www.controleng.com : Latest News http://www.controleng.com/ en www.controleng.com : Latest News http://www.controleng.com/typo3conf/ext/tt_news/ext_icon.gif http://www.controleng.com/ 18 16 TYPO3 - get.content.right http://blogs.law.harvard.edu/tech/rss Tue, 21 May 2013 07:00:00 -0400 Machine vision speed, quality, innovation http://www.controleng.com/industry-news/single-article/machine-vision-speed-quality-innovation/fe632a56c2f70ff76fb55dde443a2db9.html Advanced applications for machine vision in automotive, robotics, quality, and safety use hybrid... Advanced applications for machine vision in automotive, robotics, quality, and safety use hybrid technologies, vision for robotic or machine guidance and in-line part inspection, and 3D imaging. Technology and imaging standard advances help. The articles below appeared in the Control Engineering May 2013 North American print and digital edition and are linked below, online, with additional information and images. Quality control measurements for smooth surfaces Hybrid laser-camera technology is ideal for surface measurement in many industries. The camera detects a laser projected onto an object at a specific angle. Next generation: Robots that see Visual servo control: Vision used for robotic or machine guidance also can be used for in-line part inspection to enhance product quality with traditional feedback systems. See online video. 3D vision system performs rope wear analysis Three-dimensional (3D) imaging can be used to verify rope and cable quality to measure pitch length and diameter, and identify rope surface damage and type of wear, with accuracy surpassing current methods, to enhance safety. See photos. Advances in machine vision products, standards Recent new products and standards advances include FDA traceability, higher speed, and connectivity and integration standards. - Articles edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com. Control Engineering machine vision article library. ]]> Machine Control System Integration Plant Safety and Security Slider Homepage Item - CTL Machine Control May SyndicationType: Article SyndicationSource: CFE Media (in-house) Syndication: Discrete Manufacturing Syndication: Discrete Sensors (Proximity Presence Load Cells Limit Switches Torque Encoders) Machine Vision Fri, 10 May 2013 14:26:00 -0400 Control Engineering industrial wireless coverage http://www.controleng.com/industry-news/single-article/control-engineering-industrial-wireless-coverage/bcc3ae2c4a46d335a1046c0726f82be4.html Wireless resources: Years of wireless industrial technology, tutorials, and case history articles... Updated April 16, 2013 - Control Engineering has written and published many articles and tutorials about industrial wireless technologies, trends, and applications, along with wireless products and news. A sampling follows of various industrial wireless articles from Control Engineering, 2007 to present.* Additional links to industrial wireless articles follow. Wireless technology tips from Control Engineering wireless webcast Wireless technology tips and answers follow, resulting from feedback and questions submitted during a Control Engineering wireless webcast. Device configuration and calibration are two different processes. Some devices can do both. Courtesy: BeamexGetting a grip on handheld HART communication and calibration devices If you see your handheld communicator as just for commissioning new devices, you’re missing much of the value of these versatile tools. Here’s how to get more from your handheld. Electric utility stretches sensor coverage Multi-drop WirelessHART supports new temperature points to improve efficiency. WirelessHART extends your reach: The easy way to add new instrumentation A look at the benefits and considerations of deploying WirelessHART device networks. Minimize growing pains when installing new field sensors and actuators. Enomondo SRL uses wireless field instruments.Biomass power plant deploys wireless instrumentation for predictive maintenance Enomondo S.r.l. uses new field instruments to extend its visibility into a new boiler and complex fuel pre-treatment operation. Commercial tablets get industrial enclosures Making tablets rugged: Industrial-grade environmental protection can help ruggedize and protect Apple iPad, Google Android, and other tablet computers. Embedded systems in a connected world Engineering and IT Insight: Embedded systems are often mechanically connected to other systems, and planning for network connectivity will allow them to also be electronically connected. See 8 requirements to add for embedded system design (including wireless). Figure shows wireless networks used for industrial applications. For 2013, information is being gathered on individual protocols. Courtesy: IMS Research (Part of IHS Inc.)Research: Wireless use in industry What wireless technologies are being used for industrial applications? IEEE 802.11, Bluetooth, and wireless are widely used. More information is being gathered. Webcast covers industrial wireless applications, technologies Experts discussing an overview of industrial wireless technologies, the need for a long-term strategy, and best practices for wireless system design in harsh real-world settings, with application examples presented by system integrators. Is HF or UHF industrial RFID better? Identify the right RFID technology: Knowing the difference between HF and UHF is important for industrial applications.  Bluetooth technology can be a robust, easy-to-use wireless solution for industrial applications, such as robotics. Courtesy: connectBlueIndustrial wireless: Bluetooth can be robust, easy to use Technology Update: Bluetooth offers optimal features to satisfy industrial requirements of robustness, reliability, and seamless, coexistent operation with Wireless LAN networks. In addition to low power consumption, Bluetooth allows for multiple wireless links, offers fast connections, and has easier configuration and setup than many other wireless technologies. Machine Safety: Can hand held devices play a role? Wireless hand held devices (smart phones, tablets, pads, etc.), common in daily life, are emerging on the shop floor. Can they improve machine safety?  Converging automation standards Competing standards and protocols [including wireless] often cover the same ground but are not compatible, to the dismay of end users. Sometimes they can be brought together to benefit vendors and users. Infinite wireless Control Engineering International: Remote control, wireless instrumentation, wireless retrofits, and wireless power transmission technologies will increase the value of industrial wireless applications. The network neighborhood function allows the master to know how each device is connected relative to one another, which means a failed device can be removed and replaced with a new one without any extra user configuration. Courtesy: Pepperl+FuchsIndustrial RFID trends Factory automation RFID technology trends differ from those of logistics or commercial RFID systems. Factory floor RFID components are more industrial and hardened for less downtime, with faster data acquisition. Combining wireless, photoelectric sensing technologies Technology Update: Wireless and photoelectric sensing technologies have merged to create sensors without wires. Global cellular M2M connections growing to more than 325 million by 2016 Mobile operators are intently focused on developing and expanding their activities in the cellular M2M market as a key growth opportunity in the face of increasing saturation and maturity of the core mobile voice/data services market. Lei Jin, executive editor, Control Engineering China, demonstrates a Motorola Solutions HC1 Headset Computer at Rockwell Automation’s 2012 Automation Fair. CFE Media photo by Mark T. HoskeHeadset