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Contents
A4 Using diagnostic functions
to improve system safety
Some diagnostic capabilities are built into smart instruments, while others
are designed into a process.
A10 Specifying industrial enclosures
Ask these 10 questions before specifying or modifying industrial enclosures
to optimize your operation.
A14 Ensuring effective decision support in a crisis
Machines can support humans when facing a stressful situation. Using a stan-
dards-based approach can reduce the likelihood of a problem escalating.
A20 Automation products
C OMMENT
Of safety, protection, and crisis management
I
f you think about it, safety is implied through-
out this entire issue of AppliedAutomation
safety for processes, equipment, and from
disasters.
In the cover story, the author addresses safe-
ty issues by advocating diagnostics. He writes:
Among the best practices and technologies
available today are diagnostic functions built
Jack Smith into smart field instruments that are capable
Editor of identifying covert failures as they happen.
Using diagnostic functions to improve system
safety, the author explains how to make temper-
ature sensors smarter and safer, and spot tricky
thermocouple failures and leaking rupture disks.
In addition, he discusses adding diagnostics to
the physical protection layer.
In manufacturing, so much emphasis is
placed on sophisticated equipment that its
easy to overlook the enclosures in which this
equipment is mounted. The second article asks
10 questions that should be considered before
specifying or modifying industrial enclosures.
ON THE COVER Online, non-intrusive corrosion/erosion monitors provide a continuous measurement of wall thickness. Watching the rate of metal loss
over time can help predict time to failure. Courtesy: Emerson Automation Solutions
A4
A10
Industrial enclosures are essential for hous-
ing and protecting wiring and cables, electrical
equipment, and machinery controls. Theyre
also effective protection against radio and elec-
tromagnetic interference and other uncontrol-
lable environmental elements such as direct
sunlight, the author writes.
The third article presents a topic that isnt
often discussed, but should be: crisis man-
agement. And it begs the question: What role
should humans play in avoiding disasters? The
author advocates a standards-based approach.
He writes: Arguably, the most advanced deci-
sion support systems may be found in the
aircraft industry. But even these can go wrong
sometimes, and it comes back to the skills and
training of humans to avoid potential disasters,
aided by a standards-based approach.
And as the author concludes: So, maybe
there is a balance between humans and
machines that can ultimately make all of us
safer. Lets try to find it.
Applied Automation June 2017 A3
 C o v e r s t o ry

Using diagnostic functions

to improve system safety
some diagnostic capabilities are built into smart instruments, while others
are designed into a process.

By Mark Menezes Making temperature sensors smarter and safer

Emerson Automation Solutions Many temperature measurement applications suf-

E
ffective process automation systems depend
on many types of field devices, controllers,
and networks to provide basic control func-
tions along with safety-instrumented functions.
Unfortunately, all these systems can fail in a
variety of ways, allowing problems to develop
or escalate if not countered quickly and effectively.
Users cannot assume failures simply dont happen, so
they must make appropriate plans for how to deal with
these possibilities.
Among the best practices and technologies avail-
able today are diagnostic functions built into smart
field instruments that are capable of identifying covert
failures as they happen. This improves safety, and also
can predict failures before they happen, improving avail-
ability. In other cases, a plant may design its own diag-
nostic, adding devices such as pressure relief valves,
rupture disks, and corrosion/erosion monitors in critical
places to watch for larger things going wrong. Lets con-
sider all three approaches.
fer from electrical noise, spiking, and signal dropouts.
Noise can come from radios, motors, and lightning.
Other problems can be caused by wiring problems,
mechanical shock, or vibration. Temperature measure-
ments are more susceptible than most other field instru-
ments because the sensorsresistance temperature
detectors (RTDs) and thermocouples (TCs)provide
very low-amplitude signals that must then be processed
and amplified by the transmitter before being sent to the
logic solver. For example, the signal strength of a TC is
about 1/400th the strength of the 4-20 mA signal pro-
vided by the transmitter. For this reason, best practices
suggest locating the transmitter as close to the sensor
as possible, minimizing the length of the lead wire
(see Figure 1).
Even with close coupling between sensor and trans-
mitter, noise or dropouts still can be problematic in
some installations, so most users apply damping to
suppress spikes and dropouts. While damping improves
stability, it slows down the response of the transmit-
ter to rapid changes in process temperature. Because
redundant sensors typically are exposed to the same

Figure 1: Temperature transmitters provide critical signal processing functions for temperature sensors along with diagnostics, and come
in many shapes and sizes to satisfy any application. As shown here, the Rosemount 248 temperature transmitter is available in a variety
of form factors, both wired and wireless. All graphics courtesy: Emerson Automation Solutions

