OCTOBER 2023

OFFICIAL PUBLICATION OF THE INTERNATIONAL SOCIETY OF AUTOMATION www.isa.org/intech

What Control Engineers Should

Know about Industry 4.0

Remote Monitoring for Asset

Reliability

Loop Diagrams and Process Loop Sheets

Diaphragm Seal Pressure Transmitter

Maintenance

Programming Languages for

Automation and Control

Cloud-based Advanced Data Analytics

 OCTOBER 2023
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OCTOBER 2023 | VOL 70, ISSUE 5

FEATURES
INDUSTRY 4.0

13 What Controq Engineers

Shouqd Knowabout
Industry :
By Charlotta Johnsson, Margret Bauer
and Kristian Soltesz
steeq
A industryexampqeshowshow
thetwodiscipqinesintersect:

ASSET MANAGEMENT

25 Remote Monitoring for

Asset Reqiabiqity
By Brian Dubaskas and Navin Rajashekar DATA ANALYTICS
nce
O fieqddevicesgatherthedatad s rom
F RawData to
considerthesefourstrategiesforre J
moteanaqyDcs:
Meaningfuq Insight
By Katie Pintar
MAINTENANCE ow
H cqoudJbasedadvanceddataana J
qyDcsempowersprocessengineers:
32 PressureTransmitters9
Improving Diaphragm
Seaq Maintenance
By Nicole Meidi
DEPARTMENTS
evL eqmeasurementsystemsandother 2 Advertisers Index
appqicaDonsbenefitfromimproved 8 Talk to Me
flushingringdesigns: By Renee Bassett
NavigaDng the GrayJtoJGreenWorkforceTransiDon
CONTROL SYSTEMS
10 Executive Corner
36 Understandingoop L By Peter Chin

Diagrams and Process ReqiabiqityThrough theens

L ofSustainabiqity

51 Association News
oop
L Sheets ISAAutomaDon andeadership
L Conference Brings
By John Robert Davis and Graham Nasby TopTech Experts to Coqorado Springs
etaiqed
D drawingsconformingtothe
55 The Last Word
ANSIFISAJ:Jdnstru
I mentaDon By Jack Smith
SymboqsanddenDI ficaDondstandard The vEoqving Language ofAutomaDon Engineering
showhowaqqdevicesandequipment
arewiredtothecontroqsystem:

INTECH OCTOBER 2023 5 WWW.ISA.ORG/INTECH

 TOCO REB GVOdL SSUE
I  UB
P LAIC F O TIACIL THFO N TENI E RNTIA SOLANO TY
EIC UTO
A FO TIAM NO

EDITORIAL & PRODUCTION ADVERTISING & SPONSORSHIP

CHIEF EDITOR: Renee Bassett, [email protected] Rick Zabel, PUBLISHER, [email protected]
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 TALK TO ME | PERSPECTIVES FROM THE EDITOR

Navigating Industrial Workforce Transitions

By Renee Bassett, InTech Chief Editor

TheSiqverTsunami:The conD ngentffitend to have a different concep J

ray
G JtoJGreenTransiDon:The D on ofthe empqoyeeKempqoyerreqaD onship
reat
G ReDrement:oN matter than do oqderempqoyees in the >gray? group:
hat
w ouy caqqitdmostexperts
Previousways ofworking and interacD ng
agreethegqobaqorkforce
w is
between empqoyers and empqoyees are being
inthemidstofanevoquon:
D cross
A industries
disrupted byGen Zfs entryinto theworkforce
andgeographiesdaby
B oomers
B arereDr J
because ofdifferent expectaD ons regarding
ingffiorchangingjobshiqe
w choosingtoork
w
atmosphered cuqtured and support atworkd
qongerffiandforcingcompaniestoadapt:erhaps
P
according an arD cqe fromJohns Hopkins
nowhereisthattruerthanithin
w themanufac J
University: McKinseyfs gqobaq research shows
turingdindustriaqandengineeringsectors:
that six factors are parD cuqarqyimportant to
Todayaqargechunkoftheorkforce
w is youngerindustriaqworkers9
occupiedbyaby
B oomers
B PwQdeneraD
G on z an easyappqicaD on processwith cqear
XP:wQdandiqqenniaqs
M P:wQ:Withover communicaD on and a quick D me to hire
daby
B oomers
B perdayreachingtheage z rapid careerprogression and cqearperfor J
ofrdtheouy ngestorkersffi
w eneraD
G onZffiwiqq mance feedback
consDtuteaboutwofthe orkforce
w by: z theabiqitytoork
w inahybridorkpqace
w
ccording
A totheU:S:reau
u B of abor
L PatqeastinnonmanufacturingroqesQdwith
StaDsDcs deopqe
P bornfromtordthe faceJtoJfaceinteracDonsprimariqyreserved
qatterears
y ofthebabyboomdheqdanaverage forsituaDonswheretheycqearqyaddaqu
v e
of:jobsfromagessto:earqy
N haqfof z the opD on to expqore muqD pqe empqoyers
thesejobsere
w heqdfromagessto:sA oreven muqD pqe careers
ageneraDongrowingpu ithou
w ttheinternet z a strong focus on diversityd incqusiond and
andsed
u toorking
w ith
w theirhandsdboomers sustainabiqityd incquding aworkpqace that
thrive intheinstaqqaDondtransportaDondand aqqows forseqfJexpression and sancD ons
engineeringindustries:Theyareaqsomoreqikeqy nonincqusive behavior:
thananyothergeneraDontohaveattended It mayaqso heqp to rememberthat this
coqqegedandnearqytwoJthirdshaveadegree: evoquD on oftheworkforce is nothing new:
Youngerworkersd on the otherhandd >grew In d the US Congress heqd hearings on
up in aworqdwhere the internet made goods >AutomaD on andTechnoqogicaq Change? and
and services readiqyavaiqabqeffioften instantqy its associated impact on jobs: Chiefamong
orwith sameJdaydeqiveryffiand aqqowed them its findingswas that the USwas >facedwith a
to conduct much oftheirsociaq qives onqined? threatened shortage ofscienD stsd techniciansd
says McKinsey :Theseworkersffithe >green? and skiqqed qabor:?The more things changee:

INTECH OCTOBER 2023 8 WWW.ISA.ORG/INTECH

 EXECUTIVE CORNER | TIPS AND STRATEGIES FOR MANAGERS

Reliability Through the Lens of Sustainability

By Peter Chin

It isweqq known throughout industrythat oor

P reqiabiqityaqso affects conD nuous pro J
a high degree ofreqiabiqityis required for cessesffiresuqD ng in qost producD ondwasted
process pqants to achieve maximum avaiqabiq J energyd and excess use ofrawmateriaqsffias
ityand reduce unpqanned events: Howeverd weqq as the need to reprocess resources to
not everyone mayiniD aqqyconnect improved upgrade orrepqace product:
reqiabiqityto enhanced sustainabiqity:
In both casesd even more energyis
oor
P reqiabiqityand excessive downD me required forrestartsd as both batch and
negaDveqyimpact sustainabiqityin myriad conD nuous processes are designed to run
ways: Devicesd such as reqieforisoqaD on at maximum efficiencywhen there are no
vaqvesd that do not operate as required can interrupD ons: Some ofthese faiqures may
resuqt in emissions to the atmosphere that resuqt in the need to perform maintenance
directqydegrade sustainabiqity:These emis J on equipment orproducD on unitsd expending
sions mayresuqt in product qosses and other more energyand resourcesd and increasing a
waste that aqso affect sustainabiqity: pqantfs carbon footprint:

Otherdevice faiqures mayresuqt in down J ortu

F nateqyd there areways to address
Dmedwhich aqso negaD veqyimpacts sustain J these and otherreqated issues: Most funda J
abiqity:or
F batch processesd enD re producD on mentaqqyd one can make product reqiabiqitya
runs can be qost8 energyand otherresources keyconsideraD onwhen seqecD ng measure J
must be expended to repqace the batch ment and finaq controq devices in everypart
and to dispose ofwaste:This is parD cuqarqy ofthe producD on system:This is especiaqqy
probqemaDc forbatcheswith qong processing important forvaqvesd as these are rouD neqy
Dmes andveryhighvaqued as is often the case exposed to process media and the eqementsd
in the qife sciences industry: and often contain muqD pqe moving parts:

INTECH OCTOBER 2023 10 WWW.ISA.ORG/INTECH

 EXECUTIVE CORNER | TIPS AND STRATEGIES FOR MANAGERS

As newpqants are designed orexisD ng fa J advice to pqant personneqdwith onsite

ciqiDes upgradedd it is cruciaq to considerusing assistance avaiqabqe as required: Newad J
devices thatwiqq improve reqiabiqityd such as vancements invirtuaq reaqitycan qink service
smart instruments andvaqves:Technoqogicaq providerexpertswith process pqant person J
advances invaqve automaD on and monitor J neqdwhich is parD cuqarqyusefuqwhere access
ing can provide the informaD on needed to to certain qocaD ons maybe chaqqenging at
faciqitate predicD ve orpreventaD ve mainte J short noD ce: Somevendors can monitorfieqd
nance:When appqied to criD caq processes and devices remoteqywith a team ofexpertsd
keyequipmentd these types ofadvances can adding furthervaque:
reduce unpqanned downD me:

Adding orupgrading fieqd devices has

typicaqqyrequired addiD onaqwiring from each
Devices that do not operate as
device to the automaD on systemdwhich is required can result in emissions
often quite costqyand D me consumingd and
to the atmosphere that directly
mayrequire downDme:These issues can be
addressed in twoways:
degrade sustainability.
Manyfieqd devices are nowavaiqabqe in
wireqessversionsd eqiminaD ng the need for
These soquD onswiqq become ubiquitous
fieqdwiring:Whenwiring is requiredd it can
as more fieqd devices are digiD zedd and as
often be connected to flexibqe IFO mounted
newermodeqs ofexisD ng digitaq fieqd devices
in the fieqdd so home runwiring to the au J
become more inteqqigent:These deviceswiqq
tomaDon system in the controq room is not
take advantage ofmore powerfuq networking
needed.
technoqogiesd bothwired andwireqessd for
Finaqqyd aqq fieqd devices shouqd be main J both onJpremises and cqoudJbased con J
tained correctqyto ensure maximum upD me: necD ons:This improved connecD vitywiqq
Manyprocess pqants operatewith reduced resuqt in qowerstorage costs fordatad aqong
staffd so fieqd device maintenance mayrequire with easierand more secure remote access:
engagementwith a service providerd typicaqqy These advanceswiqq increase reqiabiqityand
avendord preferabqyavaiqabqe FFr upD med and in turn deqiversustainabiqity
worqdwide: Ideaqqyd thisvendorwiqq provide improvements:

ABOUT THE AUTHOR

Peter Chin is thevice president ofmarkeD ng forEmersonfs Finaq Controq business
unit: He has qived andworked across fourconD nents and has experience in muqD pqe
industries: Chin has a BacheqorofEngineering degree fromeicester
L UniversityPUKQ
and an MBAfromWashington Universityin Stou
L is:

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INDUSTRY 4.0

What Control
Engineers Should
Know About
Industry 4.0

A steel industry example shows

how the two disciplines intersect.

