Hart 1

Application Guide
Keep Your Plant Competitive
Get More from What You’ve Got
Unleash the Power – See What You Can Do
Realize the Potential
Unleash the Power – Your Wish is HART’s Command
Unleash The Power - HART May be All the Fieldbus You Really Need
WirelessHART™ Information Unchained
WirelessHART Overview Presentation by HCF Executive Director

Ron Helson and HCF Chief Engineer Wally Pratt to ISA SP100
Committee on 22 May 2007. Recorded - Slides and Audio
The Complete HART Guide Sponsors

© 2005 HART Communication Foundation
Copyright © 1999-2005 HART Communication Foundation. All rights reserved.
HART® is a registered trademark of the HART Communication Foundation. Any use of the word “HART” hereafter in this
document implies the registered trademark. All other trademarks used in this document are acknowledged to be trademarks of their
respective companies.
For additional information contact:

HART Communication Foundation
9390 Research Boulevard
Suite I-350
Austin, Texas 78759 USA
Tel: 512-794-0369
Fax: 512-794-3904
HART APPLICATION GUIDE
Preface
In today’s competitive environment, all companies seek to reduce operation
costs, deliver products rapidly, and improve product quality. The HART®
(highway addressable remote transducer) protocol directly contributes to
these business goals by providing cost savings in:
T Commissioning and installation
T Plant operations and improved quality
T Maintenance
The HART Application Guide has been created by the HART

Communication Foundation (HCF) to provide users of HART products
with the information necessary to obtain the full benefits of HART digital
instrumentation. The HART communication protocol is an open standard
owned by the more than 100 member companies in the HCF. Products that
use the HART protocol to provide both analog 4–20 mA and digital signals
provide flexibility not available with any other communication technology.
The following four sections provide you with an understanding of how the
HART technology works, insight on how to apply various features of the
technology, and specific examples of applications implemented by HART
protocol users around the world:
T Theory of Operation3
T Benefits of HART Communications
T Getting the Most out of HART Systems
T Industry Applications
© 2003 HART Communication Foundation Page 1

THEORY OF OPERATION
Theory of Operation
The following sections explain the basic principles behind the operation of
HART instruments and networks:
T Communication Modes
T Frequency Shift Keying
T HART Networks
T HART Commands
Page 2 © 2003 HART Communication Foundation

THEORY OF OPERATION
Communication Modes
MASTER-SLAVE HART is a master-slave communication protocol, which means that during
MODE normal operation, each slave (field device) communication is initiated by a
master communication device. Two masters can connect to each HART
loop. The primary master is generally a distributed control system (DCS),
programmable logic controller (PLC), or a personal computer (PC). The
secondary master can be a handheld terminal or another PC. Slave devices
include transmitters, actuators, and controllers that respond to commands
from the primary or secondary master.
BURST MODE Some HART devices support the optional burst communication mode.
Burst mode enables faster communication (3–4 data updates per second). In
burst mode, the master instructs the slave device to continuously broadcast
a standard HART reply message (e.g., the value of the process variable).
The master receives the message at the higher rate until it instructs the slave
to stop bursting.
Use burst mode to enable more than one passive HART
device to listen to communications on the HART loop.

THEORY OF OPERATION
Frequency Shift Keying

The HART communication protocol is based on the Bell 202 telephone
communication standard and operates using the frequency shift keying
(FSK) principle. The digital signal is made up of two frequencies—
1,200 Hz and 2,200 Hz representing bits 1 and 0, respectively. Sine waves
of these two frequencies are superimposed on the direct current (dc) analog
signal cables to provide simultaneous analog and digital communications
(Figure 1). Because the average value of the FSK signal is always zero, the
4–20 mA analog signal is not affected. The digital communication signal
has a response time of approximately 2–3 data updates per second without
interrupting the analog signal. A minimum loop impedance of 230 Ω is
required for communication.
20 mA
Digital
Signal
“1” “0”
“1”
“1” “0”
“1”
“0” “0”
“1”
Analog
Signal
4 mA
Time
Note: Drawing not to scale.
Figure 1: Simultaneous Analog and Digital Communication

THEORY OF OPERATION
HART Networks
HART devices can operate in one of two network configurations—point to
point or multidrop.
POINT-TO-POINT In point-to-point mode, the traditional 4–20 mA signal is used to

communicate one process variable, while additional process variables,
configuration parameters, and other device data are transferred digitally
using the HART protocol (Figure 2). The 4–20 mA analog signal is not
affected by the HART signal and can be used for control in the normal way.
The HART communication digital signal gives access to secondary
variables and other data that can be used for operations, commissioning,
maintenance, and diagnostic purposes.
Control System
Multiplexer or Other Host
Application
Barrier
Handheld Terminal
Field Device
Note: Instrument power is provided by an interface or external power source

that is not shown.
Figure 2: Point-to-Point Mode of Operation

THEORY OF OPERATION
HART Networks
MULTIDROP The multidrop mode of operation requires only a single pair of wires and, if
applicable, safety barriers and an auxiliary power supply for up to 15 field
devices (Figure 3). All process values are transmitted digitally. In
multidrop mode, all field device polling addresses are >0, and the current
through each device is fixed to a minimum value (typically 4 mA).
Use multidrop connection for supervisory control
installations that are widely spaced, such as
pipelines, custody transfer stations, and tank farms.
Control System or Other Host

Application
Handheld Terminal
Input/Output (I/O)
System
Field Devices
Note: Instrument power is provided by an interface or external power source that is

not shown.
Figure 3: Multidrop Mode of Operation

THEORY OF OPERATION
HART Commands
The HART command set provides uniform and consistent communication
for all field devices. The command set includes three classes: universal,
common practice, and device specific (Table 1). Host applications may
implement any of the necessary commands for a particular application.
UNIVERSAL All devices using the HART protocol must recognize and support the
universal commands. Universal commands provide access to information
useful in normal operations (e.g., read primary variable and units).
COMMON Common practice commands provide functions implemented by many, but

PRACTICE not necessarily all, HART communication devices.
DEVICE SPECIFIC Device-specific commands represent functions that are unique to each field
device. These commands access setup and calibration information, as well
as information about the construction of the device. Information on
device-specific commands is available from device manufacturers.
SUMMARY TABLE
Universal Commands Common Practice Commands Device-Specific Commands
• Read manufacturer and • Read selection of up to four • Read or write low-flow cut-off
device type dynamic variables • Start, stop, or clear totalizer
• Read primary variable (PV) • Write damping time constant • Read or write density calibration
and units • Write device range values factor
• Read current output and • Calibrate (set zero, set span) • Choose PV (mass, flow, or
percent of range • Set fixed output current density)
• Read up to four predefined • Perform self-test • Read or write materials or
dynamic variables construction information
• Perform master reset
• Read or write eight-character • Trim sensor calibration
tag, 16-character descriptor, • Trim PV zero • PID enable
date • Write PV unit
• Write PID setpoint
• Read or write 32-character • Trim DAC zero and gain
message • Valve characterization
• Write transfer function (square
• Read device range values, root/linear) • Valve setpoint
units, and damping time • Write sensor serial number • Travel limits
constant • User units
• Read or write dynamic variable
• Read or write final assembly assignments • Local display information
number
• Write polling address
Table 1: HART Commands
Note: Table 1 is a partial list of HART commands. See Appendices B, C,

and D for more detailed information.

THEORY OF OPERATION
HART Commands
ESTABLISHING Each HART device has a 38-bit address that consists of the manufacturer
COMMUNICATION ID code, device type code, and device-unique identifier. A unique address
is encoded in each device at the time of manufacture. A HART master must
WITH A HART know the address of a field device in order to communicate successfully
DEVICE with it. A master can learn the address of a slave device by issuing one of
two commands that cause the slave device to respond with its address:
T Command 0, Read Unique Identifier—Command 0 is the preferred
method for initiating communication with a slave device because it
enables a master to learn the address of each slave device without user
interaction. Each polling address (0–15) is probed to learn the unique
address for each device.
T Command 11, Read Unique Identifier by Tag - Command 11 is useful
if there are more than 15 devices in the network or if the network
devices were not configured with unique polling addresses.
(Multidropping more than 15 devices is possible when the devices are
individually powered and isolated.) Command 11 requires the user to
specify the tag numbers to be polled.
DEVICE Some HART host applications use device descriptions (DD) to obtain
DESCRIPTION information about the variables and functions contained in a HART field
device. The DD includes all of the information needed by a host application
to fully communicate with the field device. HART Device Description
Language (DDL) is used to write the DD, that combines all of the
information needed by the host application into a single structured file. The
DD identifies which common practice commands are supported as well as
the format and structure of all device-specific commands.
A DD for a HART field device is roughly equivalent to a printer driver for a
computer. DDs eliminate the need for host suppliers to develop and support
custom interfaces and drivers. A DD provides a picture of all parameters
and functions of a device in a standardized language. HART suppliers have
the option of supplying a DD for their HART field product. If they choose
to supply one, the DD will provide information for a DD-enabled host
application to read and write data according to each device’s procedures.
DD source files for HART devices resemble files written in the C
programming language. DD files are submitted to the HCF for registration
in the HCF DD Library. Quality checks are performed on each DD
submitted to ensure specification compliance, to verify that there are no
conflicts with DDs already registered, and to verify operation with standard
HART hosts. The HCF DD Library is the central location for management
and distribution of all HART DDs to facilitate use in host applications such
as PCs and handheld terminals.
Additional information, not provided by the DD, may be required by some
host applications for screen formatting and other uses.

BENEFITS OF HART COMMUNICATIONS
Benefits of HART Communications

The HART protocol is a powerful communication technology used to
exploit the full potential of digital field devices. Preserving the traditional
4–20 mA signal, the HART protocol extends system capabilities for
two-way digital communication with smart field instruments.
The HART protocol offers the best solution for smart field device
communications and has the widest base of support of any field device
protocol worldwide. More instruments are available with the HART
protocol than any other digital communications technology. Almost any
process application can be addressed by one of the products offered by
HART instrument suppliers.
Unlike other digital communication technologies, the HART protocol
provides a unique communication solution that is backward compatible
with the installed base of instrumentation in use today. This backward
compatibility ensures that investments in existing cabling and current
control strategies will remain secure well into the future.
Benefits outlined in this section include:
T Improved plant operations
T Operational flexibility
T Instrumentation investment protection
T Digital communication

Improved Plant Operations

The HART protocol improves plant performance and increases efficiencies
in :
T Commissioning and installation
T Plant operations
T Maintenance
COST SAVINGS IN HART-based field devices can be installed and commissioned in a fraction
COMMISSIONING of the time required for a traditional analog-only system. Operators who
use HART digital communications can easily identify a field device by its
tag and verify that operational parameters are correct. Configurations of
similar devices can be copied to streamline the commissioning process. A
loop integrity check is readily accomplished by commanding the field
transmitter to set the analog output to a preset value.
COST SAVINGS IN The HART protocol supports the networking of several devices on a single
INSTALLATION twisted wire pair. This configuration can provide significant savings in
wiring, especially for applications such as tank monitoring.
Use HART multidrop mode to connect multiple instruments to
a single cable and reduce installation costs.
Multivariable devices reduce the number of instruments, wiring, spare

parts, and terminations required. Some HART field instruments embed PID
control, which eliminates the need for a separate controller, and results in
significant wiring and equipment cost savings.


IMPROVED HART-communicating devices provide accurate information that helps
MEASUREMENT improve the efficiency of plant operations. During normal operation, device
operational values can be easily monitored or modified remotely. If
QUALITY uploaded to a software application, these data can be used to automate
record keeping for regulatory compliance (e.g., environmental, validation,
ISO9000, and safety standards).
Numerous device parameters are available from HART-compatible
instruments that can be communicated to the control room and used for
control, maintenance, and record keeping (Figure 4).
Field Control Room

Device
Figure 4: Examples of Device Parameters Sent to Control Room

Some HART devices perform complex calculations, such as PID control
algorithms or compensated flow rate. Multivariable HART-capable
instruments take measurements and perform calculations at the source,
which eliminates time bias and results in more accurate calculations than
are possible when performed in a centralized host.
The HART protocol provides access to all information in
multivariable devices. In addition to the analog output
(primary variable), the HART protocol provides access to
all measurement data that can be used for verification or
calculation of plant mass and energy balances.
Some HART field devices store historical information in the form of trend
logs and summary data. These logs and statistical calculations (e.g., high
and low values and averages) can be uploaded into a software application
for further processing or record keeping.


COST SAVINGS IN The diagnostic capabilities of HART-communicating field devices can
MAINTENANCE eliminate substantial costs by reducing downtime. The HART protocol
communicates diagnostic information to the control room, which
minimizes the time required to identify the source of any problem and take
corrective action. Trips into the field or hazardous areas are eliminated or
reduced.
When a replacement device is put into service, HART communication
allows the correct operational parameters and settings to be quickly and
accurately uploaded into the device from a central database. Efficient and
rapid uploading reduces the time that the device is out of service. Some
software applications provide a historical record of configuration and
operational status for each instrument. This information can be used for
predictive, preventive, and proactive maintenance.

Operational Flexibility
The HART protocol allows two masters (primary and secondary) to
communicate with slave devices and provide additional operational
flexibility. A permanently connected host system can be used
simultaneously, while a handheld terminal or PC controller is
communicating with a field device (Figure 5).
Analog
HART Interface
Digital Data
(2–3 updates
per second)
Primary Master: Power

Control System Supply
or Other Host
Application
Transmitter
Secondary Master
Figure 5: Multimaster System

The HART protocol ensures interoperablility among devices through
universal commands that enable hosts to easily access and communicate the
most common parameters used in field devices. The HART DDL extends
interoperability to include information that may be specific to a particular
device. DDL enables a single handheld configurator or PC host application
to configure and maintain HART-communicating devices from any
manufacturer. The use of common tools for products of different vendors
minimizes the amount of equipment and training needed to maintain a
plant.
HART extends the capability of field devices beyond
the single-variable limitations of 4–20 mA in hosts
with HART capability.

Instrumentation Investment Protection

Existing plants and processes have considerable investments in wiring,
analog controllers, junction boxes, barriers, marshalling panels, and analog
or smart instrumentation. The people, procedures, and equipment already
exist for the support and maintenance of the installed equipment. HART
field instruments protect this investment by providing compatible products
with enhanced digital capabilities. These enhanced capabilities can be used
incrementally.
The HART communication protocol enables you to retain your
previous investments in existing hardware and personnel.
At the basic level, HART devices communicate with a handheld terminal

for setup and maintenance. As needs grow, more sophisticated, on-line,
PC-based systems can provide continuous monitoring of device status and
configuration parameters. Advanced installations can also use control
systems with HART I/O capability. The status information can be used
directly by control schemes to trigger remedial actions and allow on-line
reranging based on operating conditions and direct reading of multivariable
instrument data.
COMPATIBILITY OF As HART field devices are upgraded, new functions may be added. A basic
HART REVISIONS premise of the HART Protocol is that new HART instruments must behave
in precisely the same manner as older versions when interfaced with an
earlier revision host system.

Digital Communication
A digital instrument that uses a microprocessor provides many benefits.
These benefits are found in all smart devices regardless of the type of
communication used. A digital device provides advantages such as
improved accuracy and stability. The HART protocol enhances the
capabilities of digital instruments by providing communication access and
networking (Table 2).
Benefits HART Instruments Digital Instruments

Accuracy and stability ✓ ✓
Reliability ✓ ✓
Multivariable ✓ ✓
Computations ✓ ✓
Diagnostics ✓ ✓
Multiple sensor inputs ✓ ✓
Ease of commissioning ✓
Tag ID ✓
Remote configuration ✓
Loop checks ✓
Adjustable operational parameters ✓
Access to historical data ✓
Multidrop networking ✓
Access by multiple host devices ✓
Extended communication distances ✓
Field-based control ✓
Interoperability ✓
Table 2: Digital Instruments Versus HART Instruments

GETTING THE MOST OUT OF HART SYSTEMS
Getting the Most out of HART Systems

To take full advantage of the benefits offered by the HART communication
protocol, it is important that you install and implement the system correctly.
The following sections contain information that can help you to get the
most from your HART system:
T Wiring and Installation
T Intrinsic safety
T HART multidrop networks
T Control system interfaces
T Multiplexers
T Reading HART data into nonHART systems
T Universal handheld communicator
T PC configuration software
T Commissioning HART networks
T Device status and diagnostics
T Connecting a PC to a HART device or network
T PC application development tools
T Control in field devices

Wiring and Installation

In general, the installation practice for HART communicating devices is the
same as conventional 4-20mA instrumentation. Individually shielded
twisted pair cable, either in single-pair or multi-pair varieties, is the
recommended wiring practice. Unshielded cables may be used for short
distances if ambient noise and cross-talk will not affect communication.
The minimum conductor size is 0.51 mm diameter (#24 AWG) for cable
runs less than 1,524 m (5,000 ft) and 0.81 mm diameter (#20 AWG) for
longer distances.
CABLE LENGTH Most installations are well within the 3,000 meter (10,000 ft) theoretical
limit for HART communication. However, the electrical characteristics of
the cable (mostly capacitance) and the combination of connected devices
can affect the maximum allowable cable length of a HART network. Table
3 shows the affect of cable capacitance and the number of network devices
on cable length. The table is based on typical installations of HART
devices in non-IS environments, i.e. no miscellaneous series impedance.
Detailed information for determining the maximum cable length for any
HART network configuration can be found in the HART Physical Layer
Specifications.
Cable Capacitance – pf/ft (pf/m)

Cable Length – feet (meters)
No. Network 20 pf/ft 30 pf/ft 50 pf/ft 70 pf/ft

Devices (65 pf/m) (95 pf/m) (160 pf/m) (225 pf/m)
9,000 ft 6,500 ft 4,200 ft 3,200 ft

1
(2,769 m) (2,000 m) (1,292 m) (985 m)
8,000 ft 5,900 ft 3,700 ft 2,900 ft

5
(2,462 m) (1,815 m) (1,138 m) (892 m)
7,000 ft 5,200 ft 3,300 ft 2,500 ft

10
(2,154 m) (1,600 m) (1,015 m) (769 m)
6,000 ft 4,600 ft 2,900 ft 2,300 ft

15
(1,846 m) (1,415 m) (892 m) (708 m)
Table 3: Allowable cable lengths for 1.02 mm (#18 AWG)

shield twisted pair

Intrinsic Safety
Intrinsic safety (IS) is a method of providing safe operation of electronic
process-control instrumentation in hazardous areas. IS systems keep the
available electrical energy in the system low enough that ignition of the
hazardous atmosphere cannot occur. No single field device or wiring is
intrinsically safe by itself (except for battery-operated, self-contained
devices), but is intrinsically safe only when employed in a properly
designed IS system.
INTRINSIC SAFETY HART-communicating devices work well in applications that require IS

DEVICES operation. IS devices (e.g., barriers) are often used with traditional
two-wire 4–20 mA instruments to ensure an IS system in hazardous areas.
With traditional analog instrumentation, energy to the field can be limited
with or without a ground connection by installing one of the following IS
devices:
T Shunt-diode (zener) barriers that use a high-quality safety ground
connection to bypass excess energy (Figure 6)
T Isolators, which do not require a ground connection, that repeat the
analog measurement signal across an isolated interface in the safe-side
load circuit (Figure 7 on page 19)
Both zener barriers and isolators can be used to ensure an IS system with
HART-communicating devices, but some additional issues must be
considered when engineering the HART loop.
HAZARDOUS SIDE SAFE SIDE
Zener Barrier
Power Supply
1–5 V Output
Transmitter Signal
250 Ω Load Resistor
Figure 6: 4–20 mA Loop with a Zener Barrier

Intrinsic Safety
HAZARDOUS SIDE SAFE SIDE
Power
Isolator Supply
1–5 V Output
4–20 mA Signal
Transmitter
250 Ω Load Resistor
Figure 7: 4–20 mA Loop with Isolator
DESIGNING AN IS Designing an IS direct-current loop simply requires ensuring that a field

SYSTEM USING device has sufficient voltage to operate, taking into account zener barrier
resistance, the load resistor, and any cable resistance.
SHUNT-DIODE
When designing an IS loop using shunt-diode barriers, two additional
BARRIERS
requirements must be considered:
T The power supply must be reduced by an additional 0.7 V to allow
headroom for the HART communication signal and yet not approach
the zener barrier conduction voltage.
T The load resistor must be at least 230 Ω (typically 250 Ω).
Depending on the lift-off voltage of the transmitter (typically 10–12 V),

these two requirements can be difficult to achieve. The loop must be
designed to work up to 22 mA (not just 20 mA) to communicate with a
field device that is reporting failure by an upscale, over-range current. The
series resistance for the same zener barrier may be as high as 340 Ω. To
calculate the available voltage needed to power a transmitter, use the
following equation:
Power Supply Voltage – (Zener Barrier Resistance + Sense Resistance) ×
Operating Current (mA) = Available Voltage
Example: 26.0 V – (340 Ω + 250 Ω) × 22 mA = 13.0 V
Any cable resistance can be added as a series resistance and will reduce the
voltage even further. In addition, the power supply to the zener barrier must
also be set lower than the zener barrier conduction voltage. For example, a
28 V, 300 Ω zener barrier would typically be used with a 26 V power
supply.

Intrinsic Safety
While it is difficult to meet the two requirements noted above for a network
using shunt-diode barriers, it can be done. Following are two possible
solutions to the problem:
1. Shunt the load resistor with a large inductor so that the load resistor
impedance is still high (and mainly resistive) at HART signal
frequencies, but much lower at direct current. This solution, while it
does work, is physically somewhat inconvenient.
2. Use an IS isolator rather than a shunt-diode barrier. The output voltage
on the hazardous side is usually specified as greater than X Vdc at
20 mA (typically 14–17 V). This value already includes the voltage
drop due to the internal safety resistor, so the only extra voltage drop is
that due to cable resistance. System operation at 22 mA requires
reducing the 20 mA voltage by 0.7 V (340 Ω × 2 mA).
DESIGNING AN IS The implementation of HART loops in an IS system with isolators requires

SYSTEM USING more planning. An isolator is designed to recreate the 4–20 mA signal from
the field device in the safe-side load circuit. Most older isolator designs will
ISOLATORS not carry the high frequencies of HART current signals across to the safe
side, nor will they convey HART voltage signals from the safe side to the
field. For this reason, HART communication through the isolator is not
possible with these older designs. (It is still possible to work with a
handheld communicator or PC with an IS modem on the hazardous side of
the isolator.) When retrofitting HART instruments into an existing
installation, inspect the system for isolators that may have to be replaced
(any isolators that will not support HART signals).
Major suppliers of IS isolators have introduced
designs that are fully HART compatible. Modern IS
isolators provide trouble-free design and operation
and transparent communication in both directions.
IS device suppliers can assist with certification and performance

specifications for their HART-compatible products. Field device
manufacturers will also supply certification details for their specific
products.