A4 June 2017 Applied Automation

electrical and physical conditions, most users will set
the same damping for all, so this slow response is a
common cause.
A better approach is to use a signal validation capabil-
ity built into a transmitter as part of its signal processing
and diagnostic functions. The thermal inertia of a tem-
perature sensor inside a thermowell makes extremely
fast temperature changes, such as from 200C (392F)
to 400C (752F) in half a second, physically impossi-
ble. Even if the transmitter sees such an instantaneous
and unrealistic shift between successive readings, it can
reasonably assume the change is a spike (or dropout
if the change is moving lower), and simply repeat the
last good measurement. This approach provides stabil-
ity without damping or slow response, but it should not
be applied where the measurement can legitimately see
fast full-scale excursions.
Although a sensor can be damaged by a single extreme
mechanical shock, most failures are caused by ongoing
vibration, loose or corroding connections, or chemical
attack. These weaken the sensor and wiring, causing
the frequency of spikes and dropouts to increase over
time. The transmitter can detect and trend this increasing
frequency and predict impending failure, alerting mainte- Figure 2: Users need to monitor the space between the PRV and the
nance early enough to take action and prevent total signal rupture disc to ensure no build-up of back-pressure. Use of a wireless
loss. Signal validation digs more deeply into the condition pressure gauge minimizes lifecycle cost.
of the sensor itself, which can improve both safety and
availability of temperature measurements.
perature. But transmitters also can use their resistance
Spotting tricky TC failures measuring circuitry, which would be used with an RTD, to
Heres a typical application where validation can predict monitor the resistance of the TC. While resistance of the
sensor failure. In hydrocarbon processing applications, TC cannot be used to determine temperature, it does help
TCs are often preferred over RTDs when fast response to detect and predict failures.
or high temperatures (greater than 600C or 1,112F) are Changes in TC circuit resistance can suggest several
involved. TCs are typically more physically robust than things. If resistance goes to infinity, the circuit is open. If
RTDs, but they can fail in a way not readily apparent. The resistance decreases from its normal level, there is prob-
junction at the tip where the dissimilar wires are joined ably a short circuit. If resistance increases, the wire or
is the measuring point, but if physical shock or vibration termination is probably corroding. These changes may be
breaks down the insulation and the two wires form a con- immediate, but more often theyre gradual, so measuring
tact (short circuit) somewhere else, the new contact point and trending resistance changes can be used to predict
becomes the measuring point, wherever it might be. failure and improve availability.
Because this new junction is invariably farther from
the hot process, in most hydrocarbon applications, a Adding diagnostics to the
damaged TC will read low, although the opposite is true physical protection layer
in cryogenic applications. Most processes are danger- If both the basic process control system (BPCS) and
ous when they run too hot, so a low reading can create safety instrumented system (SIS) fail, a plant relies on
a safety risk. Because one physical shock could dam- physical protection to reduce the consequences of an inci-
age multiple TCs designed to be redundant, especially dent to employees and the community. As with the BPCS
when they are installed close to each other or the lead and SIS, for each hazard the user must identify and quan-
wires are routed in the same bundle, this problem can tify the risk of a physical protection failure, and must apply
manifest itself as a common cause. best practices and technology to minimize the possibility of
Modern smart temperature transmitters are configurable it happening. For example, in the case of an over-pressure
to accept either RTD or TC inputs. When configured for event, most hydrocarbon and chemical processing plants
a TC, they use their voltage circuitry to determine tem- rely on pressure relief devices for physical protection, such

Applied Automation June 2017 A5

 C o v e r s t o ry

as pressure relief valves (PRVs) and Users in hydrocarbon New instruments combining acous-
rupture discs. tic and temperature sensors capable
The PRV is set to open when the of capturing telltale sounds from mal-
process pressure approaches the and chemical plants often functioning valves can identify direct
safe limits of the process equip- releases as well as ongoing leaks
ment or piping, with the excess from incomplete valve seating. Such
pressure typically vented to the
install a rupture disc just devices can be wired, or can com-
flare. It has the highest pressure municate via WirelessHART, in either
setting and should only work if all upstream of the PRV. case, sending data to the BPCS.
the other safety instrumented func- PRVs often simmer, releasing small
tions fail. Excess flaring causes amounts of product, before pressure
environmental impacts, usually resulting in penalties. reaches the full release point. An acoustic instrument can
Although the PRV will close itself after the pressure detect simmering, providing operators with another indica-
returns to a safe condition, it is common for dirt in the tion of a possible developing incident, and giving them
process fluid to prevent it from fully re-seating, leading time to call for maintenance, or to make a process adjust-
to small, ongoing leaks. These leaks are often difficult to ment and avoid the release entirely.
detect, yet over time can cause significant process loss
and environmental impact. Because PRVs are mechani- Spotting leaking rupture disks
cal devices, there are no electronic elements capable of Users in hydrocarbon and chemical plants often install
providing diagnostic functions. But as smart transmitters a rupture disc just upstream of the PRV. In the case of a
can improve performance of temperature sensors, new toxic or hazardous fluid, the rupture disc provides a more
devices can add diagnostic capabilities to these simple positive barrier and layer of protection to minimize the risk
but critical physical protection devices. of PRV leakage. Where the process contains a corrosive
fluid, only the rupture disc is normally wetted. This means
the plant often can avoid having to install an expensive
PRV made from a corrosion-resistant material. Only the
rupture disc has to be made from an exotic alloy.
Unfortunately, this approach creates another risk (see
Figure 2). If a small pinhole leak appears in the rupture
disc, any leaked fluid will be trapped between the rupture
disc and the PRV. This creates a backpressure on the
outside of the disk, so instead of bursting at the design
pressure, the disc will not burst until the rising process
pressure can overcome the disk and the pressure between
the disk and valve.
Under these conditions, the burst pressure may
exceed the safe design limit of the process, risking an
uncontrolled and potentially catastrophic release into
the environment. To prevent this, the American Society
of Mechanical Engineers (ASME) recommends install-
ing a pressure gauge or instrument between the rupture
disc and the PRV to monitor the pressure in the space
between the devices. This can be a wired device, but
given that these are typically located in physically inac-
cessible, hazardous, or toxic environments, such loca-
tions are particularly well suited to wireless devices.

Online corrosion/erosion monitoring

Figure 3: Online, non-intrusive corrosion/erosion monitors provide
a continuous measurement of wall thickness. Watching the rate of
metal loss over time can help predict time to failure.
Users in hydrocarbon processing industries under-
stand where their processes are corrosive or erosive.
Engineers carefully design piping and other mechani-
cal systems to last at least until the next scheduled
outage. In the meantime, expected corrosion/erosion
hotspotsfor example, on the outside elbows of
pipesare manually inspected, annually or more often.
Unfortunately, the rate of corrosion or erosion on a

