process
Emerson, Yokogawa user groups meet;

ICS Cybersecurity event gathers experts
and solutions; GE Oil & Gas to merge
with Baker Hughes; Festo multitasks at
new Ohio plant
29 / Resources
Information to do your level best
46 / Develop your potential
FOPDT modeling
A good way and a better way to test a first
order plus dead time model.
49 / Ask the experts
How to determine open-loop gain?

What to do when the process overshoots
the mark.
51 / Roundup
Terminal terminusand I/O

The latest choices in I/O and terminal
blocks are more flexible than ever.
53 / Exclusive
Easy, reliable, safe level measurement

Rosemount 5408 radar level transmitter
and 2140 vibrating-fork level detector.
54 / Products
Selections from our editors inboxes.
You choose.
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Customize your training
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it be on-site, on-line or
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a training package that is
tailored to meet your needs.
55 / Control talk
Success in career and system migration

The motivations and rewards often seem
to have a lot in common.
58 / Control report
Busy fall
Big data, cybersecurity, election results or
other chores all need the same response
from you.
Find out more about

Endress+Hausers unique training:
www.us.endress.com/training
Circulation aUdited december 2015
Food & Kindred Products
12,824
Chemicals & Allied Products
10,797
Systems Integrators & Engineering Design Firms 8,103
Pharmaceuticals
4,405
Primary Metal Industries
4,290
Petroleum Refining & Related Industries
4,198
Miscellaneous Manufacturers
3,171
Electric, Gas & Sanitary Services

Rubber & Miscellaneous Plastic Products
Paper & Allied Products
Stone, Clay, Glass & Concrete Products
Textile Mill Products
Tobacco Products
Total Circulation
3,451
3,380
2,874
1,604
803
120
60,020
N o v e m b er / 2 0 1 6 www.controlglobal.com
Control
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EDITORS PAGE
Cubs win
nce upon a time, not so long ago and for

about 10 years, I was on a team of loveable
losers. On hiatus from Control between
2003 and 2012, as editor of Plant Services magazine I did all I could to champion the cause of
asset reliability through proactive maintenance.
Convinced of the intrinsic rightness of converting critical equipment from catastrophic
breakdown and wasteful preventive to the advanced technologies of predictive maintenance
(as part of a world-class, risk-based, reliability-centered asset management program, of
course), I sat at the feet of crusty gurus as we
wondered aloud how any successful company
could survive, how any reasonable person could
not see the light, and embrace the power of vibration, ultrasound, infrared and oil analysis.
But again and again, most plants found they
couldnt get it done. They couldnt spare the
labor, training and equipment dollars long
enough to get enough ROI for sufficient time to
sustain the effortto get over the mountain and
reach the promised realm of reliability.
And of the few that could, many found themselves slipping back when management recognized and rewarded their good work and savings
by cutting their budgets and letting go the very
people who made it happen.
Their handhelds, cameras and sample containers gather dust, and the fresh trainees
knowledge slips away as their days are again
filled with emergency repairs, expediting replacement parts and rigging workarounds.
Every now and then, a vendor PR person from
my Control days would realize we were talking
about asset management, and would want to
tell me again how their instruments and valves
can monitor their condition and send alerts to
operations when maintenance is needed, and I
would say, Thats nice. But let me know when
youre ready to connect that beautiful DCS and
its plantwide network to sensors on real equipment that has bearings, gears and windings, and
call me when you get it integrated with asset
PAUL STUDEBAKER
management systems so it alerts the right people, and maybe even sends them a work order.
Well, as you probably know, on Nov. 2, the
Cubs won the World Series, ending the teams
108-year streak as loveable losers. Thats nice.
But the week before, at the Emerson Global Users Exchange in Austin, I learned the company
is making a major-league push into rest-of-plant
asset condition monitoring.
As part of Emersons Plantweb digital ecosystem, the companys pervasive sensing initiative uses wireless and fieldbus to connect a new
generation of low-cost sensors and provides analytics for insights into asset performance.
This year, the company added technologies
to monitor pipes and vessels for corrosion and
erosion; medium-voltage switchgear for hot
spots, partial discharges and humidity; toxic
gases; and process temperatures with sophisticated surface-mount sensor/transmitters. There
also are pressure gauge, steam trap, relief valve
and power monitoring applications.
A new Asset Health Advisor performs diagnostics and provides alerts for predictive maintenance. It takes in heat exchangers, blowers,
compressors, cooling towers and pumps.
By building condition monitoring and predictive technologies into the plant, whether by
making them part of the automation system or
by using a separate Industrial Internet of Things
(IIoT) infrastructure, Emerson and other automation, sensor and analytics suppliers are reducing the needs for handhelds, for making
rounds, and even for specialized training, as
much of the knowledge is being built into software applications or made available via monitoring and analysis by off-site experts.
Its great that the Cubs have ended the Curse
of the Billy Goat. Im even happier that soon,
asset management wont require so much time
at the feet of crusty reliability gurus.
EDITOR IN CHIEF
pstudebaker@putman.net
Their handhelds,
cameras and sample
containers gather
dust, and the fresh
trainees knowledge
slips away as their
days are again filled
with emergencies.
11
CONTROL ONLINE
Its high time to upgrade systems
SPECIAL REPORT
The latest critical trends in I/O systems take advantage of the versatility and communications
capabilities of intelligent, congurable I/O. Being able to install universal I/O based on approximate point count, then congure or recongure it later to match the needed process variables
allows construction and installation to proceed independent from engineering, taking I&C off the
critical path. Intelligent I/O transmits more than just the measured and manipulated variables,
opening the possibilities for integrating capabilities from condition monitoring and predictive
maintenance to all the potential of the Industrial Internet of Things (IIoT). Heres the latest I/O
system coverage from the annals of Control. For a deeper dive into I/O technology, applications
and analysis, download the March 2015 Control State of Technology Report on I/O Systems.
Trends in HMI/SCADA
SPECIAL REPORT
The key to better decisions isnt just more data;

its getting the right information delivered the
right way at the right time. This downloadable
special report curated by the editors of Control provides a concise, single-volume overview
of the trends and technology that are enabling
SPECIAL REPORT:
decision support with HMI/SCADA. Articles
Trends
in
include:
HMI/SCADA
How to design a better operator-centered
system
Developing a lasting plan for managing
alarms
Using visible data for operational excellence
Understanding and minimizing HMI/SCADA system security gaps
Our Trends in HMI/SCADA report is available at http://info.controlglobal.com/special-reporton-hmi/scada-hmi
How advanced systems are
simplifying operators ability
to respond to what matters.
A market analysis by ARC Advisory

Group estimates that globally, in
excess of USD $65 billion in control
systems have reached their end of
life, with more than 80% of those
systems having been in service
for over 20 years. This whitepaper
explains why the time is now to upgrade to a new control system migration standard.
http://info.controlglobal.com/online-control-system-migrations_io
NERC CIPs continue to expose the grid

Cybersecurity expert Joe Weiss discusses NERC CIP in the wake of the
Ukranian hack. www.controlglobal.
com/blogs/unfettered/the-nerc-cipscontinue-to-expose-the-grid-to-significant-cyber-vulnerabilities-evenafter-the-ukrainian-hack
BLOG & NEWS
he latest critical trends in I/O systems take

advantage of the versatility and communications capabilities of intelligent, configurable I/O. Being able to install universal
I/O based on approximate point count, then
configure or reconfigure it later to match the
needed process variables allows construction
and installation to proceed independent from
The rise of configurable I/O
engineering, taking I&C off the critical path.
Intelligent I/O transmits more than just the
measured and manipulated variables, opening the possibilities for integrating capabilities
from condition monitoring and predictive maintenance to all the potential of
the Industrial Internet of Things (IIoT).
Our latest State of Technology eHandbook explores more. http://info.controlglobal.com/the-rise-of-configurable-io_io
WHITE PAPERS
The rise of configurable I/O
Pepperl+Fuchs acquires ecom

The move will accelerate new developments in technology and products,
according to CEO Gunther Kegel.
http://www.controlglobal.com/industrynews/2016/pepperl-fuchs-acquires-ecom-instruments
Sponsored by
Industrial computers field guide and resources
12
www.controlglobal.com N O V E M B E R / 2 0 1 6
At the 2016 Yokogawa User Conference, Sandy Vasser told how he and
his team at ExxonMobil set out to
improve their own project execution
processes, and catalyzed industry
change in the process.
http://www.controlglobal.com/articles/2016/yokogawa-article-1
ControlGlobal E-News
Multimedia Alerts
INDUSTRIAL
COMPUTERS
FIELD GUIDE
& RESOURCES
White Paper Alerts
Industrial computers, PCs and many of their counterpart devices can take
almost any form these days, and serve in almost any setting thanks to
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and other advances. This is good news for users and applications in harsh
environments, but it can be hard to sort out all the available options.
Here is a bounty of instructional materials, products and
other resources that can help you do just that.
BEGIN
Go to www.controlglobal.com and
follow instructions to register for our
free weekly e-newsletters.
e-NEWSLETTERS
Industrial computers, PCs and many of their

counterpart devices can take almost any form
these days, and serve in almost any setting
thanks to miniaturization, diskless and fanless
technologies, more capable software and other
advances. This is good news for users and applications in harsh environments, but it can be
hard to sort out all the available options. This
report includes a bounty of instructional materials, products and other resources that can
help you do just that.
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You can do intrinsically safe wireless

Regarding Where wireless meets intrinsic safety, (Control, Oct. 16. p. 26, www.
controlglobal.com/articles/2016/wherewireless-meets-intrinsic-safety), you can
put wireless network access points in unclassified areas (or zone 2, which does not
require intrinsic safety), so wireless sensor
networks with intrinsically safe (IS) transmitters can be easy, provided you pick the
right wireless topology. Only the wireless
sensors need to be in the area requiring
intrinsic safety.
However, this requires a full mesh
topology. There are many wireless networks using IEEE 802.15.4 radio, but
theyre not the same. By full mesh topology, I mean capable of seven or more
hops from the sensor to the gateway,
allowing the data to be routed around
metal obstructions in the plant. WirelessHART already supports seven or
more hops. The two to four hops currently supported by other networks are
not sufficient. By using a full mesh topology, you only need the gateway at the
edge of the plant unitthere is no need
for powered backbone routers in the middle of the plant units.
If there is any weak spot in the WirelessHART network, simply drop in an
additional device as a routeran IS, battery-powered device needs no power wiring and is very simple to deploy.
I agree that IS power over Ethernet
(PoE) is an issue at the moment. Apart
from the Ethernet switches, are there any
field devices actually supporting it? Another problem is that there are no standard
IS parameters (I, U, P, L and C), so lots
of engineering is needed to demonstrate
safety. When you replace any part with another model, you have to redo it. So, avoid
this problem by placing the gateway at the
edge of the unit as unclassified or Zone 2.
JONAS BERGE, jonas.berge@emerson.com
Human factors and Deepwater Horizon

The worst shame of the movie [Truth
meets fiction, Control, Sept. 16, p. 86,
www.controlglobal.com/articles/2016/
deepwater-horizon-film-likely-sacrifices-re-
Ready to win
Top 50 automation suppliers jockey for
advantage when the market returns
MEASURE THICK FLOWS
FAST BOILER CONTROL
QATARGAS CUTS FLARES
HAZARDOUS WIRELESS
al-safety-discussion-for-hollywood-tropes]
is that it seeks to demonize big oil. In one
of its most egregious moments, it makes it
look as if the control panel operator knew
something was going to happen, but held
back the information because of company
direction. In the official review, the operator said the information/data flow to view
the process was terrible enough that when
the crap hit the fan, she was completely befuddled and confused. This is not the fault
of an operator. It has been blamed on human error, and now in the Hollywood version, on political complicity.
The real fault lies in poor human factors in the control system HMI. Billions
of dollars have been invested in researching the interaction of humans with operating equipment. The blowout was potentially avoidable, but engineering mistakes
will always be there. The point is, once the
engineering failed, the tragedy could have
been mitigated, perhaps even avoided. So,
while a company may not be complicit in
direct actions to prevent the loss of human
life, its lack of making access to tools that
could have given humans visibility into
the incident is disappointing. Like most
companies, theyre content with technology thats decades in arrears because it is
sufficient, when in actuality it is not. ROI
is hard to measure for human factors until
the holes in the Swiss cheese line up.
STEPHEN APPLE
stephen.apple@schneider-electric.com
N O V E M B E R / 2 0 1 6 www.controlglobal.com
15
LESSONS LEARNED
Controlling the smart cars, part 2

BL A LIPTK
liptakbela@aol.com
[This article suggests improvements in controls

for self-driving cars based on experience in the
process industries. The state of the art, as exemplified by the Tesla accident May 7 in Williston, Fla., is discussed in part 1 (Sept 16, p.
52, www.controlglobal.com/articles/2016/analysis-of-the-recent-self-driving-tesla-crash).]
ver the past century, general industry

(power, chemical, oil, nuclear, etc.) faced
the same safety concerns that the automobile industry is facing today. One camp argued that manual control is safer because all
sensors can fail, computers can freeze, etc.,
while the other camp argued that automatic
control is better because operators can be intoxicated, untrained, tired, distracted, etc.
Both camps assumed theres no third option.
It took a long time to realize that one must
not choose between manual and automatic
control, but should benefit from both simultaneously. In other words, one should always
consider both, and select the safer one for
control. This is called Selective Safety Control (SSC).
It would be wise for the transportation industry to learn from the experience accumulated in other industries, and not attempt to
rediscover the wheel.
People asked
whether the autopilot
was on or off at the
time of the Tesla
crash in Florida.
This is the wrong
question.
16
Where we are today

In just the U.S., more than 35,000 people died
in car accidents last year. According to most
estimates, smart cars could eliminate 95% of
these accidents. Yet 71% of the American public believes that smart cars are less safe than
regular ones. These numbers contradict each
other, and thats unfortunate because technological advances require public support, but
that support wont evolve until theres confidence in the safety of such technological advances. This is the reason Im writing this series of articles.
Many smart cars are electric, and the ac-
ceptance of electric cars is growing. Tesla

sold 50,000 of these cars in 2015, 82,000 in
2016, and has approximately 400,000 customers on its waiting list for next year. In 2017,
it hopes to market an electric car (Model 3)
that will cost around $35,000 and can travel
240 miles on one charge. Other car manufacturers (GMs Bolt, Nissans Leaf, BMWs i3,
Volkswagens e-Golf, etc.) place less emphasis on driving distance per charge because
theyre focusing on commuting.
The smart car designs on the road today
use autopilots, and require drivers to keep
their hands on the steering wheel, so they
can take over control when needed. As of today, Tesla has some 70,000 such cars on the
road, and others like Mercedes-Benz plan to
start selling them in 2017. Tesla is also working on driverless carsit will have all the
sensors needed for autonomous driving in its
Model 3, but will not enable the system until
more testing is performed. Model 3 has some
300,000 preorders, which Tesla will start filling in 2017. Other manufacturers, like GM
and Audi, are also taking an incremental approach by developing cars capable of gradually updating from the autopilot mode of
operation to the driverless one. Others are
starting out with limited application goals
an example is Google (working with Otto),
which plans to market trucks that will be
self-driving only on highways. Development
of completely driverless cars is still in the testing or field trial stage (Uber in Pittsburgh,
Google in California, Ford, etc.) and are generally expected to be available by 2021.
Autopilot vs. driverless

People asked whether the autopilot was on or
off at at the time of the Tesla crash in Florida.
This is the wrong question. Just as we dont
need to turn on the seat belt alarm to be reminded the buckle is closed, the autopilot
should have been on all the timein addi-
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LESSONS LEARNED
2
3
G
L
VC
U
R
3
4
FIRST-GENERATION SENSORS AND ZONES

