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Whilst every effort is made to ensure technical accuracy of the information supplied on iceweb.com.au, Keyfleet Pty Ltd and its employees accept no liability for any loss or damage caused by error or omission from the data supplied. Users should make and rely on their own independent inquiries. By accessing the site users accept this condition
Posted by: Jim Russell, June 2013
Tips For Starting An Alarm Management Program - Kim Van Camp and Todd Stauffer - Using The ISA-18.2 Standard Can Help Process Engineers Understand, Simplify, And Implement A Sustainable Alarm Management Program. This article presents four practical tips for starting an effective and sustainable alarm management program that conforms to the tenets of a relatively new process industry standard for alarm management published by ISA - from Emerson Process Management.
Thermistors As Accurate Temperature Sensors - Introduction and Methods - Darren O'Connor, and Kasandra O'Malia - This two-part article describes how to use a simple voltage divider circuit with a thermistor to achieve high-accuracy temperature readings over broad measurement ranges. Part 1 discusses the circuit and various temperature estimation methods. Part 2 of this two-part article shows a method to a real-world application and how, by combining estimation methods with thermistor characterization data, high accuracy measurements can be achieved over a wide temperature range using the simple voltage divider circuit - from Sensors Magazine.
Posted by: Jim Russell, May 2013
Sight
Glass Selection and Maintenance Tips Webinar - Glass is a critical
element in process observation equipment, and understanding the properties
of glass is important for proper specification.
This streaming video webinar covers the physical characteristics of
glass, ways to maximize its strengths and minimize its weaknesses, plus
sight glass safety and maintenance –
You will have to register to access this Webinar -
On-line Engineering Tutorial on Sight Glass Technology as it applies to chemical processing and pharmaceutical processing. You will have to register to download this webinar. This free webinar begins with an overview of the essential aspects of glass, noting the various formulations used in chemical, food and pharmaceutical process observation equipment. Concentrating on sight glass selection, installation, and proper maintenance, the webinar explains how to safely and effectively use sight glasses in process applications ranging from standard lines to exceptionally demanding applications with high temperature, high pressure, and sanitary requirements.
LED
Lighting for Sight Glass Applications
Step-by-Step Guide to Sight Glass Selection - Sight glass components allow operators to safely observe processes inside tanks, pipes, reactors and vessels. When it comes to selecting a sight glass, a wide variety of factors should be considered in order to ensure optimal performance. The guidelines that follow give tips and step-by-step advice on how to best select the ideal sight glass for a specific application. Start by defining the process to be observed, with considerations given to temperature, pressure, impact, physical characteristics of the process media, flow, and whether or not the process has sanitary requirements. With these factors in mind, one can begin the process of selecting the type of sight glass that best suits the needs of the process - From L.J. Star Inc.
The following videos are from Tofino
Security, it is recommended that they are viewed in the following sequence;
(1) What
is Cyber Security? - Our
modern lifestyle relies on critical infrastructure and industrial plants
that use complex networks of computers, PLC controllers, remote terminal
units and other specialized equipment. However as these industrial networks
have become more complex and interconnected, Cyber Security becomes more and
more important to ensure their continued safe and reliable operation. This
video examines the current state of cyber security in SCADA and industrial
control networks, talks about how we got to this point, and lays the
foundation for discussing how to improve the security of these systems.
(2) We're
Secure - We Have A Firewall! - Many companies already use firewalls to
isolate the plant and enterprise networks. What's so bad about this
approach? Aren't these networks already protected? In this video, we'll
explore the types of cyber security issues we often see in plant networks
and learn how these issues can impact plant operations in spite of these
firewalls.
(3) Security
Strategies that Work on the Plant Floor - The previous video in this
series showed that a firewall on the plant network could not protect us
against many cyber security threats. But if that doesn't work, then what ARE
we supposed to do to protect our plant? IT engineers have been dealing with
cyber security issues for years. This video examines the security strategies
that they have found to work, and see how we can implement them on the plant
floor.
(4) Why
Is Cyber Security still a Problem in SCADA and Control Networks? - IT
engineers have been dealing successfully with cyber security issues for
years, and there are many security products in daily use in enterprise
networks. Why is cyber security such a challenge on control networks? Why
can't the same tools and techniques be used to secure these systems? The
answers to these questions lie in understanding the unique requirements of
control and SCADA networks, and applying cyber security strategies in ways
that are appropriate to these applications.
(5) How
does Tofino Protect my Plant? - Previous videos in this series have
discussed how Defense in Depth can be an effective strategy to secure
control networks. So how exactly does Tofino implement Defense in Depth? And
what makes it the best solution? This video takes a deeper dive into the
components of the Tofino Industrial Security Solution, and examines how they
work together to implement cyber security on the plant floor.
Study Of Flow Instability And Its Implication On A Severe Service Control Valve Using Computational Fluid Dynamics (CFD) - Jeetendra Singh and Sudhakar Paranjothi Rajan - Some valve designs use finned plugs to divide the flow through the seat area into multiple, smaller jets in order to reduce the effective jet diameter, which helps in reducing the noise level in the valve. In this design flow instability develops inside the valve which creates high rotational moment on plug assembly. Anti-rotation pin is used to arrest rotation of plug. In some cases, the turbulent flow can be so severe as to result in the anti-rotation pin breaking. In this paper, analyses have been carried out to study flow instability and its implication on the rotational moment produced.
Mokveld Subsea Control Valves Service Norwegian Oil Field - One of the technology gaps to be addressed was the development of large fast-acting subsea control valves. Several operators recognised the unique advantages of Mokveld's axial flow design in topside severe service control applications and approached Mokveld to investigate the axial flow concept as the basis for a subsea control valve.
Large Size Quarter Turn Control Valves can Improve Safety in Pipelines - Carlos Lorusso - Most control valve applications in pipelines are related to system start-up and shut down, emergency operations, delivery control, fluid speed control for pipeline internal examination. Selection of the right control valve is a key factor for long term successful performance for large applications where the safety and security of supply are important considerations. This document presents considerations for control valve selection to improve the safety and operation of oil and gas pipelines. Axial control valves are used when high pressure drop, high flow coefficients, low noise levels and bubble tight shut-off are required. Common applications include compressor start-up, shut-down and High Integrity Pressure Protection Systems (HIPPS). Triple offset valves (TOV) are used for large volume flow control, bubble tight shutoff, pressure drops of less than 30%.Typical applications include delivery point and controlled blow down. Ball valves are used for speed control for intelligent pig travel during pipeline examination and cleaning operations - from Tyco and pipeline conference.
Mokveld Choke Valves, a Concept that Works - Chokes are critical for the safe and economic production of the world’s oil and gas reserves. In the past simple needle-and-seat chokes were adequate as pressure cuts were low and the applications of adjustable chokes were less demanding. Also, in that era, adjustable chokes employing the rotating disc principle provided satisfactory performance. A number of factors have changed the demands on chokes. Operating pressures have increased. Safety and reliability are becoming increasingly important. And finally, the economics of the equipment, seen over the life of the field, are vital for the profitable development of the field. The new challenge was met by Mokveld with a proven expertise in control valves. Mokveld pioneered in the use of cages in production chokes. A cage-type choke has a multiple-orifice cylinder - the cage - and a piston which is connected to the stem. The movement of the piston modulates the area of the fluid passage. As a result of the impingement effect generated in the cage-type design, the erosive action of the fluid is fully under control. Also, noise is reduced to safe levels.
High Integrity Pressure Protection System (HIPPS) - Andrew Chu - A High Integrity Pressure Protection System (HIPPS) is a Safety Instrumented System (SIS) designed to prevent an unsafe condition caused by pressure arising (e.g. due to separator outlet blocked in the choke valve downstream, blocked pipeline, etc). The decision to utilize a HIPPS in addition of utilize a PSV shall be based on the study of risk. The aim of this study is to determine a certain SIL requirement. This study will conclude whether some process condition need to have a HIPPS or its ok to protect it by a PSV valve only - from the Instrument Engineers Blogspot.
HIPPS ...for Cost-Effective Risk Reduction - Ken Bingham and Scott Lawson - With the oil and gas sector booming, many hydrocarbon processing facilities are trying to increase production to meet rising demand. These plants, initially designed and engineered, sometimes decades ago, to deliver a specific level of production, are being expanded or revamped in some way. When new gas production sources are tied into a gas plant, for example, the existing pipelines and processing equipment face the risk of overpressure in excess of design capacity. This may result in the unplanned release of hydrocarbons into the atmosphere via a triggering of a mechanical relief device such as a PSV (pressure safety valve), the undesirable burning of these hydrocarbons through the flare system or the worst case scenario of a rupture, fire and explosion. With the adoption of various standards including ASME, API, and the performance based, non-prescriptive standards IEC 61508 and IEC 61511, conventional thinking is evolving to include the application of high reliability safety instrumented systems (SIS) to replace and lessen the need for additional PSVs and expanded flare systems. HIPPS, an abbreviation for high integrity pressure protection system, is a specific application of a SIS designed in accordance with IEC 61508 which is growing in popularity. With HIPPS, the protection against overpressure is achieved by quickly isolating the source causing the overpressure, as compared to conventional relief systems where the overpressure is relieved to atmosphere - from ACM.
Optimizing Pressure in Subsea pipes with HIPPS - Jacob G. Hoseth, Bernard Humphrey - Most of the ‘easy’ oil fields have now been discovered, making it likely that new fields will be more difficult to develop than in the past. For those fields where high pressure is the main technical challenge, a subsea High Integrity Pipeline Protection System (HIPPS) which, by confining the high pressures to the wellhead area, allows existing infrastructure to be used. When subsea HIPPS is installed, the flowline and riser pipe wall thickness can be rated to just the flowing pressure. A modularized, flexible system, subsea HIPPS helps oilfield operators to reduce the cost of developing pipeline solutions without compromising safety - from ABB.
API RP 17O - Recommended Practice for Subsea High Integrity Pressure Protection System (HIPPS) - This RP addresses the requirements for the use of high integrity pressure protection systems (HIPPS) for subsea applications. API 14C, IEC 61508, and IEC 61511 specify the requirements for onshore, topsides and subsea safety instrumented systems (SIS) and are applicable to HIPPS, which are designed to autonomously isolate downstream facilities from overpressure situations. This document integrates these requirements to address the specific needs of subsea production. These requirements cover the HIPPS pressure sensors, logic solver, shutdown valves and ancillary devices including testing, communications and monitoring subsystems. You will need to purchase this standard.
HIPPS-Based No-Burst Design of Flowlines and Risers - Nikolaos Politis, Hugh Banon, and Christopher Curran - A methodology is proposed for design of subsea flowlines and risers coupled with a subsea high-integrity pressure protection system (HIPPS) for fields with high shut-in tubing pressure (SITP). The proposed approach uses a design pressure that is lower than the SITP while maintaining a high reliability against burst failure. This approach enables an inherently safer design and ensures that the system integrity is not compromised in the unlikely event that HIPPS valves fail to close upon demand. The proposed design methodology is supported by a combination of analytical and experimental results. Further, an example is provided for demonstration purposes - from spe.org
DNV HIPPS - An introduction to High Integrity Pressure Protection System (HIPPS) as utilised on high pressure Subsea Systems - from DNV.
Subsea HIPPS - HIPPS is an instrumented safety system that is designed and built in accordance with the IEC 61508 and IEC 61511 standards. Additionally API RP 17O – Recommended Practice for Subsea HIPPS - provides guidelines for using the IEC standards in subsea systems. These international standards refer to safety functions (SF) and Safety Instrumented systems (SIS) when discussing a solution to protect equipment, personnel and environment. A system that closes the source of over-pressure within 2 seconds with a determined reliability level is usually identified as a HIPPS. A subsea HIPPS is a complete functional loop consisting of; (a) The initiators that detect the high pressure (b) A logic solver, which processes the input from the initiators to an output to the final element and (c) The final elements, that actually perform the corrective action in the field by bringing the process to a safe state. The final element consists of a valve and fail safe actuator and possibly solenoids.
Checklist for Pressure Sensor Selection - 15 Tips to Ensure Performance Meets Your Expectations - Elden Tolman - We have all experienced the frustration of a problematic sensor, even when the supplier tells us everything seems to be working properly. What we often find is that while the sensor may be “working,” it is often not the right sensor for the application. Successful pressure measurement usually comes down to one thing—selecting the right sensor for your application. There are so many considerations that it is easy to overlook a key element until it’s too late. Nearly a decade of working with pressure sensors in various applications has convinced me that the most common reason for problematic pressure measurements is the failure to select the right sensor. Even industry veterans can fall into this fine spun trap. This article presents 15 fundamental considerations when selecting a pressure-sensing device- from Flow Control Network.
Specifying A Pressure Transducer – How To Select Pressure Range And Device Type - Mitch Berkson and Dave Field - When choosing a pressure transducer for a particular application, usually the first question which arises is: “For what pressure range should the transducer be rated?” This simple question begets a bevy of related ones, namely: “What is the pressure range in which the device typically operates? Does the device occasionally need to measure pressures outside this range? What pressure must the device withstand and still operate within specification when returned to its normal range? What pressure must the device withstand without failing even if it will function properly after returning to the normal operating range?” Closely related to the pressure specification is the type of device to choose - absolute, gage or sealed gage. The following sections will first address pressure selection and then device type - from Sensata.
Posted by: Jim Russell, April 2013
****
Flammable Facts Poster - This poster from MTL gives a quick look at the most important facts associated with Electrical Equipment in Hazardous Areas.
Equipment Protection Level (EPL) - EN 60079-14 standard of March 2010 introduced a method for risk assessment that considers the equipment levels of protection (EPL). EPLs were introduced to allow an alternative approach to the methods currently used for the selection of Ex equipment. The traditional design approach assigns the appropriate types of protection for specific areas using statistical data, based on how is most likely or frequent an explosive atmosphere. EPL indicates the risk of ignition intrinsic to the equipment, independently from the type of protection adopted. It was recognized that it is advantageous to identify and mark all the products based on their intrinsic risk of ignition. This should make easier the equipment selection. This method is an alternative and not a substitute of the traditional one and so far has created some difficulty in understanding – from Cortem Group.
Hazardous Areas Technical Guide - This publication provides a brief overview of the essential aspects of explosion protection. Ultimately, safety in a potentially explosive atmosphere is a team effort. Manufacturers have a responsibility to ensure only safe equipment is placed on the market. Installers must follow the instructions provided and use the equipment only for its intended purpose. Finally, the user has a duty to inspect and maintain the equipment in a safe working order - from Warom.
Maintaining
Installations In Hazardous Areas - Thomas Klatt and Andreas Hennecke -
Flameproof enclosure (Ex d) and intrinsic safety (Ex i) are very common
equipment protection methods in Process Automation.
One reason to use Exd is the amount of energy which could not be
provided via Exi. This disadvantage has gone with the introduction of
intrinsically safe, dynamic methods of arc prevention such as DART or Power-i.
This white paper shows that when using intrinsic safety, installation,
maintenance and inspection costs will be reduced.
This paper addresses decision makers and professionals responsible
for automation systems in hazardous areas. A good understanding of the
principles of explosion protection is required – from PEPPERL+FUCHS.
Safety
Controls and Burner Management Systems (BMS) on Direct-Fired Multiple Burner
Heaters - Although some detailed and prescriptive guidelines have been
around for many years, the rate and degree of adoption varies significantly
within the industry. Most operating companies have their own “standard”,
which may still vary from facility to facility. In addition to this, for
each installation, it is not unusual for adjacent heaters built two years
apart to have a different BMS design, simply because different engineering
contractors built them. With increasing government legislation and
regulations as well as mounting lawsuits for accidents in which applicable
codes and guidelines have not been adhered to, it is important to review the
BMS requirements for both existing and new heater installations - from
Onquest.
Playing it Safe - How Information Management Technology is essential to meet more stringent Process Safety and Regulatory Compliance - Process Safety and Compliance are universal issues across all the world’s plant industries and individual regulatory authorities are increasingly collaborating to share ideas and to normalise globally consistent, best-practice requirements. These authorities have recognised the potential of Information Management technologies for supporting safe and compliant operations and we can expect to see their use progressively being encouraged, expected and mandated as regulations advance. But the issue is not only one of maintaining regulatory compliance. The US Centre for Chemical Safety claims that an average offshore incident costs an Owner Operator $80 million, so there is a serious economic incentive involved as well.This paper examines current capabilities, opportunities and likely future directions in the application of technology. For convenience, reference will be made to new offshore regulations emerging in the USA, as these are likely to set benchmarks for global regulatory standardisation - from ICEweb Sponsor AVEVA.
Pitting
and Crevice Corrosion of Offshore Stainless Steel Tubing - Gerhard
Schiroky and Anibal Dam - Oil and gas platforms regularly use stainless
steel tubing in process instrumentation and sensing, as well as in chemical
inhibition, hydraulic lines, impulse lines, and utility applications, over a
wide range of temperatures, flows, and pressures. Corrosion of 316 stainless
steel tubing has been observed in offshore applications around the world.
Corrosion is a serious development that can lead to perforations of the
tubing wall and the escape, under pressure, of highly flammable chemicals.
The two prevalent forms of localized corrosion are pitting, often readily
recognizable, and crevice, which can be more difficult to see. Many factors
contribute to the onset of localized corrosion
Corrosion
of Duplex Stainless Steels in Seawater - Bengt Wallén - In the
following paper a review of most types of corrosion occurring in seawater
applications is given. With just a few exceptions, only tests using real
seawater have been taken into consideration. Whenever possible, the
behaviour of superduplex steels is compared with that of super austenitic
steels – from Avesta Sheffield.
It’s Stainless Steel, it Shouldn’t Rust - This is often the kind of statements heard from individuals when discussing a failure of process piping or equipment. It is also an indication of how little is actually understood about stainless steel and the applications where it is used. For years industries have used stainless steels in their process piping systems. Most of the time stainless steel components provide satisfactory results. Occasionally a catastrophic failure will occur. The purpose of the information contained within this document is to bring an understanding to stainless steel, it’s uses, and why it will fail under certain conditions. This paper discusses the different classes of stainless steel, heat treatment, corrosion, welding, and finally material selection. As with any failure, it is imperative the cause of the failure be identified before a proper fix can be recognized. Most often the cause of the failure is identified as the wrong material being used in the wrong application - from CSI.
Rust
on Stainless Steel - Walter J. Sperko - Rust on stainless steel is ugly.