Intrinsic Safety
MULTIDROP IS HART multidrop networks are particularly suitable for intrinsically safe
NETWORKS installations. With a multidrop configuration, fewer barriers or isolators are
required. In addition, because each field device takes only 4 mA (for a total
of 16 mA in a four-device loop), plain zener barriers can be used. With a
250 Ω load, 25 V – (340 + 250 Ω) × 16 mA = 15.5 V, which is well above
the transmitter lift-off voltage and leaves a margin for cable resistance.
IS OUTPUT LOOPS For output devices such as valve positioners, direct-current voltage
considerations will vary depending on the drive requirements of the device.
Zener barriers may be possible. If not, modern HART-compatible output
isolators are appropriate.
IS CERTIFICATION If the HART loop contains an IS-approved handheld communicator or

CONSIDERATIONS modem, slight changes may be needed to meet IS installation certification
rules. Handheld communicators and modems add the HART signal voltage
to the voltage level coming from the zener barrier or isolator. For example,
a handheld communicator typically adds a maximum of 2 V to the loop.
Therefore, when used with a 28 V zener barrier, a total of 30 V may
theoretically be present in the loop. The allowable capacitance must be
reduced by about 15% to account for this increase in voltage.
IS NETWORK The cable length calculation must include the resistance of both the zener
CABLE LENGTH barrier and the load resistor.
CALCULATIONS

HART Multidrop Networks

The HART communication protocol enables several instruments to be
connected on the same pair of wires in a multidrop network configuration
(Figure 8). The current through each field device is fixed at a minimum
value (typically 4 mA) sufficient for device operation. The analog loop
current does not change in relation to the process and thus does not reflect
the primary variable. Communications in multidrop mode are entirely
digital.
Master Device
Modem
Auxiliary Power
Supply
Transmitters
Figure 8: Multidrop Configuration

Standard HART commands are used to communicate with field instruments
to determine process variables or device parameter information (see HART
Commands on page 7). The typical cycle time needed to read information
on a single variable from a HART device is approximately 500
milliseconds (ms). For a network of 15 devices, a total of approximately 7.5
seconds is needed to scan and read the primary variables from all devices.
Reading information from multivariable instruments may take longer, as
the data field will typically contain values for four variables rather than just
one.
The typical multidrop network enables two-wire measurement devices to
be connected in parallel. Two-wire loop-powered and four-wire
active-source devices can be connected in the same network. If both two-
and four-wire devices are used in the same network, three wires must be
used to properly connect the devices (see Water Treatment Facility
Upgrade on page 45).

HART Multidrop Networks

MULTIDROP WITH HART field controllers can also be wired in a multidrop network
HART FIELD (Figure 9). Each analog output signal from the transmitter/controllers is
isolated from every other output signal, which provides a cost-effective
CONTROLLERS HART network configuration. In this case, the analog signals are not fixed
and are used for the output signal to the controlled device.
Handheld
Terminal Computer or
DCS
Power HART Interface
Supply Power Supply
Impedance
4–20 mA
+ – + – + – + – + – + –
HART
Transmitter
Control Valve
Figure 9: HART Controllers with Multidrop
APPLICATION Connecting HART field devices in a multidrop network can provide

CONSIDERATIONS significant installation savings. The total cable length in a multidrop
network is typically less than the maximum cable length in point-to-point
connections because the capacitance of the additional devices reduces the
distance that the HART signal can be carried (see Wiring and
Installation on page 17).
To save on installation costs, use HART multidrop
networks for remote monitoring stations, tank farms,
pipeline distribution systems, and other monitoring
applications in which fast update rates are not required.
CONFIGURING Using the polling address structure of the HART protocol, up to 15 devices
DEVICES FOR can be connected in a multidrop network. The analog current of a HART
device can be fixed by setting its polling address to a number other than
MULTIDROP zero. With the HART protocol, each field instrument should be configured
OPERATION with different polling addresses or tag numbers before being connected to a
multidrop network—otherwise, the master will not be able to establish
communication with the slave devices.

Control System Interfaces

When you change your existing control system by adding a HART
interface, it is important to understand the complete functionality offered by
the HART interface. While several control-system suppliers offer HART
interfaces, not all interfaces provide the same functionality.
Control systems such as a DCS, PLC, or SCADA/RTU (remote terminal
unit) implement only the functionality required for a given application. For
example, a flow-control system may only read the primary variable of a
device and provide no additional support for viewing or changing
configuration information. Other control-system interfaces provide
comprehensive HART support, maintaining complete configuration records
for all connected devices.
Contact your system supplier for specific details on their HART
interface(s). Use the form in Appendix A to obtain information from
control-system suppliers to identify specific characteristics of their
products.
HART I/O Many HART-compatible I/O subsystems have multiple analog channels on
SUBSYSTEMS each I/O card. Suppliers choose whether to provide one HART interface per
channel or to share one HART interface among several channels. The
number of shared channels per HART interface impacts the frequency of
data updates from a HART field device and the HART functionality that is
supported.
HART I/O FOR For the best performance and flexibility, one HART interface should be
MULTIDROP dedicated to each I/O channel. Systems that share only one HART interface
among several I/O channels may not support multidrop networks. The
SUPPORT effective update rate of a multiplexed interface is slow enough that the
performance of multiplexed multidrop networks would not be practical.
Some suppliers enable multidrop support by fixing the HART interface to
one specific I/O channel. However, the other channels on that card may
then not be available for HART communications.
HART I/O FOR Burst mode is an optional implementation in a field device. Receiving burst
BURST MODE mode messages is optional in a host as well. To take full advantage of burst
mode, the I/O system should have one HART interface for each channel. If
SUPPORT the HART interface is shared by more than one channel, messages sent by
the field device may not be detected by the control system. If the system
does not have the ability to configure burst mode in the field device, a
handheld terminal or other configuration tool is required.

Control System Interfaces

DATA HANDLING All HART-compatible control systems can read the digital primary variable
from a slave device. However, some system architectures may not be able
to accommodate textual data (e.g., tag and descriptor fields). In these cases,
the controller is able to read the process variable, but may not have direct
access to all other data in the HART device.
PASSTHROUGH Some control systems are integrated with a configuration or instrument-

FEATURE management application. In these systems, the control system passes a
HART command, issued by the management application, to the field device
via its I/O interface. When the control system receives the reply from the
field device, it sends the reply to the management application. This function
is referred to as a passthrough feature of the control system.
GATEWAYS Gateways can be used to bring HART digital data into control systems that
do not support HART-capable I/O. Some systems support HART gateways
with communication protocols such as Modbus, PROFIBUS DP, or TCP/IP
Ethernet. The typical HART gateway supports all universal commands and
a subset of the common practice commands. Support varies depending on
the gateway supplier. Some gateways support access to device-specific
information.
SCADA/RTU RTUs used in SCADA systems use a special telemetry to communicate

SYSTEMS with the control system. RTUs have the same considerations regarding
multidrop and burst mode support as other systems. However,
implementation is made more complex because RTUs often communicate
to an upper-level host using a communication protocol other than HART
(e.g., Modbus). While there are many benefits to implementing HART in an
RTU (support of multidrop, burst mode, and multivariable instruments),
HART data are only available to the central host system if the telemetry
protocol supports the transfer of HART commands or specific HART data
(see Multidrop for Tank Farm Monitoring on page 40).

Multiplexers
HART-compatible multiplexers are ideal for users who want to interface
with a large number of HART devices. Multiplexers can be modular and are
capable of supporting both point-to-point and all-digital (multidrop) HART
communication modes. Communication between a multiplexer and a host
application depends on the multiplexer capabilities (e.g., RS232C, RS485,
Modbus, and TCP/IP Ethernet).
When installing HART multiplexer systems, the following capabilities
should be considered:
T Number of HART channels supported
T Number of HART channels that share a HART modem
T Burst mode support
T Multidrop support
T Method of communication with the host computer or control system
MULTIPLEXER AS HART multiplexers can be used as the primary I/O front end for a
THE PRIMARY I/O HART-based control or monitoring system (Figure 10). Typically, a PC acts
as the host, providing the human-machine interface and performing other
SYSTEM high-level functions. The multiplexer continuously monitors the field
devices, reports the current readings and instrument status to the host, and
passes HART commands from the host computer to the field devices.
Multiplexer
Field
Devices
SCADA
Field Device
Figure 10: HART Multiplexer as the Primary I/O System
PARALLEL When a traditional 4–20 mA control system is using the analog signals for
MONITORING WITH measurement and control outputs, a HART multiplexer can be added to the
network to gain access to the digital HART signal. Using a multiplexer
A MULTIPLEXER enables a supervisory computer to monitor diagnostics and device status,
access configuration information, and read any additional process inputs or
calculations not provided by the 4–20 mA signal.

Multiplexers
Use a HART multiplexer to gain access to the digital
HART signal.
Two types of multiplexers are used in conjunction with a control system. A

multiplexer wired in parallel with the field wiring is commonly used when
the control system wiring is already in place (Figure 11).
Automation and
Display System
Supervisory
Controllers Computer
I/O
Transmitter Multiplexer
Control Valves
Figure 11: HART Multiplexer with Existing I/O

A multiplexer can also be an integral part of the control system as a
third-party I/O (Figure 12). As an I/O system, the multiplexer can include
IS barriers and other filtering capabilities and provide services to the field
device, such as galvanic isolation or power. For this type of installation, no
additional terminations or space are required. The multiplexer can also act
as a gateway to convert the HART messages to another protocol such as
Modbus, PROFIBUS, or Ethernet.
.
Automation and Supervisory

Display System Computer
Controller
I/O
Transmitter Control Valve
Figure 12: HART Multiplexer Integrated with I/O

Reading HART Data into NonHART Systems

Many HART products are able to perform more than one measurement or
output function (e.g., make multiple process measurements, calculate
process information, and provide positioner feedback information). All of
this information can be easily accessed digitally. However, existing
controllers or interface equipment may not have the ability to read digital
HART data. Products are available that can read HART digital signals and
convert them to analog or contact information, which enables any
traditional analog/digital I/O to take full advantage of the benefits of
HART-communicating devices. The Rosemount Inc. Tri-Loop module and
the Moore Industries Site Programmable Alarm (SPA) are two such
products.
HART The Tri-Loop module monitors a HART loop for a bursting message and
DATA-CONVERSION converts three of the four possible variables in HART command number
three to analog outputs (Figure 13). The conversion enables the field device
PRODUCTS to provide a total of four analog signals over a single pair of wires run from
the field.
.
Channel 1
4–20 mA
Channel 2 Signals for
Secondary
Channel 3 Variables
Field Terminals
Rail-Mounted
Tri-Loop Module Control System
Figure 13: Tri-Loop Module

Reading HART Data into NonHART Systems

The SPA module continuously communicates with any HART-capable
device and provides contact closure outputs (alarm trips) based on the
information received (Figure 14). For example, the SPA can be configured
to monitor the device-status information inherent in the HART
communication protocol and trigger events such as local on/off applications
or alarms. The SPA can also initiate emergency shutdown action if
problems are detected with a field device in critical loop applications.
HART 4–20 mA and HART

Transmitter HART Digital Communicator
Signals
Control
System
Process
and
Diagnostic
Data
Annunciator
HART Master Shutdown

Controls
Event
Recorder
Figure 14: SPA Module

Both HART Tri-Loop and SPA provide multivariable product support on a
loop-by-loop basis.

Universal Handheld Communicator

The 275 Universal HART Communicator is available from major
instrumentation suppliers around the globe and is supported by all member
companies in the HCF. Using HART DDL, the communicator can fully
communicate with and configure any HART device for which it has a DD
installed. If the communicator does not have the DD for a particular
network device installed, it can still communicate with that device using the
universal and common practice commands (see HART Commands on
page 7). The HCF provides centralized control and registration for all DDs
that can be loaded into the communicator. An index of registered DDs can
be found on the world wide web at <http://www.hartcomm.org>.
Use the 275 Universal HART Communicator to
communicate with and configure any
HART-communicating device.
Figure 15: 275 Universal Handheld Communicator

PC Configuration Software
Many instrument manufacturers, as well as some independent software
developers, offer HART communication software for PCs with capabilities
similar to and beyond those offered by a HART handheld communicator.
Use special software applications to continuously
monitor the status of connected field devices and log
status changes as they occur, which may help reduce
the costs of regulatory compliance.
The software packages listed in Table 4 are used for configuration

management, parameter tuning, and data acquisition with a HART device.
The list is not comprehensive, and all software applications are not
functionally equivalent. A number of product-specific software
applications are also available for diagnostics. An RS232 HART interface
or other interface device connects the PC running the HART application
software to the field devices.
SUMMARY TABLE
OF HART Software Application Manufacturer
SOFTWARE Asset Management Configuration and calibration

Fisher-Rosemount
Solutions (AMS) management
CONF301 HART
Configuration management Smar International
Configurator
CONFIG Configuration management Krohne
Cornerstone Base Configuration and calibration Applied System
Station management Technologies
Cornerstone Applied System
Instrument configuration
Configurator Technologies
Configuration management
H-View Arcom Control Systems
and data acquisition
IBIS Configuration management EB Hartmann & Braun
IBIS Configuration management Samson
K-S Series Configuration management ABB
Mobrey H-View Configuration management KDG Mobrey
UTSI International
Pacemaker Configuration management
Corporation
SIMATIC PDM Configuration management Siemens
EB Hartmann & Braun/
Smart Vision Configuration management
Bailey Fischer & Porter
XTC Configuration
Configuration management Moore Products Co.
Software
Table 4: HART Software

Commissioning HART Networks

HART-based instruments have several features that significantly reduce the
time required to fully commission a HART network (loop). When less time
is required for commissioning, substantial cost savings are achieved.
DEVICE Before installation, manufacturers usually enter device tags and other
VERIFICATION identification and configuration data into each field instrument. After
installation, the instrument identification (tag and descriptor) can be
verified in the control room using a configurator (handheld terminal or PC).
Some field devices provide information on their physical configuration
(e.g., wetted materials)—these and other configuration data can also be
verified in the control room. The verification process can be important in
conforming to governmental regulations and ISO quality requirements.
The commissioning process can be further streamlined by connecting a PC
configurator to each HART loop online, either by integration with the
control system or by using one of the many available HART multiplexing
I/O systems (see Multiplexers on page 26). With this centralized approach,
there is no need to move the configuration device from one termination
point to the next while commissioning all devices on the network.
LOOP INTEGRITY Once a field instrument has been identified and its configuration data
CHECK confirmed, the analog loop integrity can be checked using the loop test
feature, which is supported by many HART devices. The loop test feature
enables the analog signal from a HART transmitter to be fixed at a specific
value to verify loop integrity and ensure proper connection to support
devices such as indicators, recorders, and DCS displays.
Use the HART protocol loop test feature to check
analog loop integrity and ensure a proper physical
connection among all network devices.
AS-INSTALLED A HART configurator also facilitates record keeping. As-installed device

RECORD KEEPING configuration data can be stored in memory or on a disk for later archiving
or printing.

APPENDICESAPPENDICESAPPENDICES
Device Status and Diagnostics

Most HART field instruments provide both status information and
diagnostic information. The HART protocol defines basic status
information as information that is included with every message from a field
device. Basic status information enables the host application to
immediately identify warning or error conditions detected by the field
device. Status messages also enable the user to differentiate between
measurements that are outside sensor or range limits and actual hardware
malfunctions. Examples of status messages are:
T Field device malfunction
T Configuration changed
T Cold start
T More status available
T Analog output current fixed
T Analog output saturated
T Nonprimary variable out of limits
T Primary variable out of limits
HART instruments can implement extensive, device-specific diagnostics.

The amount and type of diagnostic information is determined by the
manufacturer and varies with product and application. Diagnostic
information can be accessed using the HART communication protocol.
Host applications using DD files can interpret and display diagnostic
information. Applications not using DD technology may require product-
specific software modules to interpret diagnostic information.
Many manufacturers offer special software applications for their own
products. Some modules allow you to customize for specific products.
Manufacturers of valve actuators have made extensive use of this capability
to provide preventative and predictive diagnostic information that greatly
enhances the value of their products as compared to conventional actuators.
Several software applications are available that provide continuous
communication with field devices using a HART-compatible multiplexer
and HART I/O (see Multiplexers on page 26). These applications provide
real-time monitoring of status and diagnostic information.

Connecting a PC to a HART Device or Network

PCs are commonly used for HART host applications for configuration and
data acquisition. A specially designed device (Table 5) allows the HART
network to be connected to the RS232C serial port or PCMCIA slot of a PC
(Figure 16).
Product Name Manufacturer
Commubox Endress + Hauser
FSK-Modem EB Hartmann & Braun
HT311 RS232 Interface Smar International
VIATOR PCMCIA HART

MACTek
Interface
VIATOR RS232 HART Interface MACTek
Table 5: HART Interfaces
PC/Host
Application
RS232 HART
Interface Handheld Terminal
Field
Device
Power
Supply
Figure 16: RS232 HART Interface

PC Application Development Tools

Software drivers are available to assist in the development and integration
of PC applications with HART networks. Table 6 shows a partial list of
products available.
Product Name Description Manufacturer
Hview Provides DDE server Arcom Control Systems
HRT VBX 16-bit Visual Basic driver Borst Automation
HRT OCX 32-bit ActiveX Control Borst Automation
HART OPC HCF (via member

OPC Server
Server companies)
HL-LinkPro HART driver for LabVIEW Cardiac Systems Solutions
Table 6: PC Development Tools

Control in Field Devices

Microprocessor-based smart instrumentation enables control algorithms to
be calculated in the field devices, close to the process (Figure 17). Some
HART transmitters and actuators support control functionality in the
device, which eliminates the need for a separate controller and reduces
hardware, installation, and start-up costs. Accurate, closed-loop control
becomes possible in areas where it was not economically feasible before.
While the control algorithm uses the analog signal, HART communication
provides the means to monitor the loop and change control setpoint and
parameters.
PC-Based Operator
Interface
Modbus Link
(RS232) Muiltiplexer (HART Master)
4–20 mA to
Position Valve
HART Transmitter Control Valve

with PID Slave
Figure 17: Transmitter with PID (HART Slave)

Placing control in the field enhances control functionality. Measurement
accuracy is maintained because there is no need to transmit data to a
separate controller. Control processing takes place at the high update rate of
the sensor and provides enhanced dynamic performance.

Control in Field Devices

HART FIELD A HART field controller takes advantage of the HART protocol’s
CONTROLLER simultaneous analog and digital signaling by converting the transmitter’s
traditional analog measurement output into a control output. The analog
IMPLEMENTATION signal from the smart transmitter (controller) is used to manipulate the field
device (Figure 18). The analog output signal also carries the HART digital
signal, which is used for monitoring the process measurement, making
setpoint changes, and tuning the controller.
Bypass
Capacitor
+ Smart
Power Transmitter
Supply
Control
Resistor Valve
Figure 18: Smart Transmitter with PID

The communication rate of the HART protocol (2–3 updates per second) is
generally perceived as too slow to support closed-loop control in the central
host. With control in the field, the control function no longer depends on
the HART protocol’s communication rate. Instead, the control signal is an
analog output that is updated at a rate that is much faster than can typically
be processed in a conventional control system. Processing rates vary from
2–20 updates per second, depending on the product. The HART digital
communication rate remains sufficient for monitoring the control variable
and changing setpoint values.

INDUSTRY APPLICATIONS
Industry Applications
Many companies in a wide variety of industries have already realized the
advantages of using the HART communication protocol. This section
describes some applications in detail and outlines the tangible benefits that
result. The applications have been grouped into the following sections:
T Inventory-management applications
T Cost-saving applications
T Remote-operation applications
T Open-architecture applications

Inventory-Management Applications
Accurate measurements for inventory management are essential in all
industries. The HART communication protocol enables companies to make
sure inventory management is as efficient, accurate, and low cost as
possible.
HART MULTIDROP Tank level and inventory management is an ideal application for a HART
NETWORK FOR multidrop network (Figure 19). The HART network digital update rate of
two PVs per second is sufficient for many tank-level applications. A
TANK LEVEL AND multidrop network provides significant installation savings by reducing the
INVENTORY amount of wiring from the field to the control room as well as the number
MANAGEMENT of I/O channels required. In addition, many inexpensive
process-monitoring applications are commercially available to further cut
costs.
Transmitters
Storage
Tanks
HART Field
Multiplexer
Figure 19: Inventory Management with Multidrop
One company uses a HART multiplexer to digitally scan field devices for
level-measurement and status information. The information is forwarded to
the host application using the Modbus communication standard.
Multivariable instruments further reduce costs by providing multiple
process measurements, such as level and temperature, which reduces the
wiring and number of process penetrations required.

