Ethernet-APL

gears up
The two-wire, single-pair Ethernet (SPE) network prepares to work
in intrinsically safe (IS) and other hazardous areas

Why ratio control might

be right for the job
The cost of
getting it wrong
I/O systems get
smarter, simpler

M AY 2 0 2 3

01_2305CT_Cover2.indd 1 5/10/23 5:01 PM

We’re sensing big
when you buy proce
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Starting at $87.00 (QPSL-AP-42)
The Trumeter ADM100 is a universal power meter
Pressure sensors measure pressure at a specific
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value or trip point to a control device.
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* See our Web site for details and restrictions. © Copyright 2022 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405 the #1 value in automation
 MAY 2023 • VOLUME 36 • NUMBER 5

40
COVER STORY

Ethernet-API gears up
The two-wire, single-pair Ethernet (SPE) network prepares to work in intrinsically safe (IS) and other hazardous areas

by Jim Montague

ENVIRONMENTAL MONITORING
51 55 DEVELOP YOUR POTENTIAL

NWR refinery automates Why ratio control might

pipeline maintenance be right for the job
New refinery streamlines CO2 contribution to the You first need to weigh the pros and cons
Alberta Carbon Trunk Line and saves $6 million of the variables in play
by Jim Montague by R. Russell Rhinehart

Control® is published 10 times by Endeavor Business Media, LLC. 1233 Janesville Ave., Fort Atkinson, WI 53538. POSTMASTER: Send address changes to: Control, PO Box 3257, Northbrook, IL 60065-3257. SUBSCRIP-
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are not to be taken as official expressions of the publishers, unless so stated. The publishers do not warrant either expressly or by implication, the factual accuracy of the articles herein, nor do they so warrant any views
or opinions by the authors of said articles.

www.controlglobal.com MAY 2023 • 5

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• Monitoring of all information enables predictive
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 CONTENTS
Coriolis Mass
Departments
Flowmeters
9 EDITOR’S PAGE 37 RESOURCES
In pursuit of leadership Understanding Ethernet-APL
There aren't born leaders, Control's monthly resources guide
only lifelong learners

38 INDUSTRY PERSPECTIVE
10 NET ZERO BEAT Non-contacting radar technology’s
Powering up lithium-ion growing application landscape
battery production Product evolution and industry-
A new facility promises to apply robust specific innovation create emerging
automation and digital technology to opportunities in new markets
battery manufacturing

59 ASK THE EXPERTS

27 LESSONS LEARNED Configuring feedforward control
Heat balance of our planet of heat transfer
Detection of global temperatures over Feedforward control can anticipate
past millennia requires outstanding the error that’s likely to occur as soon
Coriolis flow measurement:
technology as the load starts to change
Simultaneous measurement
of mass flow, density,
temperature and viscosity
29 ON THE BUS 61 ROUNDUP
The cost of getting it wrong Level stays level-headed Benefits
Identifying uncertainty and errors up Frequency modulated continuous
• Universal measuring
front can help avoid catastrophes later wave, Ethernet-APL enable accuracy
principle for liquids/gases
in difficult, hazardous settings
• Multivariable measurement
30 WITHOUT WIRES • High measuring accuracy:
I/O systems get smarter, simpler 63 CLASSIFIED/AD INDEX typically ±0.1% o.r.,
Often overlooked, I/O systems remain Find your favorite advertisers listed optionally: ±0.05% o.r.
critical to any control loop neatly in alphabetical order. (PremiumCal)
• Measuring principle
independent of the
32 INDUSTRY PERSPECTIVE 64 CONTROL TALK
physical fluid properties
Why modularization matters Talking machine learning, deep
and the flow profile
for today’s Industrial PCs learning and nonlinear controls
There are benefits to using thin client Why you should be intrigued, • No inlet/outlet runs needed
technology for applications in process- and why you should be cautious
ing industries Find the right solution for your
flow measurement needs
66 CONTROL REPORT
34 IN PROCESS What's left unsaid
Trihedral traces SCADA evolution Make sure that Ethernet protocols
OSIsoft founder Kennedy dies; will perform as needed
Ethernet and wireless grow, fieldbuses
shrink; Engineers Without Borders
Download
partners with Bentley the eBook >

www.controlglobal.com  MAY 2023 • 7

 BORN, WHERE VALUES
ARE VALUED.
THE 6X®. AVAILABLE NOW!
Technology is only as good as the people who make it. That’s why the new
VEGAPULS 6X is the result – made by over 1,800 valuable employees, 60 years
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 EDITOR’S PAGE

Endeavor Business Media, LLC

30 Burton Hills Blvd, Ste. 185,
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800-547-7377

EXECUTIVE TEAM

CEO
In pursuit of leadership
Chris Ferrell

President There aren't born leaders, only lifelong learners

June Griffin

CFO
Mark Zadell
A funny thing about leadership: when the worst of times are upon
COO
Patrick Rains us, the best leaders tend to shine brightest. While I wouldn’t label
CRO
these days as the worst business environment we’ve ever seen—
Reggie Lawrence far from it—the post-pandemic processing industries certainly face
Chief Administrative and Legal Officer their share of turbulence ahead. Those challenges come in the form
Tracy Kane
of tighter standards and expectations for sustainability, workforce
EVP/Group Publisher
Mike Christian
shortages and supply disruptions, to name a few.
The motivation to do great things is alive and well as we hear en-
EDITORIAL TEAM
thusiastic plans and new innovations to address each of those chal-
Editor in Chief
Len Vermillion, lvermillion@endeavorb2b.com
lenges. However, without great leadership, motivated executives,
investors and workers—as well as their best laid plans—tend to be-
Executive Editor
Jim Montague, jmontague@endeavorb2b.com come a mass of malaise with no real progress in sight.
Digital Editor Leading through turbulent times takes experience and practice.
Madison Ratcliff, mratcliff@endeavorb2b.com
That was the theme of the recent Measurement, Control and Auto- LEN VERMILLION
Contributing Editor mation Association’s (MCAA) recent Industry Forum in Arlington, Editor-in-Chief
John Rezabek
Texas. Shane Filer, general manager, Neal Systems Inc., and an lvermillion@endeavorb2b.com
Columnists
Béla Lipták, Greg McMillan, Ian Verhappen MCAA board member, opened the multiday gathering by saying,
Editorial Assistant “There’s something different when leaders come together. Leader-
Lori Goldberg
ship asks things in a different way.” And many of the industry’s lead-
"Without great
DESIGN & PRODUCTION TEAM ers were interested in picking the brains of their peers, as more than
leadership, motivated
300 attendees, including representatives from 137 member compa-
executives, investors,
Art Director
Derek Chamberlain,
nies, made this year’s gathering the group’s largest event ever.
and workers—as well as
dchamberlain@endeavorb2b.com
While there, they heard from Capt. Mike Abrashoff, former com-
their best laid plans—
Production Manager
Anetta Gauthier, agauthier@endeavorb2b.com mander of the USS Benfold—once considered one of the worst run
tend to become a mass
ships in the U.S. Navy before he famously turned it into one the
of malaise with no real
Ad Services Manager
Rita Fitzgerald, rfitzgerald@endeavorb2b.com
best. Abrashoff made some important points about what it takes to
progress in sight."
PUBLISHING TEAM be a great leader, the first being that no one is a born leader, and it
VP / Group Publisher takes a lifelong pursuit to be good at it. This is exactly why the heads
Keith Larson, klarson@endeavorb2b.com
of so many measurement and control companies came to Texas—to
Midwest/Southeast Regional Sales Manager find out what it takes to be and to produce quality leaders.
Greg Zamin, gzamin@endeavorb2b.com
704/256-5433, Fax: 704/256-5434 They will need those leaders as economic turbulence will hang
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847/516-5879, Fax: 630/625-1124 Economics, said during the conference’s final presentation, the U.S.
Classifieds Manager / Circulation requests
economy will still be slowing as we go through the remainder of this
Lori Goldberg, lgoldberg@endeavorb2b.com year until the end of 2024. However, he points out, the GDP will
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www.controlglobal.com MAY 2023 • 9

NET ZERO BEAT

Powering up lithium-ion battery production

by Len Vermillion

WHILE the automotive industry has

taken the first steps in establishing lith- KorePlex is set to open in Maricopa County, Ariz.
ium-ion battery manufacturing in North
America, a new venture is coming online
in Arizona, and it’s one of the first inde-
pendently operated cell manufacturing
facilities in the U.S. Called KorePlex, the
gigafactory developed by Kore Power, a
developer of lithium-ion battery cells and
modules for the e-mobility and energy
storage sectors, is getting an efficiency
and production assist from Honeywell’s
end-to-end, integrated Battery Manufac-
turing Excellence Platform (MXP).
The facility promises to apply robust
automation and digital technology to formation-finishing area. This centralized the first to come online, but there's a
battery manufacturing, which has been approach will allow Kore Power to reach laundry list of others soon to follow. All
largely manual. The new facility isn’t tied target capacity faster, while improving the new gigafactories will be compet-
to a joint venture and will manufacture production yields and improving safety. ing for those expensive materials. “It's
cells for customers in several industries. Meanwhile, the digital Honeywell MXP critical to use what [materials] you have
“I think that's the big difference, and platform lets users scale their enterprise efficiently, so using this new state-of-the-
that's going to, hopefully, give them the and achieve operations with superior yields art automation and connectivity, these
competitive advantage to be successful starting from the first day of operations. companies are going to be ahead of the
in the market,” says Frederick Wester- Coupled with production optimization and game,” Falzone says.
berg, vertical customer marketing direc- improved efficiencies, the technology can They’ll also be ahead of the game
tor at Honeywell. reduce energy consumption. Also, the plat- when it comes to sustainability. “Sustain-
According to a National Renewable form provides online quality management ability and efficiency, these things go
Energy Lab (NREL) report, traditional with complete production traceability/gene- hand-in-hand. You can't have one with-
lithium-ion cell manufacturing has many alogy of the cells produced. out the other,” Westerberg says.
inefficient, manual operations, lead- Efficiency is vital in cell production An operation can’t be sustainable
ing facilities to commonly operate at a because battery cost is often the main without high yields and high throughput.
70% production yield at steady-state. driver of high prices for products utilizing So, addressing the efficiency of the oper-
“KorePlex will be a new state-of-the-art, lithium-ion. For example, electric vehicles ation by integrating individual machines
lithium-ion battery facility, that uses end- are expensive because their batteries are into a holistic system, and then optimiz-
to-end connectivity, digitizing the entire expensive. The first step to solving that ing the operation is the one major area of
process for a more sustainable and novel market conundrum is to reduce produc- sustainability that MXP can impact, ac-
approach to cell production,” adds Alec tion costs, according to Westerberg. cording to Westerberg.
Falzone, lithium-ion battery initiative “We're dealing with lithium, nickel, Falzone adds traceability and geneal-
leader at Honeywell. cobalt, different oxides of metals, oils. ogy insights can pinpoint where some-
KorePlex will be the first fully digitized You can't scrap these things easily. thing occurred. “So instead of shipping
and integrated lithium-ion cell manufac- They're extremely expensive,” he says. a million cells to your recycling partner,
turing facility using MXP. With continu- “Getting efficiencies up is extremely which have to be shipped to the recy-
ous closed-loop control, Honeywell’s important to reduce production costs to cling facility because it's not on the same
Battery MXP will enable Kore Power to the point where EVs and energy storage site, you would ship a fraction of that,”
visualize and control its entire lithium-ion are more affordable.” he says. “The visibility into the process
battery production process in real-time, That’s especially true as the competi- piece by piece gives you that insight to
from mixing, coating and assembly to its tion heats up. KorePlex may be one of make intelligent decisions.”

10 • MAY 2023
AN ADVERTISING SUPPLEMENT TO MAY 2023

70 YEARS of
instrumentation
leadership
Endress+Hauser celebrates milestone,
builds for the future

SPONSORED BY 2 THE PRINCIPLES OF SUCCESS 10 TIMELINE: THROUGH THE YEARS

5 CONQUERING THE DIGITAL FRONTIER 12 WRITING A NORTH AMERICAN SUCCESS STORY

8 CULTIVATING TOMORROW’S WORKFORCE 14 CONTINUING THE JOURNEY

The principles of success
Dr. Klaus Endress has seen his family’s company grow by leaps and bounds,
and he’s excited for the future

For Dr. Klaus Endress, lead- production at the corporate level, and in 1995 I became
ing Endress+Hauser after CEO of the Endress+Hauser Group. So, when I was
taking over from his father finally entrusted with the company, I already had quite
Dr. Georg H. Endress, who a bit of experience under my belt.
founded the company in The Group had a turnover of around 420 million The Endress family
1953 with Ludwig Hauser, is euros with some 4,300 employees and a sufficient result. continues to grow.
a great honor and a great re- Becoming CEO of such a company was a great honor and
sponsibility. On the Group’s an equally great responsibility. Of course, I didn’t want Q: Endress+Hauser has continued to thrive, even after 70 you must develop all its parts. That’s what we’ve always
70th Anniversary and as he prepares to move on from to disappoint my father, but to continue developing his years. What do you think was crucial for this success—and done at Endress+Hauser.
heading the Supervisory Board, the man who served 45 life’s work. He was the pioneer who founded the company what is needed to succeed in the future? We have enlarged our interface with the market and
years with the company discusses his father’s legacy, the together with Ludwig Hauser. He created something A: When I started as the Group’s CEO in 1995, I asked customers worldwide, opened new regions and industries for
Group’s success and its future. out of nothing—and I set out to make something even myself where I could get inspiration, what was right sales, expanded our portfolio, built global production capac-
more beautiful out of it! I could never have done what my and what would remain right over time, and who could ity, and strengthened our innovative powers. And we have
Q: What did it mean for you to take over responsibility for the father did because I was not and am not a pioneer. But support me in my deliberations and decisions. My father developed efficient management and support structures for
Endress+Hauser Group from your father and continue his work? vice versa, he would never have been able to do what I was no longer available. Of course, there are many books, the Group. Even in the past few years, which were marked
A: Please allow me to elaborate a bit on this answer, for achieved. So, it was a timely handover, just as the hando- consultants, even real gurus in this field. But I found by a lot of uncertainty, first with the pandemic and with the
I assumed responsibility much earlier. My father asked ver 19 years later to my successor, Matthias Altendorf. inspiration in nature. Living nature has evolved very suc- war in Europe, Endress+Hauser was always able to deliver.
me when I was 16 years old if I would like to become his The cooperation between Matthias and myself as cessfully over more than three billion years; its sustainable So, as we go into the future, we can build on many things we
successor. I said, "Yes.” But, of course, this was associated Supervisory Board president further boosted the com- principles are my model for entrepreneurial action. have done well in the past. As long as we maintain our focus
with many expectations. pany over the past 10 years. Every successor stands on the I like to compare our company to a tree: the crown with on the market and customers and keep improving, we won’t
I finished high school in Switzerland, studied shoulders of their predecessors. I think my father and Mr. its leaves stands for sales as the surface to the market and run out of work even one hundred years from now!
industrial engineering at the Technical University in Hauser, who also dedicated almost 20 years to the company, customers, the roots for anchoring production and develop-
Berlin, then went to the U.S. for two-and-a-half years would both be extremely proud to see Endress+Hauser ment in technology and the procurement markets. Lean Q: What is your fondest memory growing up with your
for my first professional experience. Back in Europe, today. We have a shareholder family of more than 75 but sustainable structures connect these two surfaces. father being the organization’s founder?
I worked my way up at Endress+Hauser: starting in members and a family charter with established institutions In the company, these are the innovation and logistics A. My father was quite strict; performance was important
industrial engineering, then in sales in Frankfurt, that keep the family close and connected. We meet six processes and supporting functions such as finance and to him. But he always supported us eight children in our
head of controlling and finally managing director of times a year in larger groups to cultivate our commonalities controlling, human resources, IT, legal or communications. development. He attached great importance to a good
our German subsidiary based in Maulburg, Germany, and strengthen our collaboration. We live up to our com- A large tree has taken many years to grow. It evolved education. He made many things possible for us, even
which, at the time, was a combined sales and produc- mon rules and values. That’s the whole secret. Of course, it’s every day, and no part has been neglected. This is perhaps when money was tight in the family. He always said, “Your
tion company. In 1992, I took over responsibility for a lot of work, but it’s also a pleasure to see it work! the most important insight: for the company to thrive, education is the only thing no one can take away from you!”

Reflecting change
Endress+Hauser’s logo design has evolved
to include new colors and symbols
of the growing business.
1953 1980 1987 1995 2004 2012

MAY 2023 • SPECIAL ADVERTISING SUPPLEMENT 2 3 SPECIAL ADVERTISING SUPPLEMENT • MAY 2023
Q: Is there a company milestone you A: Many of his thoughts and values sense, the CEO of the shareholder
remember your father being very are still very much alive in our family. The Family Council is the
excited about? family and the company. One of his most essential link between the
A: As the company’s founder, sales favorite phrases was, “We serve our family and the company. Its task is
milestones were always important. In customers and learn from them.” to decide on important issues in the
my father’s eyes, they were proof that So, not to look at what’s in it for relationship between the family and
he had achieved something, a sign of you, but what you can do by putting the company, to accompany members
success. So, he was very pleased when customers first. This keen focus is in their careers, and to inspire the
Endress+Hauser exceeded the one paramount to our success. Custom- younger generation. Only if the fam-
billion euros threshold in the year ers are any company’s driving force. ily functions well can the company
before his death. Without ours, we wouldn’t be where also function well.
we are today. Because of our custom- Additionally, I’m an enthusiastic
Q: What do you think your father and ers, we can thrive. horseman. I have kept horses for
Mr. Hauser would say to you today decades, but for a long time, I didn’t
about the company? Q: The Group announced a genera- have much time for this hobby. Now,
A: I am sure they would be extremely tional change. As you prepare to move I ride almost every day. Since I was
proud of what their company has be- on from your current role as President 19, we have had dogs. I'm often out
come and what we, their successors, of the Supervisory Board, what does the and about with our family dog, Maya,
have made of it. I think they would next chapter of your life hold? biking in nature. That is quality of
say, “Well done!” A: From next year on, I will no longer life for me. Finally, I look forward to
have an active role in the company spending more time with my wife
Q: What are the most important values after almost 45 years of working for and grown children.
and skills your father had that you’ve Endress+Hauser. But I remain chair-
.continued to carry on through his legacy? man of the Family Council, in some Q: What advice do you share with your
children, grandchildren, nephews and
nieces—the next generation of family
members—coming up in the company?
A: The same I tell all young people: use
the opportunities you have for a good
education, gain experience, go out into
the world at a young age and acquire all
the skills you need to realize your goals
and dreams. You must always support
young people in their development.
You must give them wings and
not tell them where to fly. They
must figure out for themselves
where to go. We can only keep the
doors open for them; they need
to enter them on their own. And
we also must remember that our
family's younger generation is
essential not only when working
at Endress+Hauser, but also as re-
Georg H. Endress with son, Klaus Endress sponsible company shareholders.

MAY 2023 • SPECIAL ADVERTISING SUPPLEMENT 4

Conquering the digital frontier
Digitalization and IIoT have opened a new world of efficiency and safety

The world continues to become more digitalized to such tion started to become very apparent not only in how
an extent that companies globally categorize it as essential the company’s products sent their variables and infor-
rather than optional. That includes process automation mation to control and host systems, but also within
industry experts, Endress+Hauser. its own ERP, CRM and service management systems.
There are two main reasons for the push toward digi- The journey’s results have helped make the company’s
talization in the industrial sector: customer expectations focus on end-to-end service and solutions even more
and market forces. Endress+Hauser has not only taken possible.
notice of its customers’ digitalization needs and expecta- “It has provided us a means to digitally connect our
tions, but also set forth on its own transformation. products to customers in a way that we never could be-
The company’s digitalization journey began quite fore,” says Jason Pennington, director of digital solutions
some time ago, mainly when the benefits of digitaliza- for Endress+Hauser.