Rust on stainless steel raises a lot of questions. Is the steel really
stainless steel? If it’s stainless, why is it rusted? Where does the rust
come from? Will it continue to rust? Will it spread? Will other forms
of attack occur, such as pitting or stress-corrosion cracking? This paper
addresses these questions for rust that occurs on a tank or pipe that is
made from austenitic stainless steel such as Type 304, 304L, 316, 316L, 321,
317, etc. It covers the sources of rusting, the effect of rust on the
performance of stainless steel and methods for prevention and removal of
rust that appears on the surface of stainless steel components. It applies
to rusting on external surfaces of piping and vessels that are exposed to
the atmosphere, including rain, condensation, fog, etc. but are actually dry
most of the time - from Sperko Engineering Services.
Corrosion
Control And Treatment Manual - This manual provides guidelines for the
control of corrosion of materials in facilities, systems, and equipment at
the John F. Kennedy Space Center (KSC), Florida. It is very comprehensive
– from NASA.
Corrosion
Protection Of Metals - Two methods of combating corrosion which are
widely used in New Zealand are cathodic protection and chemical inhibitors.
Both methods depend on controlling the charge on the metal surface, and this
can be monitored by measuring the potential of the metal. The conditions
needed to stop corrosion can then be predicted from an electrochemical phase
diagram - from NZIC.
Corrosion
and Cathodic Protection Theory - James B. Bushman -
Beginners Guide to Corrosion - Bill Nimmo and Gareth Hinds - This document gives an introduction to corrosion and its control in non-technical terms - from NPL.
Chromatography - The Basics - Chromatography is usually introduced as a technique for separating and/or identifying the components in a mixture. The basic principle is that components in a mixture have different tendencies to adsorb onto a surface or dissolve in a solvent. It is a powerful method in industry, where it is used on a large scale to separate and purify the intermediates and products in various syntheses - from the Royal Society of Chemistry.
Encyclopedia of Analytical Chemistry - The highly-acclaimed Encyclopedia of Analytical Chemistry provides a much-needed professional level reference work for the 21st Century. The Encyclopedia is the most comprehensive analytical chemistry reference available, covering all aspects from theory and instrumentation through to applications and techniques.
Gas Chromatography Troubleshooting Guide - A useful guide for seeking out Gas Chromatograph faults - from msp.
Explosion Protection for Process Analysis - Safe operation up to the explosion limit - Jürgen Poidl and Helmut Schulz - Gas analysers are used for the continuous on line measurement of the composition of process flows in chemical production systems. These measurements provide support to key process functions of controlling and monitoring the temperature, humidity, and chemical composition of gases and liquids. In some cases, commercial considerations and demands are resulting in the operation of production processes in chemical plants increasingly close to the explosion limit. It is therefore essential that the explosion- protected gas analysers used for monitoring the explosion limit continuously supply the necessary and reliable data to the process control systems. Using the special safety systems it is possible to operate gas analysers, the electrical equipment and the safety devices even when the process conditions are close to the limit - from Stahl.
Fire Prevention Requirements for Information and Communication Technology (ICT) rooms - Best Practice Document - This document provides specification of the Norwegian HE sector’s recommended fire protection requirements for ICT rooms. The aim of this document is to raise personnel awareness concerning the fire protection issue, and to enhance the quality of fire protection measures within the sector. Furthermore, it is intended that the recommendations in this document will form the basis of expansion, renovation and new building projects, and that they will be applied in everyday work contexts - from Terena.
Acoustic Volume Mapping - An ideal solution for bulk solids and powders - acoustic volume mapping can help you make informed inventory control and usage decisions. This system measures the volume of bulk solids and powders in any size or shape of storage vessel. It accurately measures bulk solids and powders in any type of container, silo or open bin – regardless of the type of material or product characteristics – to provide continuously reliable volume and inventory information Also it measures challenging applications that were previously not possible, including buildup loads and random irregularities that can occur over time.
The Following Links can be found on ICEweb's Datalogger page which has just been upgraded thanks to our Sponsor HINCO.
Guide to Choosing Occupancy and Light On-Off Data Loggers – 5 Important Considerations - In 2010, the residential and commercial sectors in the United States used approximately 499 billion kilowatt-hours (kWh) of electricity for lighting, equal to 13% of all electricity used nationwide (U.S. Energy Information Administration). In commercial buildings alone, 35% of all energy cost is attributed to lighting (2005 Buildings Energy Data Book, U.S. Department of Energy). Often the first step in any new facilities project is convincing decision makers that a project is worthwhile and will pay off. Before committing to costly equipment upgrades and making changes to electrical systems by installing hard-wired light sensors, it’s a good idea to first acquire data on room occupancy and lighting use in a facility to determine where best to implement permanent changes. Portable occupancy and light on/off data loggers are the solution. They are battery-powered, matchbox-sized devices that can be easily mounted on ceilings, light fixtures, and stairwells – anywhere data are needed.
Using
Data Loggers Beyond Equipment Scheduling -
Brenden Millstein - While data loggers are a great tool for identifying
equipment-scheduling opportunities in buildings, their usefulness far exceeds
just that one function. This paper discusses how the use of inexpensive data
loggers and some spreadsheet analysis can provide all the evidence needed to
make powerful building-specific cases for saving money by replacing failed
air-handler economizers. It also describes how information from data loggers can
be used to accurately calculate the energy savings that can be realized from
variable frequency drives (VFDs) on pumps and fans, supply air resets, and
boiler lockouts.
Analyzing
Air Handling Unit Efficiency
- Michael Rosenberg - Operating a heating, ventilation and air
conditioning (HVAC) system at optimum efficiency in a commercial setting is
complicated, to say the least. There is a very real chance that any number of
setpoints, levels, and feedbacks at boilers, chillers, pumps, fans, air delivery
components and more can cause costly inefficiencies. This 20-page guide,
Analyzing Air Handling Unit Efficiency with Data Loggers, explores the air
handling systems of an office building to illustrate how data loggers can be
used to help optimize their performance. The guide provides 13 best practices
for improving air handler efficiency and reducing costs, while maintaining a
comfortable working environment for building occupants.
Finding
Hidden Energy Waste with Data Loggers - 8 Cost Saving Opportunities -
Paul H. Stiller - The first step to reducing building energy costs is
identifying energy waste. Statistics on utility bills or name plates on
equipment, while useful, are not enough to identify what practices and equipment
are contributing to high energy use. Portable data loggers can be used to obtain
critical energy use information in a wide range of commercial building types –
from manufacturing plants to office buildings. This 12-page best practices
guide, Finding Hidden Energy Waste with Data Loggers, describes the data logging
equipment you need to obtain information on energy consumption and environmental
conditions in commercial buildings. It covers eight common forms of energy
waste, and provides an overview of how to gather and analyze data and calculate
savings for each opportunity.
Top
Ten Alarming Blunders - Proper Alarm Methods Improve Safety, the
Environment, and Plant Profitability - Kevin Brown - Ineffective alarm
systems pose a serious risk to safety, the environment, and plant
profitability. Too often, alarm system effectiveness is unknowingly
undermined by poorly configured alarms. Static alarm settings cannot adapt
to dynamic plant conditions, and many other nuisances result in alarm floods
that overwhelm operators when they instead need concise direction. Alarm
systems are the primary tool for identifying abnormal situations and helping
plant personnel take timely, appropriate action to move their processes back
to operational targets. For operators considering undertaking an alarm
management program, taking the time to examine common alarming blunders is
important to ensure steps are taken to avoid them
Wireless
Plant: Complete Coverage - Becoming an important part of a company’s
infrastructure both outside and inside a plant environment. The wireless
infrastructure can be used for both network and process data communication,
however coexistence must be considered early in the design of plant-wide
wireless systems. This article details a mesh network infrastructure
complete with I/O, gateways and IS equipment capabilities – from MTL.
Who’s Afraid of IEC 61508/61511? - Harvey Dearden - This paper highlights some key issues for owner/operators that may help maintain the right perspective on the requirements as they apply to the limited circumstances that are typical of most process operations. It has to be said that the 61508 standard is something of a monster. That is not to say that we should turn tail and run however. But how are we to respond? The key is to keep the thing in perspective. In detailing a completely comprehensive, rigorous approach for the lifecycle requirements for protection systems from the simplest through to the most complex, the standard does become somewhat impenetrable. Things do improve with 61511, but it still could not be described as an easy read. The intention here is to highlight some key issues for owner/operators that may help you keep the right perspective on the requirements as they apply to the limited circumstances that are more typical of most process operations - from IDC.
Protection
Functions as Probabilistic Filters for Accidents - Andreas Belzner -
“Protection Functions” are instrumented control system functions for
machinery or process installations, which are implemented for preventing
specific accidents. Frequently, such functions induce an emergency shutdown
of the controlled machinery. The over-speed protection function of a turbine
is a typical example. The prevented accidents may affect assets only
(equipment damages, production losses). They may endanger the health and
safety of people, the environment or other values. Since the protection
target is not relevant in the current context, the generic term
“protection function” is used in this paper rather than “safety
instrumented function”. For such protection functions, two sets of
requirements are typically specified; (1) Functional Requirements and (2)
The Importance of a Clear Safety Requirements Specification as Part of the Overall Safety Lifecycle -Andy Crosland - The need for specifying requirements clearly is recognised best practice for most automation projects, so it makes sense to be extra-vigilant when dealing with safety systems. Many project specifications cover functional and user requirements in great detail, but often miss the key safety considerations set out in IEC 61511. As well as the obvious benefits of a clear specification from the outset, the Safety Requirement Specification (SRS) is the essential reference document for the mandatory IEC 61511 Safety Lifecycle task of SIS Safety Validation. You will be shown the key SRS considerations, particularly why this information is so important at Validation time - from IDC.
Functional Safety and Engineering Judgement - Harvey T.Dearden - Discussion of the role of professional judgement in the context of the functional safety standards IEC 61508 and IEC 61511. It is the role of a professional engineer, having acquired the appropriate competencies, to exercise professional judgement with due regard to pertinent guidance. In terms of the functional safety standards, engineers should recognise that we approach compliance asymptotically along a curve of diminishing return; we may approach closer and closer to full compliance, but it requires ever increasing effort and investment. There is a point where the marginal increase in compliance does not warrant the additional effort, which may be more gainfully employed on other safety concerns. Professional judgement must be exercised to identify when this point has been reached - from IDC.
The following links are from ICEweb sponsor IDC
Technologies.
Protection
against Lightning Physical Damage and Life Hazard - SANS 10313:2010
& IEC 62305 Part 2 & 3 Explained - T.J. Manas - This paper covers
the process of assessing the risk of damage caused by lightning and give an
in depth description of the requirements of protecting structures and living
beings against the hazards of lightning - from IDC.
Lightning
Protection for Equipment on MV feeders - WJD van Schalkwyk and M. du
Preez - This paper presents the influence of lighting on MV feeders
supplying small power users (400/230V). Attention is given to insulation
failures leading to poor power quality. In order to minimize power
interruptions, lightning related trips are reduced mainly by minimizing MV
equipment failure. Examples of arc quenching are also studied.
Lightning
Protection of Rail and Related Industries - AM (Bert) Hanekom - The rail
environment is challenging and merciless. The overhead traction structure
literally forms a huge lightning antenna. This requires a systems thinking
approach to protect elements that are rail bound, rail mounted or in close
proximity to the track, against lightning surges. What makes things even
more challenging is the rapid growth in the use of low powered electronic
devices in the rail environment. For example, signaling installations have
evolved from mechanical interlockings to being based on sophisticated
electronic sub elements. Additionally, condition monitoring of the rail
infrastructure has brought in numerous electronic systems. Hence the
critical need for lightning protection in all aspects of the rail network.
The author’s real experience in lighting protection of rail systems is
shared with you.
The
Need to Ensure Energy Co-ordination of Surge Arresters in terms of SANS
10142:2009 section L.1.3.3 - Paul van As - This is a topic which is
regularly overlooked and probably the most common cause for failure of surge
arresters. Many people believe that the more surge arresters you install the
better the level of protection obtained. This is all very well if viewed
purely from a voltage protection perspective but can lead to premature
failure of surge arresters. Cascading of surge arresters based purely on
voltage protection levels without fully understanding energy co-ordination
is a recipe for disaster. Many suppliers of surge arresters tend to sell
their products purely on surge handling ability (kA), reaction time and
clamping voltage. Obviously the surge arrester that reacts the fastest is
the first to operate and hence takes most of the energy. In many cases this
can lead to low energy, fast reacting surge arresters being overstressed
causing damage to equipment. In light of the above problem SANS 10142-1:2009
section L.1.3.3, which states “When more than one SPD is connected on the
same conductor, coordination between them shall be ensured.” Many
manufacturers and sellers of surge arresters have no idea as to how their
surge arresters will react when cascaded with each other. This problem is
further aggravated when different surge arresters from different
manufactures are installed in an installation.
Lightning
Protection for Industrial Plants - Phillip Tompson - This paper provides
an outline of a systematic approach to determine and apply lightning and
surge protection to industrial plants such as water and sewerage and oil and
gas facilities. All too often when lightning strikes an industrial plant,
equipment is damaged and operations curtailed there is an initial rush to
get the plant operational again. This is a reasonable response. Then comes
the question of how to protect the plant against the next lightning strike.
Inevitably the approach taken is ad hoc and the result is very often a
lightning protection system that does nothing to protect the equipment that
was originally damaged. Indeed by taking a systematic approach, applying the
Australian standard, carrying out a risk assessment, then acting upon the
results of that risk assessment both cost effective and successful solutions
can be found.
Accurate
Soil Resistivity Testing for Power System Earthing - Rodney Urban, Karl
Mardira - Soil resistivity data is of fundamental importance in performing
earthing system analysis. Reliable data is required to achieve good
correlation between design and measured earthing system performance. The
findings of numerous soil resistivity tests in the Sydney area for rail
system earthing design is presented in this paper. The installations were
inside the rail corridor where testing was often very restricted or not
possible due to hazards, space limitations and adjacent buried metallic
services or structures. A comparison of the results indicates the possible
variation of soil resistivity at various depths over small distances and how
this can be accommodated in the design process.
Arrester
Earthing Resistance - Tony Gillespie - An analysis of the earthing
resistance for surge arresters on the distribution network. The simplified
analysis is based on lumped parameter circuit impedance values for a
lightning strike.
Power
System Earthing Due Diligence - Gaye E Francis and Richard M Robinson
- There have been two primary paradigms of safety risk management
co-existing uneasily over the last few decades. One is related to hazard
based risk analysis driven by technical professionals using target levels of
risk and/or safety. The other is the precaution based risk analysis driven
by the courts focusing on ‘due diligence’ being a demonstration that all
reasonable practical precautions are in place based on the balance of the
significance of the risk vs the effort required to reduce it. The
publication of the EG-0, Power System Earthing Guide, Part 1: Management
Principles by Energy Networks Australia in May 2010 supports the hazard
based / risk target approach to risk management whilst the impending (2011)
national Model Workplace Health and Safety Act requires a positive duty of
care for responsible officers to exercise ‘due diligence’. This paper
will investigate the underlying conflict between the two positions and the
manner of expected resolution using EG-0 as the focus.
Thanks to ICEweb Sponsor Zedflo
our Laser
Level Instruments and Instrumentation page has been updated with new
links, these include:
- The
Lowdown on Radar Level Measurement - Free-Air or Guided-Wave -- Which Do
You Use When? - Walt Boyes - Radar level measurement is basically divided
into two groups, free-air and guided-wave - from the excellent Control
Global
- Application
Considerations for Continuous Level and Inventory Monitoring of Powder
and Bulk Solids - Continuous level measurement is about one
thing, e.g. answering the question “how much stuff do I have”. There are
many applications where you need to know how much material is in a bin, silo
or other vessel type. Usually the desired engineering unit is expressed in
terms of volume or weight. “Measuring” volume or weight is not always
the most practical approach, sometimes it isn’t even viable. Take those
silos you have, how do you weigh the ingredients if the silos weren’t
installed with load systems? Not an easy or inexpensive question to answer.
So what do we do? This is where continuous level measurement sensors and
systems come into play and offer a viable and cost effective approach.The
purpose of this white paper is to discuss and inform about the application
considerations when you need to measure the level of material continuously
or simply determine on a continuous basis how much stuff you have in your
vessels - whilst this document is about many of the technologies available
it does have a section on Laser level - from Blue Level Technologies.
Thanks to ICEweb Sponsor Zedflo
our Test
and Calibration Instruments page has been updated with new links, these
include:
- Calibration
Intervals, A Manufacturer’s Perspective - David Deaver - The analysis
tools that are currently available for Calibration Intervals focus on setting
intervals to achieve a desired reliability target. This paper suggests there is
another perspective that these tools do not currently address; consequence cost
or accumulated liability. A case is made that sometimes the reliability target
is a secondary consideration to managing this consequence cost. The paper also
addresses how manufacturers establish calibration intervals. The paper presents,
and defends, the practice of using no analysis whatsoever in establishing the
manufacturer's recommended calibration interval - from Fluke.
- Electrical
Measurement Safety Program - Every day, an average of 9,000 U.S. workers
suffer disabling injuries on the job. Anyone
performing electrical measurements should understand the safety standards and be
certain their tools meet code. This page from Fluke is an excellent Safety
Resource.
- Video
- Electrical Measurement Safety - This hour long session provides an
awareness of electrical measurement hazards; a better understanding of the
safety specifications for digital multimeters and testers; an understanding of
the four installation measurement categories and; how to minimize and avoid
electrical measurement hazards- You will need to register to see this video -
from Fluke.
- 10
Mistakes People Make Working on Electrical Systems - Jim White - This
list gets you thinking. We go through life making small mistake after small
mistake and nothing happens, until we happen to get the wrong alignment of small
mistakes and have an accident. Once the accident starts, we have no control over
it, so the best thing to do is to avoid the small mistakes and tighten up the
way we work – from Shermco Industries and Fluke.
Thanks to ICEweb Sponsor Zedflo
our Ultrasonic
Flow Metering page has been updated with new links, these include:
- Clamp-on
Ultrasonic Flowmeters - How they Measure Up - Clamp-on ultrasonic
flowmeters – portable or permanent – are valuable tools for helping
district energy providers, building
owners and managers and others measure and manage their system performance
in a number of ways. These units provide the baseline and load profile
information needed to effectively optimize system efficiency and reduce
energy consumption – and costs - from Siemens.