MULTIDROP FOR In one tank farm application, 84 settlement tanks and filter beds on a very
TANK FARM large site (over 300,000 m2) are monitored using HART multidrop
networks and HART RTUs (see SCADA/RTU Systems on page 25). The
MONITORING HART architecture required just eight cable runs for 84 tanks, with 10–11
devices per run (Figure 20). Over 70 individual runs of over 500 m each
were eliminated. Cable savings were estimated at over $40,000 when
compared to a conventional installation. RTU I/O was also reduced, which
resulted in additional hardware and installation savings. The total installed
cost was approximately 50% of a traditional 4–20 mA installation.
HART Multiplexer Control Room
Storage
Storage Tanks
Tanks
Figure 20: Tank Farm Monitoring with Multidrop

UNDERGROUND Underground salt caverns are frequently used for crude oil storage. One
PETROLEUM customer pumps oil from barges into the storage caverns. An ultrasonic
flowmeter records the total flow. To get the oil out of the caverns, a brine
STORAGE WITH solution is pumped into the cavern through a magnetic flowmeter. Brine
HART and crude oil flowing in both directions are measured and reported to the
COMMUNICATION DCS using the HART communication protocol for accuracy. The DCS
tracks flow rate and total quantity to maintain a certain pressure inside the
FOR ACCURACY
caverns (Figure 21).
HART Transmitter
Interface
HART Transmitter
Interface
Oil Caverns Field Instruments
Note: Digital accuracy for flow accuracy and flow totals
Figure 21: Underground Petroleum Storage

Cost-Saving Applications
Use HART multidrop networking to reduce
installation and maintenance costs.
WASTEWATER A Texas wastewater treatment plant replaced stand-alone flowmeters and

TREATMENT PLANT chart recorder outstations that required daily visits for totalization with a
HART system. HART-based magnetic flowmeters were multidropped into
UPGRADE HART RTUs to create a cost-effective SCADA network. The use of HART
technology reduced system and cable costs, enhanced measurement
accuracy, and eliminated time-consuming analog calibration procedures.
A system of 11 HART multidrop networks was used to connect 45
magnetic flowmeters from different plant areas. Each flowmeter
communicated flow rate and a totalized value over the HART network.
Multidrop networks eliminated the need for additional hardware and PLC
programming while providing a more accurate totalized value. Complex
and costly system integration issues were also avoided—for example, there
was no need for synchronization of totals between the host and field PLCs.
Multidrop networking further reduced the installation cost by reducing the
required number of input cards from the traditional 45 (for point-to-point
installations) to 11. Maintenance was simplified because of access to
instrument diagnostic and status data.

APPLIANCE A consumer appliance manufacturer used the networking capability of the
MANUFACTURING HART protocol to measure level, flow, and pressure. HART multidrop
provided substantial wiring and installation savings as well as digital
WITH MULTIDROP accuracy with the elimination of the analog to digital (A/D) and digital to
analog (D/A) conversions of the instrument and PLC I/O. Figure 22 shows
pressure transmitters connected to a PLC via smart transmitter interface
multiplexers.
Storage
Tanks
Highway
PLC
Communication
Module
Smart Transmitter Terminal

Interface Block Module
Figure 22: Multidrop Network Example

REMOTE The benefits of remote monitoring and rezeroing of smart transmitters
REZEROING IN A using the HART protocol are dramatically illustrated in this example of two
smart transmitters that control the fluid level in lauter tubs in a brewhouse
BREWERY application. Similar benefits would be realized in any application involving
a closed vessel.
Two smart transmitters are installed on each lauter tub—one on the bottom
of the tank and the other about nine inches from the bottom. The bottom
transmitter is ranged ±40 inH2O; the upper transmitter is ranged
0–30 inH2O. As the lauter tub is filled, the bottom transmitter senses level
based on pressure. When the level reaches the upper transmitter, that point
is marked as the new zero-level point, and the upper transmitter becomes
the primary sensing instrument for the lauter-tub level. The nine-inch
zero-level offset from the bottom of the tank is necessary to accommodate
loose grain that settles in the bottom of the tank.
Transmitters that are coordinated and working together control fluid level
in each lauter tub to within a few barrels. However, the upper transmitter
requires periodic maintenance or replacement and rezeroing. An undetected
false upper-transmitter level reading can cause a tank level error of up to
40 gallons.
The usual procedure for transmitter rezeroing takes about 95 minutes and
has been required as frequently as twice a day. Rezeroing a transmitter
using configuration software and PLC interface modules eliminates the
need to locate and identify the problem at the site as well as the need for
verification by control-room personnel and greatly reduces the chance for
inadvertent errors. Estimated total time to rezero each transmitter is
reduced to 15 minutes.
Through the configuration software’s instrument-status and diagnostic
capabilities, a false level indication can be automatically detected while a
lauter tub fill is in progress. The affected transmitter can then be
automatically rezeroed by programming logic in the programmable
controller to issue the appropriate command to the instrument.

WATER HART transmitters and a control system with HART capability were
TREATMENT chosen to upgrade a water treatment facility. The completed installation
reduced capital, engineering, and installation costs. The process dynamics
FACILITY of the water treatment facility allowed the HART instruments to be used in
UPGRADE all-digital mode without compromising plant performance.
The water treatment plant is divided into two areas, each with 14 filters.
Each area is controlled by a separate control system for complete
autonomy. A HART network monitors each filter for filter level, filter bed
differential, and filter outlet flow. The multidrop installation used a
three-wire system in order to accommodate both the two-wire and the
four-wire devices (magnetic flowmeters) in use (Figure 23)
(see Multidrop on page 6).
4 mA Pressure
Transmitters
12 mA Main
Power
Magnetic
Flowmeter
4 mA
Figure 23: Multidrop Networks with 2-Wire and 4-Wire Devices

Because the water treatment facility had a modular design, the use of
HART instruments allowed the configuration from the one filter network to
be copied to the others, which reduced the implementation time.
Engineering, system configuration, drafting, commissioning, maintenance,
and documentation were simplified. A reduced I/O card count also saved
money.

IMPROVED A cleaning materials supplier required periodic checkup of the instrument
DIAGNOSTICS condition and configuration information as compared to the initial
installation. The field transmitters provided a historical record of status
changes along with current configuration information. Periodic download
of this information was made possible using PLC ladder logic developed
for HART instruments.

Remote-Operation Applications
UNMANNED Choosing the HART communication protocol for all-digital communication
OFFSHORE GAS in a wide-area network enabled one company to have real-time monitoring
and control, access to diagnostics, and maintenance capabilities—all from a
PRODUCTION WITH remote location.
HART NETWORKS
Over half of the 500 transmitters on 15 platforms could be multidropped
with update rates of three seconds (six devices), which resulted in
substantial savings in wiring, I/O, and installation. The remaining devices
(flowmeters) required a faster response and were wired point to point using
digital HART communications to transmit the process data. The flowmeters
used the optional burst mode, which provided an update rate of 3.7 times
per second. All-digital communications provided maximum accuracy and
eliminated potential errors from input scaling, conversion, and drift (see
Multidrop on page 6).
Radio Antennae
Primary Standby RTU

RTU
Modbus Link
HART
Multiplexers
Transmitters
Transmitters
Figure 24: RTU Application

Each platform’s RTU provided a link to approximately 50 temperature,
pressure, and flow transmitters (Figure 24). The RTU used the multimaster
capability of the HART protocol to enable the second RTU to act as a hot
standby, which monitored activity and was able to take over if a failure
occurred. The RTUs provided links with the emergency and safety systems
and a local interface for maintenance personnel. The Modbus protocol was
used for communication to the central SCADA system.

Remote-Operation Applications
VENEZUELA In a Venezuela gas-lift project, HART multidrop technology was used for
GAS-LIFT PROJECT remote operation of offshore gas-lift production wells at considerable
savings (Figure 25):
T 30% decrease in installation costs
T 16:1 reduction of input modules
T Reduced cost of I/O cards in the RTU
T Remote reranging
T Remote access to the transmitter status for improved process uptime
Radio Antennae Microwave Towers
Configuration
and
Maintenance
Tools
Control
Room
Electric Valve HART Transmitters
Figure 25: Offshore Gas-Lift Project

Open-Architecture Applications
OIL REFINERY The best way to judge the openness of a communication protocol is by the
EXPANSION number of products supported. By this standard, the HART protocol is
perhaps the most open of any field-communication protocol available
today.
In a major refinery expansion, an oil company weighed the advantages of
using either a proprietary system or a HART-based system. The results
indicated that the company could use HART digital instruments in 92% of
their applications, compared to only 33% with the proprietary system.
Choosing HART products resulted in an incremental $23,000 in savings
due to commissioning efficiencies and ongoing maintenance and diagnostic
capabilities.
The oil company used a traditional control system with analog I/O and
supplemented the control capability with an online maintenance and
monitoring system. All of the HART field devices were monitored from a
central location (Figure 26).
Ethernet Link Maintenance

Control Station
Display
System
Controller
HART I/O I/O

Multiplexer
HART
Transmitter Control Valve
Fisher
Fisher
Figure 26: Online Implementation

HART WITHIN A HART field devices can be seamlessly integrated with PROFIBUS DP
PROFIBUS networks using the HART/DP Link, which enables the connection of four
HART devices and facilitates the passthrough of HART commands to host
NETWORK applications on the DP network (Figure 27). The HART/DP Link supports
IS installations.
PCs with HART Applications
PLC
PROFIBUS
DP
Remote I/O DP/PA

Link
DP/ASI Link
HART/DP
Link
Profibus
PA
HART
Instruments
Figure 27: HART Within a PROFIBUS Network

HART/DDE Cost-effective level- and temperature-monitoring systems can be designed
SERVER using HART multidrop networks and commercially available HART/DDE
interface software. HART/DDE interface software allows any compliant
application (e.g., spreadsheet) to directly read the process data and status
information available in HART field devices. A HART interface module
connected to the PC’s serial port is needed for this HART monitoring
application (Figure 28).
Spreadsheet
Data Logging
RS232 HART
Interface
Power Supply
Transmitter
Figure 28: Multidrop Network

WHERE TO GET MORE INFORMATION
Where To Get More Information

WHAT To serve the growing interest in HART-related products, the HCF publishes
INFORMATION IS a library of additional documents, articles, and overviews. The following
information is currently available:
AVAILABLE? T HART specifications
T Technical overview
T Application notes
T Technical assistance
T Training classes
WHERE TO FIND By Mail

INFORMATION HART Communication Foundation
9390 Research Blvd, Suite I-350
Austin, TX 78759 USA
By Phone
Call 512-794-0369.
By Fax
Send correspondence to 512-794-3904.
By E-mail
Send correspondence to <[email protected]>.
Online
Visit the HCF website at <http://www.hartcomm.org>.

GLOSSARY
Glossary
275 HART A handheld master device that uses the HART communication protocol and
Communicator DDL to configure or communicate with any HART smart device
Bell 202 A U.S. telephone standard that uses 1,200 Hz and 2,200 Hz as 1 and 0,
respectively, at 1,200 baud; a full duplex communication standard using a
different pair of frequencies for its reverse channel; HART uses Bell 202
signals but is a half-duplex system, so the reverse channel frequencies are
not used
Burst (Broadcast) Mode A HART communication mode in which a master device instructs a slave
device to continuously broadcast a standard HART reply message
(e.g., value of a process variable) until the master instructs it to stop
bursting
Cable Capacitance Per The capacitance from one conductor to all other conductors (including the
Unit of Length shield if present) in the network; measured in feet or meters
Cable Resistance Per The resistance for a single wire; meausred in feet or meters
Unit of Length
Closed-Loop Control A system in which no operator intervention is necessary for process control
Communication Rate The rate at which data are sent from a slave device to a master device;
usually expressed in data updates per second
DCS See Distributed Control System.
DD See Device Description.
DDL See Device Description Language.
Device Description A program file written in the HART Device Description Language (DDL)
that contains an electronic description of all of a device’s parameters and
functions needed by a host application to communicate with the device
Device Description A standardized programming language used to write DDs for

Language HART-compatible field devices
Distributed Control Instrumentation (input/output devices, control devices, and operator

System interface devices) that permits transmission of control, measurement, and
operating information to and from user-specified locations, connected by a
communication link

GLOSSARY
Glossary
Field The area of a process plant outside the control room where measurements
are made, and to and from which communication is provided; a part of a
message devoted to a particular function (e.g., the address field or the
command field)
Field Device A device generally not found in the control room; field devices may
generate or receive an analog signal in addition to the HART digital
communication signal
Frequency Shift Keying Method of modulating digital information for transmission over paths with
poor propagation characteristics; can be transmitted successfully over
telephone systems
FSK See Frequency Shift Keying.
Gateway A network device that enables other devices on the network to

communicate with a second network using a different protocol
HART Command Set A series of commands that provide uniform and consistent communication
for all master and slave devices; includes universal, common practice, and
device-specific commands
HART Communication Highway Addressable Remote Transducer communication protocol; the

Protocol industry standard protocol for digitally enhanced 4–20 mA communication
with smart field devices
HART Loop A communication network in which the master and slave devices are
HART smart or HART compatible
Host Application A software program used by the control center to translate information
received from field devices into a format that can be used by the operator
Interoperability The ability to operate multiple devices, independent of manufacturer in the

same system, without loss of functionality
Intrinsic Safety A certification method for use of electrical equipment in hazardous

(e.g., flammable) environments; a type of protection in which a portion of
an electrical system contains only intrinsically safe equipment that is
incapable of causing ignition in the surrounding environment
Intrinsic Safety Barrier A network or device designed to limit the amount of energy available to the
protected circuit in a hazardous location
IS See Intrinsic Safety.
© 2003HART Communication Foundation Page 71

GLOSSARY
Glossary
Master Device A device in a master-slave system that initiates all transactions and
commands (e.g., central controller)
Master-Slave Protocol Communication system in which all transactions are initiated by a master
device and are received and responded to by a slave device
Miscellaneous Series The summation of the maximum impedance (500 Hz–10 kHz) of all
Impedance devices connected in series between two communicating devices; a typical
nonintrinsically safe loop will have no miscellaneous series impedance
Modem Modulator/demodulator used to convert HART signals to RS232 signals
Multidrop Network HART communication system that allows more than two devices to be
connected together on a single cable; usually refers to a network with more
than one slave device
Multimaster Multimaster refers to a communication system that has more than one
master device. The HART protocol is a simple multimaster system
allowing two masters; after receiving a message from a slave device, the
master waits for a short time before beginning another transmission, which
gives the second master time to initiate a message
Multiplexer A device that connects to several HART loops and allows communication
to and from a host application
Multivariable Instrument A field device that can measure or calculate more than one process
parameter (e.g., flow and temperature)
Network A series of field and control devices connected together through a

communication medium
Parallel Device The summation of the capacitance values of all connected devices in a
Capacitance network
Parallel Device The parallel combination of the resistance values of all connected devices
Resistance in the network; typically, there is only one low-impedance device in the
network, which dominates the parallel device-resistance value
Passthrough A feature of some systems that allows HART protocol send-and-receive

messages to be communicated through the system interface
PID Proportional-integral-derivative
PID Control Proportional-plus-integral-plus-derivative control; used in processes where

the controlled variable is affected by long lag times

GLOSSARY
Glossary
Point to Point A HART protocol communication mode that uses the conventional
4–20 mA signal for analog transmission, while measurement, adjustment,
and equipment data are transferred digitally; only two communicating
devices are connected together
Polling A method of sequentially observing each field device on a network to

determine if the device is ready to send data
Polling Address Every HART device has a polling address; address 0 is used for
point-to-point networks; addresses 1–15 are used in multidrop networks
Process Variable A process parameter that is being measured or controlled (e.g., level, flow,
temperature, mass, density, etc.)
Protocol A set of rules to be used in generating or receiving a message
PV See Process Variable.
Remote Terminal Unit A self-contained control unit that is part of a SCADA system
RTU See Remote Terminal Unit.
SCADA See Supervisory Control and Data Acquisition.
Slave Device A device (e.g., transmitter or valve) in a master-slave system that receives
commands from a master device; a slave device cannot initiate a transaction
Smart Instrumentation Microprocessor-based instrumentation that can be programmed, has

memory, is capable of performing calculations and self-diagnostics and
reporting faults, and can be communicated with from a remote location
Supervisory Control and A control system using communications such as phone lines, microwaves,
Data Acquisition radios, or satellites to link RTUs with a central control system
Zener Type of shunt-diode barrier that uses a high-quality safety ground

connection to bypass excess energy

tale of two plants
Two HART Projects Keep

Plants Competitive
A tale of two different projects in two different industries
that achieve similarly impressive results
W
hen end-users deploy devices enabled
by the HART Communication Proto-
col, they quickly discover the technol-
ogy’s reliability, ease of use, flexibility, robustness,
and cost-effectiveness. They also learn how HART
has proven itself in the field, whether it’s in pro-
cess control or power plant applications.
Kevin Kerls, of biotechnology manufacturer
Genentech Inc. in South San Francisco, and Jerry
Lowery, of the Ohio State University in Colum-
bus, also attest to the essential value of HART in
industrial automation applications.
“You can use HART to implement all the high-
value functions of other bus technologies—Foun-
dation fieldbus, Profibus and DeviceNet—but at a
fraction of their cost by using infrastructure that
you probably already have in your plant today,”
explains Kerls, a senior automation engineer in
Genentech’s automation group. Kerls is helping
automate Genentech’s CCP2 facility in Vacaville,
Calif. which is currently under construction and
is expected to produce 200,000 liters of oncology
pharmaceuticals by 2009.
“In a regulated industry, it’s critical to manage de-
vice configurations,” says Kerls. “Integrating HART
Communication with our distributed control system
photo courtesy of the Ohio State University
(DCS) allows us to mitigate both of these risks.”
Meanwhile, on Ohio State’s main campus,
Lowery also extols the virtues of HART. Most work toward,” he explains. “HART is the way to go.
technicians are familiar with HART-enabled com- It makes life so much easier.”
municators. “The technicians love them. They’re
superior for the technicians,” says Lowery, a con- Ivy Towers, Hot and Cold HART
trol systems engineer at OSU’s McCracken Power Operating continuously, the McCracken plant
Plant. Another important feature is that HART is an provides 85% of the Buckeyes’ steam-based energy
open standard. “It gives everyone a common thing to needs. The steam is used for heating, humidifica-
S- Advertising supplement to CONTROL

tale of two plants
tion, sterilization, chilled-water, compressed air and He used the valve positioner digital PV to validate
domestic hot-water production. The plant has five the valve’s position. If the valve didn’t reach proper
industrial boilers. Presently, the oldest is a Babcock position in 30 seconds, an alarm would sound and
& Wilcox (B&W) D-Style, 600-psi, 220,000 lbs/hr a warning would be displayed on the HMI screen.
unit. Two new 200-psi Nebraska D-style units that The DigPV, which proved that the valve was not
produce 220,000 lb/hr of steam were installed in seating properly, and the digital secondary vari-
2004-05. Two more Nebraska Ds are now being able (DigSV), in this case positioner temperature,
installed, and the 200-psi, 150,000-lb/hr units are ex- indicated that a temperature “exceedance” had oc-
pected to be online by January 2007. Co-located at curred. “The HART secondary value or device tem-
the plant are seven York chillers, and three Caterpil- perature on the original positioner was trended and
lar emergency diesel generators. proved that the device never exceeded its maximum
Lowery doesn’t mince words about how impor- operating temperature of 50 ºC,” adds Lowery.
tant HART is to the plant. “We have approximate- These data convinced the vendor to replace
ly 200 to 250 HART-enabled devices. Without the valve positioner, “and the problem went
HART, this plant wouldn’t operate,” he says. away,” Lowery notes. This is important because
HART also helps the plant’s technicians save the vendor originally claimed the boiler’s opera-
time finding instrument problems. “We don’t tion had overheated and caused the SH vent-
have to spend as much time looking for what’s control valve to become stuck.
wrong,” adds Lowery. Ohio State also convinced the vendor to fix six
For example, staffers recently observed inter- SH vent valves saving approximately $10,000.
mittent signal failures on a temperature trans- Also, the combined digital PVs and SVs’ perfor-
mitter on one boiler’s mance not only saved a
superheater (SH) vent “We have approximately 200-250 potential $300,000 cost
control, which caused of replacing the existing
the vent to go into the HART-enabled devices. This plant superheater, but also led
wrong position. How- the vendor to install a
ever, thanks to a HART- wouldn’t operate without HART.” more reliable positioner.
enabled Honeywell Lowery appreciates
DCS system on the B&W boiler, they were able to this digital value functionality. “Digital PVs are
quickly correct the problem. extremely valuable in critical loops to validate the
“This was the first time we’d seen this type of analog position with the digital position,” he adds.
HART information,” he explains. The spreadsheet Besides diagnostics, having analog and digital
showed data with a log/time-stamp describing an communication available simultaneously with
event. In this case, descriptions included “primary HART is particularly valuable to Lowery. “This
variable (PV) was out of sensor limits” or “bad: capability is extremely important when validating
check measuring” and “field device malfunction.” loops. We use the digital PVs to validate analog
Once the staff found the event descriptions in the PVs on critical positioners. It just tells us what
event log, they solved their problem the same day. is wrong with the device,” he states. “And on
“We knew exactly what was wrong. The technician critical loops, if the analog PVs and digital PVs
went out, and repaired the resistance temperature don’t match up within a certain percentage of
device (RTD),” he says. “With the HART-enabled each other, we alarm that loop and have operators
DCS, our technicians know what the problem is.” investigate the actual valve position.”
Results Proven, Risks Lessened Buckeyes’ Assets Managed