5 SPECIAL ADVERTISING SUPPLEMENT • MAY 2023

Successful digital transformation He adds that the evolution of multivariable measure-
These days, instruments can create help desk tickets on ment and bringing more quality aspects and diagnostics, in
their own. In addition, the devices can produce alarms addition to the overall core measurement, have impacted
and recommend possible remedies. They provide a the industrial sector.
secure means from a remote desktop into a device to Additionally, changes in the supply chain, particularly
help solve a customer’s challenge before they might regarding sourcing “greener” and safer materials, whether
even know they have one. These are just a few examples for consumption or the good of the environment, have been
of the capability digitalization has brought to the table, just as impactful. For example, Endress+Hauser vetted its
according to Pennington. suppliers to be more inclusive, reputable and sustainable.
As digitalization has flourished and the Industrial As a result, it’s become part of the overall product picture.
Internet of Things (IIoT) has emerged, three core areas of Another change is the growing importance of cybersecurity.
process control have seen the most changes. The first and “It’s a very real thing for us today that maybe 25 years
most apparent involves what one can see and feel: minia- ago didn’t exist,” Pennington says of the importance of
turization, power consumption, connectivity, HMIs and cybersecurity in an increasingly digital world.
how people interact with devices. Cybersecurity is part of how instruments and systems
ASICs were infused with microprocessors and pressure- are now designed and built.
to-current transducers became microprocessors and cur- “It’s about digging down into the components as they
rent-to-pressure transducers became 4-20mA transmitters. become more connected in the world today,” he adds.
Meanwhile, a myriad of field buses emerged. Pennington
says it’s been a pursuit to simplify, if not eliminate, wiring. Journey and breakthroughs
“So, combined with the idea of what more powerful One of the significant milestones in Endress+Hauser’s
microprocessors can support, our devices have evolved into digital journey happened when the company connected
process analysis tools for our customers that also happen to its internal processes and production systems to benefit
measure process variables,” he points out. its customers.

MAY 2023 • SPECIAL ADVERTISING SUPPLEMENT 6

 He points out that staying ahead
One of the significant milestones of the evolution comes from dialog
with customers. It helps create a
in Endress+Hauser’s digital journey broader enterprise view of some of the
products. In fact, Endress+Hauser has
happened when the company been able to use Heartbeat Technol-
ogy and Netilion Connect, an API
connected its internal processes platform, to provide customers the
capability to create a calendar in their
and production systems to system and the devices know if they’re
safety-important, safety-critical,
benefit its customers. fiscally-critical or regulatory. For
devices that are not on the calendar
within the customer system, they can
have Netilion run Heartbeat verifica-
tions on the devices. When they pass
verification, they’re able to produce a
certificate with that ISO stamp and
close the work order. Connected de-
Throughout every production step, devices provided a safer environment, vices can have Netilion run Heartbeat
from the time a piece arrives on the both electrically in hazardous areas verifications either by calendar sched-
Greenwood campus, it’s scanned and and their operations. uling or on-demand. This process
logged. “We know who touched it, In addition, printed circuit delivers insightful information to the
where it came from, how it got here boards have allowed for the creation user but can also be automated to ef-
and if it’s authentic.” of traceable and highly reliable fectively perform its own maintenance
A QR code on each prouct diagnostics. and work order management. The
helps digitize processes, allowing ISO recognized verification results are
data-minded customers to get all the End-user expectations stored within the Netilion Library and
necessary information to check on Manufacturers and representatives presented to the user.
reliability, build a Pareto analysis, or have an opportunity now with tools The process lets customers autono-
track alarm trends over time. Those are such as Heartbeat Technology® as mously maintain their systems, and if
only some of the capabilities available well as other remote diagnostics, to there’s a failure in the functionality of
to customers. support their end-users through the the verification, Endress+Hauser can
The process also guards against product lifecycle. Such support on provide diagnostics, remedies and even
counterfeit parts. an ongoing basis is another frontier the spare parts information. Penning-
There have been other break- in digitalization: moving from being ton says such systems represent the
throughs in the digitalization journey connected to using connectivity to devices’ “connected spirit.”
for Endress+Hauser. Pennington solve challenges or to advance busi- Endress+Hauser and the entire
points to flow as an area that has seen ness objectives. industrial sector are continuing the
a digital evolution of products. “Sourcing data through this digitalization journey. The more
Over time, flow devices be- connectivity is the easy part. It’s digitized the industry becomes,
came more advanced on the power how you do it and more importantly, safely integrating data can help cre-
management front. In addition, the what you do with it that matters,” ate more reliable, safe and efficient
evolution of Safety by Design meant Pennington says. systems and processes.

7 SPECIAL ADVERTISING SUPPLEMENT • MAY 2023

Cultivating tomorrow’s workforce
From a Design and Innovation Studio to internships, building the next generation
of process control engineers

As future generations of engineers enter the workforce, Building awareness

they’re discovering opportunities in the industrial sector, One of the most significant initiatives of the past year
even if they hadn’t previously known what all it has to has been the development of the Design and In-
offer. Thanks to efforts to increase awareness of science, novation Studio in Greenwood, which extended its
technology, engineering and math (STEM) opportuni- programs to younger minds.
ties at many schools and universities, more students are Their experience is more than simple show-and-tell.
learning about careers in the industrial sector. Moreover, The students actively engage with instrumentation and
those efforts are strengthened by the efforts within the other tasks usually done by engineers for the company.
industry itself, where budding engineers are learning They work with robotics and coding, and activities are
even more about the alluring opportunities in process usually done in the context of fun. For example, they’ll
control and automation. engage in a PTU® (Process Training Unit) scavenger
Many aspiring engineers know about fields such as hunt, 3D printing, or assembling a building blocks
construction, welding, machining and other areas of need Coriolis flowmeter.
that we often hear about. Many aren’t thinking or know “There are lots of fun, engaging ways that they can
about what can be done with process control. Conse- learn about STEM and our industry,” Otte says.
quently, the lack of exposure to process control contributes The studio is a collaborative effort between
to the growing need to cultivate future talent, according Endress+Hauser and Purdue University’s Indiana Man-
to Nicole Otte, director of workforce development for ufacturing Competitiveness Center (IN-MaC). Purdue
Endress+Hauser USA in Greenwood, Ind. established a series of Design and Innovation Studios
Otte, along with Devina Fernandez, workforce through grant funding at several schools and three at
development specialist in the company’s Houston, Texas, other manufacturers in Indiana, but those three were au-
location, spearhead the company’s efforts to make the tomotive. Endress+Hauser inquired about establishing a
up-and-coming generations of workers aware of all that studio for a different manufacturing and STEM-focused
process control careers have to offer. strand and was awarded a grant.
“Process control is at the foundation of every From these schools, eight are local school districts
product we use, everything that we encounter daily,” in the Southern Marion and Johnson County area from
Otte explains. “I was just speaking to a group of middle rural Indian Creek to suburban Greenwood, including the
schoolers and telling them that our instrumentation is most urban and diverse school in the area.
what is being used so they can safely consume the food The company also hosts classroom visits, organizes
and beverages they like to eat and drink. They were really advisory boards for high school teachers and high school
excited about it.” interns, and offers job shadowing. Meanwhile, they are
Endress+Hauser has built a full continuum of engaging colleges where Endress+Hauser executives and
workforce development programs to reach students from personnel help with senior capstone designs and serve on
kindergarten to college. In addition, the programs reach advisory boards.
beyond schools to non-traditional paths such as military “Sometimes you get a request for 450 students, so we
personnel re-entering the workforce or career adults try to design an experience that breaks them down into
simply looking for a change. smaller groups so they can see the PTU, and they can

MAY 2023 • SPECIAL ADVERTISING SUPPLEMENT 8

see the space here and go into the the business side and covers the The company’s internship program
other areas, to be exposed to multiple full spectrum of all the different focuses on meaningful experiences
STEM activities,” Otte says. areas in the company, according to that ultimately helps build its talent
Fernandez. pipeline. The goal is for interns to
Meaningful experience Fernandez says Endress+Hauser move toward working in the process
Another one of the company's excit- is building a very robust learning control industry, with the company, its
ing workforce development initiatives experience for its interns, intending representative partners or customers.
is the evolution of its college and to build a future workforce. “We had two interns who in-
high school internship programs. “We look at how rigorous the terned with us twice, one of which
Endress+Hauser has a 20-year projects are and the skills the interns had an international internship in
history of internships. The program should expect to have at the end of Spain,” Otte said. “The other one
has interns from engineering to the summer,” she adds. interned after his freshman year,
and then did a co-op with us during
his junior and senior years. They're
both coming back as full-time em-
ployees into the rotational program
in June. Very, very powerful.”
Some of those interns get an
early start as seniors in high school.
The new program sees high school
students spend about 10-15 hours a
week with the company.
Fernandez also mentioned
the company’s Community
Career+Education Forum where
students, parents, educators and
manufacturing professionals gather
to learn about STEM and career
opportunities in advanced manufac-
turing today.
This event takes place in both
Greenwood and Houston with plans
for several of Endress+Hauser’s local
representative partners committing to
host their own event.
Today, there are a variety of op-
portunities for each member of the
education and workforce ecosystem
to get involved. Cultivating the
Endress+Hauser engages workforce of tomorrow starts with
next generation engineers in inspiring and educating the youth
many ways, including its Design
of today. With its various pro-
and Innovation Studio in
Greenwood, Ind. grams and on-site opportunities, at
Endress+Hauser, the future is now.

9 SPECIAL ADVERTISING SUPPLEMENT • MAY 2023

 THROUGH THE YEARS

With funding of 2,000 Deutsche Marks, Endress+Hauser USA relocates from Beverly,
‘L Hauser KG’ was established in 1953. Mass., to Greenwood, Ind. Seven acres of land
The company’s name came from Ludwig were purchased from a local farmer and a 5,000
Hauser’s wife, Luise. sq.-ft. facility is built with 11 employees and
sales reach $490,000. Twenty-three years later,
in 1997, the company invests in an expansion of
the Greenwood campus, building a 60,000 sq.-ft.
sales center for the growing team.

In 1961, Endress+Hauser moves to a new,

modern site in Maulburg, Germany. Endress+Hauser launches Liquiphant, its
first level switch for vibronic point level
detection. Today, the Liquiphant product
line measures reliably and is not
affected by changing media prop-
erties, flow, turbulences, gas
bubbles, foam, vibrations or
build-up. The device is easy to
use, has a digital connection
and gives real-time
data at hand.

1953 1955 1961 1971 1974 1977 1983

Ludwig Hauser retires. Production
starts in the U.S. in the same year. Endress+Hauser starts to
produce flowmeters with just
The early years for Georg H. Endress
three employees in a former
(right) and Ludwig Hauser (left) were
military barracks in Reinach,
pivotal. Georg H. Endress files his first
Switzerland (Basel-Landschaft).
patent at the Swiss Federal Office for
Further acquisitions add liquid
Intellectual Property in 1955. Innovation
analysis, temperature mea-
is a cornerstone of Endress+Hauser’s
surement technology, pressure
success and continues to fuel the spirit
measurement technology and
of growth and creativity. Today, the com-
system products to the portfo-
pany has a total of 8,900 active patent
lio in the following years.
and patent applications.

MAY 2023 • SPECIAL ADVERTISING SUPPLEMENT 10

 Endress+Hauser releases its new generation of Coriolis
and Electromagnetic flowmeters, Proline 300/500.
The launch of the new generation continues its legacy of
exceptional measurement quality and unmatched accu-
racy of mass flow, volume flow and density.

In 2021, Endress+Hauser
launched a new generation
of liquid analysis sensors.
Production expands in Greenwood with a 95,000 sq.-
Memosens 2.0 digital tech-
ft. flow manufacturing facility. In 2013, an additional
nology provides simple,
83,500 sq. ft. is added to the facility. The expansion
safe, and connected
of production allowed for more technologies to be
liquid analysis.
produced in the U.S., including thermal mass flow.

Endress+Hauser releases the

first self-calibrating thermom- In 2021 Endress+Hauser in-
eter, the iTHERM TrustSens®. troduced the new generation
The iTHERM TrustSens stands of the Deltabar. The Deltabar
out from other thermometers PMD78B differential pressure
with fully automated inline transmitter minimizes ambient
self-calibration. This results and process temperature ef-
in high product safety and in- fects on measurement thanks
creased plant availability. to the TempC membrane.

1984 2006 2013 2017 2019 2021 2023

Endress+Hauser strengthens its

analysis portfolio. The Group acquires
Analytik Jena, which opens the door
for laboratory business. Investments In 2023—and 70 years later—
in optical analysis technologies, in- Endress+Hauser continues to march
cluding TDLAS and Raman spectros- forward as the People for Process Au-
copy, strengthen Endress+Hauser’s tomation. The company celebrated the
advanced analytical portfolio and seven-decade milestone at each loca-
underscore the strategic goal of sup- tion across the globe in February 2023.
porting the customer from labora-
tory to process.
Endress+Hauser USA acquires early
expertise in calibration. Calibration
ensures that instrument measure-
ment is accurate and within the
limits required to produce a quality
product. Today, Endress+Hauser helps While a groundbreaking ceremony was held in 2019 for the
customers stay in compliance while Houston campus, doors opened with a ceremonial ribbon
reducing their costs and increasing cutting in 2021. The $38.5 million LEED-certified facility
process up-time. houses a state-of-the-art PTU® Process Training Unit, an
office space for the Endress+Hauser team, an office space
and warehouse for Vector Controls and Automation Group,
and an office space and lab for Analytik Jena.

11 SPECIAL ADVERTISING SUPPLEMENT • MAY 2023

Writing a North American
success story
From humble beginnings Endress+Hauser USA grows with the help of its customers and partners

Seventy years ago, the ideas and strategies developed in a representative partners as the keys to the evolution of
small, private apartment in Lörrach, Germany, set the build- the business. “The company has evolved over the years to
ing blocks of an eventual multibillion-dollar company. Swiss meet the ever-changing needs of its customers which has
engineer Dr. Georg H. Endress, only 29 years old then, and included more and new services and solutions based on
German bank manager Ludwig Hauser, 58, launched the and customized to our customers’ specific needs for their
company on the back of 2,000 Deutschemarks and a knack own growth and success. That is especially true as many
for electronic level measurement technology. companies are experiencing challenges to keep the same
Endress’s instrumentation expertise and Hauser’s numbers of people and thus the capabilities of subject
business savviness proved to be the perfect match. For matter experts at the plant level. Moreover, those pres-
40 years, Endress led the company across new markets sures continue to mount as more workers retire and new
and fields of application. After Endress’s tenure, his son, generations opt for other industries.
Dr. Klaus Endress, led the company along with strong “Experts [at the plant] are harder to find,” Lucey says.
involvement from the Endress family. In 2014, Matthias And that’s where Endress+Hauser can be of service to its
Altendorf would fill those shoes. customers.
Today, Endress+Hauser employs 16,000 and generates As a family-owned group, Endress+Hauser has always
more than $3.6 billion in yearly sales. The company now focused on people and maintaining and building relation-
owns sales centers in more than 50 countries and produc- ships with its customers over its 70 years of existence.
tion centers on four continents. While that’s not always easy, considering the ups and
In 1970, as Endress+Hauser continued its growth as a downs of the market and the occasional super-disrupter
global player, the company started its US operations. This such as the pandemic, the ability to continue investing
move has proven to be a vital part of the organization’s even during difficult situations has been an advantage.
overall success. More importantly, having stable, family-owned leader-
One important philosophy of the company is to ship has helped keep the focus on people, especially the
manufacture for each region of the world in the region. workforce and Endress+Hauser’s domain expertise. Lucey
And, this is true for the North American region and the says not having to reduce the workforce under challenging
US specifically. Because of that, 85%-90% of everything times has prepared the Group to offer its customers added
the company sells to its US customers is built in the US. value support with specific applications, instrumentation,
It’s an important piece of the value we offer our customers services and solutions and retain knowledgeable talent in
in the US, according to Todd Lucey, general manager of the organization.
Endress+Hauser USA. That includes recent endeavors into becoming what
the company terms “a main instrument vendor” (MIV).
Enduring partnerships The project-oriented concept focuses on services from
As the US business continues to grow—it currently front-end engineering design to procurement, warehous-
stands at more than $600 million in revenue—company ing, receipt verification, startup and commissioning. Lucey
executives such as Lucey are quick to credit the endur- says the company has done “more than 20 MIV contracts
ing relationships they’ve established with customers and with customers in recent years.”

MAY 2023 • SPECIAL ADVERTISING SUPPLEMENT 12

 Endress+Hauser USA’s customer center
in Greenwood, Ind.

Regional relationships One of those representatives, Vector Controls and Auto-

Endress+Hauser USA works completely with repre- mation Group, recently celebrated its 10th anniversary.
sentatives as its sales channel and has continued to Endress+Hauser was the driver behind the creation of
refine its partnerships with its representatives over the Vector Controls and Automation Group formed from
past two decades. The critical part of success in this merging six smaller organizations together. “I think that
model is finding representative organizations with was significant just because we were trying to find the
leadership and ownership that have the same culture as right representative organizations and we didn’t have
Endress+Hauser. That culture includes reinvestment into a good way to do that,” Lucey says. “Bringing those
the business, growing the business, and willingness, for organizations together was something most people said
example, to take a 25-person representative organization couldn’t be done and wouldn’t work. It was very compli-
and grow it to 100 people. According to Lucey, those are cated, with many owners and different thoughts. It took
the types of commitments that Endress+Hauser USA a long time, but we all stuck with it. Jared Boudreaux
has from all its representatives. [president and managing director] and the leadership at
“We see them just as Endress+Hauser and they see Vector made that happen.”
themselves as Endress+Hauser,” Lucey says. “I always Vector Controls and Automation Group shares
tell people that a typical representative-principal re- Endress+Hauser USA’s facility in Houston, Tex-
lationship has a lot of dynamics to it. We have differ- as, which was inaugurated in 2021. In addition,
ent dynamics in the model that we’ve chosen with our Endress+Hauser continues to make investments in new
representatives, but the resolution to the dynamics is projects and buildings.
that we’re all one team, and one team is strong enough “Family leadership sees the growth of the North
to withstand individual dynamics that you might have American market as critical,” Lucey says. “We’re 12%
with one representative versus another. to 15% market share [in the U.S.]. We want to be at
“We had an inflection point when we brought on our 25%, 30% market share. So, the growth opportunity is
representative partner, TriNova, in 2002. This fundamen- still here.”
tally changed how we viewed our channel partners.” In its 70-year history, Endress+Hauser has always been
Some representative organizations were formed from in the business of doing good business. And just as history
the ground up to partner with Endress+Hauser USA. does, it repeats itself.