Figure 1: These are the types of sensors and their observation zones that are being
used in the first generation of smart cars. The instruments are: computer (C), lidar (L),
radar (R), ultrasonic (U), video camera (VC). On some cars, as many as 12 cameras are
used. Observation zones are: (1) Protection zone detected by 360 rotating lidar, (2)
rear-collision protection and lane change assistance zone, (3) self-parking function, (4)
traffic light, lane departure, collision avoidance and emergency brake assist functions,
and (5) cross-traffic and pedestrian-detection function.
tion to the driver always being ready

to take over. The important difference between the design that existed
in the Florida eccident and the correct one is that neither the driver nor
the autopilot should be able to overrule the other (be the primary source
of control). However, whenever they
disagree, the control system (SSC)
should automatically select the safer
one to control braking, accelerating
or steering.
As I noted earlier, smart cars have
great lifesaving potential because
they can provide safe driving even if
the driver is tired, panicked, drunk,
under the influence of drugs, inexperienced, distracted or has slow reflexes, decreasing vision and hearing,
etc. Yet their lifesaving potential is
18
reduced because all computer systems can fail, and even if they dont
fail, their software can be hacked or
be insufficiently sophisticated to recognize complex situations.
Its for this reason that the software
packages in operation (Figure 1) can
safely handle only simpler tasks such
as changing lanes, stopping at red
lights, parking or keeping safe distances between vehicles, but they
cant yet distinguish between, say, a
pedestrian trying to hitch a ride or a
police officer flagging the car down.
Such fuzzy conditions havent yet
been effectively enshrined in computer code, while the human driver
can usually recognize them.
A great advantage of smart cars is
that the software of the whole fleet
can be improved over the air whenever new information becomes available. In other words, whenever the
causes of an accident are determined
and the software is modified to prevent reoccurance of that accident,
the revised software package can be
immediately transmitted wirelessly
to the entire fleet. As a result, the
safety of the fleet can be continually
improved.
Advocates of driverless cars argue
that using the autopilot is less safe
than autonomous driving because
even if the drivers hands are on the
steering wheel, the driver, being passive, cant be expected to snap back
and make split-second decisions
when needed. They refer to studies
that have found that the time needed
to wake up the average driver is 17
seconds, and a car moving at 65 mph
travels five football fields during that
time. Yet as of today, driver-assisted
collision avoidance software (autopilot) is better developed, and so for
some years more, the hands on the
wheel mode of driving is likely to
prevail.
Its also interesting to note that the
major process control firms (ABB,
Emerson, Honeywell, Schneider
Electric, Siemens, Yokogawa, etc.)
seem to be doing very little to develop sensors and control software
for this new market. Newer companies are starting to fill this gap, such
as Nirenberg Nouroscience, Otto or
Saips in the fields of machine and
computer vision, and Velodyne in
the area of miniaturized lidar (laser
imaging and ranging), etc.
[The next part in this series will discuss the capabilities of todays sensors,
potential for developing additional or
better ones, and improvements in control software packages needed to improve smart car safety.]
Bla Liptk, PE, control consultant and editor of the
Instrument Engineers Handbook is seeking new
co-authors for the new edition of that multi-volume
work. He can be reached at liptakbela@aol.com.
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On the Bus
Control at the edge, revisited

john Rez abek
contributing Editor
JRezabek@ashland.com
Every little skid had

a different little PLC.
Some used ladder
logic and some used
weirdly structured
text reminiscent
of HP calculators
reverse Polish.
20
very compressor in the facility went down

at once that day, when a PLC redundancy
switchover didnt transfer in time. The engineers didnt know that each P453 remote
I/O processor had a dip-switch-selectable timeout settingif it didnt hear from the logic
solver before the timeout, all the associated I/O
would go to the zero power state. And so they
did, when the startup team decided to invoke a
switchover one day, much to the dismay of the
commissioning manager for the new unit.
Before PLCs, compressor interlocks were all
solved in local panels using relay logic. This
natural distribution of logic solving lent a certain fault tolerance to the process; at least (barring a total power outage) only one critical piece
of machinery would go offline at a time. The
disadvantage was, interlocks implemented with
hardwired relay logic were difficult to configure, costly and labor-intensive to build, difficult
to troubleshoot, difficult to modify, and subject
to mechanical assaults on reliability in the form
of lose wires, vibration, corrosion and unseen
jumpers. This was why the early adopters were
eager to move logic to the magical PLC.
Fortunately for us, it took less than 10 years
for PLCs to become powerful and inexpensive
enough for each compressor to have its own, individual, local, dedicated PLC. This was a great
capability, but it also introduced a new challenge:
every little skid that arrived, from truck loading
to wastewater filters, had a different little PLC
aboard. Some used ladder logic and some used
weirdly structured text reminiscent of HP calculators reverse Polish. One site tried to stem the
divergent solutions by specifying, for example,
all logic shall be solved by Modicon 984 PLCs,
only to find that 1) there were several grades of
that generation of 984s, and 2) systems integrators
that favored another PLC wanted to charge a premium for the deviation, but frequently didnt excel at programming the PLC of choice. Modbus
was still developing as a de facto standard, so networking the growing and divergent field of PLCs
www.controlglobal.com N o v e m b e r / 2 0 1 6
to the built-for-purpose DCS host was expensive

and complex, requiring painstaking mapping of
PLC coils and registers for the DCS to display.
The DCS, which Ill emphasize stood for distributed control system, was itself more centralized and less distributed than the network of little PLCs out in local panels and skids. But few
entrusted the PLC to do much closed-loop control, since most of the analog measurements were
wired to the centrally-located DCS I/O, and control could be solved with greater determinism than
the master-slave polling network of Modbus over
RS-232/485. So critical, closed-loop control, indeed nearly all PID control, remained centralized
despite the DCS moniker. And so it remains.
But today, I can go on Amazon and buy a
credit-card sized Raspberry Pi, already in its
third generation, for less than $50. You can load
a stripped-down Windows 10 OS on Raspberry
Pi, and I have little doubt such a platform could
solve PID or even invert a matrix for model-predictive control. Not that you would, but the
point is that astounding computing power and
networking capability have become cheap and
ubiquitous. Control at the edge is becoming
part of the IoT vernacular as it pertains to access
control and security, but also because microprocessor-based devices at the edge are smart
enough to invoke actionsto solve logic or do
closed-loop controlwithout having to phone
home to a central host or human operator.
Process control professionals have had control at the edge since the days of local pneumatic controls, and this heritage lives on almost unnoticed in every valve positioner with
a servo solving proportional or PID to position
the valve stem where its directed. While we
might not have trusted PID to 1990s-vintage
PLCs, why not empower valve positioners and
their ilk to execute rudimentary control loops?
To the degree networks and standards can provide easy, consistent and seamless access to device-resident controls, the vision of truly distributed control may finally dawn upon us.
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WITHOUT WIRES
Redefining determinism
IAN VERHAPPEN
SENIOR PROJECT MANAGER, AUTOMATION

CIMA+
Ian.Verhappen@cima.ca
The control system

can easily be made
to believe that
updates are as
regular as necessary
to be viewed as
deterministic.
22
s automation professionals, one issue we

have about control loops is ensuring were
able to support real-time control. Back
when Ethernet was 10 MB/s with multiple drops
on one port, collisions were a concern and impediment to its adoption because we couldnt
guarantee delivery of every message, every time,
at a repeatable frequency. Ethernet wasnt real
time enough, and hence not deterministic, or
so we believed. So we waited until we got faster
switched networks that almost eliminate the
chance of a message not getting where it should
be when it should. We still lose packets, but we
can recover fast enough to satisfy our definitions of determinism and real time.
In fact, what were really doing is confirming that the definition of determinism depends
on the application. In factory automation or robotics, response times often need to be in milliseconds, while continuous processes, being
essentially analog, are scanned at high enough
frequency to allow us to model the system, with
high enough generally accepted as six times
(6x) the process frequency/response time (process time constant plus process delay). Many
use a rule of thumb of 10x, though I suspect
its to provide a margin of error, and its easier to
move the decimal point than divide by 6.
Another underlying assumption in conventional PID is that control is executed on a periodic basis, which implies a regular scan and
update rate. Fortunately, the scan rate for continuous processes, where flow is likely the fastest
changing loop, is normally seconds long.
Control systems and their networks are complicated enough to design and build without
having to calculate the definition of determinism for every loop, and then design hardware to
match. So instead, we configure our systems to
scan the I/O at one or perhaps a few different
scan rates, based on the applications in the facility. This is one reason why the scan rates for
PLCs are in milliseconds (as required by factory
applications from which they evolved), while a
DCS, which scans many more points per cycle,

can have scan rates of seconds. A continuous
process doesnt change that much that quickly,
and if it does, a different system such as an SIS,
provides the necessary extra protection.
Wireless sensor networks (WSN), on the
other hand, have update rates of 15 seconds
or longer (updating only when the process has
changed outside the prescribed window, resulting in a non-periodic basis to preserve battery life). And since theyre mesh systems, the
signal itself is retransmitted multiple times, increasing the risk that an update can be lost, so
the control system and algorithm must also be
able to handle a loss of communications.
If this sounds similar to some of the challenges associated with legacy 10 MB/s Ethernet,
where updates can be affected by a collision or
a node malfunction, perhaps our systems arent,
nor need to be, as deterministic as we think. As
long as we have reliable communications with
the WSN access point, the control system can
easily be made to believe that updates are as regular as necessary to be viewed as deterministic.
Terry Blevins, Mark Nixon and Marty Zielinski published an interesting paper Using
Wireless Measurement in Control Applications (www.controlglobal.com/articles/2012/
addressing-control-applications-using-wireless-device/) describing one approach to modifying the PID algorithm, and in particular the
reset (integral) component, for irregular signal
updates. Other manufacturers are taking different approaches, and if your system does not have
a specific solution, with the processing ability
of todays control systems, theyre able to create simple process models to fill in the gaps between the updates, much like weve done with
manually analyzed samples for many years.
In the end, as demonstrated above, everyones
definition of real time and hence determinism
depends on the application. Or perhaps we can
argue that determinism no longer has the same
clout as it did when things were slower.
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In Process
Emerson users interact and enlighten

The 2016 edition of Emerson Global Users Exchange in Austin, Texas, accelerated learning
and innovation, and gave its customers the tools and know-how to do it.
everal thousand users, integrators,

technical experts, managers, leaders and friends gathered for Emerson Global Users Exchange 2016, Oct.
24-28 in Austin, Tex., and feasted on
their usual cornucopia of technical innovations, end user experiences, conference sessions, workshops, training
sessions, exhibits and networking.
Time here is well spent getting fresh
ideas, making good connections, finding the energy and urgency to solve
tough problems, and work with rapid
technology change, says Steve Sonnenberg, chairman, Emerson Automation
Solutions (www.emerson.com), which
recently transformed its internal structure to focus on two business platforms,
combining its former Emerson Process
Management and Industrial Automation businesses into one organization.
Were continuing the same sales, support, engineering and services as in the
past, and now we can better address life
sciences, food and beverage and packaging industries. Were working harder to
be a trusted partner.
Following his appointment as chairman, Sonnenberg added his former
role is being filled by Michael Train,
executive president, Emerson Automation Solutions, whos served as president of Emersons global sales, analytics group and Asia-Pacific divisions.
Operational Certainty
Train stressed the continuing advantages
of Emersons Top Quartile and Project
Certainty programs for improving their
engineering, products and services. Plus,
he announced that Emerson is introducing its Operational Certainty consulting
practice with expanded project execution methods, workshops and services.
By helping customers leverage the
best practices of Top Quartile perform24
Releasing AMS ARES platform to

deliver asset and device health data,
enabling maintenance decisions
that increase availability; and
Detailing recent acquisitions, including Pentair Valves and Controls for
pressure management, isolation valves
and controls; Permasense for wireless
corrosion monitoring; and FMC for
blending and transfer technologies.
Supreme sessions
Earnings assist
Michael Train, executive president,
Emerson Automartion Solutions, reports
Top-Quartile practices can help customers improve their earnings by 15%.
ers, Emerson can help improve their

earnings as much as 15%, says Train.
Innovations aplenty
To provide users with even better tools
and services, Emerson debuted a host
of other solutions, services and initiatives at the event. They included:
Launching its expanded Plantweb
digital ecosystem, a scalable portfolio
of standards-based hardware, software,
intelligent devices and services for securely implementing the Industrial Internet of Things (IoT) with measurable
business performance improvement;
Collaborating with Microsoft to
help manufacturers realize business
impact and value of the Industrial Internet of Things (IoT) with help from
Emersons revamped Plantweb digital
ecosystem and Connected Services,
powered by Microsoft Azure IoT Suite.
Following yet another tradition, five

Best-in-Conference Award winners
were chosen from among the 300 sessions delivered at Emerson Exchange.
The five tracks and winners were:
Solve and support: Fighting Irish
tackle alarm managementimplementing an alarm management
program @ UND power plant by
Thomas Cole, UND Power Plant,
Bill Farmer, Novaspect, and Todd
Stauffer, exida
Measure and analyze: A wireless
odysseyfrom resistance to enthusiasm by Alan Weldon, Hunt Refining, and Donna McClung and Steve
Moore, both of Emerson
Operate and manage: Intelligent
solvent tank farm management
by Matt Rauschke of 3M and Kyle
Nystrom and Colin Singer, Novaspect
Final control and regulate: Natural
gas pipeline integrity improvements
reducing risks with pressure control station reinforcement by Niko
Boskovic and Andrew Loge, FortisBC,
and Reese Dawes, Spartan Controls
Business management and career development: Better listening, better
lifelisten like a pro by Nikki Bishop
and Bruce Smith, both Emerson
For more coverage, visit www.controlglobal.com/emersonexchange.
Make the Right

Safety Choice.
You depend on your cars

safety devices to provide
reliable protection when you
need it the most. Have the same
amount of condence in your Safety
ety
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Instrumented Systems instruments
the FS Functional Safety Series from Moore Industries.
Products including the new STZ Dual Input Smart HART
Temperature Transmitter have been designed and
built from the ground up to strict IEC 61508 standards,
ensuring safe and reliable function particularly in
environments where hazardous or emergency situations
are likely to occur.
Demand Moore Reliability

To learn more about our Functional Safetyy Dual Input
p Smart HART
Temperature Transmitter, go to: www.miinet.com/safetyseries
Or call 800-999-2900
In Process
Yokogawa and users

partner for a
brighter future
Just before Hurricane Matthew charged
up the Florida coast, Yokogawa Users
Conference and Exhibition 2016, Oct.
3-6, in Orlando, delivered an equally
strong but positive surge of technical
presentations, exhibits, corporate initiatives and networking opportunities
to help hundreds of users, system integrators, suppliers and other attendees
weather todays economic storms.
The market is facing challenges,
and innovation is a key driver to sustaining growth, says Takashi Nishijima, CEO, Yokogawa Electric Corp.,
who spoke via video. We must re-create ourselves to create wealth and value
to society. Yokogawa is moving into the
future one step at a time. Well be working with you to build greater bonds of
trust and to stimulate growth.
Opportunities for co-innovation were
described by Dr. Tsuyoshi Ted Abe,
vice president and CMO, Yokogawa
Electric Corp. Analysts are always looking at the short range, says Abe. Let me
focus on the long range. Our big, hairy,
audacious goal (BHAG) is sustainable
processes. While Yokogawa today has
many industrial customers, our future
customers are todays children. We must
all work together, to contribute to save
the earth for our children. Leadership
does matter, but not only at Yokogawa.
Lets work together for a co-innovative
tomorrow for our bright future.
To help its customers overcome todays challenges, Centum Vigilant Plant
(VP) DCS and its supporting sensors,
I/O, networks, ProSafe-RS SIS and other
components continue to offer a rocksolid foundation backed by Yokogawas
deep knowledge of process control and
optimization. Yokogawa launched the
first DCS on the market in 1975, and its
continued to offer progressive compatibility for effectively aging in place, ex26
Big-time sustainability
Dr. Tsuyoshi Ted Abe, vice president and
CMO, Yokogawa Electric Corp., reported
that its goal is sustainable processes.
plains Gene Chen, product manager for