- How
Can Clamp-On Ultrasonic Flow Meters Identify what Product is Flowing from
Outside the Pipe? - John Accardo -Many
petroleum pipelines flow multiple products such as diesel fuel, gasoline and
jet fuel. Between each of these products lies an interface where the flow
stream transitions from one product to another. Pipeline operating companies
depend on instrumentation to indicate what fluid is in the pipe and when an
interface occurs in order to manage the pipeline’s operations. For
example, flow arriving at a terminal is stored by product type in specific
storage tanks. By knowing when an interface arrives, a valve can be switched
to route the new fluid to its respective tank. Certain additives (e.g., Drag
Reduction Agent “DRA”) may only be injected for specific fluids. So, you
can see that knowing what fluid is presently in the pipe is critical to
proper operation of the pipeline. Using a non-intrusive instrument for this
purpose adds another level of benefits, including low cost installation, no
loss of pressure, no interruption of the DRA, and the ability to allow pig
passage through the measurement point.
- Are
there Differences between Clamp-On Ultrasonic Meters Used for Onshore
Purposes and Those Used for Offshore Projects? - Leslie Bottoms - While
the basic technology used is the same for onshore and offshore projects,
there are some differences between clamp-on ultrasonic meters in these
applications. Offshore environmental conditions require a higher level of
protection from the elements. The
main concern with instrumentation when used offshore is the constant
exposure to salt air and sea spray. This
combination can easily corrode housings and cables which are exposed to the
elements all day, everyday. A
typical onshore application may involve temperature swings from 20 to 110
degrees F, but in most cases, the instruments used in these locations are
generally protected from the sun and rain by sheds or some form of
additional shelter. However,
when located offshore, protection is limited to the instrument enclosure,
due to size and weight limitations. In
addition, temperatures are often exceeded at both ends of the scale.
- Siemens
SITRANS FUS1010 Clamp-On Flowmeter Installation Guideline - In this Video
learn how to get started with the FUS1010 clamp-on ultrasonic flowmeter,
including identifying and selecting sensors, choosing a mounting location and
programming the meter. SITRANS FUS1010 is the most versatile clamp-on meter on
the market today, with maintenance-free external sensors that eliminate the need
to cut the pipe or stop the flow.
- Validating
SITRANS F US Clamp-on Flowmeter Performance - Video - Learn how to use several simple diagnostic tools on any
SITRANS F US clamp-on ultrasonic flowmeter to ensure that the flowmeter is
operating properly and the readings are as accurate as possible. The SITRANS F
US flowmeter line from Siemens provides precise measurement of liquids and gases
and features maintenance-free external sensors that eliminate the need to cut
the pipe or stop the flow.
- Theory
of Operation: Ultrasonic Doppler Flow Meter - This video details how a
Doppler Flow Meter works - from Instruments Direct.
- Theory
of Operation: Ultrasonic Transit Time Flow Meter
Choices in Automated Level Detection-Part 1 and Part 2 – This article provides a useful overview of level instrumentation techniques and technologies – from the excellent processonline.com.au
Posted by: Jim Russell, March 2013
Measuring Flare Gas within the European Union Emissions Trading Scheme - Simon Harwood and Jack Koeken, Sr - Prior to the European Union Emissions Trading Scheme, the measurement of flare gas on oil and gas production facilities in the North Sea was driven mainly by statutory regulations that required operators to simply report emissions to the Environment Agency. Consequently, there was never an economic incentive to install metering equipment. Importantly, depending on the Industry and size of the facility, the Trading Scheme stipulates different levels of accuracy for the instrumentation used to measure both fuel gas and flare gas. For the oil and gas industry, flow meters used to report emissions from flares fall within the Tier 3 accuracy level which, means they must have a degree of uncertainty (accuracy) better than ±7.5 percent of the measured value - from Fluid Components.
A New Paradigm for Thermal Dispersion Mass Flowmeters - John G. Olin - The ASME Standard and Recent Technology Advances - Since the publication of the American Society of Mechanical Engineers (ASME) standard on thermal dispersion mass flowmeters in 2011, there have been major advancements in the technology. A review of that standard and a discussion of technology advancements provide the background to understanding ground breaking innovations in sensor design. That, along with a comprehensive algorithm facilitated by current hyper-fast microprocessors, has created a new paradigm for the measurement of the mass flowrate of gases by means of thermal dispersion technology - from Sierra Instruments.
Thermal Dispersion Mass Flow Measurement Handbook - Accurate mass flow measurement of gas is difficult to obtain. Thermal mass flow technology is a method of gas flow measurement that does not require correction for changes in process temperature or pressure. Thermal mass flow technology also has a benefit of measurement at low velocities and greater turndown capabilities than those obtainable with other gas flow measurement devices.
Tracking Natural Gas with Flowmeters - Wayne Shannon - Thermal mass flowmeters provide advantages over other options for metering the consumption of natural gas by individual combustion units throughout the facility.
Thanks to our sponsor Prochem ICEweb's Tubing,
Instrument Fittings, Heat
Tracing and Bundles, Instrument
Manifolds and Monoflanges
How to Keep Analysers Cool in the Field - Anthony Leong and Martin Hess - Field-based process analysers are often sited in remote environments where they need protecting against harsh environmental conditions, and high daytime temperatures. For optimum performance and reliability, their electronics and sample conditioning systems must be maintained within prescribed temperature limits, requiring that the environmental protection shelter is well insulated and incorporates some form of cooling. Most analyser shelters currently use air conditioning (AC) systems to protect against high temperatures. These are expensive - especially if they need to be explosion-proof - and can account for a high percentage of the capital, energy and maintenance costs of a typical oil or gas analyser installation. Furthermore, they do not easily scale down to suit small shelters, and their performance decreases by as much as two thirds at high ambient temperatures. One recent trend is to employ passive cooling technology. Originally developed for pipeline instrumentation shelters in remote desert locations without an electricity supply, passive cooling systems (PCSs) have been deployed successfully over the past decade - from the excellent Pacetoday.
Expanding plant Networks with WirelessHART - With process instruments getting ‘smarter’ every year, their capabilities are often underutilised. Important data that could help save costs remains unused. This potential can be tapped by using WirelessHART. Intelligent devices, whether they are valve positioners, temperature devices, flow meters or level meters, supply additional data such as secondary process variables or device diagnostics that can be used to obtain a better insight into the process. This data can be made accessible using a HART data transfer protocol. Although new control systems are HART enabled, the many legacy control systems in the field frequently lack the ability to collect HART data. The WirelessHART standard can be used in both retrofit and greenfield installations, providing distinct advantages for each - from Process On-Line.
Innovative Passive Fire Protection Cabinets Extend Margin of Safety for Critical Plant Shutdown Equipment - The cabinets ensure that equipment such as emergency shutdown valves remain operational by keeping them below 60 degrees Centigrade for periods of up to 64 minutes in the event of a hydrocarbon-based fire, to allow time for controlled shutdown - from Intertek,
Understanding Safety Life Cycles - IEC/EN 61508 is the basis for the specification, design, and operation of safety instrumented systems (SIS) - The international standard IEC/EN 61508 has been widely accepted as the basis for the specification, design, and operation of safety instrumented systems (SIS). In general, IEC/EN 61508 uses a formulation based on risk assessment: An assessment of the risk is undertaken and, on the basis of this assessment, the necessary safety integrity level (SIL) is determined for components and systems with safety functions. SIL-evaluated components and systems are intended to reduce the risk associated with a device to a justifiable level or “tolerable risk.” When considering safety in the process industry, there are several relevant national, industry, and company safety standards used when determining and applying safety within a process plant - from ISA and InTech.
Fluid
Density’s Effect on a DP Flow Control Loop – A short but useful
article on how an orifice-plate flowmeter measurement in a flow control loop
is affected by an increase in fluid density – from Spitzer and Boyes
Understanding Safety Integrity Level
(SIL) - Understanding Safety Integrity Level - This brochure targets
safety applications and Emergency Shutdown Systems.
It provides an excellent overview of the concept.
Thanks to our sponsor McCrometer the V-Cone page has been extensively upgraded with more GREAT links to comprehensive technical information.
Posted by: Jim Russell, February 2013
Buying a Temperature Controller? - Understand the Specification Before you Order - Arthur Holland - A review some of the features and specifications of the commonly used discrete panel-mounted controllers. A review of all makes and features is impossible here, so to supplement this column, my best advice is, extend your reading to catalogs, operation manuals, FAQs and web sites of the top manufacturers. Technology help lines are so overloaded that they become impenetrable and direct you to existing sources of help. Rightly so - but be prepared to quarry your way through some hard to read material. With product knowledge in your brain and an eye on your process you can make a sound and economical choice of controller.
Resistor Colour Code Calculator - This calculator displays the value, the tolerance and performs a simple check to verify if the calculated resistance matches one of the EIA standard values - from Hobby-Hour.com
Instrumentation Terminology - Glossary of Terms - from Instrumentation World
Developments in the Field of Electronic Ignition Flaring Systems - With the developments in chemistry and petrochemistry on one hand, and concern for the environment on the other, more and more requirements are being set for the emission of flaring systems. Flaring systems have undergone considerable development, from a pipe with a perpetual flame to a well thought-out combustion system with pilot flame burners, purge gas, steam injection and automatic ignition - from Smitsvonk Holland BV.
Install Electronic Flare Ignition Devices - This technology replaces the intermittently or continuously burning flare pilots with electrical sparking pilots similar to a modern gas stove. These sparking pilots require low electrical power that can be supplied from a battery with solar recharge in remote sites. In addition to using electronic flare ignition devices for pilots, facilities may also install sensors to detect the pilot sensors to detect the pilot flame and shut off fuel gas if the pilot is extinguished - from EPA.
Flare Pilot System Safety - John Bellovich, Jim Franklin, and Bob Schwartz - One of the worst nightmares a plant manager can experience is a complete flare system outage. The flare system is the last line of defense for many refining and petrochemical facilities and, when out of commission, can cause the shutdown of the entire facility. Flare ignition failure may lead to unburned venting of dangerous gases, and may develop into an explosive hazard leading to the loss of property and equipment, or worse, injury to personnel or loss of life. The safety and effectiveness of flaring are dependent upon one or more continuously burning pilots for immediate and sustained ignition of gases exiting a flare burner. Because pilot failure can compromise safety and effectiveness, it should be detected quickly and accurately to allow prompt automatic and/or operator response. Proper disposal of process and waste gases during routine and/or emergency conditions is crucial to help operating facilities protect plant employees and the surrounding community, and to avoid hundreds of thousands of dollars in fines. These reasons alone make the pilot monitoring and ignition system the most important component of any flare system. The advanced flare pilot systems explained in this article offer increased protection from harsh environmental conditions and rapid notice of pilot flame failure. Recently published industry standards for flare pilot design and performance are also discussed - from John Zinc Company.
European Test Procedures For the Functionality of Cables Under Effects of Fire - Since the year 2000 there is a European test procedure regarding the functionality of cables in case of fire - EN 50200. This test procedure in its latest version of 2006 is leading to the fire protection classifications PH 15, PH 30, PH 60, PH 90 and PH 120. But for the practice this test procedure is insufficient. The European standard EN 50200 is applied for cables with a diameter of up to 20 millimetre. For larger cable diameters a similar test procedure had been developed in parallel to the EN 50200. This procedure is called EN 50362:2003 - from Dätwyler Cables.
Why
Should You Specify Cable Glands? - How often have we heard:- "We
don't specify Cable Glands, as long as they have the relevant certification
then it must be fit for purpose. We leave it to contractor to sort out. We
are too busy concentrating on the high value, long lead time items to bother
about such an insignificant value product. In a recent paper presented at
the Hazard Ex conference by a Senior Manager of CENELEC Standards
Inspections, it was stated, "Resources should be directed at
eliminating the following common faults; Unauthorised modifications, badly
made-off or unsuitable cable entry devices and Corrosion.
Discrete
Wireless - Bill Lydon - Wireless discrete monitoring and controls
standards emerging - Industrial wireless is proving valuable for automation
professionals in many areas of industrial automation with products and
standards emerging. People are comfortable with wireless since they use it
in their daily lives with cell phones, personal computers, security
monitoring, and other devices. Wireless standards to date have focused on
analog sensors, but there is growing interest and adoption of wireless for
discrete monitoring and for controlling digital output points. Discrete
monitoring and control points significantly outnumber analog input and
outputs in automation systems and are the largest installation cost on most
projects. Discrete points monitor contact closures from a wide range of
sensors and use contact outputs to control a wide range of devices,
including motors, two position valves, and solenoids. If wireless cost and
reliability improve to compete with hardwiring, this would be a real
improvement in automation systems. Today, wireless sensors are being applied
to select applications that have a high return on investment as a low-cost
means for monitoring hard-to-reach locations and deploying new innovative
applications. Examples include connecting far distant sensors that are too
expensive to wire, such as tank monitoring/control, and as an alternate to
electromechanical slip rings on rotating machines connecting electrical
signals from a stationary to rotating structure - From the ISA and InTech.
Selecting Temperature Measurement and Control Systems - Steve Byrom - How to get accurate data and perform reliable control from systems designed for the rigors of industrial applications - Measuring and controlling temperature is undoubtedly the most common measured parameter because it is critical to so many operations and tasks. Accurate temperature measurement and control is vital to the quality of manufactured goods, such as finished metal components, and to the efficient and safe operation of a process or system. In today’s market, there are myriad devices for monitoring and controlling temperature, ranging from simple temperature controllers to complex distributed control systems. Most temperature measurement and data acquisition products are well-suited for the job for which they are intended, but care must be taken when applying them in harsh industrial environments - from the ISA and InTech.
Posted by: Jim Russell, January 2013
The Following are from the very useful
InstrumentationPortal.Com
Calibration
Form - Calibration forms provide a list of actions to be done when
performing instrument calibration. Instrument Calibration is required to
make sure that instrument will function properly prior to installation.
Before shipping, vendor has already done the calibration after setting the
range to pre-determined value as requested by the end-user. It is common by
contractor to re-check the instrument by performing bench calibration.
However, some end-users prefer to install the instrument without undertaking
this test. Following are some typical calibration forms for transmitters,
gauges and control valves.
Transmitter
Calibration Form
Control
Valve Calibration Form
Pressure
Gauge Calibration Form
****
Wireless
Technology Guide - Wireless Communication is used by all of us on a
regular manner: Cellphones, WLAN and DECT telephones are all around and
widely accepted in consumer applications. As these technologies have
improved, they have started to make their way into industrial applications.
But the requirements and boundary conditions in the industrial world are
different from the consumer world. Industrial applications require higher
quality products and, more important, an increase in technical support. To
set up a wireless system which fullfills its duty in the required quality,
some knowledge of the following topics are required:
- physical basics of wireless communication
- antennas
- modern wireless technologies
- available standards, their properties, advantages and disadvantages
- requirements in industrial applications
If some of these topics are unknown, setting up a wireless system can be
difficult and debugging a nonworking wireless system is based on luck and
not on know-how. Therfore, it can be very valuable to understand some basic
principles rather than skill or knowledge. This short introduction describes
some information which might be useful when setting up and debugging a
wireless system in an industrial application – from Pepperl + Fuchs
Minimizing Arc Flash Exposure in Industrial Applications - This white paper will discuss the definition of an arc flash, including its risks, consequences and causes, industry standards to protect against arc flash and a solution to minimize arc flash exposure – from Turck.
What to Know When Selecting Your Cable Solution - When selecting the proper cabling for industrial applications, it is important for users to consider performance strengths and limitations associated with each cable solution in order to select cabling that meet an application’s exact needs. This white paper will address the differences between AWM recognized cable and UL listed cable, describing the testing requirements listed cables must satisfy and highlighting the benefits associated with ITC and PLTC cables, such as durability, reliability and longevity – from Turck
Identifying Tray Cables for Your Next Installation - Though rapidly increasing in popularity, tray cables are still a point of confusion for many. While the term “tray cable” is being heard everywhere, many do not understand what exactly a tray cable is or the benefits of using tray cables. Another gray area for many comes from the variety of types of tray cable, what each means and in which applications each type should be used. This paper defines what a tray cable is, describes the different types of tray cables, provide uses and standards for each type of tray cable. It will also provides a reference guide regarding the applications and governing standards for each tray cables type - from Turck.
A New Era of Liquid Chromatography: Improving HPLC Throughput with Automation and Real Time Diagnostics - Today's drug discovery labs are charged with moving thousands of samples through HPLC and MS screening processes. If your lab is operating 24x7 to keep up with the throughput demand, every second counts. To achieve high throughput, not only must the run time of a single analysis be shortened, but the total cycle time of the injection sequence and run time needs to be optimized. Solvent management automation and real time diagnostics allow you to increase sample throughput and maximize system uptime while meeting the need to produce reliable results and identify leads. This automation and diagnostics can be achieved by installing an in-line real time flow measurement device in the solvent management system - from Brooks Instrument.
Calibration and Standards in Flow Measurement - Richard Paton - Calibration is defined as follows: ‘The set of operations that establish, under specified conditions, the relationship between values of quantities indicated by a measuring instrument or measuring system and the corresponding values realized by standards.’ It is important to recognize at the outset the definition of a ‘calibration’ and to note that the ‘comparison’ applies only to the conditions at the time of the calibration. The purpose of calibration is to increase the confidence in the reading obtained from the flowmeter in service - From IDC.
Tuning of PID Controllers in both Open and Closed Loop Control Systems - This covers the application of procedures for open and closed loop tuning and how to calculate the tuning constants according to Ziegler & Nichols - from ICEweb sponsor IDC.
Applying Tank Farm Safety Standards for Petroleum Storage Tanks in India - S. K. Ravindran and John Joosten - Like other process industry operations, petroleum tank farms present difficult challenges for automation and safety technology. Tank farms, storage areas and loading/unloading sites all need effective safety solutions to protect personnel, assets and the environment. The consequences of incidents at these facilities can be enormous. The tank farm environment, being a hazardous area, requires continual monitoring of critical process parameters. Accurate and reliable tank level monitoring is especially important to prevent overfill situations. Some overfills are small and easily contained, but the accumulation of product from repeated overfills or a single large spill can cause significant soil and ground water contamination. Worse yet, recent catastrophic incidents at tank farms and terminals can be traced to ineffective safety technology leading to loss of level control and, ultimately, to loss of containment. Tank farm operations benefit from a holistic approach to industrial safety, which integrates advanced technology at all plant protection layers - and the people who interact with that technology - to help end-users achieve their safety objectives.This white paper describes various standards and recommendations as per international and Indian publications addressing safety in petroleum storage tank farms. It also discusses possible technologies/solutions, which can be used to comply with industry guidelines and create a safe work environment - from Honeywell.
