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Up to 300HP!
The DURApulse GS4 series of Variable Frequency Drives (VFD)
includes many of the same standard features as our other
GS drives including dynamic braking, PID, removable keypad,
plus so much more:
• Single-phase input capability on all • Built-in PLC (up to 10k steps) for v*64XLFN6WDUWPHQXVVLPSOLI\FRQoJXUDWLRQ
230VAC models drive-related logic and I/O control • Smart keypad stores up to four sets of drive
• V/Hz control or sensorless vector control • Built-in analog, discrete, high-speed and FRQoJXUDWLRQVIRUEDFNXSDQGWUDQVIHUWR
for improved speed regulation relay I/O with expansion capabilities additional GS4 drives
• 100kA Short Circuit Current Rating (SCCR) v6HULDO02'%86578$6&,,DQG%$&QHW • Fire mode and circulative control mode
v£&WHPSHUDWXUHUDWLQJSOXVpDQJHPRXQW protocols included v)LHOGXSJUDGHDEOHoUPZDUH
capability for industrial environments v2SWLRQDO(WKHUQHWFDUGVLQFOXGH02'%86 v)UHHGULYHFRQoJXUDWLRQDQG3/&
v6726DIH7RUTXH2ç789FHUWLoHG TCP and EtherNet/IP™ protocols Programming software

Upgrade I/O capabilities AND

communications options

4 Digital Inputs 6 Digital 6 Relay

2 Digital Outputs Inputs Outputs

Research, price, buy at:

CONNECTING THE UNCONNECTABLE EtherNet/IP™ Modbus TCP
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EMPATHY’S ROLE IN HMI DESIGN durapulse-gs4
JANUARY 2019

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* See our Web site for details and restrictions. © Copyright 2018 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405 the #1 value in automation
 What’s in our new AC Drive?
Features galore AND a wealth of options starting at only $429.00!
3/&LQVLGH &LUFXODWLYHFRQWUROPRGHDQG
A fully functional PLC is built in to the GS4 drive. Capable PXOWLPRWRUFRQWURO
of up to 10k steps, it’s perfect for drive-related logic
requirements. Control the drive and I/O with standard ladder DURA The GS4 drives offer five different control modes for
circulation pump control. A single GS4 can control up to
PULSE
logic (and our FREE downloadable PLC software, GS-Logic). 8 motors in a cyclic or cascading fashion by using a
Advanced PLC features include 32-bit math, Gray Code,

4
combination of VFD control and across-the-line control.
drive frequency control, read/write drive parameters,
real-time clock/calendar with support for daylight savings GS Relay outputs on the drive operate contactors that allow the
VFD to control one or more motors, while additional relay
time and full drive PID control. And it’s all on-board! outputs provide across-the-line control of other motors via
separate contactors.
6DIH7RUTXH2II
The Safe Torque Off (STO) function is a basic drive-
integrated safety feature. Use this input signal to ensure
that no torque-generating energy can flow to the motor.
This function is often used in emergency stop situations
and/or to prevent unintentional motor starting.

N$6&&5UDWLQJ
A 100kA Short Circuit Current Rating (SCCR) is required
for personnel safety in many factory environments and to
meet a host of regulatory requirements including:
• NEC Article 409
• UL508A
• NFPA70E
SCCR is defined as the maximum short circuit current a
component or assembly can safely withstand when 3,'FRQWUROrLQFOXGLQJVOHHSDQGZDNH
protected by a specific overcurrent protective device, or for The GS4 series drives support full PID control The Sleep Mode function is actuated when
a specified time interval. The use of high-speed class J or to automatically apply accurate and respon- the frequency of the output command or the
class T fuses on the incoming power is required for these sive corrections to a control function with feedback signal falls below the Sleep
installations. external influences. Proportional, Integral, Reference point for a specified period of
Derivative (PID) control is a mainstay in indus- time. When asleep, the drive output is off and
ŕ&UDWLQJ trial control, bringing complex processes it simply monitors Wake-up Reference point.
The excellent heatsink design of the GS4 series provides a up to speed with little or no overshoot, or A separate Wake-up Delay Time can be used
50°C rating, allowing the GS4 drives to operate in harsh controlling pressure, force, feed rate, flow to delay the Wake-Up routine.
ambient conditions (that’s 122°F!). GS4 series drives rate, position, etc.
can also be “flange mounted” - see details at right. This
allows the use of a smaller enclosure, or reduces the need
to cool the enclosure, or both! )ODQJHPRXQWLQJ
You have several I/O choices: All GS4 drives up to 215 HP can be through C frame drives have optional
6 Digital Inputs 4 Digital Inputs )LUHPRGH “flange mounted”, a through-mounting flange mount kits, while the D through
6 Relay Outputs 2 Digital Outputs Run Fire mode during emergencies for uninterrupted smoke technique that puts the drive’s heatsinks F frame models come with the flanges
removal and system pressure. Sometimes called “run until on the outside of the enclosure. This already attached. The largest G frame
Cooling
destruction” mode, this feature should be used as a measure is outside allows the use of a smaller enclosure, drive isn’t normally mounted in an
of last resort; it can be useful, even life-saving in certain enclosure or reduces the need to cool the enclosure, so it doesn’t have provisions
situations (keeping a stairwell clear of smoke, for instance). enclosure, or both! The smaller A for flange mounting.
The drive will ignore all alarm inputs, and reset immedi-
ately on any trips. Use with caution, especially during any
testing that is required.

25+ Helpful videos with more added every week! All the above plus much more starting at only $429.00, check out the DURAPULSE
http://go2adc.com/gs4-vids GS4 Series of AC drives at www.automationdirect.com/durapulse-gs4
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 JANUARY 2019 • VOLUME 32 • NUMBER 1

26
COVER STORY

Tap vintage expertise

End users toast the companies that provide
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by Control staff

Features

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 CONTENTS
New possibilities, new experiences