13 SPECIAL ADVERTISING SUPPLEMENT • MAY 2023

Continuing the Journey Klaus Endress and
Matthias Altendorf
components of this approach. To this
end, we have cultivated a culture that
Endress+Hauser’s next Supervisory Board leader is ready to take on the future dispels fear and fosters stability, which
becomes the fertile ground for creativ-
The first 70 years for Endress+Hauser tion, emerge over the coming years. marked by an increasing level of digi- ity,” he says. “Such a culture empowers
were filled with successes and Its strategic approach: “From the talization and the push for automa- and enables people to give their best.”
achievements. The company grew region, for the region,” has enabled tion to increase productivity. Mean- The company’s direct link to its
from a small, family-owned busi- Endress+Hauser to gain market while, the advent of the Industrial customers and ability to design a
ness in Europe to a global enterprise share over the past two decades. Still, Internet of Things (IIoT) has added value stream to cater to custom-
and leader in the process control and globalization has made it essential to new domains such as mobile applica- ers’ needs is a unique proposition
automation space. But its story still strike a new balance between proxim- tions, cloud computing, Software as that Endress+Hauser prides itself
has more to be written, and CEO ity to customers, the resilience of sup- a Service (SaaS), Infrastructure as a upon. The goal is always to remain
Matthias Altendorf expects the ply chains and the ability to innovate. Service (IaaS), Analytics as a Service innovative, relevant and valuable to
journey to continue while upholding “We must meet the changing (AaaS), digital twins, and augmented customers. The best way to main-
Endress+Hauser’s spirit, quality and needs of our customers while main- and virtual reality. we can contribute with our work learn from it. To continue doing so, tain that success is to seek a “deeper
power of innovation. taining our operational performance,” Altendorf says those changes can to make the world a better place,” Altendorf says they must maintain understanding of their challenges,”
Endress+Hauser has a history of Altendorf says. be a positive for the industry, provid- he says. “Through process and lab the freedom to move and operate according to Altendorf.
outperforming the markets and has Globalization is one of many ed they are met with the right course instrumentation and automation, unencumbered. This requires financial Endress+Hauser can look to the
never given in to the temptation to disrupters posing challenges to of action. He says it is inspiring to see we enable companies, communities stability beyond the mere maximiza- future with confidence and to the
strive solely for low costs, even during companies these days. Like its peers, how Endress+Hauser has developed and countries to enhance the lives of tion of shareholder value. It requires a past with pride.
challenging times such as the recent Endress+Hauser has experienced as a company on a global scale while countless individuals.” human-centric business approach. “The world needs process auto-
global pandemic. Altendorf says that fundamental changes in the process maintaining its focus on doing right The company’s guiding principle “We believe that our custom- mation to improve in every aspect,
will stay the same, even as new chal- industry, particularly over the past by people and their futures. has always been to remain open to ers, employees, shareholders and the and we are glad to be part of that
lenges, such as increasing globaliza- two decades. Those changes are “It is encouraging to know that the world and actively engage and communities we serve are all vital journey,” Altendorf said.

From apprentice to CEO cial system that Endress+Hauser rep- while at the same time ensuring that able to look back on a decade of ex-
Having served as CEO of was much simpler: It was to start a holds are the same that helped him resents. In addition, he likes proving you don’t become an obstacle to the cellent results. In that time, the com-
Endress+Hauser since 2014, Matthias learning journey while earning an grow with the company. that the company’s entrepreneurial development of the social system that pany gained market share year after
Altendorf is set to become the presi- income that would provide him with “Our brand values of commitment, approach and his own leadership style you are entrusted to lead,” he says. year and became a global leader in
dent of the Supervisory Board next some form of independence in life. excellence, sustainability and friendli- are more sustainable and successful Still, he has made lasting memories process instrumentation. He believes
year. At the same time, Peter Selders “I’ve always been a very respon- ness aptly describe what you need to than pure shareholder value thinking. over his three decades at the compa- that success is because of custom-
will take over the reins as CEO. It’s sible person, hungry to learn and embody to be successful in our busi- The journey hasn’t always been ny. What stands out the most, he says, ers’ trust in Endress+Hauser.
been a long journey for Altendorf, grow, but also humble enough to ness,” he says. “When you combine easy, but he knows the most signifi- is how the company has navigated “It’s never a single action or deci-
who started his career at 16 years realize that I’ve also been very lucky these values with curiosity, openness cant challenge he’ll ever face as a crises, coupled with seeing the joy in sion by a CEO; it’s always the ‘we’ that
old. He’s quick to point out that in my life,” he says. and a willingness to continue learn- leader is himself. the faces of people in the company. matters, not the me,” he says. “My
becoming CEO was the furthest thing Altendorf credits the good advice ing, they carry you a long way.” “You have to overcome your own He took over an already well-run greatest achievement will be that we
from his mind at that time. he received that helped him improve. Today, he enjoys doing something biases, personal limitations and the company and further developed it have found a good successor who will
In those early days, his motivation He says the values Endress+Hauser for people, developing them in the so- constraints of your own socialization successfully, and he’s happy to be do an even better job than I did.”

MAY 2023 • SPECIAL ADVERTISING SUPPLEMENT 14 15 SPECIAL ADVERTISING SUPPLEMENT • MAY 2023
 We offer process application expertise
through our products, solutions and services.

SUPPORT
+ SUCCESS You optimize your process for maximum safety, reliability
and efficiency, with minimum impact on the environment.

Customers around the world trust us when it comes to

process automation. Our shared goal is plant safety, availability
and efficiency. We are with you every day, everywhere.

People for Process Automation

Do you want to learn more?

www.us.endress.com
 LESSONS LEARNED

Heat balance of our planet

Detection of global temperatures over past millennia requires outstanding technology

THE temperature of any object is a function of the

balance between the quantities of the incoming
and outgoing energies. Temperature rises if the
incoming energy is greater, and drops if the outgo-
ing is greater. In the case of Earth—a warm object
surrounded by cold outer space—the incoming
energy comes from the sun and the outgoing en-
ergy is the sum of the energy emitted and energy
radiated back into outer space (Figure 1).
Earth rotates as it travels around the sun, and
if there was no atmosphere, its surface facing
Figure 1: When incoming and outgoing energies are
the sun would be hot and the other side would
the same, Earth's temperature is constant.
be cold. The conditions would be the same as
on the moon, where the surface facing the sun BÉLA LIPTÁK
reaches more than 100 °C, while the dark side Under steady-state conditions, 70% of the total liptakbela@aol.com
cools to about -150 °C during the lunar night. incoming solar radiation is absorbed (19% by the
It’s our atmosphere that protects our planet from atmosphere and 51% by Earth's surface), while
such a temperature cycle because it absorbs 30% is reflected into outer space. The cooling ef-
some of the solar heat during the day and trans- fect of outer space is the same as the incoming
"Under steady-state
mits some of that heat back to the planet's sur- (absorbed) energy, amounting to 70% of the total
conditions, 70% of the
face during the night. It, in effect, provides Earth solar radiation as it leaves our planet as heat (in-
total incoming solar
with thermal insulation. frared radiation) (Figure 2).
radiation is absorbed
(19% by the atmosphere
and 51% by Earth's
outgoing heat
incoming solar radiation: 100%
340 W/m2
radiation: 71% surface), while 30%
is reflected into
reflected solar
outer space."
emitted by emitted by clouds: 9%
radiation: 29% atmosphere: 50%

reflected by clouds
& atmospherre: 23%

atmospheric window:
absorbed in 12%
atmosphere: 23%

back
convection: evaporation: radiation:
5% 25% surface 100%
radiation:
117%
reflected by absorbed by
surface: 7% surface: 48%

Figure 2: Heat balance exists when solar energy absorbed by the atmosphere and the planet surface equals (19%
+ 51%) the cooling effect (infrared (IR) loss of 70%) of outer space.

www.controlglobal.com MAY 2023 • 27

LESSONS LEARNED

The average temperature of Earth's surface during the pre-

Albedo values
industrial period of 1880-1900 was 13.9 °C. By 2022, it had in- (% reflected)
creased to 14.97 °C and is still rising. The media usually reports
the present value of global warming as 1.1 °C. However, the zero Moon
6%-8%
reference of these reports isn’t always between 1880 and 1900.
Also, it’s not usually, clearly stated from what segment of the
planet's surface the measurements were collected.
Water bodies
This sgment should always be the area between the latitudes 10%-60%
Fresh snow (varies with Sun altitude)
45° N to 90° N in the northern hemisphere. To illustrate this, the 80%-95%
zero reference for the data in Figure 3 is the average tempera- Earth's albedo
Forests (average) 31%
ture for the period between 1960 and 1990, and it’s between 10%-20%
Dark roof 8%-50%
1951 to 1980 in Figure 4. In Figure 3, the blue lines show global Crops, grasslands Light 35%-50%
10%-25%
temperature and the red lines show atmospheric CO2 concentra- Grass Asphalt
tion during the last half-million years. 25%-30% (black top)
5%-10% Concrete, dry 17%-27%
We can see that during the last half-million years Earth's aver-
age global temperature cycled between 3 °C and -10 °C as the Figure 5: Melting reduces the area of highly reflective snow (~80%)
distance between its surface and the sun cycled. The time peri- with low-reflectivity land or water (~20%). If all ice on the planet
ods between major ice ages were somewhat more than 100,000 melted, sea levels would rise by 60 m (220 ft)
years. During that period, the temperature decreased about 1 °C

per 10,000 years. It has since risen about 1 °C per 1,000 years.
6
Temperature in degrees centigrade (compared with 1960-1990 baseline)
350 Atmospheric carbon dioxide (CO2 in parts per million)
The last ice age ended about 12,000 years ago, so during the
4
last half-million years, Earth's average temperature never rose
2 above 3 °C or dropped below -10 °C.
300
0 What does this tell us about the heat balance of our planet?
CO2 (ppm)

It tells us that global temperature follows the cyclic change in its

-2
250 distance to the sun. It also tells us this effect is amplified by the
-4
variation in the highly reflective ice cover of the planet. That’s
200 -6 because, as the area of the ice cover shrinks, heat absorption
-8 rises and global temperature rises as well.
150
Right now, we’d be at the end of the last interglacial period,
-10
450000 400000 350000 300000 250000 200000 150000 100000 50000 when global temperature sually starts to drop. However, this is
Years Before Present
prevented by (what's never occurred during the last half-million
Figure 3: Global values of atmospheric CO2 concentration (red) and years)—recent warming caused by human activity. Global tem-
temperature difference from the 1960 to 1990 average (blue). perature increased about 1 °C during the last 60 years (Figure
4). This speed of temperature rise is much faster than the rate of
temperature changes, which the combined Milankovitch cycles
1.0 NASA Goddard Institute for Space Studies (v4)
Hadley Center/Climatic Research Unit (v4.6) can produce (Figure 3). This is added proof that global warming
0.8 NOAA National Center for Environmental Information (v5)
Berkeley Earth is (and can only be) caused by human activity.
0.6 Cowtan & Way
The quantity of solar heat reflected into outer space is drop-
0.4 ping because of the melting of the ice, which reflects much more
0.2 heat than does either land or water (Figure 5). This self-acceler-
0.0 ating process can, not only bring global warming to the tipping
-0.2 point, but also be reversed by "whitening" the human footprint by
-0.4
using lighter colored roofs, roads, agriculture, etc.
Temperature Anomaly (ºC)
Common Baseline 1951-1980 Accurate measurement of the yearly rise of global warm-
-0.6
ing that amounts to only 0.02 °C/year or the detection of global
1860 1900 1920 1940 1960 1980 2000 2020
temperatures over past millennia requires outstanding technol-
ogy. For more, see my column, “Can we reliably measure the
Figure 4: Human activity is not only preventing the end of the current rate of rise of global warming at 0.01 °C/year” in Control, June
interglacial period, which would have started cooling, but is acceler- '20 (www.controlglobal.com/home/article/11296663/can-we-re-
ating the rise of global warming. liably-measure-the-rate-of-rise-of-global-warming-at-001c-yr).

28 • MAY 2023 www.controlglobal.com

 ON THE BUS

The cost of getting it wrong

Identifying uncertainty and errors up front can help avoid catastrophes later

AN adage called Segal’s Law states, “a man with incoming boiler feedwater), who loaded years of
one watch knows the time, but a man with two history for an incoming waste gas stream. Aver-
watches may never be sure.” But the fellow with aging a pitot tube/differential pressure flowme-
two watches has something the former doesn't: a ter’s output in the site’s historian didn’t announce
measure of uncertainty. While both might be in er- that it was using the uncompensated measure-
ror, the degree to which his instruments differ can ment. Standard cubic feet (SCF) or pounds per
support a judgement of “good enough.” hour (PPH) are, in essence, mass flow measure-
Accuracy to the millisecond might be critical for ments, and any D/P flowmeter only indicates a
a rendezvous in orbit, but not for catching the L mass flow accurately (with a typical uncertainty
train. We can say for all measurements, the value of ±2%) at its “sizing conditions.” This is the tem-
of accuracy depends on the consequences of get- perature, pressure and composition (specific grav-
ting it wrong. ity) at one selected operating point. There was a
Sometimes we learn this lesson by trial-and-er- compensated measurement in the system, but
ror. In the 1980s, a chemical facility was required there wasn’t anyone around who may have asked, JOHN REZABEK
to reduce its volatile organic compound (VOC) “What tag are you using again?” Contributing Editor
emissions and constructed a waste heat boiler/ After startup, the new economizer was a JRezabek@ashland.com
incinerator to combust the VOCs in the stream. A smashing success, demonstrating improved en-
service provider specializing in emissions mea- ergy recovery from the boiler flue gas, thanks to
surements was contracted to monitor the stack increased surface area. But in a few months, the
"Accuracy to the milli-
of the new apparatus. Their extractive analytical flow across the somewhat fouled economizer was
second might be critical
equipment determined the minimum temperature moving it off its mounting, stressing connections
for a rendezvous in or-
to achieve the 99.99% destruction target. enough to create leaks. Eventually, entire sections
bit, but not for catching
Inadvertently, they adopted the unchallenged of the economizer had to be bypassed, costing
the L train. We can say
certainty of the man with a single watch. When many thousands of dollars in daily energy losses,
for all measurements,
a sister facility 1,000 miles away faced the same as well as increasing greenhouse gas emissions.
the value of accuracy
task, they used the results from the first measure- Even tighter tolerances were haunting a small
depends on the conse-
ment to make many design choices. But when the batch brewer, who was befuddled by the rapid at-
quences of getting it
second incinerator was commissioned, it proved tenuation and undesired off-flavors in his flagship
wrong."
incapable of achieving the target destruction of lager. The Braumeister really wants to “drive the
VOCs. The combustion specialists were stumped. car,” that is, use his kit without assiduous or nerdy
How could they miss by so much? insights into the nuts and bolts of the brewery.
It was revealed the culprit—a “Type K” thermo- What wasn’t obvious was the installation details
couple—was configured in the original installa- of the temperature sensors in his fermenters. All
tion as a “Type J,” making it appear that 99.99% were installed through the glycol (coolant media)
destruction was achieved at hundreds of degrees jacket, without any isolation or insulation. Conse-
cooler. Delays and costly upgrades of burners, quently, the actual temperature was consistently
control valves and fuel pipelines followed. The higher than what was indicated, with the error
designers were diligent about not overdesigning growing as the fermenter cooled.
the incinerator, but their reliance on an inaccurate When operating a processing plant, it’s not un-
measurement cost millions of dollars. usual that “two watch” situations confront us. In-
In today’s lean staffing environment, advice to strumentation and control professionals are valu-
validate the accuracy of a measurement can be able when we identify uncertainty and errors, and
scarce. This was true for a mechanical engineer work with our process counterparts to confront
specifying a new economizer (a preheater for the costs of getting it wrong.

www.controlglobal.com MAY 2023 • 29

 WITHOUT WIRES

I/O systems get smarter, simpler

Often overlooked, I/O systems remain critical to any control loop

SENSORS, and by extension associated input/ All of these solutions require local, normally
output (I/O) cards, are often overlooked but UPS, power. Fortunately, manufacturers of power
critical parts of any control loop. Like all parts of supplies offer a range of rail-mounted, redundant
control systems, the capabilities of I/O systems power supplies with local battery backups suit-
continue to evolve. Enhanced capabilities and Eth- able for installation in Class 1 Division 2 (Zone 2)
ernet/packet-based communications to connect environments.
various control system nodes have a significant Ethernet-Advance Physical Layer (Ethernet-
impact on that evolution. APL) offers the opportunity to make another step
Several DCS manufacturers have distributed change in how we connect to field devices. APL
I/O, claiming to increase design flexibility and can supply power and Ethernet signals over one
save cabling costs by supporting installation of I/O twisted-pair cable. One cable goes to each cabi-
“in the field” or at least closer to it. PLC suppli- net. Or, if redundancy is needed, it can use two
ers have the same idea, offering remote I/O that cables or maybe a ring, which is just two cables
IAN VERHAPPEN can be installed in a cabinet close to field devices going to different places.
Solutions Architect and communicate back to the controller via Inter- One fortuitous aspect of Relcom’s legacy field-
Willowglen Systems net protocol (IP)-based communications. Other bus, Megablock, is that it was the same length as
Ian.Verhappen@ control systems reduce hardware dependence by the equivalent number of terminal blocks (posi-
willowglensystems.com making I/O software configurable. tive, negative, ground) that it replaced. It had four
Intelligent terminal manufacturers also offer fieldbus devices in the same space on a terminal
slice I/O, in which each terminal block sits on a strip as 12 terminal blocks. In my project, I also
"The traditional multi- backplane, connected to either a PLC or com- had to change my field devices to Foundation
conductor cable to the munications card. This is like the PLC model, but Fieldbus, which wasn't trivial. However, it would
central control room is with the advantage of supporting almost any pro- have been easier if I'd built an APL-connected
rapidly becoming a thing tocol and the flexibility of only buying I/O the user gateway converted my existing protocol to its
of the past." requires, which has a smaller footprint than the packet-based equivalent (i.e. HART to HART/IP).
DCS or PLC options. This option appears closest Even so, it wouldn’t have been much harder to
to the Open Process Automation Forum's (OPAF) have the gateway also change to a different proto-
distributed control node (DCN) concept. col such as Profinet or EtherNet/IP.

Figure 1: From a real estate standpoint, developing something so it's “backwards compatible” has the potential
to make the Open Process Automation Forum's (OPAF) distributed control node (DCN) a reality.

