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AutoQuiz: What Should an Engineer Include in a Final Automation Project Report to Senior Management?

The post AutoQuiz: What Should an Engineer Include in a Final Automation Project Report to Senior Management? first appeared on the ISA Interchange blog site.

AutoQuiz is edited by Joel Don, ISA’s social media community manager.

This automation industry quiz question comes from the ISA Certified Automation Professional (CAP) certification program. ISA CAP certification provides a non-biased, third-party, objective assessment and confirmation of an automation professional’s skills. The CAP exam is focused on direction, definition, design, development/application, deployment, documentation, and support of systems, software, and equipment used in control systems, manufacturing information systems, systems integration, and operational consulting. Click this link for more information about the CAP program.

A final report on a highly visible automation project will be distributed to senior leaders and several operations managers. In preparing this report, an engineer would be well served to:

a) define any geometric tolerance symbols present in report diagrams
b) explain how troubleshooting procedures solved unexpected crises and plan deviations
c) include an executive summary, and, as appropriate, use bulleted lists in the narrative
d) review how cost, performance, and schedules were estimated, measured, and controlled
e) none of the above

Click Here to Reveal the Answer

Choices A, B, and D may represent important aspects of the overall understanding of the report, but these are details that can be examined once the overall conclusions are absorbed, if there is a desire to do so.

The correct answer is C, “include an executive summary, and, as appropriate, use bulleted lists in the narrative.” Very often, senior leaders and management have limited time to spend on any one topic. An executive summary and bullet-item lists allow them to understand the basic outcomes and conclusions of your project in a concise, logical, and efficient format.

Reference: Nicholas Sands, P.E., CAP and Ian Verhappen, P.Eng., CAP., A Guide to the Automation Body of Knowledge. To read a brief Q&A with the authors, plus download a free 116-page excerpt from the book, click this link.

About the Editor
Joel Don is the community manager for ISA and is an independent content marketing, social media and public relations consultant. Prior to his work in marketing and PR, Joel served as an editor for regional newspapers and national magazines throughout the U.S. He earned a master’s degree from the Medill School at Northwestern University with a focus on science, engineering and biomedical marketing communications, and a bachelor of science degree from UC San Diego.

Connect with Joel
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Source: ISA News

How to Select a Platform to Implement a Batch Automation Solution

The post How to Select a Platform to Implement a Batch Automation Solution first appeared on the ISA Interchange blog site.

This post was written by John Parraga, a process specialist with ECS Solutions.

Making a platform selection to implement a batch automation solution should start with the evaluation of the end user’s short- and long-term requirements. Unfortunately, end users sometimes make decisions solely based on the short-term objective of cost. This is not always compatible with meeting long-term requirements.

Here are some aspects to consider before building a solution:

1. Number of recipes that need to be maintained. Controller-based solutions are limited in the number of recipes they may store, whereas PC-based solutions are not.

2. Complexity of each of these recipes. Some controller-based solutions are not capable of automatically looping back or allowing decision branching in the recipe based on process conditions. In addition, their transition conditions are simplistic and may not be able to evaluate expressions.

3. Ability to make adjustments using parameters and report values. Can the parameters and report values of the running recipe be used dynamically to adjust other set points within the same batch?

4. Multi-unit recipe coordination. This requires all levels of recipe definition: the ISA-88 standards define procedures, unit procedures, and operations. The communication and exchange of information between recipes running in different units is handled as part of the functionality of PC-based solutions. In controller-based solutions, custom code needs to be implemented to coordinate the interunit activities.

5. Distribution of necessary logic. Is the logic required to perform different tasks (pertinent to ISA-88 phases) programmed in a single controller, or is it distributed among multiple controllers? With controller-based sequencers, all phases required by the recipe must reside in the same controller. A PC-based solution can create recipes whose phases reside in multiple controllers and can even be distributed among assorted controller brands and models.

An integrated architecture deploys a PC-based solution to communicate with the controller-based firmware solution, creating a distributed batch solution.

6. Use of class-based recipes minimizes the number of recipes, as well as the complexity of multi-unit routing options. They are only possible with a PC-based solution, though. Controller-based solutions require building the same recipe for each unit.

7. Rules regulating recipes. Kosher recipes or recipes with allergens cannot run against specific units. Controller-based recipes manage these requirements by simply specifying the requirements or preferences.

8.Protection of the recipe as intellectual property. Encapsulating the best practices regarding how to make a product, intellectual property (IP) can typically be accessed by any programmer or user of a controller-based solution. PC-based solutions isolate the know-how of the product IP from the controller program. System integrators and developers are only exposed to the capabilities of the equipment, which can be designed, implemented, and tested without exposing how the products are made.

9. Recipe versioning. It can be useful to recall how a product was made using a previous version of the recipe, without having to go to databases to rebuild the procedure.

10. Approval process. Managing the approval process for releasing recipes to production limits who can make changes to recipes and may enforce a consensus before it can be run. This functionality is only available in PC-based solutions.

11. Network infrastructure. Some believe that, despite poor network communication, a recipe can continue running through its steps until completion using a controller-based solution. Consider, however, the need for human-machine interface control, as well as what happens to the batch data.

Controller-based solutions can be applications developed to run as controller code. This approach uses a significant amount of controller memory. Another approach uses the sequencing engine built into the firmware of the controller. Using off-the-shelf functionality and not custom code, this approach also has limitations, but has more versatility. A PC-based solution offers much of the short- and long-term functionality required by most end users, but requires licensing the product.

Recently, an automation vendor released functionality that allows the PC-based solution to communicate with the controller-based firmware solution, creating a distributed batch solution that maximizes the benefits of each option. With the distributed batch solution, parameters and report information can be communicated between the controller-based and PC-based solutions.

About the Author
John Parraga is a process specialist with ECS Solutions, Inc., a member of the Control System Integrators Association (CSIA). Parraga has more than 25 years of batch process automation experience.

 

Connect with John
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A version of this article also was published at InTech magazine



Source: ISA News

Industry 4.0 Concepts for Discrete Manufacturing Applied to Process Automation

The post Industry 4.0 Concepts for Discrete Manufacturing Applied to Process Automation first appeared on the ISA Interchange blog site.

This article was written by Bill Lydon, automation industry authority, journalist and former chief editor at InTech magazine.

Industry 4.0 initially focused on discrete manufacturing, and now there is a growing focus on applying Industry 4.0 concepts to process automation. The same concepts are being applied to process automation to achieve a holistic integration of automation, business information, and manufacturing execution function to improve all aspects of production and commerce across company boundaries for greater efficiency.

The “Process Sensor 4.0 Roadmap” is a big step toward creating fundamental building blocks to advance process automation system architectures. A number of NAMUR working groups are part of Working Area 2 (WA 2), Automation Systems for Processes and Plants.

Process Sensor 4.0 Roadmap

The Process Sensor 4.0 Roadmap highlights the opportunity to optimize process control and value-added production with “smart,” networked communicating sensors. These “smart” sensors provide services within a network and use information from the network as a foundation with which to implement Industry 4.0 cyber-physical systems within future process industry automation systems. Fundamental Industry 4.0 for Process concepts include process applications with direct communications from field devices simultaneously to process control, business systems, supply chain, engineering, and planning systems. These sensors are implemented by leveraging embedded computing technology, which has become pervasive in consumer and computing products. This is intended to facilitate the change from rigid, preconceived, hierarchical production systems to dynamic, flexible, self-configuring and self-optimizing, integrated, and intelligent networked systems and processes.

The road map was initiated by NAMUR and VDI/VDE in collaboration with several prominent leaders in the industry, including ABB, BASF, Bayer Technology Services, Bilfinger Maintenance, Endress+Hauser, Evonik, Festo, Krohne, Lanxess, Siemens, and Fraunhofer ICT.

