Cnt20111201

DECEMBER2011
Schweppes’ Sweet
Controls Upgrade
Sampling Systems Need TLC
Southern States Chemical Does
Electronic Marshalling
The numbers for the Top 50 automation
companies look very good, but the
recovery feels wobbly. Could that be
a broken bridge over the next hill?
EXCLUSIVE TO THE WEB
Pfizer’s iPads on the Plant Floor
Good Maintenance Means
Sustainability

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CONTROL (ISSN 1049-5541) is published monthly by PUTMAN Media COMPANY (also publishers of CONTROL DESIGN, CHEMICAL PROCESSING, FOOD PROCESSING, INDUSTRIAL NETWORKING,
PHARMACEUTICAL MANUFACTURING, and PLANT SERVICES ), 555 W. Pierce Rd., Ste. 301, Itasca, IL 60143. (Phone 630/467-1300; Fax 630/467-1124.) Address all correspondence to Editorial and Executive Offices, same ad-
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D E C E M B E R / 2 0 11 5
F E AT U R E S
C O V E R S T O R Y
28 / What’s Next?
The numbers for the Top 50 automation companies look
very good, but the recovery feels wobbly. Could that be
a broken bridge over the next hill? by Walt Boyes, David
Clayton, Inderpreet Shoker
D I S T R I B U T E D C O N T R O L S Y S T E M S
37 / Blending Controls Sweeten
Soda Pop
Schweppes Australia consolidates process and logic
controls in its syrup room. by Jim Montague
P R O C E S S A N A L Y Z E R S
40 / Sample Conditioning
Systems Need Love Too
Process users and integrators must design and match
SCSs with application requirements, complete applica-
tion data sheets, and deploy climate-controlled shelters.
by Robert Sherman and Jim Montague
Can you really use an iPad on the plant floor? Pfizer
shows how. www.controlglobal.com/articles/2011/ipad-
hits-plant-floor.html
ARC’s Ralph Rio discusses the connection between
good asset management and sustainability. www.con-
trolglobal.com/multimedia/2011/asset-management-
sustainability-connection.html

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D E PA R T M E N T S
D E C E M B E R / 2 0 11 www.controlglobal.com 7
Chemicals & Allied Products ...............................................................................12,548
Food & Kindred Products.....................................................................................12,638
Paper & Allied Products.........................................................................................3,470
Primary Metal Industries........................................................................................5,445
Electric, Gas & Sanitary Services...........................................................................3,116
System Integrators & Engineering Design Firms....................................................8,912
Rubber and Miscellaneous Plastic Products ..........................................................4,403
Stone, Clay, Glass & Concrete products.................................................................2,057
Textile Mill Products ..............................................................................................1,361
Petroleum Reﬁning & Related Industries................................................................3,877
Tobacco Products......................................................................................................115
Total circulation....................................................................................................63,006
CIRCULATION AUDITED JUNE 2010
ASK THE EXPERTS
ROUNDUP
9 / Editor’s Page
But Wait—We’re the Good Guys!
Does that make morally dodgy deeds less
dodgy?
11 / On the Web
Christmas at the Plant-Floor Level
See our online coverage of the invasion of
the plant floor by the tablet and its apps.
13 / Feedback
More on measuring tank levels and cyber-
security. Our readers react.
14 / Security Spotlight
Cyber Warfare and the Control Systems
Community.
The best defense is open communication
between users, vendors and government
agencies. We’re all in this together.
19 / On the Bus
Operations Drives Reliability
A respected, well-trained operator who ac-
cepts responsibility for his machine could
be your best maintenance tool.
20 / In Process
Illinois water system hacked—or not;
ODVA defines new energy object; ABB
and McCrometer acquire new business
units; and more news.
27 / Resources
Need power supply info? Check these on-
line sources.
42 / Ask the Expert
Our experts tackle differential pressure im-
pulse lines and solar power economics.
44 / Roundup
Process automation software on display
here.
46 / Control Talk
Analyze This!
McMillan and Weiner talk with process an-
alyzer expert Jim Tatera.
49 / Ad Index
And now some words from our sponsors.
Check these pages.
50 / Control Report
Simplicity = Freedom
Southern States Chemical discovers the vir-
tues of electronic marshalling.
The latest in solar cell technology is
bringing costs down and efficiency
Model 0260.
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WALT BOYES
EDITOR IN CHIEF
wboyes@putman.net
E D I T O R ’ S P A G E
Talking like a good
citizen and then
acting like a thug is
repugnant,
unethical and
carries with it the
seeds of its own
destruction.
different on some issues. If, for example, we
had not gone to war in Iraq, or if we had not
led a NATO coalition against the Taliban in
Afghanistan, or if…the list is endless…we
wouldn’t be in danger from cyber attack from
those quarters.
It is the same theme that was roundly con-
demned after the murders on 9/11. The reduc-
tio ad absurdum of this argument is that if the
United States had only supported the Nazi
genocide, there wouldn’t be an Israel, and the
Palestinians and Wahabi Muslims wouldn’t
have any reason to hate us. Silly? Stupid? Yes!
While that argument has logical flaws you
can drive the U.S.S. Enterprise through, the
other side of the discussion bothers me as well.
It is becoming apparent that the U.S. govern-
ment had at least some involvement in the use of
the Stuxnet malware to damage the Iranian ura-
nium enrichment plant last year. The rumormill
in cybersecurity land says that Duqu, the “son
of Stuxnet” variant that has been deployed re-
cently is a “warning” from the U.S. government
to other countries about the dangers of attack-
ing us through cyber means. That’s as may be.
The theory appears to run that because we’re the
good guys we can do those things, and they be-
come therefore “good.” Manifest Destiny.
But, if Stuxnet or Duqu or the recent U.S.
government-sponsored assassinations were per-
petrated against Americans by a foreign gov-
ernment, the U.S. government and citizenry
would be screaming that these were unaccept-
able acts of war or terrorism.
I am troubled by this apparent schizophrenia
in the body politic. But more, I am troubled by
the suggestion that those are the only two in-
tellectual stands possible. Much of my trouble
comes from the ideals that we Americans say
we stand for and have so many times missed
the mark on.
We Americans have always believed that if
we do things of questionable morality, ethics or
legality, that we get the Good Guys’ Seal of Ap-
proval anyway. And we don’t understand why
that looks significantly different from the out-
side staring in.
That same sense of schizophrenia has struck
in economic terms. Companies that have made
such a huge noise about “stakeholdership,”
while moving offshore and reducing their
U.S. labor force and trying to end pension and
health benefits—while at the same time paying
their top executives something like 400 times
as much as the average worker—give me the
same sort of cognitive dissonance I see in our
reaction to cyber terrorism.
It seems to me that what we’re talking about
is ethical citizenship. Whether that citizen is
a government (and I most emphatically do not
mean just the United States’) or a corporation,
talking like a good citizen and then acting like
a thug is repugnant, unethical and carries with
it the seeds of its own destruction.
In his keynote at Emerson Global User Ex-
change in October, Emerson’s president, Steve
Sonnenberg, said he wanted Emerson to be the
end users’ trusted partner and adviser. He pro-
posed that one of the ways to do that is to man-
age ethically. Steve could not be more correct.
It applies in government as well as in the way
companies relate to their customers and to their
employees.
In the immortal words of Walt Kelly’s be-
loved Pogo, “We have met the enemy and he
is us.” And just remember how long ago those
words were written.
This is aimed primarily at citizens of the United States, but it isn’t entirely an American
phenomenon. So, even if you aren’t an American citizen, you might want to read and
think about this. People have been suggesting for a while that we’d be in significantly
less danger from external cyber attack if the political stance of the United States were
But Wait–We’re the Good Guys!