By Charlotta Johnsson, Margret Bauer,

and Kristian Soltesz

Control engineering is a well-established time that engineers consciously encounter

discipline with a long and prominent his - the subject of control systems.
tory1. It is diverse in its applications but has
While control engineering is rooted in
a strong unifying core to it: the notion of
mathematical theory and tools, Industry 4.0
dynamic systems and control theory. Many
relies on a variety of technologies. Industry
engineers will have encountered it as part
of their education, as control engineering 4.0 is a new and still-evolving paradigm in

courses are taught to electrical, mechanical, which digitalization is expected to revolu-

chemical, aerospace, and industrial engi- tionize industry and core technologies are
neers. Quite o en, though, this is the only still emerging. The term was coined in 2011

INTECH OCTOBER 2023 13 WWW.ISA.ORG/INTECH

INDUSTRY 4.0

bya German government taskforce and has riginaqqy

O dthereere
w ninepiqqarsortech J
been adopted bytheWorqd conomic
E oru
F m noqogiesonwhichthevisionofndu
I stry:
PWEFQ 2: Its concepts are know n to engineersd reqied:Thesetechnoqogieshavebeenadapted
corporate managers and poqicymakersd but it somewhatbuttheoriginaqsintroducedin
can be difficuqt to grasp and define: incqude9simuqaDon8cyberJphysicaqsystems
Pacomputersysteminwhichamechanismis
In this arDcqewe address the intersec J
controqqedormonitoredbycomputerJbased
Don ofcontroq engineering and Industry :
aqgorithmQ8roboDcs8andarDficiaqinteqqigence
byexamining the underqying methods and
PAIQdbigdataanddataanaqyDcs:
technoqogies asweqq as oneverD caq industryffi
steeqmakingffiso readers can discoverhow Sowhyis controq not qisted as one ofthe
controq engineering is heqping to drive the important technoqogies ofIndustry :5 One
deveqopment ofthis newproducD on era of answeris that controq engineering itseqf
Industry :: couqd have been singqed out as a technoqogi J
caq driverbecause controq is one aspect of
History and definitions mostffiifnot aqqffipiqqars:Anotherreason is that
Industry :d the fourth industriaq revoquD ond controq engineering and Industry : terms
is nowroughqy years oqd and there is overqap but address different funcD ons in

increasing agreement and cqearerdefiniD ons different appqicaD ons:

ofwhat it comprises:The first three industriaq sA showninigu

F redcontroqengineering
revoquDons had concrete drivers9 mechaniza J reqiesonseveraqffimostqymathemaDcaqffitooqs
Dond eqectrificaD ond and the advent ofcom J andtechniquessuchassystemanaqysisdstate
puters: Industry : has no singqe technoqogy esDmaDondandmodeqingandsimuqaDonto
associaDon8 severaq technoqogicaq advances performdifferenttypesofcontroqincqudingop J
and design principqes drive it: Its underqying maqd
D adapDed
v qineardnonJqinearandinteqqigent:
principqe is digitaqizaD on: Simiqarqydndu
I stry:ses
u itscoretechnoqogies

Control Industry 4.0

System Modelling & State Simulation Cyber Physical Robotics AI, Big Data,
Analysis Simulation Estimation Systems Analytics

USES

Optimal Adaptive Linear Nonlinear Intelligent Internet Augmented 5g & Cloud Additive Data Block-
Control Control Control Control Control of Things Reality Computing Manufac- Security chain
turing

Figure 1. Control engineering uses technologies or techniques like systems analysis, modeling/simulation
and state estimation to perform or enable various types of control. Similarly, Industry 4.0 uses its core
technologies and techniques to enable new technologies that can be applied to manufacturing and
industrial processes as well as to consumer products, financial services and more.

INTECH OCTOBER 2023 14 WWW.ISA.ORG/INTECH

INDUSTRY 4.0

andtechniquestoenabqenewtechnoqogiesthat With simuqaD on used byboth controq

canbeappqiedtomanufacturingandindustriaq engineering and Industry :d and one couqd
processesaseqq
w asconsumerproductsdfinan J easiqyjump to the concqusion that this is the
ciaqservicesandmore: most obvious intersecD on ofthe two areas:

Control Engineering: Key Points for Industry 4.0 Practitioners

tA the core ofcontroq engineering qies the task ahumancanactasaqqthreebuiqdingbqocks9
ofmaking a physicaq quanD tyfoqqowa desired es
y E andearsaresensorsdmanuaqinterven J
trajectoryoverD me: Manyseparate aspects of ons
D byhandaretheactuatordandthebrainis
controq engineering are required to make this thecontroqqer:nI themostcompqexformdthe
happen9 modeqingd anaqyzing and simuqaD ng threebuiqdingbqocksaresubsDtutedith
w auto J
the systemd seqecD ng sensors to measure or maDcacDonsdeqectronicsensingdandopDmized
esDmatevariabqesd finding an actuatord and software:
designing a controqqer: ontroq
C engineeringisahiddentechnoqogy8it
TheDmeJvaryingbehaviorofaprocessdmod J canbefoundaqmosteverywheredoftenwithout
eqedbyadynamicsystemdcanbefoundinmany anyonePexceptthecontroqengineersQknowing
aspectsofengineeringandbeyonddthusmaking aboutit:Withoutcontroqdmanytechnicaqap J
controqengineeringatruqymuqDdiscipqinary pqicaDonsouw qdnotorkd
w impqyingthatcontroq
subject:Otheraspectsofcontroqengineering engineeringisofgreatimportanceinourqives:
incqudeimpqementaDonandassessmentof Whiqe funcD oning controq systems can
theperformanceofacontroqsystem:ontroq
C operate underthe radard controq systems that
engineeringissomeDmesreferredtoascontroq faiq areveryvisibqe9 airpqane crashesd nucqear
systemsdfeedbackcontroqdorautomaDccontroq: powerpqant meqtdownsd and autonomous
or
F brevitydinthisarDcqeew aqsorefertocon J vehicqes going astrayare some exampqes of
troqengineeringassimpqy>controq:? faiqed controq systems:
Threeimportantbuiqdingbqocksmakepu a ontroq
C engineeringisaqwaysameanstoan
controqsystem9thesensordtheactuatordandthe enddsuchaskeepingthetemperatureinareactor
controqqeritseqf:Thesebqocksarearrangedina constanttoproduceanewproduct:oN onedoes
feedbackqoopdcomparingtheprocessariabqe
v controqengineeringbecausetheyant w acontroq
toadesiredsetpoint:nI itsmosttriviaqformd system8thereisaqwaysapurpose:

BUILDING BLOCKS OF A CONTROL SYSTEM

Setpoint Process Variable
Controller Actuator Process Sensor

Negative Feedback

The important building blocks in a control system are sensor, actuator, and controller. They are
arranged in a feedback loop, comparing the process variable to a desired setpoint.

INTECH OCTOBER 2023 15 WWW.ISA.ORG/INTECH

INDUSTRY 4.0

But the truth is more compqex:The differ J SimuqaD ond roboD cs andAIFdata anaqyD cs
ent mathemaDcaq modeqs that underqie a are being not just to produce smart phone
simuqaDon need to be disD nguished:Are they ordeqiveryrobotsd but theyare being used
dynamic modeqs reqaD ng to the driving ofa within manufactured products:
vehicqe5Are theymodeqqing the bodyofa car5
O n that pointd I ndu stry : is simiqar
The first concerns controq engineeringd the
to controq engineering: I n the au tomobiqe
second does not.
indu stryd for ex ampqed I ndu stry : tech J
The narrow aspect of indiv idu aq controq noqogies and concepts affect the actu aq
strategies separates them from the broad manu factu re and assembqy of cars: B u t
appqicaD on of new I ndu stry :Jreqated tech J >controq engineering? in the au tomotiv e
noqogies qike I nternet of Thingsd au gmented indu stry often concerns the dev eqopment of
reaqityd G Fcqou d compuD ng and the rest: aqgorithms for speed controqd shock absorp J
I n factd u nqike controq engineeringd I ndu stry tiond and so on w ithin the carffiw hich is not
: has gained so mu ch tracD on that it has necessariqy reqated to the produ ction of the
entered the consciou sness of the generaq v ehicqes:
pu bqic: A s the new technoqogiesf spaw n are
It is impossibqe to qist aqq the appqicaD ons of
appqied to more than ju st indu striaq produ c J
controq in everyIndustry : technoqogy:The
D ond the term has grow n beyond its originaq
reason is not onqythe fuz ynature ofIndustry
definiD on:
: definiD onsd but aqso the compqex struc J
or
F exampqed a ceqq phone app that aqqows ture ofmodern producD on technoqogyand
you to book an apartment inyourcityor the different appqicaD ons ofcontroq specific
autonomous robots deqivering food orpack J to differentverD caq industries: So herewe
ages is not an exampqe ofthe qatest industriaq wiqq examine one metaqs industryexampqe
revoquDon: But theirdeveqopers are using the forwhich controq engineering is cruciaq9
Industry : technoqogies to enabqe them: steeqmaking:

With simulation used by both control engineering

and Industry 4.0, one could easily jump to the conclusion that
this is the most obvious intersection of the two areas.
But the truth is far from it.

INTECH OCTOBER 2023 16 WWW.ISA.ORG/INTECH

INDUSTRY 4.0

Figure 2. The steelmaking process is made up of continuous processing steps sequenced that require
a large amount of energy and thus integration with the electricity grid. Source: Journal of Cleaner
Production4?

An application viewpoint: z Thirdd a qarge numberofresources and

steelmaking amount ofenergyis required during the

producD on stages:As a resuqtd sophisD cat J
An entrypoint to understanding the intersec J
ed process opD mizaD on and improvement
Don ofIndustry : and controq is to focus on
schemes are important and financiaqqy
an industryand different appqicaD onswithin
worthwhiqe:
it:We chose the metaqs industryforseveraq
F igu re show s the standard steps in a
reasons9
steeqmaking process9 I n the meqt shopd scrap
z Firstd the steeqmaking process is made up metaq or iron ore is meqted in a fu rnace and
ofconsecuD ve processing steps that are variou s chemicaqs are added before the
simiqaracross the gqobe: meqted materiaq is cast conD nu ou sqy: Sqabs
z Seconddwhiqe the processing steps are of metaq are then formed into qong sheets
conDnuousd theyare sequenced discreteqyd of metaq in a hot roqqing miqq: The metaq
resuqDng in avarietyofoperaD ng pracD ces: sheets are roqqed ou t fu rther in a profiqe or

INTECH OCTOBER 2023 17 WWW.ISA.ORG/INTECH

INDUSTRY 4.0

coqd roqqing miqq: The su rface of the sheets and controq ofthe motorspeed:Whiqe these
is fu rther treated chemicaqqy and mechani J individuaq controq objecD ves are achieved
caqqy before storing them in a w arehou se with feedback asweqq as feedforward controq
for fu rther u se in carsd shipsd or hou sehoqd strategiesd there is aqso a need formuqD vari J
appqiances: B ecau se of the qarge and precise ate controq as an overarching strategyin the
amou nts of energy requ iredd the stages of coqd roqqing miqq 5.
the steeqmaking process requ ire integraD on
The controq aspectsffiimpqemented in an in J
w ith the eqectricity grid:
dustriaq controq systemffiinteract directqywith
Aqq the processing stepsd from meqt shop to the process:Theyare shown at the bottom
warehoused require individuaq controq soqu J ofFigure : OtherautomaD on soquD ons that
Donsd as shown in Figure : invoqve feedback eqements and decision mak J
Controq in conD nuous casD ng is reqated to ing overdifferent D me scaqes are depicted on
the qeveq ofmoqten steeq as the qadqe is emp J top ofthe basic controq qayer:
Ded into the tundish: Controqqing the qeveq is or
F exampqedscheduqingsoquDonscaqcuqate
criDcaq forhighJquaqitysteeq anddwhiqe qeveq whichbatchwiqqbeproducedatwhatDme
controq is a standard appqicaD ond it is hard to onaspecifiedpieceofequipment:nergy
E
measure the qeveq in the tundish and empty managementsoquDonsareconcernedwith
the qadqe according to the controq instrucD on: managingtheoveraqquseofeqectricityor
Hot and coqd roqqing miqqs aqso require con J othersourcesofenergysuchasheat:nomaqy
A
troq ofthe mass flowd the gap ofthe roqqersd detecDonisimportantforquaqitymanagement

Hor izo ntal Inte gr ation

Automation Solutions in Steel Manufacturing Vertical Integration

Planning

Anomaly detection

Energy Management

Scheduling Speed Optimization

Control Control Control Control Control Control

Melt Shop Continuous Hot Rolling Profile Cold Surface

Casting Mill Rolling Mill Rolling Mill Treatment

Figure 3. The typical automation applications in steel manufacturing are shown in orange over the
various process steps, shown in blue.

INTECH OCTOBER 2023 18 WWW.ISA.ORG/INTECH

INDUSTRY 4.0

Industry 4.0: Key Points for Control Engineers

ndu
I stry:referstotheincreaseinautomaDon andexchangedatadcommandsandinforma J
anddigitaqizaDoninmanufacturingandproduc J on
D amongdifferentsystems:Thedataand
Donprocessesandprocessindustries:tI reaches informaDonexistedbeforedbutitas
w difficuqtto
beyondearqierindustriaqinnovaDonsqikethe integrateandse:
u
introducDonofthesteamenginedeqectricityd
ThereiscriDcismthatndu
I stry:mayonqy
andcomputersffiaqqofwhichhavesignificantqy
beahypetopicandnotatangibqerevoquon:
D
changedindustryinpast>industriaqrevoquDons:?
Thepreviousthreerevoquons
D ere
w buiqton
n
I eachindustriaqrevoquond
D newdisrupDev concretetechnoqogiesPmechanizaDondeqectrifi J
technoqogiesappearedandpavedthegroundfor caDondcomputerizaDonQdhereas
w ndu
I stry:is
anewavw eofinnovaDons:Whentheeffectof buiqtonthesomewhatmoreintangibqeconcept
theinnovaDonsas
w qargeenoughditrevoquon
D J ofdigitaqizaDon:Someproponentsarguethatthis
izedthenormofhowthingsere
w seenanddone: isonqybecauseew areinthemiddqeofthisnew
Theserevoquons
D aqsohadagreatposiDev impact eraandthereforecannotseeitcqearqy:
onnaDonsfeconomicgrowthandqivingstandards:
Industry : has gained much tracD on
When itwas first introduced in 1d by through government iniD aD ves in manycoun J
a strategic think tank ofthe German govern J triesd someD mes referred towith aqternaD ve
mentd Industry : had nine underqying piqqars9 names such as smart industryorsmart manu J
the Internet ofThings PIoTQd augmented reaqity facturing: Companiesdwho embrace changed
PARQd simuqaDond addiD ve manufacturingd sys J invest in researchd and newtechnoqogies fare
tem integraDond cqoud compuD ngd autonomous betterin an uncertainworqdwith changed
systemsd cybersecurityd and big data anaqyD cs: prerequisites :This speaks forthe paradigm
shift that is Industry ::
Thediversityofthesetechnoqogiesshowsthe
compqexandnebuqousnature
GLOBAL INDUSTRIAL REVOLUTIONS
ofndu
I stry:dbutniD
u ng
aqqpiqqarsistheincreased 1st revolution 2nd revolution 3rd revolution 4th revolution

>digitaqizaDon?ofprocesses
andtheresuqDngavaiqabiqityd
interchangeabiqitydandcon J
necDity
v ofinformaDon:ne
O
niD
u ngaspectofndu
I stry: Mechanization Electrification Computerization Cyber-physical
Systems
technoqogiesisconnecDity
v :
tI isnowpossibqetoconnect In each industrial revolution, new disruptive technologies appeared and paved
machinesandoperaDonaq the way for a new wave of innovations. When the effect of the innovations was
systemsdqocaqqyandremoteqyd large enough, it revolutionized the norm of how things were seen and done.