NAMUR is an international association of user companies established in 1949. It represents their interests concerning automation technology. Organizational goals include adding value through automation engineering and facilitating “frank and fair dialogue” with manufacturers.

VDE Association for Electrical, Electronic and Information Technologies is one of Europe’s largest technical-scientific associations, with more than 36,000 members. The organization has primary offices in Frankfurt, Berlin, and Brussels, as well as 29 branch offices throughout Germany. VDE also works closely with the Institute of Electrical and Electronics Engineers (https://www.ieee.org).

VDI/VDE Society for Measurement and Automatic Control (GMA) is a joint organization of VDE and VDI, which orients users about the current trends in automation that are supported by innovations in information technology (IT), microelectronics, optics, and sensorics (advanced measuring technologies). The Society organizes meetings, conferences, seminars, and other events to promote the transfer of know-how.

The Process Sensors 4.0 Roadmap goes beyond previous road maps, which tended to focus almost exclusively on technical requirements of sensors and their operating principles. Instead, the new road map focuses on how to achieve greater efficiencies with sensors that have embedded intelligence, communications, and an information system interface based on Industry 4.0 concepts. The road map describes how communication and the management of information will become increasingly important as information from sensors is integrated into business systems. The road map notes new technology will simplify application engineering and maintenance using “plug and play” smart sensors. The report shares how new developments, from IT and medical technology, are creating the possibility for improved process sensors, leveraging miniaturized components with extremely low pricing. These devices also utilize advances in configuration software to simplify project engineering and maintenance. For example, new smart sensors may be able to measure several metrics, calibrate and optimize themselves, and interact directly with other sensors and actuators, thus performing control and automation independently.

The road map identifies the necessary requirements, as well as the communication abilities, of smart process sensors from simple temperature sensors to more complex ones. Important smart sensor features noted in the road map include:

  • autonomous sensor interaction (peer to peer)
  • sensor verification (logical verification using adjacent sensors)
  • plug and play (self-configuration/parameterization)
  • virtual description supporting continuous engineering
  • traceability and compliance
  • self-calibration
  • self-diagnosis
  • connectivity and communication using a unified protocol (OPC UA)
  • maintenance and operating functions
  • energy self-sufficiency (energy harvesting)
  • wireless sensors
  • sensor data access rights control
  • standards compatible (i.e., good manufacturing practices, U.S. Federal Drug Administration)

The application of Industry 4.0 and Internet of Things concepts and technologies is part of an ongoing discussion with ramifications throughout the entire industry. Smart sensors with embedded intelligence that can communicate for control and integrate with enterprise business systems represent a clear system architecture change for process automation and control leveraging advances in technology.

NAMUR Working Group 2.6

NAMUR Working Group 2.6 (WG 2.6) “Fieldbus” published the position paper, An Ethernet communication system for the process industry to be a basis for discussion about future systems.

WG 2.6 Fieldbus is under the umbrella NAMUR work area “Automation Systems for Processes and Plants.” It is addressing issues that include solutions and systems for the management, steering, control, inspection, and communication of production plants assigned to the area between field and company control levels. The scope includes cross-cutting issues, such as new technologies and sustainable automation engineering solutions.

The position paper serves as a basis for discussion in the dialogue with manufacturers. It describes the requirements to be met by an Ethernet fieldbus system for the process industry, taking into account previous experience with existing fieldbus systems, as well as desirable future properties. Considerations include the special characteristics of the process industry, such as very long plant service life and the resulting long use of process control systems and field devices, as well as stringent requirements for safety and availability, which are special challenges for digital and networked communication structures. The introduction of an Ethernet-based communication system calls for a precise definition of the requirements for a system that is specifically designed for the process industry. In addition to the requirements described in NE 74 (NAMUR fieldbus requirements) new aspects were identified.

Overall concept

What is needed is a modular overall concept to meet different plant requirements, such as topological conditions, link length, bit rates, explosion protection, safety instrumented systems, and the integration of existing fieldbus systems. The focus is the classical field devices of the process industry in terms of sensor and actuator systems, such as pressure, temperature, level, flow, and positioner. In addition to classical field devices, which are often also used in explosive atmospheres, the overall concept shall be integrated via the same protocols as all other equipment of the process plant, such as the motor starter, frequency converter, weighing and analytical systems, as well as energy measuring systems and building services. It shall describe them by means of profiles. As a result, all information will be available for processing to all systems involved and can be used consistently in engineering and configuration tools.

Protocols

NAMUR calls for protocols IEC 61784-2 CPF 2/2 Ethernet/IP and IEC 61784-2 CPF 3/5 Profinet IO CC B to become minimum binding requirements for the process industry. These protocols need to be adapted to meet the process industry’s special requirements, including the following:

All bus participants (e.g., field devices, process control systems, and infrastructure components) must be able to communicate with each other in an interoperable manner without any interference to ensure long-term bus operation.

The two protocols specified must be supported by all bus components in terms of mandatory functions (e.g., transmission of measuring values).

In addition to the deterministic protocol specified, other standard protocols shall be interoperable (i.e., simultaneous operation with other protocols must be possible without any interaction). The same protocol shall be used irrespective of the physical layer used (i.e., also for wireless or fiber optical solutions).

Field-device interfaces

The physical layer connects the typical sensor and actuator systems used in production plants of the process industry. Wired connections shall be designed as two-wire cables with signal transmission and energy supply of field devices. The physical layer shall be suited for use in both explosive and nonexplosive atmospheres (which is in keeping with current fieldbus solutions).

Connections

Field connections will be based on NAMUR NE 74, Fieldbus Requirements.

Explosion protection

The large area covered by production plants calls for distribution equipment, such as switches, to be installed in hazardous areas. This requires components with an adequate type of explosion-proof protection. Field devices in hazardous areas are typically connected according to the “intrinsic safety” type of protection. Proof of intrinsic safety must be limited to a comparison of parameters. The applied explosion protection shall be internationally recognized.

EMC

Devices and components will conform to the NE 21 electromagnetic compatibility (EMC) requirements.

Binary signals

Simple interface modules, preferably compact two-wire devices or modular mini-I/Os, shall be provided for binary signals, such as switches, initiators, solenoid valves, and signal lamps. As a rule, direct bus connection shall be possible.

Safety instrumented systems

A special protocol version for safety applications shall be available and transmitted via the same medium as normal protocols (“black channel” principle). An adequate number of safety-oriented field devices and controls must be available. As in the case of conventional safety instrumented systems, the sensor/actuator systems of the field devices and the bus coupling of the field device signal shall be proven in use or at least meet safety integrity level 2 requirements. This ensures adequate reduction of systematic errors without, however, being explicitly certified. To ensure safe data transmission, protocol stacks in accordance with IEC 61508 are used in the sensors and actuators that put the reliably generated signals on the bus. The protocol that ensures safety (safety layers in addition to transmission layers) can be selectively activated by a switch in the field device. This means that the devices can be used for both safety-related and nonsafety-related equipment. These devices shall be commissioned in the same way as standard devices. A hardware switch to lock parameterization is required.

Field device integration (NE 105)

The device packages required for field device integration shall be available in the devices and capable of being transmitted to central tools following NE 105 Specifications for Integrating Fieldbus Devices in Engineering Tools for Field Devices.

Transmission of measuring values

Measuring and control values shall be transmitted without a configuration file. To this end, it is necessary to agree on defined profiles, such as AI, AO, DI, and DO.

Configuration

Parameterizing, configuring fieldbus devices, signal flooding, and connecting additional devices must not interfere with the transmission of measuring data and shall be possible during ongoing operation.