A6 June 2017 Applied Automation

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 C O V E R S T O RY

HART diagnostics from safety systems

T
he control and monitoring systems in many control system (DCS). The hardwired link is usually
plants only use the 4-20 mA analog signal from Modbus or Ethernet.
their HART devices, missing out on the value The wireless adapter shown in Figure 4 has been
provided by the HART information. This is particularly evaluated by Exida as a component and has an
true for smart instruments and valve actuators used FMEDA report available online. It does not affect the
with safety systems, which send analog loop, and therefore has
their analog signal to a dedi- a minimal effect on SIS loop cal-
cated logic solver, meaning valu- culations.
able process variables and con- A limitation for using wireless
dition diagnostics never make it adapters in SIS loops has been
back to the control system. the availability of different types
But there is a solution, as of certifications for the device,
many users can access the which in the past was only
HART information in their safety Figure 4: Wireless adapters, such as the intrinsically safe (IS). The wire-
THUM from Emerson, can send HART data
devices by outfitting their exist- less adapter in Figure 4 now
via a wireless network, and the options
ing sensors and actuators with is rated for use in hazardous
for users to deploy them in hazardous
wireless adapters. These adapt- areas in North America where
locations grow as the availability of haz-
ers connect to HART devices the explosion-proof method of
ardous ratings increases.
and communicate variables and protection is used. The adapter
diagnostics via a WirelessHART connects directly onto HART
network. The adapter converts a wired HART input devices via a threaded conduit, creating a rated
to a WirelessHART output, and this wireless signal is assembly. This new explosion-proof certification is
sent to a gateway through a WirelessHART network. especially useful in SIS applications where it can be
The gateway is hardwired to the target system, such used to access stranded variables and diagnostic
as an asset management system or a distributed data from safety systems.

given asset is not easy to predict and can vary widely
day-to-day due to changes in flowrate, fluid composition,
temperature, pressure, use of corrosion inhibitors, and
other conditions. The risk to a user is that a faster-than-
expected rate of metal loss can lead to a catastrophic
loss of containment over a relatively short period of
time, even days or weeks.
A better approach than periodic manual inspection is
continuous online monitoring. Available in either wired
or wireless versions, online sensors attached to the out-
side of the pipe or vessel use ultrasonic technology to
measure metal thickness continuously. Historical data
determines the rate of metal loss and expected time to
failure. While a small number of corrosion/erosion sen-
sors provide immediate safety and labor benefits from
reduced need for manual inspection of hot spots, the
real payback comes when a user combines a network
of wall thickness sensors with other sensors to measure
and predict fluid corrosion/erosion, including intrusive
coupon-based sensors, temperature (intrusive or clamp-
on), pH, flow, pressure, and others (see Figure 3).
Comprehensive, plant-wide visibility and corrosion/ero-
sion prediction allows users to operate more aggressively
without increased risk:
 Extends time between shutdown intervals
 Reduces use of corrosion-inhibiting chemicals
 Increases capability to use opportunity crudes, lower-
cost but more highly corrosive/erosive feedstocks.
Diagnostic functions, whether they are built into a
smart device, or something designed within a given
plant, help detect problems early while they are still
easy to manage. Discovering that a TC is quietly cor-
roding before there is a loss of operation, a PRV is
headed toward failure before a more catastrophic inci-
dent, or a pipe is about to start leaking, can prevent
downtime, avoid environmental damage, and prevent
fatalities. There are many ways to put these measures
into place, provided a plant is willing to make the criti-
cal first steps.
Mark Menezes manages the Emerson Automation
Solutions measurement business in Canada, including
pressure, temperature, level, flow, and corrosion. He has
a chemical engineering degree from the University of
Toronto, with an MBA from York-Schulich. Menezes has
20 years of experience with Emerson, and 27 years of
experience in process automation.