DCS and safety instrumented systems
(SIS) at Yokogawa. Yokogawa delivers
easy upgradeability thats simple and fast;
low complexity and easy expandability; highest proven field reliability with
a bulletproof foundation; applications
that migrate forward for continued value
and reduced lifecycle costs; and knowledgeable engineers to execute, solve your
problems, and ensure benefits throughout the solution lifecycle.
For more coverage, including Controls show daily on technical and other
sessions, visit www.controlglobal.com/
articles/2016/live-from-yokogawa-2016.
ICS Cybersecurity
event gathers experts
and solutions
Security experts from industry, government, academia and elsewhere
presented and exchanged their experiences at ICS Cybersecurity Conference 2016, Oct. 24-27 at Georgia
Tech University in Atlanta. They represented multiple worldwide industries, government and military defense
departments, industrial control system (ICS) suppliers, cybersecurity researchers, consultants and educators.
The keynote address was delivered by
Adm. Michael Rogers, director of the
U.S. National Security Agency (NSA)

and CyberCommand. He addressed
many security issues related to control
systems, such as tradeoffs of remote access, value of air-gapped systems and the
need for educating management. Rogers
also asked private industry to work with
NSA to help identify precursors to cyber
attacks; addressed the recent distributed
denial of service (DDoS) attack using
IoT botnets; stated that secure control
systems need to be designed from the beginning and not use bolt-on security.
Joe Weiss, control system cybersecurity expert and Controlglobal.coms
Unfettered blogger, reports this years
event had several main themes:
General lack of understanding about
Level 0,1 devices;
Issue of control system incidents not
involving network malware (physics
issues);
Continuing cultural and knowledge
gaps between ICS and IT security,
IT forensics, safety and senior management
Continuing lack of universally-accepted definitions, particularly OT
and cyber incidents;
Ongoing scarcity of ICS cybersecurity
information and incident sharing, including no adequate guidance on preventing ICS cyber incidents from recurring; and
Ability of skilled hackers to compromise ICSs, as well as efforts to identify new ICS zero-day attacks.
For more coverage, visit www.control
global.com/blogs/unfetteredobservations-and-implications-from-the-2016-icscyber-security-conference.
GE oil and gas unit

merging with Baker
Hughes
GE (www.ge.com) and Baker Hughes
(www.bakerhughes.com) announced
Oct. 31 that theyve agreed to combine
GEs oil and gas business and Baker
IN PROCESS
EXPANSIONS AND CONTRACTIONS

Emerson Automation Solutions (www.emerson.com) and
Flexim (www.exim.com) are combining their ow portfolios.
They report their collaboration will enhance ow consulting and
selection; reduce piping, design and installation costs; and help
their customers execute more effective capital projects. Emerson project teams, using Flexims clamp-on, ultrasonic ow-metering tools with Emersons broad, in-line ow metering, can
consult early and throughout project cycles to reduce engineering, piping, and installation costs, and schedule risk.
GE Digital (www.ge.com/digital) and Gerdau (www.gerdau.com)
agreed Sept. 19 to work together to transform the steel producers
industrial operations by implementing GE Digitals Asset Performance Management (APM) solution, GEs SmartSignal and Historian software as well as services, remote monitoring and analytics expertise at 600 assets in 11 Gerdau plants across Brazil.
Pepperl+Fuchs (www.pepperl-fuchs.us) has bought ecom instruments GmbH (www.ecom-ex.com), a leading provider of
mobile industrial devices for hazardous areas, and developer of
explosion-proof cell phones, 4G smart phones and tablet PCs.

Pepperl+Fuchs reports its acquisition complements its portfolio
and know-how in explosion protection with mobile solutions.
Advantech (www.advantech.com) has launched its WebAccess+IoT Solution Alliance program, which is based on its WebAccess IoT software suite. The program is a market-oriented
cooperation model aimed at building win-win partnerships by using WebAccess to link solutions, partner strengths and strategic
co-marketing to penetrate focused vertical markets and applications in the IoT industries. Joining WebAccess + IoT lets members
buy non-expiring, virtual points that become digital currency.
Schneider Electric (www.schneider-electric.com) has acquired
software supplier MaxEAM (www.maxeam.com) to strengthen
its asset management portfolio, including enhancing Schneiders Avantis.Pro software. Together, theyll give customers a
single point of contact for support and delivery services, and
more closely align future product development, according to
Schneider Electric.
Simplifying processes.
Enhancing connectivity.
Delivering reliability.
Industrial Box Thin Client
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Technical Features
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ACP ThinManager-ready and Emerson DRDC options
Dual
Resources
Level measures up
Controls Monthly Resource Guide
BOILER DRUM INSPECTION GUIDE
The 2016 edition of Clark Reliances
Boiler Inspection Guidelines for Drum
Level Instrumentation is easy to understand and concisely presents ASME
Section I water gauge inspection requirements for handy, on-the-job reference by boiler operators. It includes
code requirements for water columns,
water gauge valves, gauge glass, remote
level indicators, magnetic water level
gauges and water column isolation
shutoff valves, as well as 2015 Code
changes and CSD-1 requirements
and recommendations from Section 7.
The guide also lists the most common
non-compliant, drum-level arrangements and solutions. Copies are available at www.boilerinspectionguide.
com, and free to qualified recipients.
Cl ark-Reliance Corp.
4 40-572-1500; w w w.clark-reliance.com
LEVEL SENSING INTRODUCTION

The Level Sensor article at Omega
Engineerings website covers non-contact ultrasonic, contact ultrasonic and
capacitance technologies. It also provides questions to help choose level
measurement sensors, and answers frequently asked questions. Its at www.
omega.co.uk/prodinfo/level-measurement.html#faq.
Omega Engineering
w w w.omega.co.uk
DP LEVEL FOR ROOKIES

This online feature article, Beginners
Guide to Diffential Pressure Level
Transmtters, by David Spitzer presents the not-so-straightforward basics of this measurment technique.
To help users avoid costly mistakes, it
shows readers how to understand DP
level measurement, and its techniquea

and limitations. The guide also covers
three different techniques used to calibrate pressure level transmitters. Its located at http://info.controlglobal.com/
differential-pressure-lp
CONTROL
w w w.controlglobal.com
BASICS OF LEVELAND HISTORY

This classic, 10-minute video hosted
by former Control editor Walt Boytes
examines all the essential concepts of
measurement, including some of its
earliest origins in, where else, Egypt,
where floods from the Nile made early
level measurement a necessity. The
video also demonstrates methods for
selecting the correct level technology
for different types of process applications. Its located at www.youtube.com/
watch?v=-MQU0xgh6bA.
CONTROL
w w w.controlglobal.com
ULTRASONIC VS. GUIDED WAVE

This 13-minute video is presented
by Jason Beck of Flo-Corp., who explains the some of the basic physics
and characteristics of ultrasonic and
guided-wave radar technologies, shows
how their capabilities work in process
applications, demonstrates potential
issues with each method, and shows
how viewers can find the most useful
solution for their requirements. Its located at www.youtube.com/watch?v=siAMerrbpPU.
strates how to perform open-tank level

measurement with a Rosemount 1151
DP transmitter, though the methods and concepts presented are useful for many technologies. It also covers set up, calibration, system layout,
output wiring, input calibration and
bench calibration hook-up, and other
tasks. Its located at www.youtube.com/
watch?v=xfo9n_ly8sA.
Northern Alberta Institute of Technology
www.nait.ca
ADVANTAGES AND DISADVANTAGES

The level measurement entry in the
Encyclopedia of Chemical Engineering Equipment by the Chemical Engineering Dept. at the University of
Michigans College of Engineering
covers the many of the main types of
level measurement technologies with
descriptions and photos. However, it
also presents the advantages and disadvantages of each level measurement
method. Its at http://encyclopedia.
che.engin.umich.edu/Pages/ProcessParameters/LevelMeasurement/LevelMeasurement.html.
Universit y of Michigan
w w w.engin.umich.edu/che
CAPACITIVE LIQUID LEVEL
OPEN TANK LEVEL
This 4.5-minute, blackboard-style

video by U.K.-based Gill Sensors &
Controls provides a quick summary
of the primary aspects of capacitive
level sensing, including behavior of
the dielectric, and shows how different probe materials can serve the
needs of different applications. Its located at www.youtube.com/watch?v=0du-QU1Q0T4.
Initially intended for students at NAIT,

this 17-minute tutorial video demon-
Gill Sensors & Controls

w w w.gillsc.co.uk
Flo-Corp.
w w w.flo-corp.com
If you know of any tools and resources we didnt include, send them to ControlMagazine@Putman.net with
Resource in the subject line, and well add them to the website.
29
hats so big about big data? Isnt it just more datamore

of the same old information from the same places,
which many users are finally waking up to and using?
Well, yes, many of the usual data handling methods, software
and devices are being trotted out again under the Big Data
buzzword, and so they must have a new banner and be called
something new even if theyre not.
However, despite the hype and distractions, there are persistent differences between traditional data and big data that
cant be ignored. Some of these differences include information sources not accessed before, data types not analyzed
previously, and new management and storage technologies.
These distinguishing features are summarized in big datas
oft-cited four Vs: volume, variety, velocity and value.
The challenges presented by big data are being met by
augmented and new analysis tools, networking pathways
30
and flexible cloud computing services. Most come from IT,

and thanks to ever-lower microprocessor, software and computing costs, theyre now arriving in force in process control
applications, on plant floors and in the field.
Dig deep, find treasure

Consequently, though cautious end users remain reluctant
to migrate, others are finding ways to cope with all the new
data streams coming from newly connected, Internet-enabled devices, identify previously unseen correlations and
trends, and achieve unprecedented operating gains.
For example, Avangrid Renewables (www.avangridrenewables.us) in Portland, Ore., collects lots of time series
and other information from its 3,000 U.S. wind turbines
and other generating assets, and seeks to coordinate it with
related operations, independent system operator (ISO),
B I G D ATA
weather, market and pricing data (Figure 1). Main sources
include OSIsoft PI, SCADA, SQL databases and SAP. Avangrid wanted to examine and better visualize its existing
OSIsoft content, so it could understand operations better
and improve decisions.
Avangrid especially wanted to more accurately report and get
paid by the ISO for lost generating capacity during required
curtailment periods, but it needed deeper turbine ramp-down
cost data to prove its economic losses. We knew we were losing
money, but determining the actual impact required investigating years of turbine data, says Brandon Lake, senior business
systems analyst at Avangrid Renewables.
To that end, Avangrid enlisted Seeq Corp. (www.seeq.
com) and its data investigation and discovery software,
which integrates information from historians, databases and
analyzers without altering existing systems. Its software uses
a property-graph database geared toward querying relationships across nodes to work with data and relationships between data in objects called capsules, which store time
periods of interest and related data used to compare machine and process states, save data annotations, enable calculations, and perform other tasks.
Lake reports that Avangrid tried to compile ramp-down data
before using Excel, but it took too much time and labor. With
Seeqs software, we were able to isolate shutdown events, add
analytics and determine what was happening in just hours,
says Lake. In the past, this would have taken days or weeks.
Once its participating wind farms isolated shutdowns and
ramp-down events, determined curtailment times, added
pricing and other setpoints, and determined differential
power-generation scenarios to determine losses, Seeq could
export the data to Excel and identify revenue the wind farms
could claim. Depending on its ISO contracts and wind
availability or curtailment, Lake reports that Avangrid saves
$30,000 to $100,000 per year.
What do you have? What do you want?

Despite its obvious advantages, big data is still a hard sell
for many users because they must shift their data-gathering
gears not just to new tools, but to new ways of thinking
mostly to understanding what big data is and how it can
serve their applications and goals.
While traditional data architectures move structured information through an integration process before warehousing and analyzing it, Oracle Corp. (www.oracle.com) reports
in its Enterprise Architects Guide to Big Data that big
data uses distributed, multi-mode, parallel data processing
to handle its larger, unstructured data sets, and employs different strategies, such as index-based retrieval for real-time
storage needs and map-reduce filtering for batch processing
storage. Once filtered data is discovered, it can be analyzed
directly, loaded onto other unstructured or semi-structured
databases, sent to mobile devices, or merged with regular
data warehousing (Figure 2).
Business systems
IoT sensors
Cloud IoT
platform
Context
Context
Control
network
Historian
Manufacturing
systems
Business
systems
CASH BLOWS IN
Figure 1: The 400-MW Klondike Wind Power Projects in Sherman
County, Ore. (top) is one of several Avangrid Renewables wind
farms in the U.S. using Seeq data investigation and discovery
software (bottom) to integrate information from historians,
databases and analyzers, and recover lost-generation revenue
from the local grid. Source: Avangrid
Weve always handled many forms of information, and

to us, big data begins with multiple streams and events produced by people, machines and processes. However, big
data ties these streams together with heuristics and analysis,
so users can relate what couldnt be related before, and find
new links and efficiencies, says Ian Tooke, consulting director at Grantek Systems Integration (https://grantek.com)
in Oak Brook, Ill. We do environmental controls for pharmaceutical and warehouse applications, and we can use big
data to tie changes in environmental factors to the state of
drugs in storage. For example, humidity can affect glue viscosity when were making corrugated substrates, but now we
can use this new data to make adjustments, which can help
improve the shelf life and effectiveness of some drugs. Similarly, there are many regulations for manufacturers about
keeping pharmaceuticals cool in storage, but fewer rules for
trucks and distribution warehouses, so we provide environmental monitoring in warehouses and on trucks.
Jim Toman, lead consultant for manufacturing IT at
Grantek, adds that food manufacturers are also looking at their
control and support systems for more traceability by gathering
environmental measurements, and applying statistics to help
meet production line setpoints. Food manufacturers are shiftN O V E M B E R / 2 0 1 6 www.controlglobal.com
31
B I G D ATA
cause predictive analytics and machine
learning use the same mathematics as
APC, such as neural networks to model
relations between data parameters.
tions, shipping, maintenance and end of

life. Its a powerful idea that these digital
threads can connect, and that any part of
the lifecycle can reach the other stages to
do useful things. If we can design knowing more about manufacturingand
Wide net, big haul
No doubt the best-known aspect of big get data from users to flow back to the
data is the namesake amounts of infor- fabricatorsthen we can make different
mation its servers take in, though the less decisions in digital manufacturing and
glamorous chore is making sense of it all, achieve greater value, but its still hard to
get those stages to work together.
and putting that intelligence to use.
Scott Howard, regional sales manManufacturing generates more data
than any other sector of the economy, ager, Statseeker (www.statseeker.com),
but only a little bit of it is used, and so adds that, Big data begins by collecting
there are huge opportunities to create whole bunches of information because
value by using that information, says at first its users dont know what matters,
Bill King, CTO of the Digital Manu- so they gather everything, and then try to
facturing and Design Innovation Insti- find correlations and statistical threads,
tute (http://dmdii.uilabs.org) at Univer- such as more closely matching equipsity of Illinois Labs (www.UILabs.org) ment performance to effects on quality
in Chicago. This data is produced at and end products. Statseeker makes a
every stage of the manufacturing lifecy- networking monitoring tool that checks
Black
participating ports every 60 seconds.
cle, including
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Reynolds Tobacco Co. (www.rjrt.com),
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CANADA
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sales@mac-weld.com
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Ave, Sarnia,
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E-mail:
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Pasadena,
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bytes
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Phone: 1 519-332-1388
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QMS is
is certified
certified to
to ISO
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9001:2008
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QMS
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certified
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big
data
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Phone: 1 519-332-1388
Phone:
1 832-429-3400
Mac-Weld QMS
is certified to ISO 9001:2008
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doesnt
necessarily
add
value.
So,
our
Mac-Weld QMS is certified to ISO 9001:2008
www.mac-weld.com
process controls engineering group, control engineering group and manufacturing from testing for poor quality to preventing it by ensuring that their process
controls and documentation give them
better traceability, and then maintaining
that genealogy through manufacturing
and distribution, he adds.
While traditional process data is
stored in historians and crunched later
for standard deviations, big data can also
participate in more advanced statistical
analyses, such as clustering, regression
and multivariate modeling, and consider correlations among many more
variables, says Mike Boudreaux, connected services director, Emerson Automation Solutions (www.emerson.com).
The process control industries already
do process optimization and predictive
maintenance, and big data can enable
predictive analytics and machine learnMac-Weld logoadvanced
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icon April 7, con2016
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trol (APC).
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is
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gross
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but it puts
these concepts in context beMac-Weld logo Brand mark and icon April 7, 2016
The
promise
of
The
promise
of
The
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The
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every
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promise
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time.
The
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precision
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time.
precision
every
time.
precision
every
precision every time.
time.
32
Structured
Reference and
master data
Enterprise
integration
Transaction
data
Data
warehouse
Analytic
capabilities
Your Global Automation Partner
Unstructured
Management, security, governance
Machine
generated
Distributed
file system
Text, image,
audio, video
Key value
data store
Map
reduce
Discovery
lab
Data
warehouse
Analytic
capabilities
Management, security, governance
More data, better paths