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Updated every business day, the Control Global online magazine is available at no charge.
Go to www.controlglobal.com and follow instructions to register for our free weekly e-newsletters.
KATHERINE BONFANTE
MANAGING EDITOR, DIGITAL MEDIA
kbonfante@putman.net
C O N T R O L O N L I N E
www.controlglobal.com/thismonth
Search this site | Tips
I bet when you wrote your letter to Santa, you asked him to bring you a tech-
nological device. Was in an iPad? I only ask because the iPad is one of the top
Christmas gifts ideas for 2011. If you don’t have one or one of its competitors
already, you will soon.
This device is pretty cool. You check email, watch movies, make phone
calls, take pictures, play games, surf the Web—and get real work done. I use
mine to build and blast Control’s daily newsletters. Our VP of Content, Keith
Larson, uses his for budget reports, client presentations and much more.
And the iPad is not just for office work. In “The iPad Hits the Plant Floor”
(www.controlglobal.com/articles/2011/ipad-hits-plant-floor.html), Michele
Vaccarello-Wagner, managing editor of our sister pub-
lication www.PharmaManufacturing.com, tells how
manufacturing companies such as Pfizer and MBX
Systems are using this wireless device at the plant-floor
level. Since the tablets were incorporated onto MBX’s
warehouse floor, workers have increased productivity
by 14% and reduced defects by 20%.
The iPad and other mobile devices will become part of your everyday tools
to get your job done. Just read Managing Editor Nancy Bartels’ article “Infor-
mation Wants to Be Everywhere.” In it, Bartels reports that a total of 70% of
the American workforce will be mobile by 2012.
Even though mobile devices can make our jobs easier, security for this
equipment is also a must—especially at the plant level. Bartels’ article also
points out 10 security questions you should ask when upgrading your plant
and workers to a mobile network. Learn more at www.controlglobal.com/ar-
ticles/2011/MobileDevicesInformation1104.html.
Another article that focuses on mobile technology at a manufacturing and
automation processes level is “FDT—Your APP for Smart Device Informa-
tion Integration!” This article, written by Garry Cusick shows how FDT pro-
vides the enabling features for process automation the same way the “app”
does for “smart phones.” Go to www.controlglobal.com/articles/2011/fdt-
your-app-for-smart-device-information.html.
Now, if Santa is bringing you an iPad or any other mobile device that you
can use at the plant floor level, stop by our SoundOff! Blog “Are you using
the iPad at the plant floor?” (http://web-post.community.controlglobal.com/
content/are-you-using-ipad-your-daily-operations), and let us know about it.
Happy Holidays and enjoy your technological toys!
Christmas at the
Plant-Floor Level
ControlGlobal E-News
Multimedia Alerts
White Paper Alerts
Go to www.controlglobal.com and
follow instructions to register for our
free weekly e-newsletters.
Solutions for Multiple HMI Applications
See case studies offering real life suc-
cess stories. www.controlglobal.com/
wp_downloads/111101-proface-hmi-
applications.html
Aspect Object Technology
The practical application of aspect ob-
ject technology in a distributed control
system. www.controlglobal.com/wp_
downloads/111025-abb-dcs.html
Hazardous Location Guide
Understand hazardous locations and
protection methods. www.control-
global.com/wp_downloads/111018-pf-
hazardous-guide.html
Is There a Tricorder in Your Near Future?
Handheld technology is growing, but
few vendors have taken handhelds
beyond simple applications. www.con-
trolglobal.com/articles/2006/111.html
Wireless Devices in Factory Automation
An Overview of Adoption Trends
www.controlglobal.com/articles/2008/
WirelessDevicesFactoryAutoma-
tion0812.html
Portable Device Safety in Hazardous
Areas
Safety factors to consider when oper-
ating mobile devices at the plant-floor
level. www.controlglobal.com/arti-
cles/2004/129.html

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TECHNICALLYSPEAKING F E E D B A C K
executive team
publishing team
foster reprints
editorial team
design & production team
Measuring Tank Level
[Editor’s note: The following email ex-
change was prompted by the September
“Ask the Experts” column (www.control-
global.com/articles/2011/valves-vs-vfds-digi-
tal-level-transmitters.html) and a question
on digital level transmitters. Editor in chief
Walt Boyes was one of the experts who an-
swered the question, and he received and
answered the following response.]
Robert Proctor, Birmingham-Toledo
Sales:I“I was pleased to read your response
regarding tank level in the September edi-
tion of Control. Thank you for remember-
ing the weighing world.
“Our technology often seems to be for-
gotten as users rush to less accurate, while
more expensive, solutions. I agree that
load cells are the best choice to accurately
gauge tank level. An accuracy of 0.01% of
load cannot be approached while utilizing
the tools suggested by others.
“I do have one clarification, though.
In order to install load cells under a four-
legged tank, one would not be able to use
‘at least two,’ as two load cells would cause
the tank to be uneven, and blocking up
the remaining two legs would eliminate
virtually all accuracy. One could utilize a
‘tank-level’ set of four load cells in which
two ‘live’ cells are placed under oppos-
ing corners, while two ‘dead’ cells are op-
posite. Perhaps this is what you intended
when you stated ‘at least two.’
“Thanks again for remembering those
of us who concentrate the majority of our
time on the most accurate form of gath-
ering plant information—the weighing
world.”
Boyes: Actually, I was thinking of Kis-
tler Morse-style strain gauge devices that
are installed into each leg. Maybe they
don’t make them anymore. Your solution
makes perfect sense.
Proctor: They do make them.
Cybersecurity
[Editor’s note: The “Unfettered” blog, writ-
ten by Joe Weiss, has been busy with the ad-
vent of Stuxnet, Duqu and now the “Illinois
Water Hack.” Weiss’ Nov. 7 post on control
system cyber forensics (http://community.
controlglobal.com/content/need-control-
system-cyber-forensics#new) generated the
response below.]
Patrick Coyle, Chemical Facility Se-
curity News: “This is one reason why the
U.S. Dept. of Homeland Security (DHS)
is setting up its CyberFetch program. It
won’t deal exclusively with control sys-
tems, but it will pro-
vide a more secure
communications
portal for cyber fo-
rensics profession-
als to share infor-
mation. Hopefully,
ICS equipment pro-
viders will join the
community as well.
Unfortunately there is no word yet when
CyberFetch.org goes live.”
[Editor’s note: Comments on Weiss’ first
report of a water system attack, (http://com-
munity.controlglobal.com/content/water-
system-hack-system-broken#new) reveal
some of the confusion resulting from disclo-
sure restrictions by various agencies.]
Virgin Automation: “If the ‘hackers’
were able to access the control logic, they
would need to have the control software
and address logs to determine pump I/O. It
simply doesn`t make sense. Can you imag-
ine the size of this ‘pump’ that distributes
to a municipality? It sounds like sensation-
alism to me.”
Jeffreycarr: “Are you referring to the hy-
droelectric plant [in Russia]? No one that I
know viewed that as a cyber attack. It was
more likely the result of out-dated equip-
ment. If you have evidence that it was a cy-
ber attack against the dam, please share!”
Bill Maloney: “Can you share who
made this disclosure and who this disclo-
sure was made to? Was it a public disclo-
sure, or was it made to something secured
like DHS’s HSIN?”
[Editor’s note: As we go to press, it’s clear
the attack was on a small community opera-
tion in Illinois, but whether it was indeed
a “cyber attack” is still not clear. The FBI
and DHS say it isn’t. The facility says it is.
Follow Weiss’ posts to “Unfettered” at www.
controlglobal.com.]
SEPTEMBER2011
EXCLUSIVE TO THE WEB
SEMS AFTER DEEPWATER
HORIZON
COMMUNICATION FOR
OFFSHORE PLATFORMS
TAKE A BITE
OUT OF
LIFECYCLE
COSTSAUTOMATION SAVES
PRECIOUS WATER
REAL-TIME OPTIMIZATION
OF FUEL USE
VARIABLE-FREQUENCY
DRIVES FOR
SUSTAINABILITY
AU
TOMATION
CA
N NO
T ONLY
CO
NTRO
L
A PROCESS
PLAN
T;
IT CA
N ALSO
CUT ITS
LIFECYCLE
CO
STS.

14 www.controlglobal.com D E C E M B E R / 2 0 11
CyberWarfareandtheControlSystemsCommunity
In control systems, the communication and work between vendors, asset owners and
engineers that take place on a daily basis can be vast, and security may not be the first
item on everyone’s mind; the mission is to keep the systems running, secure or not. But
the very real possibility of cyber warfare has changed that. The question is what must
the control systems community do to adapt to
the threat of cyber warfare?
Simply stated, the community must get
back to the basics of security, take part in cre-
ating better regulations, and band together to
face the threat as a community instead of as
individuals.
With the media attention given to the
Stuxnet worm since June 2010, the world has
been forced to realize the possibilities and
threats of cyber warfare. Cyber warfare took
place long before the release of Stuxnet, but
its release caused nation-states, corporations
and other groups across the world to realize
the benefits of using a domain of warfare
with limited entry costs and the possibility
of non-attribution, which is the ability to op-
erate without positively being connected to
an operation. The idea of using cyberspace
to inflict physical damage, such as damaging
nuclear centrifuges, was an unproven the-
ory to most before Stuxnet. With the theory
publicly proven true, most vendors and asset
owners realized that control systems are val-
ued and legitimate targets.
As the communities behind cybersecurity,
hacking and control systems began to over-
lap, it became obvious that it was not only
the large control systems, but also the smaller
ones that were targets. To properly hack into
a system one must understand it. Before at-
tacking high-profile targets, it is wise for
any hacker—nation-state-backed or not—to
compromise smaller control systems, or re-
lated systems, for reconnaissance purposes. A
hacker can not only understand control sys-
tems and network layouts better for future
attacks, but may also gain important infor-
mation, such as firewall and security config-
urations, trusted network access, operation
manuals, design schematics or even password
files. All of this information is important to
carrying out an effective attack against larger
control systems, such as the electrical power
grid, water filtration plants, oil refineries and
nuclear reactors. This style of reconnaissance
is perfectly demonstrated with the Duqu
malware.
In October, Duqu was discovered operat-
ing on a number of targets including those
in Europe, Sudan and Iran. These targets
have not been fully identified, but Symantec
has stated that the targets include industrial
manufacturers. Duqu is primarily an infor-
mation-gathering platform with strong ties to
Stuxnet. The kind of information gathered
from Duqu is the type that would be required
to create a cyber weapon that would target
control systems. The Duqu malware seems
to target industrial manufacturers, but this
may only represent another vector of attack
against control systems that rely on the parts
these manufacturers create.
With an understanding that all control
systems need to be protected, the focus be-
comes what smaller control system owners
and operators can afford to do in terms of
security. A limited number of people under-
stand both control systems and cybersecurity
well enough to properly defend the networks,
which makes these personnel highly sought
after and generally unattainable for many
in the control systems community. Because
of this and the fact that there is no check-
list to supplying complete security, the task
of securing networks can seem daunting and
nearly impossible. What owners and control-
lers can do is adopt a security mindset and get
back to the basics of cybersecurity.
The basics of cybersecurity begin with eval-
uating the systems. No one knows the network
layout more in depth than the owners and
Duqu is primarily
an information-
gathering platform
with strong ties to
Stuxnet. It seems
to target industrial
manufacturers.
ROBERT M. LEE
CYBERSPACE OFFICER, USAF
robertmichael.lee@gmail.com
S E C U R I T Y S P O T L I G H T