INTECH OCTOBER 2023 19 WWW.ISA.ORG/INTECH

INDUSTRY 4.0

anddrawsitsinformaDonfromthebasic Standards are required to faciqitate the

controqqayer:qanning
P soquDonsareconcerned informaD on exchange efficientqyand the main
withaqargeDmescaqeanddetermineinwhat standard here is ISA dwhich describes the
ordercustomerorderarefuqfiqqed: integraD on ofthe enterprise system and the
controq system :tA AB d itwas demonstrated
Standards are required to howthe ISA standard can be used to

facilitate the information provide the producD on scheduqe data so that

it can be sharedwith the energygrid s.

exchange efficiently and the

AnotheropD on to improve overaqq process
main standard here is ISA95, efficiencyis to connect the scheduqing and
which describes the integration the controq qayerusing keyperformance

of the enterprise system and indicators PKPIsQ: Metaqs soquD on provider

Hitachi demonstrated howto integrate pqan J
the control system7. ning and scheduqingd and the controq systemsd
thus improving the producD onyieqd asweqq
When manufacturing and processing com J
as producD on :This is one exampqe ofITand
panies speak aboutverD caq and horizontaq
TO integraD on:
integraDond theyusuaqqyreferto the exchange
ofinformaDon between the different auto J When data can be exchanged between
maDon qeveqs and across the enD re suppqy process steps and between different pqanning
chain6: Since Industry : faciqitates the and scheduqing soquD onsd energycan be used
exchange ofdata and informaD ond it enabqes more efficientqy: Energycan aqso be used at
horizontaq andverD caq integraD on: D meswhen eqectricityis more affordabqed and
producD on quaqitycan be more consistent:
Aqthough there are manydifferent aspects
ofintegraDon depending on the industryand
setup ofthe producD ond steeqmaking is D ed
Implications and challenges
What impqicaD on does Industry : have for
inwith eqectricitymanagement because it
controq engineers and howwiqq controq engi J
is an energyJintensive processffiparD cuqarqy
neering impact Industry :5 Here are some
in the meqt shopd casD ngd and hot roqqing
emerging research direcD onsd impqementaD on
miqq processeswhere heaD ng is required:
consideraD ons and potenD aq chaqqenges:
The eqectricitygrid maypose constraints on
producDon ormaymake producD on more Distributed control and network control.
profitabqe ifcarried out at specific D mes:This What the authors see in manydifferent
wiqq influence the scheduqe:As a resuqtd it is areasffisuch as in the energyorteqecommu J
necessaryto share informaD on between the nicaD on industriesffiis the desire fordistrib J
different qeveqs ofautomaD on: Sod theverD caq uted and network modeqing and associated
integraDon ofscheduqing is one aspect of controq strategies: Distributed systems and
steeqmakingwhere Industry : shines: network theoryprovide modeqing and controq

INTECH OCTOBER 2023 20 WWW.ISA.ORG/INTECH

INDUSTRY 4.0

strategies8 howeverd these have notyet found fromonetotheotherpracDcaqqy:Thereare

theirwayinto process manufacturing on a somestandardssuchasthat
CPO addressthis
widespread basis: probqemdbutitissDqqachaqqengetoconfigure
adaptersthatcaninterpretthedatacorrectqy:
The authors are onqyaware ofacademic
works in this area but are expecD ng to see In parD cuqard it is necessaryto buiqd an
success stories soon:Ahindrance is the qack asset structure as has been proposed in
ofaccurate dynamic modeqs formanyproduc J otherstandards such as ISA d NamurOpen
Don processes: vEen ifitwouqd be possibqe Architecture PNOAQdAutomaD onMLd and
to derive such modeqs in a concerted effortd others:Arguabqyd controq engineers shouqd
there is a need to update them conD nuousqy: parD cipate more in the standardizaD on bod J
ies to keep the controq perspecD ve in mind:
Control assessment. Before taking the
next qeap and deveqopingd forexampqed a
If you are a control engineer in
pqantJwide controq strategy 11d it is impor J
tant to assess the performance ofexisD ng a production related field, you
technoqogy:The assessment forms the will have a large exposure to
foundaDon to moD vate furtherinvestment in
Industry 4.0. In addition, new
newtechnoqogies9 Is itworth invesD ng in a
newscheduqing soquD on ora newintegrated
skill sets are required.
controqqertechnoqogy5The business case and
Cross-discipline knowledge required.
assessment shouqd neverbe ignored:
ontroq
C engineeringhasaqwaysbeenamuq J
Currentqyd it is possibqe to assess the per J discipqinary
D subject:ontroq
C engineershave
formance ofa pqant to point toward probqems theirhomesineqectricaqdmechanicaqdchemicaqd
with individuaq PID qoopsd but this is byno industriaqdprocessdandaeronaucaq
D engineering
means standard technoqogyd impqemented departmentsdsomeDmeseveninmathemaDcs:
everywhere 12: When it comes to the assess J sA aresuqtdcontroqengineersmaynotcombine
ment ofthe performance and maintenance forcesasmuchasmaybenecessary:f
I ouy are
ofMPC controqqersd the task is even more acontroqengineerinaproducDonreqatedfieqdd
compqicated:There are some reports in the ouy iqq
w haveaqargeexposuretondu
I stry::
qiterature 13d bu t it is not ty picaqqydone in
n
I addiDondnewskiqqsetsarerequired:esides
B
industryin a systemaD cway: theknowqedgeofcontroqtheoryaseqq
w asof

Lack of standards for information exchange. theappqicaDondsoftwareskiqqsareincreasingqy

VerDcaqandhorizontaqintegraDonrequires importantintheeraofndu
I stry::

thatinformaDonanddatabeeasiqyexchanged Engineering education changes.The dif J

betweendifferentsystems:tI isonethingto ficuqtyis knowingwhat students shouqd qearn
drawaqinebetweentwoboxesrepresenDng in theirsyqqabus: Shouqd controq engineers be
soquonsd
D butitisanothertotransferdata abqe to program a PCLora DCS5 Shouqd they

INTECH OCTOBER 2023 21 WWW.ISA.ORG/INTECH

INDUSTRY 4.0

qearn about software required to exchange that controq engineering is an u nderqy ing
informaDonwithd forexampqed a scheduqing technoqogy of I ndu stry :: How everd it is
soquDon system5We need newdegrees to not cited as an u nderqy ing piqqar in presenta J
deaqwith chaqqenges in automaD on:An under J D ons on I ndu stry :d u nqiked for ex ampqed
standing ofIndustry : and controq engineer J simu qaD on or roboD cs:
ing is required ifwe reaqqywant to reap the
One couqd argue that controq is such a
benefit ofthis newrevoquD ond understanding
fundamentaq engineering science that it
aqq aspects ofproducD on systems and soft J
contributes to aqq the different technoqogies
ware impqementaDon:
ofIndustry :: But the reaq reason couqd
simpqybe the poorunderstanding ofcontroq
Final Thoughts among poqicymakers: Controq engineering
How do controq engineering and I ndu stry :
bodies shouqd tryharderto push the topic
reqate5 I n this arD cqe w e have demonstrated
into the generaq pubqic: One approachwouqd
be to parD cipate more in industriaq forums
ABOUT THE AUTHORS and standardizaD on bodies towork against
Charlotta Johnsson Pcharqotta:
the aqarming trend ofincreasing disconnect
johnsson‘controq:qth:
between controq engineering and industry .
seQ is a professorat the
department ofAutomaDc tA the same D med controq engineers are
Controqd and the Rektor sought afterbyindustryd especiaqqyas they
ofCampus Heqsingborg at
venture into different domains: Controq
uLnd University: She is aqso the chairofISOF
engineers have aversaD qed appqicabqed and
TC s F SC on Interoperabiqityd integraDond
comprehensive skiqq set:Theirskiqqs incqude
and architecture forenterprise systems and
automaDon: anaqysisd simuqaD ond opD mizaD ond and data
anaqyD cs:These are soughtJafterin the
Margret Bauer PMargret.
context ofIndustry ::
Bauer‘hawJhamburg:
deQ is professorofprocess It often happens that controq engineersffi
automaDon at WHA academics incqu dedffistart in one controq
Hamburgd and LiseJMeitner area and then move ou tside of w hat is tradi J
professorat the Department
D onaqqy u nderstood as >controq:? I ndu stry :
ofAutomaDc Controq at uLnd University:
reqies on controq engineering know qedge and
Kristian Soltesz PkrisDan‘ skiqq setsd w hiqe controq remains a fou ndaD on
controq:qth:seQ is an associate of many of its driv ing technoqogies: With
professorat the Department
the advent of I ndu stry :d the incqu sion of
ofAutomaDc Controq at uLnd
controq in the sy qqabu s of variou s engineer J
University:
ing discipqines is more important than ever
before:

INTECH OCTOBER 2023 22 WWW.ISA.ORG/INTECH

INDUSTRY 4.0

END NOTES: REFERENCES AND CITATIONS

1 Richard C:: Dorfd h Bishopd R: H: PsQ: Modern control systems. earson
P PrenDce Haqq:
2 Schwab d K:d :The fourth industriaq revoquD on9what it means and howto respond:oreign
F ffairs:
A
3 ISOWhitepaperon Smart Manufacturing?d report ISOd October : https9FFww:iso:orgFpubqicaDonFPUB :htmq

https9FFen:wikipedia:orgFwikiFCyberJphysicaqMsystem
5 Jelali, M. (2007). Performance assessment of control systems in rolling mills–application to strip thickness and flatness control.
Journal of Process Control, 17(10), 805-816.
6 Morid Ld SaqehdT:d Seqqschopd RdVan Hoeyd M:d s: Unqocking the digitaq opportunityin metaqs: McKinseyMetaqs and Min J
ing PracDce:

Johnsson C:d Brandq :D P Q9 >Beyond the pyramid9 Using ISA forIndustry :FSmart Manufacturing?d Published in ISA
ISA InTechd pp: Jd October :
s Harjunkoskid I:d h Bauerd R: P Q: Sharing data forproducD on scheduqing using the ISAJ standard: Frontiers in Energy
Research, 2d :

Bauerd M:d uLcked M:dJohnssond C:d Harjunkoskid I:d h SchqakedJ: C: PrQ: KPIs as the interface between scheduqing and
controq:IFAC-PapersOnLine, 49PQd rsJr:

ItodT:d Caod Z:d Maegawad K:d Eimaedad N: and SaitodT: P Q: Use ofAI to enhance steeq producDonvaque chain: Hitachi
Reviewd70 PQd J:
11 L indhoqmdA : PQ: Utility disturbance management in the process industry PDoctoraq dissertaDond Department ofauto J
maDc controqd uLnd UniversityQ:
12 Bau erd M :d HorchdA :d Xied L :dJeqaqid M :d hThornhiqqd N : PrQ:The cu rrent state of controq qoop performance monitoringKa

surveyofappqicaDon in industry: Journal of Process Control, 38d J:

13 A garwaqd N :d Hu angd B :d hTamayod E : C : P Q:A ssessing modeq predicD on controq PM P C Q performance: : ProbabiqisD c

approach forconstraint anaqysis: Industrial & engineering chemistry research, 46PQd sJs: SchferdJ:d h CinardA:
PQ: MuqDvariabqe MPC system performance assessmentd monitoringd and diagnosis: Journal of process control, 14PQd
J:

SamaddT:dauB erd:d
M ortoffd
B S:diD airanod
C S:dagianod
F :d
L dgaardd
O P:F:d:::hSossehdR:PQ:ndu
I stryengagementith
w
controqresearch9erspecD
P ev andmessages: Annual Reviews in Control, 49dJ:

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DATA ANALYTICS

Remoteonitoring
M
forAssetReqiabiqity
Once field devices gather the data, consider
these four strategies for remote analytics.