computer, RFID system, rugged tablet computer Motorola Solutions products, including a headset computer, radio frequency identification system (RFID), and rugged tablet computers, were among plant-floor and automation productivity tools at Rockwell Automation’s Automation Fair 2012 in Philadelphia, Pa. 10 Control Engineering 2013 Engineers’ Choice Award finalists use wireless technologies Review these products in the list of finalists for 2013. Updated November 2012 More wireless and wireless sensors? Video Will wireless instrumentation drive wider sensor deployments? Can the convenience and low-cost of wireless instrumentation unleash a flood of pent-up demand for gathering more data? Video: Emerson’s Bob Karschnia provides some market statistics. RTU use expands, must make full use of advantages Control Engineering International: Use of remote terminal units began in the U.S. oil and gas industry in 1980s and has expanded to electricity, environmental protection, heating networks, water conservancy, and long-distance pipelines. It expanded into transportation, metallurgy, petro chemistry, logistics, and agriculture. Control Engineering China asks a Chinese expert about RTU trends.  Making fieldbus projects as painless as possible Designing and implementing a successful—and painless—fieldbus project requires mapping out network requirements as well as understanding the plant’s information, diagnostic, and maintenance needs. [Wireless technologies can help.] Industrial wireless market booming, but still underutilized Frost & Sullivan Research sees market doubling, but end users still don’t see it as a critical improvement. Wireless instrumentation deployments growing quickly HART Communication Foundation reports that WirelessHART-installed networks exceed 8,000 at major manufacturing sites worldwide. Process Instrumentation: Has wireless instrumentation delivered? Five years ago as wireless process instrumentation broke onto the scene in a big way, the promise of major deployments seemed just around the corner. Has that dream been realized? Ask Control Engineering: Where is all the wireless process instrumentation? Ask Control EngineeringIn researching an article on wireless developments for our October issue, I had occasion to review the offerings available under the WirelessHART and ISA100.11a protocols, and the lists of devices available under both were pretty short. While there have been commitments from various vendors to work with one or the other of these protocols, the number of actual “native” wireless devices available for either can be counted on one’s fingers. Ask Control Engineering: How do I know if a wireless app is secure? After reading the Dark Side of Mobility, I’m concerned about downloading a mobile app that I was thinking about. How can I tell if it is secure or not? Cellular communications for industrial automation Technology update: Cellular communications can help industrial automation, infrastructure, and systems management applications. As buildings and infrastructure applications add automation, they may use industrial wireless machine-to-machine (M2M) communications for remote, cost-effective monitoring and control of telemetry systems, sensors, cameras, industrial equipment, and other systems. Wearable technology innovation to drive market growth A major challenge for suppliers is to establish and expand the number of compelling use-cases for wearable devices. How AT+T's 2G shutdown will impact M2M Even casual industry observers are aware that the telecom giant finds itself facing a spectrum crunch. 5 best ways to extend Ethernet For many applications of TCP/IP networking, the 100-meter range limit of copper Ethernet cable becomes a problem. With conversion and extension, networks can cover distances that are measured in kilometers. Technologies include radio and cellular wireless. The dark side of mobility Wireless vulnerabilitiesSure, the idea of “iPhone as HMI” is convenient, but it opens a whole new range of cyber vulnerabilities. Is the functionality worth the risk? Many users are already deploying the technology without sufficient safeguards. See related video. Automatic guided vehicles Industry sales projections for 2012 remain strong, bolstered by key selling points such as flexibility, versatility, and evolutionary advances in controls. Wireless instrumentation: Do we need to be concerned about the protocol? It’s difficult to say what convergence of competing protocols will mean for wireless instrumentation users. Is there a value in waiting? Will changes in technology make it a moot point? Video: One vendor’s view suggests it’s more about the infrastructure. Webcast on Industrial Wireless: Where and When CFE Media - Control Engineering webcast: Where and when does it make sense, economically and operationally, to use industrial wireless for your next industrial communication application? Industrial wireless technologies continue to advance, whether you’re applying one wireless transmitter or considering a plant-wide implementation. Gain practical insights and advice from three system integrators to enhance results with your next implementation. Low energy Bluetooth wireless protocol Bluetooth low energy technology isn’t just another Bluetooth revision—it’s a whole new technology that can benefit industrial communications. Outstanding industrial wireless June 2012 cover story - Control EngineeringFrom sensor networks to long-haul wireless, industrial wireless technologies bring outstanding savings to industrial automation and process control applications. (June 2012 cover story) Wireless monitoring, asset protection PEMEX Tula Refinery increased efficiency with wireless connectivity by protecting critical assets related to cooling towers with process sensor and vibration monitoring, data collection, and analysis. Wirelessly transmitted information will help predictive maintenance; 20 hours per week of manual data collection can be used more productively. Implementing wireless solutions for industrial communication applications Wireless technology has limitations, but like any technology, it is very powerful when properly applied. Consider these factors before implementing wireless devices, including power, response time, and range, among others. Sensor-actuator wireless industrial network technologies Radar chart estimates differences between wireless sensor and actuator networks for factory automation and process automation plotting suitability across 12 logarithmic axes. Courtesy: PI (Profibus and Profinet International), www.profibus.comWhen deciding among wireless industrial networking technologies, remember that there are different kinds of wireless. For industrial applications, there are at least four, and two are compared in the radar graphic shown. Plant integration of wireless steam traps Case study notes show how multiple vendors’ technologies enable successful wireless monitoring of steam traps. Industrial wireless for automobile manufacturing Why and how are automobile manufacturing plants moving to wireless network technologies? reasons include less cable failure, easier diagnostics and reconfiguration, and faster return on investment. Harvested energy powers industrial automation sensor networks Ultra-low-power radio frequency transceivers enable a new class of short-range industrial automation sensor networks powered by harvested energy. Wireless technologies for industrial automation Wireless networks for industrial automation enhance the ability to gather time-critical information, Digest it, and react, key to continuously adapting to change with increasing reliability and profitability. No one type of wireless technology resolves all challenges. Industrial wireless or wired networks? Tips and Tricks: have obstacles, mobile applications, or a large