PERSONAL
Departments +DIGITAL
Complete e-commerce functionality
now on Endress.com
9 EDITOR’S PAGE 24 RESOURCES
Electricity in the air Skid control
I think the kids are getting ready to A monthly, topical guide to web-hosted
collect and crush my fossil-fueled cars. papers, tutorials, videos and other
educational materials.
10 CONTROL ONLINE
Our most recent, valuable and popular 42 ASK THE EXPERTS
offerings at ControlGlobal.com Remote control of fractionation
Can smart differential pressure (DP)
12 FEEDBACK cells be used for custody transfer?
Keep clarifying Industry 4.0
44 ROUNDUP
14 LESSONS LEARNED Motors and drives
Controlling the Panama Canal Recent and interesting products under
Overcoming the effects of global the topic of the month.
warming on shipping capacity and
water usage. 46 EXCLUSIVE
Intrinsically safe tablet raises power
18 ON THE BUS Pepperl+Fuchs’ ecom Tab-Ex 02 DZ1
Lissten to weak signals is the second generation based on
The whispers we are wont to ignore Samsung's Tab Active platform.
may be harbingers of situations we Introducing new possibilities
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 Easy Does It
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Electricity in the air
I think the kids are getting ready to collect and crush my fossil-fueled cars.
CAR exhaust is easy to see in the winter, as the
water vapor product of combustion condenses on
exiting the warm tailpipes into the crisp air. This
never bothered me, even back in the days when
we could also smell it as the ripe aroma of un-
burned hydrocarbons, and definitely not since it’s
been cleaned up to where a man can hardly use a
car to commit suicide in his own garage.
But lately, sitting at stoplights, in traffic or wait-
ing for trains, I find myself increasingly disturbed
by the sight of these emissions and the sound
of my own idling engine, visible and audible evi-
dence of, at best, wasting fuel and at worst, wast-
ing time, both for me and for the planet.
I recently added MotorTrend to the group of
magazines I receive each month, and noticed
that, along with gas or diesel miles per gallon and
kilowatt-hours per 100 miles (for comparison to
among conventional, electric and hybrid drive-
trains), the editors include carbon dioxide emis-
sion rates in pounds per mile. Values I found in
the February issue range from 0.66 for a Honda
CRV AWD Touring that gets 27 miles per gallon to
1.33 for a Mercedes G550 4Matic SUV that mea-
sures 14 miles per gallon.
As a measure that, for fossil-fuel-powered ve-
hicles, is really just miles per gallon in a different
format, it’s pretty pointless, but as a way to point
out that there’s a hefty carbon dioxide cost as-
sociated with every mile we drive these kinds of
cars, it’s a point well made. My 64-year-old mind
thinks, wow, about a pound per mile. Who knew?
But if and when the costs of global warming
become apparent enough to make it a line item
in the budget, I’ll be long gone, and maybe so will
you. The folks dealing with it—my children, your
children, their children—will have a hard time
making us pay for our willingness to ignore that
per-mile cost.
Some of them have gone to court to get our at-
tention, and have entered a class action lawsuit to
get the federal government to do more to prevent
climate change. A number of county and city gov-
ernments are suing fossil fuel companies, saying
www.controlglobal.com JANUARY 2019 • 9
EDITOR’S PAGE
the companies should pay the costs of the dam-
ages incurred by their products. So, far, the courts
aren’t stopping them.
Several state attorneys general have joined in
an investigation of ExxonMobil for suspected lying
to the public about the risks of climate change, or
to investors about how those risks might hurt the
oil business.
As I sit in my idling fossil-fuel-mobile, slightly
disturbed by the sight of exhaust that never both-
ered me before, I’m starting to think about those
pounds per mile of carbon dioxide emissions,
feeling a little guilty about the world I’ve condoned
and its potential future. I imagine an increasing PAUL STUDEBAKER
number of young people are much more aware, Editor in Chief
and getting ready to do something about it. pstudebaker@putman.net
Between the waste and the emissions, I’m
starting to want to turn in my fuel-burners for
electrics. The ranges of the latest electric vehicles
Some of them have
are getting high enough to handle even my most
gone to court to get
extreme commuting day (about 200 miles). Lo-
our attention, and have
cally, the Illinois Tollway system, which I use, is
entered a class action
looking at adding on-the-go charging to some
lawsuit to get the
lanes so cars can add kilowatt-hours as you drive.
federal government
Meanwhile, some electric vehicles have internal
to do more to prevent
combustion range extenders that let you drive
climate change.
them across the country if you want to use them
that way.
According to the Chicago Tribune, right now,
electric cars represent around 1% of total car
sales in the U.S. “But the arrow’s pointing straight
up for the electric car market,” it says. “Automo-
tive journalists are writing about the impending
twilight of the internal combustion engine. Ford
Motor CEO Jim Hackett has said his company
expects two-thirds of all vehicles sold by 2030 to
be either electric or hybrid, and his company is
planning its future accordingly. And the New York
Times reported. General Motors expects to have
20 electric car models in its fleet by 2030.”
That’s starting to make sense to me.
 CONTROL ONLINE
NEWS & BLOGS
Top 10 articles of 2018
With 2018 at a close, we take a look
back at the Top 10 articles at Control-
Global.com throughout the year.
www.controlglobal.com/articles/2019/
top-10-articles-of-2018
A 2018 retrospective on control
system cybersecurity
Joe Weiss looks back on the past
year of control system cybersecurity
and provides his assessment of
2018 OT and field device
cybersecurity.
www.controlglobal.com/blogs/unfettered/
a-2018-retrospective-on-control-system-
cyber-security-we-arent-as-far-along-
as-many-people-think
Siemens cybersecurity press tour
Siemens AG hosted a press tour in
Munich to share updates on the
Charter of Trust, which seeks to pres-
ent a united front and standardized
protections against cyber threats,
intrusions and attacks.
www.controlglobal.com/industrynews/
2019/siemens-partners-strive-for-
security
Off-site Insights
This blog offers a break from our
normal process automation control
coverage to take a look at how the
technology you use at work is utilized
across industries and throughout our
everyday world.
www.controlglobal.com/blogs/off-site-
insights
E-NEWSLETTERS
ControlGlobal E-News
Multimedia Alerts
White Paper Alerts
Go to www.controlglobal.com and
follow instructions to register for our
free weekly e-newsletters.
10 • JANUARY 2019 www.controlglobal.com
2019 IWIM nominations open
Nominations for the 2019 class of Influen-
tial Women in Manufacturing are open now
through March 31. Nominees can serve at
any level of their manufacturing organiza-
tion, from plant-floor technican to C-suite
officer, and should demonstrate thought leadership while fostering growth of other women in
manufacturing. To learn more or nominate women from your organization, visit the new Influential
Women in Manufacturing website.
http://bit.ly/2rwG63W
Control Amplified
Control Amplified is now available across several platforms, includ-
ing iTunes, GooglePlay, YouTube and Facebook. If you haven't heard
the new podcast yet, what are you waiting for? Subscribe to Control
Amplified for in-depth interviews with industry experts about impor-
tant topics in the process control and automation field, starting with
the Top 50 Automation Companies of 2017 and industrial wireless.
Control Amplified goes beyond Control's print and online coverage
to explore the underlying issues affecting users, system integrators,
suppliers and others in these industries. Search for Control Amplified
in your podcasting app, and download and subscribe, so you don't miss this valuable information.
www.controlglobal.com/podcasts/control-amplified
Redesigned with you in mind
The Focus on the Essentials education center has been rede-
signed based on your feedback. The new page is still filled with
Control's best educational articles, whitepapers, online presenta-
tions and more, but now on a more easily navigated page. The
new education center is specially designed to provide the most
valuable content for all process automation professionals in one
convenient location. Check out the redesigned portal now!
www.controlglobal.com/essentials
Manufacturing Tomorrow's Workforce
Keeping up with workforce issues can be difficult. Our parent
company, Putman Media, has introduced a new podcast to help
you keep up with this constantly evolving factor in your orgniza-
tion: Manufacturing Tomorrow's Workforce. Now available on
iTunes, GooglePlay and YouTube, Manufacturing Tomorrow's
Workforce focuses on important workforce topics through in-
terviews with a variety of experts. This podcast will discuss new
techniques and approaches to enact change, attract up-and-
coming workers, overcome skills gaps and much more. Download and subscribe now.
www.controlglobal.com/podcasts/manufacturing-tomorrows-workforce
FEEDBACK
Keep clarifying Industry 4.0
I appreciate your editor’s page, “The
phrase I love to hate” (Dec. ’18, p. 9, www.
controlglobal.com/articles/2018/a-little-
help-for-those-who-share-my-aversion-to-
digitalization). I took interest in the words
of Neil Mead in the book you recom-
mended from www.4sightbook.com:
“The digital factory of the future will be
full of smart, connected machines that
require less human intervention and can
be controlled and monitored remotely.
Through the use of sensors, algorithms
and software, they'll also be able moni-
tor themselves and the process they're
undertaking, while constantly adjusting for
maximum efficiency and producing data
that can be analyzed and acted on by a
computer running sophisticated manufac-
turing execution software (MES).”
I've been in the process control industry
since 1984 and have the following impres-
sion on the prior paragraph:
• The factories of 1984 that I began my
career in had smart and connected
machines. The first facility I worked in
had very sophisticated sensors using
nuclear sources that sent data to a pro-
cessor for control and display.
• This required less human intervention
than manual sampling and adjustment
to valves.
• The first project I worked on used sensor
data to predict product quality that had
previously only been measured with of-
fline lab samples. I'd consider this use of
sensors, algorithms and software.
• As a practical matter, these applica-
tions had to monitor themselves and the
process to alert operations to potential
problems. To do otherwise would have
made them unusable.
• The objective of controls from the origin
of the discipline is to make constant ad-
justments to maximize efficiency.
• The control systems I worked on pro-
duced a lot of data that was analyzed to
identify process or control problems.
• That data was also fed into a plantwide
computer system to enable manage-
ment to see how we were operating, and
make decisions.
12 • JANUARY 2019
1501 E. Woodfield Road, Suite 400N
Schaumburg, Illinois 60173
In Memory of Julie Cappelletti-Lange,
Vice President 1984-2012
EDITORIAL TEAM
THE BUS IN WINTER
COMMON-SENSE
CYBERSECURITY Editor in Chief
WHY WE STILL
USE MODBUS
Paul Studebaker, pstudebaker@putman.net
IS AUTOMATION
A JOB-KILLER?
Executive Editor
Jim Montague, jmontague@putman.net
Digital Engagement Manager
Amanda Del Buono, adelbuono@putman.net
Contributing Editor
Loop John Rezabek
Control
Columnists
Béla Lipták, Greg McMillan, Ian Verhappen
Best practices for PID
Editorial Assistant
Lori Goldberg
DESIGN & PRODUCTION TEAM
VP, Creative & Production
Steve Herner, sherner@putman.net
Is anything new here? The answer is Art Director
Jennifer Dakas, jdakas@putman.net
yes; there is new terminology and some
new technology. The problem with the Senior Production Manager
Anetta Gauthier, agauthier@putman.net
terminology is that buzzwords are being
PUBLISHING TEAM
used without clear definition. Mead, to his
credit, addresses this in his subsequent Group Publisher/VP Content
Keith Larson, klarson@putman.net
comments:
“There's no doubt that the term 'Industry Midwest/Southeast Regional Sales Manager
Greg Zamin, gzamin@putman.net
4.0' has been used and abused by some 704/256-5433, Fax: 704/256-5434
companies as a marketing tool. Professing Northeast/Mid-Atlantic Regional Sales Manager
to offer 'Industry 4.0-ready' or 'IoT compli- Dave Fisher, dfisher@putman.net
508/543-5172, Fax 508/543-3061
ant' products sounds impressive, but it's
West Coast/Mountain Regional Sales Manager
what they can actually provide to the end Jeff Mylin, jmylin@putman.net
user that’s important. Much of this digital 847/516-5879, Fax: 630/625-1124
technology isn't new, but what the Industry Classifieds Manager
Lori Goldberg, lgoldberg@putman.net
4.0 concept has done is bring a number of
disparate technologies together in a joined- Subscriptions/Circulation:
Patricia Donatiu. Circulation Manager,
up offering that allows manufacturers to 888/644-1803
better understand the features and benefits EXECUTIVE TEAM
of digitalization and smart factory solutions.”
President & CEO
Like you, the term “digitalization” makes John M. Cappelletti
me cringe. Analog-to-digital converters
VP, CFO
have been around for nearly 100 years, Rick Kasper
and our industry had digital communica- Foster Reprints
tion to sensors and actuators from long Corporate Account Executive
Jill Kaletha, jillk@fosterprinting.com
before my career began in 1984. We aren’t 219-878-6094
suddenly digital, but our industry is differ-
Finalist Jesse H. Neal Award, 2013 and 2016
ent. Explaining what's new and different
Jesse H. Neal Award Winner
in clearly defined terms is important to Eleven ASBPE Editorial Excellence Awards
ensure good decisions are made to avoid Twenty-five ASBPE Excellence in Graphics Awards
investments in vaporware and myth. ASBPE Magazine of the Year Finalist, 2009 and 2016
Four Ozzie awards for graphics excellence
PAT DIXON, P.E., PMP
Southwest region engineering manager
Global Process Automation
pdixon@global-business.net
 Call us at 1-800-463-9275
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 LESSONS LEARNED
Controlling the Panama Canal
Overcoming the effects of global warming on shipping capacity and water usage.
PAST columns have discussed the control of
non-industrial processes, showing that our con-
trol theory and process analysis principles could
be applicable to all processes, not only industrial
ones. I believe illustrating this by specific exam-
ples is useful, so this time I'll illustrate it by using
the example of the process of shipping through
the Panama Canal.
Until the 20th Century, the nautical shipping
distance between the east and west coasts of
the U.S. was 13,000 miles. Building the Panama
Canal reduced that distance to 5,200 miles, and
today some 600 million tons of goods are trans-
BÉLA LIPTÁK ported through it each year on nearly 15,000
liptakbela@aol.com ships, which corresponds to about 25% of the
planet’s seaborne, containerized cargo.
The sealevel Suez Canal between the Red and
the Mediterranian seas, built by the French engi-
The water collected
neer Ferdinand de Lesseps, successfully opened
during the rainy season
in 1869. In 1880, de Lesseps started work on the
must be enough to also
Panama Canal, but he made the mistake of trying
operate the canal during
to build a 51-mile, sealevel canal, which would
the dry season.
have required cutting through mountains of rock,
such as Culebra Mountain, in a tropical rainfor-
est region. After digging up some 60 million cubic
meters of earth and rock, and after many land-
slides, yellow fever epidemics and other accidents
that killed up to 22,000 workers, the project went
bankrupt in 1889, wiping out the savings of some
800,000 investors. De Lesseps and his son were
convicted of misappropriation of funds, and of at
least knowing that some 2,500 newspapers and
magazines, and some 150 deputies, were paid off
to promote financing of the project.
In 1904, the U.S. purchased the remaining
assets of the French project, and forced the in-
dependence of Panama from Columbia. A treaty
was then signed, giving the U.S. the right to build,
indefinitely administer and defend the Panama
Canal Zone. This agreement has sometimes been
misinterpreted as the "99-year lease," which it
was not.
That same year, the construction project, which
President Theodore Rosevelt strongly supported,
14 • JANUARY 2019
was restarted. Thanks to the chief engineer, John
Frank Stevens, the main error of the French (the
goal of building the canal at sea level) was elimi-
nated and due to the efforts of William C. Gor-
gas, chief sanitation engineer, after some 5,600
deaths, the mosquito-spread diseases were nearly
eliminated. The project was concluded two years
ahead of schedule in 1914.
Panama never fully accepted that the Canal
Zone be administered by the U.S., and tension
between the two nations increased until relations
broke in 1964. In 1979, a treaty was signed by
President Jimmy Carter, which promished that the
ownership of the canal would be transferred to
Panama in 20 years. A complicated period followed
during which the U.S. first supported the former
CIA informer-turned-dictator Manuel Noriega, then
in 1998, turned against him and invaded Panama.
Still, the treaty signed by President Carter in 1979
was respected and on Dec. 31, 1999, the canal
was turned over to Panama.
In 2006, Panama decided by a national ref-
erendum to expand the canal. This expansion
added two sets of locks (one each at its Pacific
and Atlantic ends) and widened the old canal to
allow traffic in three lanes. The construction of
the expanded waterway cost $5.25 billion, in-
volved 37,600 workers, and was completed with
44 million cubic meters of concrete and 192,000
tons of steel.
The refurbished canal was inaugurated in
2016. Today, ships large enough to carry 13,000
containers can pass through it in both direc-
tions, while the old canal could only handle ships
carrying 3,000 containers. The average pas-
sage time through the canal is about 24 hours,
which includes about 16 hours of waiting time at
the locks. During its first 20 months of opera-
tion, 3,000 new Panamax ships crossed the
expanded canal, mostly carrying Chinese goods
to the U.S. The per-ship cost of each passage
varies widely, and can reach $1 million. Because
sizes of container-cargo ships are constantly
increasing, it's already projected that the larger
www.controlglobal.com
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LESSONS LEARNED
locks serving the new expansion, com-
pleted in 2016, will become too small
by 2030.
The hydraulic lift process
The Panama Canal locks use the water
of two lakes (Gatún and Miraflores) for
their operation (Figure 1). As the ships
start to travel from one ocean to the
other, they enter the canal by entering
the first lock, in which the water level at
the time of entering is the same as the
ocean because its gate is open on the
ocean side. Once a ship is inside the
lock chamber, the ocean-side gate is
closed and water from the lake above is
admitted to raise its water level and the
ship. This is repeated in the next locks
until the ship reaches the level of the
lake. At the other end of the canal, the
opposite process takes place as the ship
is lowered in three steps to the ocean
level. The energy supply of this opera-
tion is the gravity flow of the water from
the lakes above.
Gatún Lake is one of the world's larg-
est artificial lakes, created to serve as a
water reservoir for the canal. It's filled
Gatún Lake
Atlantic Ocean
Gatún Locks Pedro Miguel Locks
PANAMA CANAL IN CROSS-SECTION
Figure 1: The Panama Canal locks are powered by gravity flow of the waters of Gatún and Mira-
flores lakes. Once a ship is inside a lock chamber, the ocean-side gate is closed and water from
the lake above is admitted to raise its water level and the ship. This is repeated in the next locks
until the ship reaches the level of the lake.
16 • JANUARY 2019 www.controlglobal.com
by the Chagres River and by rainwater
runoff from the surrounding rain forests.
The water collected during the rainy
season must be enough to also oper-
ate the canal during the dry season. It
must provide 26 million gallons of water
for the passage of each ship. When the
canal was expanded, the number of
ships, their size and the size of the locks
increased, which naturally requires
more more water. In anticipation of this
increased water demand, the capacity
of the lakes above was also increased by
increasing their water level.
Control and optimization
When a process control engineer looks
at this process, he or she will first look at
the goals of the application (the setpoints
of the control loops) and then for the vari-
ables that can be manipulated to achieve
those goal (manipulated variables). After
that, he or she will review the potential
sources of upsets.
As in many processes today, operation
of this canal will also be affected by ris-
ing global temperature because this rise
increases the length of the dry reasons
Miraflores Lake
Pacific Ocean
Miraflores Locks
in the tropics. This means the quantity
of water collected in the artificial lakes
during the rainy season must last longer
than in the past. Therefore, one goal has
to be to reduce the water requirement
of the per-ship passage. The means of
achieving that goal (the available manipu-
lated variables) include:
1. Maximizing the water savings by
optimizing the use of water-saving
basins;
2. Adjusting the passage fees to mo-
tivate the use of optimum timing
and distribution of the passage of
ships; and
3. Considering the use of adjustable-
length lock chambers.
In the first option, when a ship is low-
ered, instead of draining the water into
the ocean, it's sequentially sent to water
basins at elevations where they can serve
as the water source to lock chambers for
lifting an entering ship. This reduces the
water usage of the canal by 60%, but
only if, during a particular time period,
the number of ships moving in the two
directions is the same, they move at the
same speeds, and their water displace-
ment (size and weight) is close to be
equal. Process control algorithms can
easily calculate how to reach this bal-
ance—human operators can't—and it’s
important because otherwise, on the side
where the traffic is higher, the water in
the storage basins will run out.
Naturally, the process control algo-
rithms can only suggest the most water-
saving operation, but can’t force the
ships to follow that recommendation. Ob-
viously, the best motivation for the ships
to follow that recommendation is to in-
crease the cost of passage (manipulated
variable) if they don’t.
If global warming further increases,
eventually these steps will become in-
sufficient, and at that point, the options
will be to use pumped ocean water to
provide the hydraulic lifts, to convert
the canal into a sealevel one, or to re-
place the canal with a sealevel canal in
Nicaragua.
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 ON THE BUS
Listen to weak signals
The whispers we are wont to ignore may be harbingers of situations we want to avoid.
WE were headed to the airport for a three-day
business trip and failed to notice the faint click-
click-click, barely audible above the radio. The en-
closed levels at the garage were full so we ended
up parking on the roof, open to the elements of
the midwestern winter. The return flight from
Houston arrived after 2200 hours, and another
hour drive awaited us upon return. It was looking
up when no freezing rain or snow had accumu-
lated in our absence, but we were dismayed to
find our left front tire was flat.
Failing to notice weak signals—the character-
istic sound of a nail in the front tire, for exam-
JOHN REZABEK ple—can lead to greater calamities than a flat tire
Contributing Editor late on a winter’s night. That’s one key concept
JRezabek@ashland.com presented by Doug Rothenberg at a recent meet-
ing of the ISA Cleveland, Ohio chapter. Abnormal
situation management guru and author of what’s
A weak signal—anything
been called the most comprehensive treatise
the least bit out of the
available, “Alarm Management for Process Con-
ordinary—could be the
trol,” Rothenberg is soon to publish a new book
somber mood of a
illuminating further the discipline required for ab-
normally cheerful
normal situation avoidance.
operator or even a
We abhor uncertainty and ambiguity, so our
gut feeling.
brains work to rationalize or dismiss many weak
signals. We are quick to say, “This is what it
means” when we should think, “What could it re-
ally mean?” Rothenberg advises.
We love to create accommodating explanations
with incomplete information, Rothenberg points
out. Two measurements that normally agree
start to deviate. “Those instruments are unreli-
able—most likely it’s just drift.” Life goes on. The
waste heat boiler/incinerator starts losing tem-
perature and using more fuel. We don’t want to
think this might mean something dire is happen-
ing upstream, so, “Oh, Hidalgo is on, he always
struggles with that boiler control.” But Rothenberg
says, stand up, notice, pay attention—the signals
are talking.
For decades, our company has trained en-
gineers in the Kepner Tregoe problem solving
methodology. With K-T, as we call it, a problem
is examined and a disciplined path is followed to
18 • JANUARY 2019 www.controlglobal.com
identify observations that support or refute various
hypotheses. Rothenberg’s weak signal technique
offers the possibility of avoiding the problem—
the consequence—before experiencing it. “Real
problems can’t hide for long, so how to find them
early enough?” he asks. A weak signal—anything
the least bit out of the ordinary—could be the
somber mood of a normally cheerful operator or
even a gut feeling—weak signals don’t have to be
restricted to measurements just because we’re in-
strument specialists. But instruments could be ex-
tremely useful when seeking to confirm or refute
a hunch or a theory for the cause of a weak signal
you happen to notice.
One method Rothenberg explores is to choose
from the myriad weak signals one might observe
those few that are clearly or possibly more than
noise. Consider then, what might they indicate?
And of those potential outcomes, which are the
most dire? From there, the observer can seek
other indications that confirm or refute the poten-
tial outcome, sort of like doing Kepner-Tregoe on a
consequence that hasn’t befallen you yet.
It’s not that we don’t do such diagnostics from
time to time, but we tend to focus on the known
abnormal conditions. But as Rothenberg illus-
trates, our processes don’t just exist in the known
normal state and the known abnormal state
(which we detect with alarms)—they also wan-
der into the unknown and not normal—and it’s
these places where we haven’t been yet, where
especially dire consequences, the so-called black
swan, might be approaching.
While there is some hyperventilating about Big
Data and the IIoT, thoughtful examination of the
data—noticing what we already have—can focus
our attention on the blind spots where an avoid-
able consequence might be revealed or con-
firmed. Rothenberg’s soon to be published book,
“Situation Management for Industrial Opera-
tions” (Wiley & Sons) will give us some sugges-
tions where our human senses and minds can be
trained to see past our preconceptions—and cut
through the clutter.
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 WITHOUT WIRES
Calibrator communications
Verifying field devices involves specific demands that wireless could meet, if we let it.
WITH the increasing use of wired and wireless
digital communications, technicians and field en-
gineers are communicating with and performing
maintenance on field devices from practically any-
where—and often not at the transmitter face with
screwdriver in hand to “tweak the pots” unless
necessary to force a signal or isolate the device,
as they would when calibrating. Many practitio-
ners believe that because a digital transmitter
is factory calibrated for a wide signal range, and
they can configure the device anywhere within the
range, that calibration and configuration are the
same, which is certainly not the case.
IAN VERHAPPEN Configuration refers to setting transmitter pa-
Senior Project Manager, rameters only, without any signal forcing other
Automation, CIMA+ than simulation of inputs, and thus no traceabil-
Ian.Verhappen@cima.ca ity to a reference. Because they don’t need to
simulate input signals, several configurators on
the market are based on a ruggedized, perhaps
intrinsically safe tablet or smart phone. These de-
Running off battery is a vices, in addition to supporting the field protocol,
great way to remove one typically through a Bluetooth or USB accessory/
potential common-mode modem, also often provide WiFi- or cellular-based
source of error—the Ethernet connectivity to communicate with the en-
power supply, especially terprise maintenance system and control system.
if it’s an AC source. Calibration, on the other hand, is comparing the
device under test against a traceable reference in-
strument, and documenting the comparison. There-
fore, to calibrate a transmitter, the input needs to be
generated at the same time the output is being mea-
sured. If the calibration is done with a documenting
calibrator, it will automatically document the calibra-
tion results. Fortunately, most calibrators with digital
communications at least have the documenting
capability, thus eliminating transcription errors while
providing time-stamped end-to-end traceability. Un-
fortunately, some calibrators have limited memory,
and may only be capable of handling as few as 20
data sets before needing to be downloaded. On
the positive side, this will encourage technicians to
download their results every day, but the objective of
technology is to make life easier.
Another key consideration for calibrators is their
ability to isolate the input from the output since,
20 • JANUARY 2019 www.controlglobal.com
as we know, the simple act of measuring some-
thing affects the measurement. With calibrators,
we're both forcing or inputting the measurement
and measuring the resulting output. In my experi-
ence, running off battery is a great way to remove
one potential common-mode source of error—the
power supply, especially if it’s an AC source. Mind
you, I was using a laptop-based tool, so it would
not have the isolation that a properly designed
industrial instrument will, but it proves once again
that cheap and multipurpose are not quite the
same as dedicated and industrial.
The challenge with many calibrators is getting
the documenting information in their memory
into the main computer storage platform. All cali-
brators communicate with the calibration module
that is, hopefully, part of or at least accessible
from the instrument maintenance system. The
connection between the calibrator and hosting
computer uses a wide range of technologies from
serial (tough finding computers with this connec-
tion still) to the more common USB interface,
with the few that now support Bluetooth about
the only current wireless option. There are also
still some that require manually pulling the SD
card and installing it in the calibration company’s
standalone proprietary software, then porting
it from there (sometimes as Excel files, though
most systems support SQL) to the enterprise’s
maintenance software for archiving and, more
important, access by QA and potential statistical
analysis and control.
Calibrators continue to get better, however,
as we can see, there's still room to improve. I'm
confident we'll soon see devices with bidirec-
tional communications directly from the field to
the quality system to support and prompt techni-
cians on their rounds, while populating the central
database. All we'll need then is the infrastructure
in the plant to make it possible; so once again we
have a Catch 22—no capable field devices with-
out infrastructure, and no infrastructure because
we don’t have enough capable field devices to
justify installing it.