A second event at Ohio State involved an SH vent- The simultaneous analog-digital capability of
control valve failure. The McCracken plant’s valve HART fulfills one of the most obvious asset man-
wouldn’t open or would become stuck while par- agement functions of HART-enabled automation—
tially open, Lowery recalls. “A vent-control valve protecting equipment and keeping plants operating.
failure put the boiler superheater at risk.” Of the 200-250 HART-enabled devices at the Mc-
Lowery decided to use the HART protocol’s digi- Cracken plant, an asset management system (AMS)
tal PV (DigPV) that was accessible from the DCS. monitors 40 of them. By the end of 2007, the AMS
Advertising supplement to CONTROL S-

tale of two plants
will monitor 180-200 HART devices, Lowery says. Kerls adds it’s important that Genentech can use
“The asset manager monitors and tracks device any vendor’s flow or temperature devices as long
faults for all HART-enabled devices. Types of device as they’re HART-compatible. “If a device that we
faults—anything you can think of,” he explains. wanted had a HART option, we asked for it. For
Overall, diagnostics are much improved, he notes. almost all devices, the HART capability was free
“Our asset manager package tracks faults that occur from the vendor. But even if the HART option
in HART devices through our DCS. Small items, like cost money, we still purchased it,” he recalls.
a positioner losing its zero position are now caught
early and repaired,” Lowery says. “But without that Remote Configuration Nearby
asset management software, the problem might have The ability to view instrument health is available
never been corrected because it wouldn’t have been in Genentech’s DCS without added hardware.
seen until complete device failure.” “We’re able to view/modify instrument con-
figurations without interrupting process monitor-
Biotech’s Digital- ing,” Kerls explains.
Analog Future “Managing our instrument config- Genentech chose HART
While the university’s because buses such as
experience with HART urations reduces our regulatory Profibus, Foundation
is more traditional, fieldbus, and DeviceNet
Genentech’s attraction risk and our risk to product.” had issues concerning
to HART focuses on their design, which is
the protocol’s availabil- different from HART
ity and innovative use at the Vacaville’s CCP2 and its 4-20mA capability. “ It takes more time to
facility. There, the company is implementing get other buses operable. We get the most benefit
HART with 15% of the I/O. via HART,” he adds. Number one on Kerls’ list of
“There are a lot of instrumentation manufacturers HART benefits is an enhanced view of the instru-
that offer HART-compatible products,” says Kerls. ments., which includes status, alarming informa-
That availability plus a huge installed base makes tion, and remote configuration.
HART a proven technology, he adds. “This is tech- Genentech also values the HART protocol’s re-
nology that’s going to continue to be supported and mote capabilities. “The biggest bang for the buck
developed. It uses the same 4-20mA wiring you’d use is remote configuration and monitoring. HART
in traditional I/O, so there’s no steep learning curve.” won over all the other buses,” Kerls asserts, “be-
He emphasizes this means reduced installation costs cause it provides remote capabilities, installation
and reduced risks during startup. simplicity, and met our requirements.”
Kerls adds that HART’s simultaneous analog and Remote device setup and configuration is essen-
digital communication capability is a key attribute tial because it allows Genentech to easily backup
to the protocol’s value. “We’re able to implement instrument configurations using a central data-
HART communication over familiar 4-20mA base. The firm also can make changes to instru-
twisted-pair signal cable, a proven and simple in- ment configurations from a controlled database
stallation method,” he says. “There are no address- compliant with 21 CFR Part 11 (Title 21 Code
ing schemes, network-sizing concerns, or special of U.S. Federal Regulations Part 11: Electronic
communication requirements to deal with.” Records; Electronic Signatures from the U.S. Food
Genentech reports it also chose HART because and Drug Administration). Kerls adds this was
its Honeywell instruments are HART-enabled. “So, possible without relying on handheld devices or
we need no new infrastructure other than a new technicians’ hand-written notes.
database server. The information is seamlessly inte-
grated throughout the I/O, DCS controller, and the Overall Configuration is Crucial
process data server,” Kerls says. In other systems, Central configuration management is another area
however, he believes multiplexers or other devices where Genentech will use the HART protocol. The
are needed to pick up digital signals. “With the company will use a database to capture, view, verify,
Honeywell system, HART data is tightly integrated, test, and backup instrument configurations for more
so information is available right in the DCS.” than 1,125 instruments during the startup of CCP2.
S-10 Advertising supplement to CONTROL

tale of two plants
“HART protocol with the online configura- figuration is always correctly backed up.”
tion-management database eliminates the need And, if an instrument needs replacement, HART
for a time-consuming paper process,” says Kerls. simplifies this process. “We download the backed
“It probably saves an hour off each calibration up configuration for the old instrument from our
which basically is a half a person-year saved under HART configuration management database. These
normal operations. In initial documentation of parameters upload to the new device through the
parameters and startup, this may also save 3,000 analog I/O card,” says Kerls. “Effectively manag-
hours. These are very conservative estimates.” ing our instrument configurations reduces our
Compared to traditional I/O, Genentech can regulatory risk and risk to product.”
use HART to diagnose an instrument just by Risk to product usually means producing less at
opening a view, rather than sending someone out poorer quality. “If a critical instrument is involved
to the device’s location. “If anything goes wrong and you can’t prove you had adequate control
with that device, it’ll notify the operator though over properly configured devices, it could lead
a DCS alarm,” he adds. to regulatory action and/or a recall of the entire
Genentech reports that HART-associated batch,” says Kerls. “You’d have offline analytical
work at CCP2 is enabling more efficient man- measurements so you might not lose the batch, but
agement of instrument configuration. “Once you might spend a lot of time defending it.”
we get this up and running, part of corporate
automation engineering’s role is to disseminate Tips from the Field
information about the project throughout the Correct monitoring, particularly with HART-
corporation,” says Kerls “This also means edu- enabled instruments, also concerns Lowery, who
cating our maintenance group on our systems’ offers tips for users. “HART device diagnostics
capabilities and developing efficient processes is only as good as the vendor’s device description
to leverage HART-enabled technology.” (DD) file. The more detailed the DD file, the more
Another benefit includes building the corpora- diagnostics you’ll have,” he explains.
tion’s instrument configuration-and-calibration Lowery also suggests ensuring that the DCS
Standard Operating Procedures (SOP) on how to analog I/O is HART-enabled. “Using a third-party
use the HART protocol and Genentech’s configura- solution to strip out and send HART data via a
tion management database. serial connection will likely prevent using HART
“We’ll continue to minimize the time required digital PVs in a fast changing loop,” he says. ■
to perform configurations and calibrations,” Kerls
emphasizes. “You can put these technologies in, Future’s Surface Only Scratched
but if you aren’t educating your lifecycle group—
maintenance and the local automation engineering Ohio State’s experience with HART was so positive that
group—to use them, then the corporation never the power plant’s staff is examining tracking the drift
gets the full benefit.” of the analog PV compared to the digital PV. Also,
there’ll be more use of HART device diagnostic faults
Compliance Protects Doses in the control strategy, says Lowery. Ohio State also
Diagnostics. Maintenance. Regulatory compliance. plans to evaluate using a field device manager (FDM)
SOPs exist for them. All are taken seriously at for configuring HART devices, rather than using HART
CCP2, and HART plays a crucial role here, too. communicators. “This will help us catalog devices. We’re
“Our HART devices are installed as part of an told that if you replace a device, when you plug it in,
8,500-I/O DCS. Any device errors or alarms will the DCS will automatically give it its tag and other
automatically be available to the operators/techni- operating information,” he adds.
cians,” explains Kerls. HART allows Genentech’s Overall, Kerls is even more optimistic about the role of
staff to receive device-specific alarm values, which HART in Genentech’s future. “If HART works well at CCP2,
reduces troubleshooting time. “On a new plant, we we can just roll it out to other Genentech plants,” he says.
don’t really know what the issues will be,” Kerls “If you use HART, you’re going to save big time in lifecycle
says, “but we expect that we’ll find them quicker, management because the installation cost is no more than
which goes directly to the bottom line. Our HART if we installed traditional I/O systems.”
implementation will ensure that the current con-

hart users win big
HART Champions Stay Competitive

Reliable communications via HART bring large gains
to many process projects
T
he HART Communication Protocol pro- users say it’s simple, reliable, robust, flexible, easy
vides the toolkit for process champions. It to use, rugged and cost-effective. They also know
imparts this through a global installed base that HART keeps their businesses competitive by
of more than 20 million HART-enabled devices. providing simultaneous analog and digital com-
This is extraordinary because HART debuted just munications, as well as interoperability.
20 years ago, and only became an open standard in We asked several end-users how they’re using
1990. Not surprisingly, all major industrial-auto- HART to keep their plants competitive. They
mation suppliers support HART. Pick any process report that they’re gaining efficiencies and sav-
measurement and control application, and HART is ing money by better using their installed assets,
there. The protocol assists in chemical production, and using the intelligence in their HART-en-
water desalinization, as well as pulp and paper, abled field devices. By tapping into this informa-
natural gas and steel production. It helps manage tion, they’re now working smarter and keeping
wastewater facilities. And it’s in OEMs’ pressure competitive. The investments in many cases are
and temperature metering devices. small and the returns are big. Creative? Yes!
So, why does HART enjoy such popularity? End Difficult? No! The key is just getting started!
Appleton Paper targets better asset management
To win in the paper-coating game, pulp-and-paper Process Management’s AMS package. Appleton
producer Appleton Paper implemented HART in enhanced its instrument-configuration capability
an addition/upgrade to a coating machine in its and preventive maintenance with HART’s better
facility in Appleton, Wis. The company installed troubleshooting capability. “So far, HART has
more than 100 HART-enabled flowmeters, control been very effective,” says Sambeek.
valves, and pressure sensors. Appleton also saved by installing and con-
The papermaker targeted several criteria for the figuring fewer transmitters. “HART saved us
project. 1) Minimize costs for hardware, software, roughly $40,000 on wiring alone with its ability
training, spare parts, etc. 2) Find a simple, robust to pull multivariable information from our mass
system to inform staff about device health. 3) Use flowmeters,” adds Sambeek. Using AMS for
that system in other applications. 4) Get a database commissioning, Appleton also saved money and
for configuration, tracking, troubleshooting, etc. 5) time by remotely configuring devices. HART
Obtain access to all instrument/device data. technology saved another $10,000 or so because
“HART gave us the best opportunity to expand the company now needed 12 fewer pressure and
with the rest of our existing control systems at the 12 fewer temperature transmitters.
lowest costs,” says Chris Van Sambeek, Appleton Sambeek says HART also improved opera-
Paper’s control systems technician. tions in other areas, including “better diagnos-
The ultimate goal was better asset management. tics; control-loop validation by pulling informa-
Appleton uses HART via a leading supplier’s PLCs tion into the PLC through the HART signal;
and a supporting supplier’s HART-enabled I/O increased plant availability; better product
system to link its smart instruments to Emerson quality and utility; higher product yield; lower
Advertising supplement to CONTROL S-15

hart users win big
operations-and-maintenance costs; and en- Sambeek. “Most of our existing instruments are
hanced regulatory compliance.” HART-enabled, and the HART cards used are
Appleton succeeded with HART because the compatible with our existing control systems.”
protocol was a better fit for expansion than other And, installing an OEM’s HART-enabled cards
fieldbus technologies, adds Sambeek. into Appleton’s control PLC platform allowed the
Finding a new HART smart card that the PLC paper company to use HART data in both the
system could use also helped Appleton. This AMS and control systems. “HART provides addi-
card allowed the company to upgrade existing tional information not available to normal analog
systems with minimal equipment and costs, says systems,” Sambeek adds.
V-F Controls reduces troubleshooting time
V-F Controls Inc. in Mentor, Ohio, provides the transmitter,” says Weinstein. “It came back and
flowmetering systems to petrochem and steel- said, ‘I am a temperature transmitter.’ ”
making companies, and to the district-energy Without the HART-enabled devices, it
market for custody transfer. would’ve taken longer to detect the bad setup. “It
“Often, we assist in commissioning,” explains probably would have taken us an hour just to get
Jim Weinstein of V-F. “However, process conditions 50 feet in the air to start troubleshooting.”
often aren’t as originally anticipated.” This means Weinstein says that HART adds loop-valida-
initial set-up of the instrument must be changed. tion functions to V-F’s applications like the ability
“HART allows us to make changes in minutes, to identify the transmitter at the end of the loop
compared to hours if we used analog electronics.” or driving a 4-20mA signal in the loop to verify
“Troubleshooting is a dream with HART. One proper response at a flow computer, chart recorder,
of my first HART installations was a steam-flow or indicator. “These capabilities not only identify
metering system with differential-pressure, pressure, proper wiring terminations, they help us find poten-
and temperature transmitters. The signals were sent tial ground-loop issues and configuration errors in
to a flow computer,” he recalls.The transmitters were the transmitter or secondary electronics,” he states.
located on the piping near the ceiling of a high-bay Weinstein’s a longtime HART fan. “HART
building. “The customer had done the installation is simply the only way to go for quick start-up,
and wiring, and then called to tell us that the trans- re-ranging, and troubleshooting,” he says. “The
mitters were indicating totally erroneous readings fact that it is a standard is most important when
on the flow computer,” says Weinstein. “When we systems involve different vendors’ products.
visited the site to troubleshoot, we agreed.” “I’m not aware of any standard for digital commu-
“I thought this would be a good time to try out nication on a 4-20mA loop. As proprietary protocols
our new HART communicator. I hooked it up fall by the wayside, more instrument manufacturers
to the pressure-transmitter terminals on the flow jump on the HART bandwagon. Why carry two or
computer, and established communication with three communicators, when you can carry just one?”
Persian Gulf becomes drinkable
The Saline Water Conversion Corp.’s (SWCC) Al- racy of the data, compared to the old devices that
Jubail Phase 1 desalination and power plant was were in place for the past 20+ years.”
built on the Persian Gulf in 1982. The facility has Prasad also appreciates that HART technology’s
six 60-megawatt power plants and a desalina- analog and digital communications are simultane-
tion plant. A recent re-instrumentation project ously available. “Analog communications helped
involved adding more than 2,000 HART-enabled because of our fastest turnaround time require-
devices from various manufacturers. ments,” says Prasad. “Digital helped quickly cali-
“Despite the size of this mega project, HART brate and troubleshoot issues, including control-
Communication helped us to the core,” says T. valve-positioner feedback.”
Veeresh Prasad of Yokogawa Engineering Asia. Something else that worked best for the project
“HART also achieved best resolution and accu- was HART technology’s response time at the host

hart users win big
system. “In terms of asset management, all the de- HART-compatible input/output (I/O) cards. The
vices couldn’t give enough information to the host staff now uses PRM to crosscheck status. The re-
system,” says Prasad of the plant’s pre-HART days. sult? “HART is a very reliable platform for fastest
The protocol’s interoperability also allowed response requirements of control and automation/
SWCC to integrate a Yokogawa’s Plant Resource safety-instrumented systems. It will compete with
Manager (PRM) asset management system, using all other buses, all the time.”
Sewers safer in Wisconsin
The Milwaukee Metropolitan Sewerage District installation that reduces time to calibrate the
(MMSD) recently installed more than 200 level trans- instrument, and eliminates the need to enter the
mitters with HART interfaces in manholes. The new manhole, unless the unit fails.”
instruments were needed because the former level “It’s not critical that the signal and calibration
instrumentation wasn’t temperature compensated. be available at the same time,” he explains. “But
HART technology’s analog functions allowed an the dual functionality allows seamless operation
intrinsically safe barrier and installation calibra- of the system while the instrument is being inter-
tion in these explosion-proof areas. “The collec- rogated and updated.”
tion-system manholes are typically entered yearly Moe asserts that using HART-enabled devices
for calibration checks,” explains Eugene Moe, saved money for MMSD, and adds those savings,
senior instrumentation and control engineer for coupled with the technology’s flexibility, reliability
Earth Tech Inc., Sheboygan, Wis., which jointly and field ruggedness, are why HART devices are used
manages MMSD’s operations. “The result is an throughout Milwaukee’s sewage-treatment system.
Eastman Chemical eases the pressure
At Eastman Chemical Co.’s operation in Longview, ning the transmitter. “We can strip the HART sig-
Tex., pressurized tanks may have an allowable nal, and get full range from transmitters in which
working pressure of 63 psig, which may be 10 the scale has decreased,” he says. “When we have
times more than the span of the pressure transmit- upsets where the process went out of the expected
ters. According to Josh Lowery, electrical engineer range, we can capture the actual reading from the
at Eastman Chemical, pressure variations in those HART signal.” HART’s remote-configuration ca-
tanks can cause problems. On startup, one tank’s pability has improved operations at the Texas fa-
pressure shot up, and popped a relief valve. A solu- cility. “HART saves us the time we used to spend
tion using HART technology includes only one going to and from the instrument,” Lowery says.
transmitter, rather than two as required before. “More importantly, hazardous-area work requires
“We use the HART signal to read the actual many more permits. Hooking up with HART in
value at the cell, and so read the full range of the the control room is much easier.” Remote configu-
transmitter,” says Lowery. This means operators ration also allows Eastman to verify field wiring
can determine the actual pressure without re-span- from the control room.
Australian Steelmaking glitches vanish
Australian steelmaking giant OneSteel’s Whyalla problems. “I read about the HART system and its ef-
SteelWorks in South Australia annually produces ficiency, so I pitched the idea to my manager,” recalls
approximately 1.16 million metric tonnes (1.30 Jeremy Pereira. “And, well, here we are.”
million tons) of steel. Fully functioning means more efficiency. Every sys-
In the electromagnetic stirrers at this facility, On- tem can be monitored and adjusted remotely, adds
eSteel uses a major vendor’s calibrator to reprogram Pereira. “It doesn’t have anywhere near as many
its HART field instruments and control elements. glitches as our old system.” That’s a blessing, he says,
OneSteel chose HART technology for a new ana- because it requires fewer technicians. “So, it definite-
log/digital interface because older systems caused ly saves money and, more importantly, time.” n

Team hart scores
Users Want Suppliers’ HART

Solutions on Their Teams
End-users implement suppliers’ HART-enabled tools to operate
their businesses better, faster, and more simply. This is the
essence of what keeps them competitive.
B
esides the benefits HART gives end-users data items—such as process variables, device status,
through approximately 20 million in- diagnostic alerts, loop current, and percent range—
stalled devices, its success also comes from built into suppliers’ HART devices.
its partnership with suppliers of HART-enabled Another reason end-users rely on these sup-
technologies. These suppliers include the world’s pliers is because HART provides simultaneous
major control-and-instrumentation vendors, such 4-20mA analog and digital channels or signals
as ABB, Emerson, Honeywell, Invensys, MACTek, over one pair of wires. Analog gives the PV, while
Magnetrol, Moore Industries, ProComSol, Sie- digital provides real-time connection to intel-
mens and Yokogawa. ligent field devices and their information. This
It’s no secret why end-users keep coming back analog-digital combination also provides better
to these and other suppliers—HART is a game- control security and loop integrity.
changing solutions enabler.
“We offer HART because our end-users world- HART Suppliers Guide Users to Future
wide expect us to support this capability,” declares T.S. Prasad Raghavendra, Honeywell Process
Magnetrol International’s Dave Miller. Solution’s product manager for HART solutions,
Eric Olson, ABB Automation Products’ business believes two key improvements will drive future
unit manager, adds, “HART is the most widely growth. The first is HART 6. Its protocol revisions
installed intelligent device technology today, and will offer better support for multivariable devices
it continues to deliver significant benefits. So, of and actuators, more device and variable-status in-
course, we remain a strong supporter.” formation, and some new and extended commands.
By implementing and using suppliers’ HART- Enhanced electronic-device-description language
enabled technologies, such as smart field (EDDL) is the other advance fueling growth, says
devices, end-users know they can be more Raghavendra. By expanding device description
competitive. Suppliers’ smart-HART solutions language (DDL) capabilities, EDDL establishes a
lower operating costs by allowing quicker de- new industry standard for advanced visualization
vice set-up and commissioning, and by enabling of intelligent-device information, while maintain-
protocol interoperability via easy integration of ing DD technology’s integrity.
multiple vendors’ technologies.
Suppliers’ HART technologies also improve Smart Devices Get Smarter
process control, increase safety-instrumented-sys- One recent upgrade involves Emerson Process
tem (SIS) integrity levels, and smooth troubleshoot- Management’s Version 8.4 of its DeltaV system
ing and maintenance. These tasks also become less software. It uses standard HART device-status
disruptive because HART grants access to 30-40 information to generate Emerson’s PlantWeb alerts

Team Hart Scores
for any HART-enabled device. This gives end-users products released in September. “More products
access to the predictive-diagnostic functionalities will follow before year’s end,” explains R. L.
in those devices. Doing this can prevent abnormal “Rick” Gorskie, senior product marketing man-
plant operating situations and enhance smart SIS. ager for Honeywell’s Industrial Measurement and
HART fully integrates with the analog signal, and Control (IMC) pressure/temperature products.
allows end-users to adopt it at their own pace and
within their budgets, adds Jim Cobb, marketing Competitive Asset Management
director of Emerson’s Rosemount Division. “HART Besides these advances, HART technology still
instruments allow us to provide cost-effective in- needs to be configured. Consequently, configura-
novations with a technology that isn’t disruptive to tion tools also keep end-users coming back to
customers’ operations and maintenance practices.” suppliers of HART-enabled technology. These tools
Likewise, Moore Industries’ HIM HART loop make it easier for end-users to integrate HART into
interface and monitor is another innovative tool that operations. And, as these tools become easier to use
provides process and diagnostic information that through suppliers’ upgrades and new systems, end-
would be otherwise unavailable with smart multivari- users get more out of their HART-enabled systems.
able transmitters and valves. All an end-user has to “As HART data becomes more integrated into
do is install HIM into a critical loop. control and asset-management systems, Yokoga-
“Smart/HART multivariable transmitters sense wa continues to enhance the powerful features
multiple process variables,” says Steve Todd, in our flow, temperature, pressure, and analyti-
Moore’s corporate marketing director. “These cal devices because we know there’s an easy way
transmitters perform an internal calculation to to maximize these additional capabilities,” says
derive a measurement, Hoag Ostling, chief
such as mass flow.” It’s no secret why end-users come application engineer
Next, the transmitters for Yokogawa Field
send the process vari- back to these suppliers—HART is a Instruments. Yokoga-
able to control systems wa’s HART solution
via a 4-20mA signal, game-changing solutions enabler. includes integrated
but Todd reports that, HART I/O modules
without HART-based control systems, end-users in its CS3000 production-control system and
can’t continuously monitor non-primary variables HART-compatible field instruments.
used to make the calculation. When end-users integrate these with Yokogawa’s
Meanwhile, Honeywell’s intelligent HART tech- Asset Excellence solutions, which provide the foun-
nology, such as its Experion Process Knowledge dation for comprehensive, condition-based mainte-
System (PKS), also makes end-users more competi- nance strategies, users gain the intelligence inherent
tive. “This is the first control system to offer I/O in protocol-enabled field devices.
with native HART 6.0 support,” says Raghav- Because asset management can occur remotely,
endra. “It’s also the first system to fully adopt suppliers also are helping end-users integrate that
the HART Communication Foundation’s (HCF) technology into operations. “The initial customer
Smart Device Configurator Model 625 (SDC-625) benefit for remote configuration via HART has
reference host technology.” expanded in recent years with the addition of asset
Other smart technology that makes HART inte- monitoring for improved predictive maintenance,”
gration easier comes from ProComSol, which now says ABB’s Olson. This has helped ABB’s end-us-
offers HART-enabled, device-configuration software. ers improve productivity and lower maintenance
DevCom2000 smart device communicator is based costs, he adds. ABB has increased its Smart/HART
on SDC-625. This HART-compliant host software capabilities through HART-multiplexer support for
accesses all HART DD features and functionality, installed systems, and with new HART-based, con-
says Jeffrey Dobos, president of ProComSol. “This figuration-and-calibration handhelds that support
includes monitoring and editing device variables, and ABB and non-ABB devices to a device-specific level.
executing all device DD methods,” he adds. Because remote connections, including wire-
Other new additions to HART’s smart toolbox less, require modems, end-users can implement
are Honeywell’s HART 6.0-certified pressure two HART-compliant devices from ProComSol,