region? Wireless may be the best choice. Tips and Tricks: 6 overlooked places to use industrial wireless How Wi-Fi industrial wireless communications can save time, trouble, and money: Flexible work cells, mobile connections, and network enabling legacy devices are three overlooked areas to apply industrial wireless technologies. Three more are... Borrowing from consumer electronics Industrial users enjoy look-and-feel practices from consumer electronics, but device designers also benefit from processors and components borrowed from smartphones that add increased functionality and energy efficiency. - connectBlue offers two Wireless LAN Rugged Ethernet Port Adapters, one for the 2.4 GHz band and one for the 5GHz band. These ready-to-use wireless devices are especially well suited for mobile, rotating, and temporary installations where there is a need fWireless LAN for industrial applications - Back to Basics: What are the differences between 2.4 GHz and 5 GHz wireless LAN in industrial applications? Apps for Engineers - Product Exclusive: CFE Media’s Apps For Engineers Software Is An “App Of Apps,” Providing An Interactive Directory Of Approximately 60 Mobile Engineering-Related Software Applications Useful For Control Engineering, Plant Engineering, And Consulting-Specifying Engineer Areas Of Coverage. Are there too many industrial networks? Short article and video discussion. Automation to go - Think Again: I’ll Take My Automation To Go, Please, And Throw In A Big Helping Of Continuous Improvement, Productivity, Quality, And Optimization, With A Side Of Safety And Industrial Energy Management, Thanks.Santa Fe Irrigation District plant communicates with operations yard (other photo) via Phoenix Contact’s high-power wireless local area network (WLAN) radio (RAD-80211-XD/HP), creating a wireless Ethernet connection in terrain that would have been too exp 3-mile WiFi connection enables mobile HMI access - Wireless Local Area Network Easily Cover 3.1-Mile Span For A California Water System, Saving More Than $15,000 Compared To A Wired Solution.  Industrial mobility: Information where needed - Industrial-Strength Mobility Is Happening With The Manufacturing And IT Workforce Today. Embrace It, Guide It, Make It Secure, Or It May Dictate How Your Business Will Change, Suggested Experts At A Recent Industry Conference. Industrial wireless - Control EngineeringTips And Tricks: 9 Tips For A Smarter Wireless Industrial Workforce - Nine Tips Help Enable An Industrial Wireless Mobile Workforce, Including Standards, Self-Healing Technologies, And The Right Blend Of Hardware And Software. Mobile Industrial Worker - Technologies Have Enabled Industrial Workers To Get Mobile, And There’s No Going Back.  WiFi Technology For Industrial Environments - Set Up A Wireless Infrastructure To Support A Wireless Mobile Workforce. Here’s Advice On Industrial Environments, Challenges Include Environment, Signal Integrity, And Protocol Selection. Belden HiVision network software ProSoft i-ViewWhose IPhone Goes Into The Plant? - When Companies Add Communication Via Wireless Devices, Who’s Device Is It? Is That My IPad, Or The Company’s? Wireless Apps, Cloud Services Transform Decision Making, Data Management For Packaging Lines - Dairy Products Producer Balances Quality And Consistency During Facility Expansion, Incorporating And Monitoring New Product Filling And Packaging Lines And Associated Equipment Integration Platform Designed To Unite Disparate Systems - Fieldbus Foundation Unveils Foundation For Remote Operations Management, Which Aims At Transforming The Industrial Remote Operations Market. Video: Larry O’Brien Explains The Underlying Technical Concepts.  [Foundation for ROM is important because it is the first example integrating ISA 100.11a, WirelessHART, wired HART, and wired H1 protocols into one standard environment.] Cloud-based automation is the topic of the Control Engineering December 2011 cover story and related online extras.Pushing IT Infrastructure Into The Cloud Helps Stone Manufacturer Focus On Core Business - Increasingly, Cloud Technology Is Being Embraced By Companies As A Way To Do More With Less. For Example, A Fast-Growing Stone Manufacturing Company Recently Pushed Its Entire Infrastructure Out To The Cloud. Security Considerations For Wireless Implementation - Whether Specifying A New Wireless Installation, Expanding An Existing Implementation, Or Evaluating Wireless Protocols, The Security Issues Are Similar. Understanding Them Can Improve The Security And Signal Quality.  IEEE 802.15.4 channels are used by ISA100.11a devices. Courtesy: Honeywell Process SolutionsIndustrial Wireless: Field Device Mesh Network 101 - With Wireless Transmitters, There Are No Wires To Troubleshoot. If Designed Properly, The Data Goes From The Transducer To The Control Via Multiple Wireless Paths. Here’s How Wireless Communication Is Handled Between Wireless Field Devices And The Host Application.  Automation Helps Transportation, Says IEEE Vehicle Electronics Expert - Control Engineering China Interviews Lingxi Li, Assistant Professor At The Department Of Electronic And Computer Engineering, Indiana University-Purdue University, Also Chairman Of IEEE Vehicular Electronics And Safety Conferences. Sensing, Wireless, And Other Control Technologies Are Improving Transportation. IEEE 802.22(WRAN) Expected To Help Internet Of Things, Smart Grid In China - IEEE Recently Published The WRAN 802.22 Standard (Wireless Regional Area Networks), Which Could Have Deep Impact Within China, Especially With Internet Of Things (IOT) And Smart Grid. Selecting Device-Level Communication Protocols - How Do Instrumentation Manufacturers Decide Which Communication Options To Offer With Each Type Of Device? Engineers' Choice Awards - Control Engineering product recognition programEngineers’ Choice 2012 product categories and finalists related to wireless: Network integration - Wireless IO; Network integration - Wireless products; and Software - Mobile apps for controls, automation, instrumentation Paper Mill In Sweden Uses Wireless Instruments To Fulfill Environmental Requirements - Rosemount Conductivity Transmitters Help Korsnäs Gävle Prevent Discharging Pollutants Into Local Waterways. Wireless IO Advantages: More Data, Less Work - New I/O Products Provide More Measurement And Control For Processes, Optimization, And Asset Condition Monitoring With Less Effort, Wirelessly. Transducer Block Specification Issued - The Specification By Fieldbus Foundation Is Designed For Wired HART And WirelessHART Devices Along With Updates To The WIO System Architecture And Data Structures Low-Energy Wireless SCADA Used For Water Application - Water And Wastewater Utility In Bogotá, Colombia, Used An Extremely Low-Power-Consumption SCADA System With A Data Logging Support Feature, Allowing The Use Of Time Stamps. Wireless Sensor Networks To Grow To $2 Billion By 2021 - IDTechEx's Research Indicates That The Market For Wireless Sensor Networks Will Grow From $.45 Billion To About $2 Billion In The Next 10 Years. Current And Emerging Applications Include ... Control Engineering Cover story: Consumer-grade smartphones and tablet computers are fast becoming commonplace extensions of industrial networks.An iPhone as your Next HMI? - Consumer-grade smartphones and tablet computers are fast becoming commonplace extensions of industrial networks, permitting process monitoring and, even (gasp!) process control. Mill uses wireless technologiesCommunicating Diagnostic Data in a Legacy Environment - A wireless add-on device captured diagnostic information that helped solve an intermittent flowmeter problem.
What is a digital certificate? - These are supposed to protect us, but they were an element of the Stuxnet attack. Vulnerabilities include local wireless communications.