Automatic addressing

Devices and components shall be addressed automatically. It shall be possible to activate entire segments or areas.

Device replacement

When replacing a device (1:1), the configuration of the previous device shall be loaded automatically and the measuring process continued without any extra effort or input. Replacing a device with a newer model of the same type and by the same manufacturer shall be possible at any time. It shall be indicated on the device which versions may be used for replacement. The interchange of devices provided by different manufacturers shall be possible over an agreed range of functions (NAMUR parameters, profiles).

Default setting

It is also necessary to deliver devices with preset uniform parameter sets (default settings) in accordance with NE 131 and NE 107.

Marking

In addition to marking in accordance with NE 53, the type plate shall have a clear and nonproprietary marking so that the devices can be identified as Ethernet devices (e.g., logo).

Diagnosis, status

The status signals according to NE 107 shall be consistently supported by devices, systems, and components.

Detailed diagnosis

Causes of changes in status (detailed information from devices and components) shall be automatically transmitted to higher-level systems.

Web server

If the devices can be configured via a web server, parameters shall be automatically matched across the entire system to prevent inconsistencies between data sets. The presentation and the parameters used shall be identical in the web server and the device package. The web server shall be provided with an access protection.

Security

Transmission mechanisms shall comply with the state of the art in safety technology (e.g., encrypted and signed). The mechanisms for filtering and blocking shall also be state of the art (e.g., MAC address filters, whitelisting, blacklisting).

Synchronization

The network time shall be synchronized.

Time stamp

The protocols shall include a time stamp.

Authentication

Authentication mechanisms shall be capable of verifying the authenticity of software and devices.

IP address

IPv6 addresses shall be used to address the devices.

Tag identification

The devices shall be identified by means of a freely configurable tag (at least 32 characters) and the MAC address.

Communication status

The system should be able to monitor the status of communication, including infrastructure components. This could be the transmission time between a field device and switch or the number of telegram repetitions.

Topology recognition

An engineering system shall be capable of automatically reflecting the logical plant topology and device hierarchy.

Redundancy

It shall be possible to implement redundant controls and infrastructure components to increase availability.

Life cycle

All devices and components shall be designed for a life cycle of more than 20 years under process industry conditions.

Compatibility and interoperability

During the entire life cycle, it shall be possible to retrofit new devices and components and replace old ones with new ones. Technical innovations shall be capable of running both new and old infrastructures and of adapting automatically to the existing infrastructure (e.g., bandwidth adaptation).

Integrating existing concepts

It is also necessary for existing fieldbus facilities to create transparent transitions between existing fieldbus and Ethernet systems. These transitions (proxies) shall have at least the same functionality as current fieldbus masters.

Certification

Certification shall ensure the conformity of devices and components with all requirements made. The certified devices shall be indicated at a central point (e.g., a website).

Costs

The costs of an Ethernet solution shall be comparable with those of 4-20 mA HART.

Industry cooperation

Other standards organizations are aligning to cooperate with the Industry 4.0 for Process initiative.

Networking: Ethernet/IP and Profinet 

Both ODVA and PROFIBUS & PROFINET International (PI) are working toward meeting the requirements, since NAMUR calls for protocols IEC 61784-2 CPF 2/2 Ethernet/IP and IEC 61784-2 CPF 3/5 Profinet IO CC B to become minimum binding requirements for the process industry (noting these protocols need to be revised to meet process industry requirements).

At the 2016 SPS IPC Drives Show, ODVA announced activities with NAMUR to advance the adoption of industrial Ethernet in the process industries. The focus will be an activity to continue the refinement of formal requirements for an Ethernet communication system for the process industry. This will be through a collaboration between WG 2.6 Fieldbus and the ODVA Special Interest Group for Ethernet/IP in the Process Industries (Process SIG). Among the topics of the cooperation are device diagnostics, defining a device profile for process devices for Ethernet/IP, and integration of HART devices into Ethernet/IP.

Another part of the cooperation was the installation of an Ethernet/IP system in the integration and industrial communication test laboratory at Industriepark Höchst, a center of the European process industry in Frankfurt am Main, Germany. “Multiple vendors are supporting the effort, including Endress+Hauser, Krohne, Rockwell Automation, and Schneider Electric,” said Olivier Wolff, ODVA Process SIG participant and employee of Endress+Hauser, a principal member of ODVA.

At a joint symposium, PI and NAMUR e.V. discussed the use of Ethernet in the process industry. The goal of the event was to evaluate, coordinate, and prioritize the requirements placed on an Ethernet communication system for process automation. The results of the discussions by experienced specialists from system and device manufacturers and expert users in this field were compiled in a position paper of the NAMUR WG 2.6 Fieldbus (convened by Sven Seintsch of Bilfinger). It will be the basis for the development of a next-generation digital communication system for use at process plants. Michael Pelz (Clariant Plastics & Coatings), head of NAMUR Working Area 2, Automation Systems for Processes and Plants, summarized the benefits of this activity, “Close cooperation between manufacturer and user organizations beginning at the early phase of a new technology unleashes great synergy potential. This provides the best opportunity for introducing a new technology, both cost effectively in production by the supplier and efficiently at the plants of the user.”

Dr. Peter Wenzel, managing director of PI, sees “special challenges for digital and networked communication structures” in the specific characteristics of the process industry, such as long plant service lives and accordingly long-term use of process control and field device technology, complex devices, and high requirements on security and availability. “This is why the successful introduction of an Ethernet-based communication system requires early coordination of requirements with users. The experts at PI are happy to engage in this task and are looking forward to intensive and fruitful cooperation with NAMUR experts.”

Industry 4.0 for Process is evolving and is consistent with other new initiatives for improving industrial automation system architectures.

About the Author
Bill Lydon is an automation industry expert, author, journalist and formerly served as chief editor of InTech magazine. Lydon has been active in manufacturing automation for more than 25 years. He started his career as a designer of computer-based machine tool controls; in other positions, he applied programmable logic controllers and process control technology. In addition to experience at various large companies, he co-founded and was president of a venture-capital-funded industrial automation software company. Lydon believes the success factors in manufacturing are changing, making it imperative to apply automation as a strategic tool to compete.

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A version of this article also was published at InTech magazine



Source: ISA News

AutoQuiz: What Is the Purpose of an Instrument Location Plan?

The post AutoQuiz: What Is the Purpose of an Instrument Location Plan? first appeared on the ISA Interchange blog site.

AutoQuiz is edited by Joel Don, ISA’s social media community manager.

This automation industry quiz question comes from the ISA Certified Control Systems Technician (CCST) program. Certified Control System Technicians calibrate, document, troubleshoot, and repair/replace instrumentation for systems that measure and control level, temperature, pressure, flow, and other process variables. Click this link for more information about the CCST program.

An instrument location plan shows the _________ of each instrument.

a) location and wiring plan
b) location, elevation, and tag number
c) specification number and tag number
d) location, specification number, and elevation
e) none of the above

Click Here to Reveal the Answer

Specification numbers (part of answers C and D) are usually indicated on instrument lists and instrument installation details. Wiring plans (part of answer A) are typically shown on conduit and wiring schedules or cabling diagrams. Although these details are useful in the installation of a plant, they are not part of the instrument installation plans.

The correct answer is B, “location, elevation, and tag number.” Instrument location plans are most often used to support new plant installations and give the installer information about the actual physical location of the installation of an instrument, the elevation of installation (at grade, on a platform, at what height on a process line, etc.), and the tag number of the instrument to be installed.