Always make the right move. Sometimes you need to guess whether you need to shut
down a process or simply swap out a sensor. With Emerson’s new Measurement Validation diagnostic, you can make
the distinction, avoiding the cost and risk associated with unnecessary shutdowns. By predicting on-scale failures
you can increase plant safety and productivity. Learn more at www.rosemount.com/848T. It’s your move.
rosemount.com/848Trev7
The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2011 Emerson Electric Co.
YOU CAN DO THAT
Whenever I get erratic temperature readings
I have to guess whether it’s a maintenance
concern or an actual process issue. If only I had
the ability to distinguish valid measurement
data from false readings, then I could avoid
unnecessary shutdowns.

controllers of those networks. Excluding the insider threat,
no attacker has this level of knowledge, and this is one of
the asset owner’s greatest defenses. End users and the com-
panies that employ them must take responsibility for their
systems and recognize when hardware and software in
their networks are missing or acting in a manner outside of
their intended use. Furthermore, if pieces of hardware or
software that are unaccounted for are attached to systems,
there should be concern. This network accountability is
not an easy task, but is much less cumbersome than surviv-
ing a network attack where business secrets are stolen or
network operations are halted.
After accepting and properly implementing network
accountability, security measures must be put into place.
An air gap—the complete isolation of your network—is
difficult, if not impossible to achieve. However, air gap
best practices are a good step towards network security.
Asset owners should ensure that their networks are not
connected to outbound connections, and that there are
methods of physical and electromagnetic security in
place. Those in charge of network security must then as-
sume this barrier of defense will be compromised. With
this assumption, other steps for security must be taken. A
defense-in-depth approach is as unique to each situation
as is the network it protects, but some security steps are
universal.
On a control system network there should be a demili-
tarized zone (DMZ) that separates internal parts of the
network from other less operationally important sections.
Firewalls with properly defined rule sets should limit traf-
fic to only what is necessary to continue operations. Net-
works should use intrusion detection systems (IDS) or
intrusion prevention systems (IPS) to look for malicious
network activity. Vulnerability assessments using trusted
software and reputable red teams should look for vulner-
abilities in the network. Identifying vulnerabilities allows
for patching and mediation to occur in areas that hack-
ers would use to compromise a network. User agreements
must be established with employees, so that proper use
of the network is clearly defined. No number of security
steps will prevent a network compromise if users are al-
lowed to use the network improperly by, for example, con-
necting personal external hard drives to it. Asset owners
must also implement access controls to limit who can
gain physical or network access to resources.
One of the most important parts of network security
is detection. As Capt. Jeremy Sparks, instructor at the
Air Force’s Undergraduate Cyberspace Training school
teaches the future Air Force’s network defenders: Preven-
tion is key, but detection is a must. Detection not only
mitigates the damage and duration of an attack, but it can
also deter and prevent an attacker altogether. One of the
most appealing aspects of cyber warfare is limited attribu-
tion. Without this aspect, the motivation of nation-states
and hackers to conduct operations in cyberspace greatly
decreases.
All of what is mentioned above is a broad look at net-
work security for control systems; it is not an all-inclusive
list. The security mindset must be used to think about
each level of the network and what would be available to
prevent or mitigate a compromise there. It is an ongoing
process that must be given proper attention and resources
even when both are limited.
Control system and software vendors must take respon-
sibility as well and provide better software and hardware
that has a focus on security instead of just availability.
Better code and hardware testing, as well as longer dura-
tions for patching support are all a great start. Asset own-
ers must participate in this process too, and work with
vendors to identify issues. Both vendors and asset owners
must then work with the government and regulation com-
mittees to identify regulations and standards that must be
enforced. The minimum standard is not something that
can foster true security, especially with systems that affect
national security. However, this is not an issue of point-
ing blame at any party involved. Instead, this is an issue
of getting the community to come together, and bringing
different experiences to find solutions.
This community is where the battle over control sys-
tems will be won. Both the cyber community and the
control systems community have very talented and pas-
sionate individuals working together to bring about posi-
tive change. The best advice for those involved in control
systems is not based in varying and ever-evolving security
practices. Instead, the single greatest piece of advice is to
reach out to the community, and share information, prac-
tices and lessons learned. There is a real fight going on in
cyberspace involving control systems, but it is not a fight
one has to wage alone. With a security mindset, network-
ing and a touch of optimism the community as a whole
can enable itself to truly secure control systems. r
[Author’s note: I want to thank the individuals I spoke with
at the 11th ACS Control System Cyber Security Conference.
The information and inspiration gained from the community
involved was invaluable. I would also like to thank the Air
Force’s Undergraduate Cyberspace Training school at Keesler
AFB, Mississippi, especially my mentors, Jeremy Sparks and
Paul Brandau, for their continued work and acceptance that
cyber security is not solely a military issue, but one that af-
fects us all.]
Robert M. Lee is an officer in the United States Air Force. However, this article
and his views do not constitute an endorsement by or opinion of the Air Force or
Department of Defense.
S E C U R I T Y S P O T L I G H T

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O N T H E B U S
JOHN REZABEK
CONTRIBUTING EDITOR
JRezabek@ashland.com
Deep down, we all
understand that
operations really is
in the best position
to improve
reliability.
area of “operator-driven reliability.” In his re-
port, he braces himself for flying vegetables
when he claims, “Operators can have a big-
ger impact on asset reliability than our main-
tenance department.” Porter demonstrated that
when operators are trained and take ownership
of the assets they use, they can achieve as much
or more than any measure of preventive, proac-
tive or predictive maintenance.
I know of more than a few maintenance and
reliability specialists who have long ago given
up on operations becoming accountable for
their assets. They’re somewhere between dis-
may and disdain, especially when it comes to
operations taking ownership and caring for
the physical assets they use in the production
of saleable product. In a lot of organizations,
the most senior operators bid off the unit for a
“day job” in maintenance, leaving behind their
young and less-experienced brethren. Should
we be shocked that there are instances where
equipment gets broken or breaks down pre-
maturely because it’s been operated or put in
service incorrectly? Weary of fixing the same
things repeatedly, instead we dream of bullet-
proof equipment no operator can break. Main-
tenance becomes the mythical fellow pushing
the rock that never gets up the hill, or he gets
squished when it rolls back over him.
Whether we feel like Sisyphus or not, deep
down, I think we all understand operations re-
ally is in the best position to improve reliabil-
ity. The idea is really pretty simple. If you know
your car needs oil and you drive it anyhow, is it
your mechanic’s problem that it breaks down?
But, imagine you’re a parent who’s trying to get
your teenage sons or daughters to drive the fam-
ily car mindfully and pay attention when the
trouble lights come on. Changing a culture of
“drive it into the ground” to one of ownership/
stewardship can seem next to impossible.
Twenty-five years ago I sat in a week-long
seminar conducted by Bill Tillman, a veteran of
DuPont. Tillman’s message that week was that
maintenance and operations needed to stop be-
ing adversaries, and start figuring out how to
communicate and help each other. But today’s
plants are turning over the generation of ad-
versarial pessimists to a younger demographic.
These “newbies” might be happy to step into
the role of pilot/captain, crew and caretaker.
Do our organizations have the vision to support
people like Porter who are positioned to shape
a new way of operating? It sounds to me like Ir-
ving Oil is doing it.
Porter spent a year or two studying, interview-
ing, developing and training. For two pilot proj-
ectsatIrving’sCrudeUnitandFCC,he’sinvolved
about 70 of 300 salaried operators. He’s been able
to redefine their roles, emphasizing housekeep-
ing, communication, standardized rounds and
thoughtful, thorough procedures. He also ex-
ploits some jazzy technology, such as wireless
PDA’s that load centrally stored guides for stan-
dardized operator rounds and checklist-guided
forms for isolation and preparation of equipment
for maintenance. In a year his pilot program has
claimed $200,000 in reduced maintenance costs.
Irving’s project has focused on large assets
such as pumps, compressors and exchangers.
But once the culture of focus and caring be-
comes the norm, operators are going to want to
use the relevant data from digitally integrated
measurement and control devices. Is it unre-
alistic to aim for one individual per operating
crew who gets trained and proficient on in-
strumentation asset management? Future shift
teams are likely to be more like Irving Oil’s.
Whether we use HART, Profibus or Founda-
tion fieldbus, shouldn’t we be championing an
infrastructure to deliver instrumentation asset
management as well?
Operations Drives Reliability
Irving Oil is an energy company operating a large, sour-crude-capable refinery in St.
Johns, New Brunswick—Canada’s largest refinery—producing refined products primar-
ily for export to New York Harbor. At a workshop in October, Irving’s Mark Porter—a
25-year veteran of its operations department—presented his refinery’s progress in the