30 • MAY 2023 www.controlglobal.com

 INDUSTRY PERSPECTIVE | SPONSORED CONTENT SPONSORED CONTENT | INDUSTRY PERSPECTIVE

Why modularization matters perform these types of updates completely

for today’s industrial PCs remotely from one central location. This
is especially critical in large-scale process
automation applications, where facilities
There are benefits to using thin client technology for applications in the process industries may span many acres, and may include
hazardous locations or even clean room
facilities with restricted areas. So, having
IN today’s industry, the trend is to move away while the thin client in the field connects to the the ability to easily access these thin clients
from standalone PCs. Why? Many end-users in host server where the software is executed. from the safety of your office, your desk or
the process industries find benefits in modular- the control room is an important time saver
ization. Marc Seissler and Aaron Severa, both of Q: What are the benefits of using thin clients in- that creates a much more efficient mainte-
Pepperl+Fuchs, recently talked to Control editor- stead of industrial PCs? nance and support structure at the plant.
in-chief Len Vermillion about industrial PC trends
and process automation to provide some answers. Severa: First, I'd say cost savings is a very big Q: What do you offer in this area, know-
Seissler is head of product management for HMI benefit to using thin clients. There are some up- ing Pepperl+Fuchs has a seamless
and based in the Manheim, Germany, headquar- front costs and some are long-term costs.Initial portfolio?
ters of Pepperl+Fuchs. Severa is a regional prod- costs could be due to some of the lesser-grade Pepperl+Fuchs offers a seamless portfolio of industrial PCs covering an extensive list of
uct manager and Level 2 technical support for the hardware that's required in thin clients. For ex- Severa: We have a very wide-reaching classifications and installation scenarios.
Americas region. ample, a low-power processor has less RAM and portfolio that covers an extensive list of
MARC SEISSLER there's typically smaller hard drives, which means area classifications and installation sce-
Head of Product Management, Q: Let’s talk about technology trends, specifically cost savings can be realized. narios—from simple things like a small, emergency stops to an HMI. The SECs even install them where standard IT equip-
HMI, the trends you see in the industrial PC market. Long-term savings can come from a couple form factor-boxed thin client, which is can kind of do a little bit of everything to ment might face problems, even due to
Pepper+Fuchs of different avenues. The first is from energy a unit without a display to panel mount make products fit perfectly into custom- increased heat under a table.
Seissler: In general, when we talk about industrial consumption. Thin clients use low-power pro- products, to standalone, pedestal- ers' applications. When you go into a biopharma plants,
PCs, there are basic requirements that are known cessors. They also use significantly less power mounted workstations. Pepperl+Fuchs, you may find no control room at all.
by the industry. Typically, we talk about rugged than traditional PCs, so you can save on energy especially in process automation, is Q: What are some of the solutions for dif- Their processes are typically batch ori-
devices that give long-term support for end users. costs. Second, thin clients typically have a known for our hazardous location prod- ferent verticals? ented. Their operators work at the shop-
This becomes more important, particularly when longer useful lifecycle than traditional PCs, so ucts, and with our HMI portfolio, it's re- floor level with an HMI system that they
there are transitions from operating systems and they're typically replaced much less often. This ally no different. We cover the complete Seissler: We are set up very broadly, and use to connect a decentralized control
shorter lifecycles at the software and hardware reduces maintenance and qualification costs. In range of hazardous locations, and we we work from the life sciences industry system (DCS), which is often in parallel
levels. We also try to have a platform that offers our experience, thin clients are replaced about have an HMI product for every one of to the chemical industry to oil and gas to a manufacturing execution system
long-term availability to customers with operating half as frequently as PCs. them—from Zone 2 and Zone 1 products applications with our products. Each of (MES) to monitor production tasks they
system migrations. Another big benefit is security. Within client with ATEX and IECEX certifications for those verticals has different types of ap- need to execute.
The big trends that we see today are all-around installations, in most cases, there's no really criti- Asia and Europe's markets to Division 2 plications, which differ in how the end- Typically, HMIs are used that are mo-
modularization. What does this mean for HMIs? It cal data that's stored locally on the thin client. All and Division 1 products that comply with users operate their plant or their system. bile. For these applications, we use mobile
typically means that you split the display from the that data is stored on the central, IT-implemented the North American certifications, such When you look at the traditional chemi- cards, which can even be in a setup with
AARON SEVERA computing technology. The computer is typically server. Other features, such as blocking USB stor- as UL or Intertek. cal industry, where continuous produc- a duplex monitor system with one screen
Regional Product Manager and a rugged, box PC, and this is now an exchange- age devices, as well as right filters and application On top of that, we have solutions tion processes (e.g. steam crackers) are having the DCS picture and the other
Level 2 Technical Support, able component. In case of an upgrade, or even whitelisting, are things that help keep thin client engineering centers (SEC). These are implemented, you will hardly find any screen having the MES system, which are
Americas, in case of a failure of the display or the computer, installations safe and secure. located around the world, and they're HMIs on the shop-floor level. Most of typically, completely separated from each
Pepperl+Fuchs you can migrate or replace these components in Another benefit is software management. If you fully capable of working with applications those plants are typically controlled from other. You also find customers or applica-
the field. That's something we've seen becoming think of a very large installation with many thin cli- that involve any type of customizations a control room, and in those applications, tions that are in between, where there's a
more important in recent years. ents spread around a big facility, any sort of patch or tweaks to our standard products to fit we see a demand for thin clients but in control room and operators on the shop-
What we also see from the overall control or update you might need to do could become the needs of end-customer installations. a form factor-boxed thin client. These floor level. Those customers benefit from
system perspective is a strong trend away from really tedious. This is especially true if you had This could include tasks like creating a devices are typically installed under the that seamless portfolio, where we have the
standalone industrial PCs to more distributed to add these patches one by one locally at every mobile cart-type product that users can tables, etc. same software solutions and management
infrastructure, where you have a thin client in haz- single thin client in the field. wheel around to different areas of the Our users benefit from having the same capabilities, just in different packaging of
ardous areas or on the shop floor. You also have a Luckily, with these thin clients, there are usu- process. Or, it could be something like software and long-term availability on those the hardware. This is a seamless solution
host server somewhere in a more protected area, ally great management tools. For example, the adding heaters or coolers to a design, or devices. Since they're rated for higher for the process industries, when it comes
which runs the software and the applications, Pepperl+Fuchs VisuNet control center allows you to other things like adding pushbuttons or operating temperature ranges, you can to thin client solutions.

32 • MAY 2023 www.controlglobal.com www.controlglobal.com MAY 2023 • 33

IN PROCESS

Trihedral traces SCADA evolution

Fifth VTScadaFest event features training, education and networking

A record-setting number of visitors attended the fifth VTScadaF-

est (www.vtscada.com/vtscadafest) on March 27-30 in Orlando, Glenn Wadden,
and were treated to a 50-year tour of supervisory control and president of VTScada
data acquisition (SCADA) technology and a peek at its future
by Glenn Wadden, president of VTScada by Trihedral, a Delta
Group company.
The modern SCADA era began in 1971 with the introduc-
tion of Intel’s microprocessor; took off in the mid-1980s with the
introduction of Microsoft Windows 3.1 in 1992; and continued
with the popularization of TCP/IP networking technologies that
allowed SCADA systems to span multiple computers and syn-
chronize their operations.
“Moore’s law lowered the cost of what could be monitored,
and we saw soaring I/O counts, ultimately spawning the Indus-
trial IoT,” said Wadden. “Lots of cheap I/O meant booming vol-
umes of data, with tag counts regularly numbering in the tens To confront these challenges, VTScada software has a built-in,
and hundreds of thousands.” application-version control utility that manages changes by record-
Today, Wadden sees control rooms fading in importance, ing what system edits were made when and by whom, and allow
with alarms providing a primary means of managing opera- users to rewind systems to any previous version. Also, Trihedral
tions. Meanwhile, virtual machines and cloud environments al- continues to update versions of VT Scada every two weeks, re-
low SCADA users to create new apps quickly, even on remote flecting the company’s sprint development process and commit-
hardware, even cyber-threats, intrusions and attacks multiply. ment to cybersecurity, while maintaining backward compatibility.
Wadden adds another issue in SCADA development is removing This gives users a routine update cycle to ensure they benefit from
“configuration bottlenecks,” which led Trihedral to pioneer online new features, bug fixes, and security enhancements.
application development by multiple concurrent editors, and use For full coverage, visit www.controlglobal.com/events/vtscada-
templates, import tools and modular code. fest-2023/article/33004489/vtscadafest-2023

OSIsoft founder Kennedy dies Kennedy was born in 1943 in Portland, Oregon, and was raised
Dr. J. Patrick Kennedy, 79, founder and CEO of OSIsoft and its on a farm south of Lawrence, Kansas. He earned B.S. and Ph.D
PI System real-time data management software, died on April degrees in chemical engineering from the University of Kansas.
9 after a 10-month battle with interstitial lung Kennedy is survived by his wife of 56 years, Patty, three
disease. He established OSIsoft in 1980 as children and their spouses and grandchildren, as well as his
Oil Services Inc., and ran it for just over 40 brother in San Diego. No memorial ceremony is presently
years in San Leandro, Calif., before it was planned. His family requests privacy, and suggests donations
acquired by AVEVA (aveva.com) on 2021 for to UNICEF (unicefusa.org) in his name in lieu of flowers.
about $5 billion.
Dr. J. Patrick
Close to ubiquitous in all the process in-
Kennedy,
founder and dustries, “OSI PI” long performed data ac- Ethernet and wireless grow,
CEO of OSIsoft quisition, historizing, analysis, delivery and
visualization, and continues to serve as an en-
fieldbuses shrink
terprise infrastructure for managing real-time data and events. The industrial network market is expected to grow by 7% in
It automatically collects from multiple sources, such as sen- 2023, according to the latest study by HMS Networks (hms-
sors, instruments, analyzers, I/O, controllers and software; orga- networks.com). Each year, the company analyzes the industrial
nizes it using OSIsoft and third-party PI Interface software; and network market to estimate the distribution of new connected
gives users access via common formats including PI Process- nodes in factory automation worldwide. HMS defines a node as
Book software, Microsoft Excel and web browsers. a machine or device connected to an industrial field network.

34 • MAY 2023 www.controlglobal.com

 IN PROCESS

The study found that industrial Ethernet the Process Automation Device Informa- Dr. Al Beydoun, president and executive
still shows the highest growth, and now tion Model (PA-DIM). “The introduction director of ODVA. “EtherNet/IP process
accounts for 68% of all new installed of process device profiles to EtherNet/IP device profiles will help end users oper-
nodes, compared to 66% last year. is another step in meeting the require- ate plants with superior yields, minimal
Fieldbuses declined to 24%, while wire- ments of the process industries,” says downtime and reduced costs.
less grew to a 7% market share.

| PI11-01USA |
Engineers Without
Borders partners Industrial automation and process
with Bentley technology combined with EtherCAT
Engineers Without Borders Interna-
tional (www.ewb-international.org) re-
and PC Control
ported Apr. 20 that it’s partnering with
Bentley Systems (www.bentley.com) to
bring together the global EWB move-
ment and unite the engineering sector,
so millions more people can benefit
from addressing today’s most pressing
challenges. The partnership includes
five years of core funding and execu-
tive insights, and will strengthens the
capacity of EWB International to drive
collaboration and cooperation within
the movement, deliver better results,
and unlock its global impact.

EtherNet/IP gains
device profiles System-integrated explosion protection from Beckhoff:
automation and process technology integrated into one system – barrier-free up to Zone 0/20
comprehensive range of components for explosion protection
ODVA (www.odva.org) reported at Han-
ELX series EtherCAT Terminals featuring intrinsically safe interfaces
nover Messe on Apr. 17 that process
explosion-proof CPX series Control Panels and Panel PCs
device profiles have been added to the flexible and powerful EtherCAT fieldbus
EtherNet/IP specification to give users TwinCAT control software with specific process technology interfaces
another tool to optimize plant operations. direct connection of intrinsically safe field devices
These profiles are reported to provide integrated control concept for all industries with Ex protection requirements
a standard format for process variables
and diagnostics across many devices for
smoother vendor interoperability and eas-
ier DCS and PLC data integration from
EtherNet/IP-enabled field devices.
EtherNet/IP process device profiles Scan to discover
are available for Coriolis, electromagnetic all the benefits of TwinCAT 3: with process Complete Ex range:
system-integrated technology interfaces from panels and Panel PCs to I/Os
and vortex flowmeters, and standard and process technology
scaled pressure devices. This lets users
take advantage of EtherNet/IP devices
with better communication of critical di-
agnostics, such as NAMUR NE 107 sta-
tus signals and improved alignment with

www.controlglobal.com MAY 2023 • 35

2305CT_Beckhoff.indd 1 4/24/23 1:26
 IN PROCESS

SIGNALS AND INDICATORS • I ndiana-based Lebanon Utilities (lebanon-utilities.com) reported

• T he OPC Foundation, (www.opcfoundation.org) reported Apr. Apr. 19 that it’s improving its wastewater treatment infrastructure
17 that it’s expanding the OPC UA networking standard with a by upgrading a lift station with two of Tsurumi Pump’s (www.
representational state transfer (RESTful) API to allow worldwide tsurumipump.com) FM-rated Avant MQC Chopper pumps that
access to data made available by implementations of more than operate smoothly and reduce callouts. These FM-rated pumps of-
90 standardized information models by IT applications. fer impeller options and horsepower ratings from 4 hp to 215 hp,
• ABB (go.abb/processautomation) reported Apr. 20 that it’s col- while the Avant line can handle flows up to 14,000 gpm.
laborating with three partners, Skovgaard Energy, Topsoe and • To help decarbonize its operations by 2030, Danfoss North
Vestas, to build the world’s first dynamic, green, power-to-ammo- America (www.danfoss.com) announced May 2 that it’s agreed
nia (PtA) plant. Located in Lemvig, Denmark, this demonstration to buy about 75 megawatts of solar power starting in 2025
plant will run on energy from its own wind turbines, and avoid from a solar farm that CIG Capital is building in the Texas pan-
using electricity from the grid. This project is already under con- handle. The six-square-mile solar farm is scheduled to start up
struction, and is expected to start production in early 2024. spring 2025, and have a capacity of 509 MW.
• Rockwell Automation Inc. (www.rockwellautomation.com) • United Flow Technologies (www.uft.com) reported Apr.10 that it
reported Apr. 18 that it’s partnering with the non-profit Water acquired Kodru-Mooney (www.kodru-equipment.com) last October
Council (thewatercouncil.com) to promote corporate water and Macaulay Controls Co. (www.macaulaycontrols.com) this
stewardship worldwide. This will be accomplished with TWC’s past March. The two acquisitions are expected to accelerate UFT’s
Wave verified, corporate water stewardship program and Rock- strategic position into the Midwest and Texas regions, add product
well’s water-related sustainability products and services. categories to the platform, and strengthen OEM partnerships.

LINEAR
POSITION
SENSORS POISED TO LAUNCH YOUR BUSINESS
INTO THE INDUSTRIAL FUTURE

1 800 633 7609 | temposonics.com

2304CT_Temposonics.indd 1 3/22/23 1:09 PM

36 • MAY 2023 www.controlglobal.com
 RESOURCES

Understanding Ethernet-APL
Control’s monthly resources guide

APL ORGANIZATION ESSENTIALS panelists also compare APL to existing two modules Softing is developing. The
This website, “Ethernet-APL,” is ground technologies, suppliers’ progress on solu- second post, “Ethernet-APL—network
zero for everything about the emerg- tions, and rail field switches. It’s at www. topologies,” details three variants, includ-
ing single-pair Ethernet (SPE) network- youtube.com/watch?v=dsNls9kGyKQ ing connecting directly using regular
ing technology for hazardous areas. It PEPPERL+FUCHS Ethernet, or using truck technology and
includes a 90-second introductory video, www.pepperl-fuchs.com/apl APL switches with autonomous power
FAQs, 18-page whitepaper, 120-page en- or an added energy source. The first
gineering guide, progress reports, blog, STANDARDS, NETWORK, POWER is at industrial.softing.com/news/blog/
library and details about the four stan- This six-page article, “Ethernet-APL for ethernet-apl-the-new-gold-standard-for-
dards development organizations (SDO) evolving field devices and the future of process-automation.html and the second
and 12 suppliers that maintain it. industrial Ethernet” by Taro Endoh, Shuji is at industrial.softing.com/news/blog/
ETHERNET-APL Kuwahara and Seiichiro Takahashi, ex- ethernet-apl-network-topologies.html
www.ethernet-apl.org plains how APL can meet the require- SOFTING
ments of process automation (PA) plants, industrial.softing.com
INTRO VIDEO FROM FIELDCOMM shows what benefits it will bring and what
This 40-minute video, “Ethernet-APL” by challenges are expected to emerge, and- HIGH-AVAILABILITY SAFETY
the FieldComm Group, covers all the ba- describes the prospects and expecta- This 13-page whitepaper, “Ethernet-APL
sics, such as definitions, layered model, tions of Yokogawa’s contribution. It’s at in the field for high-availability safety ap-
Internet connectivity, ISO OSI model, reg- web-material3.yokogawa.com/1/32505/ plications,” shows how it can be applied
istration and others. It’s at www.youtube. files/rd-te-r06402-005.pdf consistently to enable functional safety.
com/watch?v=Lm88SjCV0og YOKOGAWA It covers benefits such as applications
FIELDCOMM GROUP www.yokogawa.com up to SIL 3, increased accuracy and flex-
www.fieldcommgroup.org ibility, and challenges such as device
TWO SHORT VIDEOS FROM E+H requirements. It’s at files.pepperl-fuchs.
CONNECTIONS, PROTECTIONS These 2.5-minute videos, “What is Eth- com/webcat/navi/productInfo/doct/
This online article, “The Ethernet-APL ernet-APL?” and “Ethernet-APL: simple, tdoct7122__eng.pdf
engineering process” by Dr. Karl-Heinz fast digital" from Endress+Hauser, trace PEPPERL+FUCHS
Niemann, covers its context in the ISO/ its history and development by the four www.pepperl-fuchs.com/apl
OSI protocol stack, design needs, differ- SDOs and their supplier partners; shows
ences from regular Ethernet, cabling and how it’s supported by other protocols PROFILE OF P&G’S TESTBED
connection technologies, network struc- like Profinet, EtherNet/IP, OPC UA and This online article, “P&G gets simpler,
tures, explosion protection, network traf- HART IP; and details how it gives us- smarter with Ethernet-APL,” shows
fic and shielding concepts. It’s located ers loop-powered communications with how Procter & Gamble developed an
at r-stahl.com/en/global/blog/post-detail/ straightforward and reliable network- Ethernet-APL demonstration project at its
the-ethernet-apl-engineering-process ing. They’re at www.youtube.com/ Corporate Engineering Technology Lab
R. STAHL watch?v=OYCkTptlViY and at www.you- (CETL) in West Chester, Ohio. The demo
www.r-stahl.com tube.com/watch?v=x6WGadify2E was implemented on the lab's Smart
ENDRESS+HAUSER Process Cell (SPC), and showed that
EXPERT PANEL DISCUSSION www.endress.com Ethernet-APL wiring was easy and robust,
This 65-minute video, “Networking and that devices on the network looked
Lounge about Ethernet-APL,” pres- COSTS AND TOPOLOGIES like any other Ethernet components. It’s
ents a roundtable discussion hosted The first of two blog posts, “Ethernet- at www.controlglobal.com/network/indus-
by Pepperl+Fuchs at its Online Summit APL—the new gold standard for process trial-networks/article/11287467/pg-gets-
event in July 2020. The session features automation” covers technical fundamen- simpler-smarter-with-ethernet-apl
Gerd Niedermayer of BASF, who details tals, shows how Ethernet-APL can make CONTROL
its test installation of Ethernet-APL. The networking cost-effective, and previews www.controlglobal.com