Making connections with M2MM2M in manufacturing eases legacy network connections - Machine-to-machine technologies are moving into new markets and making machine processes and network connections more efficient. Low-powered wireless systems enable connections to machines and devices that were not easily monitored with previous technologies.

Energy harvesting: challenges for wireless monitoring applications - Energy harvesters deserve the attention they're receiving, the advent of what can be made possible through the use of ambient energy to power devices has intrigued a wide variety of technologists, developers and adopters.

Machine Safety and Wireless Devices - Conventional machine safety has been challenged for the last 10 years with new technology and standards. Safety automation has led the new technology pack while NFPA 79 took the lead on the standards side. Both combined in 2002 to introduce safety PLCs, safety fieldbus, and e-stops on a safety rated bus. The latest challenge to conventional safety is wireless (aka cableless). June 2011 wireless application cover story - Control Engineering- Cover Story - Wireless Applications: Less Cost, More Productivity, Compliance - What does industrial wireless do for you? There’s up to 90% installed cost savings. Look for productivity, security, and regulatory compliance advantages. Banner SureCross Wireless automated solution provides accurate pond level monitoring and prevents accidental release of untested water. Courtesy: Banner Engineering- Wireless application: Toyota plant monitors detention ponds wirelessly - Wireless monitoring of detention pond levels helps Toyota Motor Manufacturing Kentucky comply with requirements of the Water Quality Act of 1987. Figure 1. Western Refining’s production facility near Gallup, N.M. Courtesy: Honeywell- Wireless Application: Western Refining cuts wiring costs, improves performance - After a site survey, a wireless system is being integrated with existing power and network infrastructure. Up to 90% of the installed cost of conventional measurement technology can be for cable, conduit, and related construction. Wireless also optimizes plant productivity and reliability, and improves safety and security. - Industrial Wireless Webcast at www.controleng.com/webcasts Powercast Lifetime Power Wireless Sensor System broadcasts RF energy to power wireless sensors without batteries or wires up to 80 ft away from the transmitters.- Technology Update: Low-power designs for automation - Microchip Technology provides microcontrollers with low-power capabilities, Powercast harvests energy to power wireless sensors, and STMicroelectronics demonstrates a chip for a smart power design to reduce electronic components’ energy consumption.

GlaxoSmithKline wireless application- Wireless instrumentation monitors water usage at pharmaceutical plant - GlaxoSmithKline uses Rosemount wireless pressure and flow transmitters; provides network for future expansion.

Libelium Meshlium Xtreme multi-protocol router supports five wireless standards - WiFi, ZigBee, GPRS, Bluetooth and GPS – as well as wireline Ethernet, to help connect wireless sensor networks to the Internet.- First multi-protocol wireless router - Libelium Meshlium Xtreme multi-protocol router supports five wireless standards - WiFi, ZigBee, GPRS, Bluetooth and GPS – as well as wireline Ethernet, to help connect wireless sensor networks to the Internet. Libelium said it is the first multi-protocol wireless router to bridge ZigBee and the Internet.

Figure 5: Generic cloud instrument- Cloud Instrumentation: Data without infrastructure - Will instrumentation and other devices in your plant be communicating via the cloud rather than your own networks? While it may not happen tomorrow, the technology is advancing and may be closer than you think. What is this cloud, and what can it do for you?

Submit a tip or trick- 9 tips for better industrial SCADA communications - Tips & Tricks: Wireless technologies can improve supervisory control and data acquisition applications. Match technologies to your needs, reduce costs, consider a hybrid approach, and heed six more pieces of advice. See graphic, table.

- Technology Update: Why WirelessHART? With other industrial wireless communications options available, process industry engineers may ask, ‘What is WirelessHART, and what is it good for?’

J.B. Titus, machine safety blogger- Machine Safety blog: Wireless Control and Wireless Safety! Dec. 22, 2010 - Safe wireless (also known as safe cableless) is often applied to a machine using a “zone” concept to reduce the wireless communication distance. As wireless machine communications increase, application questions include... - Ask Control Engineering blog: Creating your own cellular network, Dec. 17, 2010, While it is relatively simple for you to set up many types of wireless networks such as Wi-fi, ISA100.11a, WirelessHART, and many other proprietary systems, cellular is probably not one you will do on your own. It is possible... Siemens Scalance wireless system replaced infrared communications for crane movement at Blue Bell Creameries.- Inside Machines: Wireless Ethernet, PLCs add productivity to Blue Bell Creameries, Dec. 13, 2010, Upgrade with Siemens Scalance WLAN and Simatic PLCs adds productivity and eases training on aging automated storage and retrieval system for Blue Bell Creameries, a Texas-based ice cream maker. - Connections without Wires Webcast: How wireless technology creates new paths to productivity, Dec. 6, 2010 - Industrial wireless technology is already settling in as a proven networking technique for device-level and data backhaul applications. Learn which wireless protocols to use in what applications, considering reliability and security. Now available for on-demand viewing. - Ask Control Engineering blog: Bluetooth for industrial applications, Dec. 3, 2010, How many different devices can use Bluetooth without interfering with each other? Emerson wireless at Tecpetrol- Wireless instrumentation helps boost production, cut costs at Argentine natural gas producer, Dec. 1, 2010 - Tecpetrol uses data from Rosemount wireless transmitters. Results in production increase of $4 million while reducing maintenance costs by 62% and supervisory control costs by 35%. - Inside Machines: Crane Moves with IEEE 802.11n wireless, Dec. 23, 2010 - With the range of motion of industrial gantry cranes (in some cases over a kilometer), wireless Ethernet allows connectivity with moving equipment, avoiding the safety hazards and risk of moving wires or fibers. Wireless ROI in 2 months in oil and gas application- Wireless helps plains exploration and production, 2 month ROI, Nov. 8, 2010 - Plains Exploration and Production (PXP) Company automated its steam injection metering and data acquisition systems with a large network of WirelessHART transmitters and industrial broadband radios for a 10-times increase in transmitter accuracy and return on investment in 2 months. - Ask Control Engineering blog: Cellular communication for remote I/O, Nov. 5, 2010. Dear Control Engineering: I was looking at the announcement about using cellular service for industrial devices. Is this really practical? Wouldn’t it be hugely expensive? FHSS- How to choose wireless technology for industrial applications, Oct. 27, 2010 - Wireless technologies are being adopted for simple monitoring, control to supervisory control and data acquisition. Wireless provides reliable data communications in interference-heavy environments. Information follows to help choose the best wireless technology for an industrial application. - Wireless instrumentation helps pipeline operator with diagnostics, Oct. 10, 2010, Atlas Pipeline – Westex improves production efficiency at gas processing facility, joining old equipment to new control room. - Murphy’s 7 laws of industrial wireless communications - Applying wireless technologies for industrial communications doesn’t have to be as tough as Murphy’s Law (if anything can go wrong, it will), if you remember these Murphy’s 7 laws of industrial wireless communications. Wireless troubleshooting tips follow, including the number-one cause of wireless woes. - Wireless technology moves into broader process control applications, Sept. 29, 2010 - As technology evolves, users are now moving beyond mainstream monitoring applications to wireless measurements for control in harsh and remote environments. - The Case for Wireless Standards Convergence, Aug. 25 - Should end users care if wireless standards for field devices come together? One user offers his thoughts. - Ask Control Engineering: Apple's problems and wireless instrumentation, July 16, 2010 - Should I be concerned about similar reception difficulties with wireless instrumentation devices after the Apple iPhone 4 challenges? - Pillar to Post: Evolving Wireless Technology, July 9, 2010.

Yokogawa wireless pressure sensor using ISA100.11a communication.- ISA100.11a compliance group releases conformance test kits, July 8, 2010 - ISA100 Wireless Compliance Institute delivers package to verify wireless device interoperability and stack conformance.

- IEC approves WirelessHART as first international wireless standard for process automation, April 7, 2010 - Final IEC vote confirms broad global acceptance of WirelessHART by end users and suppliers, says HART Communication Foundation.