team hart scores
including its universal serial bus (USB) HART EDDL further standardizes the user interface for
modem, HM-USB, and its wireless Bluetooth managing intelligent devices, and eliminates the need
HART modem, HM-BT-BAT. for Windows resource files, supplemental files, and
Another supplier providing access to HART other modifications, previously required by some as-
data is MACTek with its Viator RS232 and USB set-management applications.
HART interfaces. These HART-compliant technol- In fact, Invensys Process Systems’ Foxboro Au-
ogies allow a host PC to communicate to a HART- tomation unit recently announced plans to embed
enabled device made by any supplier, according to HART’s SDC-625 technology into Foxboro’s
Thomas Holmes, MACTek’s president. process automation system. “This HART technol-
“What this means to end-users is that these ogy will enable customers to take advantage of the
modems work the first time,” Holmes emphasizes. new enhanced EDDL,” says Betty Naylor-McDe-
This capability means end-users can communicate vitt, Foxboro’s marketing director. Automation
with their HART-enabled devices without worrying and control device vendors can program sequential
about the modem’s reliability or capability when interactive steps for calibrating and starting up field
serving in an industrial environment, he adds. devices in EDDL, she adds. And enhancements to
In response to today’s trend of connecting smart EDDL let device vendors define user interfaces for
devices via PCs to configure and manage intelligent plotting, trending, and storing device data.
device lifecycles, Holmes reports that a PC-HART- To make EDDL more available through HART
modem combination lowers costs, and makes and other fieldbuses, Emerson and Siemens Auto-
device configuration easier, especially with many mation & Drives announced a new technology-
parameters. Another advantage of this combination sharing effort in July. They’ll expand some systems
is its improved use of device capabilities that suppli- to give end-users more access to HART and other
ers build in to produce and maintain database con- fieldbus standards. Siemens will add interfaces
figurations, Holmes notes. These capabilities may to its Simatic PCS 7 process-control system and
be used, for example, in radar tank-level applica- its Simatic process device manager. Emerson will
tions to display the shape of a tank. End-users may expand its DeltaV and Ovation control systems
use these data to diagnose device health, validate and its asset management system (AMS) suite. The
operations, and to replace instruments. two companies plan to release their first products
in this cooperative effort in mid-2007.
EDDL Aids Operations Through all of these new technologies and
Suppliers also offer new solutions involving upgrades to existing ones, suppliers have helped
HART’s EDDL enhancements, which fit into Smart/ HART become widely accepted by global custom-
HART technologies, and integrate easily into end- ers. “HART’s efforts to take this ‘communication
users’ industrial operations. These include improved standard’ to the next level with Release 6.0 shows its
user interfaces with support for menus, windows, drive to remain one of the world’s premier commu-
tabs and groups, as well as added graphic support nication options for the process control industry,”
for graphs, trends, charts, and dial indicators. adds Honeywell’s Gorskie. n
Affordable DD Based Configuration Using Your PC
ProComSol, Ltd designs and manufactures both the hardware and software needed
to perform complete HART device configuration and monitoring using your PC.
DevCom2000 software uses the registered DD’s from the HART Foundation, allowing
full access to all device parameters, including Methods. The HM-USB USB HART
modem and the HM-BT-BAT Bluetooth HART modem offer significant cost savings
and productivity benefits. Units meet industry standards for USB, Bluetooth, and
HART connectivity. Order this affordable solution online using our secure website.
ProComSol, Ltd
Process Communication Solutions
Tel. 216.221.1550 • Fax 216.221.1554 • www.procomsol.com • [email protected]

HART FORWARD
Use The Tools You Have

S ome tools sit in your toolbox and are rarely used. Other
tools are attached to your tool belt and used daily. In
some cases we overlook the added benefits and capabilities
and other intelligent device information into the control,
asset management or safety system. This supplement is
loaded with useful tips on how to identify projects that
that a tool can provide because, well, we just don’t think of provide a high ROI and significant value to your operation.
it that way. Do you think of HART as a tool in your toolbox In this supplement, we review how small and gradual in-
or one that is on your tool belt and used daily? vestments will enable plants to avoid unplanned shutdowns
Remaining competitive in today’s global economy is no and unnecessary maintenance costs. Optimizing your assets
small task. We need every possible
resource and asset maximized “HART Communication is one
to provide that competitive edge
needed to survive. We spend time of those tools that might be
wishing for things we might like to
have and in reality the wish might
in your toolbox but needs to
be sitting right in our toolbox. be moved to your belt!”
HART Communication is one
of those tools that might be in your toolbox but needs to be and increasing the efficiency of your staff contribute to
moved to your belt! When you open it up, you will find a making HART a low-risk and cost-effective decision—one
powerful, easy to use and cost-effective field communication that is easy to deploy and to justify. Finally, we identify the
protocol solution that lowers operating cost, increases plant benefits of the enhanced Device Description Language and
availability and helps with regulatory compliance. Based on wireless HART. We continue to invest in HART technology
the industry standard 4-20mA, this robust, low-risk protocol to make sure it addresses your need to remain competitive.
is the right tool for the job. Regardless of the make and vintage of your control system or
In this 5th annual HART supplement, we present ideas, the type of HART-enabled field devices you may already have
information and testimonials on using the POWER of installed, there are many solutions available from the 160+
HART and getting more from what you’ve got installed. HART Communication Foundation member companies that
HART is the tool you can use to make your plant run more can help you put the POWER of HART to work in your plant.
efficiently by putting it to work with your plant automation, Get more from the HART devices you’ve got working in
safety and asset management systems—maximizing your you plant. Why? Simple—in order to become or remain
assets. As pointed out in this document, HART-enabled competitive. You need to think of HART as the tool you
projects are easy to find, install, use, and to justify. In most use daily to solve critical problems or better yet, identify
cases, the pay back is quick and benefits significant. and avoid them before they become problems.
Field instruments are becoming more intelligent and Getting more information is as easy as contacting your
more open with advanced functions and diagnostic features device or system suppliers or by visiting www.hartcomm.
that are powerful tools to achieve corporate objectives. org. The HART Communication Foundation is here to edu-
Enabled by HART Communication, today’s control systems cate, train and assist you to get more from what you’ve got
and I/O interfaces can painlessly integrate the intelligent in- and to UNLEASH the POWER of HART.
formation from these devices and put it in the hands of plant Is HART on your tool belt?
personal to maximize and optimize the operation. New tools
& technology enhancements like the DD-IDE development
environment, HART 6 and the enhanced Device Descrip-
tion Language contribute to HART’s ability to be one of the
most useful tools on your belt. Ron Helson
We will help you identify big opportunities when you Ron Helson, Executive Director,
move from part-time to full-time communications with HART Communication Foundation
HART-smart field devices and the integration of diagnostics 512-794-0369; [email protected]

HART VALUE
I
t’s ironic; in their endless quest to reduce costs In 1993, the HART Communication Founda-
while increasing output and quality, many tion (HCF) assumed ownership of the protocol and
manufacturers have been ignoring one of the responsibility for administering and maintaining
most potent technologies for achieving those ends. it. As part of its mission, HCF tests systems and
Not only that, it’s a technology in which most of devices for HART compliance and provides educa-
them already have made substantial investments! tional services to vendors and users.
The technology? HART. For years, instrument In HART’s early years, many instrument vendors
and systems vendors have been incorporating quickly adopted the technology, but the remote
HART communications capabilities into field connectivity was complex due to the need for ad-
devices, enabling those devices to send digital ditional wiring and hardware, such as multiplexers.
information, including diagnostic information Sandro Esposito, Masoneilan’s diagnostic product
and secondary variables, to host systems. (The manager, says this lack of seamless connectivity
HART Communication Foundation estimates that created “islands of automation” for the user.
more than 15 million HART-capable devices are Charlie Piper, fieldbus product manager for
installed worldwide.) But with the exception of Invensys’ Foxboro business unit, agreed.
maintenance personnel tramping into the field with “There are more than 500 different HART
handheld communicators to configure instruments,
most users have left HART’s benefits untapped.
Those days are coming to an end, however. Instru-
People are realizing that HART is
ment vendors are providing open access to their de- capable of delivering many of the
vices through readily available device descriptions;
control systems providers are including HART I/O same benefits as fieldbus.
hardware in their products as well as asset manage-
ment software; and many vendors are marketing devices in the marketplace, and there’s lots of
products that enable the owners of legacy, analog- information you can get about their performance,
only systems to access the power of HART. such as when valve positioners are starting to wear
So, with HART data more accessible and poten- out or stick,” he says. “But until recently no one
tially useful, key questions users face are: had come up with a way for all the host vendors to
What’s the best way for my company to access have a user interface to do these neat things with
that data? everyone else’s devices.”
How do we identify applications in which we can Today, however, most vendors make their Device
use HART to generate business value? Description (DD) files openly available. HCF
maintains and distributes a library of hundreds of
A Brief History DDs that enable any HART host (e.g., control sys-
HART, an acronym for Highway Addressable Re- tem, configurator, asset management system, safety
mote Transducer, was developed in the late 1980s system, etc.) to communicate with a vast array of
and became publicly available in the early 1990s. field devices. That development is coupled with
Unlike other recent field communications pro- the development of comprehensive applications to
tocols, such as Foundation Fieldbus and Profibus, monitor assets, such as Siemens’ Process Device
which are totally digital, HART is a “hybrid” Manager, Emerson Process Management’s AMS
analog/digital technology. An instrument’s primary Device Manager, and Honeywell’s Asset Manager
variable is transmitted via the industry standard PKS. As a result, users now are able to access most
analog 4-20 mA signal, but up to four secondary – if not all – of their device information from a
variables and device diagnostic information can single screen, regardless of device manufacturer.
be digitally “piggybacked” on it. As a result of In recent months, HCF has developed new tools
these digital communications capabilities, users and technologies to make development of HART-
have access to extensive data from their devices, compliant DDs easier. These include the new De-
including diagnostic information and -- in the case vice Description Integrated Development Environ-
of some instruments -- multiple process variables ment (DD-IDE), which is designed to streamline
(i.e., a pressure transmitter also might be capable development, testing and maintenance of DDs and
of providing temperature data). facilitate the creation of product applications with

HART VALUE
DD capabilities. are realizing that HART is capable of delivering

“The DD-IDE supports the iterative DD devel- many of the same benefits as fieldbus.”
opment style with a fast and efficient integrated
tool set. Each step in the edit-build-test cycle is Identifying High-Value Applications
supported in a DD-aware editing environment,” Industry experts are nearly unanimous that the
says Wally Pratt, HCF’s chief engineer. greatest return on HART technology investment
Also near completion is the Enhanced Device lies in the ability to continuously monitor the field
Description Language (EDDL) specification. EDDL instruments. Masoneilan’s Esposito notes that dras-
gives vendors the ability to add new capabilities to tic reductions in maintenance staffs during the past
decade have made automated monitoring of field
Keys to HART value instruments an absolute necessity in many plants.
• Identify the most critical loops in your plant By being able to watch and track the condition of
first and begin monitoring them via HART on plant floor devices, maintenance and operations
a full-time basis. Other less essential loops can personnel can spot problems in the making and
be monitored offline periodically. take action before they cause process upsets and
• An outsider can bring fresh perspective. So unplanned shutdowns. Conversely, being able to
consider bringing in an outside consultant to see that a device is working well enables users to
help you identify areas where you can realize avoid unnecessary maintenance activities.
maximum benefit from HART-based solutions. “If you have a lot of HART devices in your instal-
• Make a business plan to determine if the cost lation, and you’re not monitoring them on a continu-
of incidents is higher than the cost of invest- ous basis, you’re missing a great deal of opportu-
ing in HART-enabled I/O. nity,” says Tom Holmes, president of MACTek, a
• Employ a diagnostic tool to monitor loops manufacturer of HART modems. “There’s diagnostic
and field instrument performance and iden- information, alarms, alerts and confirmations of
tify potential troublespots that could benefit whether the analog signal is good or bad.”
from full time monitoring via HART. Industry experts recommended a number of
• Take advantage of resources and training pro- strategies to help users identify the most high-val-
vided by HART Communication Foundation. ue applications involving continuous monitoring.
• While HART is used primarily for equipment Emerson’s Cobb suggests that plants go about
monitoring and configuration purposes, don’t taking advantage of HART gradually.
overlook opportunities to use it in appropri- “One of the nice things about HART is that you
ate control applications. can add its capabilities to your plant, loop by loop,
and gradually take your facility from analog to a
DDs while improving cross-platform compatibility fully integrated HART plant,” says Cobb.
and facilitating device set-up. (See details else- “I’d start with online monitoring of my most criti-
where in this supplement.) cal assets. That’s where I’m going to get the most
HART-enabled instruments deliver greater value from predictive diagnostics, such as being
value than ever before, says Dave Smith, manager able to avoid unplanned shutdowns and prevent-
of Yokogawa’s plant network technology center. ing off-quality products,” adds Cobb. “At the same
“The processing power of the devices is increasing time, I might start using HART to monitor other in-
greatly,” says Smith. “Therefore, field instruments struments offline and gradually, as my maintenance
feature additional functionality, including diagnos- budget allows, bring other assets online.”
tic type functions, predictive functions and others.” Marcelo Dultra, vice president of sales and
Jim Cobb, marketing manager of Emerson marketing for Smar International, recommends
Process Management’s Rosemount Division, notes plant audits as a means of identifying areas ripe
that users are increasingly aware of the capabili- for improvement via HART. “They should do a full
ties of the digital field. “One of the reasons is that check of what equipment they have installed and
suppliers are better implementing features to use what technologies they’re using. This kind of thing
the capabilities of HART devices,” says Cobb. usually takes a maximum of two or three days,” says
“Another reason, ironically, is that there’s been so Dultra, who adds that Smar, as well as other vendors
much talk about fieldbus in recent years. People and consulting firms, provide such services.

HART VALUE
“It’s always good to get opinions from outside the firm to operators that the valve actually responded to
plant, from people who have seen other operations. If the movement command.
you work a long period in your own plant, you miss Robert Hotard, a product manager with instru-
some points that are important, especially when it ment-maker K-Tek, also suggests that users take
comes to the technologies available today,” he adds. advantage of HCF’s expertise in planning HART-
Prasad Raghavendra, Honeywell’s product manager based projects. “The first thing I’d recommend to
for all systems-related HART products, recommends anyone interested in HART is to go to the Founda-
that users review a history of process upsets and their tion’s website (www.hartcomm.org),” says Hotard.
causes to identify areas that are ripe for HART-en- “There’s a lot of information there that’s available
abled continuous monitoring. “Make a business plan to everyone and explains in great detail how to use
out of that to determine if the cost of incidents are the protocol and the benefits that are possible. I’m
higher than the cost for investing in HART-enabled I/ currently writing some manuals for K-Tek prod-
O,” says Raghavendra. “That’s a fairly simple method ucts, and in them I specifically reference the HCF
that would clearly indicate whether it was worth it for website.”
the customer to make the investment.”
In some instances, he says, the benefits from in- Don’t Overlook Control Opportunities
vesting in HART will be plain. “For example, your While most facilities use HART for applications
plant could be having problems caused by simple related to device configuration and maintenance,
incidents like sensor failures. If you’re simply users also should look for opportunities to use
relying on a 4-20 mA signal, the operator will see HART data for process monitoring as well. For
a local trip, but everything in that group of devices example, in applications where conditions such as
becomes suspect. This requires the operator to call temperature, pressure and levels change relatively
maintenance and initiate what could be an exten- slowly, users can reduce the number of instruments
sive debugging process. With HART, however, if they need in the field by acquiring multiple vari-
there’s a sensor failure, the device tells you that ables from a single device. Hotard points to tank
it’s the source of the problem, saving you time and farms as being ideal sites in which to make use of
resources in correcting the malfunction.” HART for applications such as inventory monitor-
“Processes that could benefit the most from this ing. (see accompanying story).
technology are those with a large number of re- In relatively small operations, users can set up
mote-connected HART devices that can be brought modest, but effective SCADA systems that utilize
in to a control system through a remote HART I/O,” HART technology, says Mactek’s Holmes. “You
says Eric Olson, a senior product manager with could continuously monitor up to eight points using
ABB. “This could include processes such as those a PC equipped with eight USB HART modems.
in the oil and gas or wastewater treatment indus- That’s very do-able,” says Holmes.
tries, where there are many satellite I/O stations.” “For software, you could use a dedicated data
Foxboro’s Piper recommends that users employ acquisition package such as Wonderware’s InTouch
a diagnostic tool such as ExperTune’s PlantTriage, software, or something as basic as a Microsoft Excel
to monitor loops and field instrument performance spreadsheet. I think there are plenty of operations
and identify potential troublespots that could ben- such as bakeries or small specialty chemical plants
efit from full time monitoring via HART. that can’t justify spending the money for a large con-
HART can play an important role in refineries, trol system. But with HART input and a PC, you can
mills and power plants that employ process safety build yourself a quick and dirty DCS,” he adds.
systems. To maintain a system’s Safety Integrity Level
(SIL) rating, safety system valves must be periodically Liberate the Genie
tested to ensure that they will move if called upon in Having HART capabilities at your disposal, but
an emergency. Full-range tests can be conducted only not taking advantage of them, is like keeping the
during plant shutdowns, but these occur only every genie stuffed in the lamp. By carefully examining
two to three years. However, by stroking a valve by as your facility, looking at the HART capabilities you
little as 10 percent, which does not disrupt a process, already have, and carefully weighing the need for
plants can ensure the reliability of their safety valves. additional investments, you can take full advantage
A valve positioner has the ability, via HART, to con- of opportunities for improvement.

JUSTIFYING HART
Selling UP!
Justifying HART Investments to Management
“A
no-brainer!” The no-brainer attitude stems from the fact that
“Mom and apple pie!” most plants already have made substantial invest-
“So obvious, it’s barely worth ments in HART technology. So, say the experts, it
discussing!” only makes sense to put those capabilities to use.
These are some of the immediate responses “If you’ve bought 4-20 mA instrumentation in
from systems and instrumentation suppliers and recent years, chances are good that it’s already
users when asked how maintenance and operations HART-enabled,” says Prasad Raghavendra, a
departments should go about justifying investments
in HART technology to plant managers.
But a no-brainer to a plant maintenance manager
A no-brainer to a plant maintenance man-
may not necessarily strike the same chord with a ager may not necessarily strike the same
senior financial manager. Consequently, personnel chord with a senior financial manager.
who want to start reaping the benefits of HART need
to develop strategies that take into consideration
the HART capabilities the facility already has (e.g., systems product manager for Honeywell. “And if
installed HART instruments, HART I/O, etc.), ad- you’re considering buying new instrumentation, the
ditional investments needed, and the benefits the incremental investment in buying HART-enabled
company will realize from those expenditures. devices rather than those capable of only 4-20 mA
Intelligent Field
ERP
Communication CMMS
• HART data integration with HMI
control, asset management
and safety systems
• Systems communicate with

HART devices “full time”–
HART Data
both 4–20mA and digital

Control
• Systems detect impending
problems and provides alerts
• Continuously validates control

HART
signal integrity
I/O
• Automatically detects deviation
in device/system data
• Continuous device diagnostics
• Multi-Variable device data

available to improve operations HART Field Devices

JUSTIFYING HART
is extremely small. So it becomes easy to decide to unnecessary maintenance, particularly on valves.

go with HART without having to make a big case.” “You’re going to make your workforce more
If you’ve purchased your control system during efficient, because you can get them focused on
the past few years, odds are good that it has native working on the right stuff,” says Jim Cobb, market-
HART I/O, meaning you can bring the digital HART ing manager for Emerson Process Management’s
signal, including diagnostic information, secondary Rosemount Division. “This is especially true of the
process variables, etc., directly into the system. valve diagnostics. It’s probably the one that hits you
In addition, HART Communication operates over right in the face.”
existing wires, so much of the physical infrastruc- Being able to keep an eye on valve performance
ture you need already is in place. via HART and compare it against valve signatures
Most plants, however, will have to invest at least a will reveal to plants when the device actually needs
small sum in equipment and/or software to take ad- maintenance.
vantage of HART capabilities. These include HART ‘If your current mode of maintenance involves
multiplexers, which strip the HART digital signal shutting down every six months and checking
from the 4-20 mA signal and route it to PC-based valves, transmitters, etc., the use of HART may en-
software applications equipped to accept HART in- able you to reschedule and reduce those activities,”
put; and HART modems, which are PC I/O cards that says Marcelo Dultra, vice president of sales and
enable users to communicate with devices via HART. marketing for Smar International. “If you can show
In putting together a case for those investments, that a valve can run eight or nine months, you might
maintenance and operations departments should not have to shut down every six months. There’s
stress to management the situations that won’t occur enormous value in that.”
as a result of using HART. Specifically, HART will In plants that employ safety systems, testing
enable plants to avoid unplanned shutdowns and safety valves periodically is absolutely essential. Af-
Inergy’s Bakersfield Plant Moves Gas With HART

Inergy, headquartered in Kansas City, Mo., is tank that would send readings on temperature
a major provider of propane and services to and level back to Inergy’s control system. “We
600,000 customers. While most of its operations could have put separate temperature and level
are in the Southern, Midwestern and Northeast- transmitters into each of 40 tanks, but that
ern states, the company operates a natural gas involved quite a bit of instrumentation and
liquids site in Bakersfield, Calif., that includes wiring. Instead, we purchased instruments from
processing, storage and terminal services. K-Tek, each of which was able to monitor both
Propane manufactured at the facility is stored of those variables,” says Clifton.
in bullet tanks, each of which holds 10,000 to The transmitters send 4-20 mA level read-
15,000 gallons of propane. It is critical for the ings back to the plant’s programmable logic
company to monitor levels and temperatures in controller equipped with a HART gateway and
each of the containers, since propane expands use a HART digital signal to communicate tem-
as temperatures rise. If pressure increases too perature and level information. Using the two
much, the company must vent gas into the at- readings, the system is able to calculate the level
mosphere and risk violating stringent California in each tank accurately and display it on the
environmental regulations. system’s HMI.
Ken Clifton, instrumentation and electrical su- “With this system, we’re able to get two read-
pervisor at the plant, says personnel used to rely ings for the price of one, and it’s worked well
on sight glasses and “spinner” gauges mounted for us,” says Clifton. “We’ve had a few minor
in the tanks to visually judge levels. “Our people problems, but none involving use of the HART
would have to actually go out there and look at Protocol.”
the tanks to determine the levels,” he says, add- “In fact,” adds Clifton, “all the instrumenta-
ing that it was inefficient. tion we put in this plant has the HART Protocol,
To improve the situation, Inergy decided three because it makes troubleshooting easy for our
years ago to install field instruments in each instrumentation techs.”