ICEweb's Control Valve Page Upgraded - Thanks to our sponsor Samson Controls a total of 33 new technical papers and engineering articles have been added to ICEweb's Comprehensive Control Valve Page. The page covers a broad range of design, selection, specification and maintenance subjects.
Fire
Systems Integrity Assurance - Experience has shown that fire
detection and protection systems are not always designed or specified in
sufficient detail to ensure that they meet the performance criteria necessary to
reliably achieve their intended role; this can result in fire systems not
providing the performance required when called upon to do so. The OGP has
produced a Fire System Integrity Assurance report, which provides guidance on
issues involved in the assurance of fire system integrity from development of
appropriate performance criteria through to routine system testing and
inspection, in order to assess ongoing performance against the original
criteria. The objective of the report is to provide a high level model of the
steps to be addressed in assuring fire system integrity and to give guidance on
technical points to be considered at each stage, drawing on practical experience
from oil and gas installations - from OGP.
Human Factors Engineering in Projects - This report is concerned with human factors issues that can reasonably be expected to be within the scope of Capital Expenditure (CAPEX) funded engineering projects, including the design and layout of platforms, process plants and associated piping, equipment and facilities; control rooms (including the Human Machine Interface (HMI) to Distributed Computer Systems (DCS) and other computer systems), as well as buildings (including administration, accommodation, warehouses and workshops) - from OGP.
Verify Fluid Flow to Your Analyzer and Keep Your Plant Running - Sam Kresch - No matter how sophisticated a fluid analyzer system may be, it will be ineffective if a sample flow fails to reach the analyzer sensor or if the sample is contaminated or stale. The most advanced systems in the world cannot provide accurate results without a valid fluid sample. Gas chromatographs (GCs), mass spectrometers, optical spectrometers and photometers are a few examples of analyzer technologies applied in process and plant systems that need sample flow assurance. It is an accepted industry best practice that sampling systems have some type of flow monitor to assure valid samples and analysis - from Fluid Components.
How to Manage Vaporization in an Analytical System - D Nordstrom and T Waters - When done properly, this process ensures that all compounds vaporize at the same time, preserving the sample’s composition - from Swagelok and Hydrocarbon Processing.
Comparing
Differential Pressure Transmitter Accuracy - Ted Dimm - Differential
pressure transmitters are extremely versatile instruments fitting a broad
range of applications in various process industries. Accuracy is a key
performance measure for any process-measuring device, and is an important
factor for proper device selection and maintenance. Differential pressure
devices are very versatile, but it is not always easy to understand,
calculate, or compare accuracies between devices. This document is intended
to help the reader better understand what manufacturers’ accuracy
statements mean, what specifications are important for a given application,
and how to properly compare various product capabilities - From Honeywell
Process Solutions.
Black
Carbon – the Elephant in the Room! - Jim Mills - Traditionally,
ambient particulates have been measured gravimetrically according to their size.
This article Jim Mills, demonstrates that the time has come to change or at
least augment the way ambient particulates are monitored and regulated. It
explains why the measurement of Black Carbon could change the way we look at
particulate pollution, so that focus will be given to strategies that could
result in improvements to human health AND make a very significant contribution
to the fight against climate change. Also outlined is the rationale behind a new
€3million EU funded project (Carbotraf ) which will use Black Carbon
measurements to inform traffic management systems in both Glasgow and Graz.
Posted by: Jim Russell, December 2012
Partial-Stroke
Testing on final Elements to Extend Maintenance Cycles - Thomas
Karte and Karl-Bernd Schärtner - In the process industry, the testing of
safety instrumented systems is an inherent part of the safety approach.
Usually, function tests are performed once a year on the entire instrumented
system, consisting of sensor, logic solver, and final element.
Further scheduled testing routines depend on local requirements and
even involve removing valves from the plant and inspecting them in the
workshop. These common procedures have not lost their importance even in
view of the IEC 61508 and IEC 61511 standards. However, these standards
require a quantitative analysis of safety equipment and SIL (Safety
Integrity Level) ratings. The probability of failure for the safety loop and
its individual components need to be calculated. The degree of coverage of
the performed tests plays a key role. As a result, maintenance cycles can be
planned more flexibly and even extended in some cases. This changed
approach to safety is accompanied by the development of smart positioner
diagnostics. This article discusses the opportunities of partial-stroke
testing and the risks involved - from ICEweb sponsor Samson
Controls.
General notes for the Calculation and Selection of Actuators - These general notes from Samson Controls are useful.
Emergency Shut Down Valves (ESD) - Quarter-turn valves are the most common ESD control valves for actuation. Automatic control valves are fitted with hydraulic, pneumatic and electric actuators that respond to changes in pressure, flow or temperature, and automatically open or close the valve. Danger and damage from fire at refineries, petrochemical and offshore installations can be minimized by efficient protection of the systems controlling the plant.Remote valve operation station of fire proof actuator with accessories and air reservoir system to guarantee three complete cycle in the event of fire pneumatic operated with “Darchem” fire proof protection - from our sponsor Samson Controls.
Functional
Safety of Globe Valves, Rotary Plug Valves,
Ball Valves and Butterfly Valves
Performance
Based Gas Detection System Design for Hydrocarbon Storage Tank Systems -Srinivasan
N. Ganesan and Edward M. Marszal - The design of hydrocarbon gas detection
systems using risk analysis methods is drawing a lot of attention because
industry experts have come to a consensus that design codes used in
traditional gas detection system design work are not sufficient for open
door process areas having serious hazards, such as fire, flammable gas and
toxic gas. The ISA Technical Report TR 84.00.07 provides
guidelines for the design of fire and gas systems in unenclosed process
areas in accordance with the principles given in IEC 61511 standards. This
paper presents an overview of the design of gas detection systems using risk
assessment methods that are described in the ISA technical report. These
methods are statistical in nature and are used to assign and verify targets
for the performance metrics (detector coverage and safety availability) of
gas detection systems. This paper also provides an overview of the
performance based safety life cycle of gas detection systems from conceptual
design stage to operations and maintenance - from isssource.com.
Gas
Detection Reference Guide - This comprehensive design guide from Scott
Safety covers;
- System architecture and application, Designing a Gas Detection System,
Industrial Hazards, Common Hazards by Industry, Fixed vs. Portable
Detection, Warnings, Alarms and Response Functions.
- Sensor technology including; Catalytic Bead Sensors, Infrared Sensors,
Electrochemical Sensors, Photo Ionization Detector, Metal Oxide
Semiconductor Sensors,Sensor Performance Factors and Flame Detection.
- Glossary of gas detection terms
Gas Detection Infrared Sensors Broaden Scope of Platform Gas Analysis - Jeff Markley - Catalytic detectors reveal the presence of combustible gases through a change in the resistance of the embedded coil - but their sensitivity can be affected by airborne contaminants. Infrared sensors allow open path detectors to detect gas up to 200 metres away - from Offshore.
Carbon
Monoxide (CO) Information - The European standard for domestic Carbon
Monoxide (CO) alarms is EN50291 and this also provides details of where you
should and should not install a CO alarm in a domestic property. The key
points from this standard are as follows:
- Ideally, an alarm should be fitted in every room that contains a fuel
burning appliance
- If there is an appliance in a room where people sleep then a unit should
be installed in that room.
- If a room has a flueless / open flued appliance then a unit should be
located in that room.
- If an appliance is in a frequently used room (kitchen, sitting room) then
locate a unit in the room(s).
Fixed-Point Industrial Gas Detection - These gas detectors are used extensively on floating production storage and offloading (FPSO) vessels, as well at onshore and offshore oil and gas facilities.
Gas Detection Sampling Systems for use in a wide range of Applications including the Printing and Coating Industry - Sampling systems are particularly useful when detection of flammable or toxic gases cannot be done by simply locating a detector in the required area. Factors preventing this may include physical location, temperature, humidity, dust, air flow and corrosive environments. A sampling system can be used to precondition a gas sample to enable accurate detection in both safety and process control type applications.
The Benefits of IR Gas Detection for Oil and Gas Applications - Gem Bayless - Gas detection has been through a number of evolutions since the birth of the industry over 50 years ago. A major milestone in its history has been the introduction of Infrared (IR) gas detection, which uses a Hydrocarbon gases ability to absorb IR light at a pre-determined wavelength. Thanks to its notable value, which includes a fast speed of response (typically T90 in less than 5 seconds), fail-to-safety operation, immunity to poisons and ability to work in inert atmospheres, IR detection is fast becoming a popular method of detection - particularly within the oil, gas and petrochemical industries -from Honeywell and PetroOnline.
Integrated Fire and Gas Solution - Improves Plant Safety and Business Performance - Fire and gas (F&G) detection and mitigation systems are key to maintaining the overall safety and operation of industrial facilities. F&G systems include offshore petroleum exploration and production, onshore oil and gas facilities, refineries and chemical plants, marine operations, tank farms and terminals, pipelines, power plants, mining and paper mills. A F&G safety system continuously monitors for abnormal situations such as a fire, or combustible or toxic gas release within the plant; and provides early warning and mitigation actions to prevent escalation of the incident and protect the process or environment. By implementing an integrated fire and gas strategy based on the latest automation technology, plants can meet their plant safety and critical infrastructure protection requirements while ensuring operational and business readiness at project start-up - From Honeywell.
Code of Practice for Visual Alarm Devices (VADs) Used for Fire Warning - This Code of Practice gives recommendations for the planning, design, installation, commissioning and maintenance of facilities using VADs to give the primary warning of fire to certain persons in and around buildings, other than single-family dwellings - from LPCB.
Visual Alarms - Why are visual alarms required? - One American in a hundred has a severe hearing loss; nearly one in ten has a significant loss. In 1984, the Digest of Data on Persons with Disabilities reported that: "(t)he severity of hearing problems was strongly associated with age. persons 65 and older constituted 69 percent of the population with the most severe hearing trouble...but only 8.7 percent of the population without hearing trouble." Those who are deaf or hard-of-hearing--a growing percentage of our population, due largely to the growth in the numbers of older persons--depend upon visual cues to alert them to emergencies. A visual alarm provides persons with hearing loss the same warning delivered to hearing persons by an audible alarm. Audible fire alarms have been a standard feature of building construction since the life safety codes of the early 1900s. However, visible signals did not appear even in accessibility codes until 1980. Early standards required relatively dim flashing lights at exit signs--an alarm system that was effective only along an exit route. As accessibility, life safety, and building codes were revised, however, they began to incorporate alarm technology that was developed for use in schools for persons who are deaf and in factories where ambient noise levels made audible alarms ineffective - from US Access Board.
Fire and Explosion Guidance Part 2: Avoidance and Mitigation of Fires - The primary objective of this document is to offer guidance on practices and methodologies which can lead to a reduction in risk to life, the environment and the integrity of offshore facilities exposed to fire hazards - from Logical Software.
Fire and Explosion Guidance Part 1: Avoidance and Mitigation of Explosions - The primary objective of this document is to offer guidance on practices and methodologies which can lead to a reduction in risk to life, the environment and the integrity of offshore facilities exposed to the explosion hazards - from Logical Software.
Simplified
Approaches to Fire and Explosion Engineering - Steve Walker, Brian Corr,
Vincent Tam (BP), Justin Bucknell and Pat O’Connor
Fire and Explosion Guidance Part 0: Fire and Explosion Hazard Management - The updated Fire and Explosion Guidance has been prepared to encourage an integrated approach to the management of Fires and Explosions. As such, it complements the Safety Case and should help those persons with responsibilities for the safe design, construction and operation of installations to manage fire and explosion hazards- from Logical Software.
Protection
of Piping Systems Subject To Fires and Explosio
The
iPhone is Coming to the Plant Floor – Can we Secure it? - Eric
Byres - This is an issue that industry needs to come to terms with
quickly if we are ever going make our plant floors secure. What is your
company doing about mobile devices on the plant floor? Does it have a
strategy?
Precisely Connecting Signals in Process Control Systems - Proper signal transmission is often an immense project, particularly in process plants: Several thousands of field signals need to be wired to the DCS (Distribution Control System). In doing so, the clear and simple connection of the wires, their shielding, the protection against lightning and surges, as well as the conversion of the signals must be implemented in a precise and efficient way. In response to these requirements, Weidmüller has designed a variety of precisely tailored solutions for connecting signals in process control systems.
Weidmüller App - Latest news and information about Weidmüller's products whenever you want - Information is available via buttons aptly named ie. 'News', 'Product Catalogue', 'Search', 'User Information', 'Enquiry List', 'Company Profile' and 'Innovations'.
Quick Selection Guide Modular Terminal Blocks - Need a terminal? Choose from the huge range detailed here.
Just the Right Tool for your Application - This informative brochure is sorted by application areas. That way you can quickly find the quality tool you are looking for. It also contains useful tool tips
Industrial Ethernet Handbook - A Practical Guideline - This guideline is intended for planners, installation engineers and startup engineers for Industrial Ethernet (IE) networks. It communicates, from experience, tips, tricks and shortcuts that make the work easier. This guidelines is not an IE compendium from a basic manual. Thanks to valued ICEweb sponsor Weidmuller Australia.
Posted by: Jim Russell, November 2012
Address SCADA Security Vulnerabilities NOW, Not Later - Eric Byres - Who is responsible for fixing the thousands (some say 100,000) of vulnerabilities that exist in PLCs, DCS, RTUs and other automation devices that are in use in facilities around the world?
SCADA Security Basics: Integrity Trumps Availability - Eric Byres - There is more to consider when it comes to industrial security priorities.
SCADA Security Basics: Why Industrial Networks are Different than IT Networks - Heather MacKenzie - This blog looks at SCADA security from another angle, which is “Why is securing Industrial Networks different than securing IT Networks?” It covers three ways to address these differences.
Shamoon Malware and SCADA Security – What are the Impacts? - Heather MacKenzie - The most destructive post-Stuxnet discovery of advanced threats is a malicious malware known as Shamoon. Like Stuxnet, Duqu and Flame, it targeted energy companies in the Middle East, this time Saudi Aramco, Qatar’s RasGas and likely other oil and gas concerns in the region. It is a new species however, because it did not disrupt an industrial process as Stuxnet did, nor did it stealthily steal business information as Flame and Duqu did. Instead it removed and overwrote the information on the hard drives of 30,000 to 55,000 (yes those numbers are correct!) workstations of Saudi Aramco (and who knows how many more at other firms). Nothing this damaging has been seen in a while. As a Kaspersky Lab expert commented “Nowadays, destructive malware is rare; the main focus of cybercriminals is financial profit. Cases like the one here do not appear very often.”What does Shamoon mean for SCADA and ICS Security? This is an interesting article into what is in effect cyber terrorism.
Selecting and Placing Gas Detectors for Maximum Application Protection - Dave Opheim - Many industrial processes involve dangerous gases and vapors: flammable, toxic, or both. With the different sensing technologies available, and the wide range of industrial applications that exist, selecting the best sensor and locating them properly for the job at hand can be a challenge - from Detector Electronics Corporation.
The Detection of Hazardous Gases - The detection of hazardous gases has always been a complex subject and makes choosing an appropriate gas monitoring instrument a difficult task. This chapter provides A simple guide to the various sensor technologies available and Terms Definitions and Abbreviations - from International Sensor Technology.
Gas Sensor Calibration - Gas sensors need to be calibrated and periodically checked to ensure sensor accuracy and system integrity. It is important to install stationary sensors in locations where the calibration can be performed easily. The intervals between calibration can be different from sensor to sensor. Generally, the manufacturer of the sensor will recommend a time interval between calibration. However, it is good general practice to check the sensor more closely during the first 30 days after installation. During this period, it is possible to observe how well the sensor is adapting to its new environment - from International Sensor Technology.
Sensor Selection Guide - Each of the following sensor, electrochemical, catalytic bead, solid state, infrared and photoionization detectors must meet certain criteria to be practical for use in area air quality and safety applications - from International Sensor Technology.
Catalytic Combustible Gas Sensors - Catalytic bead sensors are used primarily to detect combustible gases. They have been in use for more than 50 years. Initially, these sensors were used for monitoring gas in coal mines, where they replaced canaries that had been used for a long period of time. The sensor itself is quite simple in design and is easy to manufacture. In its simplest form, as used in the original design, it was comprised of a single platinum wire. Catalytic bead sensors were produced all over the world by a large number of different manufacturers, but the performance and reliability of these sensors varied widely among these various manufacturers - from International Sensor Technology.
Hydrogen Detection in Oil Refineries - This white paper offers a practical approach for the deployment of fire and gas detectors that maximizes detection efficiency. The approach is based on the notion that any one detection technique cannot respond to all hazardous events and consequently, the risk of detection failure is reduced by deploying devices that have different strengths and limitations.
Diversified Technologies for Fixed Gas Detection - Edward Naranjo and Gregory A. Neethling - Over the years, a variety of gas detection technologies have been developed for the oil, gas, and chemical process industries. The advent of embedded electronics, sophisticated firmware, new materials, and spectral techniques has prompted remarkable improvements in detection. In many cases, technology development proceeds through parallel routes with each technology staking its own specialist market. Catalytic bead sensors and infrared detectors are two examples of conventional sensing methods with wide customer acceptance. Likewise, comparatively newer technologies like open path, gas cloud imaging, and ultrasonic gas leak detection have made inroads into the safety instrumentation market, not due to their novelty, but because they solve customers’ problems like no technology before them. In such a world of competing solutions, it is tempting to think single technologies will provide answers to most industry challenges. Offshore platforms, onshore terminals, gas compressor stations, and other facilities, however, are complex environments no single type of detector is bound to cover completely. Experience has shown it is in fact the combination of gas detection schemes that provide the enhanced level of safety that customers demand.
Fundamentals of Combustible Gas Detection - A Guide to the Characteristics of Combustible Gases and Applicable Detection Technologies - from General Monitors.
Combustible Gas Safety Monitoring: Infrared vs. Catalytic Gas Detectors - When designing a combustible gas safety monitoring system for oil/gas, petrochemical or other applications, how do you decide whether to use infrared or catalytic gas detector technology? Both sensing technologies have their advantages dependent upon your application’s specific requirements. A thorough analysis of your application’s unique field environment is needed to ensure optimal performance, safety, reliability and cost-effectiveness. A quick decision, of course, can lead to poor detector choices as well as safety, performance, maintenance, and life-cycle cost consequences - from General Monitors.