- News and comment: Can WirelessHART and ISA100 converge? March 31, 2010 - Emerson Process Management offers its thoughts on how the two main competing wireless instrumentation protocols can come together. - More on wireless interoperability, March 2, 2010. - Wireless sensor networks, the next 10 years - Feb., 24, 2010 - Wireless sensor networks (WSNs), self-organizing, self-healing networks of small "nodes," have huge potential across industrial, military, and other many other sectors, according to IDTechEx. - Pillar to Post blog: Wireless interoperability? What is that? Feb. 18, 2010
Wago 750-644 Bluetooth RF-Transceiver module was introduced for cost-effective I/O-based communications, company says.
Wago 750-644 Bluetooth RF-Transceiver module was introduced for cost-effective I/O-based communications, company says.
- Control Engineering Engineers' Choice awards - Wireless technologies - Feb. 1, 2010 - Wireless technologies were well represented among the products receiving awards, under the Network Integration category (wireless I/O systems, wireless I/O controllers, and wireless products - general) also under Process Control (wireless position monitor and wireless radar guage).
Yardmaster can view and access same information as trainmaster and pin-puller.
Yardmaster can view and access same information as trainmaster and pin-puller.
- Wireless at the Hump Yard , a railroad application - Jan. 1, 2010 - Norfolk Southern Railway automates manual processes with RFID scanners and HMI software processed through eight PCs. - RFID tag test results: Very fast ROI for some applications - Dec. 31, 2009 - RFID tests prove tangible return on investment for airline baggage tracking; Odin tests show radio frequency identification accuracy at 99.9% and less than 90% for barcode. - Wireless: No doubts about IEEE 802.11n advantages, say Rockwell Automation, Cisco - Dec. 23, 2009 - IEEE 802.11n wireless protocol offers industrial automation networking applications better performance for control, said Rockwell Automation and Cisco at Automation Fair. Protocol performance is shown.
The wireless measurement technology deployed at the site is a networked infomechanical system (NIMS) based on NI
The wireless measurement technology deployed at the site is a networked infomechanical system (NIMS) based on NI's LabView software and CompactRio hardware.
- Wireless Monitoring of Rainforest Carbon Flux - Dec. 1, 2009 - High-flying wireless sensors using robotic control allow researchers to take measurements three dimensionally to quantify complex carbon exchanges. - How to stretch wireless I/O throughout manufacturing - Dec. 1, 2009 - Adoption of flexible wireless I/O designs represents one of the simplest and most straightforward ways to stretch a wireless infrastructure investment. Wireless I/O technologies are affordable, secure, and can be implemented without disrupting existing operational processes. - Wireless Technology as a Work in Progress - Nov. 1, 2009 - Strategy and tactics: Process industry users, vendors discuss obstacles to implementation, appropriate applications, and standards for plant-level wireless. - Transparent Wireless at Cano Petroleum - Nov. 1, 2009 - Cockrell Ranch Waterflood oil recovery project uses a wireless SCADA system to gather, assemble, transmit information from the wells to produce detailed production models and maximize output. - Plant Deployment Demonstrates Wireless Standard - Nov. 1, 2009 - Installation in a brownfield chemical plant shows interoperability within ISA100.11a and practicality for instrumentation improvements in long-established operations. Apprion Ion network combines WiMAX (IEEE 802.16) and Apprion Ionizers (IEEE 802.11) in a wireless application network for real-time information delivery to operators in 4-square-mile plant.
- Wireless Enables Huntsman Project Zero - Nov. 1, 2009 - One of the largest and most ambitious industrial wireless application networks to date helps chemical manufacturer Huntsman strive for zero product defects, zero safety incidents and injuries, zero environmental releases, and zero unscheduled downtime. - Wireless networks: Adding cellular technology to the industrial toolbox - Nov. 30, 2009 - Can cellular networks provide a practical alternative for industrial use? While it may not be your primary wireless technology, in certain applications, cellular is practical and economical. - ISA 100.11a wireless demonstration project in operation - Oct. 7, 2009 - Wireless system installed at Arkema chemical plant seeks to prove device and infrastructure interoperability using equipment from multiple vendors operating under same standard. ctl090629motorolawirelesssq.gif
- Think Again: Wireless prosperity - July, 1, 2009 - Recent Motorola survey cites movement in wireless investments. - Wireless Standards - July, 1, 2009 - ISA100 Wireless Systems for Automation aims to unify industrial wireless technology. Here's how 600 members from 200 companies work together to meet that goal. - How to Improve ROI with RFID - April 1, 2009 - Determine if radio frequency identification (RFID) on the manufacturing production line can improve your return on investment (ROI). - The Transparency of Wireless - April 1, 2009 - Cover story: Wireless networking and device manufacturers have gone to great lengths to create products that are secure, easy to work with, and operationally indistinguishable from wired equivalents. - Wireless on the Factory Floor - March 1, 2009 - Is the plant floor ready for wireless network communications? Yes, and here's advice, so you are not up in the air about wireless technologies. ctlx_icon_wirelesss.gif
- Industrial Wireless Implementation Guide - Aug. 1, 2008 - So you've dabbled in wireless or thought it might save time, effort, or dollars. This primer helps with technology selection; subsequent articles in this supplement reveal trends, user views on wireless, and implementation advice. - 2007 Wireless Communications for Industry - Aug. 1, 2007 - (under supplements, lower right, five more articles, covering: How to optimize wireless infrastructure for application needs, Machine builders: Driven by consumer standards, 3 Approaches to Process Plant Wireless, WiFi on the plant floor, and Wireless Keeps Machines Coordinated.) Other resources Webcast library includes a wireless and other industrial networking topics. Control Engineering Automation Integrator Guide: Find experts with wireless experience in the Automation Integrator Guide. Also see the Industrial Network Product channel, which includes wireless news and products . * If you see articles that we've published since then (or back to 1997) that you'd like linked here, let me know with a comment below. I'll continue to update the page. Also please comment on any that you find particularly useful, or leave some of your own advice, if you'd like, in the article, or below. Thank you. - Compiled by Mark T. Hoske, content manager, CFE Media, Control Engineering, www.controleng.com. Control Engineering webcasts include more on wireless and Ethernet. http://www.controleng.com/media-library/webcasts.html ]]> ArchivedSyndication: Industrial Networking (Wireless Ethernet Sensor Networks Fieldbus IoT) Syndication: HMI Operator Interfaces GUI Historians Dashboards Syndication: I/O Modules Terminal Blocks Data Acquisition Syndication: Process Instrumentation Process Sensors (Temperature Pressure Level Flow) Syndication: Information Systems Software (Asset Management Alarm Management CMMS MES SCM ERP Production Scheduling CAD T&A OM) Syndication: Codes Standards Regulations Syndication: Automation & Controls (building automation system building automation controls BACnet energy dashboards energy simulators) Syndication: Codes and Standards (federal state AHJs third-party associations) Syndication: Electrical (distribution generation protection) Syndication: Green and Environmental (USGBC LEED AP Dept. of Energy Energy Information Administration EPA photovoltaic solar panels wind turbines) Tue, 16 Apr 2013 06:00:00 -0400 Machine Safety: What are fault exclusions? http://www.controleng.com/industry-news/single-article/machine-safety-what-are-fault-exclusions/e3c04c33292b11b80706dc832c3ce785.html Where did the term “fault exclusions” derive? Can you simply choose any fault to exclude? Who would... Does a definition exist? I’ve examined several ANSI, NFPA, IEC and ISO standards. I found several uses of the term “fault exclusion” in IEC 62061, ISO 13849-1 and ISO 13849-2, however, I could not find the term in the definitions section of these standards. Additionally, I could not find the term used in NFPA 79, RIA 15.06, ANSI/PMMI B155.1 or any of the current ANSI B11 standards except one – ANSI B11.TR6 – 2010, Safety Control Systems for Machine Tools. Here’s the definition: 3.22 fault exclusion: The elimination from consideration of a specific identified failure within the Safety-Related Parts of the Control System because its probability is low relative to the systems‘ required performance, through design, selection of components, or implementation of additional measures. Furthermore, in Clause 4 of the General Design Considerations section you’ll find the following additional clarifications for use: 4.6.2 Fault Exclusion During the analysis, certain faults may be uncovered that cannot be detected