Guide to alarm management

The definitive guide to best practices for effective alarm management and a concise summary of the new ISA standard

PAS has recently published the second edition of The Alarm Management Handbook by Eddie Habibi, PAS Founder and CEO, and Bill Hollifield, PAS Alarm Management Principal Consultant. It is the most comprehensive best-practices book available for designing and maintaining an effective alarm management system.

Ineffective alarm systems continue to haunt the processing and power industries worldwide, contributing to plant upsets and shutdowns. Alarm management improvement has been identified by many industrial companies as a critical business and safety improvement imperative in recent years. In response to this market need, PAS published the first edition of The Alarm Management Handbook in 2006. With the release of the new ANSI/ISA-18.2-2009 Management of Alarm Systems for the Process Industries, PAS has updated the book to incorporate the ideas presented in it. This new standard sets forth the work processes for designing, implementing, operating, and maintaining a modern alarm system in a life-cycle format. The 2nd edition includes a summary of the standard’s scope, regulatory impact, requirements, recommendations, and other details.

The new edition also includes much additional practical information on benchmarking alarm system performance, developing a comprehensive alarm philosophy, solving nuisance alarm problems, performing alarm rationalization, implementing advanced alarm handling techniques, and improving the operator HMI for optimum situation awareness and incident mitigation.

“The Alarm Management Handbook is a very practical guide to implementing an alarm management program, presented in a unique and entertaining style,” says Nicholas P. Sands, ISA-18 Co-Chair. “This edition provides new information, and ties the guidance in the previous edition to the new ISA-18.2 standard.”

Complex motion applications improvments

Motion controller can control up to 40 axes of synchronized motion at extremely fast loop rates

GE Intelligent Platforms has launched its advanced motion controller, PACMotion firmware version 1.5. PACMotion is designed to control up to 40 axes of synchronized motion all at the exact same servo update loop rate of 1ms independent of the number of motion axes. With this announcement, GE is making PACMotion the motion controller of choice in a host of new areas, including packaging, material handling, and automated assembly. By enabling connectivity to a wider variety of off-the-shelf devices, users will find PACMotion available to serve many more applications, which can lead to lower system cost.

Firmware version 1.5 features two axis analog servo control allowing control of one or two third-party amplifiers using a 10 VDC analog speed or torque command. A PACMotion module controls four axes, and each module can use two of those axes for third-party servos through this upgrade. Mixing of FANUC and analog axes on the same PACMotion module is also supported.

“This new version will allow users to connect a much broader range of devices to the exceptional functionality of PACMotion,” said Paul Derstine, Product Manager for GE Intelligent Platforms’ Control and Communications Systems. “There are times when a custom motor, linear actuator or linear hydraulic servo valve is required in an application. At other times in a machine retrofit, the servos are already in place and do not need to be replaced. This new firmware will open options for PACMotion to be used in many different areas to control machines enabling cost saving for the OEM on new machines by using lower cost servos and on field retrofits by enabling the reuse of existing servos.”

Program access to the event queue provides the machine operator with the ability to obtain diagnostic/troubleshooting information on the operator interface. Because customers need access to the most recent sequence of events/errors rather than the last axis or module error, this enhancement allows users to access the event queue data right within the program, without the need of accessing via Proficy® Machine Edition on a personal computer. The chronological sequence of the events is preserved aiding users in determining the exact sequence of events leading up to an error or machine shutdown. Access to such real-time sequential event data enables faster diagnosis of machine or line stoppages yielding increased machine uptime and enhanced productivity.

Several enhancements to PACMotion’s powerful cam functionality allow for tighter synchronization of axes. The Cam Load-Data feature allows exact positioning of all slave axes relative to the current position of the master prior to machine start-up rather than having to ramp slave axes to synchronize with the master. Ensuring precise synchronization can reduce product scrap at the beginning of a production run improving production yield. The new Cam Exit Distance feature enhances the flexibility of the cam feature by allowing for controlled exiting of a cam profile at a predetermined master position along the profile path. Exiting a cam before the end of the profile provides greater dynamic control flexibility to respond to machine or line events such as a jam or product changeover preventing additional product loss of production down time.