By Brian Dubaskas and Navin Rajashekar more efficient than anD cipated:As pqants
impqemented remote systemsd theysawthat
theywere abqe to consoqidate resourcesd
tA the end ofthe COVIDJ pandemicd many empowering a smaqqergroup ofpeopqe to
process manufacturers qearned an unex J monitorand maintain assetsd processesd and
pected qesson9 underthe right condiD onsd software overawidergqobaq aread aqqwithout
targeted remotework can be significantqy increasing costs due to traveq:

INTECH OCTOBER 2023 25 WWW.ISA.ORG/INTECH

DATA ANALYTICS

erhaps
P even more importantqyd as the mean it can be aqqowed to run to faiqure:The
pandemicwaned and fewerpeopqe than ex J earqiertechnicians detect probqemswith an
pected returned to the process manufactur J assetd the qowerthe maintenance cost to
ing sectordue to reD rements and personneq fix it:or
F exampqed ifa team sees a motor
shortagesd organizaD ons qearned that in many bearing beginning to faiq and doesnft actffior
casesd remotework freed theirqimited staffto worsed is not aware ofthe flawin the first
focus on highvaque tasks: pqaceffitheyrisk the enD re motorfaiqingd a
coupqing breakingd ora fire:
Aresuqt ofthis change has been a shift in
thewaymanyorganizaD ons handqe machine To avoid these types ofprobqemsd baqance
reqiabiqityanaqysis: More than everbefored ofpqant assetswere typicaqqymonitored
pqants are turning to remote anaqysis pro J through manuaq roundsffia D meJconsuming
grams to suppqement orrepqace onsite ma J processwhere an individuaqwouqdvisit each
chineryheaqth monitoring:or
F some pqantsd assetwith a handheqd device and recordvi J
remote anaqysis is a more costJeffecD veway braD on readingsd then return to the office and
to conDnue the machineryheaqth monitoring anaqyze the data:Teamswouqd set aqarms to
theyhave qong reqied upon:or
F othersd it is a
doorwayto improved operaD on thatwouqd
Organizations expect their
be otherwise out ofreach:
plant staff to collect data
In eithercased understanding thevaque of
remote anaqysis and foqqowing fourkeystrate J
from balance of plant assets,
gies to impqementaD on are criD caq to geDfing analyze it quickly, and solve
the most out ofanyremote anaqysis program:
problems before they interrupt
The value of remote analysis production, all with fewer
Historicaqqyd majorassets in a pqantffithose people.
most essenDaq to operaD on orthosewith
the potenDaq to create safetyhazards upon noD fythem ofprobqems detected in the data
faiqureffiwouqd be equippedwith an onqine coqqected from rounds: Howeverd this system
monitoring system:And pqants that had was not efficient: In manycasesd bythe
enough equipment towarrant muqD pqe D me a handheqd device detected a probqem
systems often empqoyed a fewanaqysts on severe enough to triggeran aqarmd significant
theirreqiabiqityteam: damagewas aqreadydone:The soquD onwas
reacD ved not predicD ve:
Howeverd baqance ofpqant assetsffithose
that are important to efficient operaD on but To compqicate things furtherd todayfs pqants
not criDcaqffisD qq require monitoring: Highqy operate in a highqycompeDD ve environment
efficient reqiabiqityteams recognize that just where peak efficiencyis criD caq to profit J
because an asset is qess criD caqd it does not abiqityd safetyd and sustainabiqity:As a resuqtd

INTECH OCTOBER 2023 26 WWW.ISA.ORG/INTECH

DATA ANALYTICS

organizaDons expect theirpqant staffto coq J onsite:As reqiabiqityteams evaquate remote

qect data from baqance ofpqant assetsd anaqyze anaqyD cs soquD onsd theycan significantqy
it quickqyd and soqve probqems before they improve theirchances ofsuccess byfoqqowing
interrupt producD ond aqqwith fewerpeopqe: fourkeystrategies:

ortu
F nateqydwireqess technoqogyenabqes

1
reqiabiqityteams to cost effecD veqyimpqement
as manyvibraDon measuring points as they
needdwithout expensive hardwiringd and em J
powers them to coqqect the data conD nuousqy
Collect the right data
RemotedataanaqyDcsdoesnotrequire
without the need to commitvaquabqe person J
extensivewireqessmonitoringsoquDons:tI is
neq towaqkarounds: Due to this paradigm
possibqetocoqqectdataforaremoteanaqyDcs
shift in reqiabiqitymonitoringd todayd more
programusingscheduqedmanuaqroundswith
data is coqqected in pqants than everbefore:
ahandheqdanaqyer:
z TeamscoqqecDngdata
But this newnormaq creates its own viamanuaqroundsmustensuretheycoqqect
set ofprobqems: Massive amounts ofdata consistentdata:or
F exampqedifatechnicianis
provide qittqevaque iftheycannot be turned coqqecDngdataon>motoroutboardhorizontaqd?
into acDonabqe informaD on: Reqiabiqityteams thedatamustbecoqqectedfromthesame
have significantqymore data to anaqyzed but spoteachDmedataskthatcanbeparDcuqarqy
theyhave feweranaqysts to accompqish that difficuqttoaccompqishifseveraqdifferent
work:Anaqysts have an increasingqyniched techniciansaqternateontheroute:
speciaqizedd and expensive skiqqsetd making
One strategyto ensure consistent coqqec J
them hard to findd and even harderto retain:
D on ofdata is to mark the qocaD on forcoq J
Consequentqyd manypqants have a massive
qecD on on each asset to remove guesswork:
investment in data coqqecD on infrastructured
Howeverd an even betterstrategyis to create
without an efficientwayto turn this data into
comprehensive training to ensure every
acDonabqe informaD on:
technician knows exactqyhowto coqqect
Remote anaqysis is the soquD on to this dataffiwithout significantvariaD onffion every
probqem:Teams impqemenD ng a remote asset in the pqant: Such a training pqan shouqd
anaqysis soquDon send theirdata to anaqyD cs beweqq documented so newtechnicians can
experts: Ifthese experts are internaqd theycan be brought up to speed as quickqyas possibqe:
provide anaqysis formuqD pqe sites: Iftheyare
or
F teams usingwireqess condiD on moni J
externaqd theytypicaqqyprovide anaqysis fora
toringd coqqecD ng data is significantqyeasier:
widevarietyoforganizaD ons:
Withwireqess triaxiaq sensorsd as qong as
Ateam can choose to do thiswith aqq their the device is instaqqed at the right qocaD onffi
datad oreven use such a soquD on to augment typicaqqyas cqose to the bearing as pos J
the anaqysis theyare aqreadyperforming sibqeffiteamswiqq knowtheyare geDfing the

INTECH OCTOBER 2023 27 WWW.ISA.ORG/INTECH

DATA ANALYTICS

right reading each D me: In addiD ondwireqess preparing them to idenD fyroot cause ofthe
sensors ensure that readings are takenwhere most compqex probqems:
theyare neededwithout faiq and ensure
consistencyoftesD ng scheduqe: Regardqess of
howbusythe staffis on a given dayorwho is
80% or more of the day-
out ofthe pqantd the right datawiqq come in at to-day asset problems in a
the rightDme: typical process plant will
One otherkeystep in coqqecD ng the right likely be the most common
data is performing a criD caqityassessment to
ones: balance, misalignment,
ensure the team is receiving the correct data:
SafetyJcriDcaq assets and those that interrupt under-lubrication, etc. 20%
producDonwiqq be the most important and of problems, due to their
wiqq qikeqybe covered bymore compqex sys J
complexity, typically will be
tems: But forbaqance ofpqant assetsd idenD fy J
ingwhich systems have sparesdwhich have far more time-consuming to
the most impact on producD ondwhich are the analyze.
costqiest to repaird and more can heqp teams
determine data coqqecD on frequencyforeach
machine to ensure theyare not overqoaded In a typicaq process manufacturing pqantd
with data ortaxing thewireqess network: sw ormore ofthe dayJtoJdayasset prob J
qems qikeqywiqq be the most common ones9
baqanced misaqignmentd underJqubricaD ond etc:

2
Have the right team perform
These probqemswiqq be easyfornearqyany
anaqyst to idenD fyand isoqated and then heqp
pqant personneqwith resoquD on: Howeverd the
analysis other w ofprobqemsd due to theircompqex J
Assuming remote anaqysis cannot be ityd typicaqqywiqq be farmore D meJconsuming
performed in house due to a qack ofquaqi J to anaqyzed andwiqq require deep experD se
fied personneqd the next step is choosing a forresoquD on:Areqiabiqityteam using remote
providerforremote anaqysisd and it is criD caq anaqysis to drive efficiencyneeds someone
to have experienced peopqe reviewthe who can soqve such probqems quickqy:

pqantfs data:The bestvibraD on anaqysts ighqy

H experiencedpersonneqwhohave
carrycategory or cerD ficaD on from the orked
w inmuqDpqeindustrieswithmuqDpqe
InternaDonaq OrganizaD on forStandardizaD on gqobaqcustomerswiqqhaveseenmanymore
PISOQ: ISO category or anaqystswiqq have unusuaqprobqemsthanotheranaqysts:They
years ofexperience andwiqq be more qikeqy wiqqdiagnoseprobqemsmorequickqydand
to have seen awidevarietyofissuesd better theywiqqbefarmorequaqifiedtoheqpteams

INTECH OCTOBER 2023 28 WWW.ISA.ORG/INTECH

DATA ANALYTICS

idenDfytheseverityofaprobqemandwhether quickqyshowteams ofanyexperience qeveq

itneedstobefixedtodaydorcanait
w amonthd howto prioriD ze theiracD on:
orevenaeard
y forascheduqedoutage:
Assets in green are heaqthyand require no
oreov
M erdhighqyexperienceddcerDfied acD on:Yeqqowassets have deveqoping prob J
anaqystswiqqbebetterpreparedtoperform qems that shouqd be addressedwhen teams
thecompqexmuqDariate
v anaqysisnecessaryto have avaiqabiqity: Red assets are experiencing
uncoverthemostcompqexprobqems:naqy
A sts criD caq faiqures and shouqd be addressed
primariqyusevibraDontoidenDfyissuesdbut immediateqy:
thebestproviderswiqqaqsobeabqetoork
w
AhighJquaqityanaqyD cs report aqso offers a
withthepqantfsreqiabiqityteamtocheckother
singqe page overviewofthe pqant as awhoqed
processariabqes
v toheqpdiscoverrootcause
showing teams howmanyassets theyhaved
whennecessary:f
I somethingintheprocess
howmanyare in each stated and howmany
changesditcanhaveasignificantimpacton
are in otherstages: Providedwith such a
assetreqiabiqity:n
A ISOcategoryoranaqyst
viewd anyreqiabiqityteamd regardqess ofsize or
wiqqhaveamucheasierDmeusingtheavaiq J
experience qeveqd can easiqymaintain a hoqisD c
abqedatatoidenDfythosechanges:
viewofpqant heaqth:

TeamsaqsoneedaccesstodeeperanaqycD

3
Insist on meaningful reports
detaiqsdsuchasspectrumdavw eformdimpacDngd
orotherariabqes
v necessarytoidenDfyprob
qems:Whiqenoteveryteamiqq
w ant
w orneed
J

suchdeepdatadpqantsith
w onsiteanaqystsiqq
w
The most meaningfuq reports from a remote
requireaccesstotheinformaDontheyneedto
anaqyDcs groupwiqq idenD fyprobqems and
makekeydecisionsabouttheirassets:
do so in awaythat fits the needs ofawide
varietyofstakehoqders:Teams need different erhaps
P most importantqyd reports shouqd
reports foreach roqe:or
F exampqe9 not just qist asset heaqthd but aqso provide ac J
D onabqe informaD on to resoqve probqemsd and
z Areport that an onsite anaqyst can exam J
the reasoning behind those decisions:Teams
ine and evaquate:
shouqd be abqe to read a report and know
z Areport that a technician can qook at to
exactqywhat to do to soqve the probqems that
guide his orheracD ons:
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track and trend reqiabiqityand performance: oreov
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First and foremostd anaqyD cs reports providefeedbacksotheycanreportwhatthey
shouqd quickqyand easiqyidenD fyprobqems findwhentheyperformrepairs:rmed
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and drawfocus towhat needs to be done thatinformaDondremoteanaqystscancqosethe
first:The best reports provide a simpqe qooponprobqemsdensuringcorrecDev acDons
>greendyeqqowd red?viewofasset status to resuqtedinexpectedoutcomes:

INTECH OCTOBER 2023 29 WWW.ISA.ORG/INTECH

DATA ANALYTICS

frequentqymisidenDfyfauqts:Reqiabiqityteams

4
Customize solutions to the
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ork
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ABOUT THE AUTHORS

Brian Dubaskas is the reqiabiqitysoquD ons service management office supervisorat
Emersond responsibqe forReqiabiqitySoquD ons Service Management and Managing
EmersonfsAsset CondiDon Monitoring Service: Brian has beenwith Emerson for
yearsd and he has over years ofexperience invibraD on anaqysis and condiD on
monitoring: Brian hoqds anAS degree in eqectricaq engineering technoqogyfrom
ennsy
P qvania State University:

Navin Rajashekar is a director of gqobaq serv ices at Emersonfs Reqiabiqity SoquD ons
bu sinessd responsibqe for ensu ring the su ccessfu q depqoy ment of asset condiD on
monitoring soquD ons: At Emersond Nav in has heqd a variety of roqesd incqu ding
director of gqobaq serv ices: He hoqds a B S degree in C hemicaq Engineering from
Worcester Poqy technic I nsD tu ted and an M B A degree from the University of Tex as
in Au sD n:

INTECH OCTOBER 2023 30 WWW.ISA.ORG/INTECH

MAINTENANCE

Pressure Transmitters:
Improving Diaphragm
Seal Maintenance
By Nicole Meidi
Level measurement systems
and other applications
benefit from improved
flushing ring designs.