Siemens, partners strive for cybersecurity
Charter of Trust members detail multiple cybersecurity initiatives during press tour in Germany
EFFECTIVE cybersecurity requires cooperation by users, system
integrators, contractors, suppliers and clients up and down pro-
duction streams and supply chains. But how can all those play-
ers learn to collaborate?
Probably the most comprehensive efforts so far is being
spearheaded by Siemens AG and 16 of its primary industrial
partners, who recently signed their jointly developed Charter of
Trust (www.siemens.com/press/charter-of-trust), which is seek-
ing to present a united front and standardized protections again
cyber threats, intrusions and attacks. As part of their efforts, Sie-
mens hosted a press tour in and around Munich in late Novem-
ber to provide an update on the partners' progress.
"Trust needs a level playing field, and that means having a base-
line that everyone can follow," says Eva Schulz-Kamm, global head
of government affairs, Siemens, who reported at the company's Mu-
nich campus that it's been rethinking its approach to cybersecurity
ever since the Stuxnet virus emerged in 2010. "We've learned that
digitalization creates risks as well as opportunities, which means we
can't have smart devices enabled by microprocessors and network-
ing without addressing their cybersecurity issues, too. Cybersecu-
rity is crucial for increasingly digitalized economies, but we and our
business partners can't jointly achieve it without trust, which is why
we're taking it so seriously. Trust is the differentiator, but it's costly,
and must be seen as investment that will deliver a return later."
Charter essentials
Siemens and eight initial partners launched the Charter of Trust
last February at the Munich Security Conference, and the group
quickly grew to 16 members at National Infrastructure Week last
May. They presently include AES Corp., Airbus, Allianz, Atos,
Cisco, Daimler Group, Dell Technologies, Deutsche Telekom,
Enel, IBM, MSC, NXP, SGS, Siemens, Total and TÜV SÜD AG.
The partners signed the Charter of Trust with three objec-
tives: protect data of individuals and companies; prevent damage
to people, companies and infrastructures; and create a reliable
foundation on which confidence in a networked digital world can
take root and grow. These objectives led to 10 key principles:
• Ownership of cyber- and IT security;
• Responsibility throughout the digital supply chain;
• Security by default;
• User-centricity;
• Innovation and co-creation;
• Education;
• Certification for critical infrastructure and solutions;
• Transparency and response;
• Regulatory framework; and
• Joint initiatives.
www.controlglobal.com JANUARY 2019 • 21
IN PROCESS
CYBERSECURITY SHOWCASE
Franz Köbinger, industrial security marketing lead, Siemens AG, details
the company's multiple cybersecurity efforts and solutions at its booth
during the recent SPS IPC Drives 2018 tradeshow in Nürnberg, Germany.
Siemens reports it's bringing the first three principles to life,
respectively, by establishing a new cybersecurity unit in January
2018; providing a multilayered security concept to give its plants
all-around and in-depth protections; and applying its holistic se-
curity concept throughout the lifecycles of the 15 million Simatic
products it manufactures each year. To achieve its regulatory
framework goal, Siemens is also participating in a network of
cybersecurity-related organizations, such as ISA, FIRST, CERT
community and SAFEcode.
"About 90% of smaller companies and other organizations
have already experienced cyber incidents, so many users and
governments have been asking how Siemens can help because
you can't do cybersecurity alone if you've got a microprocessor
that's networked to the cloud," adds Schulz-Kamm. "We want to
create a global sandbox where we and others can test our cyber-
security solutions. This doesn't mean everything will be secure,
but it will mean we can do something about it, lead by example,
and raise the bar on cybersecurity."
Partners weigh in
Several other Munich-based signers of the Charter of Trust echoed
sentiments expressed by Siemens representatives about how their
agreement can help them and their clients achieve stronger protec-
tions and present a more united front on cybersecurity.
"We were an early participant in the Charter of Trust and keen
to drive its 10 commandments because without them, we'll never
get to a more stable market that can continue to grow because
users can trust their devices and are willing to share their data,"
says Lars Regar, CTO, NXP Automotive (www.nxp.com).
Just as the Industrial Internet of Things (IIoT) and edge-based
IN PROCESS
methods are transforming other applications and industries, NXP
reports they're also penetrating its primary businesses, and re-
quire effective cybersecurity to succeed in these new areas.
"High-performance sensing is needed for precise recogni-
tion of analog and human environments, such as robots and
autonomous vehicles," explains Regar. "We've been working with
Siemens on devices that can deliver data outside of line-of-sight,
such as equipping traffic signals with long-range RFID sensors
that can work with car-to-car communications to inform vehicles
of situations coming up. However, these applications must have
secure connectivity and communications."
Likewise, experts at the Watson IoT Center in Munich report
that IBM also joined the Charter of Trust to engage with policy-
makers to collaborate, educate and raise awareness about cy-
bersecurity, and raise the bar for it with tangible measures and
results. "Together, we strongly believe that effective cyberse-
curity is a precondition for an open, fair and successful digital
future, and by adhering to and promoring the Charter of Trust's
principles, we're creating a foundation of trust for all," says Jona-
than Sage, government and regulatory affairs, IBM. "We're also
doing roadshows to get others to join, and trying to bring more
cybersecurity down to the industrial and measurement levels
where we're also located." For instance, to achieve the Charter of
Trust's "Principle 6—Education," IBM is requiring cybersecurity
training for all its employees, and establishing a mobile cyberse-
curity facility for conducting simulated data breaches as part of
its training for staff and partners.
Angelika Steinacker, CTO for Identity and Access Management
(IAM) and IoT, IBM Security Europe, reports that, "All of cyberse-
curity is related to identity, so we're bringing our experience in this
area to the Charter of Trust and vice versa." For example, "Principle
2—Responsibility throughout the digital supply chain" includes IAM
for connected devices, so Steinacker adds that, "Taxonomy, stan-
dardization and industry-based IAM frameworks are needed."
In addition, Dave Braines, CTO for emerging techniology, IBM
Research UK, reports that IBM is also developing fully homomor-
phic encryption that will let users analyze data while it remains
secure and private. This method is based on lattice cryptogra-
phy, and basically allows data to be viewed so calculations can
be performed, but doesn't give access it.
Security joins safety
Another member of the Charter of Trust, TÜV Süd (www.tuv-sud.
com) and its four-year-old cybersecurity services division, TÜV
Süd Sec-IT, support it due to how fast the cybersecurity field is
evolving. For example, conventional tools like virus scanners and
firewalls aren't enough anymore, which is fueling demand for
"predict, detect, prevent and respond solutions."
"The sheer numbers of connected devices in the future mean
there will be a lot more vulnerabilities, so TÜV Süd has been shift-
ing its focus from testing and verification for functional safety to
also diving into cybersecurity," says Andy Schweiger, managing
22 • JANUARY 2019 www.controlglobal.com
director, TÜV Süd Sec-IT. "We're also moving from testing and
certification before a product goes to market to continuous testing
of firmware and software updates. In addition, where virus con-
trol used to be signature-based, it's moving to become behavior-
based, which is where machine learning and artificial intelligence
(AI) can help by showing how viruses can occur and spread."
TÜV Süd Sec-IT also recently established its Octoforce team
of cybersecurity experts to do accredited data protection test-
ing within TÜV Süd's community and procedures, and produce
reports and recommendations. Stefan Vollmer, CTO at TÜV Süd
Sec-IT, reports that Octoforce has two main teams, penetrating
testing and threat intelligence, which seek to better understand
cyber threats and attacks to help prevent them.
To furher mitigate some cyber intrusions and attacks, Stefan
Laudat, lead consultant at TÜV Süd Sec-IT, reports it's develop-
ing its TÜV Attack Surface Detection (ASD) service that includes:
• Digital footprint of an entity;
• Automated and manual red teaming;
• Device fingerprinting based on AI;
• OSINT-based digital reputation;
• Intelligence-led penetration testing;
• Critical asset identification; and
• Top management risk reports.
"TÜV ASD will also align OT and IT departments, combine their
internal processes with best practices, and achieve complete risk
awareness by using best-in-class tools and intelligence orches-
trated with artificial intelligence (AI) and machine learning (ML) to
determine weaknesses in infrastructure, web, cloud or social engi-
neering," explains Laudat. "We'll also deliver impartial, easy-to-un-
derstand reports, updated metrics and indicators, intelligence and
forecasting targeted at customers and/or third parties."
Solutions on display
The press tour concluded with a one-day visit to the recent SPS
IPC Drives 2019 tradeshow in nearby Nürnberg, which included
demonstrations of Siemens cybersecurity solutions.
"We're integrating Claroty anomaly detection technology with
Palo Alto firewalls, so HMIs can talk to PLCs, but not to other de-
vices," explains Stefan Waronka, global head of Siemens Indus-
trial Security Services. "This lets us create firewalls rules, so we
can do micro-segmenting of networks for improved cybersecu-
rity. Customers are also asking for security that's integrated into
operations centers on the IT, and we're supporting those efforts,
too. We also have McAfee's security information and event man-
agement (SIEM) scaled down into Siemens components, where
it can run standalone or be integrated into those devices.
"We're also using a secure product development lifecycle that
complies with IEC 62443-2-1, while our development team uses
TÜV Süd-certified blueprints. Siemens Industrial Security Ser-
vices is a comprehensive, modular, scalable portfolio that gives
users everything they need to assess, implement and manage
their applications securely."
 IN PROCESS

SIGNALS AND INDICATORS

• T he Industrial Internet Consortium (IIC, www.iiconsortium.org)
and the OpenFog Consortium (www.openfogconsortium.org) an-
nounced Dec. 18 that they've agreed to combine the two consortia
in industrial IoT, fog and edge computing, and finalize details in
early 2019. Their combined memberships will continue to develop
and promote best practices for fog and edge computing.
• Emerson Automation Solutions (www.emerson.com) reported
Dec. 13 that it's acquired Advanced Engineering Valves (www.ae-
valves.com), a 10-year-old manufacturer of valve technology that
helps LNG users operate more efficiently. Emerson also announced
Dec. 11 that it's acquired iSolutions Inc. (www.isolutions.com),
Calgary, Alberta, a consulting group with expertise designing and
implementing data management solutions.
• Measurement, Control & Automation Association (MCAA,
https://themcaa.org/) announced Dec. 20 its board of directors for
2019. Mike Waters, president and CEO, SOR Controls Group Ltd.,
was elected chairman, while Scott Saunders, president, Moore
Industries International Inc., will serve as vice chairman. MCAA's
new directors include Deryl Bell, president, Carotek Inc.; Russ
Graybill, director of product marketing, Yokogawa Corp. of America;
Stephen Santangelo, president, Palmer Wahl Instruments Inc; and
Colin Sheridan, president, Tel-Tru Manufacturing Co. The board
also includes past chairman Bharat Naik, president, Reotemp
Instruments, and directors Mike DeLacluyse, president, Lesman
Instrument Co.; Bill Edinger, general manager of process instru-
mentation, Siemens Industry; Gary Johnson, president, Azbil North
America Inc; and Jim Winter, director of global process business,
Rockwell Automation.
• ABB (www.abb.com) reported Dec. 7 that it's commissioned two
digital substations in Tolve and Vaglio, in southern Italy's Basili-
cata region. The substations will integrate and transmit electricity
generated by local wind farms, and contribute to Italy’s 2030 goal
to meet 28% of its energy needs with renewables. Products pro-
vided to the substations include ABB Ability automation and con-
trol systems, intelligent protection equipment, transformers with
sensors, digitally enabled switchgear and communication.

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Skids and modular systems on the move
Control's monthly resource guide
INTEGRATING PROCESS
CONTROLS, SKIDS
This online article, "The challenges in
integrating a process control system with
skid-based equipment: a case study"
by Robert Patrick, vice president of
engineering at Superior Controls Inc.,
a CSIA-certified system integrator in
Seabrook, N.H., examines two ways to
integrate process control systems (PCS)
with three different types of equipment
on skids. The article details questions
to ask, how to develop specifications,
identifies further issues that can arise,
and shows how a system integrator can
implement the most appropriate devices
for each application. It's located at
http://superiorcontrols.com/press-
releases/the-challenges-in-integrating-
a-process-control-system-with-skid-
based-equipment-a-case-study/
SUPERIOR CONTROLS INC.
http://superiorcontrols.com
FABRICATION, COOLING
TOWER PROJECT
The first of these two about four- to five-
minute videos, "Fabrication of a modular
skid" by M. Davis & Sons Inc., details
the company's history, engineering ap-
proach and capabilities for designing,
building and implementing process
skids. The second video, "DuPont cool-
ing tower project," show how the firm
carried out a project for a major cus-
tomer, and how it coordinates electri-
cal, piping and steel activities during
assembly. The first video is at www.you-
tube.com/watch?v=-inKzbHMzfU. The
second video is at www.youtube.com/
watch?v=Cxx8bIpqjSI&t=134sor
M. DAVIS & SONS INC.
www.mdavisinc.com
If you know of any tools and resources we didn’t include, send them to ControlMagazine@Putman.net with
“Resource” in the subject line, and we’ll add them to the website.
24 • JANUARY 2019 www.controlglobal.com
COMPILATION OF CASES
This online library, "Modular process
case studies," consists of more than 30
examples of skid builds and other proj-
ects carried out by Epic Systems. Topics
include pilot and demonstration, prod-
uct and commercial plant, continuous
process, industrial distillation, emulsion
systems, batch mixing, batch reactor, in-
dustrial pipe bridge, heat transfer, clean
in place (CIP) and wastewater treatment,
and more. It's located at www.epicmodular
process.com/case-studies
EPIC SYSTEMS
www.epicmodularprocess.com
ADDING BATCH PROCESSES
This blog entry, "OEM skid integration for
batch processes," by Robbie Peoples,
PE, integration manager at Cross Inte-
grated Systems Group, a CSIA-member
system integrator and one of six divisions
at Cross Co. in Knoxville, Tenn., outlines
the challenges of integrating skids for
batching, and includes four primary
guidelines for accomplishing it, includ-
ing allocating operating modes, following
standard operating states, defining status
feedback and standardizing communica-
tions. Visitors can also download a case
study about the Jack Daniel's distillery
on which the blog post is based. It's at
www.crossco.com/blog/process-control-
integration/oem-skid-integration-batch-
process
CROSS CO.
www.crossco.com
SHORT-SUBJECT VIDEOS
Many of the close to 30 short videos at
S&S Technical's YouTube channel cover
skid building, related equipment and the
firm's other capabilities. Topics include
skid solutions, quality assurance, walk-
throughs, piping, insulation, bidirectional
LPG loading and transfers including pro-
pane. They're located at www.youtube.
com/user/skidsolutions/videos
S&S TECHNICAL INC.
www.skidsolutions.com
MODULAR PLANTS WHITEPAPER
The 36-page whitepaper, "Modular
plants" by Dechema, covers the motiva-
tions, concepts and levels of modulariza-
tion, infrastructure and utilities, analyt-
ics, required working areas and gaps,
standardization and interfaces, planning,
apparatus development, scale-up, auto-
mation, logistics and supply chain, regu-
lations and other topics. It's at https://
dechema.de/dechema_media/modular-
plants.pdf
DECHEMA
https://dechema.de
LABORATORY SKID RENOVATION
This 33-page research paper, "Process
control laboratory skid refurbishment"
by Danny Crowder, summarizes the
condition of a salvaged process con-
trol skid, which the author reports was
originally built by others, but hopes will
be salvaged to serve the curriculum for
chemical engineering students at the
University of Akron. The paper covers
testing procedures, process equip-
ment, utilities, process and electri-
cal safety equipment, potential control
loops, budgeting considerations and
recommendations. It's at https://idea
exchange.uakron.edu/cgi/viewcontent.
cgi?article=1491&context=honors_
research_projects
IDEAEXCHANGE@UAKRON
https://ideaexchange.uakron.edu
 Brutal conditions.
Strict regulations.
Complex processes.
But you always
need to
measure up.