“GE’s PACMotion is the motion controller of choice for OEMs that need an integrated motion and machine logic solution. The proven dependability of GE products allows them to deliver unprecedented productivity in their machines through increased productivity, flexibility, and reliability. Unique features such the PACcore multi-processor architecture allows simultaneous updating of any number of axes with no performance degradation, on-demand data exchange providing real-time access to motion data asynchronous to the logic program scan and the ability to change nearly any motion parameter on the fly (even during a move) provides a powerful solution for complex motion control,” Derstine said.

More choice in controllers

Yokogawa Electric Corporation has released three additions to the UTAdvanced® controller series: the UP55A and UP35A program controllers and the UM33A digital indicator with alarms. Completing the UTAdvanced series, these new products give Yokogawa's customers greater choice in configuring systems and support a wider range of applications.

Development background
Indicating controllers are instruments that measure and display temperature, pressure, flow rate, and other types of data, and also display data on equipment operation. They are mounted on and control the operation of relatively small-scale stand-alone devices like industrial furnaces and semiconductor manufacturing machines.

The UTAdvanced controllers were first developed and introduced by Yokogawa in 2009, and have been primarily used in applications that involve the control of fixed values within preset targets. In response to the rising need for such controllers in other types of applications, Yokogawa has developed three new products. The UP55A and UP35A program controllers carry out programmed pattern control (control over time according to a preset pattern), and the UM33A digital indicator outputs an alarm when an input signal reaches a preset value.

Product features
1. UP55A and UP35A program controllers
· Support of the PROFIBUS-DP and CC-Link industrial communication protocols has been added. This allows these controllers to be connected with a wider range of PLCs, which are often mounted on other devices, and gives customers the flexibility to build an optimal multivendor system.
· In response to the needs of customers who wish to program patterns at a PLC, the processing of program data from PLCs has been speeded up.

2. UM33A digital indicator with alarms
· This digital indicator now has eight alarm outputs and eight screen display points, twice the number of the previous model.
· A dedicated program eases the task of entering alarm values and other information, eliminating the need to input them using the keys on the front panel of each device.

UTAdvanced digital indicating controllers come standard with a sequence control function based on the ladder logic programming language, which is widely used by engineers. This product series improves design efficiency and reduces costs by eliminating the need for relays and other types of peripheral devices, and has enjoyed great success in the market. These controllers can be used to build systems that rely on various industrial communication protocols such as PROFIBUS-DP and CC-Link.These standard communication protocols are widely used with field devices; PROFIBUS DP and CC-Link are registered trademarks of the PROFIBUS User Organisation and the CC-Link Partner Association, respectively.

Main target markets
Key target markets are production-line operations in industries such as electrical equipment, machinery, chemicals, foods, semiconductors, and automobiles; and companies that design, build, and maintain air conditioning, power, and other types of in-plant facilities

Applications
Include the measurement, display, and control of temperature, pressure, and flow rate in research and development facilities and manufacturing operations, including heat treatment, washing and sterilising.

Evolving wireless technology drives growth in World comms test services market

The increasing complexity of wireless networks, bolstered by the constant introduction of technologies demanding obscure skills, has greatly enhanced the need for communication test services. Because standards in the communications market are constantly evolving, triggering the improvement of test equipment and corresponding services, suppliers should improve their service portfolio to address volatile market conditions and the subsequent needs of end users.

World Communication Test Services Market is part of the Test & Measurement Growth Partnership Services programme, which also includes research in the following markets: World Gigabit Ethernet Test Equipment Market, World Triple Play and Next Generation Services Test and Monitoring Equipment Market, and World Wireless Test Equipment Market for I&M. All research services included in subscriptions provide detailed market opportunities and industry trends that have been evaluated following extensive interviews with market participants.

New analysis from Frost & Sullivan, World Communication Test Services Market, finds that the market earned revenues of $472.2 million in 2009 and estimates this to reach $677.9 million in 2015. The end users covered in this research service include network equipment manufacturers (NEMs), service providers (SPs) and enterprises.