Reference: Goettsche, L.D. (Editor), Maintenance of Instruments and Systems, 2nd Edition

About the Editor
Joel Don is the community manager for ISA and is an independent content marketing, social media and public relations consultant. Prior to his work in marketing and PR, Joel served as an editor for regional newspapers and national magazines throughout the U.S. He earned a master’s degree from the Medill School at Northwestern University with a focus on science, engineering and biomedical marketing communications, and a bachelor of science degree from UC San Diego.

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Source: ISA News

The Positive Impact of the 2019 ISA Annual Leadership Conference

The post The Positive Impact of the 2019 ISA Annual Leadership Conference first appeared on the ISA Interchange blog site.

This post is authored by Paul Gruhn, president of ISA 2019.

The 2019 ISA annual leadership conference was our largest annual leader conference in many years. For example, there were 130 leaders registered for the event in 2014. This year there were 209. What might be the reasons for that?  

One might have been the location. This year’s meeting was held at Paradise Point Resort in San Diego, California. Built during the early 1960s, the resort’s ambiance was that of an exotic South Seas paradise complete with lagoons and waterfalls. There was an abundance of tropical and subtropical flowers and foliage among cabana-style cottages. Each cottage featured a picturesque view of Mission Bay, the lagoons, or the tropical gardens. The weather was gorgeous, with only one cloudy day during my nine-day visit.  

Another reason might have been the positive response to furthering our strategic objectives and goals. Department, division, district, section, and committee leaders discussed what each of their groups could do to promote the strategic objectives, goals, tactics, and key performance indicators that have been the focal point of our work this past year. Limiting this discussion to just objectives (3-5 years out), and goals (up to 1 year out), these targets would be:  

1. Member Programs: Enhance member value and expand engagement opportunities to nurture and grow a more diverse and global community to advance the automation profession.  

  • Review the value proposition for membership and benchmark to similar Societies. This review should consider the career stage, global location, and benefit from the employer’s perspective. 
  • Launch an online community. 
  • Review and define a “healthy” section. This review should consider the location, number of members, and years of existence. 
  • Review and define a “healthy” division. This review should consider the number of members and years of existence. 
  • Engage and grow the young professional member community within ISA.  

2. Industry Reach and Awareness: Establish and advance ISA’s relevance and credibility as the home of automation by anticipating industry needs, collaborating with stakeholders, and developing and delivering pertinent technical content.  

  • Prepare a comprehensive analysis of stakeholders; Identify, analyze, map, and prioritize stakeholder groups and their needs and expectations.
  • All parts of ISA will contribute to and operate from a single society-wide plan that will coordinate and drive the development and dissemination of ISA’s technical content in multiple forms. The program will define opportunities, priorities, responsibilities, dependencies, and expected outcomes.  

3. Technical Education and Certification: Become the recognized leader in automation and control education, providing training, certifications, and publications to prepare the workforce to address technology changes and industry challenges in the most flexible and relevant ways.

  • Assess the global needs and viability of ISA’s training and education program. 
  • Develop and deliver agile modular training and certificate programs that can serve as a model for automation community stakeholders. 
  • Develop testimonials and statements to better promote the value proposition of ISA certification and education programs.  

4. Finance and Governance: Create opportunities for members to improve critical leadership skills, to build a network of industry professionals, and to develop the next generation of automation professionals.

  • Complete an operational assessment using a third-party association expert to review our governing documents and structure for optimal operations.  

There are too many tactics (up to 3 months out) and key performance indicators to list in this brief article. The point of this significant effort is to get all the different operational areas of ISA to row their collective boats in the same direction.  

Another reason might have been the nature of our awards gala. The gala was a bit less formal than years past and did not include a sit-down meal. Instead, we held the “formals and flip flops” dinner on the beach. People line-danced to DJ’ed music provided by our very own Brandon Cornthwaite. I wore the upper half of my tuxedo sporting swim trunks and flip flops. While the music officially ended at 10 p.m., many continued the party well beyond that. We enjoyed the camaraderie and have formed long-lasting friendships over the years.  

Another might have been the nature of some of the fun events we planned. For example, Saturday morning for 40 people started at 6 a.m. with the I-S-A-mazing race. Six teams competed in a treasure hunt, collecting clues from all over the resort. No doubt, many other resort dwellers must have thought we were crazy, but running around the island before sunrise was a real hoot!  

Another might have been the positive and transparent nature of the Council of Society Delegates meeting. While there were no resolutions that required the delegate body to vote, the group heard reports from their society leaders, along with a presentation from the organizational consulting firm that the Executive Board has been working with during the year. We have been reviewing our governing and operating documents that total approximately 200 pages. I believe the delegates understand the need for such an assessment (much like visiting your doctor for a check-up, even if you’re feeling fine), and can see the early stages of the transparent nature the Executive Board will use in communicating the expected changes that will be put forth for the delegate body next year.  

Another might have been the impact of the surplus budget we set for 2019. (That hasn’t happened in a decade.) It was announced that we expect to end the year with an even greater surplus than originally planned. An even larger surplus budget is planned for 2020, still accounting for growth and expansion efforts, along with a variety of activities scheduled for ISA’s 75th anniversary in 2020.  

Another might have been the impact of membership growth in 2019. That also hasn’t happened in a decade.  

Another might have been the many standards committees that met before, during, and after the leader meeting; 18.2 (alarm management), 75 (control valves), 84 (safety instrumented systems), 95 (enterprise-control system integration), 96 (valve actuators), 101 (human-machine interface), and 112 (supervisory control and data acquisition).  

Another might have been that two of the 14 ISA districts held their annual district leadership conferences the day before the leader meeting. That was an excellent way for even more volunteer leaders to get more bang for their buck, receive more training, and meet and interact with even more society leaders.  

It does not get much better than this! Volunteer leaders are feeling positive! If you are an ISA volunteer and missed this meeting, you missed a significant, positive, and fun event! Perhaps you will consider attending next year’s conference in Puerto Rico.

About the Author
Paul Gruhn is a global functional safety consultant at AE Solutions and a highly respected and awarded safety expert in the industrial automation and control field. Paul is an ISA Fellow, a member of the ISA84 standards committee (on safety instrumented systems), a developer and instructor of ISA courses on safety systems, and the primary author of the ISA book Safety Instrumented Systems: Design, Analysis, and Justification. He also has contributed to several automation industry book chapters and has written more than two dozen technical articles. He developed the first commercial safety system modeling software. Paul is a licensed Professional Engineer (PE) in Texas, a certified functional safety expert (CFSE), a member of the control system engineer PE exam team, and an ISA84 expert. He earned a bachelor’s degree in mechanical engineering from the Illinois Institute of Technology. Paul is the 2018 ISA president-elect/secretary.

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Source: ISA News

Drones in Industrial Automation: Vital Mobile Platforms for Sensor Delivery

The post Drones in Industrial Automation: Vital Mobile Platforms for Sensor Delivery first appeared on the ISA Interchange blog site.

This post was written by Peter Fuhr, PhD, Marissa Morales-Rodriguez, PhD, Sterling Rooke, PhD, and Penny Chen, PhD.

Factories, refineries, utilities (water/wastewater, electric), and related industrial sites are complex systems and structures with inspection and maintenance procedures required for optimal operation and regulatory compliance. For example, consider just the bulk electric power system, which comprises more than 200,000 miles of high-voltage transmission lines, thousands of generation plants, and millions of digital controls.

More than 1,800 entities own and operate portions of the grid system, with thousands more involved in the operation of distribution networks across North America. The interconnected and interdependent nature of the bulk power system requires a consistent and systematic application of risk mitigation across the entire grid system to be truly effective. Similar situations are found throughout the automation industry, which also frequently has aging infrastructure.