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©2019 Magnetrol International, Inc. experts at magnetrol.com
FEATURE EYEBROW
TAP VINTAGE EXPERTISE
End users toast the companies that provide the best in process control.
ENGINEERING, installing and maintaining automation
systems for safe, efficient, quality production takes many
talents. Along with a real grip on the technologies and
techniques of process control, you must have a good
understanding of manufacturing principles, finances,
people and more.
One of the most important tools in your belt is your
hard-won knowledge of what works. Through real-world
experience, you’ve found products and brands you can
rely on to give the best combination of performance,
ease of use, reliability and reasonable cost.
But no single automation professional is expert in
every one of the myriad categories of process control
hardware, software and systems necessary to properly
support today’s plant. Where do you turn when it’s time
to identify a new source for one of the less familiar needs
26 • JANUARY 2019
by Control staff
of your facility? Who do you want to consult—your pur-
chasing department? Your local reps? Magazine editors?
The web?
How about your fellow professionals who read Control?
That’s who we poll to determine our annual Readers’
Choice Awards.
A veritable who’s who
The professionals who took the time and made the ef-
fort to complete our lengthy, fill-in-the-blank surveys
worked hard at it. For each of more than 80 categories,
they decided whether or not they had the experience
to name up to three suppliers who, in their opinion, de-
liver the best technology. If so, they decided who those
suppliers would be, ranked them one to three, typed in
their names, and moved on.
www.controlglobal.com

What does it take to deliver the best tech-
nology? No respondent was able to fill in all
the blanks—many felt qualified to fill in less
than half the categories. Clearly, naming the
best supplier isn’t a casual decision. Today’s
industrial facilities increasingly rely on ven-
dors to not only deliver high-performance,
rugged, durable equipment and expert
services at rock-bottom prices, but to back
those products and services with competent,
immediate, 24/7 support. Only the strongest
suppliers can generate the loyalty that leads
to a place in our Readers’ Choice Awards.
Determined solely by readers’ responses,
the awards you’ll find on the following pages
name the vendors that provide the best tech-
nology in categories from software and systems
to instrumentation and final control elements. If
you’re not sure which ultrasonic flowmeters are
the best choice, what valve actuators provide
the finest control, whose SCADA package leads
the pack, or where to turn for excellence in
any of our 83 categories, the Control Readers’
Choice Awards arm you with a quick reference
to the preferences of your peers.
Cautions and congratulations
As you review this year’s winners, remember
that the fill-in-the-blank format of the survey
means every supplier has an equal chance—
the choices are not limited to a selection of
entries determined by vendors, editors or
other people who are not practicing process
automation professionals.
In the survey, we ask end users to vote
only in those categories where they have
personal experience. A vote for a specific
company should mean the respondent has
found its products to be better than other
companies’ in that category.
Every vendor named in the accompanying
tables has been designated as offering the best
value by a significant number of respondents.
Since more respondents have experience with
companies that have higher installed base or
market share, the results are inevitably biased
toward the larger companies. Furthermore,
there are certainly small companies that don't
make the list, no matter how excellent their
technologies, just because they are relatively
unknown. If you have a favorite smaller sup-
plier, consider yourself fortunate and don't
be concerned that they aren't in our Readers'
Choice Awards.
While we ask respondents to write in the
www.controlglobal.com
Best in Control: Readers'
Choice Awards by Process
name of the company, some write in the Automation Discipline
names or numbers of specific products or
software packages. We strive to recognize and
Continuous Regulatory Control
translate these responses into parent com-
1. Emerson Automation Solutions
pany names. In short, the Control Readers'
2. Honeywell Process Solutions
Choice Awards offer a reference list of brands 3. Rockwell Automation
that readers like you say offer the best—a ver- 4. Schneider Electric
itable who's who of plant equipment, software 5. ABB
and service providers. 6. Yokogawa
We’ve done our best to get experienced 7. Siemens Industry
automation professionals, people who have 8. GE Automation & Controls
the necessary perspective and wisdom to Safety/Emergency Shutdown
judge, without prejudice or penalty, who 1. Schneider Electric
makes the best stuff for process control. 2. Rockwell Automation
We express our heartfelt appreciation to 3. Emerson Automation Solutions
the hardy respondents who took the time to 4. Siemens Industry
share their valuable wisdom by selecting our 5. Honeywell Process Solutions
winners, and we congratulate each listed 6. (tie) ABB
vendor on being recognized in our Readers’ 6. (tie) HIMA
Choice Awards. 7. Yokogawa
Batch Process Automation
First up: Best in Control 1. Emerson Automation Solutions
Best in Control categories are broken down 2. Rockwell Automation
into six automation disciplines and by 10 verti- 3. Siemens Industry
cal industries. These platform categories are 4. Honeywell Process Solutions
dominated by the largest companies in process 5. Schneider Electric
automation, with little change in rankings from 6. ABB
year to year. But this year, Honeywell Process 7. Yokogawa
Solutions returned to first in Continuous Sheet/ 8. GE Automation & Controls
Web Monitoring & Control and rose to fourth in Sequential Logic Control
Batch Process Automation. Schneider Electric 1. Rockwell Automation
rose to third in Sequential Logic Control, fourth 2. Siemens Industry
in Continuous Regulatory Control, and fifth in 3. Schneider Electric
Batch Process Automation. 4. Emerson Automation Solutions
Rockwell Automation notched up to sec- 5. ABB
ond in Continuous Sheet/Web Monitoring & 6. Honeywell Process Solutions
Control, where Emerson Automation Solu- 7. GE Automation & Controls
tions bumped up to third. We welcome Yok- 8. Yokogawa
ogawa into the winners circle in Supervisory Continuous Sheet/Web Monitoring & Control
Control and Data Acquisition. 1. Honeywell Process Solutions
2. Rockwell Automation
Infrastructure supports the system 3. Emerson Automation Solutions
While many process automation product cat- 4. ABB
egories have seen extensive consolidation 5. Siemens Industry
through mergers and acquisitions, infrastruc- 6. Schneider Electric
ture remains dotted with independent com-
7. GE Automation & Controls
8. Yokogawa
panies that haven’t been bought, including
Pepperl+Fuchs in Intrinsic Safety, Moore Indus- Supervisory Control & Data Acquisition (SCADA)
tries for Signal Conditioners, and Phoenix Con- 1. Schneider Electric
tact in Power Supplies and Terminal Blocks. At 2. Rockwell Automation
the same time, Emerson Automation Solutions 3. Emerson Automation Solutions
replaces SolaHD because of its acquisition.
4. Honeywell Process Solutions
5. Siemens Industry
Wire and Cable remains led by the familiar
6. GE Automation & Controls
Belden, Southwire and Lapp, with Anixter
7. ABB
returning to the winners this year in fourth
8. Yokogawa
JANUARY 2019 • 27
BEST IN CONTROL BY DISCIPLINE AND INDUSTRY
Chemicals Electric Power Food & Beverage Metals, Minerals Oil & Gas
Manufacturing Generation Manufacturing & Mining Extraction
Continuous Regulatory Emerson Automation Emerson Automation Emerson Automation Rockwell Automation Emerson Automation
Control Solutions Solutions Solutions Solutions
Emerson Automation Emerson Automation Rockwell Automation Rockwell Automation Emerson Automation
Batch Process Automation Solutions Solutions Solutions
Continuous Sheet/Web Rockwell Automation
Monitoring & Control
Safety/Emergency Shutdown Schneider Electric Schneider Electric Rockwell Automation Rockwell Automation Schneider Electric
Supervisory Control Emerson Automation
Schneider Electric Schneider Electric Rockwell Automation Schneider Electric
& Data Acquisition Solutions
Sequential Logic Control Rockwell Automation Rockwell Automation Rockwell Automation Rockwell Automation Rockwell Automation

Petroleum Pharmaceuticals Plastics & Rubber Pulp & Paper Water & Wastewater
Refining & Life Sciences Manufacturing Manufacturing Processing
Continuous Regulatory Honeywell Process Rockwell Automation Rockwell Automation Emerson Automation Rockwell Automation
Control Solutions Solutions
Emerson Automation Rockwell Automation Rockwell Automation Emerson Automation Rockwell Automation
Batch Process Automation Solutions Solutions
Continuous Sheet/Web Siemens Industry ABB
Monitoring & Control
Safety/Emergency Schneider Electric Rockwell Automation Rockwell Automation Schneider Electric Rockwell Automation
Shutdown
Supervisory Control Honeywell Process Rockwell Automation Rockwell Automation Schneider Electric Schneider Electric
& Data Acquisition Solutions
Sequential Logic Control Rockwell Automation Rockwell Automation Rockwell Automation Rockwell Automation Rockwell Automation

INFRASTRUCTURE place. We welcome Phoenix Contact to Wireless Infrastructure this

Input/Output System
1. Rockwell Automation
2. Emerson Automation Solutions
3. Siemens Industry
4. ABB
5. Honeywell Process Solutions
Intrinsic Safety
1. Pepperl+Fuchs
2. Rockwell Automation
3. MTL Instruments
4. Phoenix Contact
5. R. Stahl
Power Supply
1. Phoenix Contact
2. Rockwell Automation
3. Emerson Automation Solutions Wireless Infrastructure
4. Siemens Industry
5. Acopian
Signal Conditioner
1. Phoenix Contact
2. Pepperl+Fuchs
3. Acromag year in fourth place, and ABB to Terminal Blocks in fifth.
4. Moore Industries
5. Rockwell Automation Seek your own level
It seems so simple to automate the elementary tasks of looking at
Terminal Block
a sight glass or dipping in a stick, but level remains an area where
1. Phoenix Contact
instrumentation based on the simplest principles (like some things
2. Weidmuller
float) competes with nuclear radiation and microwave radar to pro-
3. Rockwell Automation
vide the least expensive, most reliable and exactly appropriate way
4. Wago
to deal with fluids from flammable hydrocarbons to sticky foams,
5. ABB
clumping solids and elusive interfaces.
Wire & Cable However, once you know what you want, there are still some
1. Belden specialized companies that may win your loyalty. And if you are
2. Southwire surprised that a favorite one of those smaller companies isn't in
3. Lapp our rankings, you may find that it's owned by one of the majors—
4. Anixter we roll those votes up into a single total for the parent company.
5. Alpha This year, a notable change is Endress+Hauser’s rise to first
place in Level Switch, Ultrasonic. New and returning winners in-
1. Emerson Automation Solutions clude Varec for Level Gauge, Inventory Grade; AutomationDirect for
2. Cisco Level Gauge, Magnetostrictive; Magnetrol for Level Switch, Vibra-
3. Honeywell Process Solutions tion; Wika for Magnetic Level Indicator; Omega Engineering for Level
4. Phoenix Contact Gauge, Ultrasonic, and Level Switch, Electrical Property-based; and
5. Rockwell Automation Endress+Hauser and VEGA Americas for Level Gauge, Laser. There
are no losers on these charts.

28 • JANUARY 2019 www.controlglobal.com

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Flow keeps rolling
For years now, advances in flow detection and measurement
have centered more on accuracy, reliability and communica-
tions than the measurement technologies themselves. In a way,
it helps that the large system companies have bought up many
niche manufacturers because it means they can truly recom-
mend the best technology for the job. Some are so good, our vot-
ers think they make instruments in categories where they don’t.
This year, unchanged first-place winners in all the flow catego-
ries belie stiff competition in some of the technologies. Krohne is
new or returning for Magnetic Flowmeter, ABB for Thermal Mass
Flowmeter, Ametek for Open Channel Flowmeter, GE Dresser for
Turbine Flowmeter, and Endress+Hauser for Turbine and Positive
Displacement flowmeters.

LEVEL INSTRUMENTATION
Level Gauge, Capacitance/
Admittance/Conductance
1. Endress+Hauser
2. Emerson Automation Solutions
3. Ametek Drexelbrook
4. Magnetrol
5. VEGA Americas
Level Gauge, Float/Displacer
1. Emerson Automation Solutions
2. Magnetrol
3. Endress+Hauser
4. Schneider Electric
5. ABB
Level Gauge, Guided Wave
1. Emerson Automation Solutions
2. Endress+Hauser
3. VEGA Americas
4. Magnetrol
5. ABB
Level Gauge, Non-Contacting Radar
1. Emerson Automation Solutions
2. Endress+Hauser
3. VEGA Americas
4. Siemens Industry
5. ABB
Level Gauge, Inventory Grade
1. Emerson Automation Solutions
2. Endress+Hauser
3. Honeywell Enraf
4. VEGA Americas
5. Varec
Level Gauge, Laser
1. ABB
2. Emerson Automation Solutions
3. Endress+Hauser
4. Keyence
5. (tie) Binmaster
5. (tie) VEGA Americas
Level Gauge, Magnetostrictive
1. Emerson Automation Solutions
2. Orion Instruments
3. ABB
4. MTS
5. Automation Direct
Level Gauge, Radiometric (Nuclear) 3. Endress+Hauser
1. VEGA Americas 4. ABB
2. Endress+Hauser 5. SOR
3. Thermo Scientific Level Switch, Ultrasonic
4. Emerson Automation Solutions 1. Endress+Hauser
5. Berthold Technologies 2. Emerson Automation Solutions
Level Gauge, Ultrasonic 3. Magnetrol
1. Endress+Hauser 4. VEGA Americas
2. Emerson Automation Solutions 5. Ametek Drexelbrook
3. Siemens Industry Level Switch, Vibration
4. VEGA Americas 1. Endress+Hauser
5. Omega Engineering 2. Emerson Automation Solutions
Level Switch, Electrical 3. VEGA Americas
Property-based 4. Magnetrol
1. Endress+Hauser 5. Ametek Drexelbrook
2. Emerson Automation Solutions Magnetic Level Indicator
3. Magnetrol 1. Orion Instruments
4. VEGA Americas 2. Emerson Automation Solutions
5. Omega Engineering 3. ABB
Level Switch, Mechanical 4. Endress+Hauser
1. Magnetrol 5. WIKA
2. Emerson Automation Solutions