Figure 2: Traditional architectures (top) send structured data through integration to
warehousing and analysis, but Oracle Corp. reports that big data (bottom) uses distributed, multi-mode, parallel data processing to handle larger, unstructured data sets, and
employs different strategies for real-time and batch processing. Source: Oracle Corp.
ing managers are working to decide. The

control engineering group does factory automation and integration for the upper levels, while the process controls engineering
group examines operating trends, OEE
issues and other details. As a result, these
three groups came up with five points for
deciding what data is useful. These include: total product produced by the work
cell, good product quality, rejects, work in
process, and amount of work in intermediate work in process.
We stumbled onto Ignition SCADA
software, and added it to our new processes, including our largest manufacturing process with 70,000 tags, and were
now connecting it to all our manufacturing, which includes 40 acres under roof.
Whats really challenging is the pace of
change, and how all the pieces of our
SCADA and other systems are evolving
in relation to each other. This is another
way that Ignition helps because now we
can put in standards for HMI and screen
development, which reduces development time and cost and ultimately improves our product and quality.
Big fish handling and filleting

Beyond its larger and more varied
sources and the amounts of information
it takes in, big data is also distinguished
by how its information is handled and

stored. While traditional data management involves gathering, compressing,
simplifying and asking questions, and
then slicing and dicing big chunks of information for analysis, big data is about
shuffling many more small pieces of data
through as fast as possible with database
strategies like online transactional processing (OLTP) or online analytical processing (OLAP).
Where we traditionally used RTUs to
manage our wells and drilling pads, our
construction schedules are so aggressive
now, and bringing so many wells, controls
and I/O into our central control pads, that
its no longer efficient to use RTUs only,
says C. Kisha Herbert, PE, staff electrical
engineer at QEP Resources (www.qepres.
com), an independent crude oil and natural gas exploration and production firm in
Denver. In addition, Herbert reports that
QEP has built 32 drilling and production
facilities since July 2012, and each has
160-220 I/O points. It also employs a variety of automated valves, manifolds and
skid equipment.
To help automatically and quickly
manage all the new data coming in from
its new wells, pads, sensors, controls and
other components, QEP recently adopted
ControlLogix PLCs from Rockwell Auto-
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Sifting through suds

Figure 3: Sierra Nevada Brewing is using Ignition software and Dynamic SQL programming to visualize data streams and find failing RTDs in two cellars with 10-14 beer
fermentation tanks each, which have layered, glycol-jacketed zones that generate two
different data flows and about 2 million software database rows per year.
Source: Sierra Nevada Brewing
mation (www.rockwellautomation.com).
On a typical QEP pad and production facility, well locations are protected
through constant monitoring of protective shutdown devices; alarm and event
logs are used to review and track specific information and recent events; and
standardized ControlLogix PLCs and
RSLogix software are helping us meet
our aggressive schedules and maintain
safe, standard process controls, explains Herbert. Understanding local
regulations and requirements upfront
and having good controls is a big help,
but ControlLogix enables the remote
I/O points at our remote pads to provide
useful information to our central con34
trol pad. This is easier than using the

former RTUs because they require a
lot of linear programming to run their
loops, routines and subroutines.
Chirayu Shah, marketing manager, visualization and information
software, Rockwell Automation, adds
that, Because information is coming in from so many more places,
such as unstructured sources, video
feeds and social media, users that can
leverage this data can make more educated decisions. Process data is no
longer isolated at sites where its generated, so it can also join with input
from outside facilities such as business intelligence, gain a wider con-
text, and function at higher levels in

both large and small organizations.
Though it also uses longstanding
statistical tools, Emersons Boudreaux
adds, big datas innovation is that it
applies them using web-based and
cloud-computing services carried out
by distributed computing and storage
infrastructures, such as Hadoop, Cassandra, Mongo DB and others. These
services are based on data storage models that use map-reduction to reduce
information into usable forms, he
said. They also build server clusters
that share data across many servers,
and process data in parallel to return
results quicklymuch like searching,
clicking and getting immediate results
via the web and Internet.
For process control users, Boudreaux adds that big data is an opportunity to get more insights, actionable
intelligence and value from information theyve been collecting for decades. For example, Batch Analytics
software embedded in Emersons DeltaV DCS has protected services for taking process equipment information
from valves and gas chromatographs,
and uses big data methods to visualize them; take transactional snapshots
to collect their histories and identify
trends; and employ machine learning to predict equipment failures and
model complex fault scenarios. This
is why Emerson recently announced
that its Plantweb digital ecosystem and
Connected Services will be powered
by Microsofts Azure IoT Suite.
Because we didnt have access to
big data sets before, the traditional approach was theoretical and used physics models and equations, which were
time-limited and had to generalize
among many applications, explains
Boudreaux. Now, were using big
data to develop empirical equations
and models describing actual behaviors, which are more effective because
theyre individualized. As computing
gets faster and software costs go down,
we get closer to continuous monitoring
and management thats more tailored
to each user.
Plan for big data success

Similar to any new technology emerging on the process control front, big data can
only help users make better decisions if they understand what it is, how it can affect their controls and processes, and how they can use it to optimize operations.
Some of the primary tasks include:
Investigate business areas, facilities and applications that could benefit from
big data;
Inventory existing processes, data sources and analysis devices and software
for information gaps;
Evaluate possible big data tools, including software and statistical packages,
server strategies for data storage, and virtualized and cloud-based computing
services;
Examine how to coordinate big data devices and software with existing data acquisition systems, historians, and diagnostic and analytics functions;
Determine and enable cybersecurity capabilities for planned big data implementation, including software, servers, networking and cloud devices; and
Apply chosen big data solution, but schedule and periodically carry out future
reexaminations, and make adjustments as needed.
Your Global Automation Partner
WARNING
Not suitable for repairing

flimsy connectors
(or your reputation).
Organize and analyze

Of course, big data only delivers on its
even bigger promises when users can get
useful nuggets they can turn into better decisions, efficiencies and profits. In
process control applications, this often
means better predictive analytics and
maintenance, and/or improved remote
monitoring and optimization.
For instance, Sierra Nevada Brewing
Co. (www.sierranevada.com) in Chico,
Calif., recently enhanced critical temperature controls on its fermentation tanks by
improving its data visualization tools with
Ignition SCADA software, and efficiently
sorting through reams of batch data to proactively identify failing resistance temperature devices (RTD) and other issues. The
brewery has about 100 tanks at its plant,
including two main brewing cellars, each
with 10 to 14 beer fermentation tanks (Figure 3). Each of the 15-foot-wide tanks has
layered zones and two or three RTDs that
can generate two different data flows for
the same three- or four-week batch. Temperature is controlled by the solenoids and
glycol flowing to jackets on the tanks and
by an overall chiller plant.
We wanted, at a glance, to show there
was either no problem or there was an item
we needed to look at, says David Lewis,
technical services manager at Sierra Nevada. We also wanted bar graphs show-
ing number of batches per year per tank, as

well as number out-of-spec incidents. We
also wanted to drill into data about the last
several batches, so we could check the details of several out-of-spec incidents.
Ignition let Sierra Nevada moved batch
data into tables from 200-300 tanks, brew
kettles and supporting devices. We capture data every five minutes, and we already
had about 10 years worth of information in
our database, says Lewis. In early alert attempts, we had to determine which RTD
was indicating it was beginning to fail, for example, by causing the chiller to run on. We
also needed to figure out which data tails to
exclude, though this might mean missing
some stuck solenoids, and we had to avoid
email overload. So, we stepped back, prioritized our data, and tried to make it more
proactive. We also required an appropriate
context in which we could see everything
together, so wed know when operations
were happening that were supposed to be
happening, instead of looking tank by tank
and batch by batch. This meant bringing in
much more data, but then separating useful
signals from noise.
Because data is captured in five-minute
intervals for the brewerys more than 100
tanks, Lewis reports this generates about
five software database rows of data per tank
per batch. At about 2,000 batches annually, Sierras brewing operations produce a
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B i g d ata
Major big data tools
To bring in and use big and non-traditional information
streams, there are many software packages, data management and storage methods, new communication protocols,
programming tools, and cloud-computing services, coming
mostly from the IT side. Heres an incomplete list and glossary of the primary players:
Cassandra (http://cassandra.apache.org), or Apache
Cassandra, is a free and open-source distributed database management system designed to handle lots of
data across servers with high availability and no single
point of failure
Cloudera (www.cloudera.com) provides Apache Hadoop-based software, support, services and training
Dynamic SQL is a programming method that lets users
build SQL statements dynamically at runtime
Hadoop (http://hadoop.apache.org/Hadoop) is an opensource, Java-based programming framework that supports processing and storage of large data sets in a
distributed computing setting. Its part of the Apache
project sponsored by Apache Software Foundation
Mongo DB (www.mongodb.com)is a free, open-source,
cross-platform, document-oriented database program
total of 2 million software database rows per year. To access

this data and begin to improve decisions, he adds that he and
his colleagues are using Dynamic SQL programming to build
queries for their database. Sierra also uses Tableau (www.tableau.com) data visualization software to view database results,
which are displayed in conjunction with Ignition software.
Our MES is located on one server and batch data is on
the DAQ server. This means critical data was on different
servers, but our initial cross-server queries werent working,
and replicating data from one server to another was too cumbersome, says Lewis. We needed data from 2,000 batches
with their own start and stop times, so we ran a query string
using Dynamic SQL, joined one with another, did it 2,000
times, and it crashed. So, we threw a Hail Mary, and cut
and pasted the 2,000 queries into Tableau, and five minutes
later, we got the 2 million rows we needed.
Lewis adds that all displays for its newly enabled database
were built with Ignition, which allows users to click on each
batch and see a profile for it. Then we can use known and
previous failure patterns to better determine when the next
RTD is going to fail, adds Lewis. We can see drift and behavioral changes in the graph for a batch, and fix problems
before they become failures.
Similarly, Nick Moceri, president of SCADA Solutions
(www.scadasolutions.com) in Irvine, Calif., showed how his
company is using IoT-based remote monitoring and control
to let its clients legacy wind turbines ramp electricity production up or down more quickly in response to fluctuat36
classified as a NoSQL database program. It uses

JSON-like documents with schemas
MySQL (www.mysql.com) is an open-source database and Oracles big data intelligence platform and
application
Power BI 9 (https://powerbi.microsoft.com/en-us) is Microsofts data visualization/business analytics tool
SAP Hana (http://go.sap.com/product/technology-platform/hana.html) is an in-memory, column-oriented, relational database management system developed and
marketed by SAP SE
Spark Streaming (http://spark.apache.org/streaming) is
an extension of the core Spark API that enables scalable, high-throughput, fault-tolerant stream processing
of live data st reams
Splunk (www.splunk.com) produces software for
searching, monitoring and analyzing machine-generated big data using a web-based interface
Tableau (www.tableau.com) is data visualization software that joins databases and graphics
TrendMiner (www.trendminer.com) is a predictive analytics tool for the process industry
ing grid demand and to avoid negative pricing, which may

require 200 turbines to be adjusted in 10 minutes or less.
SCADA Solutions added its in-house software to Opto 22
(www.opto22.com) controllers and other components.
Many older wind farms werent built with the Internet
in mind, but now they need to add Internet protocol (IP)
switches that are addressable to a server, so they can be
brought into a central location, says Moceri. IP-addressable switches, controls and servers allow us to get ahead
of the game, optimize production, and perform predictive
maintenance that extends turbine life. In fact, one wind
farm in Palm Springs, Calif., went from flat results to a 16%
production improvement and complete return on investment in just three months.
To begin to implement a big data strategy, Granteks Toman
suggests it cant be done merely from the ground up, and instead requires an organization-wide strategic plan. You cant
just look at the needs of individual silos. You have to reach out
to the rest of the company, evaluate systems in place, and identify other data silos that can be leveraged, says Toman. Many
times, organizations have blinders on, so they need to bring in
someone who isnt in the existing culture to poke around, and
mediate between the engineering and IT sides on how they
can adopt some best practices and standards for big data. This
isnt just converging data technologies; its about convincing
process people to practice and benefit from them.
Jim Montague is Controls executive editor
SAFETY SYSTEMS
Cybersecurity
in the SIS world
Find and slay the dragons lurking in
the typical safety instrumented system.
by William L. Mostia, Jr., P.E.
ybersecurity is a growing concern in the process industries, and a number of good articles have been written
about it for industrial control systems (ICS)many full
of doom and gloom. Here, we will divide the ICS into two
parts: safety instrumented systems (SIS) and all other ICS
components, which we lump into the basic process control
system (BPCS). There are distinct differences between the
SIS and BPCS in function, design and cybersecurity.
The SIS and BPCS differ in regard to cybersecurity from
a process safety perspective, how traditional SIS design practices can help provide cybersecurity, and how cybersecurity
concerns can affect the design of the SIS.
This article examines some of the differences between
the BPCS and the SIS, SIS vulnerabilities to cyberattack
and other security concerns unique to the SIS. It also covers
how traditional SIS design can help with cybersecurity, and
how traditional design practices of the SIS are affected by
cybersecurity. Due to its size limits, one article cant cover
all aspects of designing or securing a SIS in the presence
of cybersecurity threats, but its instead intended to provide
food for thought on this topic.
When a cyberattack gets physical
38
Governmentand statesupported
Terrorists
Company
Public
tor
vec
eat
Thr
Its important to note that operating a chemical plant or refinery is complex, with many checks and balances as well
as human beings to provide 24/7 oversight and some level
of resilience. A cyberattack is really a cyber-physical attack
because it involves a system with direct connections to the
real world, as opposed to attacking a computer and data. A
process plant is also a system designed to work in the presence of failures (even multiple ones) and uncertainty, even
if the failure mode is unknown, whether it be a cyberattack,
control valve failure, pump failure, etc.
For example, if a tower is over-pressurized, chances are
youll have an independent, high-pressure alarm, possibly a
high pressure override of the tower reboiler, an SIS and a relief valve protecting it, plus operator observations. This illustrates how defense-in-depth achieves process safety, which
also provides protection against a cyberattack as an initiating
cause. This is not to say that cybersecurity is not important

for process safety, but rather that it must be considered in
the mix of potential failures and safeguarding against those
failures.
Figure 1 illustrates the overall cyber-domain including the
SIS. Generally speaking, only digital systems are a concern
for a direct cyberattack, however, even analog or mechanical
systems arent as completely immune as one might think. For
example, the safe operating limit database (alarm and trip setpoints), asset management (changes in device parameters), SIS
field instrument calibration databases (incorrect calibrations),
and even the relief valve database (incorrect trip setpoints and
test intervals) can potentially be corrupted by a cyberattack,
leading to failure in the SIS or other process safety systems under the right circumstances.
Threat vector
BPCS
SCAI
SIS
Unknown unknowns
THE CYBER DOMAIN