“SPs opine that the demand for test services in wireless technologies is greater than that of wireline technologies, due to their complexity and susceptibility to problems,” says Frost & Sullivan Research Analyst Prathima Bommakanti. “Likewise, the need for test services is expected to increase as wireless networks continue to become more complicated.”

Due to the introduction of long-term evolution (LTE) and worldwide interoperability for microwave access (WiMAX) technologies in the network, the overall complexity of networks is escalating. This is particularly evident in the operation stage and during the transition of technology in the network. Moreover, the deployment of LTE and WiMAX is likely to increase the service requirements of operators as they are expected to incorporate mobile broadband, video-on-demand and other high-speed services that will boost the revenues for network operators.

One of the most consistent trends has been to offer voice over Internet protocol (VOIP), data centre and Internet protocol television (IPTV) instead of an integrated triple-play network. However, with SPs transitioning from separate voice, video or data services to integrated triple-play services, there is a need for equipment and services to test and monitor networks that supply voice, video and data simultaneously.

Despite promising potential, the economic downturn significantly hindered the growth of the total world communication test services market. Capital budgets remain tight, as SPs, NEMs and small and large enterprises attempt to generate more revenues out of their existing networks, creating a delay in their purchasing decisions. Likewise, vendors should assure the return on investment (ROI) for services offered, as end users have reduced capital expenditure (CAPEX)/operating expenses (OPEX) budgets.

“Providing superior services that match customer requirements at competitive prices is one of the key challenges faced by suppliers in the total world communication test services market,” explains Bommakanti.

Tempearture Calibrators upgraded

In a relaunch and upgrading of their CS series calibration sources, the new enhanced range from Eurolec comprises of three dry block “black body” sources for calibration with a temperature control system and a pocket for a reference thermometer. A selection of probe holes at the rear provides options for contact/probe thermometer accuracy checking and the ‘black body’ at the front provides a means of checking infrared non-contact thermometers. Model CS173 features a range of +30.0 to +199.0°C and models CS174 & CS175 feature a range of 40.0°C below ambient (approx. -20°C) to +85.0°C.

In addition, all models feature a 2 position Precision Accuracy Check (PAC) function where at the touch of a switch, the accuracy of the unit is confirmed at 2 preset points. All models also include an RS232 output socket – USB output is an option. Model CS175 features0.01C resolution and± 0.05C accuracy. For precision accuracy checking over an extended range, precision reference thermometers RT162 or PC Temp RT2 kits with 0.01C resolution are recommended. These thermometer kits are supplied complete with a System Calibration Certificate traceable to UKAS.

These innovative units avoid the inconvenience and time lost due to external calibration; are quick and easy to use and will provide considerable cost savings when compared with external or contracted on-site temperature calibration.

Wireless & battery free alliance!

The S4 group has joined the EnOcean Alliance.

EnOcean and EnOcean Alliance members have developed a wide range of wireless and battery free sensors, switches, controllers, and actuators. Because all members of the alliance follow the same set of standards all products are interoperable.

There are multiple BACnet to EnOcean gateways available today but none of them provide full functionality and bi-directional support. S4 plans to deliver a BACnet-EnOcean Router and associated EnOcean Hotspot technology that will enable all EnOcean domains in a building to be brought together as enterprise assets utilizing BACnet IP.

The high level design has been completed for some time. They’ve recently put a lot of effort mapping BACnet functionality into EnOcean telegrams to identify places where there are challenges in offering full functionality in the gateway. Their findings have been shared with the BACnet wireless working group and with the EnOcean Alliance and we are all working together to find the best path to providing this service. The major areas needing work include:

• Providing support for devices that are inactive except when an external stimulus generates the energy to make the device operational.
• Providing an Override and Release mechanism within the EnOcean technology.
• Emulating the Priority Array within the gateway.

As part of the membership in the EnOcean Alliance they will be helping to mold the direction of the EnOcean technology by working with the technical working groups. Their experience in building the OPC-N2 Router and BACnet-N2 Router has paved the way for this project and helped to identify areas where additional planning and coordination are needed.