FLOW INSTRUMENTATION
Coriolis Flowmeter 3. Siemens Industry Turbine Flowmeter 3. Emerson Automation Solutions
1. Emerson Automation Solutions 4. ABB 1. Emerson Automation Solutions 4. ABB
2. Endress+Hauser 5. Ametek 2. Endress+Hauser 5. Yokogawa
3. Krohne Positive Displacement Flowmeter 3. Badger Meter Vortex Flowmeter
4. Yokogawa 1. Emerson Automation Solutions 4. GE Dresser 1. Emerson Automation Solutions
5. ABB 2. Brooks Instrument 5. Omega Engineering 2. Endress+Hauser
Magnetic Flowmeter 3. FMC Technologies Ultrasonic Flowmeter (Closed Pipe) 3. Yokogawa
1. Emerson Automation Solutions 4. Badger Meter 1. Emerson Automation Solutions 4. Schneider Electric
2. Endress+Hauser 5. Endress+Hauser 2. Endress+Hauser 5. ABB
3. Yokogawa Thermal Mass Flowmeter 3. Krohne Flow Switch
4. Krohne 1. FCI 4. GE Automation & Controls 1. Endress+Hauser
5. ABB 2. Endress+Hauser 5. Siemens Industry 2. FCI
Open Channel Flowmeter 3. Emerson Automation Solutions Variable Area Flowmeter 3. Emerson Automation Solutions
1. Endress+Hauser 4. ABB 1. Brooks Instrument 4. Dwyer
2. Emerson Automation Solutions 5. Sierra 2. Krohne 5. Magnetrol

30 • JANUARY 2019 www.controlglobal.com

Temperature and pressure cook along
Pressure and temperature switches and transmitters play ma-
jor roles in field instrumentation. This year, our only change in
the top rankings is that FLIR Systems took over first place in
Infrared Imaging/Thermography.
Lower in the rankings, Honeywell Process Solutions is back
for Pressure Transmitter and Temperature Transmitter, JMS
Southeast for Thermocouple, and Williamson for Infrared Tem-
perature Sensor.
Outfitting the interfaces
Software needs a place to run and a way for operators to run
it. That may be in a centralized control room or various loca-
tions across the plant—either way, you often need pieces

TEMPERATURE & PRESSURE

Pressure Transmitter Resistance Temperature Detector Temperature Transmitter Infrared Imaging/Thermography
1. Emerson Automation Solutions 1. Emerson Automation Solutions 1. Emerson Automation Solutions 1. FLIR Systems
2. Endress+Hauser 2. Omega Engineering 2. Endress+Hauser 2. Fluke
3. Yokogawa 3. Endress+Hauser 3. Yokogawa Temperature Switch
4. Honeywell 4. (tie) Pyromation 4. Honeywell 1. Emerson Automation Solutions
5. Schneider Electric 4. (tie) JMS Southeast 5. Schneider Electric 2. Ashcroft
Pressure Switch Thermocouple Infrared Temperature Sensor 3. Omega
1. Emerson Automation Solutions 1. Emerson Automation Solutions 1. Fluke 4. Endress+Hauser
2. Ashcroft 2. Omega Engineering 2. Omega Engineering 5. United Electric
3. United Electric 3. Pyromation 3. FLIR Systems
4. Endress+Hauser 4. Endress+Hauser 4. Emerson Automation Solutions
5. SOR 5. JMS Southeast 5. Williamson

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www.controlglobal.com JANUARY 2019 • 31

 from this eclectic collection of specialized hardware.
This year, Schneider Electric took top place in Process Loop
Controller. The company also showed up, along with Honeywell
Process Solutions in the Annunciator category, and along with
Phoenix Contact, in the Industrial Computer category.
The Industrial Computer category collects many votes for Dell
and HP, reflecting either support for non-industrial PCs or the
rising tendency for computational power to be allocated to serv-
ers. If either of those are your style, they may be your winners.
Intelligence in software
Software powers the control system’s brains and communications,
so it’s no surprise that many software winners are the same compa-
nies we saw at the top of the equivalent platform categories.
This year, Schneider Electric (with its Wonderware, Foxboro,
Invensys and Triconex brands) took the lead in Supervisory
Control and Data Acquisition (SCADA) Software, where Sie-
mens and Honeywell Process Solutions made fresh appear-
ances. ABB showed up in OPC Connectivity and Asset Man-
agement; Honeywell Process Solutions in Human-Machine
Interface (HMI); Emerson Automation Solutions and Siemens
in Design/Documentation; and Schneider Electric in Advanced
Process Control Software.
Elsewhere in the field
Here’s our collection of essential field equipment, instrumenta-
tion and devices that don’t fit into another major category. Don’t
be confused by Pentair’s name change to nVent—and that’s still
where we count all the Hoffman votes.
These categories are led by solid performers that remain at
the top. In the rest of the rankings, Honeywell Process Solu-
tions is back for Data Acquisition System, GE Druck for Portable

INTERFACES
Annunciator
1. Ametek
2. Rockwell Automation
3. Ronan Engineering
4. Honeywell Process Solutions
5. Schneider Electric
Industrial Computer
1. Rockwell Automation
2. Advantech
3. Siemens Industry
4. Schneider Electric
5. Phoenix Contact
Operator Interface Terminal
1. Rockwell Automation
2. Siemens Industry
3. Schneider Electric
4. Red Lion Controls
5. Emerson Automation Solutions
Panel Display
1. Rockwell Automation
2. Siemens Industry
3. Red Lion Controls
4. Schneider Electric
5. ABB
Process Loop Controller
1. Schneider Electric
2. Honeywell Process Solutions
3. Yokogawa
4. Emerson Automation Solutions
5. Rockwell Automation
Recorder
1. Yokogawa
2. Honeywell Process Solutions
3. ABB
4. (tie) Endress + Hauser
4. (tie) Schneider Electric

SOFTWARE
Advanced Process Control
Software
1. Emerson Automation Solutions
2. Rockwell Automation
3. Honeywell Process Solutions
4. ABB
5. Schneider Electric
Alarm Management Software
1. Honeywell Process Solutions
2. Emerson Automation Solutions
3. Rockwell Automation
4. Schneider Electric
5. PAS
Asset Management Software
1. Emerson Automation Solutions
2. Rockwell Automation
3. Schneider Electric
4. ABB
5. Honeywell
Calibration Management
Software
1. Fluke
2. Emerson Automation Solutions
3. Beamex
4. Rockwell Automation
5. Endress+Hauser
Design/Documentation Software
1. Autodesk
2. EPLAN
3. Intergraph
4. Emerson Automation Solutions
5. Siemens Industry
Human-Machine Interface
Software
1. Rockwell Automation
2. Schneider Electric
3. Siemens Industry
4. Emerson Automation Solutions
5. Honeywell Process Solutions
Loop-Tuning Software
1. Emerson Automation Solutions
2. ExperTune
3. Rockwell Automation
4. Honeywell Process Solutions
5. Control Station
OPC Connectivity
1. Matrikon OPC
2. Kepware Technologies
3. Rockwell Automation
4. Emerson Automation Solutions
5. ABB
PLC Programming Software
1. Rockwell Automation
2. Schneider Electric
3. Siemens Industry
4. GE Automation & Controls
5. AutomationDirect
SCADA Software
1. Schneider Electric
2. Rockwell Automation
3. Emerson Automation Solutions
4. Siemens Industry
5. (tie) ABB
5. (tie) Honeywell Process Solutions
Simulation Software
1. Emerson Automation
Solutions
2. Rockwell Automation
3. Honeywell Process Solutions
4. Schneider Electric
5. Aspentech

32 • JANUARY 2019 www.controlglobal.com

CT1901_26_35_CoverStory_RCA_v2.indd 32 1/10/19 3:08 PM

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ELSEWHERE IN THE FIELD Calibrator, and ABB for Remote Terminal Unit and for Vibration
Data Acquisition System Remote Terminal Unit Instrumentation, where it shares the fresh limelight with Metrix.
1. Rockwell Automation 1. Rockwell Automation
2. Schneider Electric 2. Schneider Electric A look inside analyzers
3. National Instruments 3. Emerson Automation Solutions As the ability to make sensitive composition measurements has
4. Honeywell Process Solutions 4. Siemens Industry largely moved from the laboratory to the plant floor, few and
5. OSI Software 5. ABB highly specialized manufacturers are able to combine precision
with the ruggedness and stability required for industrial-strength
Enclosure Instrument Fittings
reliability. The companies with the right engineering and fabrica-
1. nVent 1. Swagelok
tion chops change little from year to year.
2. Rittal 2. Parker Hannifin
Of note for 2019, ABB took first place and Ametek broke
3. Saginaw Control & Engineering 3. Hy-Lok
into Process Spectrometer. Draeger showed up in Ambient Gas
4. Hammond Manufacturing Vibration Instrumentation Detector, Yokogawa in Humidity/Moisture Analyzer, Agilent in
5. Hubbell Weigmann 1. GE Energy Process Chromatograph, and Thermal Fisher Scientific in Stack
Purge System 2. Emerson Automation Solutions Gas/Emissions Analyzer.
1. Pepperl+Fuchs 3. ABB
2. nVent 4. Fluke Final elements make their moves
Portable Calibrator 5. Metrix This year, we complete the recognition of ABB’s acquisition of
1. Fluke Weighing System/Load Cell Baldor Electric by migrating the top name in the Electric Motor
2. Emerson Automation Solutions 1. Mettler Toledo category to ABB Motors & Mechanical. We welcome Marathon
3. Beamex 2. Hardy Process Solutions back to Electric Motor, Festo and Metso to Pneumatic Valve Ac-
4. GE Druck 3. Rice Lake Weighing Systems tuator, and Festo and Cameron to On/Off Valve.
5. (tie) Honeywell Process Solutions 4. Siemens Industry Thanks again to all the process control professionals who
5. (tie) Yokogawa 5. BLH Nobel completed the surveys and chose the winners of the 2019 Con-
trol Readers’ Choice Awards.

ANALYZERS
Ambient Gas Detector 5. ABB 4. Hach 3. Yokogawa
1. Emerson Automation Solutions Humidity/Moisture Analyzer 5. Schneider Electric 4. Siemens Industry
2. MSA 1. Vaisala Process Spectrometer 5. Agilent
3. ABB 2. GE Measurement & Control 1. ABB Stack Gas/Emissions Analyzer
4. Thermo Fisher Scientific 3. Emerson Automation Solutions 2. Emerson Automation Solutions 1. Emerson Automation Solutions
5. Draeger 4. Ametek 3. Thermo Fisher Scientific 2. Yokogawa
Density/Concentration Analyzer 5. Yokogawa 4. Yokogawa 3. Ametek
1. Emerson Automation Solutions pH/ORP/Conductivity Analyzer 5. Ametek 4. ABB
2. Endress+Hauser 1. Emerson Automation Solutions Process Chromatograph 5. Thermal Fisher Scientific
3. Yokogawa 2. Endress+Hauser 1. Emerson Automation Solutions
4. Thermo Fisher Scientific 3. Yokogawa 2. ABB

FINAL CONTROL ELEMENTS

Control Valve 4. Flowserve 2. Metso 3. Siemens Industry
1. Emerson Automation Solutions 5. Honeywell 3. Flowserve 4. Schneider Electric
2. Samson Controls Pneumatic Valve Actuator 4. Festo 5. Yaskawa
3. GE Energy 1. Emerson Automation Solutions 5. Cameron Electric Motor
4. Flowserve 2. Flowserve * Includes Emerson Industrial 1. ABB Motors & Mechanical
5. Metso 3. Festo Automation (ASCO) and Emerson 2. Siemens Industry
Electric Valve Actuator 4. Metso Automation Solutions brands 3. GE Power Conversion
1. Emerson Automation Solutions 5. Samson Electric Motor Drive 4. Marathon
2. Rotork Controls On/Off Valve 1. Rockwell Automation 5. WEG
3. Auma Actuators 1.Emerson Electric* 2. ABB

34 • JANUARY 2019 www.controlglobal.com

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 Empathy aids HMI design
by Nandita Gupta
How to design safer, more usable HMIs by being more inclusive
THE goal of any human-machine in-
terface (HMI) should be to make tasks
efficient and user-friendly. In the past
10-15 years, there's been a shift in HMIs
from task orientation to usability/user
experience. Just as mainstream users
get error messages like "this password
doesn't meet requirements,” but have no
idea what the requirements are and get
unhelpful feedback, industrial operators
working on HMIs face similarly frustrating
issues. Consequently, HMI designs that
include end users and operators have a
higher probability of success and can re-
duce these frustrations.
Engineers and designers can get stuck
trying to make solutions that look good to
them and their view of the world, but what
does "good" look like? This can be relative
and subjective, especially when people
aren't on the same page. Engineers focus
on making products technically good, but
this may not always meet the needs of a
paper machine operator, who needs a sim-
ple way to do his job efficiently. Starting an
HMI design from scratch can be a daunting
task—one may not know where to begin,
and overwhelming research results and
available methods can be misleading.
Humans are also prone to making mis-
takes. We need to understand there's not
36 • JANUARY 2019 www.controlglobal.com
a perfect human, who makes no mistakes,
nor will the system they use never pose any
issues. The goal of a safe and reliable HMI
should be to handle errors and make the
system failsafe, so when issues do arise,
they're dealt with in a failsafe manner where
no one gets hurt. Focusing on user needs
and expectations, and including those on
the front end of the design, has a huge im-
pact on accounting for potential issues.
Design considerations
Psychology plays an important role in
HMI design. Even though people are
unique and think differently, humans
have inherent characteristics that drive
behaviors, and understanding these nu-
ances can help HMI design. For example,
an e-stop button should be in the top
left corner of screens in North America,
where our eyes scan left to right, top to
bottom, so information in the top left cor-
ner is noticed quickly.
Human-centered design should be
implemented for HMIs, and as part of this,
co-design including operations and man-
agement teams ensures well-rounded de-
sign. Involving users early helps build trust,
and results in stronger designs. Designing
for usability and accessibility ensures HMIs
can be used by a range of people, includ-
ing those with visual or cognitive disabilities.
Accessibility also means incorporating the
needs of other users, including those from
different cultures and countries.
Empathic design is crucial to an effective
HMI, which should be designed and struc-
tured for end users, not its designers. There
are resources that can produce efficient
HMI design and improve usability/user
experience. One classic reference is the
"Eight Golden Rules of Interface Design"
by Ben Shneiderman, a computer scientist
and professor at the University of Mary-
land's Human-Computer Interaction Lab1,
which can be applied to HMI design:
1. Strive for consistency. Consistent
sequences of actions should be required
in similar situations; identical terminology
should be used in prompts, menus and
help screens; and consistent commands
should be employed throughout. In an
HMI, this means applying the same naviga-
tion structure throughout the project, and
maintaining consistency of buttons and be-
haviors through the HMI.
2. Let frequent users use shortcuts. As
frequency of use increases, so do users'
desires to reduce interactions and increase
pace of interactions. Abbreviations, func-
tion keys, hidden commands and macro
facilities help expert users. In one HMI proj-