Diaphragm seaq pressure transmitters are This arD cqe discusseswhat flushing rings
commonpqace across industry:Whether ared outqines the qatest design improvementsd
theyconsist ofan integraq orremote seaq and detaiqs benefitswhen theyare used in
configuraDond theyoffera reqiabqewayto qeveq measurement systemsdwhich is the
measure pressure and qeveq in awidevariety most common appqicaD on:
ofappqicaDons:Whiqe the specificaD on of Aflushing ring is posiD oned between the
properdiaphragm seaqs and capiqqaries isweqq diaphragm seaq and a tank connecD ond as
documentedd flushingFcaqibraD on ring seqec J shown at the top ofthis arD cqe:These rings
Don is often qess understood: can be made ofavarietyofmateriaqs and

INTECH OCTOBER 2023 32 WWW.ISA.ORG/INTECH

MAINTENANCE

typicaqqyhave one ormore process connec J Whiqe qess expensive iniD aqqyd standard
Don portsd each serving avarietyoffuncD ons: types offlushing rings require the userto
specifythe correct piping andvaqve compo J
Ifpqugging andFormateriaq buiqd up is a
probqem in the tank nozzqed the ports on the nentsd and ensure the materiaqsd OJringsd and

flushing ring can be used to inject airdwaterd pressure and temperature raD ngs are appro J

orsoqvent to cqean the face ofthe diaphragm priate forthe appqicaD on:Theyaqso require

seaq and cqearanydeposits that maybe onJsite assembqyand have muqD pqe potenD aq

forming:This improves reqiabiqityand extends qeak points due to the numberofrequired

theDme between tank maintenance outages: fiDfings:

In parDcuqarqydifficuqt appqicaD onsd the flush An aqternaD ve is a prefabricatedd boqtJ

ports can be connected to a soqenoiddwhich through flushing ringwith integraqvaqves
acDvates intermittentqyto inject an appropri J PFigure Q:These types offlushing rings are
ate fluid to keep the tank nozzqe cqear: fireJsafe and come in awidevarietyofflange
sizesdwith manywetted materiaq opD ons:
Flushing ring features Needqed baqqd and gatevaqve opD onswith
Different styqes offlushing rings are avaiqabqe assorted connecD on types and materiaqs
withvarying price points and capabiqiD es: ofconstrucD on are avaiqabqe to suit most
The standard type shown at the top ofthe appqicaD ons:
arDcqe has one ortwo threaded and pqugged Acommon instaqqaD onwiqq have avent and
ports and is boqted between the diaphragm drainvaqve forcaqibraD on appqicaD onsd orit
seaq and the tank: Nippqes and smaqq isoqaD on mayjust have a singqevaqve forflushing ap J
vaqves can be added to these ports to faciqi J pqicaD ons:This flushing ring assembqycomes
tate draining andvenD ng: prefabricated and qeakJtestedd so instaqqaD on
is quick and easy: It aqso has fewerpotenD aq
qeak points than standard flushing ringsd and
it can be stocked as a singqe assembqyfor
quick change out:

Figure 1. One alternative

to a standard flushing ring
comes pre-assembled
and leak-tested, and
offers a variety of process
connections, materials of
construction, O-rings, and
valve types. This example is
the Rosemount 319T.

INTECH OCTOBER 2023 33 WWW.ISA.ORG/INTECH

MAINTENANCE

Flushing ring alternatives

Recentqyd newcompact flushing ring designs
have been introduced PFigure Q:These have
aqq the features and benefits ofa standard
ring assembqybut add tangenD aq injecD on of
the process fluid into the ring:

TangenD aq flu id injecD on creates a vortex

cqeaning acD on that removes residu e bu iqdJ
u p u p to five D mes faster than a standard
design: It aqso can cqean u p to w more
diaphragm seaq su rface aread prov iding a
significant advantage in appqicaD ons that Figure 2. Compact flushing ring assemblies take
up much less space than traditional flushing
are difficu qt to cqean: PSee the operaD on of a
rings, and feature tangential fluid injection,
compact flu shing ring compared to a stan J providing superior cleaning. This example is the
dard design in this v ideo :Q Rosemount 319C.

The compactd integraqvaqve design ofthis difference ofthe two readings to determine
newtype offlushing ring qets it fit in much the resuqD ng head pressuredwhich is con J
Dghterspaces than a tradiD onaq flushing ring: verted to tank qeveq using the same method
discussed previousqyPFigure Q:
Flushing rings in action
Fqushing rings are someD mes referred to
One main differenD aq pressure appqicaD on
as caqibraD on rings because theyenabqe easy
is measuring the qeveq ofprocess media in a
caqibraD on ofthe qeveq transmitterwithout
tank: Ifthe tank isventedd the transmitteris
taking the tank out ofservice: CaqibraD on ofa
typicaqqyinstaqqed at its base to detect head
differenD aq pressure transmitterrequires the
pressure:This pressure reading is converted
upperseaq to bevented and removed from
to qeveq based on the specific gravityofthe
pressuredwhiqe the qowerseaq is subjected to
tank contents using the foqqowing formuqa9
a known caqibraD on pressure to span and zero
Tank Level (inches) = the transmitter:
Head Pressure (inches of water column)/
Ifno flushingFcaqibraD on ring is instaqqedd
Specific Gravity of liquid
an inJservice transmittercaqibraD on requires
Ifthe tank is cqosed and undervariabqe removaq ofthe enD re assembqyto cqean
pressured a second diaphragm seaq is added at the diaphragm seaq:This procedure takes
the top ofthe tank to detect the tankvapor an extended amount ofD med duringwhich
pressure:This second seaq is connected to the the process is offline: Diaphragm seaqs can
qowside ofthe differenD aq pressure trans J be quite heavdy so between the mechanicaq
mitterd aqqowing the device to measure the effort invoqvedd asweqq as the potenD aq for

INTECH OCTOBER 2023 34 WWW.ISA.ORG/INTECH

MAINTENANCE

hazardous materiaq exposure during the or

F these reasonsd flushingFcaqibraD on
flange breaksd caqibraD ng a diaphragm qeveq rings and tank isoqaD onvaqves are strongqy
transmitterwhiqe the tank remains in service recommendedwhenevera tank cannot easiqy
can be quite chaqqengingd and potenD aqqy be removed from serviced and in othersitua J
dangerous: D onsd such aswhen squdge ordebris is pres J
ent in the process media:
The instaqqaD on offlushing andForcaqibra J
Don ringswith integratedventFdrainvaqves
makes caqibraDon much simpqer: FqushingF
Conclusion
When caught up in the detaiqed specificaD on
caqibraDon rings aqso make the flushing
ofdiaphragm seaqs and differenD aq pressure
procedure significantqysaferand fasterd and
instrumentsd it is easyto forget flushing rings:
it avoids potenD aq diaphragm seaq damaged
Howeverd this component is often cruciaq to
which can easiqyoccurwhen a seaq is un J
maintain reqiabqe performanced enabqe easy
boqted and boqted back into pqace:
and safe inJservice maintenance ofthe seaqs
and the instrumentd and ease caqibraD on:

f
I aflushingringdoesmakesenseforthe
appqicaDonditisise
w toevaquatetheariou
v s
opDonsthatarenowavaiqabqedparDcuqarqy
compactdesignsith
w fasterandmorethorough
cqeaningcapabiqiDes:arD
P cuqarqyinaqarge
projectith
w aide
w ariety
v oftransmittersdpre J
fabricatedandfactoryJtestedflushingringsiqq
w
providesignificanteconomicandperformance
advantagesascomparedtotradiDonaqdesigns:

sA isoftenthecasedthebestdesignsrequire
attenDontodetaiqateverystageandforeach
Figure 3. This diagram shows a typical dual-seal componentdincqudingflushingrings:Theresuqt
level transmitter installation with flushing rings and iqq
w bemanyears
y oftroubqeJfreeservicedith
w
vent/drain valves. Calibrating the transmitter while
easiercaqibraDonandimprovedsafety:
keeping the tank in operation is much easier and
safer if flushing rings are installed. All figures courtesy of Emerson.

ABOUT THE AUTHOR

Nicole Meidl is a product managerforEmersond speciaqizing in Rosemount DPqeveq
and manifoqds products: In hernineyearswith Emersond she has aqso managed
Rosemount pressure transmittersd MuqD Variabqe transmittersd and Eqectronic Remote
Sensorsystems: Meidq hoqds a BacheqorofScience degree in mechanicaq engineering
and an MBAd both from the UniversityofSt:Thomas in St: Pauqd Minn:

INTECH OCTOBER 2023 35 WWW.ISA.ORG/INTECH

CONTROL SYSTEMS

Understanding Loop Diagrams

& Process Loop Sheets
Detailed drawings conforming to the ANSI/
ISA-5.1-2022, Instrumentation Symbols and
Identification, standard show how all devices
and equipment are wired to the control system.
By John Robert Davis and Graham Nasby

rom
F an instaqqaD on and maintenance eqectri J diagramsFprocess qoop sheets and expqains
cianfs point ofviewd two ofthe most usefuq whycreaD ng and maintaining them isworth
types ofdrawings that can be incquded in a the effort:
contract drawing set are qoop diagrams and
process qoop sheets:These detaiq drawings From P&IDs to process loop
showhoweach piece ofequipment Pe:g:d sheets and diagrams
instrumentd motorstarterdvaqve actuatord Piping and instrument diagrams PPhIDsQ are
etc:Q is to bewired to the controq system: deveqoped at the beginning ofa project to
This arDcqe provides an overviewofqoop define the equipmentd pipingd and automaD on

INTECH OCTOBER 2023 36 WWW.ISA.ORG/INTECH

CONTROL SYSTEMS

and controq components needed to impqe J PLQ

D formatdwherethesameinformaDonis
ment a processd incquding the controq qoops: shownbutintheformofmoredetaiqedwiring
PhID drawings provide an overaqq summary instrucDonsonawireJbyJwirebasisdownto
ofthe process:Togetherwith faciqityqayout theterminaqscrew:
drawingsd the PhID drawings provide an
overaqqviewofa faciqitydwhat it doesd and
where the equipment is qocated:or
F qarge
Loop diagrams and process
faciqiDesd an addiD onaq set ofdrawings caqqed flow sheets make it possible for
process flowdiagrams PPFDsQ are someD mes
many design issues to be seen
created to summarize the PhIDs even further:
and rectified during the design
With the PhID drawings in handd the
various design discipqines can create indi J
phase rather than during
viduaq drawing sets to showhowdifferent construction.
aspects ofthe pqant are to be buiqt:Thesewiqq
incqude structuraq drawingsd civiq engineering
Depending on the contractorormainte J
drawingsd architecturaq drawingsd mechanicaq
nance teamd eitherprocess qoop sheets or
drawingsd eqectricaq drawingsd and so on:
qoop diagrams maybe more suitabqe:The
rom
F an eqectricaq and instrumentaD onFcon J
chieftakeawayis that it is bettertowork out
tro perspecDved these drawing setswiqq aqso
thewiring detaiqs ofinstrumentaD on and con J
incqude eqectricaq powerdistribuD on PqighD ng
troq devices during design ratherthan during
paneqsd MCsQ drawingsd controq paneq draw J
construcD on: It is much easierPand cheaperQ
ings Pe:g:d PCLpaneqsQd and qoop diagrams
to make design decisions than to have an
andForprocess qoop sheets:
eqectrician trying to sort out the designwhiqe
The instrumentaD onFcontroq designer
the construcD on cqock is D cking:
determineswhetherto use qoop diagrams or
process qoop sheets:Theyboth provide simi J
A water and wastewater
qarguidance forinstaqqaD on and maintenance
example
eqectricians butd depending on the project
or
F exampqedwaterandwastewaterpqants are
typed one maybe a betterfit than the other:
typicaqqydesigned to accommodate influ J
process
A qoopsheetPPLSQprovidesthede J ent flowrates that are not consistent from
taiqsforqoopsbyiqqustraDngaqqthedevicesand one hourto the next:These flowrates are
equipmentinaninstrumentaDonqoopdhow generaqqyexpressed as qowflowrated average
theariou
v spiecesinteractdandhowthepro J daiqyflowrated and maximum flowrated and
cessdataistransmittedtothecontroqroom: are indicated in the descripD on bqocks on
tI onqyprovidessummaryinformaDonabout the process qoop sheet: In a typicaqwaterF
theindividuaqwiringdetaiqs:qternaD
A eqy
v dthis wastewaterpqantd there are generaqqypump
informaDoncanbearrangedinaqoopdiagram staD onsd screenings and grit removaqd cqarifier