Combustible Gas Detector Sensor Drift: Catalytic versus Infrared - Kelly Rollick, Allan Roczko, and Leslie Mitchell - Catalytic bead combustible sensor technology, used for decades to measure combustible gas concentrations, dates back to the 1830s. The infrared spectrum was discovered in 1800. The 1950s saw a surge in infrared spectrum use for many technological applications, including gas detection. These distinct gas detection technologies offer advantages and disadvantages, with conditions determining the better choice for specific applications - from ISA.
*****
Posted by: Jim Russell, October 2012
Performance Based Fire & Gas System Engineering - This WEBINAR features Kenexis President and CEO Ed Marszal in a discussion of how a combination of prescriptive standards and risk management techniques can be used to design a robust Fire & Gas System for use in the process industries. It runs over 2 hours and is just full of great information!
Advancing Quantitative Fire and Gas Detection and Suppression Systems Analysis - Edward M. Marszal, Kevin J. Mitchell and Henry M. Marszal - In this paper, the authors are presenting a basic analysis framework and proposing nomenclature for the purposes of standardizing analysis methods. The paper will address in some depth, the problem of quantifying optical fire detection system performance, at least in the Geographic Coverage sense, and will allude to the future steps that will be required to extend the analysis to Scenario Coverage for fire detection and then Scenario Coverage for gas detection - from Kenexis.
Interactive
Learning Modules for PID Control
Design to Humans: Lessons in HMI - Establishing a common language is often the first step to master a domain. This is especially true in the area of human-machine interface (HMI) design. HMI is the means by which a user operates a machine, system, or process (via hardwired panels or a computerized console). It also encompasses decision-support devices, such as operating procedures. Bandwidth availability from the modern HMI hardware and software has grown exponentially over the last few decades, and experts agree current Internet and web technologies cannot yet provide what most existing HMI users need: high data rates, high animation capability, and sub-second screen changes. Since humans cannot absorb information at the same rate as HMI bandwidth, it is important to design HMIs that better support the operator. In the petrochemical industry in U.S. alone, we estimate inadequacies in the means to deal with abnormal situations (including HMIs used to identify, diagnose, and deal with those situations) cost between $10 billion-$20 billion to the industry each year - from ISA and InTech.
Ergonomic Control Room Design Improves Operator Comfort and Safety - Vanessa Graves - As the power industry makes the shift from analog to digital control systems, power utilities are redesigning their control rooms to accommodate the digital control upgrades. The new technology has made it possible for operators to access most of their controls through the monitor and keyboard, rather than standing at the control boards. This represents not only a shift in technology but also a change in the way operators work. Safety is a chief concern for these power plants and a primary focus of control room design. An ergonomic approach to the design of control workstations and the layout of the control room contributes to achieving safety and performance objectives set for power plant control rooms. Effective control room design considers both form and function to create workspaces that facilitate the complex interaction between operators, technology and the environment. Raised flooring, acoustic concerns, indirect lighting and the wellbeing, health and safety of each operator all need to be addressed. Operators in the power plant control room work 24 hours a day, 7 days a week. Unlike a desk for a typical 9-to-5 office worker, which would be used 40 hours a week, these consoles are used 168 hours a week. Operators don’t get to just walk away if they need a break. So they need to be comfortable while they are at the console. Some things that are considered are knee space, countertop height, monitor height, viewing angles, reach and the amount of space the operator has behind the desk. That being said, an example of something that’s important to operators in terms of comfort is where the cup holders are located. It may seem trivial, but details like this really are critical to operator comfort and plant safety. From the layout of the room to determining the precise placement of every keyboard, mouse and telephone, not a single detail is left to chance - from Winsted Technical Interiors.
Control Room Dimension Recommendations - An excellent guide on dimension requirements - from Winsted Technical Interiors.
Back to Basics: Closed-loop Stability - Tutorial - Vance VanDoren - Stability is how a control loop reduces errors between the measured process variable and its desired value or setpoint - For the purposes of feedback control, stability refers to a control loop’s ability to reduce errors between the measured process variable and its desired value or setpoint. A stable control loop will manipulate the process so as to bring the process variable closer to the setpoint, whereas an unstable control loop will maintain or even widen the gap between them - from the excellent Control Engineering.
Loop Tuning Grows Smarter with Wireless - Limits exist on appropriate use of Wireless Loop Tuning Applications. For example, wireless PID tuning can be used in loops with slow response times—minutes or hours—such as temperature loops in larger process vessels, but such wireless control shouldn’t be used where loop response times are fast—sub-one second—or where the inability to control rapid process upsets or conditions could create damaging or dangerous situations or outcomes, expert Gregorary McMillan cautions. “For liquid pressures and compressor surge control, you have to be careful, and probably not use wireless unless you did a lot of investigation. Why? Because very bad things could happen very quickly—essentially instantaneously.” - from automationworld.com.
Addressing the Myths of Model Predictive Control (MPC) - Don Morrison - Not that long ago it was suggested in an industry article that perhaps the time was right to begin considering viable alternatives to PID control. Specifically it was advocated that the advances of model predictive control (MPC) have led to improved benefits that make it an answer to the inherent weaknesses of PID. The notion apparently touched a nerve with PID advocates who felt I was suggesting the complete elimination of PID. In reality, PID control will always have a role in the process industries, and suggesting that it should be completely swept aside is not realistic. It’s important to note, however, that MPC continues to take technological strides that are making it a bonafide alternative to PID that can produce better return in certain cases. Manufacturers have taken notice, and many more are implementing MPC into their plants and reaping benefits - from Honeywell Process Solutions and Automation.com.
Identifying Pressure Sensor Problems - How Barometric Pressure, Installation, and Drift Affect Sensor Performance - Elden Tolman - It is common for a pressure sensor to perform well at first and then later fall outside of the acceptable range of performance. Frequently such errors are classified as drift, when in reality there are other forces at play. This article reviews the influence of barometric pressure, installation and drift on sensor performance - from Flow Control.
Shift Handover -The Importance of Continuity - Shift handover has been shown to be a common source of revenue loss and safety incidents in plant operation. Both economic and regulatory pressures demand substantial improvement in the shift handover process. Every engineer knows that discontinuities are invariably a source of weakness, whether in physical structures or in continuous processes. This is particularly true in the case of shift handover but, whereas physical discontinuities may be easy to identify and remove, discontinuities in working procedures can be far more difficult. It has long been recognised in the plant industries that the discontinuities of shift handover are among the most common and potentially serious sources of problems. These can range from minor impacts on operational efficiency to the most serious safety incidents; all incur corresponding levels of economic cost. The root of the issue is the transfer of information from outgoing to incoming shift teams. This paper looks into the problems arising and describes how the latest information management technology can be used to overcome them. To download AVEVA's paper on Shift Handover visit http://www.aveva.com/en/Media-Centre/Business_Papers.aspx
Ten Easy Steps for Wireless LAN Security - Some Low Cost Ways of optimising the security of your Wireless LANS - from L-Com.
Antenna Installation Considerations - Ken Burgner - This white paper outlines installation considerations when installing a WLAN antenna including Fresnal zones, LOS, Reflections,Multipath etc - from L-Com.
Engineer the Use of your PowerPoint Slides More Powerfully - Steve Mackay – IDC Technologies - I think you will agree that most of us have used PowerPoint slides at some stage in our careers. However, I often cringe when I see how slides are used in presentations – boring, rambling and not particularly useful – with an endless list of them thrust at a disinterested and confused audience. It is certainly impossible to deliver a good technical presentation without some use of PowerPoint slides – especially using graphics and diagrams in the engineering field - a great way to keep attention and explain complexity. After all, most engineering professionals appreciate a diagrammatic representation as opposed to boring text - from Mackays Musings.
HVAC Control Valves Ball vs. Globe - No longer a Cost Issue - In the past, ball valves had been attractive to HVAC control contractors primarily because they appeared to be half the price of a comparable globe valve. However, this included the purchase price of the valve only, and not the costs of extra pipe reducers and added installation time. That said, with the advent of new ball valves and more competitively priced globe valves, the decision on whether to use a globe or ball valve is no longer dictated by price. This paper addresses some technical differences between ball and globe valves and makes recommendations on factors to consider when selecting the proper valve - from Siemens.
How Electric Control Valve Actuators Can Eliminate The Problems of Compressed Air as a Power Medium - Today, a new major technological advance is available that can help control-valve users avoid many of the problems and inefficiencies associated with using compressed air as a power medium. The new solution uses electric power and eliminates dependence on compressed air. This totally electric solution is appropriate and cost-effective for a wide variety of control-valve applications, including those found in such sectors as power generation, chemical, petrochemical, and most other process industries. While the new generation of electric control-valve actuators may not be suitable for all process applications, it is ideal for many situations, especially where users have experienced problems with frozen air hoses, lack of process precision, stick slip, and so on. Therefore, it is prudent for today’s process control engineers to take a serious look at how the design features of the new generation of totally electric control-valve actuators can benefit them - from Rotork.
Control Valve Actuators - Their Impact on Control and Variability - Chris Warnett - Electric control valve actuators provide excellent performance and are ideal for oil and gas wells in remote production fields. Instrument air supply systems are costly and require significant energy to run. If mains power isn’t available, an instrument air supply isn’t practical, especially when only a few control valves are in use at a location. Solar powered DC electric actuators are ideal for such an application - from Rotork.
Combustible Cable Pulling Lubricant Residue Can Spread Fire! - Well over a decade ago, fires at the Brown's Ferry Nuclear Plant in Alabama and skyscrapers in New York City focused the attention of cable manufacturers and design engineers on the spread of fire through cabling systems. Today's fire-retardant cables are made from specially-formulated, fire-resistant materials. They are tested to special industry specifications. These state-of-the-art, fire-retardant cables show little tendency to ignite and propagate flame, and, thus, do not support the spread of fire. It is common practice to specify fire-retardant cables, as well as "fire stop" materials, to prevent flame from spreading through electrical penetrations in fire-resistant walls, etc. The prevention of fire spread is addressed in the National Electrical Code (Sec. 300-21), as well as numerous building codes and industrial standards. Prevention of flame spread is also desirable for cable pulling compound residue, since they, too, can be present throughout a conduit system.
Cable Installation Engineering Video - This 13-minute training video examines the engineering aspects of installing cable in conduit. Topics covered include the nature of cable pulling friction; using software to estimate pulling tensions, determine pull feasibility, and design optimal cable runs; the causes of cable failure; cable/lubricant compatibility; lubricant residue combustibility; cable lubricant specification; and more.
Electrical Cable Cleaning Video - For High Voltage Electrical Splicing - This 8-minute training video on CD demonstrates high voltage cable cleaning procedures during splicing and termination. Methods are shown to remove different types of shields and compounds from insulation. The "Do's and Don'ts" of abrasion, solvent spraying, and cleaning techniques are presented, including safe methods for using SpliceMaster® cleaning solvents - from American Polywater.
Assisted Fibre Optic Cable Installation - High Air Speed Blowing, Air-Assist, Push/Pull Installation, Air Blown Cable, and Cable Jetting; all describe new methods to get cable into conduit using air. To date, the primary use of these methods has been to install fiber optic cable. Air-assisted fiber optic installation was developed and explored in the Netherlands as well as the United Kingdom in the 1980’s. While blowing methods are used to install individual fibers in tubes in LAN’s, this article will focus on the outside plant installation of jacketed, multi-fiber cable in duct. While this is typically underground duct, blowing will work for aerial duct installations as well - from American Polywater.
Estimating Tension When Pulling Cable into Conduit - When you calculate cable pulling tensions, what friction coefficient do you use? Field responses vary . . . some answer ".5" . . . others ".45," ".4," or ".35" . . . and, recently, a European engineer responded "usually .2 to .3." Who's right?? What coefficient of friction should you use in pulling equations to provide the best tension estimates for better field planning and electrical system design? - from American Polywater.
A Cost Saving Strategy for Desalination Plants - Wireless Liquid Analytical Instrumentation Comes to the Fore - As new desalination plants are built and present facilities are expanded, plant operators can realise significant cost savings by employing a recent advance in online process instrumentation – wireless technology. Two of the most promising applications for wireless technology are the measurement of pH and conductivity - from Rosemount Analytical.
Analytical Measurements Protect Recovery Furnace and Boiler in a Pulp and Paper Mill - Dave Joseph and Doug Simmers - Recovery Boiler operations can be improved considerably by using continuous analytical measurements. The information they collect can be used to optimize black liquor conversion and energy extraction in the furnace without compromising safety and reliability of boiler tubes and other components. The Recovery Furnace oxidizes concentrated black liquor, thereby generating feedstock for green liquor and the rest of the Kraft process, and simultaneously producing steam for millwide use. The furnace is optimized by controlling excess combustion air levels to maximize smelt recovery, prevent corrosion, and maximize steam production. The boiler is optimized for longevity by monitoring the quality of water used to produce steam. This also protects the boiler tubes against corrosion and pitting due to harmful mineral deposits. Effective analytical measurements can assist in optimizing these operations. Additionally, accurate analysis of both combustion flue gases and boiler water can be used to prevent explosive conditions - from Rosemount Analytical.
Measuring Odorants in Natural Gas Pipelines - Local distribution companies (LDCs) employ numerous "sniffers" who judge odorant level in the natural gas product, while generating data from field reports, customer input, and modelling programs. However, interstate pipelines span hundreds of miles that cross through various territories. Dispatching "sniffers" across vast distances is both time-consuming and costly. While "sniff testing" complies and satisfies the minimum criteria set forth in CFR, Title 49, Part 192.625, an on-line process analyzer would provide the same testing functionality with much richer quantitative data (one example: continuous trend data as opposed to discrete data points). On-line odorant analysis allows the transmission companies to schedule the minimum required visits to perform sniffing, and optimize their odorant distribution system in real-time. Secondary benefits allow them to optimize their pipeline performance by studying lag times, odorizer performance, fading effects, and other odorant issues.
Online Tail Gas Analysis in Sulphur Recovery - This system monitors real-time concentrations of H2S and SO2 in the Claus process stream, computing the control parameter for a continuously reliable air demand signal - from Applied Analytics.
Equipment
Protection Levels (EPLs) : Not as Optional as you Think! - This paper
from Inlec Engineering
introduces the new concept of Equipment Protection Levels (EPLs) for
hazardous area electrical equipment as introduced in the 2009 editions of
AS/NZS60070.10.0, AS/NZS60079.14 and AS/NZS60079.17. It covers the impact
that EPLs will have upon:
- Hazardous Area Classification
- Electrical Equipment Markings
- The selection and installation of electrical equipment and wiring systems
for hazardous areas
Practitioners will need a good working understanding of this new
'alternative' approach, even if they chose not to apply it, because although
the 'new' approach is optional, it impacts the use of the 'historical'
method.
Equipment Protection Levels and All That - One of the evil side effects of the ATEX Directive is that the IEC feels compelled to follow its more whimsical requirements. However the IEC must maintain its independence and consequently it follows similar principles but modifies the marking.The most recent manifestation of this phenomenon is the creation of Equipment Protection Levels (EPLs], which are the IEC equivalent of the ATEX categories - from MTL.
ATEX and Explosive Atmospheres - Explosive atmospheres in the workplace can be caused by flammable gases, mists or vapours or by combustible dusts. Explosions can cause loss of life and serious injuries as well as significant damage. These pages from the UK HSE will tell you more about explosive atmospheres and ATEX.
Equipment Protection Level EPL: Extended Device Marking -Discover the importance of the new Equipment Protection Level (EPL) - The selection of suitable apparatus plays an important role when setting up a plant in hazardous areas. Some of the main points include (a) Device functionality (b) Suitability for all anticipated ambient and operating conditions and (c) Explosion protection requirements - from Pepperl+Fuchs.
Electrical Apparatus and Hazardous Areas - Covers Hazardous Areas, Groups, Zones, Temperature Classes, Types of Protection,Equipment Protection Levels, Standards and ATEX - from Hexagon Technology.
Hazardous Area Classification and Control of Ignition Sources - This Technical Measures Document refers to the classification of plant into hazardous areas, and the systematic identification and control of ignition sources - from the UKHSE.
PSVPlus Software - Model Pressure Relief Scenarios and Size Pressure Relief Valves in Process Plants, based on industry standard procedures. This process software brings seamless integration between the various steps required to calculate, design, specify Pressure Relief Valves for the Oil & Gas, Petrochemical, and Fine Chemical Industries.
The
Cost of Cyberattacks - Greg Hale - Can You Afford NOT to Deploy
Best Practices? There is a spectrum of awareness and capability regarding
cyber security in industry, with the oil and gas sector being at the
forefront of implementing best practices and many other sectors still
unconvinced that it merits expenditure and resource allocation. According to
Greg companies
that implement cyber security best practices are 2.5 times less likely
to experience a major cyberattack and 3.5 times less likely to experience
unplanned downtime than companies that don’t. Cyber incidents cost
organizations:
- $558,000 in revenue losses
- $480,831 in brand damage
- $366,301 in compliance fines
- 174,309 in lost productivity
It all adds up to costing U. S. industry $6
million a day or $20 billion a year.
Guide
for Conducting Risk Assessments - This guide focuses exclusively on risk
assessment—the second step in the information security risk management
process. The guidance covers the four elements of a classic risk assessment:
threats, vulnerabilities, impact to missions and business operations, and
the likelihood of threat exploitation of vulnerabilities in information
systems and their physical environment to cause harm or adverse
consequences.
"As the size and complexity of our collective IT infrastructure grows,
we cannot protect everything we own or manage to the highest degree,"
says Ross. "Risk assessments show us where we are most at risk. It
provides a way to decide where managers should focus their attention.
"The risk assessment guidance is designed to meet the needs of a
variety of organizations, large and small, including financial institutions,
health care providers, software developers, manufacturing companies,
military planners and operators, and law enforcement groups.
Specifying Surge Relief Valves in Liquid Pipelines - Surge relief valves often last line of protection for a pipeline, saving the day when all else fails, but only if specified and installed correctly - Trilochan Gupta - A pressure surge can consist of multiple events, resulting in up to ten times the normal pipeline pressure. When a surge relief valve opens, it vents the pressure to a safety system. Probably the most infamous example of a relief valve failing is the nuclear accident at Three Mile Island in 1979, but many other incidents have occurred. In 2005, for example, relief valves were partially blamed for the BP Texas City refinery explosion. In that case, the relief valves opened properly, but they caused a flammable liquid geyser from a blowdown stack that was not equipped with a flare. In other words, the relief valves were installed improperly. In 2009, at the Sayano-Shushenskaya hydroelectric plant in Siberia, severe water hammer ruptured a conduit leading to a turbine. A transformer exploded, killing 69 people. It is not known if the plant had surge relief valves, but this is exactly the kind of problem that surge relief valves are designed to solve. To prevent similar problems from occurring in an oil pipeline, proper attention must be paid when specifying and installing surge relief valves - from the ISA and InTech.