ect, Forward and Back buttons were used 7. Support internal locus of control.
for next and previous screen changes. Experienced operators strongly desire the
3. Offer informative feedback. For every sense that they're in charge of the system
operator action, there should be system and that it responds to their actions. So, de-
feedback. For frequent and minor actions, sign the system to make users the initiators
responses can be modest. For infrequent of actions, rather than responders to it.
and major actions, responses should be 8. Reduce short-term memory load.
more substantial. For example, when an The limit of human data processing in
operator tries to start a motor with a Start short-term memory requires keeping
button, but there's a delay, feedback such displays simple, consolidating multiple
as "waiting for input" or "processing" gives page displays, reducing window-motion
feedback on the button press. frequency, and allotting training for codes,
4. Design dialog to yield closure. Se- mnemonics and sequences of actions.
quences of actions should be organized
into groups with a beginning, middle and Involve and empathize
end. Feedback at the completion of a group Human-centered design must involve
of actions gives operators the satisfaction of users in all phases, but there are differ-
accomplishment, a sense of relief, the sig- ent ways to elicit information from them.
nal to drop contingency plans/options from To empathize with users, HMI designers
their minds, and indication the way is clear can use methods such as surveys, inter-
to prepare for the next group of actions. views and affinity charts. These narrow
5. Offer simple error handling. As much and define requirements, and lead to the
as possible, design the system and HMI so ideation process (Figure 1). It's crucial to
users can't make serious errors. If an error not jump on the first design idea—and
is made, the system should detect the error think like a designer, not just an engineer.
and offer simple, comprehensible mecha- A diverse user testing group also plays a
nisms for handling it. A message stating huge role in defining user requirements.
‘XD097Xd error!’ isn't useful; a message For example, on average, 10% of the
saying, "Restart the application due to sys- population is color blind, so if an HMI is
tem error" is more beneficial. designed with reds and greens, its color
6. Permit easy reversal of actions. This coding could render it inaccessible for
relieves anxiety because the user knows er- some users. To design for inclusiveness,
rors can be undone, which encourages ex- one needs to understand users' needs,
ploration of unfamiliar options. The units of and test proposed interfaces with them.
reversibility may be a single action, a data Interviews and surveys are good ways to
entry or a complete group of actions. collect data from users. Interviews may be
Construct a Build a
point of view representation
that's based of one or more
Empathize on user needs Ideate of your ideas to Test
and insights show to others
Learn about Brainstorm Return to your
audience for Define and come up Prototype original user
whom you're with creative group and test
designing
solutions your ideas for
feedback
STEPS TO HMI SUCCESS
Figure 1: To design effective HMIs, designers must involve users early, empathize with them,
and secure their input, using various methods, such as surveys, interviews and affinity charts,
which help narrow and define requirements, and lead to the ideation process.
www.controlglobal.com JANUARY 2019 • 37
OPERATOR INTERFACE AND HMI
followed by a survey, and also document
the evolution of an HMI design. It's impera-
tive to not use a complex survey that can't
gain input. Considerations to keep in mind
for a survey for an HMI design include:
1. Use simple language and examples
if needed. For example: “Does it return to
higher-level menus with one click? (How
many clicks to get to overview screens?)”
2. Mix up questions to break up the
monotony. If the survey asks for detailed
answers to all questions, the likelihood of
users completing them is low. Creating a
mix of Y/N questions and some requiring
more detailed input will yield better results.
3. Questions requiring detailed answers
that span more than a couple sentences
should be treated as interview questions.
One-on-one interviews let users tell their
stories with less miscommunication. Sur-
veys with a follow-up summary are useful,
but may not provide the same qualitative
data as interviews. Interviews provide rich
qualitative data, and surveys provide more
quantitative data. Initial interviews with op-
erators showed the inconsistency within the
HMI system, and brought forward opportu-
nities for improvement that were needed to
improve performance. Understanding what
the user needs—not just what they want—
can be challenging. It helps to understand
the process, so you can ask more challeng-
ing, thought-provoking interview questions.
Usability surveys can help determine if
there's an aspect in the HMI that needs
more work than others. Surveys can not
only be used during initial design stages,
but can also be used later to track HMI sys-
tem performance and user experience. [An
example of a survey structure and sample
questions are included with the online ver-
sion of this story at www.controlglobal.com/
articles/2019/empathy-aids-hmi-design.]
Affection for affinity
Beyond surveys and interviews, human-
centered design requires observation and
gathering insights because there's usually
a disconnect between what people do
and what they say. Observing operators
shows designers how to make HMIs more
efficient and user friendly. During obser-
OPERATOR INTERFACE AND HMI
vations, we noticed an operator switching between three screens
to do one task that's repeated at least twice daily. This operator
was so acclimated to switching screens that it had become a re-
petitive task. During the HMI redesign, these observations were
accounted for, and the new screen halved this task's completion
time.
Collecting observations and insights for HMI design can also be
done with an affinity chart or diagram, which documents ideas,
opinions and issues during brainstorming, and organizes them into
groups based on natural relationships. They're built from the bottom
up into a structure that forces designers to deal with each field ob-
servation, and think about what it tells them about the user’s world.
This produces one hierarchical structure that tells the story of issues
across the user population when read from the top down.
This method brings out ideas for organization, and groups differ-
ent observations into a structure that made sense for the operators.
After going through this process with many operators, a pattern
emerged—all had very similar affinity charts. An affinity chart in a
paper mill (Figure 2) portrays the process created by discussions
with operators, and shows the grouping of the HMI with a focus on
tasks and actions, instead of focusing on machines. Many opera-
tors were skeptical about the process, but as the affinity chart was
formed, they were surprised at the different structure for the HMI
and screen organization. Initially, they attempted to group their tasks
in each machine area, but after they reassessed, the structure for
the various tasks was grouped by modes of operation.
For example, start-up tasks would be different than monitoring
or troubleshooting tasks. Currently, Task A, Task B and Task C in
Figure 2 are on the same area on the machine, and are grouped
together. However, for an operator to complete one task, he must go
through six different screens to complete it. With the new hierarchy,
the operator realized those six different settings/actions should be
grouped together on one screen that can complete the task/action.
Responses to this affinity diagram included, “I never saw the
HMI arranged this way!” and “This makes so much more sense. We
shouldn't need to go change the draws for the wires on four differ-
ent screens” and “This is different.”
Inclusion enables HMI design
Training and continuous improvement play an important role
in the success of an HMI project. People can be resistant to
change, and it can be hard to transition from a 15-20-year-old
HMI. The biggest advantage of involving users upfront is it en-
sures seamless training and implementation. And considering
their ideas during the design process helps drive the design. It
also gives users a sense of ownership of the final product, which
leads to a more seamless transition. People work toward things
they care about, so it's imperative to involve users from the be-
ginning. Also, user feedback on testing shows if an HMI design
meets their requirements. The designer has to plan, check and
adjust, and this feedback loop ensures more successful HMI
designs.
38 • JANUARY 2019 www.controlglobal.com
AFFINITY IS EFFECTIVE
Figure 2: This affinity chart at a paper mill shows the process created
by discussions with operators, and demonstrates the grouping of
the HMI with a focus on tasks and actions, instead of focusing on
machines. It showed that, for an operator to complete one task, he
must go through six different screens. With a new hierarchy, those six
different settings/actions could be grouped on one screen.
People are different; everyone learns and interprets differently.
Understanding the psychology of how people think and behave,
and factoring those pieces in an HMI design, improves the project's
probability for success. Applying design techniques and soliciting
user input at different stages of the project is beneficial, and imple-
mentation is more seamless than introducing a new system they've
never seen or used.
Designers may not know every user, but they can develop inclu-
sive practices to create experiences that support a wider range of
people. Inclusive design forms the bond that creates a more usable
interface. This also aids in safety as users' psychology is considered
while designing a failsafe system.
In conclusion, usability plays a huge role in HMI designs. Build-
ing a product for users isn't about how well the product works, it’s
about how well users can employ it to solve problems. Similarly, in
HMI design, when the interface design is usable and user-oriented,
operators will have a superior user experience that enables them to
complete their tasks in an efficient manner.
Footnote
1
"Schneiderman’s Eight Golden Rules Will Help You Design Bet-
ter Interfaces," Interaction Design, www.interaction-design.org/
literature/article/shneiderman-s-eight-golden-rules-will-help-you-
design-better-interfaces
Nadita Gupta is a process control engineer at Georgia Pacific. She can
be reached at Nandita.Gupta@gapac.com.
 Maximoic Era

PreChaotic Era
Minimizoic Era

2018 Connected
1/2003 1/2004 1/2005 1/2006 1/2007 5/2008 Reliability Era

Manualzoic Era Maximizoic Era

Mobilezoic
Era

Connecting the unconnectable

How Johnson & Johnson eased condition-based maintenance, change management and FDA approvals.
by Paul Studebaker

JOHNSON & Johnson (www.jnj.com) is
a multinational manufacturer of medical
devices, pharmaceuticals and consumer
packaged goods. Founded in 1886 and
headquartered in New Brunswick, N.J., it
includes some 250 subsidiary compa-
nies with operations in 60 countries and
products sold in more than 175 countries.
Johnson & Johnson brands include nu-
merous household names of medications
and first-aid supplies, including Band-Aid,
Tylenol, Johnson’s baby products, Neu-
trogena skin and beauty products, and
Acuvue contact lenses.
As a quality-oriented and regulated
manufacturer of medical supplies, John-
son & Johnson performs time-based,
son. At the time, the drivers for the new
AM system were compliance, as the
existing system was at the end of its life;
financial savings by reducing the system
footprint while maximizing ROI; and “A
standard product that drove to the fu-
ture,” Craft says. “At the time, we didn’t
realize how big a deal this would be.
“We set out to predict asset failure,
and wanted a process to support data
capture into the CMMS. We choose
Maximo. I was the technical lead and de-
signed the platform.”
Enterprise Manufacturing Location
platform
Server US Server
Dozens of sites around the world were
converted to standard naming conventions,
one workflow, and the same user interface
worldwide. “Johnson & Johnson connected
the unconnectable,” says Kevin Clark, now
vice president, Accelix, Fluke Digital Sys-
tems. “For satisfying FDA requirements, it
became one process, one technology to
pull data for 150 plants, which saves mil-
lions on validation costs.”
Clark started as a SCADA engineer with
Johnson & Johnson, “Back in the days of
pagers, not connecting easily from home,
LocalWonderware
Server xxxxxxxxx

xxxxxxxxx xxxxxxxxx
preventive maintenance according to Site OPC Siemens
Site Server PLCs
schedules written and approved by plant
Core DC Server
management and its equipment manu- Data Connector
Server xxxxxxxxx

facturers. Maintenance requirements Site OPC Schneider

PLCs
are incorporated into its production
schedules, so moving to condition-based
and predictive maintenance offers the
potential for significant savings, but must
Real time WORK Real time ASSET information
be approved for compliance. With many
documentation to CMMS to technician
facilities running locally developed regi-
mens, such efforts were generally frag-
Real time ASSET condition to CMMS triggering WO/JP/SR
mented, and limited in scope and ROI. IBM - MAXIMO 7.6
“In 2011, Johnson & Johnson made a | Confidential

collective decision to pursue a standard PROJECT ARCHITECTURE

platform for asset management (AM),” The original Maximo implementation had mobile capabilities, but was too slow communicating
says Shannon Craft, senior manager, with added alarms, instruments and iPads. The group designed an architecture using SCHAD
supply chain systems and solutions technologies and Fluke Connect to overcome the speed limitations of the existing system and
(SCSS) project delivery, Johnson & John- more fully integrate mobile.

www.controlglobal.com JANUARY 2019 • 39


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for BACnet Experts
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it was just hard,” he says. “Now, SCADA is fun. You can do it instantly and
repeatedly. That’s what’s going to make IoT explode.”
Craft adds, “By 2014, we moved 38 sites on 17 platforms into one sys-
tem—out-of-the-box Maximo. Now, we have more than 130 sites on the
same system. The trick was how to get them to use it. We had to teach them,
show them, and get them to abandon 30-year-old practices.”

• EZ BACnet Gateway Going mobile

The original Maximo implementation had mobile capabilities, “but as we got
• QuickServer Protocol into alarms, communications and iPads, the speed wasn't capable,” Craft
Gateway says. “About two years ago, we found a SCHAD mobile tool that could talk to
many services and drive data into Maximo. I learned I could build automation
into Maximo to communicate thresholds—alerts—with notifications by email,
etc. An alarm can create a work order and send it to a technician.”

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At the time, “Test-and-learn (T&L) was part of a Johnson & Johnson
Factory of the Future initiative to create an IIoT-connected plant. This
Processing resulted in a great marriage between my plan and Johnson & Johnson
priorities,” Craft says. Craft’s group designed an architecture to overcome
the speed limitations of the existing system and more fully integrate mobile
(Figure 1). The trial met or beat the target expectations (Table 1).
“The T&L was so successful, we knew we would use SCHAD,” adds Craft.
Becoming condition-based
Johnson & Johnson deployed mobile across 50 sites for work order and
inventory management. “The condition-based maintenance (CBM) portion

MONITOR VISCOSITY SIMPLY has a two-stage process,” Craft says. “First, the low-hanging fruit, with the
biggest ROI. But we’re heavily regulated, so to turn calendar-based PMs to
SENSE MIXER MOTOR HORSEPOWER runtime-based PMs, we have a lot of QC people across the globe who have to
WITH UNIVERSAL POWER CELL be convinced that their reliability will not be affected.”
EASY INSTALLATION The second step is condition-based maintenance (CBM), using tempera-
s.OHOLESINTANKSORPIPES
ture, vibration, ultrasound, etc. “with Fluke and Flir instrumentation,” Craft
s!WAYFROMSENSITIVEPROCESSES
says. “The other component for CBM is alarms and alerts, through Fluke
VERSATILE
s/NESIZEADJUSTSTOMOTORSFROM and SCHAD. This is specific to the assets, so what works, for example, on a
SMALLUPTOHP POWER
SENSOR lathe at one plant can be used at others.”
s7ORKSONPHASElXEDORVARIABLE The SCHAD QR code app can convert drawings, safety sheets, etc. for
FREQUENCY$#ANDSINGLEPHASEPOWER
mobile, digital access, which reduces mean times to diagnose and repair.
SENSITIVE
“At the end of the T&L, this was selected as the number-one project to be
sTIMESMORESENSITIVETHAN
JUSTSENSINGAMPS launched across Johnson & Johnson in 2019,” Craft says. “It was piloted in
CONVENIENT OUTPUTS eight facilities worldwide, and is now in 30.”
s&ORMETERSCONTROLLERSCOMPUTERS MIXER The T&L and pilot results revealed an opportunity in ROI that “is al-
 MILLIAMPS VOLTS MOTOR
most staggering,” Craft says. “On average, PMs were reduced by 30%,
MTTR was reduced by 20%, and spare parts were reduced by 15%.
This equates to an increase in asset availability of almost 50% across the
globe. We're doing the right PM at the right time with the right resource
and increasing the output with a reduced downtime in production. John-
son & Johnson will move into the leading position for asset management
in the world of IIoT, and reduce costs while increasing profitability. This is
our commitment."
Reducing preventive maintenance “has increased productivity 30%,”
Craft says. “On four assets, we increased throughput of 50,000 production
units—that’s increased capacity through proper planning.”
CALL NOW FOR YOUR FREE The key for getting management’s attention and approval is to put the
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 CONNECTING

TABLE 1: TEST RESULTS project in terms of their objectives. “If your

name for our ‘SCHAD CBM’ matches their
Item Baseline Target Result
goals for driving understanding and change,
Mobile work order documentation 8 min. 2 min. 1:06 min. your project should be approved,” Craft says.
“In our case, we turned the PO around in
Mobile calibration work order
9 min. 3 min. 1:46 min. two weeks, for a few million dollars.”
documentation
Craft’s group isn’t standing still. “Our col-
Mobile work order offline lective journey ends at predictability and pre-
Impossible Possible Possible
documentation
scriptive maintenance,” Craft says. Johnson
PM actual running hours & Johnson now has an internal project to
Impossible Possible Possible
automatically triggered drive reliability through data science, using
Mobile alarms and alerts thresholds, the environment and digital twins
Impossible Possible Possible to predict failures “days in advance,” Craft
management
says. “We’ve seen it happen, in one case
Mobile item counting 45 sec. 30 sec. 4.6 sec.
saving six weeks of downtime. The idea is to
Mobile items cycle counting create and use a mobile datasheet, do test-
Impossible Possible Possible
offline ing, obtain values, and populate without data
entry, the same as vibration or any condition-
All above through one log-in Impossible Possible Possible
based parameter.
User experience N/A > 90% satisfaction 92% “We’re driving change, proving results as
we expected, and more.”