A8 June 2017 Applied Automation

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 I n d u s t r Ia l e n c l o s u r e s
Specifying industrial enclosures
ask these 10 questions before specifying or modifying industrial enclosures
to optimize your operation.
By Steve Sullivan
Rittal Corporation
M
achinery and equipment are the life-blood
of any industrial or manufacturing opera-
tion. But these assets run because of the
industrial enclosures deployed throughout
the facility to house and protect the opera-
tional controls that make them function.
Industrial enclosures are essential for housing and pro-
tecting wiring and cables, electrical equipment, machin-
ery controls, and more. Theyre also effective protection
against radio and electromagnetic interference and other
A10 June 2017 Applied Automation
uncontrollable environmental elements such as direct
sunlight and heavy rain. For these reasons, plant manag-
ers in oil and gas, material handling and packaging, and
food and beverage industries rely on the controlled envi-
ronment of enclosures to protect their equipment from the
elements and keep their operations running smoothly.
10 things to know before specifying
or modifying enclosures
Because of the critical role that industrial enclosures
play across so many industries and in so many environ-
ments, its important to specify and modify enclosures
for specific environments and controls. A one-size-fits-all
approach will not work and could jeopardize important
equipment.
Sometimes, knowing what questions to ask before spec-
ifying and/or modifying industrial enclosures will save time
and money, but more importantly, will improve protection
and ensure uptime. Following are 10 critical questions for
your specifying team to consider, as well as your suppliers
for industrial enclosures or enclosure systems.
1. What is the application? Its crucial to map out
the function the enclosure or enclosure system will serve
in your facility. For example, if the enclosure serves as
an electrical drive house, it will be important to know if
it should be modified with multiple doors, a power dis-
connect, or multiple panels. You also may want to know
whether the enclosure needs to be populated with busbar
power or other accessories (see Figure 1)
2. Into what type of environment will the enclosure
be going? Using NEMA and UL ratings ensures that the
enclosure will stand up to the contaminants, moisture,
and particulates of indoor and outdoor environments. For
example, food and beverage environments will require fre-
quent wash downs with harsh chemicals, while oil and gas
operations may require protection from salt water
(see Figure 2). Another consideration is the extremes of
hot, cold, and humidity to which enclosures and systems
will be exposed.
Figure 1: The use of busbar for power management can improve
internal layout design to maximize space and reduce costs. All
graphics courtesy: Rittal Corporation
Figure 2: Stainless steel enclosures are optimal for harsh environ-
ments such as food and beverage that use harsh chemicals for
frequent wash downs.
3. What are the space restrictions outside the
enclosure? Facility managers want to fit the maximum
amount of equipment in the smallest amount of space.
Space factors to consider include where the machinery will
be located, aisle width, ease of access for maintenance,
distance to ceilings and walls, and line of sight. Modular
enclosures, for example, can be bayed in a variety of con-
figurations to meet space challenges (see Figure 3).
4. What are the temperature conditions inside
and outside of the enclosure? High temperatures can
cause costly equipment failures. As the use of electronics
in controls grows, enclosure cooling becomes increas-
ingly critical. When more than 35% of enclosure applica-
tions require cooling, traditional cooling methods such as
heat sinks and fans often are not sufficient. More robust
solutions such as chillers coupled with air-to-water heat
exchangers should then be considered.
5. What ergonomic requirements must be met for
users to interface with the enclosure? The swing of
the door, location of the mounting panel, sidewalls, LED
lighting, and a variety of modifications must be consid-
ered based on the space and use of the enclosure
(see Figure 4).
6. What material is the enclosure made of? The
choice of stainless steel or carbon steel affects both the
rating and cost of an enclosure. Depending on regula-
Figure 3: Wall-mount enclosures protect smaller control units and
HDMI interfaces to ensure longer life.
tions and environment, stainless steel might be required or
may not provide the necessary ROI to justify it against the
lower cost of carbon steel enclosures.
7. How critical are enclosure aesthetics to the facil-
ity? No longer an after-thought, the appearance and lay-
out of your facility (especially on the production floor) can
affect the critical work being performed for your customers.
By baying enclosures in neat, uniform rows, with branded
badges, facilities showcase a level of cleanliness and
safety that improves customer and employee perception.
Facility managers want to fit the
maximum amount of equipment in
the smallest amount of space.
8. How will cable be brought into and managed in
the enclosure? Its helpful to know in advance whether a
modular or uni-body enclosure system works best for your
operation. Knowing this will let you know whether cutouts
for cable entry will be done while the enclosure is standing
or on its back, or whether they can be done on an indi-
vidual enclosure panel or part at a workbench. In the latter
Applied Automation June 2017 A11
 I n d u s t r Ia l e n c l o s u r e s
Figure 4: Proper lighting makes for a safer and more efficient
working environment.
case, the user will need to know whether the enclosure
should be modified for cable entry from the roof, sides, or
baseor even all sides.
9. How difficult will it be to service the enclo-
sure and the equipment inside? Youll need to know
if the enclosures design allows the user to easily and
safely service and conduct repairs. For example, con-
sider the enclosures construction for things like remov-
ing and replacing doors and panels, ease of access
and movement in the shop or plant, inside access for
wiring or other necessary work, and ease of installing
accessories.
10. What are the internal design requirements for
the enclosure? Knowing these requirements in advance
will help you modify enclosures for the kind of equipment
to be installed. Pre-installation modifications can account
for electrical equipment, electromagnetic compatibility or
shock and vibration considerations, busbar power man-
agement, and cutouts for fans or other climate control
systems (see Figure 5).
A12 June 2017 Applied Automation
Figure 5: Busbar power management delivers a plug and play
solution for power accessories, routing, and design.
To be well-informed is to be well-armed
Enclosures are not just metal boxes. They are care-
fully controlled environments that ensure your opera-
tions run day and night. The more thought that design-
ers, specifiers, and managers put into choosing the right
enclosure for their needs, the quicker the ROI will be in
the uptime of their equipment.
When it comes to the role of industrial enclosures in
planning facility layout or augmentation, sometimes the
best answer starts with a few simple questions.
Steve Sullivan is the training supervisor at Rittal
Corporation, where he oversees instructor-led, computer
and web-based learning. He co-founded Rittal University
Online and has been with Rittal for more than 20 years.
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 CRISIS MANAGEMENT

Ensuring effective decision

support in a crisis
Machines can support humans when facing a stressful situation. Using a standards-
based approach can reduce the likelihood of a problem escalating.

Dr. Maurice J. Wilkins, build operator displays that

Yo k o g a w a E l e c t r i c look artistically great, but
Corporation can confuse the operator

O
in an emergency. But when
configured correctly, these
perator error alarms and displays can
during peri- help rather than confuse.
ods of abnor- Unfortunately, we often
mal opera- dont use this system intel-
tions has ligence to benefit the pro-
been put for- cess operator.
ward as one of the causes On March 23, 2005,
of many major recent inci- there was an explosion in
dents. But before we give the isomerization unit of
humans a bad rap, incident the BP Texas City Refinery,
reports suggest the prob- which at the time was BPs
lem often stems from poor largest facility. The explo-
procedures, inadequate sion killed 15 people and
training, and the lack of injured 170. The incident
sufficient resources. In centered around the raf-
many cases, with the right finate splitter.
skills and tools, a good BPs incident investiga-
operator can help avoid tion, led by J. Mogford,
these situations. issued a report showing
Arguably, the most several basic procedure-
advanced decision support related errors, such as a
systems may be found in level alarm acknowledged
the aircraft industry. But but not acted upon, a heat-
even these can go wrong up ramp-rate that was too
sometimes, and it comes fast, and operators trying
back to the skills and train- Figure 1: The Boeing B-17 procedure checklist became a proto- start up the unit in manual
ing of humans to avoid type for many more to come in aviation. All graphics courtesy: when procedures indicated
potential disasters, aided Yokogawa Electric Corporation it should be in automatic.
by a standards-based Moreover, operators turned
approach. on the burners before veri-
fying liquid was circulating. Later, we will examine how a
Putting humans under stress standards-based approach may have averted this incident.
Process control systems have evolved over the years Another clear example of operator overload happened
to the point where we can measure, display, and alarm on Sunday, July 24, 1994, when a lightning strike started
almost anything in almost any color. We can provide many a fire on the crude distillation unit at the Texaco Milford
different alarms on the same measurement, including vari- Haven refinery, which eventually led to an explosion on
ous high and low values, as well as rate of change. We the fluid catalytic cracking unit (FCCU). Although the