www.controlglobal.com MAY 2023 • 37

 INDUSTRY PERSPECTIVE | SPONSORED CONTENT SPONSORED CONTENT | INDUSTRY PERSPECTIVE

Non-contacting radar technology’s

growing application landscape
A: We can start with the Rosemount™
5408 Level Transmitter. It's the radar
with the most advanced capabilities. It's
Product evolution and industry-specific innovation create emerging opportunities in designed to cope with any application or
new markets condition. It's proven to be efficient in
chemical applications, as well as petro-
FIFTY years ago, Emerson began utilizing a new transmitters are affected, not only by moisture, chemical and oil and gas applications.
method for measuring tank levels: non-contact- temperature, condensation on the antenna, but It's rated for safety-instrumented appli-
ing radar technology. Taking a technology origi- also by dust and wind. And, they're prone to deliv- cations. In this case, we developed our
nally designed for military aircraft, the company ering inaccurate measurements, and require more own radar front-end to get better signal
became a leader in using radar technology for maintenance and manual checks. output, better efficiency, and more
maritime and land-based tank level applica- power that we can use to do our level
tions. Technology has evolved over those five Q: There are applications in water and wastewa- measurements.
decades and, these days, new opportunities are ter, metals and mining, food and beverage, life The next is the Rosemount™ 1408
emerging for several industries to use the non- sciences and chemical industries. Explain why Level Transmitter, where we saw a need
contacting radar thanks to the continual evolu- they're fits for non-contacting radar transmitters for hygienic, cost-effective transmitters
tion of the products available on the market. relative to other level measurement technologies? for the food and beverage industry. We
Christoffer Widahl, director of solutions manage- recognized there were legacy products or
CHRISTOFFER WIDAHL ment for radar new markets at Emerson, talked A: In many of these applications, for example, the technologies that were only partially fulfill- Emerson's Rosemount non-contacting radar technologies are used in industries such
Director, Solutions Management, with Control’s editor-in-chief, Len Vermillion, chemical industry, the media in some cases are ing our customers' needs, and we had as oil and gas, chemical processing, food and beverage, metals and mining, water and
Radar New Markets about the transformation, benefits and emerg- very aggressive and corrosive. As the name stipu- transmitters that were originally developed wastewater and process industry utilities.
Emerson ing opportunities for non-contacting radar level lates, it's a non-contacting technology. So, nothing for other industries, such as oil and gas
measurement. of the radar sensor is in contact with the liquid or or chemical, which were adapted with
the fluid it's measuring, so you don't have to worry hygienic approvals and used in food and service. You can just take action while it's the hardware on the transmitter. If the
Q: The footprint for non-contacting radar technol- about corrosion. beverage or the life sciences. still operating, and you can get a good cable breaks down, it's easy to replace
ogy is becoming broader across the application The same applies to metals and mining, where But none of these were really devel- verification that everything is still working the cable without having to replace the
landscape. What created these opportunities? you're using a lot of chemicals, but it's also quite oped specifically for these industries, according to its certification or standards. entire unit.
rough. You have solids applications with rocks, and we saw the opportunity to make The Rosemount™ 1208 Level and
A: When we started 50 years ago, the products cement or other things that are very abrasive. something that really addresses our Flow Transmitter is a new addition to our Q: Every industry values different things,
were very big, bulky and expensive. Over the Having non-contacting, top-down technology customers' needs and what they're re- portfolio. We tailored it specifically for but besides non-contacting features,
years, technology has evolved from discrete com- that's far away from the media is an advantage. ally asking for in these industries. When water, wastewater and process indus- what does non-contacting radar bring to
ponents on large boards that were very power The lifetime of the product will increase. It won’t we did our first trials with the 1408, we try utilities. With the 1208, we really fo- the table that you don't see from many
hungry and inefficeint. Everything has become break down as easily. realized there could be an issue when cused on making it even more compact, other technologies?
much smaller and less power hungry. Also, the In food and beverage, the radar is also always you're cleaning the tanks with a steam- smaller, and more efficient in terms of
cost has gone down. Now, with our sixth genera- mounted on top of the tank, measuring top-down in-place (SIP) or clean-in-place (CIP) power management. Also, we developed A: The trend is that you add more and
tion of frequency-modulated continuous wave and without contact with the media, thus mini- process. We developed a specific algo- the plastic housing that's common in more diagnostics. But to have reliable
radar transmitters, we're able to make them very mizing contamination risk. In life science, we still rithm that detects when the spray ball those industries. diagnostics, you need reliable informa-
compact and power efficient. comply with all the hygienic requirements and is starting to move, so the transmitter One thing that differentiates the 1208 tion. And you must have a lot of raw
hygienic certifications, but it's easier to put it on won't generate any alarms. from many of its competitors, especially data, or it's difficult to build those diag-
Q: The transformation radar technology has gone top. You don't have to dismount the entire system The Rosemount™ 3408 Level Trans- in the water and wastewater industries, nostics and have reliable results.
through is fascinating. Why is radar technology to do the cleaning. mitter was specifically designed for the is the M12 connector. Many of the prod- That's one thing that differentiates
superior to other technologies, such as ultrasonic One good thing about non-contacting radar in chemical industry. We added our Smart ucts for this industry have cables that are our transmitters. The latest genera-
level measurement, and what are the advantages the water and wastewater industry is that you can Meter Verification diagnostics that have molded into the plastics, which means tion of radar products feature our Fast
that non-contacting radar offers? do open-channel flow measurement with a non- been leveraged by other Emerson prod- that if, you would have a problem with Sweep Technology, which allows them
contacting radar by measuring the level. uct lines. This is also available in our ra- a cable, you have to replace your entire to send more sweeps to the media sur-
A: Legacy technologies, such as ultrasonic dar portfolio, which helps our customers instrument. That is not sustainable. So, face. With Fast Sweep, we send more
level transmitters, are sensitive to environmen- Q: Can you talk about some of the different non- verify the performance and the health of for the 1208, we added an M12 con- sweeps and get more data, which in
tal changes that typically happen when a device contacting radar transmitters that are in the level the radar transmitter. You don't have to nector that makes it more sustainable. turn increases reliability and leads to
is installed, especially outdoors. Ultrasonic level portfolio for Emerson? do anything to take it out of process or If it has any issues, it's easy to replace better diagnostics.

38 • MAY 2023 www.controlglobal.com www.controlglobal.com MAY 2023 • 39

ETHERNET-APL ETHERNET-APL

Ethernet-APL
“Ethernet-APL is attractive because it

gears up
lets us easily connect all these devices,
download data from them, and exchange
data with their DCSs,” explains Nieder-
mayer. “Where we previously had to deal
with polarity requirements and if we were
connecting the right green or red wire,
we no longer have to care about many of
these connection issues or which direc-
BY JIM MONTAGUE tion they’re going. Plus, using Ethernet-
APL gives us 10 Mbps, which is a lot
The two-wire, single-pair Ethernet (SPE) network prepares to work faster than Profibus PA’s 31.25 kbps.”

in intrinsically safe (IS) and other hazardous areas

Faster for wider reach
Thanks to its greater speed, Ethernet-
MORE often than anyone likes to think, optimizing process ap- APL can connect to more sensors, trans-
plications is a lonely business. Users must often deploy sensors, mitters and other devices, depending on Figure 2: The FieldComm Group reports that Ethernet-APL field devices will connect to Ethernet
instruments, I/O, controls and networks with far less precedence what their DCS interfaces can handle. switches, which in turn will connect to controllers and servers. Source: FieldComm Group
than they’d prefer about how well they’ll work together to fulfill “Anything that moves over Ethernet
the requirements of individual applications. This know-how is wiring and uses its protocols can also use
even more important in safety processes, so even innovations Ethernet-APL, so it’s not limited to simple Ethernet-APL will be dominant in the redundant controllers via field switches
like Ethernet-Advanced Physical Layer (APL, www.ethernet-apl. communication and control. It can relay process industries because it provides all with eight, 16 or 24 ports. These two
org) must be thoroughly evaluated before it can deliver on its alerts and alarms, perform equipment the speed and benefits that different ap- controllers include Honeywell’s Experion
promise of allowing Ethernet networking into intrinsically safe (IS) monitoring, provide motion data, deliver plications need, but users only have to run DCS and ABB’s 800 xA DCS, which are
and other hazardous areas. video, and network into hazardous ar- wire once, and can also reconfigure and connected to 238 field devices in a Pro-
“It’s very important for us to test any new production technolo- Figure 1: To evaluate Ethernet-APL networking, communications and eas with an eight-port switch,” says Paul rearchitect for new designs over time.” finet ring/loop topology via 24-port field
gies. We can’t simply trust they’ll work as expected because many devices via Profinet protocol, BASF built a field test lab in 2019-20 at Sereiko, marketing and product strategy Because it can run on existing Eth- switches that can handle 24 devices each.
applications are pioneering topics,” says Gerd Niedermayer, senior its headquarters in Ludwigshafen, Germany. The lab tests flowmeters, director at the FieldComm Group (www. ernet cabling, Ethernet-APL needs that Of course, one of Ethernet-APL’s main
E&I engineering manager at BASF for its chemical plants and level, pressure and temperature transmitters, valve positioners, sen- fieldcommgroup.org). “Traditional instru- infrastructure to reach in-place instru- advantages is its two-wire loop can run
new plants in Europe. “We need to know if they’ll work properly or sor sets, and other components, which is helping its supplier partners ments have one network trunk for dump- ments. If they have Ethernet, users can up to 200 meters in IS settings with Ex ia
not, if they deliver the advantages they claim, and if they solve our develop Ethernet-APL products. Source: BASF ing aggregated data and another for send- test and deploy Ethernet-APL. If not, they potentially explosive atmospheres, where
problems.” ing images from cameras watching vats have to work with their usual patchwork Ethernet couldn’t go before.
In the case of Ethernet-APL, BASF researched it in 2017-18, or other equipment, and each needs its of networks, and should expect to add “Because we work with so many mo-
and built its field test lab in 2019-20 at its headquarters in Lud- Endress+Hauser, HIMA, Krone, Samson, Siemens and Yokogawa. own dedicated wire bundle. Ethernet-APL an adapter card to let older devices use tor control centers (MCC) and variable
wigshafen, Germany, to evaluate communications using Profinet They provided the lab with mass and magnetic inductive flowme- can connect to all of these using the same Ethernet-APL, according to Sean Vincent, frequency drives (VFD), one of BASF’s pri-
protocol over Ethernet-APL (Figure 1). To test how Ethernet-APL ters, level, pressure and temperature transmitters, three to five network it uses for switches, and save technology programs director at the Field- mary goals for the field test lab was having
would work with its applications, Niedermayer reports that BASF valve positioners for each application, full sensor sets, and other all the time, money and labor required to Comm Group (Figure 2). at least two interfaces for each of the two
worked closely with several suppliers, including ABB, Emerson, components needed to equip a process plant. set up and maintain separate networks. “There are two sides to consider in controllers, which would also let us man-
any automation decision. The first is as- age electrical equipment over Ethernet
set management, and Ethernet-APL can with Profinet protocol,” adds Niedermayer.
provide many benefits here. The other is “We also wanted our ring network to
controls and operations, and users adopt- standardize on Profinet to reach all these
ing Ethernet-APL are beginning to report devices, and use Ethernet-APL in the in-
on what it’s doing for them,” says Vincent. trinsically safe areas.”
“Ethernet-APL is like the new kid replacing
4-20 mA and HART. It’s exciting because Development and testing
Ethernet-APL also gives users the oppor- To test Ethernet-based equipment and
tunity to replace traditional current loops, models, the field lab at BASF implements
even if it takes a while to overcome some new components in its field devices or
infrastructure hurdles.” switches, which is helping its supplier
Likewise, at BASF’s field test lab, partners develop Ethernet-APL products.
Ethernet-APL connects via Profinet to For example, in mid-2022, it installed

40 • MAY 2023 www.controlglobal.com www.controlglobal.com MAY 2023 • 41

 ETHERNET-APL

and beta tested several Endress+Hauser products in 2Q23, with other vendors The team tested 40 criteria and scenarios
items with standardized Ethernet-APL project to follow shortly after. using its standard devices and full ring
chips and two-wire Ethernet com- More recently, Niedermayer reports network’s communications stack and
munications. This is expected to let BASF and its partners conducted a scal- memory, and found their operations were
Endress+Hauser release Ethernet-APL ability test of the field lab in mid-March. very stable. The ring was examined with
communications tracking software from
Indu-Sol and Procentec, which can moni-
tor network traffic performance and iden-
tify problems.
“We’re helping develop Ethernet-APL
products because BASF is very interested
in it. We believe it has big advantages
for three new plants we’re doing detailed
engineering for now, which are scheduled
to start up in 2025,” says Niedermayer.
“These advantages are that it’s simpler,
enables plug-and-play, and makes it
easier exchange field devices, along with
allowing two-wire Ethernet to serve in in-
trinsically safe areas.”
Andrew Kravitz, product management
director instrument connectivity at Emer-
son (emerson.com), adds, “Ethernet-APL
is the latest step in Ethernet’s transition
down the ISA-95 enterprise-control inte-
gration stack from Level 3’s manufactur-
ing operations management to Level 0’s
production processes. Many users tried to
work with Foundation Fieldbus and other
protocols, but they’re often too complex.
This is where Ethernet-APL can help be-
cause it’s simpler, much like familiar 4-20
mA, and can provide power and intrinsic
safety along with communications using
two-wire, twisted, shielded-pair cable.”
However, even though everyone uses
Ethernet in their daily lives, Kravitz re-
ports it poses some added challenges in
industry. “It’s easy enough to set up Eth-
ernet and use web browsers to manage
Rugged and reliable FS Functional Safety Series individual components and gain access to
their data and diagnostics. However, this
instrumentation from Moore Industries can help ensure the
process doesn’t scale well for configuring
safety of your process and facility when you need it the and maintaining hundreds or thousands
most. Our Logic Solver, Signal Isolators and Transmitters are of devices in industrial settings,” explains
built to strict IEC 61508 standards, ensuring safe and reliable Kravitz. “We already use Emerson’s AMS
Device Manager software for bulk configu-
operation – particularly where hazardous or emergency
rations and diagnostics, and we believe
situations can occur. that Ethernet-APL users will leverage the
same tools for automating maintenance
Call (800) 999-2900 or go to: www.miinet.com/safetyseries work practices faster and without having
to do as much retraining.”

42 • MAY 2023 www.controlglobal.com

CT_Moore Industries.indd 1 4/17/23 2:02 PM
 ETHERNET-APL

Kravitz reports that traditional 4-20 mA instruments and other device-level items. at 1.2 kbps. For instance, processes that
networking has relatively higher latencies These reduced touchpoints and sim- can benefit from quicker data delivery
because it must go through the usual I/O pler network path also let Ethernet-APL include radar gauges that take 15 min-
infrastructure, while Ethernet-APL is faster capitalize on its 10 Mbps, compared to utes to provide an echo curve with HART
because it can talk directly to sensors, fieldbuses like HART that runs far slower can relay one in less than 5 seconds with
Ethernet-APL.

Simplicity saves time—and inspires

Niedermayer adds that BASF’s prior net-
working efforts usually started at the field
device with 4-20 mA, and most still do.
However, this traditional networking re-
quires analog-to-digital (A/D) conversion,
digital-to-analog (D/A) conversion, volt-
age and power, signal marshalling and
conversion, and A/D conversion again to
reach the DCS.
“With Ethernet-APL in the field, we
make one A/D conversion to reach a
field switch, and that’s all! These Eth-
ernet-APL switches, such as those that
Pepperl+Fuchs, Phoenix Contact and R.
Stahl are making, can connect via the ring
right to a controller, and again, that’s all!”
says Niedermayer. “This is a lot simpler,
which is especially helpful when we’re
starting a plant because we can see all
the loops when we connect to the asset
management station. We also don’t need
to do as many field tests and measure-
ments to do loop checks to measure
ranges in the DCS, which means we don’t
need to go into the field as much because
the process values are fully digital. This
reduces our loop check times by about
80%, which is our present expectation,
and also lets us start plants sooner.”
Beyond its speed and reach, Nieder-
mayer adds that Ethernet-APL also has
more bandwidth than typical networking
methods, so participating devices can
easily transmit and receive data in parallel
to asset management systems and redun-
dant controllers on the same wire and at
the same time. This is possible with other
protocols like Foundation Fieldbus and
Profibus PA, but their bandwidth is com-
paratively limited.
“Previously, we couldn’t do what we
wanted with our networks due to 4-20
mA’s limited bandwidth,” adds Nieder-
mayer. “With Ethernet-APL, we can do

44 • MAY 2023 www.controlglobal.com

CT_EmersonAutomationSolutions-Half.indd 1 4/20/23 2:05 PM
 ETHERNET-APL

what’s needed, just as we can get Ethernet into hazardous areas. This is why Ethernet-APL had to be a specific application of
In fact, Ethernet-APL also allows us to bring in ProfiSafe protocol the IEEE 802.3cg single-pair Ethernet (SPE), which is defined as
for safety applications along with Profinet in future safety applica- 10Base-T1L for 10 Mbps at up to 1,000 meters. “Previously, we
tions. This lets users communicate with safety PLCs via Ether- had long cable runs iand faced hazardous conditions when trying
net-APL and the ProfiSafe stack. Of course, safety applications to deliver power to the field, and this led to many complex wiring
will likely continue to maintain separate networks and redundant schemes,” explains Beydoun. “Now, with Ethernet-APL, we have
devices, but the advantage now is that they can employ the same two wires that can go up to 1,000 meters, and run at speeds up to
network structure and topology, and use the same field devices.” 10 Mbps, which allows seamless data loading.”
Al Beydoun, president and executive director of ODVA (www. While different devices and protocols can run on the same
odva.org), adds that, “The inspiration for Ethernet-APL comes physical network with Ethernet-APL as they do with regular Eth-
from seeing digital transformation elsewhere and the increas- ernet, Beydoun acknowledges they don’t provide immediate,
ing need to connect devices in the process industries at higher plug-and-play interoperability. However, he adds that protocols
speeds and greater bandwidth, as well as reach to edge devices like EtherNet/IP, Profinet, Foundation Fieldbus and others can talk
and hazardous areas where Ethernet hasn’t gone before. However, to each other via gateways and converters that can translate their
there have been some challenges along the way, such as shifting conversations and data.
from four or eight wires to using only two to reach field devices. “Users no longer need to run multiple networks, and they can
Likewise, getting Ethernet into hazardous locations meant comply- benefit from testing to ensure that Ethernet-APL is safe,” says Bey-
ing with the process industries’ requirements for intrinsic safety by doun. “To learn about and begin implementing Ethernet-APL, we
defining specifications for appropriate power classes, and devel- recommend visiting the Ethernet-APL.org website, and reading its
oping conformance tests based on common process operations.” ‘Ethernet to the field’ whitepaper and engineering guidelines. Us-

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many I/O signals in Zone 1 as ever before. Process connectivity runs on modern
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2305CT_RStahl.indd 1 4/20/23 1:31 PM

www.controlglobal.com MAY 2023 • 45
ETHERNET-APL

ers can also work with the Ethernet-APL organization’s four stan-
dards development organizations (SDO) on how to implement it
safely in their IS processes. Ethernet-APL will let them perform re-
mote commissioning and digital troubleshooting, diagnostics and
analytics, so they can detect upcoming failures and maintenance
issues earlier, but without all the old, complex networking.”
Beydoun adds that Ethernet-APL’s speed will also let users
reduce device configuration times from several minutes each to
just a few seconds, and monitor out-of-range operations and pre-
mature failures that could impact end-product quality or increase
unplanned downtime. “Overall, Ethernet-APL will emerge as ven-
dors implement its physical layer on their products, and then work
with system integrators and end users to reach all the components
in their processes and plants. With EtherNet/IP sitting on top of
this physical layer, Ethernet-APL gives user the full capabilities of
EtherNet/IP, including its CIP Security and CIP Safety network ex-
tensions. It’s also nice that Ethernet-APL allows potential reuse of
Type A fieldbus cables, but users should retest them to verify they
have the 100 ohms of resistance (± 20 ohms tolerance) that the
standard requires.”