I N P R O C E S S
Was the tiny Curran-Gardner Town-
ships Public Water District (www.cur-
rangardner.com) in downstate Illinois
the victim of a foreign-based cyber attack
or not? As of press time, that seems to be
the question.
What we do know is this: The Illinois
Statewide Terrorism and Intelligence
Center reported that “Sometime dur-
ing the day of Nov. 8, 2011, a water dis-
trict employee noticed problems with a
SCADAsystem.Aninformationtechnol-
ogy service and repair company checked
the computer logs of the SCADA system,
and determined the system had been re-
motely hacked into from an Internet pro-
vider address located in Russia…
“Over a period of 2-3 months, minor
glitches have been observed in remote
access to the water district’s SCADA
system. Recently, the SCADA system
would power on and off, resulting in the
burnout of a water pump.”
No motive was given for the attack.
Don Craver, chairman of the Cur-
ran-Gardner Water District reported to
ABC affiliate, WLS TV, Chicago, that
“There’s some indication there was a
breach of some sort into a software pro-
gram—the SCADA system—that al-
lows remote access to the wells, and the
pumps, and those sorts of things.”
According to Joe Weiss, principal at
Applied Control Systems and Control-
Global.com’s “Unfettered” security blog,
the attackers obtained access to the net-
work with credentials stolen from an un-
named SCADA vendor.
The problem is that the FBI and the
DHS both have said that, after inves-
tigation, they do not believe such an
attack occurred.
However, before anyone assumes that
this whole issue is overblown, within
days of the Curran-Gardner scare, a
home-grown hacker calling himself
“pr0f” or “@pr0f_srs” announced that he
had hacked into the South Houston Wa-
ter Utility in Texas, and he posted several
screenshots of the system on the Internet.
Pr0f himself went public with the at-
tack and explained his motives clearly—
to demonstrate just how insecure such
systems are. (Apparently South Hous-
ton’s system was accessible via a simple,
three-letter password.)
He said, “I’d like to go on record and
say that the main reason I did what I did
yesterday was essentially because I know
I am not the only person with an interest
in these systems. I also know I am not the
only person who has explored them and
read up on them. I don’t think I am alone
in suggesting that the gravity of the prob-
lem is more serious than ICS-CERT and
similar [sic] are equipped to deal with. I’d
love to see some real reform and discus-
sions between the government, manu-
facturers of ICSs and people who use
these systems happening, because there
seems to be a huge disconnect between
the parties involved.”
Boyes Named Institute
of Measurement and
Control Fellow
Walt Boyes, editor in chief of Control
magazine, has been named a Fellow of
the London-based Institute of Measure-
ment and Control (www.instmc.org.
uk), which brings together thinkers and
practitioners from the many disciplines
with a common interest in measure-
ment and control. It disseminates and
advances the knowledge of measure-
ment and control and its application at
all levels. The institute produces several
technical and academic publications
and conducts meetings, seminars, exhi-
bitions and national and international
conferences on measurement and con-
trol topics.
Fellows are selected based on their
successfully demonstrating, through
technical or other roles, significant
contribution to and superior responsi-
bility in the industry. Candidates are
expected to have more than eight years’
professional experience, of which at
least the most recent five years have in-
volved responsibility in a senior corpo-
rate, or equivalent, capacity.
Boyes is also an ISA Life Fellow.
New Energy Object
Defined in ODVA
Specifications
ODVA (www.odva.org) has announced
new editions to its specifications, which
include a defined energy object that will
Illinois Water Hack Causes Confusion
Illinois authorities and the DHS and FBI disagree.
Control’s editor in chief, Walt Boyes,
has been named a Fellow of the Insti-
tute of Measurement & Control.
HE’S A JOLLY GOOD FELLOW

I N P R O C E S S
help manufacturers aggregate and view
energy use at various levels of their en-
terprises. The updated specifications
define an energy object that will be
used to report energy use for all energy
and resource types. This energy report-
ing methodology is harmonized with
energy reporting standards defined by
the Global Reporting Initiative (GRI).
ODVA’s energy object aligns with
the Environmental Indicator Protocol
EN3 of the G3 Sustainability Report-
ing Guidelines, which is the founda-
tion of the GRI reporting framework.
The energy object will enable man-
ufacturers to build a virtual “Energy
Usage Tree” representing energy con-
sumption throughout an enterprise. An
electrical energy object is also defined
to provide electrical energy-specific
data reporting capabilities and diagnos-
tics for the electrical energy consumers
and producers found within the various
levels of an industrial facility. A non-
electrical energy object is also defined
to provide unified reporting of energy
consumption and production of non-
electrical energy data such as natural
gas, fuel oil, and steam.
“For manufacturers who want to see
how energy objects are implemented,
ODVA created an at-a-glance sum-
mary of the energy specifications. This
summary, available at www.odva.org,
will help nonmembers and members
easily see how they can adopt the ob-
jects into new products,” said Kather-
ine Voss, executive director, ODVA.
The specifications are organized as
a group of publications in the CIP Net-
works Library, and each specification is
made up of one or more volumes in it.
The latest editions of the specifications
are “The EtherNet/IP Specification,”
CIP Networks Library, Volumes One
(Edition 3.11), Two (Edition 1.12) and
Seven (Edition 1.5); “The DeviceNet
Specification,” CIP Networks Library,
Volumes One (Edition 3.11), Three
(Edition 1.12) and Seven (Edition
1.5); “The ControlNet Specification,”
CIP Networks Library, Volumes One
(Edition 3.11), Four (Edition 1.7) and
Seven (Edition 1.5); “The CompoNet
Specification,” CIP Networks Library,
Volumes One (Edition 3.11), Six (Edi-
tion 1.7) and Seven (Edition 1.5); and
“The CIP Safety Specification,” CIP
Networks Library, Volume Five (Edi-
tion 2.5).
ABB to Acquire
Powercorp
ABB (www.abb.com) has agreed to ac-
quire Powercorp (www.pcorp.com.au),
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Real Collaboration. Real-Time Results.TM

I N P R O C E S S
which is an Australian renewable power
automation company.
Darwin-based Powercorp employs
around 30 people, and offers automation
and intelligent control solutions for man-
aging renewable energy generation in
isolated grids, which ensures utility-grade
power quality and grid stability in remote
locations. This enables very high levels
of wind and solar power penetration into
isolated diesel-powered grids, which re-
duces emissions and dependency on fos-
sil fuel.
“Powercorp brings expertise for the
integration of renewable energy genera-
tion into conventional micro and remote
island grids,” said Peter Leupp, head of
ABB’s Power Systems division. “This bolt-
on acquisition will add specialist know-
how and solutions to our control systems
offering, and further strengthen our posi-
tion in the renewable space.”
Powercorp has installed several sys-
tems to integrate renewable power into
remote grids and keep generation in bal-
ance with consumption. The company
also supplies systems that dynamically
store and release energy in response to
frequency and voltage deviations to stabi-
lize small or remote grids.
The transaction is expected to close
before the end of the year.
McCrometerFormsNew
UnitviaAcquisition
McCrometer (www.mcrometer.com),
in Hemet, Calif., has bought almost all
the assets of Automata Inc. (www.au-
tomata-inc.com) in Nevada City, Calif.
Automata provides satellite and radio
telemetry, software and sensors for ag-
ricultural and rural water.
This move and the company’s earlier
acquisition of Adcon Telemetry have
provided the basis for the establishment
of a new business unit, McCrometer
Connect, which will focus on develop-
ing and selling complete wireless solu-
tions for agriculture and rural water
management applications.
“The combination of Automata and
Adcon gives McCrometer a one-two
punch in this space. While both com-
panies have experience across a wide
variety of products, it is the combina-
tion of Automata and Adcon’s commu-
nication options and sensor portfolio
that separates us from the competition,”
says Melissa Aquino, general manager
of McCrometer Connect. “Given our
combined platform, we’re able to de-
liver tangible value, such as improved
yield and water savings, to irrigation dis-
tricts and large farms.”
THE DIFFERENCE BETWEEN OPERATION
Only Winsted control room consoles combine the configuration flexibility you need
with the robust performance you demand. From modular to custom,Winsted consoles
offer an array of options and modifications that optimize aesthetics, function and
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AND CONTROL