A14 June 2017 Applied Automation

Figure 2: Capturing best-
practice procedures using
appropriate management of
change can result in signifi-
cant improvements.
media put the blame on
the lightning strike, the
incident report stated,
These events, though
significant in initiating a
plant upset, were not the
cause of the release and
explosion that occurred
five hours later. These
consequences resulted
from subsequent failures to manage the plant upset
safely.
Luckily, although there were some serious injuries, no
one was killed. Among many other things, the report cited
bad alarm management, poor human-machine interface
(HMI) display design, and a failure to follow procedures.
For example, the report stated, From the limited amount
of alarm information relevant to the event, which was pre-
served from just one of the journals, it was seen that in
the last 10.7 minutes before the explosion, the two opera-
tors had to recognize, acknowledge, and take appropriate
action on 275 alarms. At times during the morning, opera-
tors were doing nothing but acknowledging alarms.
The report went on to say the chances of operators
restoring control manually were reduced as the incident
progressed due to them being overloaded by a barrage
of alarms. There were 2,040 alarms configured, 87% of
which were high priority. During the incident, the opera-
tors had to cope with alarms coming in at a rate of one
every 2 to 3 seconds, which resulted in many simply
being cancelled. There was no evidence that a vital high-
level alarm on the flare drum that went off 25 minutes
before the explosion was ever seen.
In addition, the report indicated the FCCU HMI graph-
ics were not designed in a way to help the operators con-
trol the process. Process data was limited and color use
was confusing, so important data was not highlighted.
Much of what was displayed illustrated the structure of
plant equipment and had no relevance to operations.
Critical procedures had fallen into disuse from lack of
practice and documentation.
The role of procedures
These incidents show how the effective use of proce-
dures is one of the key items in maintaining safe and reli-
able operations under all conditions. In fact, if configured
correctly, well-planned alarms can trigger procedures in
many abnormal situations, and a well-designed HMI can
bring a developing incident to the attention of an operator
in a timely manner.
For example, the airline industry is among the safest
and most automated in the world. In fact, most modern
aircraft could not fly without the use of computer guid-
ance, yet procedures play a big part in the way aircraft
are operated. Pilots need to go through many procedures
before, during, and after a flight.
History suggests recorded procedures were intro-
duced by test pilots in 1935 after the crash of a B-17
Flying Fortress in Dayton, Ohio. The B-17 was the most
advanced bomber at the time, but the crash almost
caused the program to be abandoned due to a gust lock
still being engaged at takeoff. It was said that the plane
was too complicated to fly.
In response, test pilots developed procedures for use
during takeoff, in-flight, before landing, and after land-
ing. Boeing eventually delivered more than 12,000 of the
aircraft to the U.S. Air Corps, and they flew 1.8 million
miles without a serious mishap. An example of the B-17
procedures is shown in Figure 1. Every type of aircraft
from small private planes to the largest jumbo jet now
use procedures for all aspects of the journey, and not fol-
lowing them could lead to a pilot losing his or her license,
or worse.
Another example of outstanding use of procedures
is the now famous Miracle on the Hudson. Captain
Chesley (Sully) Sullenberger and his crew saved U.S.
Airways flight 1549 on Jan. 15, 2009, when the plane
struck a flock of geese just after takeoff from La Guardia
airport in New York. They landed the plane safely on the
Hudson. It turned out that none of the crew had flown
together before, but the procedures drilled into all airline
crew enabled them to do all the necessary things by rote.
In the process industries, we use standard operating
procedures (SOPs) for all aspects of running a pro-
Applied Automation June 2017 A15
 Crisis management
cess, under all conditions. However, some of the better
operators often tweak procedures to improve them. As
experienced operators are retiring with often less expe-
rienced operators replacing them, plants try to capture
these tweaks to develop best-practice procedures
(see Figure 2).
These procedures can be run semi-automatically,
where the control system runs the steps to a point where
the operator must confirm it is safe to continue, or the
control system runs the procedure completely automati-
cally. The machine runs the process, but there is always
a need for human oversight.
Experience counts
Under normal conditions, humans operate very well,
but as stress builds, people react in different ways. Some
become heroes in wartime situations by giving leadership
under fire, but in manufacturing we dont expect heroism.
Having several very skilled operators probably saved
Qantas flight 32 on Nov. 4, 2010. The flight, using an A380
Airbusthe worlds largest and most technically-advanced
passenger aircraft at the timehad left Singapore for
Sydney. Over Indonesia, one of the engines blew apart,
rendering almost the entire wing controls inoperable and
leaving only one engine to power the plane.
The pilots were inundated with messages: 54 came in
to alert them of system failures or impending failures, but
only 10 could fit onto the screen. The pilots watched as
screens full of messages came in. Luckily, there were five
experienced pilots onboard, including three captains who
were on check flights. Even with that much experience
available, it took 50 minutes to work through and priori-
tize the messages.
The incident report concluded that without those pilots,
the flight would probably not have made it. In fact, the
airmanship of the pilots saved the plane. If the pilots
Figure 3: Standards-based decision
support should help operators, not
create more confusion.
A16 June 2017 Applied Automation
had followed all the advice from the flight systems, the
plane would have crashed. The most senior pilot told the
others to read the messages but feel the plane. They
managed to land safely with one working engine.
There are many times when the quick thinking of an
operator has probably saved a process, but of course,
these successes dont get the same publicity as aircraft
incidents.
A standards-based approach
As stated earlier, modern control systems can have the
versatility and intelligence to help an operator, but without
guidance, these features can confuse as much as aid the
operator, hence the need for standards (see Figure 3).
With an effective HMI display, an operator can easily
see what state the process is in, and if an alarm is acti-
vated, it can be seen easily and acted upon quickly. But
process alarms also can be used to trigger an automated
action if configured correctly. The action can be a combi-
nation of informing the operator, taking corrective action,
or even halting the process if needed.
The International Society for Automation (ISA), a glob-
ally-recognized standards development organization, has
two standards and one in development addressing opera-
tor decision support:
n ANSI/ISA-18.2-2009: Management of Alarm Systems
for the Process Industries
n ANSI/ISA-101.01-2015: Human Machine Interfaces
for Process Automation Systems
n ISA106: Procedure Automation for Continuous
Process Operations.
ANSI/ISA-18.2 provides requirements and recommen-
dations for the alarm management lifecycle. The lifecycle
stages include philosophy, identifi-
cation, rationalization, detail design,
implementation, operation, mainte-
nance, monitoring and assessment,
management of change, and audit.
Using this standard should prevent
incidents like the one at Texaco
Milford Haven. Alarms are rational-
ized and prioritized so high-priority
alarms either trigger an action auto-
matically or ensure an immediate
operator response.
ANSI/ISA101.01 is directed at
those responsible for designing,
implementing, using, or managing Figure 4: A hypothetical BP Texas City raffinate splitter control room HMI with standards-
HMIs in manufacturing applica-
based decision support.
tions. The standard itself has inter-
nal standards aimed at producing
an HMI philosophy, graphic style
guide, and design toolkitall of which should lead to an  Draw on historical data for memory of what has
interface helpful to the operator. happened in the past
The ISA106 committee has produced one technical
report defining models and terminology, and is close to  Incorporate both data and models to analyze and
releasing a second report on work processes, before start- present the best options
ing the steps of developing a standard. The standard will
help define which procedures should be automated and  Assist operators in semi-structured or unstructured
under what circumstances. decision-making processes
When combined, these three standards offer powerful
tools to provide decision support in times of normal and  Support, rather than replace, operator judgment
abnormal operations.
 Aim at improving the effectiveness, rather than
BP Texas City done right efficiency, of decisions.
Returning to the BP Texas City incident discussed ear-
lier, Figure 4 shows how the integration of alarm, HMI, and In process industries, decision support of this nature
procedure management might have prevented the incident. is not yet widely available. But with the advent of less
Imagine what one of the operators could and should have expensive and more powerful computers, enhanced deci-
seen on the control-room screens prior to the incident: sion support will be more widely used to predict impend-
ing events as they are developing, allowing operators to
 The high-level alarm is tripped take corrective action.
Mary L. Cummings, former director of the Humans and
 The procedure is paused Automation Laboratory at the Massachusetts Institute
of Technology and a Navy F-18 pilot, has conducted
 There is a mismatch in the material balance research into human-automated path planning optimiza-
because no liquid is leaving the column tion and decision support. She observed: Humans are
doing a pretty good job, but they do it even better with
 The column temperature is significantly above the assistance of algorithms. This research is really
the desired value. showing the power of how, when algorithms work with
humans, the whole system performs better.
All this information could have been used by the opera- So, maybe there is a balance between humans and
tor or an automated system to alleviate the abnormal machines that can ultimately make all of us safer. Lets
situation, preventing the disaster that followed. try to find it.
An effective standards-based decision support sys-
tem can help improve process safety and provide Maurice J. Wilkins, PhD, C.Eng, FIChemE, FInstMC,
critical aid to operators in times of stress, but more is ISA Fellow, is executive advisor to Global Marketing HQ at
needed. An effective decision support system should Yokogawa Electric Corporation. He has vast experience in
be able to: process operations and human factors.