during operation without undue economic costs. Further, the probability that these faults might occur may be extremely small, by using mitigating design, construction and installation. Under these conditions, the faults may be excluded from further consideration. This includes recommended maintenance procedures. Fault exclusion can be based on but not limited to: ·  the low probability of occurrence of some faults; ·  tried and true (good) engineering safety practices; ·  application specific technical requirements for the specific hazard. Detail justification shall be given in the technical documentation for any excluded faults. ANSI B11.TR6 is a technical report and not a standard with normative requirements that “shall” be followed. ANSI standards are frequently referenced by OSHA via the General Duty Clause and therefore become law via enforcement by OSHA. As a technical report TR6 provides “guidance in understanding and implementing.” Why doesn’t this term appear in any of our domestic normative standards? Since it’s used in several international standards why hasn’t it been defined and clarified? Can anyone help the rest of us with the background for “fault exclusion”? Will there be a trend for this term rolled into everyday life for safety professionals, end users and manufacturers? J.B. Titus, CFSE Have you encountered any of these issues? Add your comments or thoughts to the discussion by submitting your ideas, experiences, and challenges in the comments section below. Related articles: Inside Machines: Does adopting ISO 13849-1:2006 change the U.S. model for compliance and enforcement? Machine Safety – does OSHA reference consensus standards for compliance? Machine Safety: Is OSHA okay with my 'acceptable' risk mitigation? Contact: http://www.jbtitus.com for “Solutions for Machine Safety”.]]> Machine Control Plant Safety and Security Tutorials Tutorials Machine Safety Share on PE SyndicationType: Article SyndicationSource: Freelance/contracted ArchivedSyndication: Safety Security (Intrinsic Process Machine Plant Arc Flash OSHA Personal Protective Equipment) ArchivedSyndication: Machine and Motion Control (Pneumatic Hydraulic Electric) Robotics jb@jbtitus.com Fri, 08 Mar 2013 15:53:00 -0500 Cyber security advice from the field http://www.controleng.com/media-library/videos/videos/in-an-interview-with-control-engineering-michael-assante-and-tim-conway-offer-security-suggestions-for-plant-operators.html In an interview with Control Engineering, Michael Assante and Tim Conway offer security suggestions... Slider Homepage Item - CTL Process Control Information Control Plant Safety and Security Videos Cyber Security InterConnection Automation: Pump Control InterConnecting Automation: Motors and Drives InterConnecting Automation: LEAN InterConnecting Automation: PLCs--Sensors and I/O Wed, 06 Mar 2013 15:55:00 -0500 New industrial cyber security video training series http://www.controleng.com/industry-news/single-article/new-industrial-cyber-security-video-training-series/95ffa120d219401f9f8f268d7268db9f.html Learn the basics of industrial cyber security concepts in this 13-part series with Matt Luallen,... This new industrial cyber security video training series provides a practical approach to the basic concepts of security for plant-floor networks. With the growing use of Ethernet and Internet connectivity with industrial networks, the opportunities for cyber criminals to invade your systems have grown by leaps and bounds. Luallen begins with the nature of cyber threats, considers why security is important, simulates an attack, offers defensive strategies, and ongoing practices for safer systems. This program is aimed primarily at users coming from the industrial side who are responsible for plant-floor networks. Its basic training can provide a general strategic direction for practitioners, plus it can serve as a foundation for more advanced instruction. When using the videos in combination with corresponding quizzes, you can receive PDHs for continuing education. Segment 4 is available above as a free sample. Series presenter Matthew E. Luallen is co-founder and president of Cybati, a critical infrastructure and control system cyber security awareness and education company. Matt has written, consulted, and trained extensively on process control and SCADA security issues. He continues to work with electric utilities throughout the U.S. and Canada on implementation of NERC CIP reliability standards. Prior to incorporating Cybati, Matt was a co-founder of Encari and still serves as the president of Sph3r3. He also served as an information security network engineer and architect at Argonne National Laboratory. Matt holds a bachelors degree in industrial engineering from the University of Illinois-Urbana, and a masters degree in computer science from National Technological University. He serves as adjunct faculty for DePaul University's capstone cyber security and control system courses, as an 13-year CCIE and certified instructor for Cisco Systems, and as a certified instructor for the SANS Institute. He is also the author of a new hands-on, control system cyber security course promoted by Cybati.  Series program 1. Technology Review—A very fast paced look at many types of hardware and software involved in security efforts, including keyboard sniffers, Ethernet routers, smart phones, and all sorts of common network devices. It may seem a bit overwhelming, but the discussion aims at giving you the huge variety of things you may have to work with. 2. Common Exposures—What are the ways that cyber criminals get into industrial networks? How can you find the vulnerabilities in your systems? There are all sorts of entrance strategies that hackers use. Once you understand these, you can begin to formulate defenses. It may be something as simple as selling a used PLC on eBay. 3. Understanding OSINT—Open source intelligence and social engineering are techniques that hackers use to get information about your networks with the intent of finding weaknesses. Some are technical, but others may be efforts to get your people to create an entrance unwittingly, or get critical information via a seemingly innocent discussion over drinks. 4. Control System Cyber Security—Why is security important, and what is going on in the defensive arms race? What are the effects of intrusions? Many intrusions are relatively minor, but what is the worst case for your facility if a hacker gets past the defenses? 5. Communications Attack Example—An actual demonstration of how an attacker can get between a controller and HMI and override information moving both directions. It isn’t as difficult as you might think. 6. Defense Techniques 1—What types of security controls you should put in place, from an operational, physical, and cyber standpoint, including concepts of defense-in-depth. Your efforts have to include all these for maximum effectiveness. 7. Defense Techniques 2—How do you protect the range of devices that serve as hosts, everything from terminal units to PLCs. This process begins by identifying all those things on your networks that are cyber assets using appropriate qualification parameters. 8. Defense Techniques 3—Everything that communicates has to have a communication pathway. How do you identify those and protect them? It can be wired or wireless, and each approach has its own challenges. 9. Common Cyber Asset Security Controls—What security controls should you install on your cyber assets, both in your plant or enterprise level? Considers patches, applications, account management, threat indicators, physical access, and more. 10. Specific Control System Cyber Exposures—What are the cyber security vulnerabilities unique to industrial networking environments? Much industrial equipment is not well hardened against intrusion, so with that in mind, what can we do to reinforce our defenses? 11. Validating Vendor Security Awareness—As you work with equipment vendors, how do you analyze those companies and determine their mindset relative to security? Some companies are better than others, so how can you make that determination? A few simple questions can tell you a lot. 12. Cyber Asset Vulnerability Assessments—How do you determine where you are on the security spectrum? Without an effective plan, such an evaluation can be painfully difficult and leave you no better off. Some simple guidelines can keep you on track. 13. Cyber Security Resources—Once you’ve finished the series, here are some useful resources that can help keep your ongoing efforts focused and effective. Total series running time, approximately 110 minutes.]]> Information Control Process Control Machine Control Plant Safety and Security Tutorials SyndicationType: Article SyndicationSource: CFE Media (in-house) Syndication: Process Manufacturing Syndication: Discrete Manufacturing Syndication: System Integration System Integrators Mon, 11 Feb 2013 18:46:00 -0500 Initial settings for PID controllers http://www.controleng.com/industry-news/single-article/initial-settings-for-pid-controllers/20714acd35d29912159075ce67f1ae1b.html Time to start the process? Here are some beginning PID values learned in the trenches that should... auto mode with the expectation that the loops will control fairly close to their setpoints without significant oscillation.