JUSTIFYING HART
The HART Difference

Analog
12 mA
Control System +4–20 mA HART Transmitter

Two Simultaneous Communication Channels 35–40 Data Items Standard in Every HART Device!
• 4–20mA channel—fast, robust & reliable • Device Identification
• Digital two-way communication channel • Calibration Data
• Process Variables
for device status, diagnostics, alerts, etc.
• Diagnostic Alerts
ter all, the last thing you want is for a valve to stick Geiger. “He may have thousands of instruments and
in an emergency. Under IEC and ISA safety system has to keep all of those different ranges and param-
standards, a plant system’s probability of failure on eters updated. The best way to do that is to have all
demand can be reduced by increasing the frequency of the information available in a single database.”
of system testing. Increasing frequency once was Sasol, an international chemical manufacturer,
impractical for many plants, since valves could can testify to the value and benefits of HART based
only be tested during shutdowns. However, plants on its use in its South African solvents opera-
now can run partial-stroke tests in which a valve is tions. In 2000, as part of the planning process for
moved only a small percentage of its full range, to construction of a butanol plant, the company set
ensure that it functions properly in emergencies. as goals the detection of field instrumentation and
If the valve actuator is HART-capable, the device valve problems before they could cause production
can confirm its actual movement to operators and loss; migration from run-to-failure maintenance
maintenance personnel. mode to predictive maintenance strategies; a reduc-
Even in terms of day to day safety for workers,
HART can play an important role. Norit Americas
manufactures activated and reactivated carbon at its
“HART will enable plants to avoid
plant in Pryor, Okla. The manufacturing process re- unplanned shutdowns and unnecessary
quires the usage of acid, coal, steam, burners and com- maintenance, particularly on valves.”
pressed air, creating a hazardous work environment. By
replacing conventional analog monitoring devices with
HART-capable devices, maintenance personnel are tion in control valve maintenance expenditures; and
able to run diagnostics and perform calibration checks improved change management.
and even make adjustments from the safety of the Sasol saw HART-based asset management as the
equipment control room through the use of a handheld means for achieving these ends. Among the benefits
set. In addition, the plant recently installed an asset the company realized through the use of HART-
management system workstation in its maintenance based asset management just in the past two years
building, allowing personnel to work on HART-capable are savings of nearly $2 million on prevention of
devices without leaving the structure. plant trips, the avoidance of unnecessary repairs,
Fritz Geiger, a systems product manager with and detection of faulty or poorly optimized valve
Siemens, notes that HART Device Descriptions positioners.
enable users to store all or nearly all of their in- Obviously, no two plants are alike, and results
strument data in a single database, thus improving that each can achieve through the use of HART can
organization, reducing expenditures on multiple vary widely. Based on their experience working with
pieces of equipment and software, and making a wide variety of users, systems and instrumentation
more efficient use of personnel. vendors have come up with a number of implemen-
“This provides high benefit for the user,” says tation tips to consider and pitfalls to avoid:

JUSTIFYING HART
Implement solutions gradually Be specific about your goals

Emerson’s Cobb notes that HART can be effectively Be specific about how you want HART to meet
implemented gradually, by tiers, making it easier to your needs, advises John DuBay, instrumentation
budget investments over a long period. ”At the low product manager for Meriam Process Technologies.
end of investment, you can stay offline and simply “Predictive maintenance is a great story, but many
monitor loops on a manual basis periodically. This can end users aren’t sure what diagnostics they’re look-
be done in the field with a handheld communicator or ing for. If you ask them about the specific diagnos-
by hooking up a PC equipped with asset management tic capabilities they’re interested in, they’re not
software, including data on all your instrumentation,” always sure.”
says Cobb. “At the next level up, you can establish
Provide easy access to HART data
To achieve the benefits of online configuration
“You’re going to make your work- and diagnostics, operations and maintenance per-
force more efficient, because you sonnel need to cooperate. However, that situation
can get them focused on working often is the exception rather than the rule, says
DuBay. “Not many operators are eager to open
on the right stuff.” up access to their maintenance crews because
they’re fearful that devices could be reconfigured
continuous monitoring via a separate asset manage- incorrectly or by accident.”
ment system. And, beyond that, if your plant has
invested in a control system with HART I/O, you can Know where the ROI is coming from
bring the secondary variables directly into it.” Masoneilan Digital Product Specialist Leo Hughes
advises that users should not expect to get substan-
Rely as much as possible tial maintenance-related ROI from new HART-
on existing equipment enabled digital valves. “The big rate of return is
Steve Todd, marketing director for Moore Indus- on the existing valves,” says Hughes. “You can
tries, which manufactures HART multiplexers graph a valve’s performance over time and see that
says, “We’ve found that customers that stand to it plateaus at a high level of performance when it’s
gain the most from HART technology are the ones new. You want to know where’s the drop-off from
that can leave as much existing equipment in place that plateau, and how steep it is.”
as possible, yet still make significant, cost-effective
process improvements. For example, if a customer Minimize scan time with multiple masters
wants valve position feedback at the control room, If you plan to use HART to continuously monitor
he can go the traditional route and run additional your field devices, update parameters, and cycli-
wiring back to the control room that provides this cally read additional values, make sure you have a
data. This gets expensive fast. A second alterna- suitable number of HART masters, says Siemens’
tive, though, is for the customer to leave everything Geiger. “If you just have one master talking to 32
else alone, and install smart HART controllers on field devices, you’ll wind up with scan time of five
the existing valves. Then, extract the stem position or 10 minutes. You don’t want that.”
data from the HART digital data using a HART
interface instrument installed in the control room.” It’s about work processes, too
Technology alone won’t deliver HART benefits if
Demand interoperability from vendors your workforce fails to alter its work processes.
“While HART is a very open protocol, not ev- “If they continue to do everything in the same
ery company subscribes to it,” says Honeywell’s way, even after they’ve put in some of these
Raghavendra. “Consequently, buyers should HART connections and asset management soft-
make sure from their vendors that the field device ware packages, they’re not going to get the pay-
and/or system fully complies with the protocol as back that they should,” says Cobb. “They need to
defined by the HART Communication Foundation. change their work practices to take advantage of
Customers also should encourage their vendors to the fact that the transmitters are delivering more,
register their devices with the foundation.” very valuable information.”

FUTURE HART
HART to the Future!

HCF turbocharges plant communications with Enhanced
Device Description Language and Wireless HART
H
ART has been a mainstay of process Organizations responsible for other digital field
automation for more than a decade, but communications protocols, including Fieldbus
don’t mistakenly equate its maturity with Foundation and Profibus Nutzerorganisation
stagnation. (PNO), have adopted the use of DDL as well. In
The HART Communication Foundation (HCF) 2004, the International Electrotechnical Commis-
staff and its members have been working for the sion designated DDL as an international standard.
past several years on enhancements that will
increase the HART protocol’s value to users. The
“Wireless HART will improve their ability
fruit of those efforts will become evident during
the coming months with the release of the new to establish full-time digital connectivity
Enhanced Device Description Language (EDDL) to field devices. It will lower the cost
and a wireless version of HART.
EDDL represents an “upgrade” to the DDL that to add points to a HART network, reduce
has been an important component of HART Com- wiring and make sensing more
munications since the very beginning. Instrument
ubiquitous throughout installations.”
vendors use DDL, a text-based language, to write
Device Descriptions (DDs), which are binary files
that identify their products to a host system and As “smart” field instrument technology progress-
provide the system with their operating parameters. es, suppliers embed more capabilities in them,
(DDs are analogous to driver files provided to PC including the ability to transmit information on
users by the makers of printers, scanners and other additional variables, perform increasingly com-
peripherals. The driver allows the PC to recognize plex math functions, provide more sophisticated
the device, configure it and control its operation.) diagnostics, etc. As a result, configuring asset man-
EDDL Benefits Device Suppliers

• Covers all devices—from
simple to complex
• Efficient development of DD’s
• Operating System independent
• Stable EDD
Users
standard
• Universal tools for all devices
• Lowers devel-
• Consistent look & feel
opment and
• Highly reliable and robust
support costs
• Safe operation
• Compatible with existing devices
• Protect investments
• Lower maintenance costs
• Lower training cost

FUTURE HART
agement and control systems to use this abundance Foundation joined the development effort.
of information has become a more complex task. Ed Ladd, HCF’s director of Technology Pro-
Complicating things further is the fact that vendors grams, says some vendors already have added
must develop and maintain separate DDLs for EDDL capabilities to their products and adds that
every different host system. major systems vendors will incorporate it into con-
To ease the burden on users and vendors alike, trol systems starting early next year. To make their
HCF, the Fieldbus Foundation (FF) and PNO have systems EDDL-capable, systems vendors must
been working together for the past three years to add an EDDL Host Service Module, which will be
develop an enhanced version of DDL that gives available from HCF, FF and PNO.
vendors the ability to add new capabilities to DDs Among the most noteworthy improvements
while improving cross-platform compatibility and enabled by EDDL is instrument vendors’ ability to
facilitating device set-up. More recently, the OPC use DDs to dictate the look and feel of graphical
EDDL Enhances HART Communication

• Electronic Device Description Language (EDDL) is the most conforming to HCF, FF, PNO and OPC specifications all
installed and important digital communication descriptive use EDDL as a means of interpreting device parameters.
language in the manufacturing and process industries.
• The EDDL enhancements provide new capabilities to
• EDDL is a text-based language used to describe the benefit users in taking full advantage of the intelligence
standard and unique characteristics of field devices. in millions of smart HART-enabled measurement and
HART was the first protocol to implement EDDL - which valve actuator devices. The enhancements provide users
enables suppliers of HART-capable instruments to with more information about the connected device while
define and document their products in a single, open giving device developers the tools they need to provide a
and consistent format. This format is readable by many consistent look and feel, regardless of the host application.
devices including handheld communicators, control
systems, PC’s and other process interface devices that • The EDDL enhancements include improved data
support DDL. visualization and display capabilities – like waveforms
and valve signatures, a standardized method to access
• Automation suppliers use EDDL to create Device Descrip- historic measurement or device performance informa-
tion (DD) files that provide a standardized method for tion and enhanced tools for high-level information
host systems to access and display valuable parameters – such as algorithmic relationships for complex device
located in field instruments so that the full capability of parameters - display and use in control systems.
the device can be accessed via the protocol.
• EDDL enhancements include an improved user interface
• EDDL is used to describe such parameters as device with support for menus, windows, tabs and groups and
status, process data measurements, device diagnostics, added graphic support for graphs, trends, charts and
multi-variable measurements and device configuration dial indicators. The enhanced EDDL further standard-
information in a digital format. As applied in the HART izes the user interface for managing intelligent devices
Protocol, this digital information is imposed on top of and eliminates the need for Windows resource files,
the industry-standard process control signal of 4-20mA. supplemental files, and other DD modifications previ-
EDDL allows the control system to read and format this ously required by some asset management applications.
information making it valuable to the user.
• The new EDDL enhancements enable users to interact
• Developed in a cooperation with Fieldbus Foundation, with their intelligent devices in new ways. Graphs,
Profibus and the OPC Foundation, the enhanced EDDL charts, and calculations assist in the configuration of
extends the capabilities of Device Description Language devices including complex instruments such as digital
to provide an industry-standard solution for advanced valve controllers, radar level gauges and multivariable
visualization of intelligent device information to main- meters. The enhancements also support storage of
tain the proven integrity of existing DD technology historical data from field devices for troubleshooting
across all four communication technologies. Devices and diagnostics.

FUTURE HART
interfaces to instrument information and set up, signal either to supplement or replace the wired
regardless of host platform. transmission of digital data.
“Using the current DDs, device attributes show HCF’s Wireless HART Working Group, compris-
up in a hierarchical tree,” says Ladd. “But with the ing representatives of numerous instrument and
new interface options and graphical capabilities, systems providers, began development of the Wire-
device suppliers create actual windows that enable less HART specification late last year and set March
users to see all of the pertinent information about 2006 as the goal for completion of the specification,
says Kelly Orth, distinguished technologist with
Emerson Process Management’s Rosemount Divi-
“Some vendors already have added sion and leader of the working group.
EDDL capabilities to their products “HART is a very lightweight protocol, so it is
relatively simple to ‘tunnel’ HART messages inside
and major systems vendors will wireless data packets,” says Orth. “At this point,
incorporate it into control systems we’ve generated a list of almost 50 requirements of
starting early next year.” how we want a Wireless HART system to behave.”
Orth estimates that only 5 to 10 percent of users
who have installed nearly 15 million HART-enabled
intelligent instruments. And, with the exception of devices use anything more than their 4-20 mA
things like colors, fonts, etc., that data will appear analog capabilities to communicate with higher level
the same way on System X, System Y or System Z.” systems. As a result, most users are missing the
Because vendors will not have to develop or opportunity to capture data that can vastly improve
maintain DDs for each host system that commu- their operations and maintenance capabilities.
nicates with their field devices, development and “Wireless HART will improve their ability to
maintenance of device description files should be establish full-time digital connectivity to field
far less complex, he adds. devices. It will lower the cost to add points to a
EDDL also will enable the incorporation of HART network, reduce wiring and make sensing
graphical elements, such as valve signatures, x-y more ubiquitous throughout installations,” he says.
graphs and bar charts, directly into the displays, The Wireless HART Working Group is consider-
eliminating the need for separate applications to ing a “mesh network” architecture for the protocol
display the data, says Ladd. to deliver reliable communications. Unlike point-
The enhanced DDL also allows persistent stor- to-point networks, in which all nodes communicate
age of data related to field devices. For example, directly with a line-of-sight “base” station, mesh
users will be able to store multiple valve signature networks allow nodes to communicate with one
files generated by DDs and compare them to their another, establishing ad hoc, redundant paths to
valves’ current states, enabling users to more easily the base.
and quickly evaluate each device’s performance “This improves reliability,” says Orth. “If a par-
and whether maintenance is necessary. ticular path is blocked, there are other ways for the
EDDL also allows vendors to include in DDs message to get through. Mesh networks also scale
instructions to host systems to execute advanced well. You just add more repeaters or routers without
math functions that provide users with important having to add much power. Also, the bigger a mesh
information about the status and operation of their network is, the more reliable it is, because more
instruments. redundant pathways are automatically created.”
Wireless HART represents the other imminent Point-to-point networks are really just a subset
improvement to the HART protocol. Today, HART of mesh networks, so the Wireless HART solution
enables communication of a device primary value will cover these applications as well.
over standard twisted-pair wiring, using a 4-20 As part of the development of Wireless HART,
mA signal, while secondary values are digitally the working group is coordinating its activities with
“piggybacked” on the analog signal via Frequency other industry wireless organizations, including the
Shift Keying or Phase Shift Keying. With Wire- ISA SP100 Wireless Committee, to ensure continu-
less HART, the primary value may still be carried ity and uniformity with wireless standardization
via wiring, but users will be able to use a wireless efforts currently under way.

HART0409_07_EDIT.qxd 8/24/04 10:28 AM Page S-7
h a r tf o r w a r d ●●●●
Get Connected with HART

P OWER. For centuries peo-
ple have tried to harness,
create and control it. In today’s
Regardless of the make and vintage of your con-
trol system or the type of HART-enabled field
devices you may already have installed, there are
economy, the ability to use the many solutions available from the 150+ HART
power at your disposal is the Communication Foundation member companies
name of the game. Corporate that can help you put the POWER of HART to work
objectives typically include: low- in your plant.
ering cost, increasing availability, HART is the easy, low-cost, low-risk and high-
improving operations
and optimizing assets.
Sound familiar? In this 4th annual HART
Field instruments are
becoming more intelli- supplement, we present ideas,
gent with advanced
functions and diagnostic information and testimonials on
features that are power-
ful tools to achieve cor- using the POWER of HART
porate objectives.
Enabled by HART Com-
munication, today’s control systems and I/O interfaces value field communication solution that most
can painlessly integrate the intelligent information likely is already installed in your plant. Put it to
from these devices and put it in the hands of plant work, get your control system in continuous con-
operators to maximize and optimize assets. tact with the intelligent capabilities of your smart
In this 4th annual HART supplement, we present field devices—Use the POWER and see what
ideas, information and testimonials on using the HART can do for you!
POWER of HART and putting it to work with your Getting more information is as easy as contacting
plant automation, safety and asset management sys- any of your device or system suppliers or by visiting
tems for maximum benefit. As pointed out in the www.hartcomm.org. The HART Communication
first article, HART-enabled products are easy to Foundation is also here to educate and help you to
install, easy to use, and easy to justify. The pay back UNLEASH the POWER of HART. ●
is quick and within your grasp.
The article “New Value from Your Asset Data” iden-
tifies big changes that have occurred concerning real-
time communications with HART-smart field devices
and the integration of diagnostics and other intelligent
device information into the control system. There are
many ways to get and use the HART data in your con-
trol systems–the key is to start today! Finally, the arti- Ron Helson,
cle “Ready for HART? Pick a High Value Project to Executive Director
Start” provides valuable tips from users of the technol- HART Communication Foundation
ogy on how to maximize your investments. 512/794-0369; [email protected]

HART0409_10_14_LEAD.qxd 8/24/04 10:29 AM Page S-10
●●●● Po w e r o f h a r t
The Power is In Your Hands

Looking for a Digital Field Network? With HART, It’s Right in Front of You
A t BP’s PTA (Purified Terephthalic Acid) plant

in Wando, S.C., managers are facing a
dilemma familiar to their counterparts at thousands
results, but most users can achieve all, or nearly all,
of the functionality they seek by tapping into the
proven power of the HART-enabled field devices
of manufacturing facilities throughout the country: they may already own. As a result, most of the bene-
do more with less. fits they achieve through the use of HART commu-
“BP is interested in maximizing our competitive nication drops right to the bottom line.
position. Our objective is to lower costs and HART’s exceptional value to process manufacturers
increase our availability. We need to use what we lies in its ability to simultaneously communicate an
have and use it better,” says A.J. Lambert, an instru- instrument’s primary variable via a standard 4–20 mA
ment and electrical reliability specialist with BP. analog signal and additional process variables and
One way plant personnel are achieving that goal is diagnostic information via digital signals on the same
by using a previously underutilized technology that wire (See accompanying article). Initially, HART was
is providing them with a remarkably detailed view of embraced by maintenance staffs who were delighted
conditions throughout their plant and the ability to to be able to use handheld communicators and cali-
reduce asset management/maintenance costs. brators, such as those made by Meriam Process Tech-
The “silver bullet” that’s generating these benefits: the nologies or Emerson Process Management, and take
HART Field Communication Protocol. “Through the them into the field. All they had to do was attach
use of HART diagnostic information, this BP plant is them to any HART-compliant instrument—regardless
saving a hundreds of thousands of dollars per year in of manufacturer–and they were immediately able to
maintenance and production costs,” says Lambert. retrieve critical information about an instrument’s
condition, its health and its range. They could also
Feel the Power perform and document calibrations and obtain much
Of course, not every plant will attain such dramatic more digital information besides.

Since then, manufacturers have developed a wide HART, we pull only five or six valves during a shut-
range of new intelligent products and added HART down. And we have a lot more information about
capabilities to existing ones, providing even greater why we’re pulling it. Our diagnostic system can
benefits to a broader base of users. For example, show us when a problem assumed to be in a valve
field device makers such as Siemens differentiate really isn’t, but is perhaps somewhere else in the
themselves by communicating additional HART data process. In other cases, we’re able to see potential
that is unique to the company’s instruments. problems in valves before they become serious.”
Siemens pressure transmitters have the ability to Petro-Canada, which is implementing projects at
monitor and store data on the highest and lowest its Montreal and Edmonton refineries to reduce sul-
pressures experienced by the entire instrument, the fur in its gasoline and diesel fuels, will use HART
instrument’s pressure capsule and its electronics, data for troubleshooting valves and field instruments,
says Lou DiNapoli, marketing manager for the com- says Pat Castelino, PE, a managing engineer with the
pany’s pressure and temperature transmitters. company’s process technology and reliability group.
“All users have to do,” says DiNapoli, “is use a “I expect a manpower reduction in the startup
HART handheld device or our Device Description phase of the project and then on a lifecycle basis,”
Language (DDL)-enabled Simatic Process Device Man- says Castelino, when asked about potential benefits
ager (PDM) software to get that information, which is stemming from the use of HART data. “We feel that
highly useful in diagnosing process problems. If you the additional information we incorporate into our
use someone else’s equipment and software, you need asset management solutions will help us establish
the Device Description for our instrument.” more effective predictive maintenance practices.”
Several factors make HART solutions relatively easy
Sophisticated Asset Management and cost-effective to implement. First, HART does not
In recent years vendors have developed sophisti- require a costly “rip and replace” strategy. The HART
cated asset management software packages, includ- protocol runs on standard wiring that most plants
ing Yokogawa’s Plant Resource Manager (PRM), already have in place and, as mentioned, there are
Siemens’ PDM, Emerson Process Management’s AMS more than 14 million HART-enabled devices already
and Honeywell’s Asset Manager PKS, that enable in use. Often, field instruments that are not HART-
maintenance engineers to view,
track and analyze the condition of
instruments remotely. In these Asset management systems
applications, data from a device
may be split into separate analog and their ability to use
and digital signals. The analog sig-
nal, carrying the primary variable, HART data are proving
is routed to the control system,
while the digital secondary values enormously beneficial
and diagnostic data are conveyed
to the asset management systems.
Asset management systems and their ability to use ready can be easily and inexpensively upgraded.
HART data are proving enormously beneficial as Because HART represents an enhancement of the
numerous users will attest. standard 4–20 mA analog field communications
BP’s Wando plant started tapping the full poten- standard, there is no need for companies to under-
tial of HART about five years ago, when it installed take major retraining programs. Courses offered by
Emerson Process Management’s ValveLink software HCF, vendors and other sources generally provide
to gain diagnostic information from its approxi- all the background information plant personnel
mately 125 most critical control valves. need to use HART effectively.
“Before using HART, we would pull out 35-50 In addition, the HART network architecture is
valves for maintenance during shutdowns every two simpler than that of most all-digital fieldbus proto-
years,” says Lambert. “There might have been a work cols, making it the ideal option for many plants.
order or some concern about a particular valve, but “If I’m putting in a 4–20 mA system with HART, the
we really didn’t know what might be wrong with it. engineering is very simplified; it’s basically a matter of
As a result, we’d spend a lot of money and time. routing wires from the control system to the final ele-
Now, with more information from ValveLink and ments,” says a major refiner’s senior engineer.