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R E S O U R C E S
Perfecting Power Supplies
Control’s Monthly Resource Guide
Every month, Control’s editors take a specific product area, collect all the latest, significant tools we can find,
and present them here to make your job easier. If you know of any tools and resources we didn’t include, send
them to wboyes@putman.net, and we’ll add them to the website.
EFFICIENT POWER SUPPLIES
“Efficiency—the Forgotten Feature”
discusses the role efficiency—the dif-
ference between the input and the out-
put power—should play in selecting a
power supply. Any loss here is reflected
in dissipated heat, which in turn af-
fects the lifetime and reliability of the
power supply unit, and can also lead
to increasing the size of enclosures or
installing some form of cooling. The
paper discusses the heat loss formula,
considerations for choosing the prop-
erly sized enclosure, de-rating and en-
ergy savings. www.controlglobal.com/
Media/MediaManager/wp_06_024_
puls_efficiency.pdf
PULS POWER SUPPLIES
630-587-9780 www.puls-power.com/us
RELIABILITY TESTING
Choosing a power supply based on
mean time between failure (MTBF)
ratings alone is not a guarantee of the
unit’s reliability. This white paper ex-
amines the methods that can be used
to correlate MTBF test data with cal-
culated values. It discusses a variety of
test methods, including MTBF, (dem-
onstrated mean time between failure
(DMTBF), and accelerated MTBF.
The reliability equation is also ex-
plained. The direct link to the white
paper is at www.controlglobal.com/
wp_downloads/pdf/081121_Sola_
DCPowerReliability.pdf
SOLAHD
800/377-4385 www.solahd.com
MAGNETICS BASICS
This white paper, “Magnetics Design
for Switching Power Supplies” from
Texas Instruments, covers basic design
principles, including magnetic field
principles, the energy plane, wave-
forms and more. It includes numerous
diagrams, formulas, definitions and
equations to assist users in the design
of switching power supplies. The paper
is free, and no registration is required.
The direct link is at www.ti.com/lit/ml/
slup123/slup123.pdf.
TEXAS INSTRUMENTS
www.ti.com
POWER QUALITY MONITORING
This tutorial provides an overview
of three-phase electricity basics and
then discusses three of the most com-
mon power quality events: leading/lag-
ging power, saq/swell/interruptions,
and harmonics. The direct link is at
http://zone.ni.com/devzone/cda/tut/p/
id/4714.
National Instruments
www.ni.com
SIGNAL CONDITIONING
This free, no-registration-required tu-
torial, “Industrial Signal Condition-
ing,” covers, among other subjects,
the industrial measurement environ-
ment, loops and analog signals, signal
integrity, and design examples such as
servo control, aluminum smelting and
grounded thermocouples. The direct
link is at www.dataforth.com/catalog/
pdf/DTF-Tutorial.pdf.
DATAFORTH
www.dataforth.com
UL RATINGS for SPDs
Specifiers and users of Surge Protec-
tive Devices (SPDs) are adjusting to
new terminology and requirements.
UL revised its 1449 Safety Standard for
Surge Protective Devices to increase
safety. The National Electrical Code
(NEC) incorporated specific language
to require the use of these safer prod-
ucts. This tip sheet will explain some
of the changes affecting specifiers and
users. The direct link is at http://ti-
nyurl.com/7dl5x7b.
MERSEN
978/462-6662 www.mersen.com/en/
PREVENT 24 VDC OVERLOADS
This white paper discusses one of the
problems of using switch-mode power
supplies: the way they respond to over-
loads or short circuits. It shows causes
of the problem and suggests a pos-
sible solution: a device installed be-
tween the power supply and its loads
that provides adjustable over-current
protection, selective coordination of
load circuits and current limiting.
The direct link is at http://tinyurl.
com/78elefh. The paper is free, but
registration is required.
SIEMENS INDUSTRY
www.sea.siemens.com
POWER ELECTRONICS GUIDE
This website contains a wealth of ma-
terials on switched moded power sup-
ply (SMPS) basics. It covers circuits,
schematics, PCBs, software, inverters,
generators, topologies, software, trans-
formers and more. It also contains an
electrical engineering reference guide,
formulas, information on PSUs, UPSs,
thermal design, power for solar and
other resources, including links to
other SMPS design sites, freeware, tu-
torials and news.
LAZAR’S POWER ELECTRONICS GUIDE
http://www.smps.us

C O N T R O L / A R C A U T O M AT I O N T O P 5 0
The numbers for the Top 50
automation companies look
very good, but the recovery
feels wobbly. Could that be a
broken bridge over the next hill?
by Walt Boyes, David Clayton and
Inderpreet Shoker
Ever have that dream where you’re running down the road
as fast as you can, and you don’t dare look back because you
don’t want to see what’s chasing you—and then suddenly
you run out of road and just as you begin to fall, you wake up
sweating and shaking?
It seems like the entire economy is having repeats of that
dream, night after night. Publicly, the leaders of the major
automation companies are trumpeting the significant ad-
vances they’ve made and the growth they’ve had since the
dark days of 2009, and many of them have recovered as if
they hadn’t ever had that little drop-off in revenue.
In just the last three or four weeks, ABB, Rockwell Auto-
mation, Invensys Operations Management, Emerson Process
Management, Siemens Industry and Schneider Electric have
all announced significant increases in bookings and profits
over the last time we surveyed the field in December 2010.
We’re sure you’ve noticed that those vendors are in the Global
Top 50 shown on the chart on page 30. Most of the Top 50
have revealed that their projected sales funnels are full, per-
haps into 2014 and beyond. Backlogs are up, too.
Last year, we said we’d probably paint a rosier picture for
you than we had before. Unfortunately that’s not really going
to happen. While some asset owners are spending on CAPEX
(capital expenditure) for new automation systems and OPEX
(operations expenditure) to optimize the systems they have,
and the automation vendors
are reporting fantastic results, there is that
possibility that the highway is going to end suddenly in a bro-
ken overpass.
So What’s Wrong?
What’s wrong is that the entire economic world is scared
to death. This is a consumer-driven economy, right? Well,
consumers in North America and Western Europe, at least,
have mostly stopped consuming in droves. Why? Well, for
one thing, their retirement plans and other investments have
taken 30% to 40% hits, about half of the consumers that own
houses are underwater (at least in the United States), and
unemployment in the largest segment of that economy (the
United States) is somewhere between the officially reported
9% and the probably more realistic 15% number. On top of
that, most consumers are worried about losing their own jobs.
But wait! There’s more!
In the Eurozone, the emperor Euro appears to be under-
dressed, to say the least. First Ireland, now Greece and It-
aly, next Spain, Portugal, and perhaps then we’ll go back
around the loop again. All of a sudden, people are begin-
ning to question the strength of even the French economy.

TOP 50 GLOBAL AUTOMATION VENDORS 2010 Worldwide
TOTAL (in millions) 88,555.4
1 Siemens 12,896.4
2 ABB Process Automation and ABB Automation Products 10,945.6
3 Emerson Process Management 6,533.3
4 Rockwell Automation 4,424.0
5 Schneider Electric 4,415.0
6 Mitsubishi Electric 3,473.6
7 Danaher Industrial Technologies 3,168.4
8 Yokogawa Electric 2,979.3
9 Honeywell Process Solutions/Sensing & Control 2,775.1
10 GE 2,200.1
11 Omron 2,199.9
12 Flowserve Flow Control Division 1,836.6
13 Phoenix Contact 1,800.0
14 Invensys Operations Management 1,758.1
15 Endress+Hauser 1,744.5
16 Ametek EIG 1,324.0
17 FANUC 1,301.1
18 Cameron Valves & Measurement 1,273.3
19 Spectris 1,231.1
20 IMI Fluid Controls Severe Service PLC 1,137.0
21 Yaskawa 1,031.6
22 National Instruments 873.2
23 MKS Instruments 853.1
24 Wika 835.1
25 azbil Group 806.7
26 FMC Eergy Processing Systems 775.5
27 Bosch Rexroth 745.1
28 Weidmuller 730.3
29 Hitachi 678.6
30 Samson 648.3
31 Wago 616.2
32 Roper Industries Industrial Technology 607.6
33 Metso Automation 583.8
34 Teledyne Instruments 575.5
35 Fuji Electric 572.2
36 Advantech 548.2
37 IFM Electronics 511.9
38 Dresser Industrial 505.0
39 Toshiba 497.9
40 B&R 491.4
41 Pepperl+Fuchs 486.5
42 Beckhoff 480.0
43 Burkert 471.0
44 Krohne 451.8
45 TMEIC 435.9
46 Turck 358.0
47 Horiba Analytical 420.0
48 Badger Meter 276.6
49 Pilz 264.3
50 ThermoElectron Measurement Systems 259.7
HONORABLE MENTION 2010
Worldwide
Parker Industrial 209.6
OSIsoft 204.0
Belden Connectivity Products 200.0
Aspen Technology 166.3
Tyco Flow Control 161.2
Magnetrol 150.0
MTL 149.8
SupCon 100.3
Hollysys 94.2
SMAR 89.8
Vega 81.9
Cashco 75.0
Opto 22 75.0
Idec 70.0
SPX Valves and Controls 66.8
MTS 57.9
Matrikon 56.0
Iconics 33.4
Pyromation 24.0
Mettler-Toledo 21.4
Racine Federated/Preso, Dynasonics, Flotech 19.6
Magnetrol 12.9