Consider, for example, the situation in a refinery or chemical processing setting with the requirement for leak detection inspection of pipes, interconnects, and systems across the plant. The current practices and challenges relating just to this task of detecting any fugitive emissions and documenting all measurements, and thereby meeting air compliance regulations, are typically “handled” by a small army of individuals with handheld or backpack-sized detectors.

They crawl through piping racks conducting measurements at each flange. Such work is performed in difficult conditions (in terms of temperature, humidity, and physical challenges) and frequently has a high level of employee turnover. Enter low-cost sensors and mobile platforms-in other words, unmanned aerial systems (UASs or drones) with enhanced sensing capabilities.

Drones: more than flying cameras

Remotely piloted aerial vehicles have been used, primarily by military forces, since the Second World War. With recent technological advancements in microprocessor computing power, sensor miniaturization, and purpose-built software, UAS technology has established a significant new niche in the evolution of aviation. Alternatively labeled unmanned aircraft systems, unmanned aerial vehicles, or simply drones, small UASs (sUASs) are becoming readily accessible for commercial, governmental, and private use across a myriad of far-ranging applications. (Note that the Oak Ridge National Laboratory’s UAS Research Center recently released a best practices guide for UAS operation by electric utilities. See the sidebars for an overview of the rules for legal operation.)

Figure 1. Some individuals view a drone as a camera with wings.

Although a “traditional” drone has a camera where video and still images may be stored on an onboard memory device or, in some instances, wirelessly transmitted to a handheld device, the operational situation changes when the drone’s sensors can directly communicate with an industrial control or supervisory control and data acquisition (SCADA) system. Such a level of integration requires bidirectional communication transmission security, as well as logical protocol synchronization.

Such communications have been demonstrated using cellular telephony as well as licensed- and unlicensed-band wireless. With respect to the information presented in figure 2, the sensor-laden drones were controlled via approved Federal Aviation Administration (FAA) rules, but with the sensor “pods” communicating directly into the utility’s core communication network via 900 MHz wireless and made available into the SCADA system (as opposed to using the same wireless channel for the drone control).

Figure 2. Multiple drones with sensors were used to measure a wide range of parameters at the EPB training site in Chattanooga, Tenn.

Multiple sensors within the “pod” measured parameters including temperature, humidity, atmospheric pressure, motion (via accelerometers), electric and magnetic field strength, coronal arc discharge, forward-look infrared (FLIR) thermal imagery, visual imagery, cell phone signals (Verizon, AT&T, T-Mobile, Sprint), and CH4 (methane).

Additional microcontrollers and specialized miniaturized network equipment were placed within the sensor pod, along with a separate battery-based power supply system tailored for the sensor package. A photo of the drone and sensor pod as it inspects an electrical distribution transformer is shown in figure 3. These proof-of-concept demonstrations-specifically showing airborne sensors providing real-time measurements of automation systems-are a glimpse into future applications.

Figure 3. Sensor-laden drone inspecting an electrical distribution transformer

Being able to conduct three-dimensional assessments and inspections using a remotely operated sensor platform has led to a flood of potential uses of UASs-both envisioned and realized. UASs of all types have already been used in a wide variety of applications in practical ways, such as aerial photography, agriculture, commercial delivery, entertainment, exploration, national defense, public safety, surveying, and thermography. Envisioned future applications will help advance precision agriculture, energy-sector remote sensing, national security and law enforcement reconnaissance, and utilities analysis. Such “future applications” benefit from the remotely or autonomously controlled mobile platform bringing a wide range of sensors to a location of interest.

Operation and flight times

Weight versus power versus flight (operational) time presents the classic trade-off in a limited fuel-supply flight operation, be it aircraft, drones, or spacecraft. Empirical data has given way to estimators regarding the battery-operated lifetime for drone operation. Figure 4 presents the estimated range based on a wide array of parameters.

Figure 4. The range that a drone can go (and return) for a variety of parameters.

Note that the figure 4 calculation incorporates overall drone weight, but specifically within the context of sensor-laden drones. It does not include the possibility of the sensor being directly powered off the same battery source as the drone itself. The working estimate for a battery-operated drone is a flight time of approximately 20 minutes. Note that there are wildly varying flight times for differing drone configurations-ranging from a few minutes to an hour. That said, the working rule of approximately 20 minutes for a standard consumer drone is accurate.

As battery technology (specifically energy density) improvements continue, the companion matter of battery-operated longer flight ranges or durations are anticipated. Given the FAA rules regarding drone operation and flight control, a set of questions arises that is typically associated with beyond-visual-line-of-sight (BVLOS) operation (and its implications on drone use in industrial settings) and flight times (“how long can the drone fly?”) (see https://www.ecalc.ch/xcoptercalc.php?ecalc).

Again, the FAA rules are quite clear regarding BVLOS, beginning with the definition: “BVLOS means flight crew members (i.e., remote pilot in command [PIC], the person manipulating the controls, and visual observer [VO], if used) are not capable of seeing the aircraft with vision unaided by any device other than corrective lenses (spectacles and contact lenses).”

Although most current UAS applications are carried out in VLOS missions, there are obvious limits to VLOS inspections. With respect to BVLOS operation for electric utilities, BVLOS allows personnel to monitor power lines over longer corridor stretches. Via the FAA Extension, Safety, and Security Act of 2016, Congress authorized the FAA to develop new rules specifically to benefit the electric power industry and other operators of critical infrastructure. Under this new legislation, the FAA will begin to develop rules enabling BVLOS flights and night flights.

Other changes are expected to streamline the permitting of UAS flights and improve commercial viability and safety while facilitating inspection of critical infrastructure. Any new rules are not expected to become part of formal regulations until 2018 or beyond. However, many operators under Part 107 are expected to apply for waivers to a number of Part 107 regulations, such as flying at BVLOS distances. Some of these waivers are likely to be granted in advance of more formal regulation changes that will arise from the 2016 act. On 28 December 2016, the FAA approved a certificate of authorization for the Northern Plains UAS Test Site in North Dakota to be the first in the U.S. to have BVLOS operability. Other locations within the U.S. now have similar exemptions to the BVLOS rule.

Coordinated flight and collaborative sensing

Advancements in control systems for UAS flight dynamics operating on inexpensive, lightweight (power and computational requiring) microcontrollers with networked wireless communications have led to instances where multiple drones fly in formation. Such coordinated flight was demonstrated during the 2017 Super Bowl halftime show and at several amusement parks worldwide. In an automation setting, the coordinated flight of multiple drones, each equipped with a variety of sensors, leads to collaborative sensing of mobile sensors.

Examples of where such “coordinated flight – collaborative sensing” (CFCS) applications exist include the possibilities of sensing chemicals-such as CH4-and environmental and ambient conditions associated with storage tanks at fracking sites (figure 5), bridge inspection, and power generation facilities (examining pipes for cracks from rapid thermal cycling of coal-fired plants due to wind generation variability).

Figure 5. A drone as a mobile sensor platform allows for measurements to occur in variety of situations, such as those associated with fracking.

UAS traffic management systems are critically important for the drone industry. These systems help keep control of flying drones, and between unmanned and manned traffic. Developments within academia, national laboratories (i.e., Department of Energy and National Aeronautical and Space Administration), and the private sector are underway for reasonable and deployable UAS detection systems.

Using drone-based sensing

It is not just drone-based sensing, but rather how to use the measurements made via such platforms that is significant. The following statements from Thomas Haun, vice president of strategy and globalization at PrecisionHawk UAV Technology, are applicable throughout the application areas where drone-based sensors may be used:

“Commercial drones are flying in. The industry needs to see beyond the UAV and focus on the real disruptor: actionable analytics via aerial data. As we prepare for widespread adoption and integration across major markets, such as agriculture, oil and gas, insurance, infrastructure, emergency response, and life sciences, businesses need an intelligent solution that combines UAV hardware and automated data analysis software to deliver tangible results at scale.”