Easy and Effective and/or downloading of archived configurations that

In addition to HART being relatively easy and cost- are right on the computer. You don’t have to go
effective to implement, plants can adopt it very through the trouble of downloading a device config-
gradually and realize benefits, even on a small scale. uration from a server, loading it into the handheld
For example, many users get their first experience configurator and then reversing the process when
with HART by commissioning instruments on the you get out to the instrument,” he says.
“bench” in maintenance shops. All that’s required is Besides producing modems for RS-232 serial
a PC equipped with DDL-enabled asset management ports, MACTek recently began producing models
software and an interface between the computer and that use USB ports. In addition to USB ports being
the field device–typically a HART modem. simpler to use, many computer vendors no longer
Thomas Holmes, president of HART modem include serial ports on their computers, making the
manufacturer MACTek Corporation, says there USB version a necessity. Also, multiple devices can
are significant advantages to using a desktop or be attached to a single USB port through the use of
notebook computer for bench or field configura- USB hubs. As a result, says Holmes, some customers
tion of HART-enabled devices rather than using have been able to set up small monitoring/data
handheld configurators. acquisition systems using several USB modems.
“All of the information you need about all of the “There’s one customer doing a fiscal metering
devices you use is right there on your computer’s application involving custody transfers of product. He
hard drive. You can do signal processing, a host of needs high accuracy and reasonable sampling rates,”
higher-level diagnostic applications data storage, says Holmes. “The application requires him to moni-
What is HART?
I n 1993, the HART Communication Foundation

(HCF) was established to provide worldwide
support for application of the Highway
addressing device status and diagnostics, cyclical
process data including floating-point digital value;
engineering units, data quality and status. The
Addressable Remote Transducer technology—or protocol also enables field devices to continuously
HART Field Communications Protocol. The HCF publish their process data and standardized
owns the HART technology, manages the operating procedures (e.g., loop test, current loop
protocol standards, and ensures that the re-ranging and transducer calibration).
technology is openly available for the benefit of Every HART device includes 35–40 standard
the industry. The ARC Advisory Group, Dedham, pieces of information, which are easily
Mass., estimates that, of the approximately 40 accessible by all HART-enabled systems. These
million field devices installed worldwide, 26% are include device identification, basic calibration
HART-enabled, making it the most widely used data, process variables (measured and
protocol for smart field instrumentation. calculated) and diagnostic alerts. All HART-smart
HART is a hybrid communications technology field devices continuously assess and monitor
in which a modulated, two-way digital signal is their own performance and return diagnostic
imposed on the industry-standard 4–20 mA status information with every message.
analog signal carrying the primary process A HART innovation was the creation of Device
variable. The digital signal conveys additional Description Language (DDL)–an object-oriented,
process variables, device status and diagnostics text-based language for modeling the character-
information that can be routed to asset istics and real-time capabilities of intelligent field
management, process control and safety devices. Instrumentation suppliers use DDL to
systems. This means that HART provides two create a Device Description (DD) file, which is
simultaneous communication channels on the similar to an electronic data sheet describing all
same wire–the industry standard 4–20 mA capabilities of the smart field device so that the
channel for fast, reliable and robust control (PV) DD-enabled host systems can communicate with
and a digital channel for real-time communi- all device features. In early 2004, the
cation of additional process/device information. International Electrotechnical Commission (IEC)
HART includes a standardized application layer approved DDL as an international standard.

HART0409_10_14_LEAD.qxd 8/24/04 1:34 PM Page S-14
tor eight HART loops. They are using eight USB of terminations you have to do per point for field
modems, connected to two four-port hubs, which, in devices,” says Pat Moyer, Rockwell Automation’s mar-
turn are plugged into two PC USB ports. They’re keting manager for distributed I/O.
using Emerson Process Management AMS Device Like a multiplexer, smart, distributed I/O sepa-
Manager to monitor the equipment.” rates the analog and digital signals and routes them
Moore Industries’ HART Interface Monitor (HIM) to the appropriate systems.
is another product particularly well-suited to small Multiplexers, including those manufactured by
MTL Instruments, enable users to sim-
plify their wiring and scale up their sys-
The digital feedback on tems incrementally. For example, by
using MTL’s MTL4840 HART connec-
the valve position also tion system, users can connect nearly
8,000 loops to a single PC communica-
can be used in safety tions port and easily configure a scan list
and get LED indications of the loop
system applications, being scanned, says Tess Thonger, a
MTL marketing manager.
a burgeoning application Because HART delivers many of the
same benefits as all-digital fieldbus pro-
for HART technology tocols, it’s not surprising that there’s
confusion in some potential users’
minds about the technology. Part of the
and medium-sized installations or those that lack problem stems from users’ mindset based on their
an asset management system, says John Emmett, initial exposure to HART, says Jim Cobb, Emerson
Moore’s London-based HART specialist. Process Management’s Plantweb marketing manager.
The Moore Industries HIM passes the 4–20 mA sig- “It’s a little bit of a case of HART having been
nal directly into a DCS or a PLC, but it also breaks out around long enough that people think they know it,
the digital signals, converts them to analog and makes but in reality, they only know the surface,” says
them available to the control system as well for alarm- Cobb. “Now, when you see some of the systems that
ing and other functions. are coming out today, they have pretty good HART
Using the two alarm relay contacts in each HIM, support. As the systems vendors start educating
users can set limits around process variables. their customers, that’s going to be the most impor-
“For example, with a smart valve positioner, you tant way the message gets out to the users.”
have the control system using a 4–20 mA signal to Joe Serafin, Honeywell’s product manager for HART
drive the valve open and closed. Using an HIM, you integration, says Honeywell tells its customers that
can read the valve position feedback over the same their choice of field communication protocols should
pair of wires and return it to the control system. In be dependent on what they want to achieve. “If they’re
addition to there being a cable savings, the alarm interested in peer-to-peer control on the wire, we tell
relay contacts act as ‘soft’ limit switches. So you can them to go with Foundation fieldbus. But if they don’t
set a trip limit within the HIM and cause a relay to want to do that, they can probably get everything else
close when the valve reaches its limit,” says Emmett. they want out of HART,” says Serafin.
The digital feedback on the valve position also can
be used in safety system applications, a burgeoning In for the Long Haul
application for HART technology (see sidebar). Few industry observers question that, in the long
Other components that enable users to implement run, the process industries will eventually migrate to
and expand their HART-based field networks are fieldbus protocols. But don’t even think about
smart distributed I/O modules, such as those pro- mothballing your HART devices anytime soon.
vided by Rockwell Automation. HART combines the reliability and robustness of
“Instead of running all of the wiring back to the today’s analog signal with the power of tomor-
control room from each individual device, our FLEX row’s digital field network. Considering the mil-
I/O is out near the field and brings the data back via a lions of HART devices already installed, the most
network. This reduces long home-run wiring runs responsible action for the industry is using HART
from multiple field devices, and it reduces the number to its full potential. ●

HART0409_17_19_INCON.qxd 8/24/04 10:31 AM Page S-17
H a r t I N Co n t r o l ●●●●
New Value from

Your HART-Enabled Assets
HART in the Control System Lets Users Realize Great Gain Without the Pain
W hile HART provides users with enormous

value through the exchange of digital data
via asset management and maintenance systems, the Source: Emerson Process Management
value of that data would leap if users could integrate
it into their real-time control systems. Fortunately,
that’s now possible.
Major control vendors who offered HART as well as
their own proprietary digital field protocols (e.g.,
Yokogawa’s BRAIN, Honeywell’s DE, Foxboro’s Fox-
Com, etc.) have yielded to user demand and enthusi-
astically embraced HART. Today, virtually every major
automation system vendor includes native HART I/O
in their control systems, meaning users can now inte-
grate secondary variables into their control schemes,
ensure that their analog 4–20mA signals represent the
actual situation in the field, and troubleshoot prob-
lems quickly to minimize process disruptions.
“A control system can be considered to have full
HART capability if it supports true, full-time com-
munication with both the digital and 4–20mA analog
signals of HART-enabled field devices,” says Wally
Pratt, chief engineer of the HART Communication
Foundation. Other important factors are smart
HART-enabled I/O with HART capability at every
channel (as opposed to being multiplexed or shared
across several channels); controllers that are HART-
aware, enabling them to use HART data; and the
ability to display HART data on operator stations. With HART-enabled field devices, operators can detect and
correct costly process overload and other dangerous conditions.
New Valuable Capabilities
Users who implement HART-enabled control sys- device. If there is a disagreement, the problem
tems gain new, valuable capabilities. Among the shows up immediately on the operator interface.
most important is the ability to validate their pro- “Information where you continuously monitor
cess data. As reliable and time-proven as 4–20 mA valve position versus the desired setpoint that you’re
signals are, external electrical noise, faulty instru- sending can represent a major cost savings, because
ments and other problematic inputs can produce if the valve is not tracking the setpoint, then your
errors that are not immediately apparent. control strategy is in jeopardy. There’s no way to do
“In control systems with HART I/O, the 4–20mA advanced control if you don’t know if the valve is
signal can be validated continuously,” says Pratt. going to the position you want,” Pratt adds.
“The I/O continuously checks the loop current for HART capabilities in control systems also enable
agreement with digital values being sent by the users to quickly detect field device problems. If a

●●●● H a r t I N Co n t r o l
system is able to display an instrument’s self-diag- Detect, Correct, Protect

nostics data as well as changes in device status, pro- In addition, HART data enables operators to detect
cess disruptions can be avoided, since operators can and correct process overload conditions. If a loop
spot and react to the problem quickly. current becomes saturated, readings go “off the scale,”
The availability of multivariable device data also and the operator essentially is blind to the situation in
enables operators to anticipate situations they might the field. Often, the problem stems from the process
not be aware of otherwise. measurement being out of range, but determining the
According to Pratt, “Most HART-enabled pressure source of the problem typically requires dispatching
transmitters also have ‘temperature’ as a secondary an instrument specialist to the field. However, if the
variable. Wouldn’t it be nice to be able to have the control system is receiving the instrument’s digital
instrument tell the control system when the instru- data, the operator is able to see the actual values the
ment temperature is about to drop below freezing, instrument is generating. Standardized device status
so a heater can be turned on, either manually or alerts also assist the diagnosis by indicating whether
automatically? All you need is the ability to read that the process condition is outside the sensor limit or
secondary variable. You can save downtime and just outside the 4–20mA range. The net result is a
possibly avoid damage to your equipment.” reduced need for emergency manpower and the pos-
HART’s Critical Role in Safety System Testing
T he HART protocol’s bi-directional, digital

communication capability has given the
technology a vital role in the testing of safety
has moved, as expected. Consequently, some
vendors are providing that capability via HART.
“The HART protocol defines a device-status
instrumented systems that protect people, the byte, which is determined by the HART
plants they work in and the environment. standard,” explains John Emmett of Moore
By their very nature, valves in a safety system Industries International. “It says things like‘ a
remain stationary nearly all the time, but in those signal has gone over-range’ or ‘a signal has
rare instances when they’re called upon to bring locked up.’ There are eight defined states in
about the safe shutdown of a process, they must HART protocol, one of which is called
work without fail. The only way to ensure that a ‘additional status available.’ That’s the one that
safety system valve will function when it’s allows manufacturers to build in their own
needed is to periodically test it. In fact, the special features, like partial stroke testing,”
length of time between tests has a major effect notes Emmett.
on the system’s Probability of Failure on Demand “Our HART Interface Module can pick up
(PFD), a factor in determining the System signals like ‘test in progress,’ so we can actually
Integrity Level (SIL) under industry regulations indicate back to the control system that a partial
governing safety systems. Lengthening the stroke test is happening. But more importantly,
interval between tests has a linear affect on the the smart positioner can detect if the valve is
PFD. So, if the length of time between tests is stuck. We can pick up that particular alert and
doubled, the PFD is doubled as well. alarm back to the control room,” adds Emmett.
“Therefore, it is imperative that these valves Emerson Process Management notes that users
be tested frequently in order to reduce the PFD of the Fisher DVC6000 Series of digital valve
and meet the target SIL rating,” says Riyaz Ali, controllers and Emerson’s AMS ValveLink
development manager for Emerson Process software for emergency shutdown solutions do not
Management’s FIELDVUE instruments. require the presence of personnel in the field
The answer: partial stroke testing. Stroking a because the controller’s software is able to to
safety valve as little as 10% does not have a provide feedback on positioner information via
significant effect on the ongoing process, but it HART. In addition, they can automatically initiate
provides enough travel to determine the valve’s partial stroke testing routines.
responsiveness in emergency conditions. Many plants using this technique have
What’s necessary in this situation is feedback extended their intervals between scheduled
from a positioner to verify that the valve actually shutdowns–results that appear on the bottom line!

With HART, processors can increase plant availability and lower operating costs.
sible avoidance of unnecessary downtime. enabled control systems are created equal. While
The availability in a HART-enabled control system some provide one-to-one I/O, others rely on multi-
of multiple variables from a single instrument gives plexed data, which creates latency. While this does
users the ability to put that data to work in their not matter a great deal in some applications (in
control schemes. which variables do not change frequently) in other
“For example, one of our customers is thinking applications such latency is unacceptable.
about doing his own level of condition-based mainte- Even with multiplexed systems, however, users
nance by taking additional information provided by can install products, such as Moore Industries’ HART
the valve—such as the number of strokes or closed Interface Module, on critical loops and place them in
times–and integrating it into the process logic,” says “burst mode.” In burst mode, a field device continu-
Dave Smith, manager, Plant Network Technologies, ously publishes data to the module. “It’s a faster way
Yokogawa Corp. of America.
The decision process will
indicate that, if a valve has Another advantage to routing
reached a level of operation as
measured by the number of HART signals to a control
strokes, the packing is worn and
the process should switch to a system rather than a
different valve, perhaps auto-
matically, says Smith. separate entity is its
“This is a big improvement
over previous ways of doing architectural simplicity
things, which involved looking
at the process variable and
deciding whether it was good or bad,” he adds. of getting information, but in addition, burst mode
doesn’t require the host to poll the devices, so there’s
Inherent Architectural Simplicity less overhead on the control system,” says Pratt.
Another advantage to routing HART signals to a No matter which control system users pick, or the
control system rather than a separate entity, such as means that the system uses to incorporate HART
an asset management system, is its architectural sim- data, they are positioning themselves to use a signif-
plicity. “There’s a lot less hardware, which means a icant source of data at the heart of the process that
lot less risk,” explains Smith. “The capital expendi- might otherwise go untapped. With this additional
ture is lower, and you don’t need multiple PCs, information in hand, operators and engineers have
multiplexers and other components.” the ability to lower operating costs and increase
Pratt cautions, however, that not all HART- plant availability. ●

HART0409_21_22_START.qxd 8/24/04 10:33 AM Page S-21
H a r t S tar t ●●●●
Ready for HART?

Pick a High Value Project to Start
When Implementing HART, Experts Advise Start Small, But Think Big
I f it’s apparent to you that HART’s potential bene-

fits go way beyond taking readings with hand-
held configurators in the field, you may be thinking
itor up to 32 of the plants most important loops,”
says a senior engineer with a major oil refiner. “That
way, you can start to realize that you can monitor
about taking some careful steps toward tapping your the health of your instrumentation and start moving
HART-enabled field instruments for value. But like from fighting fires and suffering capacity loss to
most journeys, the first steps are the most intimidat- being able to detect instrument health issues before
ing. Where to begin? What to expect? they have an impact on your business. Once you’ve
proven the value to yourself and your management,
Look Before You Leap expand to other critical areas of the facility.”
Fortunately, you can implement HART a little at a Carefully evaluate your expenditures–As men-
time, so look for projects with the most potential tioned earlier, nearly every plant has at least some of
value, start small, expand gradually, and be willing the components it needs to begin realizing HART-
to take a few prudent risks. enabled benefits. Before investing in additional hard-
Become the HART champion
in your organization–Users
involved in all aspects of plant If there are areas in which you
operations have a role to play in
implementing HART and attain- think HART can be advantageous
ing its benefits, and in most
companies, no single group to your business, why not step
“owns” HART. Consequently,
you have an opportunity to be a up and drive the effort?
HART champion in your organi-
zation. If there are areas in
which you think HART can be advantageous to your ware and software, evaluate what you already have and
business, why not step up and drive the effort? determine how much more you actually need to invest.
Select a proving ground–The fact that even the “You need a good asset database, so you can fig-
smallest HART implementation can yield benefits ure out what the critical points are in your plant,
with minimal investment can relieve some of the because they’re the only ones that really need smart
risk and anxiety that naturally accompany upgrade instrumentation,” says Louis Reeves, who is in
projects. Pat Castelino of Petro-Canada recommends charge of control valve asset management at Interna-
that users start small and carefully evaluate areas tional Paper in Pensacola, Fla.
ripe for HART-driven improvements: “It’s a big waste to spend a lot of money on mar-
”People should start off small and find very spe- velous technology where you don’t really need it,”
cific projects that they feel comfortable with. And Reeves adds. “It’s like getting an 800-horsepower
then, they should actually go through the learning engine for your Ford Mustang. Where are you going
process, deciding and quantifying benefits at various to drive it, and are you really going to use all of that
stages,” he says. Several other users and vendors had horsepower? I don’t think so.”
more specific recommendations along those lines. Joe Serafin, Honeywell’s product manager for HART
“A plant can begin by using a single multiplexer integration, says his company has a series of questions
and a stand-alone asset management system to mon- users can ask their instrument vendors to determine

HART0409_21_22_START.qxd 8/24/04 10:33 AM Page S-22
●●●● H a r t S tar t
how much information is available from their devices. to shut down processes.
”Which version of the Universal Commands (HART Question vendors thoroughly–While on a super-
5 or HART 6) does the device use? What secondary ficial level, it might seem like every vendor offers a
process variables are available from the device? Does similar level of support for HART in their systems,
the device support HART Command 48 for device- in fact capabilities vary widely. Consequently, HART
specific status? Are all available device information Communication Foundation chief engineer Wally
and features defined in the Device Description? These Pratt recommends that you carefully question ven-
are the kinds of questions users need to ask in order dor companies about their products “HART-ability.”
For example, if you’re evaluating Smart I/O,
topics for discussion with your vendor
should include:
● How much HART capability is built into
the I/O?
● Can the I/O validate and secure the 4–20
mA signal?
● What is the ratio of HART modems to
I/O channels? How often does it update
HART data to/from a device.
● How well does the system support access
to multivariable device information?
● Can you merely “push a button” on the
I/O to calibrate the loop current and/or
check the range?
● Does the I/O support multi-drop?
Even small HART implementations can yield plant-wide benefits. ● Does the I/O automatically scan and monitor the
HART–enabled field devices or is the scanning only
to determine, with all HART’s potential, if the vendor’s possible using “pass through.”
put it into his product,” says Serafin. ● Does the system make it easy to use all HART
Think in terms of benefits, not just technological capabilities? “Some vendors say, ‘Yes, we can use
capability–“If they say HART is the answer, then my the HART data,’ but it might take a little more
question is ‘How do you want to use the data?’ ” says training in one system vs. another to configure
Steve Lazzok, a support specialist with Yokogawa the thing. You want it to be easy,” cautions Pratt.
Corp. of America. “If they don’t know, it means to me ● Does it understand HART Status?
that they may be wasting their money until they have ● Can the system detect configuration changes?
a clearer plan in mind. If you’re going to bring in the “Ask questions about notification by exception.
data, how are you going to make or save money from How does the system detect changes in configu-
it? How are you going to implement preventive main- ration or status? “How do you go about perform-
tenance? How are you going to reduce accidental ing tests when there’s an error in the device?”
shutdowns? The user should consider these questions Pratt asks.
before making investments.” ● How open is the system to third party software?
Conversely, however, you should not be afraid to Train your staff in HART capabilities–Experi-
invest in HART technology on at least a small scale, enced instrument technicians and process engineers
even though the immediate payoff might not be will have little trouble familiarizing themselves with
apparent, says Dave Smith, manager, Plant Network HART’s capabilities and putting them to work, and
Technologies, Yokogawa Corp. of America. it’s unlikely they’ll require much–if any–additional
“I know that ‘technology for technology’s sake’ is a training. However, if you want an in-depth look at
difficult issue in our business, but could you have imag- HART and the way it’s used, you can obtain training
ined 15 years ago that you’d need an Internet browser from many of the vendors who sell HART-enabled
to do your job? Sometimes technology gets you some- devices and systems. In addition, the HART Com-
place that you wouldn’t have dreamed,” Smith adds. munication Foundation offers numerous courses
Users have indicated that getting the project globally, educational webcasts and a CD-based
approved is easier when you can show the ability to library of information. Need more help? Visit the
implement HART Communication without having HCF web site at www.hartcomm.org. ●

HART03_05_INTRO.qxd 9/15/03 1:35 PM Page 5
Get Connected
Contents
9 Platform for the Future