So far, there have been no defaults, but just the fear of
one has caused global stock markets to plunge.
Then too, there’s the “Crazy Eddie” effect. From an
award-winning science fiction novel by Dr. Jerry Pour-
nelle and Larry Niven, The Mote in God’s Eye, Crazy Ed-
die is the one who leads the garbage workers out on
strike for higher wages the day after the city has de-
clared bankruptcy. Does this sound a little like former
Greek Prime Minister George Papandreou to you? He’s
certainly not the only Crazy Eddie either.
And then, there’s China.
Bill Strauss, senior economist and economic advi-
sor for the Federal Reserve Bank of Chicago noted
in his presentation at Rockwell Automation’s “Manu-
facturing Perspectives” during Automation Fair 2011
that it is very hard to get economic data out of China,
and some data manipulation has to be done to make it
make sense. What we know is that the Chinese econ-
omy, after a decade or more of double-digit growth is
now running at a semi-official 9% growth rate, but it
might be 6%, or it might even be slightly negative.
We better hope not. The Chinese government has
made some significant promises to the rural poor—the
people still living in huts with dirt floors, some of them
within a half-days’ walk of Shanghai or Beijing that
they, too, would be able to live the good life of televi-
sions, air conditioners, computers and a car—the whole
consumer economy lifestyle. These people are expect-
ing results, and as Chinese history has shown, when
they don’t get results, the government loses the “Man-
date of Heaven,” and civil unrest or worse ensues. The
last time China dissolved into regional warlordism was
HONORABLE MENTION 2010
North America
Opto 22 40.0
SPX Valves and Controls 36.5
Beckhoff 35.0
Samson 35.0
Tyco Flow Control 34.2
Pilz 29.1
TMEIC 28.8
Fuji Electric 25.7
Hitachi 24.5
SMAR 24.3
Vega 24.1
Pyromation 24.0
Matrikon 21.5
Iconics 19.9
Racine Federated/Preso, Dynasonics, Flotech 17.3
MTS 16.5
Idec 13.9
Mettler-Toledo 7.9
azbil Group 7.7
TOP 50 NORTH AMERICAN AUTOMATION VENDORS 2010 North America
TOTAL (in millions) 21,779.8
1 Emerson Process Management 3,337.1
2 Rockwell Automation 2,237.2
3 ABB Process Automation and ABB Automation Products 1,621.0
4 Danaher Industrial Technologies 1,584.2
5 Siemens 1,416.8
6 GE 1,156.8
7 Schneider Electric 910.0
8 Honeywell Process Solutions/Sensing & Control 718.9
9 Ametek EIG 671.0
10 Flowserve Flow Control Division 606.1
11 Invensys Operations Management 534.6
12 Cameron Valves & Measurement 517.1
13 Roper Industries Industrial Technology 492.6
14 MKS Instruments 462.2
15 National Instruments 359.8
16 Endress+Hauser 335.1
17 IMI Fluid Controls Severe Service PLC 332.0
18 Spectris 307.7
19 Phoenix Contact 270.0
20 Yokogawa Electric 261.9
21 Teledyne Instruments 258.9
22 Omron 254.0
23 Badger Meter 249.3
24 Yaskawa 176.7
25 FMC Eergy Processing Systems 176.6
26 ThermoElectron Measurement Systems 174.7
27 Turck 171.0
28 Advantech 154.9
29 Weidmuller 146.1
30 Mitsubishi Electric 141.7
31 Toshiba 124.4
32 OSIsoft 102.0
33 Bosch Rexroth 98.3
34 Wago 92.0
35 Wika 83.5
36 Dresser Industrial 82.9
37 Metso Automation 81.1
38 Horiba Analytical 80.0
39 B&R 78.6
40 IFM Electronics 76.8
41 Cashco 70.0
42 Parker Industrial 69.2
43 MTL 64.9
44 Aspen Technology 63.5
45 FANUC 61.9
46 Magnetrol 60.0
47 Pepperl+Fuchs 57.5
48 Krohne 49.6
49 Belden Connectivity Products 48.3
50 Burkert 47.1

in the 1920s after the death of revolutionary leader Dr. Sun
Yat Sen. This time, the possibility exists that any such warlord
would have nuclear missiles. At any rate, a destabilization of
China would have, as the policy wonks say, significant adverse
effects on the global economy.
And in North America, we have unrest in the streets al-
ready, with some of those consumers without jobs, and who
are unemployed or underemployed, showing their anger at
the banks, at Wall Street and at the government for not being
either willing or able to do anything to improve the situation.
Scary, huh? You bet. Now translate that to the behavior
of manufacturing companies and the automation vendors
who serve them.
Business news commentators have been saying that com-
panies are hoarding cash. This absolutely appears to be
true, and is true both in the asset owner and automation
vendor categories. ABB, Rockwell Automation and others
have amassed large stashes of cash. Some shareholders are
arguing that this cash should be used for acquisition or in-
creased dividends or, well, just use it. Companies, on the
other hand, are clutching their cash because they are wor-
ried about the future. As an example, ABB made it through
the 2009 recession in really good shape, partly because it
had several billion dollars in cash on hand going in.
Should we all be worried? To a point, sure. But the dangers
and challenges ahead for the economy are so massive that all
we can do is what those of us who lived through it did during
the hottest part of the Cold War—keep on doing what you’re
doing and try to get through it. Or, as the public service post-
ers in London said during the Blitz, “Keep calm and carry on.”
As individuals, we can take a page from the asset owners’ and
automation vendor companies’ book. Pay down any debt. If you
have a mortgage, do your best to refinance it, and if you can,
adjust the principal. Pay cash, cut expenses and make sure you
have money left over at the end of the month and save it.
The consumer-driven economy will have to adjust to the
new consumer normal.
How Do We Do It?
Every year, we find more companies to add to the list. If you
spot one we haven’t listed and that should be, let us know. Even
though we add companies and subtract the ones that have been
acquired, we haven’t greatly changed our methodology of anal-
ysis for the past several years.
Energy,Utilities,Advanced Process Control.
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Role-Based Visualization and Advanced Process Control that act in
concert to reduce plant energy costs and environmental impact.
Learn more at

Red Lion Controls ph: (717) 767-6511 fax: (717) 764-0839 www.redlion.net
©2011 Red Lion Controls All brands and trademarks are the property of their respective owners.
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Here’s what we are including in our
definition of the 50 largest companies:
-
-
-
-
What we are not including:
-
Walt Boyes is Control’s editor in chief; David
Clayton is Senior Analyst Automation and Inderpreet
Shoker is an Analyst at ARC Advisory Group,
www.arcweb.com

The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2011 Emerson Electric Co.
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.

Schweppes Australia consolidates process
and logic controls in its syrup room with a
new automation and controls system.
by JIM MONTAGUE
Everyone loves soda pop, but it hasn’t always been available
to many of the most remote communities worldwide. How-
ever, ever-expanding markets are leading soft drink manu-
facturers to invest in more local facilities to ensure there’s
reliable production to meet increasing demand.
One of these companies is Schweppes Australia (www.
schweppesaustralia.com.au) and its facility in Huntingwood,
New South Wales. It’s one of the company’s principle produc-
tion plants in Australia and has increased its manufacturing
capacity substantially in the last eight years.
As part of its own quest to improve reliability and operabil-
ity along with its expansion, Schweppes Australia recently
upgraded the control systems in the syrup room at its Hunt-
ingwood facility. The project included migrating process
control functions that had been performed by a legacy dis-
tributed control system (DCS) to a new control system based
on the PlantPAx process control solution from Rockwell Au-
tomation (www.rockwellautomation.com).
Syrup, Batch, Clean, Repeat
To rise above mere soda water, carbonated beverage production
relies on the preparation of flavored syrups. Syrup manufacture
begins with a batch process, using the basic components of raw
sugar and treated water. At the Huntingwood plant, a contin-
uous sugar dissolver is used to mix sugar into water to create
“simple syrup.” This mixture is prepared to a concentration of
62 degrees Brix—62% sucrose and 38% water by mass—before
being transferred to one of two 40,000-liter holding tanks.
A batch of flavored syrup is prepared by manually mixing
flavor ingredients in a small ingredients tank and routing this
mixture to a final destination tank in conjunction with pre-
prepared simple syrup and added water. Not surprisingly, the
process control system is crucial to managing this mostly au-
tomated process. Operators use the control system to call up
batch menus and enter details of the required batch volume
and the destination tank to be allocated. The system automat-
ically ensures the volumes and proportions are correct and the
necessary clean-in-place (CIP) procedures are completed be-
fore routing the mixture to the final destination tank.
Schweppes Australia’s project engineer, Warren Ung, re-
ports that CIP is a crucial part of the automated process for
both the tanks and transfer lines. “All the sugar-based prod-
ucts leave scope for bacteria build-up and contamination,”
says Ung. “Cleaning involves a simple flushing, a three-step
CIP process or a five-step CIP process. The system initiates
the appropriate CIP to prevent spoilage from the previous
flavor that has passed through the tank. This is critical to
ensure no batch contamination occurs.”
Combining Controls in Software
Before its latest upgrade, the control system in Huntingwood’s
syrup room was split between a legacy DCS for process con-
trol and batching and an Allen-Bradley ControlLogix system,
in conjunction with RSView 32 SCADA software, all from
Rockwell Automation. This latter system was installed to
provide process control for additional lines transferred from
Schweppes Australia’s Alexandria plant back in 2001. While
these separate systems ran satisfactorily in parallel, the firm’s
engineers report that they grew increasingly concerned about
the reliability of the obsolete DCS, the difficulty in sourcing

spare parts and the potential for component failure resulting
in significant production downtime.
“We had a choice of either upgrading the control system
to a current version of the DCS or integrating these DCS
functions into the Rockwell Automation system,” explains
Ung. “Migrating our process control functions to the Con-
trolLogix platform was a natural choice because it could
achieve the same level of functionality as a DCS, but it also
allowed for greater flexibility for future expansion.”
As a result, Zi-Argus Australia (www.zi-argus.com) acted as
system integrator to help manage the upgrade. Ken Maxwell,
sales director at Zi-Argus, explains that a key challenge of the
project was to extract the source code out of the DCS in order
to translate the syrup batching functions into ControlLogix.
“To integrate the DCS process control into ControlLogix, we
had to painstakingly analyze every aspect of the DCS to be
in a position to replicate it in the new system,” says Maxwell.
In addition, Zi-Argus was not only assigned to replicate
the functions of the legacy DCS using ControlLogix, but
also to improve the operator interface and the reporting
components of the system. “The operator interface was im-
proved by replacing all of the screens and HMIs, and up-
grading from RSView 32 to the newest software version—
FactoryTalkView Supervisory Edition,” adds Maxwell. “The
result is a system that’s now more capable, more intuitive for
operators, and makes it easier to find faults.”
Unified Syrup Process and Support
Thanks to its upgrade project, the primary user interface for
Huntingwood’s syrup application is a SCADA and SQL server
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Figure 1: Schweppes Australia’s plant in Huntingwood,
New South Wales, uses a batch process to manufacture
flavored syrups for soda pop. The company recently
migrated from a legacy DCS to an automation and control
system based on the PlantPAx process control solution.
SWEET TALK