Applied Automation June 2017 A17

 A DV E R T I S E M E N T

SEW-EURODRIVE Power Transmission Innovation

MOVIGEAR
The MOVIGEAR Mechatronic Drive System for horizontal-
materials handling from SEW-EURODRIVE sets new standards
in terms of efficiency and functionality. MOVIGEAR not only
combines the gear unit, motor and drive electronics within one
highly reliable, efficient, and hygienically designed unit, it also
reduces total start-up cost and annual operating costs in your
material handling systemby as much as 50%!

IE3 Compliant DRN.. Motor

Our new DRN.. induction motors meet the stringent IE3 super-premium
energy efficiency standard. They also fit existing gear units allowing
for easy upgrades and retrofits of existing DRE (IE2) gearmotors.
The weight and dimensions of the new DRN motors have only
marginal changes as compared to the DRE series. Due to its
outstanding system stability, tight control, and high-cycling
capacity, the DRN.. electric motor can replace a servo motor
in many cases. Plus, its multiple brake sizes allow a higher torque
for a stopping brake or a lower torque for a VFD holding brake. And
finally, its wide HP range and various connector options enable the
DRN motor to be used in a wide variety of new and retro-fit applications.

DRC Electronic Motor

The DRC electronic motor provides an ultra-efficient motor and
electronics package for those gear units already installed in your
system. Like MOVIGEAR, the DRC electronic motor consists of a
permanent-field synchronous motor with integrated drive
electronics in a completely enclosed housing. The DRC
electronic motor offers greater flexibility allowing it to mount
to any gear unit plus, offers an optional mechanical brake.

About SEW-EURODRIVE
Engineering excellence and customer responsiveness distinguish SEW-EURODRIVE,
a leading manufacturer of integrated power transmission and motion control systems.
SEW-EURODRIVE solutions set the global standard for high performance and rugged reliability
in the toughest operating conditions. With its global headquarters in Germany, the privately held
company currently employs over 16,000 employees with a presence in 48 countries worldwide.
U.S. operations include a state-of-the-art manufacturing center, five regional assembly plants,
more than 63 technical sales offices and hundreds of distributors and support specialists.
This enables SEW-EURODRIVE to provide local manufacturing, service and support, coast-to-
coast and around the world.