Do Your Thermowells Meet the ASME Standard? - Thermowell design has become more conservative in the age of ASME/ANSI 19.3TW-2010 - Mitchell P. Johnson, J.D. and Allan G. Gilson, P.E. - Depending on process conditions there are a number of other factors that can cause a thermowell to suffer mechanical failure at insertion lengths less than one-third of the pipe. These include flow-induced vibration (wake frequency failure), dynamic (oscillating) and steady state stress, pressure, corrosion, erosion, material selection, and improper installation technique. All of these must be considered in properly designing a thermowell for a given installation. So who is responsible for making the judgment call here? The 19.3TW standard makes plain that ultimate design responsibility for a thermowell well rests with the engineer designing the system into which the well is being installed: Specification of a thermowell, including details of its intended installation and all intended operating conditions, is the responsibility of the designer of the system that incorporates the thermowell. The designer of that system is also responsible for ensuring the thermowell is compatible with the process fluid and with the design of the thermowell installation in the system - from Flow Control.
Field Device Technology (FDT) - Technical Description - FDT (Field Device Technology) is an interface specification for open data exchange between field devices and automation plants that is standardized by the international standards IEC 62453 and ISA103. In Field Device Technology, two terms are particularly important: DTM (Device Type Manager, or “device driver”) and FDT Frame Application. Both are software components whose functions can only be performed together. FDT provides a common platform for data exchange for all available device drivers (DTMs) produced under this standard. This allows complete and functional access across different network hierarchies to all device functions for devices made available by the DTM. With this capability, every device can be confi gured, serviced, and maintained via one basically standardized user interface – independent of manufacturer, device type or communication protocol. Information from an automation plant (especially communications or field devices) is needed throughout the entire life cycle of a system or application. FDT provides support with versatile and extremely helpful functions as early as planning and project engineering, then during installation and commissioning, and finally during operation and service.
The Mechanical Integrity of Plant Containing Hazardous Substances - A guide to periodic examination and testing - The Health and Safety Executive (HSE) considers maintenance of the integrity of plant containing hazardous substances to be a fundamental element of good process safety management. To this end, we believe this document provides a sound basis from which to develop arrangements for the management and delivery of periodic examinations aimed at achieving this. The guidance contained within this document should not be regarded as an authoritative interpretation of the law, but if you follow the advice set out in it, you will normally be doing enough to comply with health and safety law in respect of those specific issues on which the guidance gives advice. Whilst not being specifically related to instrumentation this comprehensive document from EEMUA is an excellent reference for anybody working or interested in Asset Management and Safety.
Fundamentals
of Gas Measurement - Pat Donnelly
Project Management Fundamentals - John “Jay” Gamble, Jr., P.E. - A good information sheet giving all the fundamentals of Project Management - from CEESI.
Posted by: Jim Russell, September 2012
Shamoon Malware and SCADA Security – What are the Impacts? - Heather MacKenzie - The latest post-Stuxnet discovery of advanced threats is a malicious malware known as Shamoon. Like Stuxnet, Duqu and Flame, it targeted energy companies in the Middle East, this time Saudi Aramco and likely other oil and gas concerns in the region including Qatar’s RasGaz. It is a new species however, because it did not disrupt an industrial process as Stuxnet did, nor did it stealthily steal business information as Flame and Duqu did. Instead it removed and overwrote the information on the hard drives of 30,000 (yes that number is correct1) workstations of Saudi Aramco (and who knows how many more at other firms).Nothing this damaging has been seen in a while. As a Kaspersky Lab expert commented “Nowadays, destructive malware is rare; the main focus of cybercriminals is financial profit. Cases like the one here do not appear very often.”What does Shamoon mean for SCADA and ICS Security? This is an interesting article into what is in effect cyber terrorism.
The following links on Solenoid Valves are
complements of our valued sponsor ASCO;
- Engineering
Information - Importance of Properly Sizing Solenoid Valves - It is important to properly size a valve as there are
undesirable effects in both undersizing and oversizing. This technical
information sheet also includes the definition of Kv, data on Flow Data, Flow
Factor, Orifice Size and sample problems.
- Solenoid
and Pressure Operated Valve Technology - Function,
Terminology and Construction Types.
- Proportional
Solenoid Valves - Most flow control valves work on an “on/off”
basis. They are either fully open or fully closed. Proportional valves, however,
operate with a “proportional” action. By varying the electrical input to a
proportional valve, the flow of the fl uid through the valve can be continuously
and steplessly adjusted between 0 to 100% of the maximum rated flow.
- Rubbers,
Plastics and Metals used in Solenoid Valves - Technical Information Sheet
- Chemical
Resistance Guide - A useful Technical Information Sheet -
ASCO valves are available to control most acids, alcohol, bases, solvents and
corrosive gases and liquids. Modifi ed or special designs are sometimes required
depending upon the fluid and application. Corrosion occurs either as a chemical
or electro-chemical reaction. Therefore, consideration must be given to both the
galvanic and electromotive force series, as well as to pressure, temperature and
other factors that might be involved in the application. This guide provides
information on most common corrosive and non-corrosive, unmixed gases and
liquids.
- Solenoid
and Pressure Operated Valve Technology - ISO 1219 Symbols - Symbols used
for different combinations of Solenoid Valves.
Solenoid Operators, Coils and Spare Parts Kits - Coil identification and
basic design considerations.
- ASCO
Solenoids - General Operating / Maintenance Instructions /
Troubleshooting Guide and Spare Part Kits.
- Solenoid
Engineering Information - Maximum/minimum pressures and
temperatures viscosity, response times, valve seat tightness degrees of
protection provided by electrical enclosures (IP code).
- Useful
Engineering Conversion Tables for Solenoid Valves
- ASCO
"Red Hat" Solenoid Valves - Selection, Installation. Maintenance and
Troubleshooting - This document from ASCO Canada provides some useful information.
- Safety
Manual for Safety Integrated Systems - This Safety
Manual provides information necessary to design, install, verify and maintain a
Safety Instrumented Function (SIF) utilizing an ASCO Redundant Control System,
RCS. This manual provides necessary requirements for meeting the IEC 61508 or
IEC 61511 functional safety standards.
- Eight
Critical Factors in Purchasing Offshore Pilot Valves - Fabio
Okada and Emma Tejada - Stainless steel pilot valves play small but critical
roles in the control of offshore platforms and other demanding oil and gas
production operations. Acting as pilots for process and larger emergency
shutdown (ESD) valves, these valves are typically installed in a platform’s
pneumatic logic control panels. The valves are usually exposed to salt water and
other challenging elements, so valve manufacturers all standardize on 316L
stainless steel valve bodies. Panel builders, assemblers, OEMs, contractors, and
end users can choose from a wide variety of models, including air-operated,
manually operated, solenoid-operated, and many more. Specifiers and buyers must
consider all the critical factors that bear on a given design’s reliability.
The April 2010 platform loss and oil spill in the Gulf of Mexico have only
sharpened the industry’s focus. In the case of pilot valves, this means that
operators must have robust valves that perform efficiently each time, every
time. This report considers several problems that interfere with the efficient,
reliable performance of conventional pilot valves in offshore use. It also
highlights design changes that have addressed these problems in newer models. Note:
Onshore drillers may also specify these valves, taking advantage of their robust
construction or consolidating purchasing when
operating both onshore and offshore sites.
- The
Insiders’ Guide to Modular Gas Valves - Gerry Longinetti and James Chiu -
Fuel gas shutoff valves represent the main line of defence in combustion devices
such as burners and boilers. They’re key to the safe operation of equipment
for non residential comfort heating, commercial and industrial heating, and
power and steam generation applications worldwide. While conventional modular
gas valve designs are popular and effective, the latest generation of valves has
even more dramatic improvements. Recent technological advancements in models
such as new modular gas valves from ASCO offer breakthrough features and
benefits. These include higher flows, more compact footprints, and greater
modularity and flexibility to enable downsizing of fuel train components, as
well as broader temperature ranges, higher close-off pressures, more immediate
availability, and reduced costs of ownership. Tapping the expertise of valve
manufacturing insiders, this report reveals how original equipment manufacturers
(OEMs) and end users alike can take maximum advantage of these new factors. It’s
intended to offer useful guidance in choosing the right valve for a variety of
vital applications.
- Seven
Breakthrough Advantages of New Steam Valve Technology -
Anne-Sophie Kedad-Chambareau and Gerry Longinetti - Solenoid based valves that
control the flow of steam and hot water are critical components for original
equipment manufacturers (OEMs) and end users of commercial and industrial
laundry, sterilizer, boiler, dishwasher, and food preparation equipment. Until
recently, specifiers and users of even the best traditional valve technology had
to accept certain limitations. For instance, flow rates were relatively
constrained, so throughput was restricted. Valve life was also comparatively
short, and maintenance or replacement somewhat time-consuming. Recently, these
barriers have been breached. New approaches and technologies, incorporated into
a new generation of products, are changing what buyers can expect. Even
differences in basic specifications can be considerable. In recent head-to-head
testing of a popular traditional valve versus a new model, the new valve’s
ambient temperature range was wider. Compared to some older designs, maximum
temperature can be improved by 60° F and pressure can be more than doubled. The
newest designs combine several features proven to offer significant benefits in
traditional valves, such as threaded bonnets, a floating PTFE diaphragm, and a
zero minimum operating differential design. They also add innovative new
approaches such as optimized geometry, DC construction, and a lower power coil.
For major performance factors, the improvements may be dramatic. This report
demonstrates how choosing the right next-generation steam valve can deliver
benefits such as 60% higher flow rates, four times longer life, and more.
- Hot
Water and Steam Service - An absolute "mine" of information
about all things associated with steam.
Intelligence for LNG Ball Valves - Intelligent valve technology can help to reach the most demanding targets in anti-surge control applications, where fast and accurate operation is needed at extreme service conditions with high pressure differentials and tight shutoff - from our valued sponsor Metso Automation.
Automatic Partial Stroke Testing Prevents Disasters - Janne Laaksonen, Metso Automation - Safety engineers throughout the world are struggling with the problem of how to best comply with new and more stringent safety requirements - IEC requirements state that manufacturers must determine and document precise levels of safety and furnish quantifiable proof of compliance. In light of these requirements, manufacturing companies feel it is necessary to reassess their traditional safety loop testing procedures. In particular, they feel it is important to improve their safety valve testing procedures in order to drive costs down and improve plant safety - from SA Instrumentation and Control and our valued sponsor Metso Automation.
Presentation:
"Unicorns and Air Gaps - Do They Really Exist?" - Eric Byres'
presentation explains:
- The current status of air gaps and industrial control systems
- The challenge of air gaps and today’s infrastructure systems
- Why real world security measures are needed
- How an oil and gas refinery deals with multiple pathways
- The importance of last-line-of-defense critical systems
This presentation will increase your knowledge of air gaps as a security
measure and provide you with practical advice on real-world security for
control systems. You will need to register to download.
SCADA Security: A Call-out to Control Engineers about Air Gaps- Recently Eric Byres discussed how security experts and ICS / SCADA vendors are giving up on the dream of the air gap as a viable security solution for the modern control system. Unfortunately, it is still all too easy to believe your control system is isolated. Recently he had a very enlightening conversation with a control engineer who thought his system was air gapped.
SCADA Security: New Vulnerability Disclosure Framework a Step Forward - In a move that may be helpful for critical infrastructure asset owners, on July 23 2012 the Industrial Control Systems Joint Working Group (ICSJWG) published a new document for disclosing Industrial Control System (ICS) vulnerabilities titled Common Industrial Control System Vulnerability Framework . It provides building blocks for a new vulnerability disclosure process that will benefit both vendors and asset owners.
SCADA Security Basics: SCADA vs. ICS Terminology - “What’s the difference between a SCADA system and an ICS system, and if there is no difference, then why do we have two different names?” - This is a good question, because unless you have worked in the industrial automation field for a few decades, the terminology can seem very confusing. Not only do we have SCADA versus ICS, we also have terms like Process Control, Discrete Control, Industrial Automation, Manufacturing Automation Systems, Distributed Control Systems, Energy Management Systems and so on.
SCADA Security Basics: Why are PLCs so Insecure? - An interesting discussion on this point which provides much "food for thought".
Posted by: Jim Russell, August 2012
Obtaining Stranded Information and Diagnostics - Most plants have hundreds, or even thousands, of HART devices, but not all of these are delivering the full range of process variables, calibration, maintenance and diagnostic data to plant operators and maintenance departments. This is because they have no means of delivering that data to the control room. One reason is that some legacy control systems are analogue, meaning they have no access to the digital HART data thus preventing operators from taking full advantage of the device intelligence. To achieve maximum insight, the existing control system must be upgraded by installing HART I/O interface cards and software modules - from SA Instrument & Control.
Human-Centered Design (HCD) in an FDT/DTM Environment - Tom Wallace - We Need a New Way to Interface With Field Devices That Increases Productivity, Reduces Training Needs, and Reduces Human Error - The process industry faces a perfect storm of factors that will change how we interact with field devices. Plants are becoming larger, more complex and subject to more regulation. Plants will have more devices, more different device types, and the devices themselves will be more complex. Also, devices and communication protocols are becoming more complex and capable. In addition, we're facing the loss of experienced workers with their replacements being less experienced and fewer in number. We face doing more work and more complex work with fewer and less experienced people. We need a new way to interface with field devices that increases productivity, reduces training needs, and reduces human error. This new way will use human-centered design (HCD) - from Control Global.
32 Minutes to Understanding SCADA Security - Engineers as well as IT staff in the process control and SCADA industries have varying levels of knowledge about industrial cyber security. We come across this regularly when talking to people at industry events or speaking with customers or partners. To help you, no matter where you are in the learning curve, we have recently released a five-part video series. This article summarizes the videos and provides you with direct access to them.
ICS Security and VLANs – Boogeyman or Helper? - Virtual Local Area Networks (VLANs) should not be counted on as a security feature of modern managed Ethernet switch networks. This is now common knowledge, both in IT departments and also in the Industrial Control Community. Indeed in Eric Byres’ article "Why VLAN Security isn't SCADA Security at all" he points out that switches with VLANS are not firewalls. But are VLANs the boogeyman of industrial control system security...or are they underestimated helpers? This article examines that question in detail.
Pipeline Integrity - New Innovations in Leak Detection for Hydrocarbon Applications - Frank Fromm - In order to ensure the integrity of their pipelines and remain in compliance with new and tougher laws, a greater number of businesses are now making the conscientious decision to install advanced leak-detection systems. These systems are capable of detecting both the presence and location of a leak, allowing a pipeline operator to address the situation quickly and effectively – before the leak can harm property or people. A variety of leak-detection systems are currently available and corporations must thoroughly evaluate the benefits of each. A leak-detection system should demonstrate consistently high levels of sensitivity, accuracy, reliability, and robustness. It should be easy for a pipeline operator to learn, understand and use. Ideally, the system should also integrate software with instrumentation in order to enhance performance and simplify maintenance. After reviewing several recent U.S. and international laws pertaining to leak detection for pipelines, this article takes a detailed look at one innovative leak detection system and demonstrate how a Taiwanese petrochemical company put this system to good use - from www.flowcontrolnetwork.com.
Flowmeter Selection Strategies Part 2 - How to Choose the Right Technology for Gas Measurements - John Frederick - Covers the topics typically covered in a comprehensive gas flow measurement course. The following describes common types of gas flowmeters and provides guidelines for their selection and usage. It also discusses the influence of basic gas properties on meter performance and examines methods and equipment for accurate calibration - from www.flowcontrolnetwork.com.
******
Total Life Cycle Investment: Changing how we think about Well Head Gas Flow Meters-Tim Hayes - Operations Engineer, Spring Gully - In a time when large capital ventures are realising the need to consider total life cycle operational costs, reviewing lower maintenance flow meter technology may see a decrease in the expected operational expenditure on large Coal Seam Gas (CSG) projects - thanks to the Origin Energy Talent Search Team.
Risky Business: Functional Safety at Origin - Peter Todd, Engineering Manager, Origin Upstream - No, this is not a review of the 1983 American teen comedy starring Tom Cruise but a brief overview of the serious subject of process functional safety. There are significant differences in the legislative frameworks both domestically and internationally under which Origin operate. Legal framework objectives are generally to prevent and minimise the effects of major accidents and near misses. As an operator, legal compliance requirements are often exceeded by adopting performance based standards. One such standard is IEC61511. In order to manage Risk it is useful to understand where errors can occur - Many thanks to the Origin Energy Talent Search Team.
Bridging the Intrinsically-Safe Fieldbus Disconnect - MooreHawke, a division of Moore Industries has released a new white paper highlighting the various methods of connecting fieldbus devices in hazardous areas without compromising safety. This paper presents an overview of different ways to safely implement PROFIBUS PA or FOUNDATION fieldbus H1™ networks in hazardous areas while maintaining cost control and the inherent advantages of fieldbus. It highlights different methods of designing and installing fieldbus in hazardous areas including Entity, FISCO and High-Powered Trunk with field barriers. Also explored is the High Power Intrinsically-Safe Trunk concept pioneered by MooreHawke. This method allows users to get up to 350mA of I.S. power into a hazardous area by utilizing a patented split-architecture design. Readers of the white paper will have a better understanding of the complexities of Intrinsically-Safe fieldbus designs along with the history of innovations that have led to the latest industry advances. The white paper also includes a full-page chart highlighting key data points and installation advantages unique to each method.
Innovative Passive Fire Protection Cabinets Extend Margin of Safety for Critical Plant Shutdown Equipment - A novel new range of cabinets to protect critical process equipment in hazardous areas against very high temperature fires has been launched by the field equipment protection specialist Intertec. The cabinets ensure that equipment such as emergency shutdown valves remain operational by keeping them below 60 degrees Centigrade for periods of up to 90 minutes in the event of a hydrocarbon-based fire, to allow time for controlled shutdown. The new 90-minute protection capability - which Intertec believes to be a first in this sector of the industry - has been tested against the ANSI/UL 1709 standard by the test body MPA Dresden.