supported by three onsite clients, which
each run FactoryTalkView SE software.
Operators use the SCADA to spec-
ify batch recipes, batch sizes, destina-
tion tanks and CIP requirements. The
SCADA and clients are linked via Eth-
erNet/IP to the ControlLogix controller,
and small HMIs are connected via se-
rial interface. ControlNet communica-
tions are used to network various process
sensors and drives back to ControlLogix,
which had its CPU in the syrup room up-
graded to handle the two additional racks
of I/O that replace the former DCS.
The project’s engineers and integra-
tors report that Schweppes’ new syrup
batching system is a model example of
Rockwell Automation’s PlantPAx solu-
tion for unified plant process control.
In general, PlantPAx provides a scalable
portfolio of enhanced process technolo-
gies, solutions and services for plant-wide
control. With built-in DCS and PLC
functionality, PlantPAx can be used for
applications involving both process auto-
mation and discrete functions.
Maxwell adds that all of Hunting-
wood’s process lines now link back to the
SQL server database, facilitating more
comprehensive and consistent capture of
data and, consequently, better reporting
capabilities. “Having all systems feeding
data into the SQL database has meant
a quantum leap forward in the system’s
ability to extract data and populate a da-
tabase,” he says. “It allows the system to
generate detailed batch and quality as-
surance reports, which can be archived
more easily.”
Ung says that the plant’s upgrade
project had a fallback position just
in case. The legacy system remained
functional during the changeover, but
this capability was never employed.
“The new system worked well upon
first initialization,” says Ung. “The
changeover ControlLogix could not
have gone more smoothly.”
In the wake of its upgrade, Schweppes
Australia is also using the TechConnect
support program from Rockwell Automa-
tion and an ongoing service agreement
with Zi-Argus. “Previously, we had no
site expertise regarding the DCS system,
and there were only a couple of people
in Australia with the technical expertise
to program or find faults in the system,”
adds Ung. “The upgraded system is far
easier for on-site personnel to trouble-
shoot, especially with the support from
TechConnect. The service agreement
with Zi-Argus Australia provides assur-
ance that unplanned downtime can be
minimized. This upgrade will help en-
sure that Schweppes continues to meet
rising demand long into the future.”
Jim Montague is Control’s executive editor.
Figure 2: Schweppes Australia’s project engineer, Warren Ung (center) and Zi-
Argus Australia’s sales director, Ken Maxwell (right) check on cabinets housing
the Huntingwood facility’s new PlantPAx process control system and Control-
Logix components that run the plant’s batch syrup production process.
CONFERRING ON CONTROLS

P R O C E S S A N A LY Z E R S
Process users and integrators must
carefully design and match SCSs with
application requirements and
specifications, complete application
data sheets and deploy
climate-controlled shelters.
by Robert Sherman and Jim Montague
Process analyzer sample conditioning systems (SCSs) don’t
get the attention they deserve. This is because analyzers
couldn’t do low-parts-per-million (PPM) analysis 40 years
ago, so users got away with crude, less-developed process
measurements. Many of these habits persist today. However,
today’s analyzers and SCSs routinely do low-PPM analyses.
And, since 1990, the U.S. Environmental Protection Agency
(EPA) has required analyses of decreasing PPM levels of H2
S
and total reduced sulfides (TRSs) in continuous emission
monitoring system (CEMS) applications, so process users
must achieve defined precision and accuracy levels.
Lacking Coordination? Be Meticulous
Unfortunately, a growing number of SCSs built by systems
integrators (SIs) have been non-functional on shipment.
This can happen when a user buys an analyzer from a ven-
dor and then has an SI design the SCS. Another problem is
when users keep an existing SCS, but it doesn’t match the
new analyzer’s requirements, and so the overall system may
not work. This problem often happens due to a lack of coop-
eration between analyzer suppliers, unaligned SIs and users.
And, users can be caught in between—sometimes incurring
fines of $100,000 per day per erroneous CEMS value.
The solution is to be meticulous! Spend the funds wisely to
get your SCS properly designed for its specific application, es-
pecially in northern climates. If users and SIs paid the same at-
tention to designing their SCSs as they do when designing an
operating process unit, then most would work reasonably well.
Likewise, most users don’t complete application data
sheets (ADS), especially for their CEMSs. It’s crucial that
analyzer manufacturers complete these sheets with all
MIN/NORM/MAX and sample-plus-matrix components
and values for each identified component. An SCS’s specifi-
cations also should describe the physical and electrical haz-
ard requirements it must meet. Also, the data sheets should
provide the system’s environmental parameters, such as am-
bient and process stream temperatures, and hazardous at-
mosphere monitoring for its emergency alarm system (EAS).
However, users will often indicate they require a 40 CFR
60 subpart JA system for a flare, for example, and know
roughly what that requires, but then tell the analyzer ven-
dor to just sell them something designed for this general
application. This means the user is also asking their SI to
have enough knowledge to give them something that “just
works.” This isn’t enough because the process details for a
given process application are often very specific.
Users often believe they don’t have the time to do SCSs
right the first time. They perceive other higher priorities,
so they hope the specified equipment will operate properly.
There’s always time to fix it later, but no time taken to prop-
erly specify it before ordering.
Diagnose, Fix–and Gimme Shelter
For example, one Gulf Coast refinery had a flare system with
a 150-ft to 175-ft long sample line. This line was operating
at nominal saturation due to water washes of the sample,
but the sample system wasn’t working properly. When asked
about the dew point of the sample, no one knew what it was!
This application had a new, insulated, heat-traced, sample-
transfer line that wasn’t specified or routed properly. The

P R O C E S S A N A LY Z E R S
vendor checked the order, and the line was specified for a
low temperature of 300 °F and a high of 360 °F. However,
it was still cool to the touch on a day when the ambient tem-
perature was 65 °F. Do you recognize a problem here?
You need to consider heat-traced enclosures for your cali-
bration gases in low-PPM CEMS applications. This is im-
portant! While ambient temperatures in northern Texas can
be -15°F in late winter, they can reach 115 °F in summer.
Add incident sunlight in southern Texas, and you can have
160 °F wall temperature for your calibration gas cylinder
stored outside on the south side of an analyzer shelter. These
ambient temperature differences can cause stratification in-
side the cylinder containing the calibration gas. The ana-
lyzer depends on uniform composition of this gas to develop
results. Previously, bottles of calibration gas were put inside
the shelter, but today they’re installed outside for safety (Fig-
ure 1). They should have a separate, climate-controlled shel-
ter for low-PPM CEMS and process analyzer applications.
Some refineries are installing a 2-ft x 8-ft footprint, climate-
controlled calibration gas enclosure adjacent to their shel-
ter, and installing their gas cylinders inside with heat-traced-
and-insulated delivery tubing to carry calibration gas from
the cylinder to the analyzer.
Similarly, because users are experiencing alteration of
sample composition due to ambient exposure of sample
transfer lines, some vendors are designing gas chromato-
graphs for installation near field application sites for hydro-
carbon and chemical processing applications.
APC, Process Physical Properties and NeSSI
Although low-PPM sample conditioning for quality is more
recent than repeatable accuracy for regulatory compliance,
process analyzers also provide signals for a growing advanced
process control (APC) engineering initiative. A distributed con-
trol system (DCS) can use percent analytical process measure-
ments and low-PPM data to improve product quality.
Now online process analyzers do require an upfront capital
outlay and an on-going maintenance effort, but they can often
provide measurements that are superior to lab-based ones when
done properly. Inferential sensors can be a good, low-cost solu-
tion too, if the correlation model’s accuracy is sufficient and the
appropriate monitoring and validity checks are put into place.
Consequently, we’re seeing more sample systems that use
the New Sampling and Sensor Initiative’s (www.cpac.wash-
ington.edu/NeSSI) modular substrate platform. Some of
these components are advertised to perform up to 10 million
cycles before needing maintenance. This is useful in dealing
with environmental measurements where we have to measure
processes every 15 minutes and do zero and validation pro-
cedures every 24 hours. Also, when switching from process
operation measurements to the EPA’s CEMS measurements,
the NeSSI substrate allows better precision for EPA reporting.
Encouraging Cooperation
Besides drafting well-written specifications that define each
party’s roles and expected results, users and their integrators
and vendors must completely fill out their application data
sheets for every SCS project. Even though it can be diffi-
cult to gather some of this process and ambient information,
these users are requiring expected process flow rates, tem-
peratures and pressures at the specific points where samples
will be extracted by the in-line sample probe.
Similarly, analyzer technicians and engineers are getting
better at arguing that proper design of analyzer SCSs will
reduce lifecycle costs. This is because many refiners are en-
couraging technical personnel to join the American Petro-
leum Institute (www.API.org), American Society of Testing
and Material (www.ASTM.org), the International Society of
Automation’s (www.ISA.org) analytical or related divisions,
and suppliers’ user groups and customer advisory boards.
Ten or 15 years ago, most analyzer technicians couldn’t
get a climate-controlled shelter for their PPM analyzers be-
cause their finance department would argue that, if an ana-
lyzer in its enclosed housing was rated to meet field-location
ambient conditions, then a separate shelter wasn’t needed.
But while a manufacturer can say an analyzer in its enclo-
sure is rated to -30 °F, they might add that, if the internals get
below 55 °F, then primary vacuum pump oil will be too vis-
cous, and it will need to be heated for several hours. If there’s
blowing rain or drifting snow where an externally mounted
analyzer is installed, then technicians can’t open its enclo-
sure because they’ll risk getting the internal circuit boards
too cold or damp. This is why users are installing more 8-ft x
8-ft or 10-ft x 10-ft footprint shelters to protect their process
control and environmental analyzers.
[Editor’s note: For an expanded version of this article, visit
www.controlglobal.com/sampleconditioning.]
Robert E. Sherman is an ISA Fellow and manager of analyzer technology at
Valero Energy. Jim Montague is Control’s executive editor.
Figure 1: A typical enclosed shelter with sample condi-
tioning system mounted on its exterior wall.
SEEKING SHELTERS