Figure 1: Along with the basic process control system (BPCS)
and safety controls, alarms and interlocks (SCAI), the safety
instrumented system (SIS) is a critical component of a process
facilitys defense against myriad cybersecurity threats that might
lead to loss of life and destruction of property.
SAFETY SYSTEMS
The role of the SIS in safety
Its important to understand how process safety is achieved
through functional safety, and how the SIS fits into the overall picture. Achieving process safety using functional safety
typically involves a defense-in-depth protective scheme consisting of independent protection layers (IPLs).
In Figure 2, we can see the SIS is not the only IPL in the
layer of protection scheme. Some IPLs are subject to direct
cyberattack and some are not. Modern design of functional
safety protection systems (FSPS) for hazardous processes is
all about preventing a hazardous condition, even in the presence of failures of some of the IPLs. The cyberattack threat
does not change that paradigm, but rather adds additional
potential failure modes of the BPCS and process equipment
that may lead to potential safety demands of unknown frequency (an important risk consideration).
A fundamental SIS design principle is that failure of
the BPCS to control the process for any reason should not
cause a simultaneous failure of the SIS protecting the process. This does not change with the introduction of the
cyberattack threat; if a cyberattack has compromised the
BPCS, it should be substantially more difficult for the
same attack to compromise the SIS either synchronously
or asynchronously.
Defense-in-depth and the related principle of requiring
multiple failures or difficultiesa tortuous path before
you have a successful cyberattackare important protective concepts. This also applies to the BPCS, where safety
controls, alarms and interlocks (SCAI) and other protective
safeguards should present a difficult path to defeat them all
to cause a loss of process safety protection and situational
awareness of the operator.
How a SIS differs from a BPCS

Her are some the primary differences between the SIS and
BPCS. The primary purpose of the BPCS is as an active,
continuous system that controls level, pressure, temperature
and other process variables designed to keep the hazardous
materials in the process under control within the safe operating envelope, while efficiently and cost-effectively making on-spec product. The vast majority of SISs, on the other
hand, operate as passive systems that sit there doing nothing
until a safety demand occurs. When the process exceeds its
safe operating limits, the SIS acts to maintain or bring the
process to a safe state. This passiveness also makes it difficult
for an intruder to analyze the system and its relationship to
the BPCS by observation alone.
Failure of the BPCS can be an initiating cause for a hazardous scenario, whereas a properly designed, low-demand
SIS cant typically be the initiating cause of a hazardeven
during a cyberattack.
The BPCS will have tens of thousands of data points
(reads and writes) and other parameters transferred digitally
between BPCS boxes via multiple paths, where the SIS may
Acceptable
risk level
Layers of protection
Risk inherent
in the process
SCAI
Other (safety
valves, etc.)
Alarms
SIS
BPCS
Process
Risk
RISK REDUCTION
Figure 2: Reducing risk typically involves a defense-in-depth
scheme of independent layers of protection including the basic
process control system (BPCS); safety controls, alarms and interlocks (SCAI); and the safety instrumented system (SIS).
have a few hundred data points, mostly reads with a limited number of writes. The BPCS will typically talk to the
SIS through only one communication path per SIS. The SIS
will also have its own internal communication structure.
In most cases, the SIS is implemented on different hardware, in some cases by a different manufacturer than the
BPCS equipment.
The SIS is periodically proof-tested, while the BPCS is
many times operated to failure. This provides a mechanism
for detecting unauthorized changes.
Cybersecurity standards for SIS

There are several standards pertinent to cybersecurity and
the SIS. The second edition of IEC 61511-1 will require that
a security risk assessment be carried out to identify the security vulnerabilities of the SIS, including both physical and
cybersecurity vulnerabilities. The standard also will require
that the design of the SIS provide the necessary resilience
against the identified security threats. This is a new, substantial requirement.
The ISA 99 committee has generated a series of pertinent standards, one of which is IEC 61511-1, ANSI/ISA/
IEC-62443-1-1, Security for Industrial Automation and
Control Systems Part 1-1: Terminology, Concepts and
Models. The ISA 84 committee also has a subcommittee looking at cybersecurity for technical reports (TR).
Theyre in the draft stages of dTR84.00.09, Cyber Security Related to the Functional Safety Lifecycle, which
is attempting to bring the principles of ANSI/ISA/IEC62443-1-1 to functional safety and the safety lifecycle.
Hopefully, they will do this in a practical manner without
too much computer-speak.
Protecting SIS assets

Protecting the SIS against cyberattacks is a simple matter of
39
SAFETY SYSTEMS
include those in this assessment. This should be coordinated
with the cybersecurity efforts on the BPCS. The identified vulnerabilities should be eliminated or their risk minimized.
Potential vulnerabilities include remote access, uncontrolled
writes, ability to program remotely, configuration database indirect attacks and cyberattacks via manufacturer or third-party
software.
Red flags include any computer equipment that is Windows-based, commercial off-the-shelf (COTS) technology,
open systems, connections to the enterprise or Internet, the
ability to write to the SIS, SIS equipment under lock and key,
and/or portable media (USB ports, memory sticks, CDs, etc.).
Ethernet and Ethernet switches (too vulnerable) are a no-no in
a SIS zone or to cross the boundary. Wireless may be an open
invitation and should be avoided in a SIS.
Dont connect to what you dont have to connect to. Risk vs.
benefit has to be factored in, particularly when convenience is
considered.
Implement intrusion detection, including monitoring for
changes in software and safety-critical parameters. Fortunately,
preventing unauthorized changes that can compromise its

safety functionality. Easy as pie, right?
To get a high-level view of your SIS and its potential vulnerabilities, draw a boundary around all the SIS assets (typically your SIS zone). Then, identify all of the communications paths and any other data, remote or physical access
paths that cross that boundary. This is illustrated in Figure
3 for a generic SIS, but your system may have more or different vulnerabilities. This conceptual boundary can help
you visualize your potential cyberattack vulnerabilities and
systematically address them.
To evaluate your cybersecurity vulnerabilities and current
protections, one of the first things to do is an inventory of all
SIS equipment, software (with version numbers), and critical
operating parameters. This should be followed by a security assessment of the SIS as required by the IEC 61511-1 2nd Ed.
This inventory will provide a baseline for monitoring changes
in your system.
Contact your equipment vendors and ask them to provide an
analysis of their equipments known cyber vulnerabilities, and
BPCS communication
Digital Analog/discrete
Conduits
(typical)
Remote access
SIS
zone
Remote access
SIS
controller
Run/off/
program/
remote switch
Windows
vulnerabilities
Original, patch
and update
software
Removable media
(memory sticks,
CDs, etc.)
Safe operating
parameters database
Original, patch and
update software
Engineering
station
Unknown
Unknownthreat
threatvector
vector
Unauthorized
access
SIS
Field
Physical access
Unknown gap
Windows
vulnerabilities
Original, patch and
update software
Remote access
Windows
vulnerabilities
Calibration
AMS
Unauthorized access
Unauthorized access
Original, patch and

update software
Remote access
DETERMINE THE BOUNDARY

Figure 3: Draw a conceptual boundary around the safety instrumented system (SIS) assets (typically your SIS Zone). Then, identify all of
the communications paths and any other data, remote or physical access paths to help visualize potential cyberattack vulnerabilities, and
systematically address them.
40
SAFETY SYSTEMS
ICSs typically have extensive logging, and the SIS should log to
them all changes in parameters and SIS accesses for programming, maintenance, etc. A cyberattack response plan should
be put into place, including operator procedures and a recovery
plan. Failure to plan is planning on failure.
SIS design for cybersecurity

Most articles on cybersecurity for ICS revolve around the conceptual approach of dividing the control systems up into zones
and conduits (essentially, protection by controlled isolation), doing a cybersecurity assessment, and placing a bunch of firewalls
or security appliances in your networks. These are important
aspects of cybersecurity, but they are not the only things to do
in designing the SIS system for protection against cyber attacks.
Many of the traditional design principles for SIS provide
some level of cybersecurity protection (e.g. independence, separation, diversity, limited digital connectivity, controlled writes,
distributed architecture, 4-20 mA signals, etc.). So legacy SIS
have some cyber vulnerabilities, but they are not as exposed to
cyber attacks as many people seem to assume. Unfortunately,
in recent times, the use of some of these principles have declined due to cost considerations, competitive differentiation
and changing demographics.
Independence, separation and diversity are philosophies
that have been cornerstones of SIS design. Independence keeps
the safety functionality separate from the control functionality.
Keeping the SIS hardware physically separate eases physical
security and isolating the SIS into zones. Having diversity in
hardware can mean different hardware from the BPCS but the
same manufacturer, or it can mean different manufacturers for
the SIS hardware. Both are good practices, but having different
manufacturers reduces common cause failures, and increases
the knowledge required to hack both systems.
The safety PLC is commonly used as a logic solver for a
SIS, and is typically the focal point of most cyberattacks on
the SIS because it communicates with the outside world and
is extensively software-based (e.g. requires programming software, software updates and patches, commonly networked,
etc.). Safety PLCs are different from general-purpose, industrial PLCs and DCS controllers, and are much less open to
unauthorized changes. SIS logic solvers that are more tightly
integrated with the BPCS or use the same hardware as the control system can be more exposed to a cyberattack. Most safety
PLCs have a hardware watchdog timer that monitors their logic
cycle. A separate hardware watchdog timer may also be a good
idea. Communication watchdogs can also be created in logic
to detect communication problems between the SIS and the
BPCS independent of the communication channel, and can
detect problems with the communication channel.
Run/stop/program/remote switch: Almost all PLCs and
certainly safety PLCs have some form of this hardware key-lock
switch that can control programming access and in some cases,
control writes to the PLC. No programming of SIS equipment should be allowed across a network connected to the
BPCS, enterprise network or outside world, even through firewalls. It should be verified with the SIS logic solver manufacturer that their key-lock cant be overridden externally through
a communication link of any sort
Read requests from the BPCS are common to transfer
the SIS status to the BPCS. These should be limited in scope.
It should be verified that problems with the PLC communication processor/port (e.g. denial of service attacks, incorrect or
garbled read requests, etc.) cant affect the PLCs safety logic
cycle or its safety functionality.
Writes: the safest approach is to not allow any writes to the
SIS logic solver from the BPCS. Most SIS logic solvers can
limit writes to specific memory locations (e.g. will not accept
writes to other locations). DCS, PLC or foreign device gateways
may also allow only certain tags be read or written to the SIS.
These features should be implemented. If you must write to a
SIS logic solver, you might consider an analog or digital input
to transfer the data.
Deep-packet inspection (DPI) security appliances and
data diodes can stop all writes, and in some cases can whitelist
read and write tags or memory locations. These security appliances must be able to get down to the write command and the
write tag or memory location to be effective. The safety PLC
should also ensure that write data values are within an acceptable range.
Non-digital SIS logic solvers such as relay logic and tripamps are directly immune to a cyber attack. Indirectly, they
may have a small cyber vulnerability if the database for their
trip and alarm points is corrupted by a cyber attack. These systems can be used as a back-up safety PLCs safety instrumented
functions (SIF). In small applications or localized systems, they
can provide a cyber-immune solution.
SIS field devices are less prone to cyberattack because the
vast majority of their outputs are 4-20 mA or on/off 24 VDC/120
VAC, which are notoriously hard to hack. Safety protocols have
been developed for digital fieldbus communications between
field devices, but are not very common for SIS. When these are
used, they may be more exposed than a 4-20 mA loop to a cyberattack. When a fieldbus safety protocol is used, the transmitters should be connected point-to-point, and high-speed Ethernet (HSE) should be avoided for SIS service.
A hardware security jumper blocks changing any of the parameters of a field transmitter, including changes via HART or
fieldbus. SIS field sensors and other applicable SIS field devices
should always have their security hardware jumper engaged in
normal operating service. Software lockouts should not be used
unless theyre the only security feature available. If an AMS system is present via HART, it should have read-only access for
SIS field devices, even if the security jumper is not engaged. All
SIS transmitters should have a deviation alarm where feasible.
4-20 mA smart transmitters typically communicate via a
HART communicator during calibration and maintenance.
There is a cybersecurity exposure due to the software in the
communicator, but it must come indirectly through corruption
41
SAFETY SYSTEMS
of the software from the communicators manufacturer.
Calibration tools are another potential cybersecurity vulnerability for SIS field devices because modern ones are digitally based, and may communicate with a database or AMS
system that would typically be on a Windows machine connected to the site enterprise network. Corruption of the calibration database could lead to miscalibration of safety transmitters.
Keeping a computer backup of the calibration data, trip and
alarm points, transmitter parameters and programs is a good
practice, and historical copies should be kept in case the current one gets corrupted. This will help you recover from a cyber
or internal security attack. Remember, plan ahead.
Final elements, such as solenoids, valves, motor starters, etc.
are typically immune to cyber attack. If your valve has a digital
valve controller or a smart positioner, it may be possible for a cyberattack to spuriously trip or cycle the SIS valve. These devices
may be communicated with by a portable Windows-based
computer, and may be subject to a cyber attack.
Bypasses are points in the SIS logic solver that are commonly a write from the BPCS to the SIS to bypass a particular sensor to allow maintenance. Erroneous activation by the
BPCS or SIS would defeat a SIF or part of a SIF. The common
practice of having a manual, bypass-enable switch that must
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be activated, with a short timeframe to enable a bypass and bypasses that time-out are good practices. Also, having a bypass
alarm generated from the SIS that restrikes periodically when
in bypass, and remotely monitoring the bypass state, are also
good practices, again, making it more difficult for a cyber intruder to enable the bypasses undetected.
Manual shutdown: IEC 61511-1 states that a manual
means (for example, emergency stop pushbutton), independent
of the logic solver, shall be provided to actuate the SIS final
elements unless otherwise directed by the safety requirement
specifications. This was put in place because there was a fear
that the PLC logic solver would not operate when required, the
PLC might go into a loop, or it might begin operating erratically (sounds applicable to a cyberattack). However, primarily
for convenience and cost reduction, its been the practice of
many people, to use the otherwise directed by the safety requirement specifications to route the manual shutdown to the
SIS logic solver because they rationalize that the logic solver is
highly reliable. From a cybersecurity perspective, this is a bad
practice because if the SIS logic solver is compromised, so may
be the manual shutdowns in this logic solver. This takes away
the operators ability to quickly implement a manual shutdown
to bring the plant to a safe state. This is particularly worrisome
for SIF where there are no other IPLs associated with the hazardous scenario.
Also, companies often have procedures that are gun-drilled
(exact and ingrained) for shutting down the plant due to power
loss, cooling water loss, etc. It makes sense that you should have
a gun-drilled procedures to shut down your plant if you suffer a
cyber attack that compromises process safety.
Reset function: Software resets may provide some protection against a cyberattack that cycles the safety PLC outputs,
but may be compromised by a knowledgeable attacker. Field
manual resets on the solenoids physically prevent the shutdown
valve from cycling, and are immune to cyber attacks.
Cybersecurity is never done