SEW-EURODRIVE, Inc. | Tel: 864-439-7537 | www.seweurodrive.com

 A DV E R T I S E M E N T

Tadiran batteries are proven to last up to 40 years

High energy lithium batteries
For applications requiring extended storage life
followed by high current drain, Tadiran offers TLM
Series lithium metal oxide batteries that pack powerful
amounts of energy into small spaces. TLM Series
batteries are ideally suited for medical applications
such as portable defibrillators and allow battery-
operated surgical drills to be small and ergonomic
while delivering the
high torque needed for
efficient drilling cycles.
Tadiran is the leading manufacturer
of bobbin-type lithium thionyl chloride (LiSOCl2 )
batteries that power remote wireless devices. These
industrial grade batteries feature extraordinarily high
energy density and high capacity along with the widest
possible temperature range, making them ideal for
use in the Industrial Internet of Things (IIoT). With an
annual self-discharge rate of just 0.7% per year, TLM Series batteries also power mil/aero
Tadiran batteries deliver proven 40-year operating life, applications, such as providing back-up power that
up to 4X longer than competing batteries that have glides UAVs to safe landings. TLM Series batteries also
annual self-discharge rates of up to 3% per year. allow miniaturized guided munitions to be periodically
tested for system readiness whereas legacy reserve/
For applications that require periodic high pulses to thermal batteries are bulkier and do not permit system
power advanced two-way wireless communications, readiness testing without exhausting the battery.
Tadiran offers PulsesPlus batteries that combine a
standard bobbin-type LiSOCl2 cell for low background
current with a patented hybrid layer capacitor (HLC)
that delivers periodic high pulses. As PulsesPlus
batteries become depleted, they feature a unique end-
of-life voltage curve that can be interpreted to deliver
low battery status alerts.

Industrial grade Li-ion rechargeable batteries

For remote energy harvesting applications, Tadiran
manufactures TLI Series industrial grade Lithium-ion
(Li-ion) batteries. Whereas consumer grade Li-ion
rechargeable batteries have a limited lifespan of
approximately 5 years and 500 full recharge cycles,
TLI Series batteries can operate for up to 20 years
and 5,000 full recharge cycles and feature an extended
temperature range. TLI Series batteries can also
deliver periodic high pulses to power advanced
wireless communications.

Toll-free: 800-537-1368 | Tel: 516-621-4980 | sales@tadiranbat.com | www.tadiranbat.com

 A u t o mAt i o n P r o d u c t s

Managed Ethernet switches

Stride managed industrial Ethernet switches from AutomationDirect offer more connectiv-
ity choices for Ethernet applications. Stride SE2 series switches provide Modbus TCP and
EtherNet/IP management capability. The Stride Web-based configuration tool is used for
monitoring, setup (quick setup, network, and redundancy settings), and advanced operations.
SE2 series managed Ethernet switches include 8-port (two versions with fiber optic ports) and
16-port fast Ethernet switches, and an 18-port Gigabit switch. The 8-port switch and 18-port
Gigabit switch models have SFP fiber optic port options. These optional SFP transceivers add
fiber connectivity at fast Ethernet or Gigabit Ethernet speed. Stride managed Ethernet switches
provide reliable network connections in harsh industrial environments. With metal housings, these Stride switches are specifically
built to withstand extreme conditions, including drastic temperature changes, electrical interference, and corrosion.
AutomationDirect, www.automationdirect.com

Servo amplifier, LED enclosure light is UL approved

single-axis controller
The Sigma-7Siec from Yaskawa com-
bines a SERVOPACK servo amplifier
with a one-axis motion controller in a
single compact package. It was cre-
ated for automation applications that
require the control of only one servo
motor, while requiring exceptionally
quick, precise, and reliable servo sys-
tem performance. The new Sigma-7Siec
builds on the legacy of the MP2600iec,
an existing Yaskawa product that offers
an amplifier/controller combination. The
new unit accomplishes both
tasks while using the small-
er footprint of an individual
amplifier, conserving space
in tight control cabinets.
Sigma-7Siec also delivers
the advantages common to
all Sigma-7 SERVOPACK
amplifiers, including
EtherNet/IP and Modbus/
TCP for connectivity, and a
built-in web server.
Yaskawa America Inc.
www.yaskawa.com
The LED System Light from Rittal Corporation is the first
UL-approved lighting system designed for industrial enclo-
sures. The LED technology, with UL E76083 certification,
shines into every corner of an industrial enclosure. The
new light delivers up to three times the luminous flux of
the closest competitor. Intelligent lighting is tailored to the
geometry of the enclosure. Light is dispersed through a
special optical cover with Fresnel structure in two designs for precise lighting. The
Fresnel lens uses a prism-like pattern to provide magnified light coverage. The cover
rotates easily, for adaptive light distribution. With enormous intensity, from 900 to
1,200 lumens, the light provides brilliant illumination.
Rittal Corporation, www.rittalenclosures.com
Control panels for hazardous areas
The CPX series control panels from Beckhoff
are designed for use in hazardous areas. The
companys new CPX control panel and Panel PC
series enable applications in hazardous areas and
classified Zone 2/22. The CPX portfolio offers a
wide selection of screen formats, sizes, installa-
tion options, and features.This means that pro-
cess industry applications can now also benefit from advanced capacitive multi-touch
technology, enabling the realization of intuitive and feature-filled operating concepts.
Beckhoff offers system-integrated solutions for explosion protection with a new and
extensive portfolio of explosion-proof components.
Beckhoff, www.beckhoff.com

Motor combines gearbox, electronics

Lenze Americas has introduced the Lenze Smart Gear g350, a compact mechatronic drive unit combining a
gearbox, motor, electronics, and software. It is available with torques of 25, 50, and 75 Nm in basic
or advanced levels (including brake). The g350 unit blends the motor and gearbox elements, so the
gear ratio slips far into the motor housing. The integrated electronics and software make it possible
for a fixed motor speed to be easily adapted via a user-friendly app for any NFC-enabled smart-
phone. At the same torque, speeds ranging from 42 to 216 rpm can be freely selected at the g350
gearbox output, resulting in a drastically reduced number of variations. This reduction then affords cost
savings because fewer in-stock components and less engineering efforts are needed. Additionally, the g350 features integrated
ramp functions and brake control options to ensure that conveyed goods are transported smoothly and safely without jerking
motions that can damage materials and increase wear and tear on machine components.
Lenze Americas, www.Lenze.com