INTECH OCTOBER 2023 37 WWW.ISA.ORG/INTECH

CONTROL SYSTEMS

fiqtersd odorcontroqdvarious types ofchemicaq bythe InternaD onaq SocietyofAutomaD on

injecDonsd and storage tanks in the process PISAQ and documented inANSIFISAJ:J d
qoopd aqq ofwhich mayaffect the flowrate: InstrumentaD on Symboqs and IdenD ficaD on:
Fqowd pressured and temperature measuring It is equaqqyimportant to ensure that the
devices transmit
data to qocaq PCLF
Use a standardized symbol and nomenclature
DCS controq paneqs
that interface
structure so everyone involved can understand the
through software components and the process. Best practice is to
with operator
follow the ANSI/ISA-5.1-2022, Instrumentation
workstaDons typi J
caqqyqocated in
Symbols and Identification, standard.
the centraq controq
room:The qoop diagram shows the processes informaD on on the process qoop sheets is
and equipment in the controq qoopd and the compqete:Aqsod aswith anydrawingsd the
process qoop sheet provides expqanaD ons sheet shouqd be assigned a revision date and
and otheressenD aq informaD on: SomeD mes incqude the name ofthe designerwho qast
the qoop diagram and process qoop sheet are updated and checked it:
combined as a singqe drawing:

Throughout the qife ofthe instrumenta J Loop diagrams explained

Don systemd incquding its construcD ond Put succinctqyd a qoop diagram is a type of
instaqqaDond commissioningd and operaD onsd detaiq drawing that showsffion an instrumentJ
process qoop sheets are accessed byperson J byJinstrument and deviceJbyJdevice
neq in muqDpqe discipqines in the enterprised basisffihowinputFoutput PIFOQ signaqs from
asweqq asvendors and contractors: It is a equipment are to bewired to the controq
resource used to document and expqain how system:oop
L diagrams showthe specific
the controq system and its instrumentaD ond wiring detaiqs down to the qeveq ofterminaq
motorstartersd andvaqve actuators have been screwsd juncD on boxesd cabqe qabeqsd andwire
designed to operate and howtheyhave been qabeqs:
instaqqed:
Most qoop drawings Psee Figure Q are
Due to the numberofpeopqe using qoop produced using a computerJaided design
diagrams and process qoop sheetsd it is recom J PCADQ package orautoJgenerated byan
mended to use a standardized symboq and advanced pqant design software package:A
nomencqature structure so everyone invoqved qoop diagram is usuaqqyfocused on a specific
in the project can understand the compo J instrument ordevice but mayincqude muqD pqe
nents and the process:The best pracD ce is to sensorsFactuators iftheyare reqated to each
use the symboqs and terminoqogydeveqoped otherprocessJwise:The use of>typicaqs?

INTECH OCTOBER 2023 38 WWW.ISA.ORG/INTECH

CONTROL SYSTEMS

Pa generic diagram that appqies to muqD pqe and incqu des many good ex ampqes and
instrumentsFdevicesQ is not recommendedd best pracD ces for creaD ng effecD ve qoop
as it defeats the purpose ofthe qoop diagram diagrams:
containing instrumentFdeviceJspecific IFO
Process loop sheets versus loop diagrams.
addresses andwiring detaiqs:oop
L diagrams
Process qoop sheetsd deveqoped qaterd are
are generaqqythe same size as otherdrawings
a type ofsummarized qoop diagram that
in the drawing package forthe pqant:or
F
incqudes addiD onaq process informaD on:They
exampqed the use ofBJsize P? ?Qd DJsize
are intended to heqp the instaqqaD on and
P? ?Qd orEJsize P? ?Q drawings
maintenance eqectricians instaqq and troubqe J
sizes are reqaDveqycommon in NorthAmerica:
shoot equipment and provide addiD onaq
Loop diagrams are not a new concept: context regarding its use:This context typi J
I SA standard I SA J:J d I nstru ment Loop caqqyincqudes minimum and maximum tem J
D iagramsd covers a generaq version focu sed peraturesd pressuresd flowsd and otherprocess
on instru mentaD on I FO w iring: Commonqy vaquesd aqongwith expected signaqvaques
know n as I SA J:d the I SA qoop diagram during startJupd shutdownd steadyJstate and
standard has been arou nd since the s atJrest condiD ons:or
F exampqed a process

Figure 1. Example of a loop diagram. Source: ISA-5.4-1991. Reproduced with permission.

INTECH OCTOBER 2023 39 WWW.ISA.ORG/INTECH

CONTROL SYSTEMS

qoop sheet fora magneD c flowmeteris proper sets of qoop diagrams or process qoop
shown in Figure : In the sampqe qoop sheetd sheets for constru cD ng and trou bqeshooD ng
a flowmeteris reading the flowthrough a faciqiD es:
barscreend totaqizing it and then sending the
Benefits of loop diagrams.Therearemany
reading to a PCLremote IFO paneq:The read J
benefitsfromtakingtheme
D tocreateqoop
ing is then used forvarious funcD onswithin
diagramsduringthedetaiqeddesignphaseofa
the automaDon system:
project:major
A benefitistheabiqitytoidenDfy
Using qoop diagrams and process qoop andfixprobqemsduringthedesignphaserather
sheets has been
standard pracD ce
for many years in
variou s indu striesd
incqu ding oiq refinerJ
iesd chemicaq pqantsd
pow er staD onsd
and other ty pes of
manu factu ring: Yetd
u sing qoop diagrams
in the mu nicipaq
water/wastewater
sector is reqaD veqy
new. The reasons
for this are many J
foqd bu t u su aqqy
can be traced to
either indiv idu aqs
not know ing abou t
them or perceiv ing
that money can
be saved by not
creaD ng them: This
is changing as more
water/wastewater
uD qiD es reaqiz e the
iniD aq and ongoing
cost sav ings resu qt J
ing from hav ing Figure 2. Example of a process loop sheet.

INTECH OCTOBER 2023 40 WWW.ISA.ORG/INTECH

CONTROL SYSTEMS

thanduringconstrucDon:tI issignificantqyqess the descripD ons in the PCLpaneq are cqearQ:

expensivetosortoutadesignissueduringthe Nextd theymust reviewthe motorcontroq
designphasePwhenitiseasytofixonpaperQ centerPMCQ orqighD ng paneq scheduqes to
thanduringtheconstrucDonofafaciqity: determine the intended powersource forthe
device:Then the eqectricianwiqq need to find
Exampqes ofpotenD aq design issues for
the instaqqaD on manuaq forthe actuatorPoften
process equipment incqude mismatched IFO
not shippedwith the actuatorQd to match the
signaqsdwrong powersuppqyvoqtagesd mis J
various terminaqs on the actuatorwith the
ranged signaq scaqingd missing IFO signaqsd and
requested IFO signaqs and powerconnecD ons:
missing instaqqaD on detaiqs:These probqems
can cause deqays and cost overrunswhen
theymust be fixed during a projectfs con J Without a loop diagram,
strucDon orcommissioning phase: a simple 10-minute
In a typicaq capitaq projectd it is not uncom J troubleshooting task can turn
mon foran hourofwork onJsite during the
into hours of difficult trial-and-
construcDon phase to be up to D mes
more expensive than an hourofwork during error troubleshooting to find
the paperJbased design phase: Using a qoop the issue.
diagram during instaqqaD on and maintenance
can save thousands ofdoqqars in terms ofD me
Because the design engineerhas qikeqy
savings and avoiding deqays associatedwith
not qooked at these signaqs togetherPi:e:d
invesDgaDon ortroubqeshooD ng:
therewas no corresponding qoop diagram to
or
F exampqedhen
w instaqqinganewmotor J be subjected to QAFQCQd often therewiqq be
izedactuatorith
w aqoopdiagraminhanddthe minorIFO errors in the design:The eqectrician
eqectricaqinstaqqaDonisassimpqeashookingpu wiqq need to resoqve the errors onJsite orissue
theires:
w Theqoopdiagramprovidesacom J a request forinformaD on PRFIQ to the design
prehensiveguidefortheinstaqqaDoneqectrician: team to obtain the necessarydata:Aqq ofthis
Thedrawingiqq
w showhat
w ires
w areneededd isveryD meJconsuming during the construc J
howtoqabeqthemdandhich
w FO
I terminaq D on phased and the contractors are under
screwstoire
w themto:ThepowerconnecDon tremendous pressure to get the pqant buiqt:
detaiqsiqq
w aqsobeshown:Theqoopdiagram
Likewised suppose an instaqqedvaqve
iqq
w aqsodetaiqandsummarizetheoqtages
v and
actuatorrequires troubqeshooD ng: In an ideaq
scaqingofaqqoftheariou
v ssignaqs:
situaD ond an asJbuiqt qoop diagram orprocess
Ifa qoop diagram is not providedd the qoop sheet forthe actuatorwiqq incqude aqq the
instaqqaDon eqectricianwiqq first have to informaD on the maintenance eqectricianwiqq
search the PCLpaneq drawings to determine need to check the powerand signaqs toFfrom
which IFO signaqs towire to the actuatorPif the actuator: PWhen a construcD on project is

INTECH OCTOBER 2023 41 WWW.ISA.ORG/INTECH

CONTROL SYSTEMS

compqetedd the design engineerwiqq prepare terminaq screws ofthevaqve actuatorhave

an updated set ofthe contract drawings beenwired andwhat the terminaqs and con J
caqqed >asJbuiqt? or>forrecord? that captures figuraD on do:Thusdwithout a qoop diagramd
the detaiqs ofwhatwas actuaqqybuiqtverses a simpqe Jminute troubqeshooD ng task can
the iniDaq pqans:Q Howeverd suppose there is turn into hours ofdifficuqt triaqJandJerror
no qoop diagram forthe actuator:The eqectri J troubqeshooD ng to find the issue:
cianwiqq have to search through PCLpaneq
drawingsd otherdrawingsd and equipment Process loop sheets explained
manuaqs to determine howthe actuatoris Process qoop sheets can take manyforms:
wired and powered: One common pracD ce is to size the sheet
to fit on US qettersize Ps:? ?Q paper:
Oftend ifthere are no qoop diagramsd
MuqD pqe sheets can be grouped on a qarger
no drawingwiqq exist that shows howthe
? r? contract
drawing forqarger
projects:Anotherd
used in otherindus J
triesd is to make the
process qoop sheets
the same size as
otherdrawings used
forthe projectd such
asANSI B orISOA :

rocess
P qoop
sheetsmaybedrawn
byhandorproduced
inadrawingap J
pqicaDonsuchas
utoC
A ADPseeigu
F re
Q:n
O smaqqprojectsd
thesheetscaneasiqy
beattachedtothe
contractspecificaDon
documentsorpqaced

Figure 3. Example of
a process loop sheet
on 8.5” × 11” paper
(portrait orientation).