www.controlglobal.com JANUARY 2019 • 41

 ASK THE EXPERTS
Remote control of fractionation
Can smart differential pressure (DP) cells be used for custody transfer?
This column is moderated Q: Can you remotely control a liquified petro-
by Béla Lipták leum gas (LPG) fractionation process from a
(http://belaliptakpe.com/), centralized control center? The distance is 400
automation and safety kilometers. If not, what are the high-risk reasons
consultant and editor of the that necessitate having a local control room at
Instrument and Automation the site of the fractionation process?
Engineers’ Handbook AHMED ELFETIANY
(IAEH). If you have an ahmed.elfetiany@outlook.com
automation-related question
for this column, write to A: My question is, how will your proposed system
liptakbela@aol.com. be protected from cyber attacks? Do you plan to
use the Internet for your remote control? If your
answer is yes, my advice is don't do it. The reason
is hacking and cyber attacks.
Today, the only reason cyber attacks are not yet
more widely used is because of fear of retaliation.
Yet, they're already used both in cyber warfare (ex-
emplified by the Israeli attack on Iran's centrifuges)
and also in industry, such as the hacker attack this
year on the Onslow Water Authority in North Caro-
lina, and one could go on (Figure 1).
In my view, the bad guys are just as smart
as the good ones, and they can not only spread
misinformation and psychologically manipulate
people, but they could turn our nuclear power
plants into atomic bombs, sink unmanned oil drill-
ing platforms, or attack the electric grid, and they
probably will, or will at least try. Some vendors
might say that their firewall is perfect, but I say
that no firewall or proprietary protocol provides
full protection. Murphy's Law still applies in this
digital age. My view is that control software should
never touch the Internet. Some might say that
placing independent barriers and protections
around a SCADA systems will keep communica-
tion paths secure, but I wouldn't try it. In my view,
remote operation through the Internet is asking for
trouble, and the same holds for all linking of plant
operations networks with the Internet.
BÉLA LIPTÁK
Liptakbela@aol.com
A: Controlling remotely in a secured way is pos-
sible and distance is not a bar. You need to con-
42 • JANUARY 2019 www.controlglobal.com
sider the following:
1.You must have standalone control and safe-
guarding systems installed locally to control
and safeguard the process. All the field In-
strumentation shall be hardwired to the sys-
tem with proper segregation.
2.You must specify failsafe condition of final
control elements.
3. You should have a remote, web-based client
for monitoring the whole process. Remem-
ber to take care of cybersecurity require-
ments—this will be a Level 4 system.
4. You can govern and alter setpoints remotely,
and start up the facility.
I hope the above explains the basic concept.
DEBASIS GUHA
Deputy manager C&I, Petrofac International
debasis_guha71@yahoo.com
A: Yes, it should be possible to control remotely.
On one of my projects, we have a remote gas plat-
form about 25 km into the sea. It's remotely con-
trolled by a centralized control room on land about
25 km away. Connectivity is redundant, fiber-optic
cables backed up by a redundant, line-of-sight
microwave link. However:
1. All required DCS/ESD/FGS hardware are
mounted locally on the platform. Hence the
response time for control and shutdown is
not dependent on distance. The ESD system
is rated SIL3.
2. There's a small local control room with a
couple of screens, which is used for startups
and also in case of disruption in all remote
communications (fiber-optic and microwave).
So far, this hasn't happened.
3. Although designed for unmanned opera-
tions, the platform is manned day and night
for operations and maintenance, but control
is from the remote control room.
With the above architecture and safeguards, we
didn't find distance an issue. Your mentioned dis-
tance is higher and process is faster; but that should
not matter if at least some of the measures listed
 ASK THE EXPERTS

Commercial facilities, measurement accuracy are the same. They

5, 2% Communications, 10, 5%
Water, 8, 4%
Transportation, 11, 5%
Postal & shipping, 2, 1%
Nuclear, 7, 3%
Info tech, 9, 4%
Public health, 1, 0%
Government
facilities, 8, 2%
Energy, 111, 53%
CYBER ATTACKS IN 2017
Figure 1: More than 200 cyber attacks were documented in 2017, with the top categories
being energy and critical manufacturing facilities. Source: ComputerWorld.
above are considered. I also suggest you
carry out a Hazop to discuss all possible
scenarios arising out of this architecture.
HARVINDAR SINGH GAMBHIR
JIO CoE – Instrumentation, controls and
automation, Navi Mumbai
Harvindar.S.Gambhir@ril.com
A: Our MIGbox series gives solution of local
control (within device) and remote monitor-
ing and operational control via our cloud
platform. Geography is "history" now. We
can easily do control from anywhere on
earth (with a couple of seconds latency in
some worst cases, and maybe four hours
or so latency from Mars).
ANAND IYER
akiyer62@hotmail.com, www.akiyer.com
A: To me, the risk of remotely controlling
assets is cyber.
JOE WEISS PE, CISM, CRISC
ISA Fellow, IEEE Senior Member,
Managing Director ISA99
Applied Control Solutions, LLC
joe.weiss@realtimeacs.com
Q: I work as a product manager for Em-
erson. In the column on custody trans-
fer (July ’18, p. 43, www.controlglobal.
com/articles/2018/why-can-a-dp-flow-
meter-be-used-for-gas-but-not-liquid),
Critical
manufacturing,
32, 17%
you stated that the DP flow turndown
on liquid service is 3:1 to 4:1, and does
not have the ability to compensate for
discharge coefficient. Rosemount’s
3051SMV with Ultra for Flow dynamically
compensates for changes in discharge
coefficient 22 times per second, and is
capable of ±1% of mass flow measure-
ment over a 14:1 turndown on flow.
BEN GOULET
Benjamin.Goulet@emerson.com
A: My column discussed standard DP
cells—you are right that smart ones pro-
vide 200:1 ∆P or 14:1 flow rangeability.
Concerning discharge coefficient com-
pensation, which is provided to correct
for gas expansion, and concerning ther-
mal expansion factors in the DP mass
flow equation, it should be emphasized
that the value of natural gas is a function
of its composition and heating value, and
pressure and/or temperature don't detect
either of them, no matter how often the
calculation is performed.
In addition, the DP cell doesn't mea-
sure mass flow (nor volumetric flow); it
measures the square root of the pressure
differential across a flow element. Also, the
DP cell is only one component in the flow
detection loop, and therefore it's misleading
to imply that the DP accuracy and the flow
are not. The flow measurement error is the
sum of all other loop component errors,
including installation ones.
You say your flow measurement error
is ±1% without stating ±1% of what. If you
are claiming a ±1% AR (actual reading) ac-
curacy at minimum flow (full flow divided
by 14), then you're claiming that your de-
tector's full scale flow accuracy is 1/14 =
±0.071% FS. If that's what you claim, that
means that in terms of ∆P, you're claiming
an accuracy of 1/200 = ±0.005% FS, which
is obviously unrealistic.
On the other hand, if your ±1% flow
accuracy claim refers to ±1% FS, that er-
ror at minimum flow corresponds to an
error of ±14% AR, which makes the mea-
surement useless.
BÉLA LIPTÁK
liptakbela@aol.com
A: Regarding the use of DP flowmeters
for custody transfer, my advice has always
been, don’t. Aside from the fact that dP
flowmeters were never intended for mea-
suring mass flow, there's the frequent error
of installation and wear of the orifice, which
doesn't maintain a sharp edge.
For the ISA CAP course, I teach that an
orifice/DP flowmeter is great for control
purposes, since even when incorrect, it is
consistently incorrect and highly useful for
flow control. I've even used orifice/DP for
measuring steam flow in an energy/mass
balance situation on a paper machine, but
that's far from custody transfer.
However, even with pressure and tem-
perature compensation, it just isn't accu-
rate enough for custody transfer. I recom-
mend a Coriolis flowmeter, or for some
liquids in a low-flow situation, a positive
displacement pump. In class, I use an
example of meter accuracy vs. tank level
measurement for custody transfer. Only a
Coriolis flowmeter can rival the accuracy
of custody transfer through tank level
measurement.
DICK CARO
ISA Life Fellow
RCaro@CMC.us

www.controlglobal.com JANUARY 2019 • 43

ROUNDUP

Drives and motors rev up capabilities

Enhanced power density, operating ranges, integration, intelligence and enclosures aid motion's mission.

INTEGRATED STEPPERS ADDED DRIVES FOR 10 HP TO 6,000 HP

SureStep advanced integrated Allen Bradley PowerFlex 755T
motor/drives have torque rat- AC drives have expanded the
ings from 54 to 340 oz-in. and power ranges and capabilities
software-selectable resolutions of their TotalForce technology,
ranging from 200 steps per and offer an expanded power
revolution. They can operate range from 10 hp to 6,000 hp
with traditional high-speed in- (7.5 kW to 4,500 kW), which
puts, but can be commanded via a 0–5 V analog input. An inter- enables harmonic mitigation, regeneration and common bus sys-
nal indexer can accomplish point-to-point moves controlled via tem configurations. TotalForce is enhanced by an adaptive tuning
ASCII communication. Free SureMotion Pro drive configuration feature using up to four automatic tracking notch filters to block
software is available for configuring advanced integrated motor/ resonance and damaging vibration, while predictive maintenance
drives. A status monitor screen aids troubleshooting. features provide real-time information about drive health.
AUTOMATIONDIRECT ROCKWELL AUTOMATION
www.automationdirect.com/integrated-motor-drives http://campaign.rockwellautomation.com/PowerFlex755TDriveSolutions

SPACE-SAVING SERVO STARTER COMBINES CONTROLS, PROTECTIONS

AMP8000 distributed servo VLT Soft Starter MCD 600 com-
drive system reduces machine bines advanced controls and pro-
footprints and control cabinet tections with increased intelligence
space needs with an ultra- for performance in fixed-speed
compact design that integrates applications. In addition, MCD 600
a servo drive into a servomotor. is more flexible to install thanks to
AMP8000 is available in flange Ethernet and serial-based commu-
sizes F4 and F5, power ratings from 0.61 to 1.23 kW, and stand- nication option cards and applica-
still torque ratings from 2.00 to 4.8 Nm (F4), or power ratings tion-dedicated smart cards. Ease
from 1.02 to 1.78 kW, and standstill torque ratings from 4.10 to of use is increased with new capabilities such as pump-clean
9.7 Nm (F5). STO and SS1 safety functions are integrated into function, PowerThrough operation and calendar- or runtime-
AMP8000 series by default. based scheduling.
BECKHOFF AUTOMATION DANFOSS NORTH AMERICA
www.beckhoff.com/english.asp?highlights/amp8000/default.htm www.danfossdrives.com

DUAL-AXIS SERVO DRIVES SIX-AXIS DRIVE RACK

AKD2G dual-axis servo drive reduces XR3 six-axis drive rack with
wiring, fuses and filtering to save space, field-replaceable, 3U plug-in
and has expandable I/O without increas- amplifiers supports linear and
ing size, as well as removable memory, PWM topologies, and can con-
dual-channel SSTO and what's reported trol any combination of brush-
to be an industry-first, drive-resident less, DC brush or stepper mo-
graphic display. Other features are work- tors at up to 320 VDC operating voltage and 30 A peak current.
bench interface, hybrid connector, and Both current loop and servo loop are digitally closed to ensure
multi-core Compute Engine/Servo on positioning accuracy and rate stability, which lets XR3 provide
a Chip that allows a loop update rate of 1.28 µs to immediately loop closure rates up to 20 kHz and handle digital and analog
accommodate changing load conditions. Velocity and position I/O processing, data collection, process control and encoder
loops updates are 62.5 µs and 125 µs, respectively. multiplication in real time.
KOLLMORGEN AEROTECH
540-633-3545; www.kollmorgen.com www.aerotech.com/product-catalog/drives-and-drive-racks/xr3.aspx

44 • JANUARY 2019 www.controlglobal.com

 ROUNDUP

ANALYZERS SIMPLIFY TROUBLESHOOTING DRIVES FOR WATER/WASTEWATER

MDA-510 and MDA-550 motor drive ACQ580 VFD for municipal water/
analyzers simplify troubleshooting wastewater applications features:
on single- and three-phase motors/ pump-clean to dislodge debris from
drives by providing guided testing impellers; sensorless flow calculation
and instructions that show where to to provide accurate flow measurement
make voltage and current connec- without a flowmeter; soft-pipe-fill mode
tions, while preset measurement to reduce water-hammer damage; and
profiles ensure data is captured for quick-ramp to protect submersible
each motor-drive section from the input to the output, DC bus pumps. It's compatible with ABB Ability
and motor. They also measure electrical parameters with 500 condition monitoring, which provides real-time status and perfor-
MHz oscilloscope, meter and recording capability. mance data from any location. It also includes integrated safety
FLUKE CORP. features, such as safe torque-off and a maximum speed limit.
www.fluke.com/en-us/product/electrical-testing/portable-oscilloscopes/ ABB
fluke-mda-500-series http://new.abb.com/drives/low-voltage-ac/industry-specific-drives/acq580

VECTOR-CONTROL INVERTER DRIVE ABOVE NEMA FOR GENERAL PURPOSE

Frenic-VG series is the supplier's Simotics Above NEMA MV449
highest-performance vector-control frame motor is reported to in-
inverter drive, and is used in high- crease the power output of its
demand, complex applications, design by 14% compared to
including cranes and hoists. It's other frames; has up to 400 hp
equipped with fast speed control power output; and can increase
response of 600 Hz, torque control motor efficiency 1.5%. MV449
accuracy within 3%, and power pairs with Sinamics Perfect
up to 900 hp with the ability to extend up to 3,000 hp with the Harmony GH180 outdoor-duty VFD, which includes a freestanding,
stack-type model. Available with various options including user- Type 4, UL50e-rated enclosure that protects against -45 °C to 45
programmable application card (UPAC), Frenic-VG provides a °C temperatures, rain or snow, and air laden with chemicals or salt.
flexible, reliable solution for a range of application requirements. GH180 can be placed up to 2.3 km away from its motor.
FUJI ELECTRIC CORP. OF AMERICA SIEMENS CORP.
732-560-9410; http://americas.fujielectric.com/VG www.usa.siemens.com/abovenema