The following table offers some time-tested default values for gain, integral time, and derivative time that will work in most common situations as a starting point during initial unit start-up. If your control system uses other tuning constant units (e.g., reset for the integral action, then you’ll have to do the conversion – I’m sure you can handle it).

The following table offers some time-tested default values for gain, integral time, and derivative time that will work in most common situations as a starting point during initial unit start-up.
The values for flow control loops and level control loops will almost always work. In a few cases, a gain of 0.8 for a flow control loop may be too aggressive and should be reduced for nervous valves or loops that tend to oscillate.

The gains for pressure and temperature loops may need to be increased, depending upon the engineering units range of the controller. If the controller has a wide range (e.g., a pressure controller with a 0-500 psig range) and tight control is required around the setpoint (let’s say in this case, SP = 400 psig), then a larger gain may be required to keep the PV close to setpoint. This is because gain works on error as a percent of the engineering units range. So, a 1.0 psig deviation from setpoint is only 0.2% of range – a gain of 2.0 would result in a valve movement of only 0.4% - not much action. In this case, a gain of 5.0 or even 10.0 might be more appropriate.

Temperature is the only variable where derivative action should be applied with confidence in the default case. In general, derivative is reserved for loops with measurement lag. Flows, levels, and pressures do not normally suffer from this destabilizing characteristic. On the other hand, process temperatures are often measured indirectly by devices in thermowells, thereby introducing measurement lag due to the inherent thermal lag. Derivative action in this case can help, since its purpose is to “reverse” the control action as the PV “reverses” its trajectory and starts heading back toward setpoint after a deviation away from setpoint. A small amount of derivative in this case is recommended.

Derivative action is totally inappropriate for “noisy” process variables, as can often be the case for flow and level (and sometimes, pressure) measurements. Derivative action acting on a noisy deviation can produce wild valve swings, depending upon the values of the gain and derivative. In the case of a noisy measurement, a solution that is often suggested is to heavily filter the PV. However, this can often introduce artificial measurement lag, further degrading control loop performance.

The recommended integral time for temperature may need to be increased (less aggressive integral action) for loops with significant process dead time and lag – for example, for controlling a distillation column temperature with reflux flow or reboiler heat.

As is always the case, you’ll need to use your experience and good engineering judgment on these types of projects, but this should give you a good starting point for configuration of these very important PID control algorithm parameters.

This post was written by Dr. Jim Ford, PE. Jim is a process control consultant at MAVERICK Technologies, a leading system integrator providing industrial automation, operational support and control systems engineering services in the manufacturing and process industries. MAVERICK delivers expertise and consulting in a wide variety of areas including industrial automation controls, distributed control systems, manufacturing execution systems, operational strategy, and business process optimization. The company provides a full range of automation and controls services – ranging from PID controller tuning and HMI programming to serving as a main automation contractor. Additionally MAVERICK offers industrial and technical staffing services, placing on-site automation, instrumentation and controls engineers.]]> Process Control Blogs Automation System Integration Engineering at 30 Frames Machine Safety Ask Control Engineering Pillar to Post Standard Profits AIMing for Automated Vehicles System Integration: Water and Wastewater Tue, 15 Jan 2013 16:14:00 -0500 Machine Safety: Where do effective safety cultures roost? http://www.controleng.com/industry-news/single-article/machine-safety-where-do-effective-safety-cultures-roost/8ca313e0fb9ebf9489aa0e21034ab524.html An improved safety culture, advocated at the business level with engineering input, can bring about... Sometimes, when new life rushes onto the factory floor via machine safety technology innovation, we have a “ta-dah” moment of realization about organizational effectiveness or the lack thereof! There has been a very interesting discussion playing out on the LinkedIn Safety Automation Forum regarding safety cultures. This discussion was kicked off by Steve Ludwig (Rockwell Automation) and his highlighting of an article written by Cynthia Carroll, CEO of Anglo American plc, titled “The CEO of Anglo American on Getting Serious About Safety.” The discussion and article are, in my mind, centered around two very distinctive organizational camps I have witnessed in industry over the past 40-plus years. Those two camps are what I call “business talk” and “engineering talk.” And, most often it’s the business talk group which runs a company, establishes company vision, lays out the short and long term goals and objectives, and establishes the industrial safety policy. In other words, the business talk group follows top-down methodologies for running the business. The engineering talk group is that part of the business that provides solutions and methodologies that implement the business talk. Engineering talk seldom sets or influences the setting of safety policy via bottom up approaches. However, they are the group usually most interested in innovative new ways to meet the corporate requirements established by the business talk within a company. With this said, it’s my opinion that the engineering talk camp generally will not engage in corporate wide adoption of innovative new safety technology by themselves. The engineering talk group is almost always the early adopter of new safety solutions but, as this graph illustrates, approximately 85% of the marketplace waits for company wide adoption before moving ahead. So, what’s the answer to facilitating earlier adoption? The answer, in my opinion, is that a company’s business case for innovative new safety technology needs to be integrated with the business talk of a company. Only then do the executives of a company become aware of a paradigm shift in machine safety that improves productivity, reduces unplanned downtime and offers additional profits to the bottom line. A recent Aberdeen Group study of more than 120 executives revealed that when executives understand that innovative new machine safety solutions are available offering opportunities for increased profitability – corporate strategies and safety policy begin to shift. J.B. Titus, CFSE A positive shift in safety policy occurs when I have witnessed a company’s “effective safety culture” in action, moving to company wide adoption of the new safety technology. There are lots of opinions on this subject but it’s been my experience that truly effective safety cultures roost at the top. Johnson & Johnson is one of these companies emphasizing employee safety in the Johnson & Johnson Corporate Credo. Your comments or suggestion are always welcome, so please let us know your thoughts. Submit your ideas, experiences, and challenges on this subject in the comments section below. Click on the following text if you don't see a comments box, then scroll down: Machine Safety: Where do effective safety cultures roost? Related articles: Designing In Machine Guarding How To Integrate Safety Safety Automation Forum The CEO of Anglo American on Getting Serious About Safety Contact: www.jbtitus.com for “Solutions for Machine Safety”.]]> Machine Control Tutorials Slider Homepage Item - CTL Weekly News Newsletter Weekly Slot 1 Weekly Slot 2 or 3 Machine Control Machine Safety Share on PE Automation Engineering jb@jbtitus.com Fri, 07 Sep 2012 11:33:00 -0400 New controller supports Visual Studio .Net programming http://www.controleng.com/industry-news/single-article/new-controller-supports-visual-studio-net-programming/e16967502616d6aae750381c01e2bb3e.html Advantech launches a RISC-based controller designed for easy user program development. The Industrial Automation Group of Advantech has introduced its new APAX-5620 RISC-based controller. With an Intel XScale PXA270 CPU, it can support Microsoft Visual Studio .Net programming, allowing PC-based users to develop their own applications easily. The APAX-5620 features two CAN bus interfaces which support CANOpen stack (DS301 and 302) and two RS-485 ports allowing it to connect to remote I/O devices as well as being able to support up to 32 APAX I/O modules. It is compatible with IEC-61131-3 based Multiprog KW languages, which allow users to download change functions and time deterministic support. It also supports the WinCE operating system. With this feature set, Advantech says it will provide an excellent cost-effective solution for a wide range of applications, such as steel production monitoring, spinning and weaving machinery, and more general factory automation. www.advantech.com Edited by Peter Welander, pwelander@cfemedia.com]]> Information Control Manufacturing IT Information Control Monthly Newsletter Information Control Slot 1 Information Control Slot 2 or 3 Industrial Networks Industrial Networks PLCs and PACs SyndicationType: Press Release - Commercial (Advertising) ArchivedSyndication: Controllers (PACs PLCs IPCs Loop Controllers DCS Relays Embedded Controllers) Tue, 04 Sep 2012 10:26:00 -0400 Distillation Columns – Internal Reflux Control http://www.controleng.com/industry-news/single-article/distillation-columns-internal-reflux-control/71bfad5077b916ca27bf3588ac81db4c.html A view from the trenches considering one of the sources of distillation column instability that is...
For a two-product distillation column (top and bottom product), there are typically five degrees of control freedom (control valves):