Cybersecurity is a complex, important topic that is ever
evolving. Many practical things can be done based on engineering analysis of the SISs vulnerabilities and data flows.
Use of the zones and conduit concept, defense in depth, and
the torturous path concepts are steps in the right direction.
The standards in this area have a steep learning curve, and
with the ever-changing cyber threat environment, may require a specialist to keep up. I will leave you with an interesting question: are identified hardware (and related software)
vulnerabilities in your ICS and SIS covered by your hardware warrantees and afterward?
[I want to thank Mark Carrigan of PAS Inc. (www.pas.com) for
the excellent discussion on cybersecurity when I was researching
this article.]
W.L. Mostia, Jr., P.E., is a frequent contributor to Control.
42
MOTORS & DRIVES
Ongoing innovations, added intelligence and

networking let motors and drives serve in unusual
applications and replace obsolete equipment.
by Jim Montague
ust when it seems like todays sophisticated motors and

drives cant possibly add more efficiencies and capabilities,
engineers conjure up new tricks and refinements, followed
by end users and system integrators who materialize new settings and challenges where they can make big gains. As usual,
the rest of us are left to wonder, How did they do that?
This is because, while long-established drives and motor
solutions might not appear unusual to most technical professionals and other onlookers, they obviously manifest as lifesavers to those most in need of their capabilities. Necessity doesnt
just lead to invention, it grants new vision along the way.
One company with this mindset is Acadian Seaplants (www.
acadianseaplants.com) in Dartmouth, Nova Scotia, Canada,
which grows and processes agricultural biostimulants in liquid and powdered forms at its plant in nearby Cornwallis. The
company starts with local, sustainably harvested ascophyllum
nodosum seaweed, from which various bioactive compounds
are extracted, clarified, filtered and concentrated in a complex
production process that requires careful process control. The final products are shipped to more than 80 countries to improve
the health and growth of plants worldwide.
CUSTOMIZE, EXPAND SEAWEED CROPS

Figure 1: Acadian Seaplants employs Allen-Bradley Centerline
motor control centers (MCCs) with IntelliCenter software from
Rockwell Automation to more easily reconfigure for different crop
biostimulant products, and increased capacity 40% at its plant in
Nova Scotia. Source: Acadian Seaplants and Rockwell Automation
Growing gracefully
Our motor controls and facility communications were hardwired before 2006, so if we wanted to change or add a step in
the production process, wed often to rewire entire areas of the
facility, says Wade Hazel, engineering manager at Acadian.
We began automating the Cornwallis facility during 20062008, but this modernization wasnt enough to meet growing
demand, so we decided to build onto the existing plant to add
capacity, and automate the new equipment to increase process
control and efficiency.
Hazel adds that Acadian supplier Graybar (www.graybar.
com) knew it was already using Allen-Bradley CompactLogix
programmable automation controllers (PACs) from Rockwell Automation (www.rockwellautomation.com), so it proposed adding Allen-Bradley Centerline motor control centers
(MCCs) with IntelliCenter software and EtherNet/IP networking. This meant Acadian could expand its capacity by integrating with existing controllers, and avoid adding hardwiring for
motor controls (Figure 1). Consisting of variable-speed drives
(VSD) and full-voltage starters, the MCCs and supporting
automation let Acadian increase seaweed processing by 50%
during 2008-09.
However, demand continued to swell, so Acadians management decided to build the new Deveau Center plant across the
street with three times the space. This included underground
piping for moving product between the plants, three more
ControlLogix PACs, expanded Centerline and Intellicenter applications, plantwide EtherNet/IP for monitoring and motion
control, and Rockwell Software Studio 5000 to set up and configure the PACs and MCCs. The new plant was finished in
2014, and its already running at 40% more capacity than its
earlier version, and can expand capacity another 250%.
This facility isnt static, added Hazel. We may need to
change functions one day, do improvements the next, or add
new processes. With all controls connected via EtherNet/IP,
many former hardwires became virtual wires, so we can make
changes faster at a lower cost. Integrated MCCs and controllers
N O V E M B E R / 2 0 1 6 www.controlglobal.com
43
MOTORS & DRIVES
LONG CONVEYOR FOR COPPER HAULING

Figure 2: Codelco is deploying ABBs 800xA control system and
Figure 3: Tata Steels Hartlepool SAW pipe mill in northeastern
Mining Conveyor Control Program (MCCP) to automate the 13-
England is replacing the 40-year-old DC motor on its pipe ex-
km conveyor and gearless conveyor drive system between its
panders gripper car with a 150-kW, 300-Amp, 1,070-rpm motor
new underground mine and concentrator plant at the Chuquica-
from Vascat S.A. and a 250-kW Powerflex 755 inverter drive from
mata copper mine near Santiago in Chile. Source: Codelco and ABB
Rockwell Automation. Source: Tata Steel and CP Automation
give us a more connected, reliable and continuous facility with

data shared more seamlessly between processes and operators.
Engineers can also access the plants computer remotely to reduce downtime compared to former onsite visits.
Based on the plant science divisions successful expansion,
our engineering team has started using CompactLogix PACs
to automate processes in the food science divisions land-based
cultivation facility, and wed like to migrate to EtherNet/IP-enabled MCCs in the animal science division in the next few
years, adds Hazel.
then its only 40-50% efficient at half speed, he explains. Synchronous reluctance gets that efficiency back up to 70% at half
speed, which is why were rolling them out.
Rotating evolution
Integrating microprocessors, intelligence, networking and
other functions into motors and drives enable them to achieve
remarkable gains, but these advances have also altered their basic nature. Process and discrete controls are more the same
now, and their technologies are adapting to fit, says Robert Sor, product marketing manager for general-purpose,
Sinamic and VG drives, Siemens (www.siemens.com). PLCs
and other process controllers arent much different now, and
many drives are much the same, even though their AC motors
may run at different speeds. In fact, increasing pressure for efficiency has pushed drives to evolve until they can now do what
servo drives did just a few years ago.
Because theyre easier and less costly to deploy, drives are
spreading to rotating equipment that hasnt used them before,
according to Sor. Over the past five to seven years, drives are
appearing on more pump jacks, fans, pumps and positive-displacement pumps. These used to have contactors and starters
because there were less concerns about saving power. However,
with the oil and gas industry down, people want to save money,
and theyre doing it with smaller, smarter and less costly drives,
and more precise variable-frequency drives (VFD).
Sor adds that similar efforts to save are spurring adoption of
more efficient, relatively higher-tech motors, such as synchronous reluctance motors. A manufacturer may add variable
speed to a motor that usually runs at full speed and 60 Hz, but
44
GET A GRIP ON PIPE EXPANSION
Tough, old environment? No problem

Thanks to these and other enhanced capabilities, size reductions and lower costs, users are increasingly willing to apply
new motors and drives in difficult environments, and replace
aging equipment they couldnt remove before.
At the Chuquicamata open-pit copper mine in Chile, stateowned Codelco (www.codelco.com) recently began developing an underground mine to access an ore body beneath the
pit. The new mine is scheduled to begin operations in 2019
and expand Chuquis capacity, but one major hurdle is it will
need one of the worlds largest, most complex and most powerful conveyor systems to get copper ore up steep gradients and
over long distances to its concentrator plant 13 km away (Figure
2). As a result, Codelco recently contracted with Tenova Takraf
GmbH (www.takraf.tenova.com) to build the conveyor system,
and Takraf enlisted ABB (www.abb.com) to automate it. So far,
its designed to have conveyor flights powered by up to 20 MW
and a total requirement of 55 MW, which will allow it to transport more than 11,000 tons of material per hour.
ABB will implement a complete power and automation solution at Chuqui, including gearless drives, motors, instrumentation and power components, which will be custom engineered
to meet onsite requirements to optimize power, control, measure and actuate the conveyor. This design will integrate the
belts power and automation through ABBs 800xA control system, and combine with its Mining Conveyor Control Program
(MCCP) to ensure optimum power quality and control.
The gearless conveyor drive system is a key feature of the
solution because it meets the conveyors extremely high load
requirements and necessary power availability, which wouldnt
have been achievable with a conventional drive solution, says
Roger Bailey, head of ABBs Process Industries division. The
gearless drive system eliminates the gearbox from the motor,
Motors & drives

which reduces part wear and required maintenance. Another advantage is the reduction in the drive system footprint and instrumentation required. Less parts increases reliability and efficiency of the
overall conveyor system by several percentage points.
Similarly, Tech Folien Ltd. (www.techfolien.co.uk) in Liverpool,
U.K., recently needed to replace the 15-year-old motor/drive system
on its extruder due to lacking spare parts and excessive energy consumption. The firm produces polycarbonate, polypropylene and
other co-extruded, blown films. As a result, Emerson Automation
Solutions (www.emerson.com) and Rewinds & J. Windsor (RJW,
www.rjweng.com) combined a Unidrive M701 VSD from Control
Techniques and an energy-efficient IE4 LSRPM motor from Leroy-Somer, both Emerson Industrial Automation firms.
Installed in a cabinet away from the line, the M701 sets the speed
control parameters of the motor, which is installed close to the line.
Control parameters are programmed via onboard drive macros. Emerson and RJWs solution is expected to save the extruder and Tech
Folien about 75% on its energy costs. Energy efficiency plays a vital role in ensuring our profitability, and this new drive and motor
combination ensures that we have complete confidence that we can
control our energy costs and maintain 24/7 operation, says David
Churm, maintenance manager at Tech Folien.
Finally, located in the heart of Tata Steel Europes (www.tatasteelconstruction.com) Hartlepool SAW pipe mill in northeastern England is an expander machine that shapes, sizes and strengthens
its pipe products with help from a large gripper car and 40-year-old
DC motor, which moves 12.5-meter pipes over the expanders head.
Used only for pipe making, this machine is unique in the U.K. However, the old motor also required frequent maintenance (and DC
drives and spare parts were scarce), consumed too much energy, and
was hobbled by an obsolete, inaccurate and slow control system that
often caused production bottlenecks (Figure 3).
Consequently, Tata sought help from Rockwell Automation and
CP Automation (www.cpaltd.net) to find a replacement. Requirements for better energy efficiency and accuracy meant an off-theshelf motor and drive wouldnt suffice, so we worked with Vascat
(www.vascat.es) to produce a bespoke, 150-kW motor at 300 A and
1,070 rpm, and Rockwell supplied its 250-kW Powerflex 755 inverter
drive with CIP Motion function and PLC, says John Mitchell,
global business development manager at CP.
To boost the new motors start/stop speed and prevent drive trips,
CP introduced a Revcon regenerative braking unit to make start/
stops more seamless, accelerate the gripper car, and move the pipes
faster. The old motor was replaced in August 2016, and Tata had also
planned to replace the expanders auxiliary drive later in 2016.
The regenerative unit is where we reaped the benefits of the
new equipment, both in increased speed and energy efficiency,
says Tony Brown, electronics engineer at Tata Steel. Also, the new
servo drives accuracy allows us to position pipe with 1-mm accuracy,
whereas the old DC systems accuracy was closer to 50 mm. This
improved accuracy coupled with a 10% increase in speed gives us
productivity improvements throughout the expander.
Jim Montague is Controls executive editor.
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DEVELOP YOUR POTENTIAL
FOPDT modeling
R. RUSSELL RHINEHART
PV
russ@r3eda.com
first-order plus deadtime (FOPDT) model is

a simple approximation of the dynamic response (the transient or time-response)
of a process variable to an influence. Its also
called first-order lag plus deadtime (FOLPDT),
or deadtime may be replaced with delay,
changing the acronym to FOLPD.
The FOPDT model is often a reasonable
approximation to process behavior, and has
demonstrated utility for controller tuning rules,
for structuring decouplers and feedforward control algorithms, in communicating essential
process attributes, and as a computationally
simple surrogate model in simulations for training and optimization.
There is no claim that the FOPDT model is a
true representation. The process is likely higher
order and nonlinear. However, a FOPDT model
is a practicable representation, balancing multiple aspects of utility.
In FOPDT modeling, typically, we consider that the influence has remained constant in the recent past, and that the process
variable (PV) had achieved a steady value.
Then, we consider that the influence makes
a step-and-hold, and holds that new value until the PV reaches its new steady state. The
75
70
65
60
55
50
45
40
35
30
150
155
160
165
170
Time (step-and-hold happened at 155)
TYPICAL COMPARISON OF FOPDT MODEL TO DATA

Figure 1: Compared to the data (dots), the FOPDT model (solid curve) has
a longer delay, changes rapidly to catch up, then rises above the process
before relaxing more slowly to the final steady state.
46
60
1.2
deadtime represents the time duration after

the influence changes during which the PV
does not change. Its like a transport delay in
a pipeline with plug flow or a laboratory analysis time.
Figure 1 compares the model to data.
Here, for clarity, the data is ideally noiseless,
s-shaped, and indicated by the dots. The stepand-hold in the influence happened at a time
of 155, but the high-order process doesnt begin to reveal a response until about 156 when
it starts to rise slowly, then achieves its fastest
rate of change at about 159.
For a best fit to the data, the FOPDT model
(solid curve) has a longer delay, and does not
begin to make a change until a time of about
157. Because it is a single lag, its fastest rate of
change is when it starts to respond.
The model has a delay longer than the process, then must change rapidly to catch up to
the process. The model rises above the process in the 158-162 time period, then relaxes
to the final steady state value a bit slower.
This model best balances the + and - deviations from the data.
Mathematically, the model could be stated
as an ordinary differential equation.
The model gain, K m, is the multiplier for

the influence change that determines the new
steady-state value for the PV. The FOPDT
model pretends that once the delay duration,
m , has passed, the PV follows a first-order exponential trajectory to the final steady-state
value. The FOPDT time-constant, m, is an
indicator of how fast the PV moves toward the
new value. In contrast to some conventions,
I used the subscript m for model, not the
subscript p for process, to acknowledge
that the model is not the process. I explicitly placed a squiggle hat over the model re-
develop your potential
1.2
50
1.0
60
40
.081.2
50
30
.061.0
40
20
.04.08
Input(s)
60
30
10
.02.06
20
0
0
20
40
10
0
SKYLINE
PATTERN
0
20
40
60
Time
60
Time
80
80
100
0 .04
120
.02
100
0
120
Figure 2: Nonlinear least squares regression is simple to implement

and a skyline input function has advantages in duration, upset size and
42
number
of excitations.
41
20
39
42
38
41
37
20
36
39
35
38
34
370
Response Response
lieve reaction curve techniques dont express

best practices in the computer era.
However, a crude approximation FOPDT
model is oftern all thats needed. In such cases, a
reaction curve technique can be a simple and fast
method to get a good-enough model.
The reaction curve technique asks you to
make a step-and-hold change in the process input, from an initial steady state, and hold the
input until the response variable levels to an
ending steady state. Unfortunately, noise and
drifting alternate influences confound the response. And, a single step pushes the process
away from a desired setpoint. Further, a push
to one side of a nominal value will misrepresent nonlinear aspects. So, for effective reaction
curve tests, we often use an up-down-down-up
pattern in the influence step-and-hold values.
This generates four reaction curves, and their
average can temper the influence of noise and
disturbances. Further, the pattern explores both
sides of the original manipulated variable (MV)
value, making compensating upsets and, ideally,
returning the process to the original value.
These steps must be large enough to make a
noticeable change in the response. If the change
is small relative to normal noise and drifts, then
the FOPDT model coefficients will have a large
uncertainty.
Once the response curves are completed, the
model coefficients are calculated from a few
points on the response curve. There are multi-
Input(s)
PV
PV
sponse variable, (t), to indicate that its the model, not ple twists on the method.
Howver, this approach requires operator attention for
the process. And, I used the prime mark to indicate that
an
extended time to wait for four steady-state periods;
the model influence, response and time are each a deviamay
create process deviations that impact downstream
tion from the initial steady conditions as well as the time
75
quality; requires the human to interpret the signal to pro70
for the step-and-hold influence. In figure 1, the change
65
vide data for the mathematical analysis; only uses a small
happens at a time of 155. Although t = 155, at that instant
60
part of the data generated; and can be substantially con75
t = 0. Similarly, the initial process value is y = 37, but the
55
70
founded by uncontrolled disturbances.
50
deviation value is y = 0.
65
45
In the computer era, by contrast, nonlinear least squares
Although the concept for the model is a response to 4060
a
regression
is simple to implement, and a skyline input
55
step-and-hold influence from an initial steady state, and
35
50
function has advantages in operational duration, magnithough this makes for convenient analytical solutions, 30it
45150
155
160
165
170
tude of upsets,
and number
of excitations
over classical
is a generic model, and not so restricted when solved with
40
Time (step-and-hold happened at 155)
methods. A skyline pattern in the controller output could
35
numerical methods. And, though the model can be equiv2.
alently stated in Laplace or z-transform notation, I wont!30 150look like Figure
155
160
165
170
The nonlinear regression method seeks to fit the model
The classic textbook method to generate FOPDT modTime (step-and-hold happened at 155)
els is the reaction curve technique, a pre-computer era to all data points, not just the selected several points in
method. Its simple to understand and implement, and it a classic reaction curve fit. So, it better reject noise and
can be derived from the analytical solution of the ODE, disturbances.
The skyline and regression method does not require
so it serves the current content of undergraduate engioperator attention or judgment, which lessens the posneering education appropriately. However, I be-
20
40
36
60
Time
80
100
120
35
34
20
40
60
Time
80
100
120
SKYLINE RESPONSE
Figure 3: The data (dots) and best FOPDT model (solid curve) from the
input sequence in Figure 2 for a pilot-scale process flow rate shows
that the model is not perfect, but is a very good representation of the
process dynamics.
47
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48
develop your potential
Though the model can be