Historical needs, removing limits

Just like any multi-year, overnight success, Ethernet-APL’s pres-
ent innovations and momentum are just the latest news in a
longer and older story. “Ethernet-APL is the holy grail of bringing
Ethernet to instruments in explosive and hazardous areas,” says
Michael Bowne, executive director of Profibus & Profinet Interna-
tional (PI) North America. “With typical four-wire Ethernet, installa-
tions in hazardous areas often require specialized equipment such
as Ex-d housings, so Ethernet wasn’t used in these areas. This is
because Ethernet simply carries too much power.”
Bowne reports this is why PI, the three other standards or-
ganizations and a dozen manufacturers spent several years
building Ethernet-APL on top of the IEEE’s existing 802.3cg
10BASE-T1L single-pair Ethernet (SPE) standard. It adds power
restrictions defined by IEC TS 60079-47 technical specification
for two-wire IS Ethernet (2-WISE) for trunks up to 1,000 meters
and spurs up to 200 meters. Ethernet-APL also follows power
guidelines for spurs, so users don’t need to worry about possible
ignitions or loss of performance.
“One of the most essential tasks for implementing Ethernet-
APL is getting rid of the attitude that ‘we can’t do Ethernet,’” says
Bowne. “It’s important to get an Ethernet infrastructure in place
because there are soon going to be many Ethernet-APL devices
available from a variety of manufacturers. Likewise, if you already
have Profibus-PA, Ethernet-APL is designed to run on the same
Fieldbus Type A cable, so you won’t need to remove those wires.”
“The beauty of Ethernet-APL is that it’s just Ethernet, so users
can utilize its 10 Mbps to do things like access to an instrument’s
embedded webserver,” adds Bowne. “When employing HART, for
example during configuration, its 1.2 kbps means long commis-
sioning times. Using Ethernet-APL for configuration will save hours

www.controlglobal.com
 ETHERNET-APL

on commissioning time alone, and enable users to access, gather, How to DIY on the physical layer
and transmit parameters much more quickly.” To implement Ethernet-APL, R. Stahl’s Fritsch reports there are
Andre Fritsch, senior product manager for remote I/O, fieldbus several questions users need to ask. First, if they’re implement-
and Ethernet at R. Stahl (r-stahl.com), adds that, “In the past, ing a greenfield application, they can go with any suitable Eth-
Ethernet for hazardous areas typically used fiber-optic lines, ernet-APL option because they’re buying new cable. However, if
which had the advantage of speed, data capacity in the hun- it’s a brownfield application, they need to determine if they can
dreds of megabytes to gigabyte range, and protection against reuse their existing cable, and if so, how much?
electromagnetic interference (EMI). However, it also had dis- “If the user already has Profibus or Foundation Fieldbus in
advantages due to installation difficulties, costly cabling, and place, they can likely reuse it for Ethernet-APL. However, if they
the inability to provide power, which meant it had to come from have 4-20 mA, then they have to be very careful, and test it,
elsewhere. This is why the four SDOs and their 12 industry part- check with the manufacturer, and determine its quality before try-
ners sought to globally standardize a copper-based Ethernet for ing to reuse it,” says Fritsch. “If their cable is 20 years old, they
hazardous areas, established the Ethernet-APL organization in may need to replace it.”
2018-19. Its original core requirements were: providing electricity If a user already has an Ethernet infrastructure, Fritsch reports
via Ethernet, though different than the Power over Ethernet (PoE) they have two main options for connecting with Ethernet-APL:
method; connectivity with two-wire copper; longer distance of • Standard Ethernet in a star topology that uses switches with
1,000 meters; and enabling process automation in hazardous eight to 24 ports to reach Ethernet-APL devices. Two disadvan-
location with the support of intrinsic safety (IS) in accordance tages are that field switches need 24 VDC power, and network
with the IEC 60079-11 standard. Ethernet-APL is just two-wire length is limited to 200-300 meters without repeaters. One advan-
Ethernet with explosion protection on top.” tage is that a ring topology at the switch level improves availability.

www.controlglobal.com MAY 2023 • 47

ETHERNET-APL

• Trunk-and-spur topology similar to and-spur doesn’t allow a ring network at “A star topology is simple because it
Foundation Fieldbus, which can deliver the field-switch level, users can imple- mainly involves connecting switches to
power from the trunk’s supply and cou- ment a daisy chain, which Ethernet-APL field switches and production devices,
plings, including IS switches. While trunk- calls “cascade mode.” even though it’s limited to 200-300
meters,” says Fritsch. “It’s classic Eth-
ernet that’s well understood. However,
it’s still important to check cable ca-
pacity and measure resistance because
Ethernet-APL spurs use Type A fieldbus
cable that isn’t always common in the
Ethernet world. Where they probably
used lower-quality, unshielded 4-20
mA wire before, they may now need
better-quality shielded, twisted-pair
cable or higher-quality Type A. It’s not
cheap, but more and less costly cable
will likely be certified Ethernet-APL-
compliant as demand increases.”
Fristch advises potential Ethernet-APL
users to determine what cable, param-
eters and other data they’ll need by con-
sulting the 118-page “Ethernet-APL engi-
neer guide” at https://www.ethernet-apl.
org/wp-content/uploads/APL-Engineering-
Guideline-V114_1.14.pdf.
To transition to Ethernet-APL once
switches and other components that sup-
port it are available, Emerson’s Kravitz
recommends that users develop a thor-
ough plan that lets Ethernet-APL convey
both the traditional process signals they
are used to originating via 4-20 mA, as
well as the rich datasets from devices
that have been traditionally underutilized
in smart process devices. However, if

We make HART accessible a process application or facility doesn’t

already have a regular Ethernet network,
it will be necessary to install one before
Connect your HART devices to Ethernet Ethernet-APL devices are deployed in
You’ve already invested in HART. Why not put that brownfield applications.
investment to work? Remote, real-time access to “The key is to have one solution that
process data increases efficiency and productivity. supports both Ethernet-APL and tradi-
Support the NAMUR Open Architecture and tional protocols and signals simultane-
Open Process Automation initiatives in your plant ously,” adds Kravitz. “Pepperl+Fuchs,
with a HART gateway from Phoenix Contact. Phoenix Contact, R. Stahl and Softing are
testing Ethernet-APL switches, and we’re
Follow the link to learn more benefits of unlocking HART
https://www.phoenixcontact.com/us-HART_Flyer updating our CHARMS modules with a
distributed carrier backplane that allows
an Ethernet-APL I/O channel alongside
the other traditional I/O signals it supports.
This Ethernet-APL capable CHARMs
solution will be available in the upcom-
© PHOENIX CONTACT 2022

www.controlglobal.com
 ETHERNET-APL
Vortex Flowmeter
VY Series debut

ETHERNET-APL AT A GLANCE As the inventor of the vortex flowmeter,

Yokogawa is bringing
Here are some vital statistics for Ethernet Advanced Physical
Layer (Ethernet-APL) networking technology:
the vortex technology to a new era
• Two-wire Ethernet physical layer (IEEE 800.2.3) for trunks up
to 1,000 meters and spurs up to 200 meters
• Provides high-speed communications of 10 megabits per sec-
ond (Mbits/sec) down to field-level devices
• Speed and distance designated as 10Base0T1L
• Communicates using Ethernet protocols, such as TCP/IP, Profi-
net, EtherNet/IP, HART IP, Modbus TCP/IP and others
• Based on existing IEEE 802.3CG single-pair Ethernet (SPE) stan-
dard, and added power restrictions defined by IEC TS 60079-47
technical specification for two-wire IS Ethernet (2-WISE).
• Administered by the Ethernet-APL organization at www.
ethernet-apl.org
• D eveloped over seven years and launched in April 2021 and Au-
gust 2022 by the Ethernet-APL organization’s four standards de- ● Realization of condition based maintenance by
velopment organizations (SDO), including the FieldComm Group, Visit our website
remote maintenance and self diagnostic

Profibus/Profinet Intenrational, ODVA and the OPC Foundation ● Inheriting the structure of the digitalYEWFLO Series
and Yokogawa's long history of achievements
• The Ethernet-APL organization’s 12 supplier members include
ABB, Emerson, Endress+Hauser, Krohne, Pepperl+Fuchs,
Phoenix Contact, Samson, Rockwell Automation, Siemens, R.
Stahl, VEGA and Yokogawa

2305CT_Yokogawa.indd 1 4/20/23 4:18 PM

ing DeltaV version 16 release timeframe. Today, we have a DeltaV

PK controller than can communicate with Ethernet-APL devices
through available Ethernet-APL switches. Beyond this, we’re al-
lowing devices to communicate with more than the DCS they
usually talk to. This will let intelligent field devices more effectively
communicate their own health and maintenance information.
Ethernet-APL is better at pulling in this kind of intelligence, which
helps users know when to act before faults happen.”

Endress+Hauser sets a good example

In a further boost to applying Ethernet in IS locations,
Endress+Hauser (eh.digital/launch-ethernet-apl) reported March
30 that it just conducted two successful load tests of a realistic
Ethernet-APL setup at its headquarters in Reinach, Switzer-
land. The tests were designed with end-user specifications from —
BASF and hardware from ABB, Endress+Hauser, Honeywell and
Connect the physical
Pepperl+Fuchs. Together, they report the tests demonstrated
that components from different manufacturers can combine to
and digital world to
create a reliable, robust Ethernet-APL system. unlock the power of data
The first test involved nearly 240 Endress+Hauser measur-
ing devices, including flow, pressure, temperature and level ABB Ability™ SmartMaster is the next generation
sensors. They were networked via Ethernet-APL and Profinet condition-monitoring platform designed for
industrial plants. Learn how it can send valuable
with Pepperl+Fuchs’ field switches and Honeywell’s con- data straight from the field, helping you efficiently
manage your instrumentation base.
trol system. The second test used ABB’s control system, and abb.com/measurement

www.controlglobal.com Let’s write the future. Together.

 ETHERNET-APL

tested it along with the field switches and measuring devices

used in the first test (Figure 3).
Endress+Hauser reports the result of both tests showed that
Ethernet-APL could be used in realistic circumstances. This is
because the tests were carried out with a maximum-sized network
layout, and Endress+Hauser adds the scalability and fault toler-
ance of the devices, controllers and network were successfully
verified. It also states that all relevant requirements, such as total
netload or redundancy switchover times, were met or exceeded.
“The load tests proved that Ethernet-APL can be used for
real. The components from various manufacturers work together
smoothly, and the systems run reliably,” says Jörg Reinkensmeier,
head of the Open Integration partner program at Endress+Hauser,
whose supplier members supported the tests. “We’re proud that Figure 3: Endress+Hauser load tested an Ethernet-APL network and
the close cooperation with our Open Integration partners made it components by integrating 238 field devices into an Ethernet-APL
possible to validate this technology. We’ve reached the milestone system at its headquarters in Reinach, Switzerland. It deployed field
of bringing Ethernet to the field level of process automation.” switches from Pepperl+Fuchs and controls from Honeywell and ABB.
Tim Shope, VP of digital transformation solutions at The two tests found that Ethernet-APL provided increased bandwidth
Endress+Hauser, adds, “Ethernet-APL will be an enabler to the and speed for easier data access and improved transmission from the
Open Process Automation Standard’s (O-PAS) vision of connect- field. Source: Endress+Hauser
ing field devices and getting more data than is available via 4-20

mA and HART. It also extends and builds on the physical Ethernet

architecture via protocols like Profinet, Modbus-TCP and EtherNet/
IP,” says Shope. “Once we get these protocols on Ethernet-APL,
Digital upgrade we’ll be able to communicate and interoperate via switches.”
Shope reports that Endress+Hauser plans to roll out three pro-
for HART and tocols on Ethernet-APL over the next two years. These include
Modbus field devices Profinet, Modbus TCP/IP and EtherNet/IP. These connections and
Ethernet-APL’s extended reach will allow process industry users to
take advantage of Ethernet’s pervasiveness as its experienced in
the mainstream IT, business and consumer realms.
commKit “Many people use Ethernet via the Internet frequently for tasks
like shopping online. Ethernet-APL gets us closer to that level, so
instruments can have a better chance of telling us what’s wrong,”
says Shope. “For example, we tied our Netilion Health condition
monitor via a REST API to cloud-based CMMS data, which allowed
the device order parts and services to fix them. As Ethernet-APL
gets more prevalent, users will be able to access production data
in their field instruments and check the health of those devices
without going through the usual I/O and control system.”
“Ethernet-APL also opens a lot of potential opportunities for
interoperability between intelligent field devices with a common in-
terface. If one device talks EtherNet/IP and another talks Profinet,
they’ll still need a gateway to translate, which could mean added
time and labor for configuration and programming. However, even
Our commKit is a complete package of hardware, software and
customer-specific consulting that allows you to quickly and easily these tasks are getting easier because organizations like ODVA
upgrade your HART or Modbus field devices for FOUNDATION Fieldbus are working on templates to unify the integration that harmonizes
or PROFIBUS PA. It saves you extensive programming effort and gives
you a digital communication interface for modern applications. Profibus, EtherNet/IP and other protocols. These profiles enable
https://industrial.softing.com an Endress+Hauser flowmeter to appear the same on the network
as another manufacturer’s flowmeter and gives us the interoper-
ability we need.”

50 • MAY 2023 www.controlglobal.com

2305CT_Softing.indd 1 4/6/23 10:44 AM

 ENVIRONMENTAL MONITORING

New refinery streamlines CO2 contribution to the Alberta Carbon Trunk Line and saves $6 million

YOU may have started up the first major refinery

in North America in 35 years, but what have you
done for me lately?
This was the not-so-subtle challenge faced by
Northwest Redwater (NWR) Partnership and its
NWR Sturgeon Refinery (nwrsturgeonrefinery.
com) shortly after it completed the first of three
design phases and went fully operational in
2020. However, the same spirit that drove NWR
and partners including Spartan Controls
(www.spartancontrols.com) to design and
build the refinery in Redwater, Alberta, Can-
ada, continues to fuel their efforts to use
automation to increase efficiency, reliability
and sustainability, too.
“The mission of this early stage was devel-
oping a maintenance and reliability program
to increase the efficiency of field technology
resources, spares management, maintenance scheduling and
uptime,” said Jamin Hrebeniuk, instrument asset specialist at
Spartan Controls. “However, maintaining uptime means reducing
some hidden risks beyond the usual maintenance costs. These
include environmental regulations, monitoring asset health, hav-
ing parts available to avoid supply chain issues and using labor
resources efficiently.”
Hrebeniuk and Harmandeep Sangha, maintenance specialist
at NWR, presented “Leveraging predictive maintenance for ef-
ficiency and reliability at a world-class refinery” at the Emerson
Exchange event last October.
Figure 1: Located 60 km north of Edmonton, NWR Sturgeon Refinery
Sustainability and finding failures processes 79,000 bpd of diluted bitumen into several products, but it
Located 60 kilometers north of Edmonton, NWR Sturgeon turns also contributes 1.2-1.4 MMt/y of CO2 as a feedstock to the 240-km
bitumen from northern Alberta’s oil sands region into diesel fuel Alberta Carbon Trunk Line (ACTL). ACTL works with partners Nutrien,
for a variety of automotive and other uses. It completed the first of Wolf and Enhance to transport and inject CO2 in wells to improve oil
three design phases before starting up, and presently processes recovery operations, and captures CO2 for permanent storage. NWR
79,000 barrels per day (bpd) of diluted bitumen into ultra-low- is predicting equipment failures and catching issues earlier with
sulfur diesel, low-sulfur vacuum gas oil, diluent and naphtha, and Emerson’s AMS Device Manager software and AMS Snap-On software.
butane and propane. Source: NWR

www.controlglobal.com MAY 2023 • 51

ENVIRONMENTAL MONITORING

However, the refinery also supports sustainability by produc- Streamline commission and startup
ing CO2 as a key feedstock for the 240-kilometer Alberta Carbon NWR Sturgeon and Spartan Controls also collaborated during
Trunk Line (ACTL), which injects CO2 in wells to improve oil re- Phase 1 to develop support functions for the refinery based on:
covery operations and captures CO2 for permanent storage. ACTL • Using a range of asset criticality levels and AMS Alert Tem-
is reported to be the world’s largest pipeline for manmade CO2 plates for determining required diagnostics levels by criticality
and has a capacity of 14.6 million metric tons per year (MMt/y) to and establishing a baseline.
which NWR Sturgeon contributes 1.2-1.4 MMt/y (Figure 1). • Conducting failure-mode analyses that are application-specific
To maintain efficiency and reliability, predict failures and re- by using AMS diagnostics and alerts to find problems.
duce downtime, Hrebeniuk reported that NWR Sturgeon is seek- • Developing job plans, procedures and application-specific
ing to predict failures closer to the points where they can start to maintenance strategies, and finding efficiencies with AMS best
be detected. This is done by catching issues early with Emerson practices.
AMS Device Manager software, and by performing 24/7 asset • Covering more assets with less inventory by developing a spare
monitoring with Emerson’s AMS Snap-On software and other parts optimization plan and making it part of the overall inven-
best practices. tory management process.
NWR Sturgeon monitors and collects data from more than
8,700 smart instruments, 261 wireless transmitters, 1,261 con- Hrebeniuk reported that NWR Sturgeon benefitted by using sev-
trol valves with smart positioners and 7,324 smart transmitters. eral labor-saving, digitalized technologies during commissioning
They’re networked via Emerson’s CHARMS electronic I/O, Wire- and startup:
lessHART protocol and wireless I/O cards to DeltaV distributed • Where technicians could typically only examine one device at
control system (DCS) and AMS Device Manager. a time in various locations, AMS users could access thousands

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2211CT_HawkMeasurement.indd 1 10/27/22 1:19 PM

52 • MAY 2023 www.controlglobal.com
 ENVIRONMENTAL MONITORING

of devices from a remote location and • After passing a stoke test, a low CV • A loose valve stem coupling block was
view multiple plant points at once. solenoid was discovered by an updated found and had “play” in the connection
• Without digital links, managers have ValveLink diagnostics test, which in- with the valve stroking after both the
limited access to technicians, and com- cludes the valve signature and perfor- travel Hi-Hi and the travel Lo-Lo alerts
munications, questions and progress mance/step test. became active in the alert monitor.
updates are a challenge. However, AMS
users can easily interface with opera-
tions and engineering colleagues.
• With data on paper, information ac-
curacy depends on possibly years-old
documentation by prior technicians,
and questions often remain about who
made what changes and when. With
AMS, changes are logged digitally in
its audit trail, and setups and other ac-
tions can be compared to digital project
documentation.

Because the more than 8,700 smart

instruments at NWR Sturgeon had di-
agnostics configured, they could also
show items like “valve installed” signa-
tures and performance tests indicating
who touched them last before servic-
ing. They could also support on-the-fly
operational support, troubleshooting
and audit configurations. Finally, device
groups were organized based on as-
set criticality, and as an initial baseline,
alerts were enabled according to critical-
ity and application-specific maintenance
strategies. AMS Alert Monitor and Valve-
Link were configured, and devices were
set up for documentation. This allowed
live operations to begin.
“It’s important to have valve assem-
bly baselines because of whatever may
happen in the future. You want to be the
last one to touch a device, so it’s ready in
OEM condition,” said Hrebeniuk. “We ran
ours in 2018, and during a small outage in
2019, we noticed some friction in a valve
at the top end of its travel. This let us ex-
amine it during a planned outage in 2022,
and schedule and budget for a repair.”