The intersection of the Industrial Internet of Things (IIoT), cyber-physical security, and sensor-laden drones presents an array of opportunities for use in automation. Standards and guidelines can help carve an orderly path forward. This path will allow industry to incorporate advanced technologies into procedures and practices as this booming market sector introduces devices and systems. It is envisioned that in the very near future drones of varying sizes and complexities-equipped with sensors-will be operated from a remotely located control center with real-time measurements intermixed with sensor data from other fixed and mobile platforms. It will monitor and record within an industrial control or SCADA system, such as that shown in figure 6.

ISA’s Test & Measurement Division and Communication Division currently have a joint working group focused on IIoT, cyber-physical security, and unmanned aerial systems with the associated examination of functional and operational security for when these devices are deployed into a control system. Additional information on these and related topics-including videos of the operation of sensor-laden drones-are available on each division’s website.

Let’s risk the machines, not the humans.

Figure 6. Integration of fixed and mobile sensors, UAS- and truck-mounted, with command, control, and real-time data coordinated at the center.

New FAA rules

The FAA’s comprehensive new regulations for the routine, nonrecreational use of sUASs-more popularly known as drones-went into effect 29 August 2016. The provisions of the new rule, known as Part 107 or Rule 107 (14 CFR Part 107), are designed to minimize risks to other aircraft and to people and property on the ground.

The FAA has put several processes in place to help you take advantage of the rule:

Waivers: If your proposed operation does not completely comply with Part 107 regulations, you need to apply for a waiver of some of the restrictions. You must prove the proposed flight will be conducted safely under a waiver. Users must apply for these waivers at the online portal www.faa.gov/uas.

Airspace authorization: You can fly your drone in Class G (uncontrolled) airspace without air traffic control authorization, but operations in any other airspace (i.e., instrument flight rules) need air traffic approval. You must request access to controlled airspace via the electronic portal at www.faa.gov/uas, not from the individual air traffic facilities.

Summary of 14 CFR Part 107 (FAA rule/Part 107)

The FAA Part 107 regulations, which legalize commercial drone use, dramatically increase the potential number of UAS users. Anyone can now legally operate a UAS as part of a business after first passing an aeronautical knowledge test and then registering with the FAA. In the first two days after the test became available, 1,338 people had completed the test with an 88 percent pass rate.

Small unmanned aerial system operational limitations

The following restrictions and limitations are based on “Operation and Certification of Small Unmanned Aircraft Systems: Final Rule” as published in the Federal Register, volume 81(124), 28 June 2016, pp. 42063-42214 (FAA, 2016).

  • sUASs must weigh less than 55 pounds (25 kg).
  • sUASs must remain within visual line of sight of the remote pilot in command and the person manipulating the flight controls of the sUASs. Alternatively, the sUAS must remain within VLOS of the visual observer.
  • sUASs may not operate over any persons not directly participating in the operation, under a covered structure, or inside a covered stationary vehicle.
  • sUASs are limited to daylight-only operations, or civil twilight (30 minutes before official sunrise to 30 minutes after official sunset, local time) with appropriate anticollision lighting.
  • sUASs must yield right of way to other aircraft.
  • First-person view cameras cannot satisfy “see-and-avoid” requirements, but can be used as long as requirements are satisfied in other ways.
  • sUASs are limited to a maximum ground speed of 100 mph (87 knots) and a maximum altitude of 400 ft above ground level (AGL) or, if higher than 400 ft AGL, remain within a 400-ft radius of a structure. They must fly no higher than 400 ft above a structure’s uppermost limit.
  • External load operations are allowed if the object being carried by the UAS is securely attached and does not adversely affect the flight characteristics or controllability of the aircraft.
  • Transportation of property for compensation or hire is allowed if:
    • the aircraft, including its attached systems, payload, and cargo weigh less than 55 pounds, total
    • the flight is conducted within VLOS and not from a moving vehicle or aircraft
    • the flight occurs wholly within the bounds of a state and does not involve transport between (1) Hawaii and another place in Hawaii through airspace outside Hawaii; (2) the District of Columbia and another place in the District of Columbia; or (3) a territory or possession of the U.S. and another place in the same territory or possession

Most of the restrictions enumerated above are waivable if the applicant demonstrates that his or her operation can safely be conducted under the terms of a certificate of waiver.

About the Author
Peter Fuhr, PhD, is a distinguished scientist at Oak Ridge National Laboratory and also serves as the technology director for the Unmanned Aerial Systems (UAS) Research Laboratory. He is the director of the ISA Test & Measurement Division.

About the Author
Marissa Morales-Rodriguez, PhD, is a research and development scientist at Oak Ridge National Laboratory. She has been working in the area of chemical sciences, concentrating on applications related to sensing, additive manufacturing, and document security. She is director-elect of the ISA Test & Measurement Division.

About the Author
Sterling Rooke, PhD, is the founder of X8 LLC, a technology company focused on industrial sensors with an eye toward cyber- and energy security. On a part-time basis, Rooke is the director of training within a Cyber Operations Squadron in the U.S. Air Force. In his role as a reserve military officer, Rooke leads airman through training exercises to prepare for future conflicts in cyberspace. He is the director-elect of the ISA Communication Division.

About the Author
Penny Chen, PhD, is a senior principal technology strategist at Yokogawa US Technology Center (USTC), responsible for technology strategy and standardization focusing on wireless, networking, and related security, and exploring new technologies for industrial applications. Chen is actively involved in ISA100, Wireless Systems for Automation, and a variety of IoT standardization activities, including IEEE P2413 IoT Architecture Reference Framework. Chen received a PhD in electrical engineering from Northwestern University. She is the director of the ISA Communications Division.

A version of this article also was published at InTech magazine



Source: ISA News

How to Solve the Biggest Maintenance Challenges in the Oil & Gas Industry

The post How to Solve the Biggest Maintenance Challenges in the Oil & Gas Industry first appeared on the ISA Interchange blog site.

This guest blog post was written by Bryan Christiansen, founder and CEO at Limble CMMS. Limble is a mobile first, modern computerized maintenance management system application, designed to help managers organize, automate and streamline their maintenance operations.

Oil and gas businesses operate in an industry that is subject to complex global and national constraints ranging from continuously fluctuating prices to strict regulatory monitoring. To thrive, these organizations need to constantly adapt to the ups and downs in the industry. Achieving this requires, among other things, excellence in their core operations — crude oil exploration, processing, and supply.

But there is one supporting function that can have a direct impact on operations and even cripple the entire venture if not well managed — maintenance management. Certainly, challenges encountered in some regions of the world will differ but there are some common maintenance challenges that impact companies across the globe.

This post examines some of the biggest maintenance challenges operators in this industry experience along with possible solutions.

1) Minimizing Production Costs

Although crude oil prices are rising, the fact remains that prices will always be volatile. The constant interplay of factors that oil companies cannot directly control – especially political and global influences – makes this unavoidable. Thus, companies that want to remain competitive in this market still need to thoroughly research avenues for extracting and producing refined products at lower costs. 

Another angle to consider is that as old wells rapidly dry up, the need for unconventional exploration such as horizontal drilling and ultra-deepwater drilling is increasing. Agreed, these techniques provide avenues for more revenue but the cutting-edge technology required comes at higher costs, risks, and complexity than traditional drilling.

This is the reality of the oil and gas industry today.    