Lightning Protection System - Ultimate Line of Defense - Mark S. Harger - Lightning, one of nature’s most destructive forces, continues to wreak havoc on lives and property especially in today’s electronic environment. On average, a lightning strike contains approximately 50 million volts carrying 18,000–20,000 amperes of current, but strikes with up to 300 million volts and 200,000 amps are not that uncommon. To protect against this destructive phenomena, a properly designed and UL-listed lightning protection system is required. The National Fire Protection Association (NFPA) 780 Standard for the Installation of Lightning Protection Systems defines a lightning protection system as “a complete system of strike termination devices, conductors, grounding electrodes, interconnecting conductors, surge suppression devices and other connectors or fittings [that] are required to complete the system.” How does this system work? Picture a hockey goalie protecting his net. He has four basic tools—gloves, mask, stick, and pads— that help him prevent the puck from entering the net. Just like a goalie, there are four main parts that comprise a lightning protection system - from Nema.
NIST Launches New Website to Educate Industry About Alternatives to Mercury Thermometers - As part of a larger effort to reduce the amount of mercury, a potent neurotoxin, in the environment, the National Institute of Standards and Technology (NIST) has launched a new website to help industry scientists and engineers decide the best temperature measurement alternative for their purposes. The website also includes information about myths pertaining to mercury and temperature measurement and how to safely package and recycle mercury-containing products.
Posted by: Jim Russell, June 2012
Well Heads, Chokes and SSSVs - Chokes hold a backpressure on a flowing well to make better use of the gas for natural gas lift and to control the bottomhole pressure for recovery reasons. In vertical pipe flow, the gas expands rapidly with decreasing hydrostatic head and the liquid moves in slugs through the tubing. The potential gas lift energy is rapidly lost and liquids fall back and begin to accumulate over the perforations. Accumulating liquids hold a back pressure on the formation. If enough liquids accumulate, the well may "die" and quit flowing. A choke holds back pressure by restricting the flow opening at the well head. Back pressure restricts the uncontrolled expansion and rise of the gas and thus helps keep the gas dispersed in the liquids on the way up the tubing - from George E King Consulting Inc.
Building a Safe Reliable Burner Management System - A new era is dawning for burner management systems (BMS). Thanks to changing and broadening regulatory standards, the door has opened to embrace the Safety-PLC based BMS solution—an approach that not only allows a manufacturing plant to include safety in one complete, integrated automation solution but also reap a multitude of benefits ranging from reduced costs and design time to improved safety and performance - from Siemens.
Burner Management Specification Tutorial Webcast - Learn how to properly specify a PLC–based burner management system (BMS) compliant to today's industry safety standards (NFPA, API, ISA) as Siemens' Certified Functional Safety Expert Charles Fialkowski and Control Global's Editor in Chief Walt Boyes discuss what’s new and relevant.
Specification of Safety-Integrated Burner Management Systems - Burner Management Systems (BMS) are one of the most widespread process safety applications. Historically, there has not been much guidance on the use of automation systems for BMS, and industry standards left much to interpretation; this changed with the release of International Society for Automation’s (ISA) technical report ISA-TR84.00.05-2010, Guidance on the Identification of Safety Instrumented Functions (SIF) in Burner Management Systems (BMS). Those with an understanding of the basic requirements of ANSI/ISA-84.00.01-2004 and other good engineering practices applicable to BMS are the audience for this report - from totallyintegratedautomation.com.
Ensuring Safety in Process Design and Operation - Steve Blair - Ever since the Deepwater Horizon accident in 2010, safety and risk management has become the subject pushed to the forefront of every business operating in the oil and gas sector. This increased safety emphasis occurs against a backdrop of technological innovation, which has resulted in the general de-manning of process plants and the requirement for engineers to have broad skill sets to cover a wider range of responsibilities. As a consequence, there is a growing requirement for instrument manufacturers to apply their knowledge and expertise to on-site safety and operational assessments. A hazard and operability study (HAZOP) is a structured and systematic examination of a planned or existing process, conducted to identify and evaluate problems that may represent a risk to personnel or equipment or prevent efficient operation. This increased drive to review safety processes can be reduced to two fundamental questions: whether a process is safe; and how an operations team will know if a specific process is not operating correctly - from the ISA and InTech.
The following links are from the 61508
Association
What
is a Functional Safety System?
- A short description.
What
is IEC 61508? - A short description.
Competence
Guidelines - The crucial component in the management of functional safety is
the competence of all those with a role to play throughout the safety system
lifecycle. Clause 6 of IEC 61508 Part 1 specifies the requirements for the
management of functional safety including reference to the need for those
involved in any part of the safety system lifecycle to have the necessary
competence.
What’s
it all about? - Functional Safety Management within
your reach - Whether you are working to IEC61511 on a process industry
application or simply using BS EN 61508, the master standard for safety
instrumented systems, Functional Safety Management is a basic requirement of the
standard. It is required in IEC61508 part 1 clause 6 and IEC61511 part 1 clause
5.
What
is Functional Safety Management? - This document gives
a concise overview about Functional Safety Management Systems,
FREE
downloadable Functional Safety Management Declaration -Describes
what to do in three simple steps.
Getting
advice and assistance
Includes details on the Functional Safety Management
Declaration form, CASS Functional Safety Management Declaration
Lodging your Functional Safety Management Declaration
- download
here in MS Word 97/2000 format (“.doc”)
- download
here in ISO 26300 file format (“.odt”)
Help pages (in pdf format):
Help
for Part 1 – download here.
Help
for Part 2 – download here.
Help
for Part 3 – download here.
Functional Safety Management Toolbox Talks - These
links give you the essential toolbox tips in just a few sheets that will help
your team to all be “singing from the same hymn sheet”
• Directors
• Senior
Management
•
Purchaser
• Project
Manager
• Project
Engineer
• Inspection
and QA
• Operations
• Maintenance
• Service
Engineer
• Sales
Person
• Installers
Cookbook Versus Performance SIS Practices - Angela E. Summers, Ph.D., P.E, and Michela Gentile - A Safety Instrumented System (SIS) is designed to achieve or maintain a safe state of the process when unacceptable process conditions are detected. An SIS is an Independent Protection Layer that is covered by the performance-based standard ANSI/ISA 84.00.01-2004. The risk reduction allocated to the SIS determines its target safety integrity level (SIL). ANSI/ISA 84.00.01-2004 allows a combination of factors to be considered in the verification of the SIL of the SIS. Performance-based practices provide flexibility to users, yet add complexity to the design process, encouraging project teams to reinvent the wheel for even widely used process equipment. For many engineering applications, prescriptive approaches are favoured due to simplicity. These so-called “cookbook” practices were very common in the process industry when ANSI/ISA 84.01-1996 was issued. They are also the backbone of many application standards and recommended practices. The cookbook typically specifies the SIS and maximum proof test interval based on analysis and accepted practice. The user must ensure that the cookbook assumptions are met by the existing equipment and mechanical integrity program. Otherwise, the installed risk reduction may not achieve the expected performance. This paper provides an example of a “cookbook” approach for a simple SIS and illustrates the effect of extending the proof test interval from 1 year to 5 years on its probability of failure on demand - from SIS-TECH Solutions.
To Err is Human: Using Technology to Try to Solve this Problem is Equally Human - In 2003, ConocoPhillips Marine conducted a study of the initial behaviours that are the root causes of incidents or accidents. It showed that for every 300,000 ‘at-risk’ behaviours there are 3000 near misses, 300 recordable injuries, 30 lost workdays and, ultimately, one fatality. In a control room scenario, if we can maximise the ability of the operator to make the correct decision when called upon, we can maximise human reliability with the aim of reducing the number of at-risk behaviours and ultimately the number of major incidents or fatalities - from www.processonline.com.au and PAS Inc.
Why is Alarm Management Required in Modern Plants? - Stan DeVries - All modern process control systems provide alarm systems to assist process operators in managing abnormal situations. Nevertheless, the integrity and effectiveness of alarm systems can either provide assistance or be a hindrance to the process operators in responding to these situations. Through the efforts of the Abnormal Situation Management Consortium, EEMUA, and other professional groups, a large amount of best practice information exists to aid the control system engineer in designing effective alarm systems. However, due to various reasons, most existing control systems must be redesigned/re-engineered in order to take advantage of these newer system capabilities and best practices. The re-design/re-engineering of alarm systems in these control systems is a responsible first step in responding to the increasing frequency of industrial incidents and to begin to address the billions of dollars that these incidents cost manufacturers annually. By any comparison, the re-design/re-engineering efforts are well worth the investment. This white paper presents a new alarm philosophy and approach to achieve these objectives.
High Fidelity Dynamic Simulation of Compressor Systems - Realize the Benefits of "20/20 Hindsight" before Commissioning a New Compressor or New Compressor Controls - Jim Jacoby, Ian Willetts PhD and Alan Wade - In recent times, the integration of turbomachinery control functions and hardware into a single high reliability platform with robust control algorithms, such as the industry leading Triconex® Tricon® platform, has led to significant improvements in system performance and operability. In the past, a compressor train might have had separate controllers for suction pressure, recycle and turbine or motor speed as well as separate relay sequencing and alarm panels, a separate vibration-monitoring package and a separate over speed trip protection package. Now, to meet the requirements of today’s industry standards, only the over speed protection system is required.
Operational Excellence - Donald Clark, Peter G. Martin PhD, Vice Charles Piper and Simon Windust - Across industries and around the globe, today’s organizations find themselves under continued pressure to optimize business performance. With the dynamic nature of the marketplace and the level of complexity, this represents an ongoing journey, requiring a focus on the fundamentals of Operational Excellence. Attaining Operational Excellence requires that industrial companies maximize the efficiency and profitability from their operations through excellent control and drive maximum business value from all their industrial assets, all while reducing negative environmental impact and improving safety. The key to addressing all of these goals lies in empowering our most critical asset – our people. Therefore, Invensys has defined Operational Excellence along four key themes: Control Excellence, Asset Excellence, People Excellence and Environment and Safety Excellence.
Competing for the Future - does Wireless Play a Part? - There are many issues that need to be considered in the implementation of a wireless sensor network. This article looks at these issues from the perspective of WirelessHART technology, but whatever wireless technology is used, the end user needs to take the following factors into consideration - from the excellent publication www.processonline.com.au
Securing SCADA systems from APTs like Flame and Stuxnet – Part 1 - Eric Byres - Recently a very complex worm called Flame has been discovered attacking companies in the Middle East, and it is an excellent example of what security experts call an Advanced Persistent Threat (APT). Figuring out how to defend against APTs is a major focus in the IT security world.
Securing SCADA systems from APTs like Flame and Stuxnet – Part 2 - Professor Paul Dorey recently presented a paper about the seven important lessons the IT world has learned in managing Advanced Persistent Threats (APTs). This article discusses lessons #2, #3 and #4, and how to apply these lessons to ICS and SCADA security.
Offshore Oil and Gas Platform: Cyber Security Implementation - An oil and gas production company operates a fixed natural gas and oil gathering and processing platform located in deep water on the US continental shelf. The platform serves multiple natural gas and oil wells connected by pipes running along the seabed back to the platform. The facility was designed to handle a high volume, thus there is a strong emphasis on reliability. Any downtime, whether caused by accidental or malicious forces, would interrupt oil and gas production and be very costly. The production company presented Cimation, a Tofino Certified System Integrator, with the challenge of maximizing the reliability and uptime of the platform.
Media Redundancy Concepts - High Availability in Industrial Ethernet - The general idea of media redundancy and redundant paths is almost as old as the use of Ethernet for industrial communications, and so is the dilemma that – by definition – Ethernet technology’s broadcast nature does not permit physical loops and therefore effectively forbids redundant communications paths. However, fault tolerance, which necessitates the use of redundant structures, is a vital basic requirement of very many automation systems. This means that the use of Ethernet for automation technology applications calls for protocols that are able to resolve the physical loops generated by the introduction of redundant pathways. To facilitate the use of redundant communications structures in office environments, the IEEE (Institute of Electrical and Electronics Engineers) specified the spanning tree protocol (STP), which was published in the 802.1D 1990 standard. For the first time this enabled all Ethernet switches to employ an algorithm to facilitate interconnected network structures, albeit with switchover times of the order of many tens of seconds. Further protocols based on the underlying STP mechanisms were subsequently developed, and these were better tailored to the specific requirements of an industrial environment, in particular with markedly reduced switchover times. This white paper will give you an overview of the current state of the technology and its solutions and also sketch a number of specific applications - from Belden.
Guide to Impulse Lines for Differential-Pressure Flowmeters - Good practice in the design and installation of impulse lines (small bore pipes) that connect a differential pressure flow meter to the instrument for measurement of the pressure difference is provided. The guide is intended to assist the designer to avoid known problems with impulse lines that can lead to incorrect measurement - from IDC and NEL.
Polarographic Oxygen Measurement For Cost-efficient, In-situ Operation - For the measurement of oxygen in continuous process analysis, several technologies are available. Because they differ widely in terms of application coverage, field performance and ease of use, the right technology has to be carefully chosen. In this white paper, we review the possibilities offered by measurement systems based on polarographic sensing technology - from Mettler-Toledo AG Process Analytics
Vortex Shedding Tutorial - Wade Mattar and James Vignos - This excellent Tutorial covers; Principle of Operation, Calculation of Mass Flow and Standard Volume, Flowmeter Construction, Application Considerations, Meter Selection, Meter Installation and Meter Configuration - from Invensys Foxboro.
Backup for Critical Processes - Stephen L. Arnold - In many industries, there are processes so critical that extraordinary methods must be taken to ensure that those processes are not halted or even stalled. To facilitate this, end users in many industries implement hot standby, or redundant systems. While it might not be practical for end users to implement a hot standby solution with a very expensive distributed control system (DCS), many end users, consulting engineers, system integrators, and others are now learning that PLC hot standby solutions can offer high availability in a more cost effective hardware and software combination. Hot standby means having two sets of process controls operating simultaneously, with the contingent or back-up system able to assume control of the process immediately if the main system falters or fails. The critical function of hot standby is to prevent an unanticipated process interruption that could result in lost production time, equipment damage, and lost raw materials - From Control Engineering.
Design to Humans: Lessons in HMI - Establishing a common language is often the first step to master a domain. This is especially true in the area of human-machine interface (HMI) design. HMI is the means by which a user operates a machine, system, or process (via hardwired panels or a computerized console). It also encompasses decision-support devices, such as operating procedures. Bandwidth availability from the modern HMI hardware and software has grown exponentially over the last few decades, and experts agree current Internet and web technologies cannot yet provide what most existing HMI users need: high data rates, high animation capability, and sub-second screen changes. Since humans cannot absorb information at the same rate as HMI bandwidth, it is important to design HMIs that better support the operator. In the petrochemical industry in U.S. alone, we estimate inadequacies in the means to deal with abnormal situations (including HMIs used to identify, diagnose, and deal with those situations) cost between $10 billion-$20 billion to the industry each year - from ISA and InTech.
Developing a Control Logic Specification - Michael Whitt -The primary purpose of a Supervisory Control and Data Acquisition (SCADA) system is to provide useful information to an operator in a timely, pertinent fashion. Sometimes, this means the data needs to display over time in a trend display or chart. Sometimes, the instantaneous (real-time) value of the data needs to be on display too. A well-written control specification will describe how the systems integrator should manipulate the data values as it permeates the control system - from ISA and InTech.
Safety Standards Essential for Automation Tools - John Dressel - Safety networks requiring special documentation in instrument engineering automation systems include emergency shutdown systems (ESD), burner management systems (BMS), fire and gas systems (F&G), and SIS or interlock systems - from the ISA and InTech.
Old Fashioned Engineering Dodges Traps - Jan Jekielek - Today’s perpetually improving technology brings new equipment, systems, solutions, and semantics. It also brings new dramatic challenges. Project requirements become greater and the level of control systems project complexity, and costs increase. With all this to keep track of, it is important to keep an eye out for myths and traps in the field and get on with the business of good old-fashioned control systems engineering. Old-fashioned control systems engineering means more than a nostalgic connotation of the good old times when job estimates were based on the supervisor’s assessment on how many people were needed for the project. It also means cultivating the principle of one-page schedules and cost updates and on-the-dot, minimized meetings, all of that allowing for maximizing the value of the project outcome. Full recognition and rejection of all kinds of humbug, regardless of the source, is one of the most distracting and de-motivating factors for any group of productive people.
Low Smoke IEC compliant Non Halogen Cables Provide Maximum Safety and Assurance - Awareness of the impact of smoke and harmful gases emitted during a fire has led to a growing demand for an alternative to the more traditional plastic halogenated cable constructions. PVC has long been used as an appropriate cable insulation and jacketing material with a high degree of flame-retardancy. However, in the event of a fire this will generate dense black smoke, with toxic and corrosive gases that can cause fatality and destruction. This fatality and destruction is attributable to the significant amounts of halogens, namely chlorine, found in PVC based compounds. On combustion, lethal gas is released, which on contact with moisture produces copious amounts of hydrochloric acid. Particularly hazardous in areas of minimal ventilation and restricted escape, the dense black smoke impairs visibility and means of escape, equipment will be damaged by the corrosive gases whilst the effects of inhalation of toxic gases can be fatal. Flame retardancy is important but so is the choice of a cable that emits smoke in very low levels and more importantly – without harmful corrosive and toxic gases. Despite stricter legislation and a more responsible attitude, lives and equipment are still put at risk due to the use of halogenated cables or cables that scarcely meet recommended industry standards - from Beldon.
Why 'Industrial Ethernet' is more than just 'Industrial' + 'Ethernet' - Justin Nga - The increasing use of digital equipment in industrial environments coupled with increased integration and data bandwidth requirements has led to growing adoption of Ethernet (IEEE 802.3) for communication in place of older serial-based communication systems. However, simply selecting ruggedised versions of Ethernet equipment originally designed for conventional IT environments will not create a true Industrial Ethernet network - from Belden and PACE.
Choosing the Right Cable for your Variable Frequency Drive (VFD) System - Brian Shuman - Like many engineering solutions, VFDs present not only benefits, but drawbacks as well. For example, the same fast switching rate of the transistors inside a pulse width modulated VFD that can accommodate an abrupt speed change in a motor (and offer precise control of processes) is also capable of generating unwanted noise in the drive system cable and in the drive itself. Electrical energy flowing in the cable contains frequencies as high as 30 megahertz. If this radio frequency energy is not contained within the cable, it can radiate out to interfere with the proper operation of nearby electronic equipment, less than robust, or commercial-grade Ethernet systems, and simple instrumentation wires even circuits that have absolutely nothing to do with the VFD system itself - from Belden.