equivalently stated in Laplace
or z-transform notation, I wont!
sibility for operator error or bias. And the skyline input
has many ups and downs, which tempers the influence
that environmental drifts have on confounding the CV
response to the MV. The skyline and regression method
does not extend the period of off-nominal production as
each + or - period is shorter, creating less objection
by a quality manager. The skyline and regression method
does not require an initial steady state, and the entire test
period takes less time.
For a nonlinear process, gains, delays and time-constants change with MV and CV. The FOPDT model is
linear, and may not provide a great match to the process
over a wide operating range. Just because the optimizer
converges on a best model, doesnt mean that the model
actually fits the data. So, after the regression, see if the fit
is satisfactory for your model-use purposes.
Figure 3 reveals the data and best FOPDT model from
the input sequence in Figure 2 for a pilot-scale process
flow rate response to controller output. The model is the
solid line, the data are the dots. It should be noted that
early-time data is usually below the model, but late-time
data is usually above. Perhaps some drifting influence was
affecting the data.
In addition, note the kinks in the model at times a bit
after 80 and 100. These are expected responses to small
changes in the MV at those times, but these are not expressed in the data. Perhaps valve stiction prevented the
valve from moving, even though the MV made changes.
Finally, this data is not expected to be a linear response.
Although the linear FOPDT model does not perfectly
match the data, its also a very good representation of the
process dynamics.
My Excel/VBA file for generating FOPDT models is
posted at www.r3eda.com. It also offers a user guide to
generate skyline data, use the software, and explain the
nonlinear regression procedure. The VBA code is open.
My entire academic career has been devoted to enabling
students with best practices in engineering. Im using the
web site to extend beyond the classroom. I hope you find
it useful.
Russ Rhinehar t, principal, the R3 Co., was head of the School of Chemical Engineering at Oklahoma State University, president of the American
Automatic Control Council, and editor-in-chief of ISA Transactions. For
more information, visit www.r3eda.com.
ASK THE EXPERTS
How to determine open-loop gain?
Pressure
This is for tuning a control valve on a

pipeline. In an open-loop gain test, with
Pump curve (P1)
a step increase applied to valve opening,
the controlled parameter increases, then settles at a number. In this case, flow increased
and then decreased to settle at x number. To
P1@35%
P2@48%
calculate my Tc, should I use the peak value
that PV (flow) reached or the final value that
System curve (P2)
it settled at? If I use x, then 63% of PV happens much sooner.
Flow (%)
Our control valve impacts all three: flow,
20
25
30
35
40
valve inlet (suction) and discharge pressure.
The flow and discharge pressure controllers
PIPELINE SYSTEM
are reverse acting, and the suction pressure
signal
controller is direct acting. After a step change Input
Figure
1: When flow is stepped from 35% to 40%, P1 and P
to valve (%)
from 30% to 35%, flow increases and then de- drop, and P2 rises. This is because at a higher flow, the pipe
40
creases to settle at a higher value than what friction
rises, leaving less P for the control valve.
A
it was before the change was made. My ques- 35
tion is: which number should I use to calcu- 30 In my answer, Im assuming that your
late K, Tp and Tc? If I use first peak for the setprocess fluid is being pumped through
25
Time
your pipeline by constant speed pump(s)
tled value, then my K and Tc will be higher.
0
Since after this peak the flow decreases, if I and that your goal is to keep the flow and the
use the final number, my K will be lower and up and downstream pressures at the control
Process
valve within the desired safe limits. Im also
hence Tc will also be lower.
(PV) that you want to tune the three
assuming
With everything descaled, my K using final variable
Flow (%)
so the one that will be in control
number for flow is 0.3425. Tp and Tc are near controllers,
the low2 sec. If I use the first peak, my K is 0.6225. will always be the one that requires
Overshoot
My Tp, of course, remains the same at 2 sec, est valve opening, and you want to use the
but Tc is 4 sec. This is liquid service. I will use open-loop method of tuning, which requires
lower numbers, so the loop is slower since our the knowledge of the process gain.
In my answer, I will t
briefly discuss both the
process is not that fast.
B
In this case, I could only do two step tests. process and the process gain determination.
B1=63%B
a pipeline
Usually, I do the step test by starting from fully Figure 1 shows the system curve of
open, so I also get a full valve profile. These and the pump curve of a constant-speed pump.
Time
have been good starting point numbers based When you step up the flow from 35% to 40%, P1
0 and P2
td rises. This
t63% is because at a
on Ziegler-Nichols or GEs ideal tuning ap- and P drop,
This column is moderated
proach. GEs tuning approach formulas are: higher flow, the pipe friction rises, leaving less
by Bla Liptk
Kp gain = 2Tc / (3KTp) %/%. Ki = Tc rep/sec P for the control valve. By applying the low-se(http://belaliptakpe.com/),
automation and safety
and Kd = Ki/4. I did not use D since it is liquid lecting envelope on the three variables (F, P1
consultant and editor
service. Of course, I adjust them in closed loop and P2), youre maximizing flow while protectof the Instrument and
with observation during setpoint changes. Units ing the pipe from excess pressure, which might
Process gain:
K = B/A
cause leakage. In my view, this goal could be
used in GE block were also important.
Automation Engineers
The second step is from 35% to 40%. 0.9A
I more elegantly accomplished if you used a variHandbook (IAEH). If you
Proportional Gain P =
have your handbook, and have referred toB.td.t
it able-speed (instead of constant-speed) pump,
have an automationalready. By the way, we use low select at the and just throttled the speed, thereby eliminatrelated question for
IntegralsoTime
I = saf3.33tding both the control valve and the associated
three separate PID outputs,
the lowest,
this column, write to
waste of energy represented by the pressure
est output controls the valve.
liptakbela@aol.com.
drop
through
it.
HITEN A. DALAL, hiten_dalal@kindermorgan.com
49
P
System curve (P2)
Pressure
Ask the Experts

20
25
P1@35%
30
35
40
Flow
(%)
P2@48%
System curve (P2)

Input signal
to valve (%)
20
40
Please note that Im using the standard terminology

for the various parameters in the
25
30
35
40
bump
test:
A
A: Test input
35
B: Test output
Input30
signal
I: Integral gain setting of controller
to valve
25 (%)
Time
K: Process gain
0
40
P: Proportional gain setting of controller
A
35
R r: Reaction rate
DEFINITION OF A
30Process
td: Dead time
variable (PV)
: Time constant (defined as t or as K/R r)
Figure
input signal
25 2: For an open-loop test, A is the change ofTime
Flow (%)
For tuning the controllers, you can use
to the valve. 0
Chapter
2.35 in the 4th edition of my handOvershoot
book, where some of the most common controlProcess
ler tuning constant and control mode setting
variable (PV)
recommendations are presented. On flow and
Flow (%)
t
pressure applications, we usually end up with
B
Overshoot
control mode values in the ranges listed below:
B1=63%B
%PB = 50 to 500
I = 20 to 200 repeat/min.
Time
D = None
t
Flow (%)
td
t63%
BLA LIPTK, liptakbela@aol.com
B
B1=63%B
Time
0
Process gain:
td
t63%
K = B/A
BUMP TEST REACTION CURVE
0.9A
Proportional Gain P = B.td.t
Figure 3: Where A is the valve signal change (Figure 2) and B is
Integral Time
Process gain:
the flow change, process gain K = B/A, proportional gain P =
I = 3.33td
K = B/A0.9A/Btdt, and integral time I = 3.33td.
0.9A
Proportional Gain P = B.td.t
If you experience an
Integral Timeovershoot
I = 3.33td
(which
you do), it can be

caused by wrong
valve characteristics,
sticking valve
or other causes.
50
Now, coming to the bump test (Figures 2 and

3), if youre interested in the open-loop gain (K)
of a linear process (such as a linear flow control valve on a pipeline), then you calculate it
by the ratio B/A: K = B/A = (% change in flow
after reaching steady state) / (bump size in % of
full stroke).
In other words, the process gain is based
on the final PV value. If you experience an
overshoot (which you do), it can be caused by
wrong valve characteristics, sticking valve or
other causes. In any case, we dont consider
the overshoot in the determination of K, but
try to eliminate it. When bump testing, I
would make the step change in both directions, to make sure that K also remains unaffected when you apply the step to reduce the
valve opening and therefore the flow.
www.controlglobal.com N o v e mb e r / 2 0 1 6
In addition to the various instrumentation reasons mentioned by Mr. Liptk,

you have to consider that your flow is
coming from a pipeline. This effect would be
more pronounced if it was a gas service.
This means that the line resistance is developed over a length of pipe. Initially, if the
pipe carries gas, the pressure in the pipe section nearest to the gas source will be high,
but as the flow establishes over the whole pipe
work, as the flow (and pressure drop) rises,
the pressure will drop at the inlet of the valve
(compared to the pressure before making the
step change by step-opening the valve).
If you check the pressure just upstream of
the valve, you should see the pressure drop
(corresponding to the lower flow). Im not
sure if in your case this is significant enough
to be considered for the tuning.
Generally, flow loops are fairly straight forward and default parameters are adequate. The
only issues Ive found for flow tuning concerned
the characteristics of the valve: linear or equal
percentage (EQ%), i.e., if the valve characteristics dont match the flow range of interest.
However, I have not done a lot with pipelines
and there may be additional issues.
SIMON LUCCHINI, Simon.Lucchini@fluor.com
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automatically push data to the cloud,
and its Wise data logger can send timestamped data to a Dropbox account. A
private-server function lets Wise modules push data to a web server via the
RESTful web service and MQTT protocol with WebAccess.
Advantech Corp.
888-576-9668; www.advantech.com
The reActionOn module for

ultra-fast safety applications
achieves safety response times
down to 100 s. This makes it
possible for time-critical subprocesses to be executed directly in I/O modules, which
reduces response times by 100
times or more. No expensive special hardware is needed to
use reAction, and programming is as easy as for conventional controls.
B&R
www.br-automation.com
CONTROL EXCLUSIVE
Easy, reliable, safe level measurement
ust as you cant have too many

Vibrating-fork detector
friends, level measurement cant
Hessel reports Rosemount 2140
get enough ease of use, reliabilcombines proven-in-use Rosemount
ity and safety. These three priorities
short-fork technology and the HART
drove development of Emerson Autofunctionality of the wireless Rosemation Solutions new SIL 3-capable
mount 2160 to create a new wired
Rosemount 5408 Series non-contactsolution. It complements the coming, radar level transmitters for continplete 2100 portfolio, but 2140 is a new
uous measurement and its worlds first
product designed for SIS and control
Rosemount 2140 vibrating-fork, liqapplications where HART is used.
uid-level detector with wired HART
Unlike 2160, 2140 includes proof testfor point-level measurement, as well
ing and smart diagnostics.
as its dedicated Rosemount 5408:SIS
Rosemount 2140 performs in
and Rosemount 2140:SIS models for
high temperatures and harsh condisafety instrumented systems (SIS).
tions unsuitable for other level deRosemount 5408 incorporates
tectors, and its easy to install and
human-centered design to simplify
maintain because there are no movLEVEL-HEADED LEVEL MEASUREMENT
operator tasks. Pictorial instructions
ing parts. Its virtually unaffected
and an intuitive software interface Rosemount 5408 Series non-contacting, radar
by flow, bubbles, turbulence, foam,
guide users, while on-board diagnos- level transmitter for continuous measurement and liquid properties and product variatics support preventive maintenance. Rosemount 2140 vibrating-fork level detector with tions. It can be used to monitor not
Rosemount 5408 can also perform wired HART for point-level measurement.
only liquids, but also liquid-to-sand
proof-testing and site acceptance tests
interface, which can be used to deremotely. In a departure from traditional pulsed-radar devices, tect build-up of sand or sludge deposits in vessels such as
Rosemount 5408 employs two-wire, 12-Vdc, loop-powered, fre- separators. An optional LCD shows switch output states and
quency-modulated, continuous-wave (FMCW) technology.
diagnostics, allowing local inspection, or data can be viewed
Running two-wire FMCW with just normal 12-Vdc power remotely from a host system such as a DCS.
is a big game changer because we can now do level measureCompatible with HART 5 and HART 7 hosts, Rosemount
ments in places where they couldnt be done before, including 2140 enables continuous monitoring of electronics and mepotentially explosive environments, explains Andreas Hessel, chanical health with smart diagnostics. For example, the frestrategic product manager, process radar level measurement, quency-profiling function continuously monitors fork vibraEmerson. We built the microprocessor and other pieces for tion, and alerts if the instrument sees an unusual frequency
Rosemount 5408 from scratch, which really gives us radar-on- or detects a trend change in the frequency.
a-chip. This means we can do two-wire FMCW for more acRosemount 2140 is clever because its a wired HART decurate and reliable measurements because, instead of pulsed tector and not a switch, so it uses changes in frequency and
radar, it provides a constant stream of microwaves. With some vibration over time to determine if its forks are coated or corlimits due to individual settings, we estimate Rosemount 5408 roded, and alerts operators when it needs maintenance or
is 100 times more sensitive than pulsed, which means much before, adds Hessel. Whats fun about Rosemount 2140 is
more accurate and reliable measurements, even with interfer- it can still be used as a simple switch when needed.
ence from foams, turbulence and condensation in tanks.
For safety applications, the detectors dedicated safety verThe transmitters safety version, Rosemount 5408:SIS, is cer- sion, Rosemount 2140:SIS, is certified to IEC 61508, with
tified to IEC 61508 for use in a SIL 2 loop with redundant in- a 97% safe failure fraction and 96% diagnostics coverage,
strumentation required. This is the only level transmitter rec- making it one of the safest SIL 2 devices available. Roseognizing that overfill prevention and SIS integration is more mount 2140:SIS also has fully-integrated, remote proof-testthan a certificate, explains Hessel. Rosemount 5408:SIS can ing, which eliminates the need to access the top of a vessel
be used in any common-practice, SIL 2 safety loop, and its to extract the detector from the process.
proof-testing interval can accommodate one-, three- or even For more information, visit www.emerson.com/en-us/automation/
measurement-instrumentation/lev el
five-year turnaround times.
53
PRODUCT INTRODUCTIONS
54
METERING PUMP MASTERS DIFFICULT FLUIDS
VENT PREVENTS BLANKET OVERPRESSURE, VACUUM
Series MP7000 mechanical diaphragm metering pumps are as rugged

as hydraulic pumps without the potential for oil contamination. Oversized
check valves, straight-through flow
design and elimination of the contour
plate improve flow characteristics for
viscous, shear-sensitive and fluids with
suspended solids. Capacities range to
27 gph and pressures to 235 psi with
10:1 turndown. An optional automatic
speed control uses variable-frequency or SCR drive.
Neptune
www.neptune1.com
Model 1100 sanitary vent enhances