For the maintenance unit, they can help increase productivity and minimize production costs through:

  • More efficient procurement and use of resources especially spare parts and inventory.
  • Automating as much of the daily maintenance process as possible. This can be achieved relatively easily through the use of most modern computerized maintenance management software (CMMS). Using CMMS will help reduce labor costs, help keep workers safer, and deliver more lean processes.  

2) Environmental Concerns

The oil and gas industry has always been a closely monitored sector and individual organizations are tasked with devising better methods for exploration/production with minimal environmental impact. 

Governments keep introducing regulatory controls, fines, and carbon reduction targets because of the often catastrophic environmental impact of oil industry-related accidents such as the 2010 Deepwater Horizon oil spill.

 The image below is courtesy of the NOAA and shows the largest oil spills in U.S. waters from 1969:

Air pollution is also a major concern and just recently, a report by the Canadian Government shows that the oil and gas sector has now overtaken transportation as the highest producer of greenhouse gases.

All these factors add to the complexity and scrutiny that oil and gas companies must operate under. To reduce their environmental impact, these organizations must comply with various restrictions on how they can use natural resources for their operations.

Take water for instance: it is a vital component for oil extraction and production. Every operator’s maintenance strategy should include a robust plan for water acquisition, transport, storage, treatment after use, and safe disposal. Without careful water management, there is a greater risk of production problems and regulatory penalties.

Their maintenance strategy should also include plans for handling effluents, hazardous byproducts, and wastes, as well as ways to detect leaks and other critical problems as early as possible. This is the most effective way to ensure minimal environmental pollution.

3) Asset Maintenance

Oil industry assets are typically complex, extremely expensive, and require specialist attention to replace or repair. These assets range from process equipment (fixed or rotating), facilities, oilfields, rigs, etc.

Each of these assets have very specific functions they perform in the production process. Plus, several oil installations are offshore and not easily accessible compared to on-land counterparts.

This means that maintenance ineffectiveness, especially of critical assets, could generate a significant financial loss for operators. In an attempt to handle this problem, a common mistake among business owners is to focus on cutting their maintenance budget. Unfortunately, this route tends to produce short-term relief with long term consequences. 

Rather, efficient and proactive maintenance strategies when well-implemented is a better option and can help offset the higher costs of new drilling techniques.

Comprehensive and timely asset management is a must as the risks of poorly-maintained assets are too high and they include:

  • Accelerated depreciation of costly assets.
  • Wasted work hours.
  • Slowed or halted production.
  • Poor quality and reliability of products.
  • Missed production and delivery quotas and deadlines.
  • Revenue loss.
  • Workers’ injuries or worse.

There are several modern maintenance strategies and tools you can use, such as predictive maintenance , IIoT technology, and mobile maintenance software, that will help optimize operations, keep production assets dependable, and reduce unexpected shutdowns.

However, whatever maintenance strategy is implemented, it is important to procure equipment that is designed to function in the operating environment, especially where there is high corrosion risk. This will help reduce asset replacement rates and ensure better functionality of the equipment over its expected lifespan.

4) Availability of Talen

According to a study conducted by Accenture Strategy, the oil and gas industry is headed for an impending shortfall in talent supply by the year 2025. The areas that will be hardest hit include petrotechnical professionals (PTPs) in the drilling, production, and maintenance disciplines.

The study further shows that many of these professionals were laid off in past down markets. Getting them to return when business improves would not be easy and their skills may be obsolete by then. What about employing new talent? Well, millennials and recent college graduates apparently don’t find the oil industry attractive.

The implications of this shortfall for maintenance teams are far reaching because specialized skills are usually required to operate and maintain most of the equipment in this industry, especially the critical assets. Additionally, it can take several years to sufficiently train new entrants to handle these maintenance roles.

To manage this situation, companies can look to outsourcing by partnering with specialist contractors to provide skilled external labor. They could also work to make their operations more digital and thereby hope to attract a younger workforce.

5) Improving Safety

There is hardly any industry that is completely risk-free but oil installations are distinctly notorious for safety problems. Nations are concerned about this fact and to help ensure maximum protection of workers, there are many regulations that oil and gas businesses must comply with. For example, the EU introduced directives in 2013 aimed at enforcing the highest safety standards for oil and gas companies. These regulations also seek to protect aquatic ecosystems and coastal environments against pollution.

Again, proactive maintenance helps here because maintenance and safety are inseparable. The goal is to deliver a twofold benefit: protect the person performing the maintenance activity and protect the equipment being maintained.

To prevent safety lapses that can easily escalate into catastrophic incidents, common issues maintenance managers should guard against are:

  • Using assets well past their lifespan without adequate monitoring.
  • Cutting maintenance budget, laying off maintenance staff.
  • Poor maintenance planning and execution.
  • Inadequate staff training, poor enforcement of safety compliance.
  • Human error that usually results in severe consequences in this industry.
  • Persistently unsafe work procedures.
  • Inadequate documentation of operating procedures.
  • Continuous pressure to fulfill production quotas. 

Safety is a big deal in the oil sector. Fortunately, companies are aware of this and they are always working to keep employees safe. They can go further by ensuring that operating procedures are clear and that safety instructions are thorough and well understood.

The old model of quick-fixes such as maintenance budget cutting and staff layoffs are proving counter-productive. Instead, the future of the oil and gas industry will depend on operators that can survive the industry’s highly volatile nature and still achieve operational excellence in all areas of business, including maintenance.

About the Author
Bryan Christiansen is founder and CEO at Limble CMMS. Limble is a mobile first, modern computerized maintenance management system application, designed to help managers organize, automate and streamline their maintenance operations.

Connect with Bryan
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Source: ISA News

AutoQuiz: What Is the Significance of the Fieldbus Intrinsic Safety Concept?

The post AutoQuiz: What Is the Significance of the Fieldbus Intrinsic Safety Concept? first appeared on the ISA Interchange blog site.

AutoQuiz is edited by Joel Don, ISA’s social media community manager.

This automation industry quiz question comes from the ISA Certified Automation Professional (CAP) certification program. ISA CAP certification provides a non-biased, third-party, objective assessment and confirmation of an automation professional’s skills. The CAP exam is focused on direction, definition, design, development/application, deployment, documentation, and support of systems, software, and equipment used in control systems, manufacturing information systems, systems integration, and operational consulting. Click this link for more information about the CAP program.

What is the significance of the fieldbus intrinsic safety concept (FISCO)?

a) It decreases the number of field devices per trunk compared with traditional area classification practices
b) It simplifies the rules governing energy storage in field cables and makes more power available to the fieldbus trunk
c) It increases safety requirements for live-working on a trunk and spurs
d) It standardizes safety documentation for fieldbus circuits in Division 2 hazardous areas, in which the explosion hazard is expected only in abnormal circumstances
e) none of the above

Click Here to Reveal the Answer

Even though a FISCO approach allows more power on a segment trunk cable than the entity approach (field barrier approach), FISCO requires each part of the system, including devices, cables, and power conditioners, to be FISCO certified. In addition, FISCO design and installation rules must be strictly followed. The FISCO installation is still bound by the requirement that no more than 115 mA can be delivered through a segment installed in a hazardous area, so approximately the same number of devices (four or five) can be installed on a single segment.

The correct answer is B. It simplifies the rules governing energy storage in field cables and makes more power available to the fieldbus trunk. FISCO considers the segment circuit as a whole, including power sources, cabling, devices, and connectors.

Reference: Nicholas Sands, P.E., CAP and Ian Verhappen, P.Eng., CAP., A Guide to the Automation Body of Knowledge. To read a brief Q&A with the authors, plus download a free 116-page excerpt from the book, click this link.