Other problems and fixes identified

during commissioning and baseline test-
ing included:
• Air supply root valve not fully open-
ing, which could have caused startup
delays.

www.controlglobal.com MAY 2023 • 53

2303CT_ControlStation-REV.indd 1 2/17/23 8:52

ENVIRONMENTAL MONITORING

Indicators raise awareness

Once the NWR Sturgeon refinery started
normal operations in 2020, AMS Device
Manager continued to play a big role,
according to Sangha. For instance, AMS
Specialist detects and validates alerts,
performs initial investigations to deter-
mine causes and severity, and corrects
minor issues or enters a detailed work
order (WO) into Maximo software. These
WOs are approved or rejected by deci-
sion makers, and corrective jobs are
planned as short-order opportunities or
deferred to a future outage.
“We have to prioritize because some- Figure 2: NWR Sturgeon refinery also uses Emerson’s ValveLink software to capture and
times we can’t bring a process down, monitor wear to valve seats and plugs. In a BFW pump valve, for example, potential wear
or there’s a long lead time to make a to a seat or plug can be indicated when a valve continues traveling negatively at 0% set-
repair,” said Sangha. “If a boiler or other point. This notification can give users more time to proactively order parts and schedule
super-critical process needs to be fixed, repairs before complete failures occur. Source: NWR
then it’s often deferred, though we try to
correct them before they became major
reliability issues. If any of these problems tively order parts and schedule repairs Snap-On software verifies inline and in-
are recurring bad actors, we also work before complete failures (Figure 2). service performances with 90-second
with our reliability improvement team “We also got a low air supply alert that online tests.
(RIT) to decide what to do.” was captured by a status monitor doing “This is more efficient than traditional
For example, to prevent a boiler feed- a baseline test for steady-state supply methods that are risky due to removing,
water (BFW) trip, NWR’s staff ran a pressure,” added Sangha. “The supply transporting, testing and reinstalling de-
valve signature for the BFW valve and pressure was low-active, and because vices,” added Hrebeniuk. “Likewise, AMS
found that a piston ring was damaged. poor valve control can equal a boiler trip QuickCheck Snap-On software and its
So, it was repaired during an outage, risk, a work order was submitted. We check sheets eliminate human errors be-
“as found” and “as left” signatures were found that a gauge on a regulator was cause we’re using live data with a date/
recorded, and it returned to satisfactory leaking; the leak was repaired and pres- time stamp. It also flags configuration
performance. The “as found” section of sure returned to the expected value.” error that may have been introduced at
the Maximo WO system is where friction some point and gives us a digital report.”
was reported on the upper end of the Regulations and results Sangha estimates that NWR Sturgeon’s
BFW valve’s travel, and recommendation Hrebeniuk added that testing and implementation of AMS Device Manager
section is where the inspection and failed baselining NWR Sturgeon’s valves and and AMS Snap-On have saved the refin-
seal ring were documented. other systems also help it comply with ery more than $6 million, which is largely
Similarly, wear to valve seats and plugs Alberta’s regulatory and reporting re- attributable to maintenance efficiencies
can be captured and monitored with quirements. These include the Alberta because the software is leveraged sus-
ValveLink software’s travel Lo-Lo alert. Energy Regulator (AER), which cov- tainably and saves on labor. “Our present
In a BFW pump valve, potential wear to ers the development of hydrocarbon maintenance program produces AMS-
a seat or plug can be indicated when a resources, and the province’s Technol- generated WOs, which drives consistent
valve continues traveling negatively at 0% ogy Innovation and Emissions Reduction value for NWR,” said Sandha. “More than
setpoint. Sangha reported this notifica- (TIER) rules on greenhouses gases. For 600 predictive and proactive AMS Alert
tion can give users more time to proac- instance, AMS Smart Meter Verification Monitor WOs have been generated and
executed. Plus, the data feedback we get
provides high value to operations and our
“Our maintenance program produces AMS-generated work orders RIT for turnaround planning. And, third-
(WO) that drive value for NWR. More than 600 predictive and party, auditor-approved regulatory compli-
proactive AMS Alert Monitor WOs have been executed.” ance is easy to manage with AMS-focused
work processes.”

54 • MAY 2023 www.controlglobal.com

 DEVELOP YOUR POTENTIAL

BY R. RUSSELL RHINEHART

YOU FIRST NEED TO WEIGH THE PROS AND CONS OF THE VARIABLES IN PLAY

THERE are several techniques that enhance PID controllers, to heat something to a target temperature depends on the pro-
termed advanced regulatory control. These were developed in cess inflow rate as well as its temperature. The steam flow rate
the 1930s and 1940s, and include reset feedback to prevent is proportional to the composite calculated value of the load,
windup, override to prevent excessive or unsafe conditions, Q? = F?C_p (T_SP-T_inflow).
and feedforward to correct an anticipated upset. Also, they The secondary (inner) loop needs to be faster than the pri-
include ratio, cascade, decouplers, gain scheduling, output mary loop for this method to offer an advantage. Some engineers
characterization and various forms of model-based adjust- use the rule of (?+3?)_secondary < ?1/5 (?+3?)?_primary.
ment. These techniques remain very useful today. Tune the secondary controller in the inner loop first, then
tune the primary controller with the inner in AUTO. To the
Ratio control bottom line primary controller, the inner loop is just part of the process.
If you notice that one process variable should be a ratio of If you tune the secondary after the primary, this changes the
(proportional to, a fraction of, scaled to or a similarly named primary’s view of the process dynamics.
relation) another influence variable (or to a calculated load or Ideally, you could calculate the ratio from first principles think-
demand), consider ratio control. In ratio control, the output of ing, and not need the primary outer-loop controller. However, real-
the primary (supervisory) controller is the desired ratio, which ity requires feedback from the primary controller to compensate
is multiplied by the wild variable/demand/load value to become for calibration errors of secondary sensors, as well as unmodeled
the setpoint for a secondary controller. and non-ideal effects.
The wild variable is usually a flow rate, but it could be a com- In ratio control, compensation happens as soon as the
pound variable calculated from material and energy balances input change is detected, which is nearly as soon as the vari-
such as a heat load. For example, the required steam flow rate able changes (given lags in sensors, controllers and valves).

www.controlglobal.com MAY 2023 • 55

 DEVELOP YOUR POTENTIAL

If the input change won’t affect the

process for a while (perhaps because
load calculations are based on far up- AT
additive
stream measurements), then the ratio
will cause compensation to happen too product
soon, creating an upset. If dynamic
compensation is needed to match the
wild
timing of the control action to the pro-
cess response to the disturbance, then
use feedforward. Figure 1: Illustration of a blending process

Blending example of ratio

Figure 1 illustrates a blending process Figure 2 illustrates a primitive control “Valve, go to 53% open.” If the valve
as an example. The wild flow is process strategy. If the reported composition is is air-to-open (fail-closed), abbreviated
stream. The additive, which may be off-target, the analysis recording controller as ATO or FC, then the ARC needs to
called a titrant, is added. The additive (ARC) adjusts the valve in the additive line act in reverse. If the analysis of additive
may be to adjust composition, pH or to return the product to the correct com- composition goes down, the controller
temperature, for example. Here it’s con- position. This primitive strategy works. output must increase to open the valve
sidered composition, and the analyzer It‘s worth noting that, if the ARC were to compensate.
transmitter (AT) measures and reports talking to the valve in English and using Here’s a problem: if the wild flow rate
the mixed-stream composition. engineering units, it would be saying, increases, control action is delayed.
The AT won’t detect the change until
after the transport delay from the mix
point to the sample point. Then, lags or
delays in the AT won’t instantly report
the full deviation. As the composition
deviation is reported, the controller be-
gins to respond, but the integral has a
time-constant and will create a second
lag. Finally, as the controller instructs
the valve to change position, the valve
will create an additional lag due to ac-
tuator dynamics. Eventually, the con-
troller will return the composition to the
setpoint, but not until the delay(s) and
several dynamic lags have passed. Dur-
ing this time, there will be a persistent
composition deviation.
Consider ratio. If the wild flow rate
doubles, then the additive flow rate
should also double. Rather than waiting
for feedback correction, double the addi-
tive flow rate as soon as the new wild flow
rate is detected.
Figure 3 illustrates a ratio strategy.
Here, the wild flow rate is measured, and
the ARC determines a flow-rate ratio.
This ratio multiplies the wild flow rate,
which becomes the flow rate setpoint for
the lower-level (secondary, inner) control-
ler. The secondary controller is within a
standard, flow-control loop.

56 • MAY 2023 www.controlglobal.com

CD_HammondMfg.indd 1 12/22/22 9:14 AM

 DEVELOP YOUR POTENTIAL

SP
now it might be saying, “Hey, x-function,
ARC use 0.125 as the ratio.” The x-operation
will also hear the wild FT say, “Hey, x-
block, the wild flow rate is 220 gpm.” The
AT
additive x-block will multiply the two numbers,
then tell the secondary flow controller,
product “Hey, FT, your setpoint is 27.5 gpm.”
In this case, the ARC continues to
be reverse-acting. If the analysis value
wild
goes down, the ARC needs to increase
Figure 2: A primitive control strategy its output, the ratio, to raise the flow rate
setpoint to correct the deviation. In some
ratio applications, the primary controller
The analyzer may be relatively noise- may have the valve on bypass. If so, the might change direction, for example, if
less, and the ARC may be PID. But the ARC will wind up to its limit of 0% or the valve were air-to-close.
flow loop is probably a bit noisy and fast- 100%. To keep its bias at the right value, The ERF signal must be the same as
acting, so the secondary should be PID. use the actual flow rate ratio as an exter- what the controller would be saying if it
It could be that the ARC isn’t in control nal reset feedback (ERF) signal. were in charge. It’s the actual flow rate
for any number of reasons, such as the The ratio strategy creates a role ratio that might not be what the ARC
valve getting stuck or reaching a limit. change for the ARC. The ARC is now wants (an operator could be adjusting
FIC may be in manual. Instrument techs talking to the multiplication block, and the valve, the valve may be at a limit, the

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www.controlglobal.com MAY 2023 • 57
DEVELOP YOUR POTENTIAL

secondary controller could be in MAN

mode). Use the lowest level transmitters erf
in the control hierarchy to determine the FIC
SP
ERF signal value. SP ARC X
There’s a strong similarity of the in-
FT
ner- and outer-loop structure between
ratio and cascade. But the difference is AT
additive
that, in cascade, the primary controller
sends a setpoint to the secondary con- product
troller. Meanwhile, in ratio, the primary
sends a ratio to a multiplication opera-
wild
tion, which sends the setpoint to the
FT
secondary.

Scaled signal calculations Figure 3: A ratio strategy with ERF

If the signals and messaging between
devices were in engineering units repre-
senting flow rates in gpm and tempera- Then multiply: • Ratio is easy to understand from a pro-
tures in oF, it would be easy for a process Product = 220 gpmW?0.125 gpmA / cess engineer’s viewpoint, using values
engineer to understand the ratio strat- gpmW = 27.5 gpmA and units of the process variables.
egy. But, of course, all these values are However, it probably needs to be imple-
scaled values in the 0% to 100% range. Then convert the product to the mented in scaled signal calculations.
As a result, the x-block needs to have 0-100% range that matches the additive •R elative to a more primitive control strat-
an operation that keeps variable values flow range for the secondary controller. If egy, ratio required two new flow trans-
consistent with the mechanistic mean- this is 0 to 125 gpm, then: mitters and a new controller. The cost
ing. For example, if the flow transmitter is of installation and maintenance of these
scaled so that 0% to 100% matches the xBlock = (27.5-0) gpmA / (125-0) gpmA devices needs to be considered when
0 to 500 gpm range, its output isn’t 220 (100-0)% = 22% the control benefit of adding ratio is being
gpm, but it is: considered.
Similarly, the divide block needs to • The inner loop needs to be about five
FT = (220-0) gpm / first convert scaled signals to their pro- times faster than the outer loop for ratio
(500-0) gpm (100-0)% = 44% (1) cess units. So, do the division and con- to provide a substantial benefit.
vert the ratio to the appropriate scaled • If the load is based on far upstream
If the ARC output is scaled so its full signal range for the ARC. If the wild flow measurements, the delay in needing to
range of 0% to 100% matches a ratio rate is zero, then the divide operation change the additive may require a delay
range of 0 to 0.2, then its output is: will encounter an execution error. If so, in the ratio implementation. Feedfor-
it needs a calculation override, and a re- ward might be a better solution.
ARC = ((0.125-0) gpmA / gpmW) / portable default value, perhaps the last • ERF is not a requirement for ratio. It’s
((0.2-0) gpmA / gpmW) (100-0)% = prior executable value. a complication to implement, and it
62.5% (2) If you choose ratio in your control de- may only solve a brief issue after some
vices, it might ask for the ranges and do infrequent situations. I like it, but others
The x-operation shouldn’t multiply the scaled signal conversions for you. But may weigh the performance pros and
44% times 62.5%, obtaining 2,750%^2. it might not. implementation cons differently, and
What it must do is reconvert the 44% to choose not to include ERF.
the wild flow rate value and the 62.5% Notes about Ratio
to the desired ratio, using the inverse of • The ratio control action happens im- Russ Rhinehart started his career in the pro-
Equations (1) and (2). mediately (as far as possible consider- cess industry. After 13 years and rising to
ing lags in sensors and final elements engineering supervisor, he transferred to a
Fwild = ((44-0)) / ((100-0)) (500-0) = and delays in scan times) when the 31-year academic career. Now “retired,” he
220 gpmW demand/load is detected. This prevents enjoys coaching professionals through books,
Ratio = ((62.5-0)) / (100-0)) (0.2-0) = demand/load changes from upsetting articles, short courses and postings on his
0.125 gpmA / gpmW the controlled variable. website at www.r3eda.com.

58 • MAY 2023 www.controlglobal.com

 ASK THE EXPERTS

Configuring feedforward control of

heat transfer
Feedforward control can anticipate the error that’s likely to occur as soon as the load starts to change

Q: We have a large heat exchanger under feed- While feedforward models can be steady- This column is moderated
back control. When the load changes, we experi- state, changes in the system dynamics or er- by Béla Lipták, who is
ence a temporary but substantial error in the con- rors in temperature measurement or the control also the editor of the
trolled outlet temperature. The heating medium models upon an upset will still cause the loops Instrument Engineers’
is steam. I’m told that feedforward control could to allow some error to occur. If you want to Handbook (5th Edition:
reduce the upset in the outlet temperature. How minimize this error, you should add cascade https://www.isa.org/products/
should we configure a feedforward loop? What op- trimming to the feedforward model to provide instrument-and-automation-
tions do we have for configuring it? dynamic compensation. In general, static feed- engineers-handbook-proce).

Z. FRIEDMANN forward control can cut the PID error by approx- If you have a question
control engineer imately half, while dynamic feedforward loops concerning measurement,
reduce the error to about 10% of the feedback control, optimization or
A1: When controlling the outlet temperature of a error (Figure 1). automation, please send
heat exchanger by using feedback control, you The heat balance of a steam-heated heat ex- it to: liptakbela@aol.com.
should realize that, even if the PID loop is tuned changer can be stated as: F1Cp(T2-T1) = Ws s When you send a question,
correctly, corrective action can only start when Where: please include full name,
an error has already developed. By comparison, F1 = flow of the incoming process fluid affiliation and title.
feedforward control can anticipate the error that’s CP = heat capacity of the process fluid
likely to occur as soon as the load (incoming pro- T2 = controlled outlet temperature of the
cess fluid flow or temperature) starts to change. process fluid
If correctly "modeled," it can cancel or reduce the T1 = incoming temperature of the process fluid
upset that the load change would cause in the WS = heating media (steam) flow
outlet temperature. S = latent heat given up by the condensing steam

PID control
Temperature

Static
feedforward

Dynamic
feedforward

0 30 60 90 120 150 180 210 240

Time, s

Figure 1: Reductions in the upsets in outlet temperature if the heat exchanger is controlled by PID feedback
control, static feedforward control or dynamic feedforward control

www.controlglobal.com MAY 2023 • 59

ASK THE EXPERTS

Cascade secondary Cascade primary

Solving the equation for steam flow of feedback loop of feedback loop
(Ws), the required steam flow Ws is: T1 – + m TIC
2 SP
Ws = W (Cp/ s) (T2 - T1).
Cp / s (T2 required)
In the case of a static feedforward m - T1 Steam
control loop, the ratio between the heat
SP FIC F2 FT
capacity of the process fluid (Cp) and the X X 2 2
latent heat of steam ( s) are estimated, W5 T2
F1 (Cp / s)
but not measured. If either change,
the static model becomes inaccurate. F1 (Cp / s)(m - T1)
For this reason, it’s desirable to add a T1 – F1 –
feedback cascade loop (Figure 2) that
corrects the model for changes in that Process Fluid
TT FT TT
ratio by generating a correcting signal 1 1 2
(m), which is included in the value of the
setpoint of the slave controller (FIC-2). T
In this configuration, the setpoint of the
Cond.
cascade master (TIC-2) is the required
process fluid outlet temperature (T2) and Figure 2: Feedforward heat exchanger control loop with dynamic feedback cascade trimming
the setpoint of the cascade secondary
(FIC-2) is corrected by the master output
signal (m), which corrects for the varia- Helium tank
tions in the heat capacity ratio (Cp/ s). (Cryogenic high pressure gas) Two stage pressurization valve
The feedback controller (TIC -2)
PCV
PT
should have an integral to eliminate any
H3
steady-state offset error that could be PSV
caused by sensors, model or the calcu-
lation errors, so it will respond only to PSV
the changes in the heat capacity ratio. Check valves
PT PT
Also, the dynamic compensator should
be tuned with the feedback controller in PCV: Pressure control valve
manual, so the integrated error will be
PT: Pressure transmitter
PSV: Pressure safety valves
zero before feedback is added. CH4 O2
BÉLA LIPTÁK
liptakbela@aol.com
Liquid methane tank Liquid oxygen tank
Q: How can automation and control (Cryogenic under 300 bar pressure) (Cryogenic under 300 bar pressure)
professionals contribute to the success
of the SpaceX project? On April 18, a Figure 3: SpaceX pressurization system
launch was cancelled due to pressuriza-
tion problems. It was briefly successful before ignition. This is provided by the mation and control engineer would have
on April 20, though a minute after liftoff, simple pressure control loop (Figure 3). warned that successfully igniting 33 en-
the rocket started to tumble and had to On April 18, this charge valve (PCV) gines at exactly the same time is rather
be destroyed. froze, and the test had to be canceled. If unlikely and therefore balancing controls
an automation and control engineer had are needed. One option is to balance the
A1: For the 33 engines that lift the enor- designed the system, this freezing poten- rocket by making the lifting force of some
mous rocket to operate smoothly, both tial would probably have been realized of the engines adjustable (variable fuel
the cryogenic liquid fuel and the cryo- and the PCV would have been heated flow) and throttle them to compensate
genic liquid oxygen tanks must be under before ignition, or absolutely dry helium for force that’s lost due to the failure of
stable, constant pressure. This is guaran- would have been used, so there would some engine(s). This balancing algorithm
teed by charging the top of these liquids have been nothing to freeze. should have the feedforward format,
with super-cooled, high-pressure (around As to the rocket's tumbling, followed so that tumbling is anticipated and cor-
300 bars) helium gas in the two tanks by its destruction on April 20, an auto- rected before it starts.