SERVOMOTOR INTEGRATES ENCODER HIGH POWER DENSITY, BRUSHLESS

IndraDyn S series MS2N KinetiMax 95 high-power drive
high-torque, synchronous (HPD) is an outer-rotor, brush-
servomotors have an opti- less, DC motor with frameless
mized, electromagnetic de- stator/rotor set with greater than
sign and new construction 87% efficiency, 95-mm diameter,
that reduces torque ripple, and 2 Nm continuous/nominal
delivers up to 30% greater torque density, and provides up to torque at 2,300 rpm, resulting in
five times overload capacity. They're available with an integrated 480 W of continuous output power, and 1,100 W peak power. It
encoder in the SIL3, PLe class with SafeMotion, and in six sizes also has 37 mm axial length, 59 mm inner diameter, low cogging
with up to five lengths each. They cover the power range from 4 torque, 24 V or 60 V winding, and high torque-to-weight ratio of
Nm to 360 Nm maximum torque, and 0.8 Nm to 215 Nm con- 3.39 Nm/kg at rated torque. Options include winding tempera-
tinuous torque at standstill. ture sensor and Hall commutation sensors.
BOSCH REXROTH ALLIED MOTION TECHNOLOGIES
www.boschrexroth-us.com 716-242-7535; www.alliedmotion.com

www.controlglobal.com JANUARY 2019 • 45

CONTROL EXCLUSIVE
Intrinsically safe tablet raises the bar
Class I/Div. 1, Zone 1 tablet keeps current with commercial techology thanks to collaborative partnership.
IT'S not easy to make devices intrinsi-
cally safe (IS) for service in hazardous
and potentially explosive atmospheres.
But, making them IS and easy to use in
dangerous settings is even more difficult,
so it helps to collaborate with friends.
This is just what Pepperl+Fuchs and its
ecom brand did when they began working
with Samsung four years ago to build their
Tab-Ex 01 intrinsically safe tablet PC based
on Samsung's ruggedized Tab Active plat-
form. It was reported to be world's first LTE-
enabled, Android tablet PC certified both
Class I/Division 1 and ATEX Zone 1, and
now their partnership has produced the
second-generation Tab-Ex 02 DZ1 founded
on Samsung's Galaxy Tab Active2.
"Even today, there aren't many de-
vices that can be used in hazardous
industrial environments or potentially
explosive areas, so there's still a lot of
pen and paper used in the field, which
means double work and less accuracy
due to manual data entry," says Lothar
Berger, director of global mobile strategy
at Pepperl+Fuchs. "Now, the advances
made by tablet PCs like Tab-Ex 02 DZ1
are going where they couldn't before."
Scheduled to be available in early
2019, Tab-Ex 02 DZ1 features:
• More capable, high-resolution
5-megapixel (MP) front camera and
8-MP, auto-focus rear camera.
• Ruggedized, IP68-certified, water- and
dust-resistant S Pen stylus for harsh
environments, use on wet displays,
and access for users wearing gloves.
• Faster, 1.6-GHz Exynos 7 Octa-
Core (Cortex-A53) microprocessor;
updated Android Oreo 8.1 operating
system (OS); and 3 gigabytes (GB) of
RAM, plus 16 GB memory, and up to
256 GB with external microSD card.
• Onboard sensors including acceler-
46 • JANUARY 2019 www.controlglobal.com
TENACIOUS TABLET
Tab-Ex 02 DZ1 intrinsically safe tablet PC
from Pepperl+Fuchs' ecom brand is the
second generation based on Samsung's Tab
Active platform, which gives it more capable
cameras, an S Pen stylus, improved micropro-
cessor and operating system, glove-touchable
screen, and facial recognition for security.
ometer, gyro, geomagnetic, Hall effect,
RGB light, proximity and fingerprint.
• Connectivity including 2.4-5 GHz
WiFi, WiFi Direct, Bluetooth 4.2, and
300-Mbps LTE Cat. 6.
• 8-in., 1,280 x 800-pixel (WXGA), glove-
touchable screen for wet settings.
• Security with Knox 2.8 facial recog-
nition software.
• -20 °C to 55 °C temperature range.
• 4,450 mAh battery with up to 11-hour
life, replaceable via a back panel.
• Side-mount Pogo pins for charging.
• Enterprise Firmware Over-the-Air
(eFOTA) for testing before deploy-
ments, so enterprises have control
over OS versions on employee devices.
"Over the past three or four years, main-
stream tablet PCs like Tab Active2 gained
faster processors, better cameras, higher
durability and other advances, which can
now be transferred to Tab-Ex 02, and pro-
vide up-to-date, ruggedized tablet PC tech-
nology in its most modern form," explains
John Gibson, head of business develop-
ment for manufacturing verticals at Sam-
sung Electronics America. "This includes a
mil spec 810 G rating for resistance to 21
different environmental attributes."
Berger reports Tab-Ex 02 DZ1 will be
available in two primary versions, includ-
ing Class 1/Division 1 with flame-proof
housing for use in atmospheres that are
likely to be explosive, and Class I/Divi-
sion 2 with ruggedized Samsung housing
and protective glass for atmospheres that
usually aren't explosive. "Class I/Division
1 and flame-proof housing traditionally
means big metal enclosures, but now we
can use resistant materials, engineer-
ing and testing to achieve this rating with
Tab-Ex 02 DZ1, even as its internal elec-
tronics behave the same," he explained.
Once users have Tab-Ex 02 DZ1 in
hand, Gibson reports local personnel and
remote experts can collaborate more easily.
"The local technician can shoot a picture
with Tab-Ex 02 DZ1's camera, showing
the device that's broken or needs service,
and superimpose an image of how it's sup-
posed to be," explains Gibson. "They can
also collaborate in sessions like using a
virtual whiteboard because they can draw
on the images on each other's screens.
This can be helpful in petrochemical facili-
ties, where local technicians may not have
all the expertise they need, and even some
remote experts may not be qualified to be
in all hazardous areas. Now, users can get
the best of both worlds."
For information, visit www.ecom-ex.com.

A meeting of the minds
Both I&E and PID perspectives must meld to produce fine temperature control.
GREG: The key to a successful control loop is
the meeting of minds. Most important is that the
Instrument and Electrical professional and the
process control specialist to get together, and un-
derstand what's needed for the process applica-
tion, as discussed in my Control Talk blog, “Many
objectives, many worlds of process control“ (www.
controlglobal.com/blogs/controltalkblog/new-
blog-entry-3). Essential is the realization of what's
important, and how instrumentation performance
plays a critical role.
To help understand the critical role of instru-
mentation, here is a meeting of the minds of “PID
Greg” and “I&E Greg” that addresses many of
the important issues that come up in temperature
systems, where the primary goal is maximization
of process performance instead of minimization
of instrumentation cost. Often, project goals are
shortsighted, not realizing that the extra cost of
better instrumentation is trivial compared to the
decrease in lifecycle costs and the increase in
plant profitability.
PID GREG: Good temperature control is often the
key to process efficiency and capacity. For chemi-
cal and biological reactor control, tight tempera-
ture control is needed to maximize product quality
and quantity. Chemical reaction rate is often an
exponential function of temperature, as seen in
the Arrhenius Equation. Side reactons can also
occur for deviations from the best temperature.
High temperatures can lead to unsafe, runaway
exothermic reactions.
For biological processes, cell growth and prod-
uct formation are extremely dependent on achiev-
ing and maintaining the best temperature. High
temperatures can cause dramatic increases in
cell death rates. Excellent temperature control is
essential to the performance of columns, crystal-
lizers, dryers, evaporators, furnaces, kilns and
many other unit operations. The best temperature
measurement reliability, repeatability, resolution
and response are critical for a PID to minimize the
control errors for load and setpoint changes. As-
www.controlglobal.com JANUARY 2019 • 47
CONTROL TALK
suming the transmitter is properly calibrated for
the sensor used, minimizing drift is necessary for
achieving the best setpoint.
How can we achieve a temperature measure-
ment with best reliability, repeatability, resolution
and response, and least drift?
I&E GREG: While the cost of an RTD may be
slightly greater than a thermocouple (TC), the sav-
ings in maintenance and better process perfor-
mance from much less drift, better repeatability
and higher resolution far exceeds the incremental
cost. Also, the savings from less wiring, calibration
and prevention of noise and mistakes is signifi-
cantly greater than the added cost of a preassem- GREG MCMILLAN
bled thermowell and sensing element with integral
mounted transmitter calibrated by the supplier. Gregory K. McMillan captures the
If the temperature of the line is high, a lagging wisdom of talented leaders in
thermowell or extension of the pipe nipple may process control, and adds his
prevent a temperature effect on transmitter. If perspective based on more than
the transmitter must be mounted separately for 50 years of experience, cartoons
accessibility, the location should be as close as by Ted Williams, and (web-only)
possible to the sensor. Class 1 special grade ex- Top 10 lists. Find more of Greg's
tension wire should be used for TCs and four-wire conceptual and principle-based
RTD leads. “Sensor matching” should be done knowledge in his Control Talk blog.
for RTDs, where the four constants of a Callendar- Greg welcomes comments and col-
Van-Dusen (CVD) equation are provided by the umn suggestions at ControlTalk@
sensor supplier and entered into the transmitter. putman.net
Even though thermowells may withstand vibra-
tion, potential damage can occur to RTDs. For
temperatures above 400 °C or significant vibra-
tion, deterioration of RTD accuracy and life may
make a TC a better choice. For temperatures
above 850 °C, a TC must be used. The TC should
be ungrounded and its material selected to meet
temperature range requirements to maximize life
and minimize drift and noise.
The repeatability, accuracy and signal strength
are two orders of magnitude better for an RTD
compared to a TC. The 1-20 °C drift per year of
a TC is of particular concern for biological and
chemical reactors and distillation control because
of the profound effect on product quality from
control at the wrong operating point. The already
CONTROL TALK
exceptional accuracy for a Class A RTD
of 0.1 °C can be improved to 0.02 °C by
“sensor matching.” The main limit to ac-
curacy of an RTD is the transmitter and
wiring. The use of four extension lead
wires for an RTD enables total compen-
sation that accounts for the inevitable
uncertainty in resistance of lead wires.
Standard lead wires have a tolerance
of 10% in resistance. For 500 feet of
20-gauge lead wire, the error could be
as large as 26 °C for a two-wire RTD and
2.6 °C for a three-wire RTD. The “best
practice” is to use a four-wire RTD un-
less the transmitter is located close to
the sensor, preferably on the sensor. The
transmitter accuracy of about 0.1 °C can
be improved by a single dry block cali-
bration since transmitter and sensor drift
is negligible.
The air in the annular clearance be-
tween the thermowell interior wall and
sensor sheath is the dominant source of
slowness in the temperature response.
For the same reason, a spring-loaded,
sheathed TC or RTD should be used to
ensure the tip of the sheath is touching
the bottom of the thermowell. The next
greatest cause of slowness is the rate of
For more puzzling dialog by recent graduates, see the “Top 10 exclamations by newbie process
engineers” at www. controlglobal.com/articles/2019/a-meeting-of-the-minds.
48 • JANUARY 2019 www.controlglobal.com
heat transfer between the fluid and ther-
mowell. Gases have a much smaller rate
and hence slower response.
Stepped thermowells should be speci-
fied with an insertion length greater than
five times the tip diameter (L/D > 5)
to minimize error from heat exchange
between the thermowell tip and pipe
or equipment connection from thermal
conduction, and an insertion length less
than 20 times the tip diameter (L/D < 20)
to minimize vibration from wake frequen-
cies. Calculations by suppliers on length
should be done to confirm that heat con-
duction error and vibration damage is not
a problem. Stepped thermowells reduce
the error and damage, and provide a
faster response.
Thermowell material must provide cor-
rosion resistance and, if possible, high
thermal conductivity to minimize conduc-
tion error or response time, whichever is
more important. The tapered tip of the
thermowell must be close to the center
line of pipe, and the tapered portion
of the thermowell completely past the
equipment wall including any baffles. For
columns, the location should be used
that shows the largest and most sym-
metrical change in temperature for an
increase and decrease in manipulated
flow. Simulations can help find this, but
it's wise to have several connections to
confirm the best location by field tests.
The tip of the thermowell must see the
liquid, which may require a longer exten-
sion length or mounting on the opposite
side of the down-comer to avoid the tip
being in the vapor phase due to the drop
in level at the down-comer.
The location of a thermowell must
be sufficiently downstream of joining
streams or a heat exchanger tube side
outlet to enable remixing of the streams.
The location must not be too far down-
stream due to the increase in transpor-
tation delay, which is the residence time
for plug flow (the pipe volume between
the outlet or junction and sensor loca-
tion divided by the pipe flow, or volume/
flow). For a length that's 25 times the
pipe diameter (L/D = 25), the increase in
loop dead time of a few seconds isn't as
detrimental as a poor signal-to-noise ratio
from poor uniformity.
For desuperheaters, to prevent water
droplets from creating noise, the ther-
mowell must provide a residence time
that's greater 0.3 seconds, which for high
gas velocities can be much greater than
the distance required for liquid heat ex-
changers.
PID GREG: If you want a comprehen-
sive, concise view of how to achieve the
best measurement and control, look for
the McGraw-Hill handbook, Process/
Industrial Instruments and Controls,
Sixth Edition, which is due out in early
2019. The handbook covers the design,
installation, calibration, commission-
ing and maintenance of every part of an
automation system, concluding with a
list of best practices for each of the 100
sections, resulting in more than 1,000
best practices. See the Control feature
article, “Best practices for PID” (Decem-
ber ’18, p. 22, www.controlglobal.com/
articles/2018/best-practices-for-pid) for
another glimpse of what the handbook
offers.
 CLASSIFIED

AD INDEX EQUIPMENT & MATERIALS

ABB .............................................................4
Allied Electronics and Automation ...............8
AutomationDirect ......................IFC gate fold
Badger.......................................................35
Digi-Key Corporation .................................11
Emerson Process Mgt/Mynah ....................52
Endress+Hauser......................................6, 7
ifm efector ................................................51
Load Controls .......................................... 40
Magnetrol..................................................25
Moore Industries........................................17
Newark ......................................................13
Pepperl+Fuchs ..........................................31
ProComSol.................................................19 VISIT US ONLINE!
PULS .........................................................23
Sierra Monitor Corporation ....................... 40 CONTROLGLOBAL.COM
The Winsted Corporation ...........................41
Vega America ............................................33
Wago Corporation ......................................29
Yaskawa America ......................................15
Yokogawa Electric .......................................3

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www.controlglobal.com JANUARY 2019 • 49

 CONTROL REPORT
Meet half-measures half way
Beware of the unseen costs of innovations, controls and labor-saving conveniences.
REMEMBER when frozen orange and other juices
came in coated-cardboard cylinders and had to
be mixed with water? Well, before we agreed to
pay double for juice and the convenience of haul-
ing large bottles, I used to avoid scooping out
those cans by puncturing them with a fork and
blowing the concentrate into a pitcher before mix-
ing. I enjoyed the fact that minimal pneumatic
pressure was enough to push even hard-frozen
juice from its can quickly and (I thought) cleanly.
I used this method dozens of times, until obser-
vant family members questioned my terrific inno-
vation, and asked if the outside of the can and my
JIM MONTAGUE breath were entirely sanitary. Foiled again.
Executive Editor In most parallel dimensions, I'd have kept this
jmontague@putman.net gross confession to myself. However, in your un-
lucky universe, I'm a trade magazine columnist
who needs to make a point. In this case, it's that
Don't second guess to discovering or developing an innovation can blind
the point it becomes the inventor to unexpected consequences. These
debilitating. That would revelations usually come from passers-by, rela-
be another mistake. Just tives and other enemies, who couldn't possibly
keep an eye peeled for know as much as I do about the initial problem,
more useful innovations great idea and tool I came up with, right?
after the first one. Because, for many of us, admitting we're wrong
is worse than dying and public speaking com-
bined, our first instinct is to ignore the critics, and
keep applying our innovation over and over. See
how great it works? How could it not be perfect?
Even labor-saving tools with long records of
success can have unanticipated results or costs
that either aren't noticed from the beginning or
aren't apparent until later. Remember when hand-
held calculators were a costly novelty, but then
dropped in price so fast that everyone had one? I
recall many school districts and teachers debated
requiring students to practice mathematical skills
such as logarithms and trigonometry before they
could use calculators in classes or tests. I don't
think that resolve lasted too long.
Of course, more recent innovations like the In-
ternet and smart phones are following similar evo-
lutions. Much of the world's knowledge is right at
our fingertips, but there's increasing evidence that
50 • JANUARY 2019 www.controlglobal.com
we're less intelligent than ever. Closer to home,
I know the best way to wake up journalists is to
keep a few facts from them, and the best way to
put them to sleep is to give them a big bundle of
information. I think this might be because floods
of input coming in all the time don't give us the
pause needed to use our atrophied critical think-
ing skills to arrive at better decisions.
Unfortunately, control and automation aren't
immune from the ironies of this innovation-driven
and convenience-fueled paradox. I also remem-
ber covering a blow-molding machine builder for
our sister Control Design magazine, who was pre-
paring to ship a machine to a bottler in Asia that
planned to package bottled water from the Hima-
layas. I think the customer wanted to duplicate the
success of Fiji water and its four-sided containers,
even though shipping water from the middle of the
Pacific Ocean likely has a terrible carbon footprint
in addition to being completely unnecessary—
apart from the priceless ability of one-upping our
fellow humans, which is well worth filling a few Hi-
malayan valleys and other places with plastic.
So what's the solution? Well, just make sure
your innovation or whatever else you're doing is
truly useful beyond the narrow radius of optimiz-
ing production for next month's stock analyst call.
No less than father-of-the-PLC Dick Morley
once chided me with the well-known aphorism
that "if a professional person mows their own lawn
lawn, they're using the most expensive lawn ser-
vice in town." This was true at first glance, until I
factored in the benefits of exercise, active medita-
tion, and character-building humility. I know I'm
not getting my recommended daily allowance of
any of them, so I keep on mowing.
Of course, don't second guess to the point
it becomes debilitating. That would be another
mistake. It's easy to remember ancient Greece's
Oracle of Dephi and its famous "moderation in
all things" motto. It's harder to follow its advice.
Maybe just maintain enough initiative to keep an
eye peeled for more useful innovations after the
first one.
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