A S K T H E E X P E R T S
D/P Impulse Lines; Chinese Solar Tech
Q
We’re in the process of installing self-regulated, heat-
traced impulse lines to a differential pressure (d/p)
transmitter that is measuring feed-water flow to a
boiler. The piping installation will not allow me to install
the transmitter below the water pipe. How do I keep my im-
pulse lines full of water when the pump shuts down? Would
it be OK to bend the tubing so as to create a water trap?
JIMMY BALLEW
Jimmy.Ballew@gdfsuezna.com
A
If on water service there is a possibility for air getting
into the impulse lines or if the lines can plug, freeze,
drain, etc., I usually avoid using d/p type sensors with
impulse lines at all and install magnetic, ultrasonic or vortex
flowmeters. The advantage of the newer vortex meters is that
they can also measure temperature.
If for some reason you must use a d/p type flow sensor, I
would consider the use of chemical seals with the capillary
filled with a non-freezing liquid or side-mounted d/p cells
without impulse lines.
BÉLA LIPTÁK
liptakbela@aol.com
A
If you’re measuring liquid flow, then the impulse lines
need to be mounted such that no air can get trapped in
them. If the orifice taps are brought out the side of the
pipe, you can mount the transmitter to the side, and put just
enough slope in the impulse tubing to ensure the water will
displace any air in the lines as they fill.
P. HUNTER VEGAS, PE
www.avidsolutionsinc.com
A
This is a typical problem where the impulse line con-
nection is limited by space availability or other pipings
nearby. When take-off taps are on the side of orifice
flanges, you have two choices:
face traced if heat is not going to affect fill fluid. Locating it
at a higher plane and zeroing out error due to cell location
will give repeatable and accurate readings.
take-off and connect the d/p with necessary support. Trac-
ing will be limited to the manifold and body of the d/p cell.
Note that over extended time your seal water will boil off
if tracing is left on, creating a likely vapor trap, resulting in
error, though minor. This can happen even if you manage to
install the d/p cell below tap level and leave the tracing on.
RAM.G.RAMACHANDRAN
ramacg@cox.net
A
The steam tracing will evaporate any liquid in the im-
pulse lines that has a pressure of less than the steam
pressure.
That’s a short answer, but we need more details. Does the
plumbing configuration allow the pump and the impulse
lines to remain full of water? Probably not, or you wouldn’t
ask. Where is the transmitter, orifice plate, flow control valve
and pump block valve (if any)? Not to mention the steam
drum, pump suction source and the type of pump.
As to bending the impulse lines when the fluid is water,
bend them any way you like as long as the transmitter can
the bottom of the orifice plate will not solve the problem,
even without steam tracing,
Figure 1. Nanosolar’s printed solar collector sheets, shown
above, may revolutionize the whole industry.
STATE-OF-THE-ART SOLAR TECHNOLOGY
This column is moderated by Béla Lipták automation and safety consultant (http://belaliptakpe.com/) and editor of the Instru-
ment Engineer’s Handbook (IEH). For the 5th edition of the IEH, contributors are invited to update old and prepare new chap-
ters. If you have control related questions or have comments on the topics discussed below, write to liptakbela@aol.com
CourtesyofNanosolar,Inc.

A S K T H E E X P E R T S
If there is something about this problem that requires full im-
pulse lines when geometry and gravity make that impossible,
investigate remote diaphragm seals with oil-filled impulse lines.
BILL HAWKINS
bill@iaxs.net
A
Bends with a transmitter above will be a maintenance
headache. I suggest using another device such as an in-
line ultrasonic or vortex meter Instead. This will also
mitigate the requirement of heat tracing.
H. S. GAMBHIR
Harvindar.S.Gambhir@ril.com
A
Why not have the seal at the transmitter and then use
fill fluid that will not freeze or care about orientation?
Another option is to close-couple a “smart” transmit-
ter and then do “all” your work (except when you need to iso-
late the device) over the signal cable remotely. Rosemount
makes a transmitter in which the sensor can be mounted on
the process, and the display is mounted remotely with cable
between the two components. This allows mounting of ca-
pacitance cell without impulse lines, and then placing the lo-
cal indication at either grade or other accessible location.
IAN VERHAPPEN
iverhappen@gmail.com
Q
At the ISA Conference in Mobile, you used a slide
showing that the American share of the global solar
collector market is only 0.5%, while China’s is 80% for
hot water and 60% for photovoltaic designs? Are their prod-
ucts so much better? If not, why are we so far behind?
H. CROWNEY
HCrowney@aol.com
A
Neither their controls, nor their converters or collec-
tors are any better and in terms of quality, they are
worse. As you can see from Figure 1, our solar technol-
ogy is one of the finest in the world. Our Nanosolar collec-
tor sheets will probably revolutionize the whole industry, be-
cause of their excellent electric conductivity and drastically
reduced cost of manufacturing (basically the collectors are
printed). Similarly, our solar roof shingles and their controls
(Fig.2) are also superior to the Chinese product.
No, this situation has nothing to do with quality, but with
politics! The Chinese government can implement business
strategies, which ours cannot. Just imagine how hard it would
be and how long it would take to have Congress pass a regula-
tion requiring that all U.S. government buildings be covered
by American-made PV solar collectors, and also require that
the cost of these installations be financed by 15-year “building
improvement” mortgages?
Yet, if it were politically possible to do, the solar industry mar-
ket would suddenly explode. It could hire more people, spend
more money on R&D, and the local government could pick the
best designs at the lowest cost. Even with the miniscule mar-
ket today, the cost of solar collectors during the last years has
dropped from $3.30/watt in 2008 to $1.20/watt today.
If in all areas where solar insolation exceeds 1,500 kWh/m2/
yr, the government buildings ordered collectors, their produc-
tion and installation would create some 1.5 to 2.0 million jobs.
Such projects would do that without any cost to the taxpayers,
because during the first 15 years, the monthly mortgage pay-
ment for these improvements would be less than the present
monthly electricity bill and after that, the fuel (the sun) would
cost nothing. Already, on a building in Westport, Conn., 46
collectors were installed at a monthly mortgage cost of $200,
less than the previous monthly electricity bill of $215.
Once such cost-effectiveness was proved on the govern-
ment buildings, the “lack of economic feasibility” argument
would be disproved, and the general public would follow the
example of the government, thereby further increasing the
demand. This increased market would create even more jobs,
would cut energy imports even more, would allow Ameri-
can manufacturers to further improve their quality, further
reduce costs through mass production. Higher quality and
lower cost would make us a player on the global market and
eventually we would beat the Chinese.
BÉLA LIPTÁK
liptakbela@aol.com
Figure 2. Dow Solar has released shingles that gener-
ate electricity from solar power. They are inexpensive
enough for a family home.
DOW SOLAR‘S POWERHOUSE SHINGLES
CourtesyofTheDowChemicalCompany

R O U N D U P
Software Supermarket
New applications, upgrades, interfaces and more for your industrial software needs.
ONLY CONNECT
Top Server 5.5 is an OPC
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network. The SNMP Agent plug-in supports SNMP version
1 and 2C and the UDP protocol.
Software Toolbox
888/665-3678; www.softwaretoolbox.com
DEVELOP FASTER
With its integrated simula-
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dynamic development process, reducing overall develop-
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B&R Industrial Automation Corp.
770/772-0400; www.br-automation.com
COMPACT PAC SOFTWARE
RSLogix 5000 design and
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control and information system with fully integrated control,
network, visualization and information technologies.
Rockwell Automation
414/382-2000; www.rockwellautomation.com
FLOW CONTROL
The Brooks Smart Interface
(BSI) Model 0260 together
with the BSI tabletop hard-
ware module, provides a
turnkey solution for monitor-
ing and controlling up to 30
mass flowmeters or mass flow
controllers. Users can display
the full-scale and measured flow rate. Operators can also dis-
play and adjust the setpoint; display device and alarm status;
and change valve override status from the main screen.
Brooks Instrument
888-554-FLOW; www.brooksinstrument.com
PAC SOFTWARE
PAC Project software suite
comes in two versions. The
free basic version includes
a flowchart-based program-
ming tool and an HMI de-
velopment and runtime
application. PAC Project Pro-
fessional adds an OPC server,
the ability to share system data with common databases, plus
support for redundant controllers, complex network archi-
tectures and legacy Opto 22 I/O.
Opto 22
800-321-OPTO; www.opto22.com
NAVIGATE YOUR CONTROL LOOPS
Engineers can minimize pro-
cess variation by using In-
tune+ Process Navigator to
monitor and diagnose control
loop performance. Process
Navigator provides long-term
protection against perfor-
mance degradation. Intune+
and Intune v. 5 together provide process control monitoring,
tuning, online diagnostics and automatic reporting of poor
performance.
ControlSoft
440/443-3900; www.controlsoftinc.com

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