They have completed a paper that is being published by the EnOcean Alliance in multiple languages. The paper takes the concepts introduced in our Connected World Conference presentation and expands them in greater detail to discuss the benefits of integrating the BACnet and EnOcean protocols through a gateway. After that paper is edited and published they are to publish it on their web site.

Collaboration for better quality water while using 10 % to 15% less energy

Goal is to increase the effectiveness of the municipal drinking water distribution network

GE Intelligent Platforms has signed a cooperative research and development agreement (CRADA) with the US Environmental Protection Agency’s National Risk Management Research Laboratory (NRMRL) focusing on connecting dissimilar data sources into a software-based platform that improves decision making capabilities across a water system. The solution is expected to increase the effectiveness of a distribution network for the delivery of better quality water while potentially using 10% to 15% less energy.

“The availability of safe, reliable drinking water has proven to be the foundation of sustainable economic and cultural growth in every society in history,” said Alan Hinchman, Global Industry Manager Water/Wastewater for GE Intelligent Platforms. “With this agreement, GE and the U.S. EPA will work with third parties to create a sensor-based, data-driven, and software-assisted system for drinking water distributions. The goal would be to optimize water quality improvement and minimize energy usage. By doing so, the product could assist water utilities and other end users with ‘greener’ distribution network operations and enhanced regulatory compliance.”

The U.S. EPA regulates drinking water quality under the 1974 landmark legislation, Safe Drinking Water Act (SDWA). The legislation resulted in continuing research in the areas of modeling, monitoring, and engineering control on water quality changes, network design and operations.

“The U.S. municipal water industry collectively consumes 4% of the total U.S. power generation,” said Thomas Speth, Acting Division Director for NRMRL’s Water Supply and Water Resources Division in Cincinnati. “Therefore one of the goals of this CRADA is to reduce energy consumption by 10% to 15%, which will have a positive impact on reducing green house gas emissions. Also since electrical generation is the largest water user in the U.S., the reduction in demand would help better manage water resources.”

The project seeks to transfer past and ongoing R&D results, as well as intellectual properties of all of the parties, into real-world applications. These technological advances will be further developed and integrated with proprietary technologies that GE and PDA Design, a Greer, South Carolina-based green technology think tank and solution provider, have related to sensor networking, wireless and wire-based multi-platform data communication protocols, real-time process equipment control, data warehousing and mining technologies. Further integration and development, implemented by these parties, will be focused on energy reduction and water quality protections.

“Today’s U.S. water system is running on aging, disparate technology and a crumbling infrastructure that experts predict is in need of $600B in replacements and repairs,” said Hinchman. “Since most utilities expanded and automated over a 30-year period while technology was rapidly advancing, many were left with a combination of different automation equipment creating an environment for information silos that make it impossible to share information with plant operators.”

It is the intent of this CRADA to develop a cost effective commercially viable solution for predictive real-time energy and quality monitoring/control platform in municipal drinking water distribution. The solution will feature:

• Open communication architectures featuring Ethernet networking for high availability and bandwidth to transfer large amounts of information or quickly stream small amount of data frequently.
• Support of mixed systems for interconnection with existing equipment and to allow for stage deployment or upgrades.
• Scalable deployment employing a building block method of interconnecting software and hardware product that offer their own value equation individually and large value collectively, will allow for faster market acceptance.
• Sensible node cost to maximize the value of the technology and leverage numerous methods of data collection including simple data collectors and low cost instrumentation. Software calculation functionality will also allow for the approximation of missing data sources.
• Dual purposing to ensure drinking water quality at a decrease cost. Energy savings and water quality are linked and must both be controlled and monitored per US EPA standards. To achieve this both energy and water quality are to be monitored and controlled.

As a leader in the Water industry, GE’s Proficy software and PACSystems controllers will be at the heart of the technology solution which is expected to go into pilot testing in late 2010. Proficy is an example of how GE’s $4 billion-a-year software and solutions services businesses are helping customers improve productivity.