60 • MAY 2023 www.controlglobal.com

 ROUNDUP

Level stays level-headed

Frequency modulated continuous wave, Ethernet-APL enable accuracy in difficult, hazardous settings

FLOATS SWITCHES WITH ¾-INCH CONNECTIONS FMCW WITH BLUETOOTH OR 80 GHZ FAST-SWEEP
Low-cost FLS-VM-800 float Rosemount 3408 level transmitter is
switches have a ¾-inch PVC a non-contacting radar device that
pipe fitting for use in HVAC optimizes ease-of-use at every touch-
condensate lines, while FLS- poin; uses frequency modulated
VD series includes a ¾-inch continuous wave (FMCW) technology
MNPT connection for mounting for accurate, reliable measurements,
to most standard ¾-inch bungs even in challenging environments,
in 55-gallon drums. They include top- and side-mount float and is SIL 2-certified according to the
switches in medium and large sizes, and are made of various IEC 61508 functional safety standard.
materials for compatibility with liquid types, temperature ranges, Likewise, Rosemount 1208 level and flow, non-contacting radar
and system pressures. ProSense switches are UL recognized, transmitters feature 80 GHz, fast-sweep FMCW on one electronic
CE marked, RoHS compliant, and have a one-year warranty. chip, which delivers accurate and reliable measurement.
AUTOMATIONDIRECT EMERSON
www.automationdirect.com/float-level-switches Emerson.com/Rosemount3408 or Emerson.com/Rosemount1208

RIGOROUS RADAR WITH ETHERNET-APL LONG RANGE IN EXTREME SETTINGS

Micropilot FMR63B 80 GHz radar T30R is a long-range radar sensor from
level sensor is built for hygiene re- Banner Engineering that provides reli-
quirements, turbulent surfaces, and able detection and position feedback
foam formation and buildup without in extreme applications. The sensor
contacting the medium—and uses can precisely distinguish between
Ethernet-APL for hazardous areas. targets and filter out unwanted ones,
It employs patented Heartbeat Veri- even in the presence of moisture or varying
fication radar accuracy index (RAI) temperature conditions. T30R provides reli-
to assess instrument accuracy without process interruption, so able detection of high-dielectric targets (such
results are traceable and ISO90001 compliant. FMR63B meets as metal or large amounts of water) and lower-
standards, such as EHEDG, 3-A and ASME BPE. dielectric materials (such as wood, rock or organic
ENDRESS+HAUSER material) in a wider range of applications.
www.endress.com/en/field-instruments-overview/level-measurement/ DIGI-KEY ELECTRONICS
Radar-Micropilot-FMR63B www.digikey.com

FLOAT SWITCHES FOR SIMPLE LIMITS INTRINSICALLY SAFE PULSE RADAR UP TO 65.6 FT
Float switches are used for simple limit value Intrinsically safe (IS), 26 GHz, pulse radar trans-
detection in liquids. These mitters from Flowline provide continuous level
switches consist of a measurement up to 65.6 feet (20 meters) with
float body with a built- a 4-20 mA analog and HART digital signal
in switching element output, and are configured via their integral
and connection cable. pushbutton display module or HART commu-
Initiators and micro-switches serve as a switch- nicator. Their non-contact liquid level sensor is
ing element, which shifts when it crosses the horizontal position intended for chemical or bulk storage or process
in either direction. They can be connected to an intrinsically safe applications in above- or below-grade tanks of
(IS) switch isolator for operating in approved hazardous area any material.
location. They also feature a sleeve or ball design, and are avail- RS (FORMERLY ALLIED ELECTRONICS
able in various lengths and cable types. & AUTOMATION)
PEPPERL+FUCHS us.rs-online.com/product/flowline/lr21-5321-30-
www.pepperl-fuchs.com 01/71000728

www.controlglobal.com MAY 2023 • 61

ROUNDUP

SWITCHES FOR LIGHTWEIGHT, FLUFFY POWDERS FMCW RADAR FOR SOLIDS AND LIQUIDS
CL-10 G Series level detectors W-200 Pilotrek is a compact, 80
provide accurate, consis- GHz, frequency modulated, continu-
tent results for lightweight or ous wave (FMCW) radar transmitter
fluffy products or bulk solids for solids and liquids. Its new WES
that pack or bridge easily. series model is a two-wire, 24 VDC,
They handle precipitated, loop-powered radar transmitter, which
fine, lightweight chemical uses the highly accurate FMCW tech-
powders with densities as low as 1 pound per cubic foot (lb/ft3). nique. WES operates as low as 12 volts
They manage foods such as 12x milled products to silk sugar, as DC, and provides ±0.078-inch accuracy,
well as heavier solids in the 10-15 lbs/ft3 range. CL-10 G is fac- 0.039-inch resolution. It also has up to 98
tory calibrated with no adjustments necessary. Specialized units feet range, 7° beam angle, and measures di-
handle temperatures exceeding 300 °F. electrics as low as 1.9.
DYNATROL DIVISION OF AUTOMATION PRODUCTS INC. NIVELCO USA LLC
800-231-2062; www.dynatrolusa.com 630-848-2100; Nivelco.com

CAPACITIVE PROXIMITY, ADJUSTABLE SENSING SONAR BED CAN MEASURE TWO DENSITIES
Capacitive proximity sensors from Carlo Gavazzi of- Orca Sonar Bed level system measures up
fer an adjustable sensing distance of 2-10 mm to two density interfaces simultaneously.
flush or 3-15 mm non-flush, and are avail- Typically, these are bed levels/RAS blanket
able in 12 mm (about 0.47 inch), 18 and floc/fluff layers. Its sonar produces a
mm (about 0.71 inch), and 30 mm high-power concentrated beam. Orca also
(about 1.18 inch) diameters with features dual, independent analog outputs
AC and DC outputs. These pat- to track two different interfaces, or clarity
ented Tripleshield sensors are simultaneously, with one sonar sensor. They
tested to withstand electrostatic also have easy calibration to track specific
discharges up to 40 KV, line density interfaces, industrial scum cleaning
transients up to 4 KV, and airborne mechanisms that don’t require mainte-
noise up to 15 V/m. nance, no wiper blade assemblies.
GALCO HAWK MEASUREMENT
www.galco.com 888-429-5538; www.HawkMeasurement.com

RADAR CHIP TAILORED TO USER SPECS DIAPHRAGM SEAL WITH COMPENSATING CAPILLARY
VEGAPULS 6X is a radar sen- EJXC80A with compensation capillary
sor for level measurement of type diaphragm seal is the latest in
liquids or bulk solids. Users the EJX differential pressure level
simply specify their application series. The compensating capil-
details using VEGA’s online configu- lary balances the volume and
rator, and receive a VEGAPULS 6X built temperature of fill fluids between
for their needs. Powered by VEGA’s cus- high and low pressure side capil-
tom radar chip, 6X is capable of highly precise and reli- laries. EJXC80A reduces the influence of ambient temperature
able measurements independent of process conditions like dust drift caused by day-to-night, season-to-season, or shady-to-
or high temperatures. And now, VEGAPULS 6X is also certified sunny swings. Combined with DPharp sensor, this solution pro-
to meet IEC 62443.4.2 cybersecurity standards, making it the vides stability for all DP level measurements.
ideal level sensor for Industry 4.0 processes. YOKOGAWA
VEGA AMERICAS www.yokogawa.com/us/solutions/products-platforms/field-instruments/
www.vega.com/radar pressure-transmitters/diaphragm-seal-system

62 • MAY 2023 www.controlglobal.com

 CLASSIFIED

EQUIPMENT & MATERIALS

Revitalize your SIEMENS system

WIDE ANGLE, VIEWABLE AT 250 FEET
1100 Series magnetic level indicator (MLI)
uses its patented, 200° vista viewing angle to
provide the most visible level indication. It’s
easy to read from 250 feet (76 meters). 1100
Series MLI includes nitrogen-purged and
sealed indicators. It also complies with EU Di-
rective 2014/68/EU (PED), ASME B31.1 and/or
ASME B31.3. With designs for flashing/boiling
and cryogenic services, SOR can customize a Get your SIEMENS Spares & Repairs
MLI for the most rigorous process conditions. ClassicAutomation.com
SOR INC.
913-888-2630; www.sorinc.com/products/mag-
netic-level-indicators/1100-series-magnetic-level-
indicators
AD1INDEX
2305CT_ClassicAutomation-CF.indd 4/13/23 3:16 PM

ABB Management Services...................................... 49

COMPACT, NO-MOVING-PARTS, POLYSULFONE
AutomationDirect....................................................... 2
ELS-1100 series single-point, optical level switch from
Gems Sensors is a compact, no-moving-parts, Azbil.......................................................................... 47

polysulfone level sensor with built-in switch- Beckhoff Automation............................................... 35

ing electronics. It's available Control Station......................................................... 53
with varied mountings, power
Digi-Key Electronics.................................................. 4
requirements and electrical ter-
minations. ELS-1100 is suitable Emerson Automation Solutions............................... 44
for high, low or intermediate Emerson Process Management............................... 68
level detection. Installation is simple and quick through the tank Endress+Hauser........................................ 6, 7, 11 - 26
top, bottom or side. The sensor offers ±1 mm repeatability and
Fieldcomm Group..................................................... 43
broad liquid compatibility. It's not recommended for liquids that
crystallize or leave a solid residue. Hammond Mfg........................................................... 56

NEWARK Hawk Measurement.................................................. 52

www.newark.com
Microcyber................................................................ 46

Moore Industries...................................................... 42
CONTINUOUS MEASUREMENT AND PUMP CONTROL
Sitrans LT500 HydroR- Pepperl+Fuchs................................................... 32, 33
anger is a digital level Phoenix Contact....................................................... 48
flow and pump controller
R. Stahl...................................................................... 45
for radar and ultrasonic
Rosemount Emerson.................................... 31, 38, 39
transmitters or any two-
wire, 4-20 mA device. Softing Industrial..................................................... 50
It’s used for radar sensor SOR............................................................................ 57
measurements at 80 GHz, and features single- and dual-point
Temposonics............................................................. 36
measurements, six relays and extensive datalogging capabilities.
Trihedral Engineering................................................ 3
It also has a full suite of pump control functions and diagnostics,
and can communicate via Modbus RTU, HART, Profibus DP and Vega Americas............................................................ 8
PA and Profinet protocols. Yokogawa Electric Corp........................................... 49
SIEMENS
800-365-8766; www.usa.siemens.com/level

www.controlglobal.com MAY 2023 • 63

 CONTROL TALK

Talking machine learning, deep

learning and nonlinear controls
Why you should be intrigued, and why you should be cautious

I was impressed with a presentation by Vivek Delta-Ps (differential pressure) in high-reflux

R. Dabholkar, titled “Engineered DMC models columns have been transformed by using scaled
with incremental mass balance constraints,” and internal reflux flow, log or piece-wise linear trans-
his comments on nonlinear control at the AIChE formation for tower compositions, and the list goes
2023 Spring Meeting. AIChE is an organization on. Even for the hard problem of pH control, I
for chemical engineers. We’re fortunate to take came across “Characterizer for control loops” by
a break from the conversations with my mentor F. G. Shinskey, May 1999, where both setpoint
self and have Dabholkar, principal APC engi- and PV of a pH control loop must be transformed.
neer at Ineos Group’s olefins plant in Chocolate Essentially, the transformed pH PID output moves
Bayou, Texas, give his view on new technologies. very slowly, where rise in pH is rapid because the
perceived deviation seen by the PID algorithm is
GREG: What are your thoughts on recent devel- small in the transformed domain, but moves rap-
opments in machine learning, deep learning and idly where change in pH is small or nearly “flat.”
nonlinear controls?
GREG MCMILLAN GREG: The benefits of using signal characteriza-
VIVEK: On one hand, I want to embrace new tion to linearize process variables (PV) and manip-
Gregory K. McMillan captures the ideas to implement them in industrial systems, ulated variables (MV) are extensive. The dynamics
wisdom of talented leaders in keeping pace with modern developments, but from open-loop response tests aren’t size- and
process control, and adds his underlying fundamentals tell me otherwise. The operating-point dependent and filtering of noise
perspective based on more than “sacred golden” principle of superposition is is more effective. Without signal characterization,
50 years of experience, cartoons only valid for linear systems, no exceptions. In the open-loop, self-regulating process gain ap-
by Ted Williams, and (web-only) other words, one can’t superimpose the effect of proaches the slope of the plot of PV versus MV for
Top 10 lists. Find more of Greg's past independent moves along with the calcu- small steps, but becomes quite different for larger
conceptual and principle-based lated future independent moves to calculate their steps spanning various changes in slope. The
knowledge in his Control Talk blog. combined effect on controlled variables. This is a change in slope can be a magnitude or more for
Greg welcomes comments and col- fundamental hurdle in practical applications of so- pH systems and nonlinear installed flow charac-
umn suggestions at ControlTalk@ called “nonlinear control.” teristics of control valves. Without signal charac-
endeavorb2b.com terization, the beneficial effects of a process time
GREG: How are linear controllers able to cope constant from the residence time in a well-mixed
with the nonlinearity encountered in practice? volume can be lost.

VIVEK: Over the years, APC engineers learned to GREG: How does a linear multivariable controller
implement global linearization of control valves with handle fast (front-end)/slow (back-end) dynamics,
respect to flow. The range of operation change in for example, in the case of an olefins plant where
the transformed valve, which is essentially a scaled composite/CLP is implemented?
flow, is linear with respect to flow. As a result, ev-
erything of interest in the transformed domain still VIVEK: Since the steady-state targets for the
behaves linearly, and the end results are anti-trans- front- and back-end constraints aren’t dynamically
formed, so they can be understood by the opera- aligned, APC engineers traditionally used CVStep
tors and engineers. This idea was also employed to (steady-state change in CV target) for up and
control level in the horizontal drums within high/low down directions to limit total furnace feed move-
limits by linearizing the level response accounting ment, so feed is pushed slowly against the back-
for the change in surface area based on the dis- end (cold-side). There are issues with this ap-
tance of level from the central plane. proach, especially with respect to CVStep-down;

64 • MAY 2023 www.controlglobal.com

 CONTROL TALK

this is when MPC gives up on feed-limit- ditions may be significant. I’ve extensively limits, rate limits and dead band. Replac-
ing, back-end constraints for a few cycles used procedure automation to automate ing PID and MPC is potentially unsafe.
depending on size of CVStep down. This difficult compressor and unit operation
is the main reason I don’t like using small startups based on learning what opera- GREG: What are the opportunities for
CVStep-down to restrict feed-cutting. tors have done and what first-principle neural networks?
Often, the CVstep-up is programmed dynamic process simulations confirm are
in a monotonically decreasing staircase good sequences. VIVEK: I’m not an expert in applica-
pattern, knowing the history of total feed Before we move on to machine learn- tion of neural networks, and I’ve yet to
the back-end constraints can handle. But ing we need to start with knowledge witness a working multivariable control
this results in abrupt changes to CVStep from plant operations, first principles, application. Once again, the principle of
around the transition points. Based on open loop tests, and what experts have superposition is a big hurdle. However,
total furnace feed, one can revise this documented in the ISA-TR106.00.01 and neural networks may be used in inferen-
based on smoother piece-wise linear ISA-TR106.00.02 technical reports on tial measurement (soft sensor) develop-
function (PWLN) with respect to total procedure automation. See the Control ment, with a good amount of validation
feed. Unfortunately, even this approach Talk Column “Continuous improvement and cross-checking on selected variables
leaves money on the table as feed push- of continuous processes” with the leader using PCA to avoid unreliable results.
ing capability is greatly reduced during of this technology. They can be used for pattern detection
the summer vs. winter. I’ve used variable A major concern is the unrealistic applied to fault detection and diagnosis
node values for total feed in the PWLN expectation that machine learning can by studying variable movements prior to,
function to account for seasonality. replace PID and MPC in the process in- for example, equipment failures in the
Another approach was first introduced dustries. For machine control, the dead past. This know-how could then be ap-
by Doug Raven, an engineering special- times are usually insignificant, and the plied to predict failures before they hap-
ist at Saudi Aramco. The idea is to push servo mechanism response is fast and pen. They could also predict raw material
the front-end, feed flow-manipulated precise. In the process industry, the prices based on past patterns among
variable further into the future by using dead times can be large and vary with many variables and discrete events along
lower, move-suppression multipliers on operating point, and the control valves with the current events that could trigger
furnace feeds. The lets the controller and variable speed drives have resolution similar responses.
move smaller at first, so the back-end
has a chance to respond. Care must be
taken not to overdo it, or else important
front-end furnace constraints, such O2
and draft output may not be adequately
honored dynamically.

GREG: Do you foresee any applications

of machine learning in the chemical in-
dustry or refineries?

VIVEK: I see applications where a

lot of manual steps are required with
the lack of repeatability, for example,
procedure-based decoking of furnaces.
It would free operators from constantly
watching the process over a long pe-
riod of time and would lead to consis-
tently safe transitions.

GREG: I think the potential for machine

learning to supplement procedure auto-
mation for handling startups, shutdowns, Visit ControlGlobal.com for an extended version of this column and to see the Top 10 things
transitions and abnormal operating con- you don’t want to hear from executives.

www.controlglobal.com MAY 2023 • 65

 CONTROL REPORT

What's left unsaid

Make sure that Ethernet protocols will perform as needed

AMONG other beats, I’ve covered industrial net- Profinet, Modbus-TCP and a few others, can be
working, fieldbuses, Ethernet and wireless long present on the same physical Ethernet network.
enough to know their primary definitions and However, their components can only talk to and
capabilities. I've observed how they’ve evolved interoperate with other devices that use the same
over the years and where they’re likely going. It’s protocol. Equipment using different protocols typi-
my loss that I’ve never plugged in anything more cally can’t talk to each other directly.
complex than a stereo speaker or laptop, but I’ve Unfortunately, this situation seemingly hasn’t
covered hundreds of people who developed, de- changed with the advent of Ethernet-Advanced
signed, integrated, installed and maintained them, Physical Layer (APL) built using single-pair Eth-
and I remember much of what they had to say. ernet (SPE) standard. Its physical networking can
The latest batch are in this issue’s “Ethernet-APL now reach devices in intrinsically safe (IS) applica-
gears up” cover story (p. 40). tions, but if they’re not using the same protocol,
At one long-ago tradeshow, I remember the they can’t talk and interoperate in hazardous ar-
JIM MONTAGUE debut of EtherNet/IP as the heir to the DeviceNet eas either.
Executive Editor protocol. More than a few visitors were visibly Oh sure, much progress has been made on
jmontague@endeavorb2b.com upset. This was because many felt its promoters adding switches and gateways that can translate
were trying to unfairly take over the Ethernet TCP/ between protocols. And, many of these functions
IP name that was long used to describe generic have been combined in unified modules and/or
“Plug and test before Ethernet defined by the IEEE 802.3 standards. It taken over by software. Despite these improve-
implementation, or you was as if someone had flagrantly overreached by ments, translating between devices using different
may want to throw a trying to name their product “computer” or “Inter- Ethernet-based protocols still requires added time,
little, plastic football at net,” and claim those well-known and long-ac- money and labor to implement, and adds latency
someone’s head.” cepted nouns for their exclusive use. I also recall to their communications.
that the booth or one near it was giving out little, More recently, advocates of the Ethernet-based
green-and-white, plastic footballs, and several at- protocols stop short of claiming outright interoper-
tendees had to restrain themselves from heaving ability for them, especially when faced with skepti-
them at the EtherNet/IP supporters. cism or pressed for details and proof. However,
Naturally, this initial outrage died down to I can still feel what they want to promote, and I
barely a whisper over the years, and EtherNet/IP guess it’s understandable. If you’ve been conflat-
prospered. However, it remained as one of those ing “open” with “interoperability” for 20 years to
gaps that never gets filled, particularly because preserve market share for a supplier, it’s probably
some parties apparently keep making it wider. At impossible to start truly advocating for users now.
least a dozen times over the years, sources have Heck, many suppliers used to claim that Ethernet
told me that EtherNet/IP is “open” and “interoper- itself couldn’t be used on plant floors until they
able” with devices using other Ethernet protocols. couldn’t deny it any longer. Today, Ethernet is all
This bit of misdirection begins by using these two over those plant floors.
words interchangeably, even though they repre- Fortunately, more testing and plugfest events
sent very different concepts. are being staged by users and system integrators
The full deception is revealed when users learn to check that devices using Ethernet-APL and the
that generic Ethernet is a physical-layer standard other Ethernet-based based protocols will function
that only defines the wire and connections, while as needed, and hopefully provide sufficient in-
its Transfer Control Protocol/Internet Protocol teroperability, too. So, plug and test before imple-
(TCP/IP) only covers their interfaces. This means mentation, or you may also want to throw a little,
that many different protocols, such as EtherNet/IP, plastic football at someone’s head.

66 • MAY 2023 www.controlglobal.com

 Measure • Control • Manage • Visualize • Network • Protect

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