INTECH OCTOBER 2023 42 WWW.ISA.ORG/INTECH

CONTROL SYSTEMS

withtheengineeringspecificaDonstocreate connected to the controq system:The qoop

anefficientandmanageabqedocument: name and numberfieqds are qocated at the
bottom ofthe sheet:The fieqds at the top of
Aprocess qoop sheet is typicaqqydivided
the form are referred to as descripD on bqocks:
into as manyhorizontaq qayersffifrom the bot J
These bqocks incqude detaiqed informaD on
tom ofthe drawing to the topffias required to
about aqq the instruments and components in
showthe enDre qoop diagram from the fieqd
the qoop diagram:Aseparate rowis created
device Pat the bottomQ to the controq room Pat
foreach instrument ordevice in the qoop:
the topQ:The foqqowing paragraphs provide an
overviewofthe exampqe Processoop
L Sheet The qist offieqds typicaqqyused on a process
shown in Figure : qoop diagram are as foqqows9

The top qayerd just beqowthe equipment z Loop name.This is a briefdescripD on of

descripDon bqocksd is the controq room or the process being monitored orcontroqqed:

administraDve office at the end ofthe qoop: z Loop number. This is a uniqued fourJdigit

The fieqd device is aqways qocated in the numberidenD fying the instrument qoop:

bottom qayerwith intermediate qayers denot J

z Item. This is a u niqu ed fou rJdigit aqpha

ing the path between the device and the idenD fier for each piece of fieqd equ ip J

controq roomd such as qocaq controq paneqsd ment in the qoop: These idenD fiersd
caqqed instru ment codesd are defined in
remote IFO cabinetsd PCLorDCS paneqsd or
the I SA J: standard for instru menta J
a fiberopDc communicaD on system: Each
D on: IdenD fiers for other dev ices w iqq be
device and piece ofequipment is assigned a
unique ID to indicate that it is in a specific
instrument qoop: Best pracD ce is to use the
ISAJ: standards forassignment instrument
IDs: Howeversome SCADsystems mayuse
different qabeqing systemsd so these qabeqs
shouqd aqso incquded ifappqicabqe:

The process qoop sheet exampqe in Figure

contains addiD onaq instaqqaD ond commis J
sioningd and troubqeshooD ng informaD on:The
foqqowing paragraphs provide an expqanaD on
ofthevarious pieces ofinformaD on con J
tained on this process qoop sheet exampqe:

Data fields. The process qoop sheet con J

tains fieqdswhere the designercan enterdata:
Each fieqd contains a keypiece ofinformaD on Figure 4. Process loop sheet with the parts of the
about the deviced instrumentd orequipment sheet labeled.

INTECH OCTOBER 2023 43 WWW.ISA.ORG/INTECH

CONTROL SYSTEMS

ty picaqqy defined in an endJu serJspecific not understand the process orpqant re J

standard: It is important to note that quirementsd asweqq as someone assembqing
there are many of the same ty pes of a controq paneqwho must idenD fyeach
instru ments: That is w hy each dev ice and piece ofequipment on the paneq bythe
piece of equ ipment shou qd be assigned process that is eitherbeing controqqed or
a u niqu e I D that is onqy u sed once at the monitored:
pqant: or
F ex ampqed I SA J: prov ides a z Quantity.Thisisthenumberofitems:Forex J
method of doing this u sing qoop nu mbersd ampqedifmuqDpqeitemsofthesametypeare
bu t each pqant may have its ow n internaq neededaquanDtyisqistedratherthanhaving
convenD on: The important takeaw ay is muqDpqerowentries:ikew
L iseifsimiqardbut
that the idenD fier mu st be u niqu e: sqightqydifferentditemsareneededitisbest
z Description.This area expqains the idenD fi J toqistthemseparateqyinseparaterows:
ers in the Item bqock:This bqock isvaquabqe
to anyone unfamiqiarwith ISAstandard
terminoqogyandForthe pqantfs instrumentF Some call loop diagrams and
device tagging system:
process flow sheets “the
z Type. This bqock provides detaiqs about
each device:or
F exampqed it mayidenD fya
instrumentation engineer’s
floweqement PFEQ as eithera magneD c flow gold mine” because they can
meterd aVenturi flowtubed oran uqtrasonic
result in considerable savings in
flowmeter:
z Criteria.This bqock contains requirements
the construction, installation,
that are unique to the device orpiece of and commissioning phases of a
equipmentd such as the coqorofa piqot qight
project.
qensd caqibrated pressured temperatured
qowJflowrange requirementsd eqevaD ons
ofqeveq switchesd and anaqysis anaqyzer The exampqe process qoop sheet in Figure
ranges:This bqock ortheType bqock may shows that the influent flowmetersends
aqso contain informaD on indicaD ngwhich a K mAsignaqvia anaqog output to aqq
contractoris responsibqe forproviding the devices throughout the diagram: In addiD on
device orpiece ofequipment: Ifthere are to providing a flowrate signaq to the controq
speciaq instaqqaD on orcommissioning re J systemd the meteraqso records the average
quirements that are unique to a parD cuqar daiqyflowand keeps a Jhourrecordd a
instrumentd thesewiqq someD mes be aqso process known as totaqizing Pdenoted bythe
incquded on the process qoop sheet: >Q? in the ISAJstyqe idenD fiertagQ:TheAand
z Tag/service.This bqock is used to idenD fy B qabeqs on the FIRQ symboqs indicate that
the item andwhat it does in the process: the same informaD on is transmitted to both
This is usefuq foran individuaqwho does devicesd meaning that there are devices that

INTECH OCTOBER 2023 44 WWW.ISA.ORG/INTECH

CONTROL SYSTEMS

showthe totaqized flowin both the controq thend there is a flowcontroqqerFPCLshown in

room and the administraD on center: a frontJfacing paneq:Though showing oqder
technoqogyd the diagram in Figure r shows
Theqinetypesusedonaprocessqoopsheet
the amount ofwiringFinstaqqaD on detaiqs that
arethesameasthoseusedontheprocess
can be incquded on a qoop diagram:
partofaqoopdiagram:Thatisddashedqines
foreqectricaqsignaqsandsoqidqinesforpiping:
igu
F reprovidesanoverviewoftheqine
typescommonqyusedtoprocessqoopsheets:
Theintentofusingprocessqoopsheetsisto
provideenoughdetaiqedinformaDonsothat
aninstaqqaDoneqectriciancanknowhowto
wireapieceofequipmentandhowitisused:

Further examples
oth
B qoopdiagramsandprocessqoopsheets
canrangefromsimpqetocompqexdepending
ontheequipmentPinstrumentaDonddevicesd
controqeqementsdetc:Qtheydescribe:The
exampqeofacompqexqoopdiagraminigu
F rer
isfromISAJ::tI showsanorificeJpqateJbased Figure 5. Commonly used line types on process
flowtransmitterPwhichusesadifferenDaq loop sheets.
pressuretransmitter
toreadtheflow
basedonthepres J
suredropacrossan
orificepqateQanda
flowcontroqaqv
v eon
apumpedfiqqqineto
atank:

The fieqd IFOwir J

ing passes through
a juncDon box in
a cabqe spread J
ing room8 there
is anotherset of
juncDon terminaqs at Figure 6. Example of a complex loop diagram.
the rearofa paneq8 Source: Figure 5 from ISA-5.4-1991. Reproduced with permission.

INTECH OCTOBER 2023 45 WWW.ISA.ORG/INTECH

CONTROL SYSTEMS

Figure 7. Example of a
more complex process
loop sheet.

F igu re show s a more compqex process epending

D onthetypeandcompqexityof
qoop sheet: I n this ex ampqed mu qD pqe I FO theprojectditmaybepreferabqetocreateaset
signaqs are w ired to a chemicaq feed pu mp: ofqoopdiagramsdasetofprocessqoopsheetsd
The process qoop sheet show s how the sig J oracombinaDonofboth:Thisiqq
w depend
naqs are w ired from the pu mp to an interface onthesystemdesignerandhat
w theyfeeqis
ju ncD on box d to a flu oride sy stem controq necessarytoprovidecqearinstrucDonstothe
paneqd and then into a P LC sy stem: Thou gh instaqqaDoneqectricianforthesystem:deaqqy
I dif
it does not show the ex act w ire terminaq bothqoopdiagramsandprocessqoopsheetsare
detaiqsd it show s the flow of the signaqs so an createddtheycanbesed
u togethertocreate
instaqqaD on or maintenance technician can anaccurateaccountofhowthesystemshouqd
easiqy see w here the signaqs are being rou ted beinstaqqedandhowithasbeeninstaqqedonce
as part of the sy stem: construcDonFcommissioningiscompqete:

INTECH OCTOBER 2023 46 WWW.ISA.ORG/INTECH

CONTROL SYSTEMS

Summary The producD on ofqoop diagrams and

process flowsheets aqso makes it possibqe for
oop
L diagrams and process qoop sheets are
manydesign issues to be seen and recD fied
two types ofdetaiq drawings thatd though
during the design phase ratherthan during
theytakeDme to prepared can resuqt in
construcD on:Though there is a cost to pre J
considerabqe savings in the construcD ond
pare these drawingsd the benefits ofhaving
instaqqaDond and commissioning phases ofa
them greatqyoutweigh the preparaD on cost:
project:These savings resuqt from the instaq J Henced manyinstrumentaD on professionaqs
qaDon eqectrician having cqearinstrucD ons on referto qoop diagrams and process qoop
howtowire and test the system instead of sheets as the >instrumentaD on engineerfs
doing the detaiqedwiring design onJtheJflyin goqdmine?ffitheyareworth theirweight in
the fieqd as part ofthe construcD on process: goqdwhen undertaking a project:

ABOUT THE AUTHORS

John Robert Davis Pjackrdavis‘aoq:comQ is a reD red instrumentaD on and automaD on professionaq
qocated in Oqdsmard Fqa:fter
A working in both the industriaq and municipaqwaterFwastewatersectors
formore than yearsd he is nowwriDng technicaq arDcqes to share hisworking experiences:
Graham Nasby, P.Eng., PMP, CAP Pgraham:nasby‘grahamnasby:comQ has more than years of
experienceworking instrumentaDond and he is the coJchairofthe ISA SCADSystems Standards
Committee:

INTECH OCTOBER 2023 47 WWW.ISA.ORG/INTECH

DATA ANALYTICS

From Raw
Data to
Meaningful
Insight

How cloud-based advanced data By Katie Pintar

analytics empowers process engineers.

The mass ex pansion of the indu striaq

Spreadsheet-caused challenges
I nternet of Things PI IoTQ has brou ght w ith
tA mostfaciqiDesdnumerousdatasourcesexist
it a su dden and significant increase in the thateachstoretheirdataindifferentdata J
amou ntd compqex ityd and accessibiqity of bases:istoricaqqy
H dspreadsheetJbasedanaqyt J
operaD onaq and equ ipment data in process icstooqsere
w usedtoaggregatedcqeansed
manu factu ring faciqiD es: Combined w ith andaqignaqqthisdatasoinsightscouqdbe
the emergence of arD ficiaq inteqqigence PA I Q extracted:owH everdthismanuaqprocedureis
and machine qearning PM L Qd this is prov iding cumbersomeandDmeJintensivedandcertainqy
the potenD aq to u ncover more meaningfu q notthemostefficientuseofanengineerfsor
insights than ever before: processexpertfsskiqqset:n
O topofthemanuaq
owH everdthejourneyfromrawdatatomean J inefficienciesdtheqackofqivedataconnecDvity

ingfuqinsightissDqqdisjointedformanyprocess qeavessubjectmatterexpertsPSMsQ
E with

manufacturers:Theqeadingcausesincqude perpetuaqqyoutJofJdateanaqyses:

qimiteddataaccessandconnecDity
v daqackof These chaqqenges make it difficuqt forSMEs
meJseriesJspecific
D anaqycaq
D soquonsd
D and towrangqe data and prepare it formeaningfuq
coqqaboraDondifficuqDesdandaddressingthese anaqysis:uFrthermored tradiD onaq soquD ons
issuesisparamounttoprocessopDmizaDon: rendered sharing data and anaqyses across

INTECH OCTOBER 2023 48 WWW.ISA.ORG/INTECH

DATA ANALYTICS

organizaDonaq teams and regions arduous Advanced anaqyD cs soquD ons aqso
ornearqyimpossibqed qimiD ng the abiqityfor strengthen the coqqaboraD on between pro J
coqqaboraDon and knowqedge transfer: cessd maintenanced and reqiabiqityteamsdwith
buiqtJin tooqs forsharing anaqyses and insights
TradiDonaq spreadsheetJbasedworkflows
in easiqydigesD bqe dashboards and reports:
are sDqq acDve in manyfaciqiD es todayd but
this severeqycrippqes organizaD ons because
these tooqs are decoupqed from reaqJD me data
visuaqizaDons:ortu
F nateqyd bettersoquD ons The lack of live data connectivity
are nowwideqyavaiqabqe:
leaves subject SMEs with
Modern advanced analytics perpetually out-of-date analyses.
TotransiDontheiranaqyDcscapabiqiDesd
increaseoperaDonaqefficiencydmaximize
profitabiqitydandachieveambiDouscorporate A root-cause analysis
objecDesffiincqu
v dingdigitaqtransformaDon One petrochemicaq and refining company
andsustainabiqitymetricsffiprocessmanufac J experienced a sqewofreactorshutdownsd
turingorganizaDonsarerapidqyimpqemenDng caused bythe faiqure ofa criD caq feed gas
moderncqoudJbasedadvancedanaqyDcs compressoron a poqyethyqene qinedwith the
soquDonsintotheirdaiqyprocedures:These inabiqityforimmediate restart: On this qined
softwarepqatformsareopDmizedtoconnect an unpqanned reactorshutdown creates a
disparatedatasourcesandimmediateqyaqqevi J minimum of hours ofdownD med cosD ng the
atethechaqqengesofqivedataconnecDvity: pqant upwards ofjd USDwith every
occurrence:These compressorswere previ J
ddiD
A onaqqydthesesoquDonsprovidenaDev
ousqymaintained on a preventaD ve mainte J
tooqsfordatacqeansingdDmestampaqignmentd
nance PPMQ scheduqed but this did not prevent
and contextuaqizaD ond empowering SMEs to
unpqanned shutdowns enD reqy:
quickqyderive reqiabqe insights referencing
aqq avaiqabqe data:With qive data connecD vity oqqow
F ing one compressortripd the ma J
right in the softwared SMEs can appqytheir chineryd controqsd and eqectricaq engineers
anaqyses to nearJreaqJD me datadwhetherit is worked togetherto idenD fythe source:
stored in the cqoud oronJpremises: Howeverd tracing eqectricaq diagrams around
the pump motorwas D meJintensived and it
Because advanced anaqyD cs soquD ons are
faiqed toyieqd a root cause:
cqoudJbasedd theyare perfect forIoTimpqe J
mentaDonsdwhich gain direct access to the Taking an aqternaD ve approachd a process
vast compuDng powerand scaqabiqityofcqoud engineer at the refinery opened a w ebpage
softwared advancing aqq types ofIndustry : in a modern advanced anaqyD cs appqica J
projectsd such as predicD ve maintenance D on to qu ickqy qocate the five most recent
programs and digitaq twins: shu tdow ns and su bsequ ent restarts Ppqanned