Theory of pH Measurement - pH is a measure of the acidity or alkalinity of a water solution. The acidity or alkalinity of a water solution is determined by the relative number of hydrogen ions (H+) or hydroxyl ions (OH-) present. Acidic solutions have a higher relative number of hydrogen ions, while alkaline (also called basic) solutions have a higher relative number of hydroxyl ions. Acids are substances which either dissociate (split apart) to release hydrogen ions or react with water to form hydrogen ions. Bases are substances that dissociate to release hydroxyl ions or react with water to form hydroxyl ions - from Emerson Process Management.
Smart pH loops for Plug-n-Play Installation Reduce Calibration Time - New technology enhances pH sensors usage because of the Smart software that's implemented in advanced pH sensors and instruments. Never before has it been so easy to calibrate, plug-n-play, and evaluate pH monitoring. Before the Smart technology emerged, the only way to calibrate the pH sensor was to carry all of the calibration equipment into the field. In many facilities, this meant carrying at least two buffer solution bottles, two beakers and one rinse bottle to the various installation sites. Then, the calibration was done on-site at a location closest to the sensor installation. So come rain or shine, sleet or snow, hot or cold weather conditions, the technician had to maintain the sensor in even the worst environmental conditions.Smart technology changes all that. Smart pH sensors have a memory which holds calibration information, so there is no need to carry equipment to field - from Emerson Process Management and PACE.
Pick the Proper Hose - Patrick Werrlein, Swagelok Company - Making a correct choice requires an understanding of hose components - The right hose keeps your process performing safely and cost effectively. The wrong hose could undermine your operations, put personnel at risk and compromise your bottom-line, sometimes without you being aware of it - from Chemical Processing.
A Guide to Wireless Sensor Technology - Brett Biondi and Jonas Berge - Since its emergence, managers and engineers have done due diligence on IEC 62591 WirelessHART, considered to be a global standard for wireless sensor based technologies. Many engineers now look to WirelessHART to cost effectively automate manual tasks, proactively maintain and monitor critical assets, comply with regulatory frameworks such as the EPA, drive productivity improvements and minimise production costs. Thousands of WirelessHART networks with hundreds of millions of operating hours are in service around the world. How are engineers using wireless to create greater competitive advantage? This article begins by understanding WirelessHART and then looks at innovative ways engineers are using the technology - from the excellent publication PACE and Emerson Process Management.
Well Heads, Chokes and SSSVs - Chokes hold a backpressure on a flowing well to make better use of the gas for natural gas lift and to control the bottomhole pressure for recovery reasons. In vertical pipe flow, the gas expands rapidly with decreasing hydrostatic head and the liquid moves in slugs through the tubing. The potential gas lift energy is rapidly lost and liquids fall back and begin to accumulate over the perforations. Accumulating liquids hold a back pressure on the formation. If enough liquids accumulate, the well may "die" and quit flowing. A choke holds back pressure by restricting the flow opening at the well head. Back pressure restricts the uncontrolled expansion and rise of the gas and thus helps keep the gas dispersed in the liquids on the way up the tubing - from George E King Consulting Inc.
Clever pumping - All In One Drives Make the Water Industry’s Pumps Intelligent - Sanna-Kaisa Ehanto - The growing use of VSDs, particularly intelligent drives for pump control, represents a major departure from the standard operating practice of using control valves to vary fluid flow. With its low energy usage and low maintenance outlay, the total lifecycle cost of a VSD-controlled pumping system can be significantly less than traditional pump technology. Other VSD benefits include smoother start-ups and production changes, more precise control during continuous operation, and faster diagnosis of potential system problems before product quality or process operation is negatively affected. The emergence of intelligent pumps is a critical step forward in the evolution of process management. With embedded intelligence, VSDs can provide pump control, pump condition monitoring, protection and traditional energy saving benefits - from ABB Drives.
To Err is Human: Using Technology to Try to Solve this Problem is Equally Human - In 2003, ConocoPhillips Marine conducted a study of the initial behaviours that are the root causes of incidents or accidents. It showed that for every 300,000 ‘at-risk’ behaviours there are 3000 near misses, 300 recordable injuries, 30 lost workdays and, ultimately, one fatality. In a control room scenario, if we can maximise the ability of the operator to make the correct decision when called upon, we can maximise human reliability with the aim of reducing the number of at-risk behaviours and ultimately the number of major incidents or fatalities - from www.processonline.com.au and PAS Inc.
Matching Valve Type to Function - A Tutorial in Valve Selection - Michael D Adkins - In selecting valves for instrumentation, the choices are many and varied. The choice depends mostly on the application the valve is to be used for. When selecting a valve for an instrumentation system, your choices may seem overwhelming. Just to name a few, there are ball valves, diaphragm and bellows valves, as well as check valves, excess flow valves, fine metering, gate, multiport, needle, plug, relief, rising plug and safety valves. Further, each of these valves comes in many sizes, configurations, materials of construction and actuation modes. To make the best choice, it is always good practice to ask the first question in valve selection: what do I want the valve to do? From www.processonline.com.au
Ensuring Safety in Process Design and Operation - Steve Blair - Ever since the Deepwater Horizon accident in 2010, safety and risk management has become the subject pushed to the forefront of every business operating in the oil and gas sector. This increased safety emphasis occurs against a backdrop of technological innovation, which has resulted in the general de-manning of process plants and the requirement for engineers to have broad skill sets to cover a wider range of responsibilities. As a consequence, there is a growing requirement for instrument manufacturers to apply their knowledge and expertise to on-site safety and operational assessments. A hazard and operability study (HAZOP) is a structured and systematic examination of a planned or existing process, conducted to identify and evaluate problems that may represent a risk to personnel or equipment or prevent efficient operation. This increased drive to review safety processes can be reduced to two fundamental questions: whether a process is safe; and how an operations team will know if a specific process is not operating correctly - from the ISA and InTech.
Using Alarm Suppression - Effective Alarm Systems Improve Operations - Charlie Fialkowki - One of the signs of an effective alarm system is that it presents alarms to the operator only when they are relevant and require their response (attention). This means the alarm system is able to track the state of the process in order to know when to present the alarm and when to suppress it. Transient plant conditions, use of different feedstocks, and unplanned process upsets make this a challenge for many process applications. Modern systems provide a powerful and easy-to-configure capability for suppressing alarms dynamically based on the state of the process and/or equipment (called automatic alarm hiding). It can be used, for example, to suppress alarms when equipment is out of service or in response to a compressor trip (which would otherwise lead to an alarm flood). Overloading the operator with stale (irrelevant) alarms or alarm floods can lead to increased operator stress, missed alarms, operator error, production losses, or worse. This article discusses how to implement designed alarm suppression (a form of advanced alarming) following the best practices and recommendations of the ISA standard ANSI/ISA-18.2-2009, Management of Alarm Systems for the Process Industries, as well as EEMUA 191, Alarm Systems: A Guide to Design, Management, and Procurement, and NAMUR NA 102, Alarm Management for Process Control Industries.
How Do you Identify the Correct Tray Cables for your Next Application? - The term tray cable is being heard everywhere but what exactly is a tray cable and what are its benefits? This educational paper from Turck will (a) Define what a tray cable is (b) Describe the different types of tray cables and (c) Provide uses and standards for each type of tray cable
Posted by: Jim Russell, May 2012
Sensors - How to Choose the Right Sensor for Your Measurement System - You can choose from many different sensors on the market today to measure all types of natural phenomena. This white paper categorizes and compares the most common sensors for measuring seven of these phenomena to help you choose the best option for your application - from National Instruments.
Proper Employment of Guided Wave Radar in Steam Loops - Keith Riley and Ravi Jethra - This white paper discusses how guided wave radar can be used to measure level in steam applications such as feedwater tanks, high pressure preheaters, hotwells and drums from www.automation.com and and Endress+Hauser.
Field Device Networking: Extending Interoperability Beyond Devices -Larry O’Brien - Testing field devices may not be enough. Most interoperability problems happen when a device tries to communicate with a host system, but that can be addressed. As a company that is responsible for developing and maintaining communication protocols that are used by a large number of equipment manufacturers and end users, interoperability is one of our greatest concerns. Interoperability in this context is the idea that equipment from a variety of manufacturers can function in the same system without having to be coaxed or forced in the form of reconfiguration or other changes. A pressure sensor from company A should function on the same fieldbus segment as another unit from company D. To facilitate that objective, our organization, like other standards bodies, specifies how this communication takes place - from Control Engineering and the Fieldbus Foundation.
Two Wire Transmitter and the 4 - 20mA Current Loop - First appearing in the 1950’s with the advent of electrical and electronic controls, the 4-20mA signal standard reigns as one of the most popular mediums for signal transmission and electronic control in industrial environments nearly 60 years later - from www.automation.com and Acromag
Measuring Level Interfaces - Measuring the Interface between Two Liquids in a Tank presents Unique Challenges - Gene Henry - A common measurement in the oil & gas, chemical, and petrochemical industries is detecting the interface level between two liquids in the same tank or vessel, such as oil and water. The dissimilar density or specific gravity of the two liquids means the lower density liquid will float on top of the higher density liquid. In some cases, the two liquids will entirely separate, resulting in a “clear” interface that will be easier to detect. In other cases, an emulsion or “rag” layer will exist between the two liquids. Other interface situations include multiple interfaces between more than two products, or the interface between a liquid and a solid. In some cases, it may be necessary to measure the thickness of the upper layer - from the ISA, InTech and Endress+Hauser.
Eclipse®705 receives SIL3 Certificate from Exida - Magnetrol International, Incorporated has announced that exida, an accredited global functional safety certification company, has certified the product reliability and the engineering change processes for the Eclipse® Model 705 Guided Wave Radar Transmitter as Safety Integrity Level (SIL) 3 capable per IEC 61508. SIL certification is obtained through analysis based on quantitative data and tests indicating the length of time between failures and expected performance in the field. A Failure Mode Effect and Diagnostic Analysis (FMEDA) confirmed that the Magnetrol® Eclipse Model 705 has demonstrated a solid field use history, includes sound engineering processes, and is designed with capable self-diagnostics. Download the IEC61508 Functional Safety Assessment here.
Posted by: Jim Russell, April 2012
Hydraulics Education Site - This technical reference site by R van den Brink has some useful information. This includes What is hydraulics?, Energy conversion in a hydraulic system, Gear Pump , Gear Pump with three wheels, Axial Piston Pump, Axial Piston Pump with Variable Displacement, Vane Pump, Vane pump with variable displacement, Axial piston pump with rotating barrel, Gearmotor, Radial piston motor 'startype' , Internal radial piston motor, Internal radial piston motor as a wheel motor, ORBIT-motor, Limited angle rotary actuator, Draining, Pressure relief valve, Pilot operated pressure relief valve, Pilot operated pressure relief valve as an unloading valve, Pressure relief valve in the motor circuit, Direction control valve, Flow control, Pressure compensated flow control, Pilot operated checkvalve, Counterbalance valve, Interactive animation of the counterbalance valve, Accumulator, Cylinder with end position cushioning, Closed loop system, Cavitation, Compressibility of fluids, The Escher-cylinder and Interesting links.
High-End Intelligent Emergency Valve Applications - Jari Kirmanen - Process facilities today are facing growing challenges to meet requirements with respect to the environment, health and safety of the plant personnel while maximizing product output and quality. With increasing energy prices, process plants must further develop their processes and maximize the yield of valuable products in an energy-efficient way. Plant run-time targets are increasing, which also set more challenges on equipment reliability and safety. De-pressurizing or pressure protection, as well as burner emergency shut-off being part of the safety integrity system, is a part of the process industry’s backbone defence against a threat to personnel and equipment. Intelligent partial-stroke devices capable of diagnosing emergency valve condition are more commonly utilized in the hydrocarbon industry. General requirements and challenges together with the benefits of using emergency valves equipped with intelligent partial-stroke devices were considered in the Hydrocarbon engineer magazine article in November 2009 [1]. This article demonstrates more closely how intelligence solutions can be utilized and what kind of added value they bring by introducing three examples of high-end emergency valve applications - Thanks to ICEweb sponsor METSO.
Building Automation Migrates towards Ethernet and Wireless - James Hunt - Buildings are becoming more automated, but what kind of communication and control networks are needed? As building electrical installations gain greater sophistication, there is a corresponding growing requirement for extensive functional diversity, convenience and efficient operation of the increasingly large number of digital products that the average building now contains. This article reports on building automation requirements, and networking techniques used to carry out energy management and control tasks - from the Industrial Ethernet Book.
From Singing to Sensing - IECEx Certifies Modern Gas Detectors and Sensors - Like a Canary in a Coal Mine - The use of canaries as gas detectors had been a mining tradition in the UK since 1911. Toxic gases such as carbon monoxide, carbon dioxide or methane in the mine would kill the bird before affecting the miners. Because canaries tend to sing much of the time, they would stop singing prior to succumbing to the gas, so alerting miners to the danger. As reliable as canaries might have been, the switch to electronic gas detectors actually made sense and brought greater safety. Technologies are evolving constantly and modern gas detection devices are state-of-the-art, extremely sophisticated devices that use sensors to identify potentially hazardous gas leaks. They are usually part of larger safety systems that can be found in a wide variety of locations such as mines, oil rigs, refineries, paper mills and industrial / waste water treatment plants. They are also widely used by firefighters. These devices often interface with control systems so that a process can be shut down automatically in dangerous situations. This is well worth a read - from IECEX.
More PROFINET Videos - Sometimes one minute is not enough to find out about PROFINET. For those occasions, try some more detailed videos from the PROFI Interface Center, featuring Hunter Harrington.
MinutePROFINET YouTube Channel - A new YouTube channel has been created by PI North America called MinutePROFINET. It describes features of PROFINET through short ~60 sec videos. As the series progresses, expect more technical aspects of the technology to be helpfully explained. Check out the first two, and subscribe: click here.
pH Sensors: Know whether to Calibrate the Sensor, Clean the Sensor, Perform a Calibration Check or ...? - Fred Kohlmann - This paper addresses knowing when to do a pH sensor calibration versus a calibration check, how to properly clean a pH sensor, how to perform a pH sensor calibration and a decision tree for step by step guidance - from the ISA and Endress+Hauser.
New Video from Moore Industries Highlights the Use of the STA Safety Trip Alarm in Safety Instrumented Systems - Moore Industries has produced a new video showing how its STA Safety Trip Alarm serves as a logic solver that goes beyond what customers would expect from a standard alarm trip. The video shows how the STA can monitor potentially hazardous events as well as initiating emergency shutdown procedures or alerting personnel of unsafe process conditions
ARC Advisory Group: Control In The Field Enhances Process Integrity - In the white paper, titled "The Business Value Proposition of Control in the Field," ARC describes the incorporation of a function block structure and other supporting functions in Foundation fieldbus providing a complete automation infrastructure for operational excellence. Embedded control functionality in Foundation devices is one of the key enablers for achieving high availability control and a stepping-stone towards single-loop integrity - from the Fieldbus Foundation.
Understanding the Use Case for Control in the Field - Control in the field vs. control in the host: Foundation fieldbus technology allows for both, so how do you choose? A new study offers suggestions. If you are a Foundation fieldbus user, you know that it supports control in the field (CIF), which allows a sensor and actuator to form its own self-regulating PID loop, independent of the host control system. While the effectiveness of the approach is well documented, what user cases make it the most compelling for application? A new study has been completed by Industrial Systems and Control, an engineering consulting group in Glasgow, Scotland, that examines how CIF operates and where it is likely to offer the greatest advantages over traditional host-based process control. In the video Dr. Andy Clegg explains the parameters of the study, and the basic findings. His report discusses how his team carried out the independent evaluation, and the circumstances under which the high determinism of CIF can outperform conventional loops driven by a PLC or DCS - - from Control Engineering.
FOUNDATION for Remote Operations Management - One of the fastest growing segments in the world of process automation is remote operations management. As the name implies, remote operations refers to the management of automation assets that are located in or are dispersed throughout remote geographic locations where it is difficult or impossible to send personnel. This is not limited to remote offshore oil platforms and oil and gas pipelines. It can also include tank farms and terminals, water and wastewater treatment facilities, and any industry or application that requires remote access to automation assets
Video - The Unveiling of FOUNDATION for Remote Operations Management - The Fieldbus Foundation has unveiled its Foundation for Remote Operations Management (ROM) solution, a new technology initiative intended to develop a unified digital infrastructure for asset management in remote applications such as tank farms, terminals, pipelines, offshore platforms, and even OEM equipment skids. The technology enables fieldbus connectivity to remote I/O and the leading industrial wireless protocols, including WirelessHART and ISA 100.11a. It provides an interface to these wireless technologies and uses Electronic Device Description Language (EDDL) and function blocks to ensure interoperability with Foundation for ROM devices - from Control Engineering.
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Increased Demands for HIPPS Final Elements -Rens Wolters describes the impact of the new IEC 61508 Edition 2010 on final elements and HIPPS - In the oil and gas industry protection against high pressure is increasingly performed by means of instrumented systems rather than mechanical safety relief valves. When the risk is high and the response time is short this application is often referred to as HIPPS (High Integrity Pressure Protection System). The applicable standards - IEC 61508 and IEC 61511 - use the generic term SIF or SIS (Safety Instrumented Function or System), whereas the industry uses HIPPS for this specific application. In the standards the element that shuts-off the incoming flow and isolates the high pressure source (on-off valve) is called the final element. A new revision of the IEC 61508 was published in 2010 and seriously impacts the HIPPS final element.
Introduction to Laser Instruments and Applications - When the laser was invented in 1960, it was amazingly, a solution looking for a problem. While the laser's weapons potential was clear, most of the uses of lasers that have changed the World were not foreseen even by the so-called experts of the time. In this chapter, we touch on perhaps one tenth of one percent of those where lasers are now indispensable, or at least have the potential to be in the future - from www.repairfaq.org
Calibration Terminology - Details on calibration terms - from Beamex.
Calibration of Test Equipment for Maintenance Purposes - The responsibility of an Approved Maintenance Organisation (AMO) is to provide within its Maintenance Organisation Manual (Policy and Procedures Manual (or equivalent document) a list of all test equipment that must be calibrated and the process to track the calibration - from Civil Aviation Safety Authority.
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