the VCI Model 1088 sanitary blanketing valve, operating at multiple
setpoints as a breather valve to avoid
vacuum or overpressurization. It has
a true sanitary blanketing connection and is available in 2-, 3-, 4- and
6-in. sizes, in 316 or 304 stainless
steel with a stainless steel weather
screen to prevent debris from entering the tank. Setpoint
range is 0.43 psi to 3.42 psi; vacuum is 0.069 psi to 0.385 psi,
depending on the size.
Cashco
785-472-4461; www.cashco.com
ALL-IN-ONE DEVICE SIMPLIFIES UPS
MEASURE OIL IN WATER QUICKLY, ACCURATELY
CBI uninterruptible power

supply (UPS) solutions
combine supply, charger,
battery care and backup
module functions in a single device. Real-time diagnostics continuously monitor battery status, charging levels, and emerging battery
faults. Available in 12, 24 and 48 VDC for multiple battery
types, they feature three charging levels (recovery, boost or
trickle), allow adjustment of charging current, and automatically distribute power between load and battery.
Altech
www.altechcorp.com
TD-120 oil in water monitor is

compact, responds in less than
1 sec., uses a remote flowcell
for easy switching of optical
configuration, and requires no
reagents or chemicals. It features extended dynamic range
(up to 6,000 ppm) with 1% accuracy, a touchscreen interface and 4-20 mA or optional
HART. A NEMA 4X/IP 66-rated 316 stainless steel enclosure and 316 wetted metallic parts are standard; other materials are available for marine applications.
Turner Designs Hydrocarbon Instruments Inc.
559-253-1414; www.oilinwatermonitors.com
DETERMINE CONDUCTIVITY HYGIENICALLY
SAFETY ANALYTICS SOFTWARE KEEPS EYE ON IPL
Memosens CLS82D four-electrode sensor measures conductivity from 1 S/cm

to 500 mS/cm and temperature from 23 to
248 F (-5 to 120 C) with 4% accuracy
0.2% repeatability. With 316L stainless
steel construction, electropolished surfaces, hygienic process connections and
IP68 protection, it can be sterilized in
place (SIP) at up to 284 F (140 C) for
clean-in-place (CIP) operations, and is
certified for EHEDG, FDA, 3-A and pharmaceutical applications.
Endress+Hauser
www.us.endress.com/cls82d
IPL Assurance provides

real-time predictive analytics on health and availability of safety instrumented systems (SIS),
alarm management systems, and other independent protection layers (IPL). It reports SIS performance
during demand; manages safety instrumented function
(SIF) performance, testing and maintenance; tracks status
of safety-related alarms; manages safety system bypass; provides a safety and operational risk dashboard, and more.
PAS Inc.
www.pas.com
C O N T R O L TA L K
How to succeed in career and system migration

Greg: Here we take advantage of the chance to
talk to Bill Thomas, who provides a great lesson on how to succeed in advancing capabilities
and opportunities in his career and the control
systems for which he was responsible. His career and the systems he improved are analogous
examples of the power of migration and the results gained from extra effort and dedication to
improvement. Bill is one of the early members
of the ISA Mentor Program. He is a very upbeat
and positive guy, who I have had pleasure of getting to know at ISA and user group meetings.
Stan: Bill, what has been your career path?

Bill: I started out as an electronics technician
in the Navy. When my enlistment was up, I
worked at a shipyard doing electronic repair and
retrofits on Coast Guard cutters. I started taking
classes at night working toward a B.S. degree in
electrical engineering.
After a while, I decided I wanted my degree a
little quicker, even though Id be poorer during
the process. I enrolled at Auburn University in
EE, and focused on power and controls. The
first year was pretty tough because, in addition
to the full course load, I also worked third shift
at a local saw mill, hoping to make ends meet.
This became my motivational factor in finishing the degree, even though I was struggling financiallyI felt that this type of job might be in
my future if I didnt get a degree.
Fortunately, after a year or so, I got a position
as a co-op at a paper mill. The co-op experience was great for me as I got to work in maintenance, in capital projects and with the automation group. With that experience, I knew that
I wanted to go into automation. Upon graduation, I went to work for a large consumer products company as a controls engineer. I worked
at their headquarters for eight years and at one
of their plants in Texas for another two years. In
2005, I went to work for 3M as a corporate engineer in the Process Information and Control
Solutions (PI&CS) group. Im presently living

in Alabama, and workng at the Decatur Plant.
Greg: What type of equipment?

Bill: I worked on automating web lines most of
my career, first doing narrow web lines for the
consumer products company and then a variety of wider lines for 3M. Some of these lines
travel at incredibly fast speeds. They were making around 1,000 products per minute. In the
past six years, Ive focused on chemical reactors
and the process industry. When I first came to
the chemical side of the site, there was only me,
a maintenance controls engineer and the project manager responsible for upgrading controls
and automation on all the chemical production units. I was lucky to work with those guys.
I dont think there is a control system that the
controls guy hasnt worked on or a problem that
he hasnt seen. We learned early that we were
GREG MCMILL AN
STAN WEINER, PE
controltalk@putman.net
Greg McMillan and

Stan Weiner bring their
wits and more than
66 years of process
control experience to
bear on your questions,
comments and
problems.
Write to them at
controltalk@putman.net.
Creatively invest your work ethic into new horizons and opportunities. For the top 10
reasons to migrate, see the online version at www.controlglobal.com/articles/2016/
how-to-succeed-in-career-and-system-migration.
55
C o n t r o l Ta l k
limited somewhat on the instrumentation side, so we convinced a retired 3M technician to give us a hand. He has
been with us ever since, and been instrumental in the success of our projects. Were now fortunate to have another
PI&CS resident engineer, an additional maintenance controls
engineer, and some technicians working on these systems.
Were responsible for the migration of about 20 reactors
and the tank farm. We decided on one controller per reactor
to maximize independent maintainability, since these reactors are going up and down. Weve completed over a dozen
of the reactors, and have about a half dozen to go. Each system can have 300-1,200 inputs and outputs.
Stan: What are some things you learned?

Bill: I was a programmable logic controller (PLC) guy, so I
had to quickly become proficient in the configuration and
implementation of a distributed control system (DCS). I
learned to standardize on a preferred, class-based library
of modules. I developed the ability to communicate better
with manufacturing engineers to make sure we get the right
functionality. I also developed a more structured methodology and better documentation in the front-end definition for
each reactor system.
Greg: What are some examples of communication needed?

Bill: In a vacuum system, we were asked to ramp down from
point A to B as fast as you can go. We did this, but the manufacturing engineer wasnt satisfied because the process variable could not keep up with setpoint, so we worked out a
compromise between speed and tightness of control. In another system, the speed of a heat-up cycle was specified, but
it was later determined that the cool-down cycle was also
critical. We needed to get creative.
Greg: Ive had process engineers ask to keep the process vari-
Greg: How did you use dynamic models?
able close to setpoint, but not move the manipulated variable.

The realization is lacking that you you cant make variability in
a loop completely disappear, and that you cant predetermine
flows as a function of time. The flows and compositions on a
process flow diagram (PFD) are a guide and arent to be taken
literally. Feedback control is designed to automatically correct
for the unknowns and disturbances, and can be tuned to provide the desired degree of transfer of variability.
Bill: We started out using simplistic tiebacks with VMware
Stan: Whats been achieved besides the elimination of ob-
on a laptop, but graduated to a workstation with Mimic.

This enabled us to get operators involved in the functional
testing of the control system. Four to six weeks before the
configuration needed to be finalized, we would do this testing to make improvements based on operator input.
solescence?
Stan: How did you contract out the work?

Bill: We split up the work between the local business partner
of our DCS supplier and some contract engineering firms,
keeping the most proprietary functionality in-house. If we
develop the ability to use source protection on the more sensitive details, we can send more outside.
Greg: How did you deal with skids?

Bill: We learned that we had to give model numbers and
performance specifications as well as manufacturer names
of the instruments we wanted. Otherwise, we would end up
with less reliable types and poor performance.
Stan: What is your general approach?

Bill: We never have time or money to do everything. We do
56
the best with what we have to get it to the customer on time.

New projects are more of a challenge in terms of a missing starting point. We help the customer understand automation is their friend and we can keep doing more in that
friendship. We make it an ongoing conversation.
Bill: Modernizing the control systems has led to better performance, principally by using signal selection and split range to
increase versatility, particularly in jacket loops. We also have
much more functionality and support available for the new
DCS. I really appreciate being able to focus on learning how
to get the most out of a new DCS rather than investing my
time getting by with an old DCS with no future.
Greg: What about your overall experience as an automation

engineer?
Bill: I feel lucky to having gotten into automation. Its like

Im building multimillion-dollar erector sets. I get to see stuff
working in action. The control system is the window into the
process and means of affecting the process. The dynamic and
visual impact is impressive. I look forward to seeing in 15-20
years how much will change. Ive gone from ladder logic, analog devices and 4-20 mA to function blocks, digital devices
and fieldbus in my career so far. At the end of the day, what
we do in automation is solve problems, and we get to see the
effect on the plant efficiency and capacity. Automation is a
challenging and rewarding profession.
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AD INDEX
11/11/11 9:53 AM
ABB6
Mac-Weld 32
Allied Electronics 10
Magnetrol International 14
ARC Advisory Group59
Moore Industries 25
AutomationDirect2
Omega Engineering48
AVG Automation 4, 5
Orion Instruments3
Baldor Electric 23
Pepperl+Fuchs,
PA Division28
Emerson Process Mgt/

Fisher 60
Emerson Process Mgt/
Rosemount27
Process Tech Sales

& Service 45
ProComSol 42
Endress+Hauser8, 9
Turck 33, 35
FCI 37
VEGA Americas 17
GE Digital 19
Wago 21
Load Controls 45
Yaskawa America 13
Control Report
Busy fall
Jim Montague
e xecutive Editor
jmontague@putman.net
Ignoring change is
actually a response,
of course, but its
not a very good
one, even though it
doesnt require
much effort..
58
s usual, and Im sure this is true for many of

you, this years autumn season has been a
frantic dash of work, deadlines, sleep deprivation, indigestion and suspiciously arthritic
stiffness. In my case, this means covering all
sides of the takeover by digital computing and
software of the process control industries and
apparently everything else. Its no stretch to say
that big data, cybersecurity, the Industrial Internet of Things (IIoT) and their permutations are
all part of the same upheaval.
I mostly write about success stories because
thats what people are willing to talk about,
even though problems and disasters make better and more instructive stories. However, with
an earthquake like the digital emergence, there
are plenty of snags, failures, restarts and other
wrenching changes. With shifts this big, theres
always some collateral damage.
Thats because we arent talking about
switching out a flowmeter, repairing an RTU or
even migrating a DCS. As challenging as those
tasks can be, depending on circumstances, they
still involve replacing known technologies with
other technically familiar solutions.
No, the rush to digital is the latest chapter in
at least two overarching evolutions from pneumatics to relays to PLCs to PC-based control,
and the parallel progression from point-to-point
hardwiring to fieldbuses to Ethernet and wireless. The difference here is moving from known
technologies to unfamiliar if not unknown
onesand digitals faster, cheaper and more
powerful software and microprocessors are only
accelerating its rise and march to critical mass
in process control and automation.
Of course, even though theyre glued to the
same smart phones and tablet PCs as their
neighbors, few process engineers can take comfort in digitals wide acceptance in mainstream,
consumer and business settings. In fact, digitals
freewheeling nature makes most process professionals more nervous because of the safety and
critical operating responsibilities they bear.
So, whats to be done? Because so many of

these shifts are pretty much inevitable, the only
solution is to make the best of it. This means
learning as much as possible to make digital
technologies safe, secure and successful in process settings. It means giving up prejudice and
denial, adopting the most useful parts of digital
technologies, and mitigating the irrelevant, unhelpful, wasteful or dangerous parts. Cybersecurity? Yes, please. Big data? Well see.
Ignoring change is a actually a response, of
course, but its not a good one, even though it
doesnt require much effort. Accepting change,
if not embracing it, and trying to work with its
details provides more options and possible opportunities. Plus, the comfort in this situation
comes from realizing this is how people cope
with every new technology and disruptive
change through history and in their lives.
Which brings me to elections. Im writing
this before 2016s contests resolve on Nov. 8. Im
not sure how any are going to go, and as a former newspaper person, I take polls with a huge
grain of salt. Like most folks, I prefer some candidates over others, and Ill be glad if the ones I
vote for win, and sad if they lose.
But what does anyone do after the smoke
clears and its time to pick up the pieces?
Whether it was a great wedding, holiday or celebrationand especially if it was a bad or even
tragic eventsomeone still needs to wash the
dishes, change the diapers and pay the bills.
Those chores are always waiting for mom, dad
or some other responsible person to get them
done. Likewise, I also remember that once election hoopla is over, the routine budget meetings
will begin again, and few if any taxpayers will
show up to help the elected officials shop smart
for the necessities we buy as a community.
As usual, our responses to DCS migrations,
digital technologies, big data, cybersecurity,
IIoT, elections, dishes and diapers are pretty
much the same. Win or lose, its time to do
some chores.
My unit is down again. Perfect.

These cheap valves just dont hold up.
I need reliable technology to keep running
24/7/365no surprises
YOU CAN DO THAT

Emersons industry leading Fisher easy-e control valveavailable in NPS 1
thru 36provides users with high performance and proven reliability. The easy-e control
valve continues to evolve, bringing you innovative and reliable technology to help solve your
toughest challenges. All valve designs undergo rigorous lifecycle testing, so you dont have to
worry about your unit going down unexpectedly. Dont trust your process to replicated valves.
Use the Fisher easy-e control valve to keep your operation running. Day and night. To learn more,
visit www.Fisher.com/Reliable
The Emerson logo is a trademark and service mark of Emerson Electric Co. 2016 Fisher Controls International LLC. D352205X012 MBB104

CNT 2016 11 01

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november 2016

The eXact I/O you need

eXactly where you need it!

Xpansion I/O has never been so practical

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

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Can selecting the right I/O save you money?

Selecting the right combination of digital fieldbus, hardwired and wireless

ABB Process Automation Division

November 2016 Volume XXIX Number 11

How to manage new information streams,

measure & manipulate

38 / Cybersecurity in the SIS world

43 / Motors & drives make magic

Find and slay the dragons lurking in typical

Innovation, intelligence and networking bring motion

The Next Level of Innovation.

Experience the future. Here and now!

The worlds rst 79 GHz high accuracy

Endress+Hauser presents: The Micropilot NMR81.

November 2016 Volume XXIX Number 11

Our most recent, valuable and popular

You can do intrinsically safe wireless,

Controlling the smart cars, part 2

Control at the edge, revisited

Emerson, Yokogawa user groups meet;

Information to do your level best

46 / Develop your potential

49 / Ask the experts

How to determine open-loop gain?

Terminal terminusand I/O

Easy, reliable, safe level measurement

Selections from our editors inboxes.

Success in career and system migration

Find out more about

Electric, Gas & Sanitary Services

Take control at thinkallied.com/relays

nce upon a time, not so long ago and for

Its high time to upgrade systems

The key to better decisions isnt just more data;

A market analysis by ARC Advisory

NERC CIPs continue to expose the grid

BLOG & NEWS

he latest critical trends in I/O systems take

The rise of configurable I/O

Pepperl+Fuchs acquires ecom

Industrial computers field guide and resources

White Paper Alerts

Industrial computers, PCs and many of their

Industry change doesnt just happen

30+ Million Pieces of Evidence...

For more info:

DRIVES & MOTION DIVISION

Protect your plant with Echotel

magnetrol.com 800-624-8765 info@magnetrol.com

2016 Magnetrol International, Incorporated

IN MEMORY OF JULIE CAPPELLETTI-LANGE,

Columnists: BLA LIPTK, GREG MCMILLAN,

design & production team