INTECH OCTOBER 2023 49 WWW.ISA.ORG/INTECH

DATA ANALYTICS

Figure 1. To troubleshoot
a critical feed gas
compressor failure,
an advanced analytics
application was used to
quickly find the most
recent shutdowns and
subsequent restarts from
decades of historical
process data and then
overlay the events to
identify abnormalities.

and u npqannedQ from decades of historicaq aqu

v eappearsdthecompressormotorisnow
process data PF igu re Q: immediateqyaddedtothemaintenanceork
w
qistforthenextpqannedshutdowndaproacDev
In this exampqed Seeqfs >Capsuqes? and
maintenanceapproachthatisexpectedto
>ChainView? tooqs qet the engineerquickqy
eqiminatenpqanned
u shutdownsduetothis
find and focus on the shutdown and startJup
faiquremode:
Dme periodsd then overqaythe events:This qed
to idenDfying abnormaqiD es in the discharge CqoudJbased anaqyD cs appqicaD ons em J
pressure profiqe ofthe two most recent powerprocess manufacturers to significantqy
startJups: InvesD gaD ng furtherd the engineer reduce newsoftware impqementaD on D me
aqso noDced earqywarning signs on the motor so theycan deqiverproducts to end users
amperage signaq:Without awaytoviewthe fasterdwhiqe improving quaqityand reducing
startJups backJtoJbackd the motordegrada J infrastructure and maintenance costs: Using
Don had gone unnoD ced byoperaD ons: pointJandJcqick interfaces fordescripD ved
diagnosD cd predicD ved and prescripD ve ana J
sA aresuqtofthisrootJcauseanaqysisdthe
qyD csd these pqatforms fuqfiqq the needs ofa
processengineerimpqementedamonitoring
range ofSMEs to derive the insights needed
soquon
D topreventfuturemotordegradaDon
to operate efficientqyand opD mize effecD veqy:
fromgoingnnoD
u cedandcausingsimiqarn
u J
pqannedshutdowns:WhenanoutJofJtoqerance Figure courtesy of Seeq

ABOUT THE AUTHOR

Katie Pintar is a SeniorAnaqyD cs Engineerat Seeq CorporaD on dwhere she
heqps companies maximizevaque from theirdata: She has a process engineering
backgroundwith a B:S: in chemicaq engineering from Montana State University:
KaDe has overfiveyears ofexperienceworking forchemicaq manufacturers to
opDmize exisDng processes and deveqop processes fornewmateriaqs: She has
experDse in batch and conDnuous processing forawide range ofchemistries:

INTECH OCTOBER 2023 50 WWW.ISA.ORG/INTECH

 ASSOCIATION NEWS
HIGHLIGHTS & UPDATES

ISA Automation and Leadership Conference

Brings Top Tech Experts to Colorado Springs
In earqyOctoberd ISAheqd its annuaq asinpersondidening
w accesstothehighJ
AutomaDon andeadership
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in beauDfuq Coqorado Springsd Coqorado: Over chosetotraveqtooqorado
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the span offive daysdACLproudqybrought toparDcipateinfaceJtoJfaceqivesessionsand
togethera gqobaq audience of automa J taqkith
w speakersdexhibitorsandeachother:
Don managersd engineers and technicians for
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Vitaqtechnicaqsessions
andanarrayoftechnicaq
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INTECH OCTOBER 2023 51 WWW.ISA.ORG/INTECH

 ASSOCIATION NEWS
HIGHLIGHTS & UPDATES

spokeon>NaDonaqbersecu
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I esand the otenD
P aq ofCarbon Credits9 Strategy
WorkforceevD eqopment:?key
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v E engineerdeverychiqdd in Safeguarding the Integrityofthe Carbon
everyarDstdeverybusinesspersondeverydoctord Credit Market:?
everycaregiverdeverydO E C everygovernment
Detaiqs on sessions and speakers are avaiq J
officiaqdeveryathqeDccoachdeveryteacheriqq
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insights:Someexhibitorexpertsaqsohosted
atTrido SoquDonsd spoke on >Unqeashing

INTECH OCTOBER 2023 52 WWW.ISA.ORG/INTECH

 ASSOCIATION NEWS
HIGHLIGHTS & UPDATES

technoqogyJdemoorpaneqJdiscussionsessions Growing as a society

attheevent:Thepen
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is at www.isa.org/awards.

INTECH OCTOBER 2023 53 WWW.ISA.ORG/INTECH

 ASSOCIATION NEWS
HIGHLIGHTS & UPDATES

voqunteers to meetupd asweqq as forseqfJ

idenDfiedyoung professionaqs and students 2024 Automation & Leadership
to gather:ASecDon and DivisionVoqunteer Conference: Charleston, SC, USA
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Over current and futurevoqunteers en J forCdAL beingheqdinCharqestond
gaged in acDviDes designed to coJcreate the SouthCaroqinadUSA:nce
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mostvibrant secD ons and divisions: deqiver>terrifictechnicaqcontentrightaqong J

sideunforgettabqeandfunexperiencesd?said
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Asketch arDst present during manyofthe His sketchesd photos andvideos from the
sessions captured his interpretaD on ofthe event are avaiqabqe in the ISAFqickraqbum .
important eqements ofthe event in reaqJD me: ffiAshqeyRagan

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INTECH OCTOBER 2023 54 WWW.ISA.ORG/INTECH

 THE LAST WORD | CONVERSATIONS AND OBSERVATIONS

The Evolving Language of Automation

Engineering
By Jack Smith

TheautomaDonindustrygrewupusingqadder In an arD cqe in theJune issue of

qogictoteqqprogrammabqeqogiccontroqqers InTech D tqed >FutureJProofing Controqs
PPCsQ
L whattodoandhowtodoit:utB theera Programming forthe dged?
E Emersonfs Darreqq
ofcqassiccomputerizedcontroqhasmovedinto Haqtermanwrote9 Programmabqe automaD on
theeraofndu
I stry:dwithitsemphasison controqqers PPACsQ >began to take on tasks
industriaqdigitaqizaDonandsoftwareimpqe J wewouqd associatewith the edge todayd
mentaDonsofcompqexsystems:Tokeepup aqthough theirdedicated reaqJD me operaD ng
withthisshiftdtheindustriaqautomaDonand systems PRTOSQ imposed some qimitaD ons:
controqengineeringdiscipqinesareevoqvingas In manycasesd users found it necessaryto
eqqd
w reflecDngtheconvergenceofoperaDonaq create compqex aqgorithmsd qike machine
technoqogyPOTQandinformaDontechnoqogy qearning strategiesd using modern informaD on
PITQsystems: technoqogyPITQKtype qanguages qike C‡‡ and
Pythond running on PCs and industriaq PCs
When I spoke w ith A rqen N ipperd C TO
PIPCsQworking in conjuncD onwithACs:?
P
for C irru s L ink SoquD ons and coJinventor of
M QTT at a recent technicaq conferenced w e In the same arD cqed Haqterman said users
got to taqking abou t this evoquD on: I asked shouqd seek product portfoqios that embrace
him to rank the programming qangu ages open programmingd softwared and com J
au tomaD on and controq engineers are u sing municaD on standardswhen possibqe: He
today: He toqd me that P y thond Javad and the said that foredge controqqersd this requires
C Jfamiqy of qangu ages PC d C ‡‡ and C pQ are Pamong significant othercriteriaQ that they
the top three: Bu t he qu ickqy cqarified that be >programmabqe using CFC‡‡d Pythond and
their prevaqence does not in any w ay excqu de othermodern qanguages suitabqe forappqica J
others. D ons qike machine qearning RMLS and arD ficiaq
inteqqigence RAIS:?
Because oftheirsimiqarsyntaxd Python and
Java are considered part ofthe CJfamiqyof In an October Robotics and
programming qanguagesdwhich aqso incqudes Automation News arD cqe D tqed >Most opu
P qar
Juqiad erqd
P and manyotherqanguages:What Programming Languages forAutomaD ond?
that famiqydoes not incquded howeverd is authorMarkAqqinsonwrote9 >According to
qadderqogicffiqong used to deveqop controq surveys conducted qastyeard RPythonS is
appqicaDons forindustriaq hardware qike PCLs the most preferred qanguage fordeveqoping
andACsffiand
P IEC r Jd a neweropen automated systems: Its open sources and
programming standard: freedom are the main pros:?

INTECH OCTOBER 2023 55 WWW.ISA.ORG/INTECH

 THE LAST WORD | CONVERSATIONS AND OBSERVATIONS

SupporDng Pythonfs pqace in frontd IEEE ydon

L points out thatd regardqess ofthe
Spectrum recentqyreqeased its th annuaq programming methodsd >manufacturers and
rankings ofthe top programming qanguages process producD on companies must digiD zed
sayingd >Thisyeard Python doesnft just remain ortheywiqq be caught in a strategic gap
No: in ourgeneraq <Spectrumf rankingebut puDfing them at a qarge compeDD ve disadvan J
itwidens its qead: Pythonfs increased domi J tage:Achieving the benefits ofdigitaqizaD on
nance appears to be qargeqyat the expense requires organizaD ons to qeverage Industry
ofsmaqqerd more speciaqizedd qanguages: It has : and IoTPInternet ofThingsQ conceptsd
become the jackJofJaqqJtrades qanguage:? technoqogyd and architecturewith open stan J
dards:Vendorcompqiance and cerD ficaD on to
What about IEC 61131-3? open interoperabqe programming standards
Coming up through theTO ranks are opend wiqq acceqerate the digitaqizaD on ofmanufac J
interoperabqe programming standards turingd producD ond and process industries:?
seeking to repqace the proprietaryprogram J
ydon
L seems concerned thatd in the
ming qanguages D ed to specific pieces of
void qeft bythe qack ofstrong conformance
industriaq hardware: In a recentAutomaD on:
and cerD ficaD on to industrial automaD on
com arDcqe d >The Missing <Industry :F
programming standards qike IEC r d >the
DigitaqizaDonf LinkffiOpen Programming
industrymaybe preempted from the outside:?
Standard Conformance h CerD ficaD ond?
Does that mean the aqqeged ITJcentric qan J
Biqqydon
L wrote9 >The fundamentaqs ofIEC
guages qike Python are >from the outside5?
rJ have been adopted byawide range
ofautomaDonvendors throughout theworqd: oncerns
C thatthese>ITJesque?soquons
D
IEC rJ is supported bythe PCopen
L ouw qdneverork
w inindustriaqautomaDonre J
organizaDon that extends the standardwith mindsmeoftheargumentsthatthernet
E couqd
speciaq interest groupsd standardsd and cerD J neverbesed
u forindustriaqnetworking:ayM be
ficaDons:These standards and cerD ficaD ons theconvergenceofTI andTO systemsmeans
incqude moDon controqd safetyd OPC UAd XML therearenoqonger>sides:?Theevoquon
D from
interchanged and reusabiqity: Due to the task qadderqogictothon
yP andrJ
C EI and
structure ofa fuqq IEC r impqementaD ond beyondspeakstohere
w theindustryhasbeen
both eventJdriven and cycqicaq RprogrammingS andisheaded:TheJoriented
C LP qanguagescan
can be accompqished:? aqqork
w togethertopromotedigitaqizaDon:

ABOUT THE AUTHOR

Jack SmithisseniorcontribuDngeditorforutomaD
A on:comandISAfs InTechmagazine:
eH spentmorethanears
y orking
w inindustryffifromeqectricaqpowergeneraDonto
instrumentaDonandcontroqdtoautomaDondandfromeqectroniccommunicaDonsto
computersffiandhasbeenatradejournaqistformorethanears:
y

INTECH OCTOBER 2023 56 WWW.ISA.ORG/INTECH