About the Editor
Joel Don is the community manager for ISA and is an independent content marketing, social media and public relations consultant. Prior to his work in marketing and PR, Joel served as an editor for regional newspapers and national magazines throughout the U.S. He earned a master’s degree from the Medill School at Northwestern University with a focus on science, engineering and biomedical marketing communications, and a bachelor of science degree from UC San Diego.

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PID Controller Tracking of Industrial Robotic Manipulators [technical]

The post PID Controller Tracking of Industrial Robotic Manipulators [technical] first appeared on the ISA Interchange blog site.

This post is an excerpt from the journal ISA Transactions. All ISA Transactions articles are free to ISA members, or can be purchased from Elsevier Press.

Abstract: This paper presents the tracking control for a robotic manipulator type delta employing fractional order PID controllers with computed torque control strategy.  It is contrasted with an integer order PID controller with computed torque control strategy. The mechanical structure, kinematics and dynamic models of the delta robot are descripted. A SOLIDWORKS/MSC-ADAMS/MATLAB co-simulation model of the delta robot is built and employed for the stages of identification, design, and validation of control strategies. Identification of the dynamic model of the robot is performed using the least squares algorithm. A linearized model of the robotic system is obtained employing the computed torque control strategy resulting in a decoupled double integrating system. From the linearized model of the delta robot, fractional order PID and integer order PID controllers are designed, analyzing the dynamical behavior for many evaluation trajectories. Controllers robustness is evaluated against external disturbances employing performance indexes for the joint and spatial error, applied torque in the joints and trajectory tracking. Results show that fractional order PID with the computed torque control strategy has a robust performance and active disturbance rejection when it is applied to parallel robotic manipulators on tracking tasks.

Free Bonus! To read the full version of this ISA Transactions article, click here.

Enjoy this technical resource article? Join ISA and get free access to all ISA Transactions articles as well as a wealth of other technical content, plus professional networking and discounts on technical training, books, conferences, and professional certification.

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Copyright © 2019 Elsevier Science Ltd. All rights reserved.



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How to Avoid Using Multivariable Flow Transmitters

The post How to Avoid Using Multivariable Flow Transmitters first appeared on the ISA Interchange blog site.

The following technical discussion is part of an occasional series showcasing the ISA Mentor Program, authored by Greg McMillan, industry consultant, author of numerous process control books, 2010 ISA Life Achievement Award recipient and retired Senior Fellow from Solutia Inc. (now Eastman Chemical). Greg will be posting questions and responses from the ISA Mentor Program, with contributions from program participants.

In the ISA Mentor Program, I am providing guidance for extremely talented individuals from countries such as Argentina, Brazil, Malaysia, Mexico, Saudi Arabia, and the USA. This question comes from Jeff Downen.

Jeff Downen is an I&C commissioning engineer with cross-training in DCS and high voltage electrical testing. His expertise is in start-up and commissioning of natural gas, combined cycle, power plants. 

Jeff Downen’s Question

Our multivariable flow transmitters on new construction sites fail a lot. If the transmitter loses the RTD, the whole 4-20 loop goes bad quality along with the HART variables. I like the three devices being separate and their signals joined in the DCS logic much more.  I understand that it is more expensive. I want to see if there was any other reasoning behind it on the engineering side and how I can help get a better up front design.

How can we avoid the increasing use of multivariable flow transmitters as an industry standard despite a significant loss in reliability, accuracy, and diagnostic and computational capability from not having individual separate pressure, temperature and flow sensors and transmitters?

Greg Brietzke’s Answer

I like Jeff’s question on multivariable flow transmitters, as it would be relevant to control engineers, maintenance/reliability engineers, as well as maintenance personnel. What is the application? What are the accuracy requirements? Can you bring the individual variables back to the DCS/PLC through additional variable assignment? Would the increased cost of infrastructure justify the increased expense of a true mass flowmeter? This could be addressed from so many different viewpoints it could be a great discussion topic.

ISA Mentor Program Posts & Webinars

Did you find this information of value? Want more? Click this link to view other ISA Mentor Program blog posts, technical discussions and educational webinars.

Greg McMillan’s Answer

I suggest you explain to plant and project personnel the advantages of separate measurements and true mass flowmeters. Separate flow, temperature and pressure measurements offer better diagnostics, reliability, sensors, and installation location that is particularly important for temperature (e.g., RTD in tapered thermowell with tip centered in pipe with good velocity profile). They can provide faster and perhaps more accurate and maintainable measurements that could be used for personalized performance monitoring calculations and safety instrumented systems.

Coriolis meters provide the only true mass flow measurements offering an incredibly accurate density measurement as well. Most people don’t realize that pressure and temperature compensation of volumetric flow meters to get a mass flow measurement only works if the concentration is constant and known. The Coriolis mass flow is not affected by component concentrations or physical properties in the same phase. Density can provide an inferential measurement of concentration for a two component process fluid. The Coriolis meter accuracy and rangeability is the best by far as noted in the Control Talk column Knowing the best is the best.

David De Sousa’s Answer

Using dedicated and separated measurements also allows for the use of hybrid virtual flowmeters in complex process applications where, for example, the technology for inline multiphase flow metering is not yet mature enough, or where physical units will greatly increase the cost of the associated facilities.

With the digital transformation initiatives associated with Industry 4.0, the use of distributed instrumentation, data-driven learning algorithms, and physical flow models, are being tested and explored more and more in the process industries, especially in upstream oil & gas wellsite applications.

Additional Mentor Program Resources

See the ISA book 101 Tips for a Successful Automation Career that grew out of this Mentor Program to gain concise and practical advice. See the InTech magazine feature article Enabling new automation engineers for candid comments from some of the original program participants. See the Control Talk column How to effectively get engineering knowledge with the ISA Mentor Program protégée Keneisha Williams on the challenges faced by young engineers today, and the column How to succeed at career and project migration with protégé Bill Thomas on how to make the most out of yourself and your project. Providing discussion and answers besides Greg McMillan and co-founder of the program Hunter Vegas (project engineering manager at Wunderlich-Malec) are resources Mark Darby (principal consultant at CMiD Solutions), Brian Hrankowsky (consultant engineer at a major pharmaceutical company), Michel Ruel (executive director, engineering practice at BBA Inc.), Leah Ruder (director of global project engineering at the Midwest Engineering Center of Emerson Automation Solutions), Nick Sands (ISA Fellow and Manufacturing Technology Fellow at DuPont), Bart Propst (process control leader for the Ascend Performance Materials Chocolate Bayou plant), Angela Valdes (automation manager of the Toronto office for SNC-Lavalin), and Daniel Warren (senior instrumentation/electrical specialist at D.M.W. Instrumentation Consulting Services, Ltd.).

About the Author
Gregory K. McMillan, CAP, is a retired Senior Fellow from Solutia/Monsanto where he worked in engineering technology on process control improvement. Greg was also an affiliate professor for Washington University in Saint Louis. Greg is an ISA Fellow and received the ISA Kermit Fischer Environmental Award for pH control in 1991, the Control magazine Engineer of the Year award for the process industry in 1994, was inducted into the Control magazine Process Automation Hall of Fame in 2001, was honored by InTech magazine in 2003 as one of the most influential innovators in automation, and received the ISA Life Achievement Award in 2010. Greg is the author of numerous books on process control, including Advances in Reactor Measurement and Control and Essentials of Modern Measurements and Final Elements in the Process Industry. Greg has been the monthly “Control Talk” columnist for Control magazine since 2002. Presently, Greg is a part time modeling and control consultant in Technology for Process Simulation for Emerson Automation Solutions specializing in the use of the virtual plant for exploring new opportunities. He spends most of his time writing, teaching and leading the ISA Mentor Program he founded in 2011.

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Source: ISA News