A20 June 2017 Applied Automation

 A u t o mAt i o n P r o d u c t s

Weight processing module

The HI 1734-WS weight processing module from Hardy Process
Solutions is a plug-in for Rockwells POINT input/output (I/O) chas-
sis. The module is easy to mount, set up, calibrate, and maintain.
The HI 1734-WS is a true weight processing module designed for
the POINT I/O systems, as opposed to passing raw analog-to-digital
(A/D) counts through to the programmable logic controller (PLC)
for interpretation as in competitive models. HI 1734-WS highlights
include fast installation and commissioning with no programming
required; connectivity to EtherNet/IP, DeviceNet, and ControlNet in
linear, star, and ring topologies; and energy efficientconsumes just 1 W when pow-
ering Hardy IT junction boxes and up to four load cells.
Hardy Process Solutions, www.hardysolutions.com
Remote tank monitoring
hatch sensor
Software development kit for OPC UA SignalFire has introduced the Hatch
Honeywell Process Solutions has introduced fully-scalable Watchdog, a wireless thief hatch sensor
software toolkit that simplifies the interconnection of indus- that monitors the status of tank hatches
trial software systems, enabling them to communicate with to mitigate environmental and safety
each other regardless of platform, operating system, or size. risks associated with accidental emis-
The Matrikon FLEX OPC Unified Architecture (OPC UA) sions. When tank hatchesknown as
Software Development Kit (SDK) is ideal for applications where minimal memory and thief hatchesremain ajar, they can
processing resources are common. Intended for use by discrete and process industry release vapors into the atmosphere.
manufacturers, commercial customers, and automation original equipment manu- Stringent regulations in controlling emis-
facturers (OEMs), Matrikon FLEX is the first high-performance developer toolkit that sions can result in fines due to leaking
quickly and easily enables any application, regardless of size, with OPC UA. tank hatches. Protecting the environ-
Honeywell Process Solutions, www.honeywellprocess.com ment also is a priority for many compa-
nies with green initiatives. The sensor
tracks the angle of the tank hatch and
wirelessly reports status (open/closed/
Compact industrial computers cracked) and changes to a central
The SmartAIO U7-300 series computers from EFCO are based on the latest Intel gateway that formats and transmits
Atom processors and highly-integrated Qseven CPU modules, and are extremely the data to a control center for remote
compact. This series of compact computers is designed for maximum network monitoring. Modbus or digital alarming
interoperability, offering gateway connectivity for Industrial Internet of Things (IIoT)- is available at the gateway. The Hatch
ready automation applications. The extended application-specific interface support Watchdog also operates as a standard
includes two Gigabit Ethernet ports, four USB ports (two wireless node in any SignalFire Remote
USB 3.0 and two USB 2.0), an HDMI connection, two Monitoring and Control Network.
RS-232 ports, two RS-232/422/485 ports, 8-bit Isolation SignalFire Wireless Telemetry
GPI, 8-bit Isolation GPO, and audio. The latest indus- www.signal-fire.com
trial PCs from EFCO also are equipped with slots for
half- and full-size PCI Express mini cards.
EFCO, http://efcotec.com/product/

Thermal data logger

The newest generation DATAPAQ EasyTrack3 data logger system from Fluke Process
Instruments simplifies thermal profiling. The data logger is equipped with a rugged
and light polycarbonate casing that withstands harsh treatment and heat up to 212F
(100C) without distortion and without harm to the electronics. Versions with four or
six thermocouple channels are available. Data is stored in a non-volatile memory
the capacity has been tripled to up to 18,000 readings per channel. The loggers use
replaceable 9-V batteries. An intelligent power management feature ensures long bat-
tery life for more than 50 profiling runs. Calibration certificates stored aboard the log-
ger can be printed anytime.
Fluke Process Instruments, www.flukeprocessinstruments.com

Applied Automation June 2017 A21

 A u t o mAt i o n P r o d u c t s

Rotary tables
GTB series servo positioning rotary tables from DESTACO features a roller-gear drive
and is a lifetime-lubricated solution that has been designed and engineered to deliver
high torque, with high speed and motion flexibility to meet demanding payload require-
ments in a wide variety of general industrial rotary table applications. The units are 34%
lower in height and 64% lower in weight when compared to competitive models, while being able
to deliver 1.4 times the torque. The units lifetime-lubrication design also eliminates the need for main-
tenance. The rotary tables produce a very high torque comparable to much larger units, but in a very
compact size. They can be mounted in vertical and horizontal orientations. Each model can support a wide range of off- the-shelf
servomotors for maximum motion flexibility and performance.
DESTACO, www.destaco.com

DIN-rail power supplies

The DPC series of highly efficient ultra slim DIN rail ac-dc power supplies from XP Power are
designed for industrial applications. Available in 30, 50, and 70 Watt single output models, the
power supplies accept the universal input range from 90 to 264 Vac without the need for input
selector switches. Taking up significantly less space on the rail by being up to 44% slimmer than
current generation DIN rail power supplies, the 30 Watt DPC30 measures just 3.6 by 3.94 by
0.89 inches. In addition, the 50 Watt DPC50 measures 3.6 by 3.94 by 1.18 inches, and the 70
Watt DPC70 measures only 3.6 by 3.95 by 1.59 inches. Offering all the popular nominal output
voltages from 5 to 48 Vdc, the single output can be adjusted up to +30% of stated nominal.
XP Power, www.xppower.com

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A22 June 2017 Applied Automation

 Control Freak?
If you like being in control, then
SEW-EURODRIVE is your perfect
partner! We put you in charge of
every move with our gearmotors
and electronics. No headaches, no
whining, and virtually no maintenance.
You build it and we move itsimple!

Dont you wish all partners were this

easy?

seweurodrive.com | 864-439-7537
Big ideas open up completely new perspectives.
We have taken another step towards mechatronic integration with
the combination of the new g500 gearbox range and the Lenze Smart
Motor. By using this single drive solution you will be able to cover a
broad spectrum of applications and reduce the number of variants
you need by up to 70%. Thanks to the excellent levels of energy
efficiency and the long life expectancy, your machines will achieve
more productivity with a maximum degree of reliability. Find out
more about our intelligent approach to solutions at www.Lenze.com. As easy as that.