• Reflux flow
• Top product flow
• Reboiler heat input flow
• Bottom product flow, and
• Pressure control valve,  the specific location of which depends upon how the pressure is controlled.
Three of these valves are needed for inventory control (reflux drum, column bottom, and vapor inventory or pressure control). That leaves two valves for achieving the primary operating and control objective, namely product composition control. These two valves are normally the reflux flow and the reboiler heat source flow. For many columns, the P&ID’s will specify a top or upper tray temperature controller that adjusts the reflux flow in a straightforward cascade for top product composition control.

Unfortunately, this type of cascade does not always perform very well, and often operators will end up breaking the cascade and using the reflux flow control in AUTO mode rather than CASC. There are several reasons for poor control loop performance – this discussion addresses one of the less recognized and often over-looked sources of process disturbance.

There are at least seven or eight different ways to control pressure on a distillation column, and several of these will result in sub-cooled reflux. Sub-cooled means that the temperature of the reflux exiting the overhead condenser is below its bubble point, the temperature at which the first bubble of vapor boils off the liquid. From a process and control standpoint, what are the implications of returning sub-cooled reflux to the column?

The purpose of reflux is to provide down-flowing liquid throughout the rectification section to contact with the up-flowing vapor in order to achieve stage-by-stage equilibrium heat and mass transfer and, hence, purification of the top product. When sub-cooled reflux is introduced to the top tray, it must be heated up to its bubble point before the lighter components will vaporize. Where does the heat come from? The only place it can come from is from condensing vapor that is approaching the top tray from below. When this vapor condenses, it adds to the total liquid flowing from tray 1 down the column. In other words, a sub-cooled reflux introduces a greater volume (or mass or molar) flow of reflux than is delivered to the column by the external reflux flow controller.

If the degree of sub-cooling was constant, then this wouldn’t be such a big source of disturbance; however, this is usually not the case. The amount of sub-cooling will vary with the temperature of the cooling medium (ambient air, cooling water, another process stream, etc.), rainstorms, and so on. To achieve satisfactory composition control, the most common approach is to employ an advanced regulatory control (ARC) technique referred to as internal reflux control.  The internal reflux, that is, the actual flow of liquid from tray 1 to tray 2, can be calculated as follows:

IR = R * (1+Cp * (TO – TR) / Λ)

Where:

R    =   External reflux flow

Cp =    Heat capacity of the reflux (e.g., BTU/lb-°F)

TO =    Overhead vapor temperature (entering the condenser)

TR =    Reflux temperature

Λ    =    Heat of vaporization of the reflux (e.g., BTU/lb)

An internal reflux controller simply uses this equation to solve for the external reflux flow required to maintain a constant internal reflux at each control execution. In effect, this controller compensates for changes in the sub-cooled reflux temperature at each control execution.

The final step is to rebuild the cascade for composition control, namely, to re-introduce the temperature-to-internal reflux cascade, with the likelihood that this cascade will be more stable, will control composition better, and will enjoy greater operator acceptance.

This post was written by Dr. Jim Ford, PE. Jim is a process control consultant at MAVERICK Technologies, a leading system integrator providing industrial automation, operational support and control systems engineering services in the manufacturing and process industries. MAVERICK delivers expertise and consulting in a wide variety of areas including industrial automation controls, distributed control systems, manufacturing execution systems, operational strategy, and business process optimization. The company provides a full range of automation and controls services – ranging from PID controller tuning and HMI programming to serving as a main automation contractor. Additionally MAVERICK offers industrial and technical staffing services, placing on-site automation, instrumentation and controls engineers.]]> Process Control Process Slot 2 or 3 Process Control Real World Engineering SyndicationType: Article SyndicationSource: Systems Integrator/consultant Syndication: Process Manufacturing Syndication: System Integration System Integrators Syndication: Control Methods (PID Advanced Process Control) SyndicationSource: Content Partner - Maverick Technologies Tue, 21 Aug 2012 17:09:00 -0400 Webcast on Industrial Wireless: Where and When http://www.controleng.com/media-library/webcasts.html CFE Media - Control Engineering webcast: Thursday, June 14, 2012 at 2 p.m. ET/1 p.m. CT/11 a.m. PT,... Industrial Networks Industrial Networks System Integration Slider Homepage Item - CTL Instrumentation Slot 2 or 3 Thu, 14 Jun 2012 13:13:00 -0400