O ver the past three years, automation suppliers
have introduced new control system interfaces,
remote I/O systems, and software applications to
leverage the intelligence in HART-smart field devices for
continuous real-time diagnostics and process information.
New Capabilities Make HART a Fieldbus to Be
Real-time connections are the key to unlocking the riches of
Reckoned With. The Protocol’s Evolution Includes
your installed HART devices and to helping you lower main-
Powerful Real-Time Applications
tenance costs, increase plant availability, improve plant oper-
ations, and facilitate regulatory compliance.
14 The HART of Asset Management In this issue, we present ideas, information, and examples
HART Capabilities Offer Fundamental Value While of putting the power of HART to work—maximizing and opti-
Real-Time Connections Deliver Results mizing assets. Our 2003 HART Plant of the Year winner is
a great example of unlocking the value in HART-enabled
devices. The Detroit Water & Sewerage Department discov-
19 Time to Tap Into HART
ered the powerful capabilities of their HART devices—already
Seize the Data. There Are Major Asset Management
installed—and combined them with other technologies to cre-
and Process Improvement Gains to Be Realized ate a solution that satisfied their customers, their management,
With HART and their technicians. We thank those of you who submitted
your plant applications for consideration as the 2003 HART
23 HART Plant of the Year Plant of the Year. Don’t miss this article because it shatters
The Detroit Water and Sewerage Dept. (DWSD) the image you might have of water system applications.
Asset management is the hot topic these days and with the
Uses HART to Eliminate Metering Disputes,
tight budgets I’m hearing about, you can’t afford to overlook
Improve Reliability, and Streamline Operations the untapped value of HART-enabled devices. HART commu-
nication is a key enabler for asset management—so get con-
nected and realize the potential of your installed HART devices!
Regardless of your control system, the 150-plus members
Ad Index of the HART Communication Foundation (HCF) have cost-
effective solutions to help you. This year, the HCF is celebrat-
Advertiser Circle No. Page No. ing its 10th anniversary, and HART technology remains the
protocol of choice for communication with intelligent process
Emerson Process Management/PlantWeb 100 S-21
instrumentation around the globe. With our continued enhance-
Endress+Hauser 101 S-8 ments to the technology—including our focus on Device
The Foxboro Co. 102 S-25 Description Language and new development tools—HART
Harold Beck & Sons 103 S-22 will remain the simple, low-cost, low-risk, and high-value
process communication solution for your plant operations.
HART Communication Foundation 104 S-28
Want to learn more? Call us—we’ll be happy to help
Honeywell Industry Solutions 105 S-16, S-17 you get connected and realize the potential of your
MACTek Corp. 106 S-11 HART applications! ◊
Moore Industries 107 S-4
Ohmart/Vega 108 S-18
Siemens 110 S-2, S-3

Smar 109 S-27 Ron Helson, Director
Yokogawa 111 S-6, S-7 HART Communication Foundation
512/794-0369
[email protected]
HART ® is a registered trademark of the HART Communication Foundation.
Advertising Supplement to CONTROL S-5

HART03_09_13_FUTURE.qxd 9/8/03 5:39 PM Page S-9
Platform for the Future

New Capabilities Make HART a Fieldbus to Be Reckoned With.
The Protocol’s Evolution Includes Powerful Real-Time Applications
A s part of a major upgrade to a

plant in Sao Paulo, Brazil,
plate and specialty glass
manufacturer Cebrace sought to
improve the volume and quality of
and felt comfortable relying on its
proven capabilities in critical situations.
Using a HART-to-Foundation fieldbus
gateway developed by Smar, Cebrace
operators were able to view and control
the-field-configuration of instruments,
Cebrace and other companies are rec-
ognizing that this proven, reliable com-
munications technology is capable of
delivering much more value. HART—
data it was receiving from its plant instruments on both networks from the introduced more than a decade ago—
equipment, so it could improve main- same Smar AssetView interface. is finally being recognized as a feature-
tenance quality. Although the plant has “The benefit for us was the ability to rich, highly capable communications
a Foundation fieldbus network in pull all of our process information technology that permits full-time com-
place, the plant elected to rely on together, improve maintenance quality, munication among field devices and
instrumentation using the HART pro- and, most important, improve our mean control systems. Among the benefits
tocol for the data it needed. time between failure,” says Pestana. HART delivers to users are a reduction
According to Benedito Adalberto Pes- in costly unplanned outages through
tana, a Cebrace engineer who worked on Feature-Rich improved, real-time troubleshooting;
the instrumentation project, plant tech- While most industrial users associate better use of field assets; and a rich,
nicians were more familiar with HART HART with handheld terminals and in- real-time flow of data that enables users
to introduce new, high-value applica-
HART Technology Enhancements Increase Value to Users tions for control and asset management.
Meanwhile, HART’s presence in
HART has been in wide use for more than 10 years, but the protocol con- plants all over the world increases every
tinues to evolve and grow in value to users around the world. day. The vast majority of installed
The HCF last year finalized HART 6, the latest version of the protocol. smart instruments are HART-capable,
HART 6 enhancements provide additional diagnostics and many new capa- and many of those that aren’t can be
bilities to improve integration with plant control and safety systems—all easily and inexpensively upgraded. In
while protecting users’ investments through backward/forward compatibil- addition, the protocol is included in
ity with existing networks and devices. Consequently, HART 6 systems can more than two-thirds of all smart
communicate with HART 5 instruments and HART 5 systems can commu- devices now being installed.
nicate with HART 6 instruments. However, access to the full range of Brian Oeder, marketing manager for
HART 6 functions requires both masters and slaves to be HART 6-enabled. instrumentation maker Ohmart/Vega,
New features and capabilities support multivariable and valve/actuator noted that his company considers HART
devices, enhance status and diagnostics, increase interoperability, and compatibility to be a basic requirement
extend commissioning and troubleshooting capabilities. Among the many of any instrument in use or being sold
new features in HART 6: today. “We don’t consider HART capa-
• Device Variable Classification: Allows control systems and other bility to be something special anymore,”
master applications to determine the number and type of process- says Oeder. “We consider it something
related variables available within a device. that is absolutely necessary for doing
• Extended Device Status: Provides an additional byte for device status business. We wouldn’t think of devel-
alerts, such as "Device Needs Maintenance." oping an instrument without HART.”
• Device Variable Status: Allows field devices to assess and report on the
quality of the data being transmitted. See the Light
• Catch Device Variable: Enables devices to share process data via peer- Still, despite HART’s universal presence
to-peer communication for use in complex flow calculations or functions. in plants around the world, many users
• Block Data Transfer: Supports the transfer of large blocks of data among are unaware of the cost-effective capa-
master applications and field devices. bilities the protocol provides and the
enormous returns they can gain with vir-

“We don’t consider HART capability to be something special

anymore. We consider it absolutely necessary for doing business.”
tually no additional device investment. into their control schemes. the protocol first became available to
“When a user finally sees the light For those unfamiliar with HART, or vendors and users in the early 1990s.
about the power of the extra informa- in need of a refresher, a quick review is Technicians in the field generally
tion in HART, they discover that the in order. HART is a digital field com- attached a handheld communicator to
bulk of the investment is already sitting munication protocol that enables intelli- each instrument to obtain additional
in their plant,” says Hoag Ostling, chief gent field devices to communicate with HART-enabled data, calibrate, and con-
application engineer with Yokogawa. control systems, asset management sys- figure the device. This provides huge
“All they have to do is tap into it.” tems, safety systems, and other mainte- benefits, but in large installations such
The evolution of the HART protocol nance and configuration tools. While as refineries, months typically pass
is being driven by several key factors. HART uses the familiar 4-20 mA ana- before the device’s communication
First is the ubiquity of HART in field log standard, it piggybacks a digital sig- capability gets used again.
devices — it’s everywhere. In addition, nal atop the analog that conveys a wealth Later, users gained better access to
virtually all major vendors of control of information, including secondary HART data through multiplexers,
systems include the native ability to measurements and data useful in device HART modems, and other devices that
communicate digitally via HART on a and process diagnostics and monitoring. enable them to access the digital device
continuous, real-time basis, meaning HART’s evolution from a mainte- data remotely and store it in PC-based
users have the ability to tap the full nance and configuration tool to a highly applications for asset management. Typ-
range of data in their field devices and capable digital network for control as ically, these systems would poll each
incorporate that information directly well as asset management began when instrument just once or twice per day in
large installations—an improvement
HCF, Profibus and FF Enhancing Device Description Language over monthly onsite visits, but still a far
cry from an up-to-the-second picture of
Earlier this year, the HART Communication Foundation (HCF) entered into an instrument’s condition.
a collaborative agreement with the Fieldbus Foundation (FF) and Profibus
Nutzerorganization e.V. (PNO) to enhance the Device Description Lan- New View From the
guage (DDL) supported by all three organizations. Control System
The jointly developed enhancements will provide additional DDL con- With the inclusion of HART in control
structs and functions to support the data visualization needs of sophisti- systems, however, users suddenly had
cated devices for full-screen graphical displays and data captures for a powerful new real-time technology
performance assessment. The DDL enhancements will allow device manu- to improve plant floor visibility, trou-
facturers to describe display layouts and persistent data storage needs bleshooting, and control.
entirely within the device DD file—including graphical display elements “We have a software tool that allows
such as photos, two-dimensional plots/charts, and data groupings by win- you to have a connection to all your
dow, dialog, tabbed-dialog, table, and/or menu. HART devices at all times so you can
DDL is an object-oriented, text-based language for modeling the char- view status and make changes online,
acteristics and real-time capabilities of intelligent field devices. Instrumen- without any interruption to the process,”
tation suppliers use DDL to create Device Description (DD) files describing says Andreas Aufenanger, U.S. product
the capabilities of their smart field device products. Procedures for proper manager, Siemens. “Whatever changes
operation and read/write access to device parameters are described in the you make to a device are instantly
device DD file. DD-enabled host applications such as handheld communi- recorded in the same central database.”
cators, calibrators, control systems, and asset management systems use Invensys’ Foxboro automation sys-
the DD file to display device information and interact with the device for tems contain HART input cards with
calibration, commissioning, diagnostics, and maintenance functions. eight channels, each with its own
HART was the first protocol to implement DDL. For more than a decade, modem circuit. These features make
it has proven its value as a stable platform for suppliers to define and doc- full-time communication with intelli-
ument the capabilities of HART-capable products in a single, open, and gent field devices fast and easy.
consistent format. DDL is the standard of HCF, but soon it will become an “We’re able to speak to eight trans-
international standard of the International Electrotechnical Commission mitters at once, so we’re getting status
(IEC) known as IEC 61804-2, EDDL. and diagnostic information every sec-
ond, rather than monthly or daily,”
S-10 Advertising Supplement to CONTROL

“We’re getting status and diagnostic information from eight

transmitters every second, rather than monthly or daily.”
says Charles Piper, Foxboro’s fieldbus uration, just like everyone else, we Benefits Abound
products manager. have an explorer view of the whole sys- Here are some of the benefits that
Yokogawa offers fully redundant tem that typically shows the network, HART users can realize today:
HART interface modules for its CEN- DeltaV controllers, workstations, and Reduce plant downtime, improve
TUM CS 3000 R3 distributed control I/O cards,” says Ramachandran. “But asset productivity: “What every cus-
tomer wants out of a fieldbus like
Leverage Your HART Instrumentation HART, first and foremost, is the abil-
ity to get faster notification of device
problems, so he can avoid either a shut-
down or off-quality production,” says
Foxboro’s Piper. By integrating HART
self-diagnostic information in control
schemes or by polling instrumentation
through a separate asset management
system, users can spot potential prob-
lems before they happen.
Harold Beck & Co., a Newtown, Pa.,
manufacturer of actuators used in indus-
trial boilers and furnaces, began incorpo-
rating HART in its products about two
years ago. Scott Kemp, Beck senior pro-
cess control engineer, says the diagnos-
Condition and diagnostic information from HART-capable field instruments can tic capability embedded in a HART
be captured from control networks by online applications and integrated with device is a major boon to users who want
enterprise asset management systems. to improve management of their plant
assets and ensure their maximum produc-
system as part of the company’s Field- what we do, that I think is unique, is tivity. “The diagnostics in HART can tell
network I/O subsystem, notes Bruce show the HART devices in this hierar- you the reason the drive won’t move for-
Jensen, Yokogawa’s manager of sys- chy. That does lots of things for you. ward right now is because of this specific
tems marketing and sales support. You can go into your system, click on problem,” says Kemp. “Or it will tell you
“These modules can be installed in an I/O card and ask it to auto-sense all how many times a drive has been over-
remotely mounted units within Class of the devices for you and populate the torqued or exceeded its temperature rat-
I, Div. 2 environments and include explorer with them.” ings. These all are features that weren’t
such options as ISA G3 corrosion Systems from companies such as available in standard analog electronics.”
resistance and a high temperature rat- Siemens, Honeywell, ABB, and others Gain additional value from existing
ing of -20-70° C,” he adds. also offer their own sets of features instrumentation: Most of the smart
In addition, Yokogawa’s Plant that enhance HART’s capabilities. instruments installed throughout the
Resource Manager—its field asset By using a control system with world are capable of measuring multi-
management solution—automates data native HART support or third-party ple variables. Using the HART proto-
collection from HART devices. The add-ons from companies such as col, manufacturers can acquire the
software functions as a standalone MACTek, Moore Industries, MTL, additional digital information from their
application or through the CENTUM and others, end users can put this data devices and incorporate it natively into
system, and allows integration, man- to work in their plants at minimal cost, their control schemes or route it to sep-
agement, and maintenance of these since many, if not all, of their existing arate systems such as PC-based asset
field devices using a common database. field devices are HART-compatible. In management systems, for monitoring
Ram Ramachandran, director of sys- addition, HART operates over the equipment health in real time.
tems marketing for Emerson Process same wiring as 4-20 mA signaling, and For example, Detroit Water and Sew-
Management, touts the tight integration little additional training is needed to erage Dept. (DWSD)—this year’s win-
of HART into his company’s DeltaV bring plant personnel up to speed. ner of the HART Communication
control system. “In instrument config- Foundation’s Plant of the Year award

“Users want to validate that the instrument they believe is at

the end of a pair of wires is exactly what they expect.”
—recently implemented a HART-based 4-20 mA connection. By comparing the device with a handheld.”
automated, system-wide metering and two 4-20 mA signals, the DCS ensures In addition to validating the presence
data monitoring application (see p23). proper positioning of the valve stem. The of the expected instrument, HART
Improve safety systems: HART HART data also allows DuPont to test enables users to spot deviations in range
serves as a valuable tool to ensure that the valve safety interlock operation from and loop current, and identify “in-band”
process plants operate safely. DuPont’s the control room by placing the appro- errors that might not otherwise be appar-
DeLisle titanium dioxide production priate DCS output in manual mode and ent. For example, a Midwest refinery
plant in Pass Christian, Miss. — HART adjusting the 4-20 mA signal to open and suffered a $300,000 disruption as the
Communication Foundation’s 2002 Plant close the valve. The SPA returns a 4-20 result of a short circuit causing an erro-
of the Year — uses the protocol to pro- mA signal derived from the device’s neous measurement signal to a critical
vide key safety interlock inputs to its HART data to verify the valve position. level control loop. The problem went
Honeywell TDC 3000 DCS and its hard- Continuous validation of data and undetected, because the "in-band" error
wired safety shutdown relay system. The instrument accuracy: “Users want to to the 4-20 mA signal made it seem as
safety interlock system has a number of validate that the instrument they though the level control was function-
on/off control valves, each equipped with believe is at the end of a pair of wires ing normally. Had the level transmitter
a HART-enabled valve-stem positioner. is exactly what they expect,” says Joe and control system been HART-enabled,
Each positioner communicates with the Serafin, Honeywell’s product manager the mismatch between the 4-20 mA and
DCS via a 4-20 mA signal. Digital HART for HART system integration. “That’s digital signals from the level transmitter
data is superimposed on the 4-20 mA con- done through HART’s ability to access would have been detected in real time
nection and is extracted by a Moore the device ID. In addition, users want (seconds), allowing the disruptive shut-
Industries SPA HART loop monitor. The to make sure the configuration on a down to be avoided.
SPA then sends the actual valve-stem device is correct, and they want to do More efficient use of operations
position data to the DCS via an additional that without having to walk out to the and maintenance personnel: The use
of HART-enabled control systems and
HART Works With Other Protocols devices enables plants to optimize the
use of operational and maintenance per-
HART can easily operate in an environment that includes other fieldbus commu- sonnel. First, training existing person-
nications protocols such as Foundation fieldbus or Profibus. Products such as nel on the use of HART is relatively
Smar’s HART-to-Foundation fieldbus gateway, in use at Cebrace’s Sao Paulo quick and painless, and migration from
plant, are enabling companies to view and operate industrial networks as uni- an analog system to the analog-digital
fied entities, even though they rely on multiple communication technologies. HART protocol is relatively simple.
While HART can exist in harmony with newer digital fieldbus technolo- During commissioning, users can
gies, users should take a close look at HART’s functionality before investing view and validate loop and field device
in newer and potentially costly technologies. There’s no doubt that these configuration from their operator or
newer, all-digital protocols can bring a wealth of benefits to users, but they engineering workstations. HART’s self-
come at a cost. For example, use of these protocols usually involves the pur- diagnostic capabilities reduce the num-
chase of new instruments, new wiring, elaborate network configuration, and ber of false alarms that otherwise would
extensive, potentially costly training for plant personnel. HART technology, result in fruitless and sometimes haz-
which is mature and proven, offers many of the same advantages as the newer ardous trips to the instrument site. In
protocols with minimal additional investment. addition, HART-enabled data on equip-
“I can bring the smart information in, and the same people who took care ment health enables plants to perform
of that transmitter yesterday can take care of it today,” says Joe Serafin, Hon- more accurate maintenance and replace-
eywell. “You can probably train someone to be an expert in HART in four ment, further eliminating trips to the field.
hours. You can’t do that with other technologies. HART is very easy and sim- Gilbert Hurtubise, consulting engi-
ple, yet it gives you the core features of other digital protocols without a lot neer on Syncrude’s expansion of its
of the overhead.” Fort McMurray, Alberta, crude oil pro-
So, the next time you hear the word “HART” don’t just associate it with duction facility, estimates that use of
maintenance personnel, trips to the field, and handheld communicators. HART has enabled the company to
Instead, think: “HART: Easy, proven, high value, low risk, outstanding results.” reduce systems commissioning labor
by as much as 70%. ◊

HART03_14_15_CF.qxd 9/15/03 2:01 PM Page S-14
HART Capabilities Provide Fundamental Value

HART Fundamentals HART Data—Overview
Field-proven, global industry Digital data: 35-40 valuable data items standard in every
standard HART device
Two communication Device identification: device tag, supplier, device type and
channels simultaneous on revision, device serial number
the same wire
Calibration data: upper and lower range values, upper and
4-20 mA analog channel: for lower sensor limits, PV damping, last calibration date
fastest possible data transfer
of control signal Process variables: primary variable plus secondary
measurements and multivariable parameters
Digital channel: for
read/write access to all Status/diagnostic alerts: device malfunction,
device data configuration change, power fail restart, loop current
fixed or saturated, primary or secondary variable out
35-40 data items standard in of limits, communication error, plus more
every HART device
Advanced diagnostics and

intelligent multivariable HART Benefits
devices
Many cost-effective solutions Highly accurate and robust communication unlocks value in
for integration with plant smart devices
systems
Simple, cost-effective, high-value, low-risk, feature-rich:
Unmatched range of products easy to use and maintain
and worldwide support
Lowers cost through faster commissioning and simplified
maintenance
Real-time diagnostics and predictive maintenance alerts

enable problem detection in seconds
Benefits multiply by real-time integration with plant control,

safety, and asset management systems

HART03_14_15_CF.qxd 9/15/03 2:01 PM Page S-15
The HART of
Asset Management
Real-Time Connections Deliver Results
Improve Plant Operations Aid Compliance
Leverage intelligent device capabilities for operational improvement Enable automated

recordkeeping of
Real-time diagnostic alerts provide early warning of device or compliance data
process problems
Facilitates automated
Reduces time from problem identification to problem resolution safety shutdown testing
Continuous validation of control information and loop integrity Advanced diagnostics

increase safety integrity
Increases asset productivity and system availability level (SIL)
Intelligent multivariable
devices aid reporting
Increase Plant Availability
Integration with systems enables detection of previously

undetectable problems
“HART does the job
Device and/or process connection problems detected in real time
for us, and you don’t
Early warning enables proactive action to minimize impact pay extra for it.”
Avoid high cost of unscheduled shutdowns or process disruptions

•••
Dennis Green, Head Engineer
DWSD, Detroit
Lower Maintenance Costs
Quickly verify and validate control loop and device configuration
Remote diagnostics reduce unnecessary field checks
Predictive diagnostics and advanced problem detection

capabilities simplify maintenance
Lower spares inventory and device management costs

HART03_19_20_START.qxd 9/15/03 2:08 PM Page S-19
Time to Tap Into HART

Seize the Data. There Are Major Asset Management and Process
Improvement Gains to Be Realized With HART
A s manufacturers wrestle the

challenges of a feeble econ-
omy, a slowdown in capital
investment, and intense competition in
a global economy, many are searching
ment manufactured from the mid-
1990s onward almost certainly is
HART-capable.
Also, be sure all future instrumenta-
tion purchases include the capability to
Modest Investments Required
Most major control vendors have incor-
porated HART I/O into their systems,
enabling users to integrate digital
HART data directly into their control
for ways to wring additional value from communicate via HART. More than schemes and applications. Users of most
their existing assets. 150 suppliers offer HART on more legacy systems do not have this capa-
Yet in their quest, many of these than 600 different devices covering bility, but fortunately, a number of com-
same manufacturers are leaving a major a wide range of measurement and panies have developed innovative
source of improvements untapped. control functions. solutions to help users get the most
Most manufacturers access HART- Identify benefit opportunities: value from their instrumentation.
enabled variables only when mainte- Determine where you can gain the most Gil Hurtubise, consulting engineer on
nance personnel go to the field to benefit most quickly by tapping into Syncrude’s plant expansion project in
calibrate them. And that, say some Alberta, acknowledges users might
experts, is like leaving money on the Top 10 HART Apps have to purchase devices for HART con-
table at a card game. nectivity and data extraction, special
“When you spend money for an asset 1. Configuration/commissioning software such as Emerson Process Man-
and then don’t do proper asset manage- 2. Calibration/ranging agement’s Asset Management System,
ment or let that asset degrade, you’re just 3. Multivariable device data PCs to read the data, etc. But he adds,
not getting the return you should,” says 4. Real-time diagnostics “All of that is offset by a big reduction
Jake Oddo, leader of a process control 5. Process/device alerts in labor, because you don’t have so
steering team for Dupont’s titanium diox- 6. Control signal validation many people running around in the field,
ide business. “In DuPont’s Six Sigma 7. Safety integrity verification verifying calibration. In an application
quality initiative, we view an underuti- 8. Remote SCADA applications such as partial valve stroking, you can
lized asset as a defect. With HART, you 9. OPC/Ethernet integration tell right from your laptop or desktop PC
can avoid that situation, and you’ve 10. Asset management/optimization whether the valve is actually moving or
already paid for that HART transmitter.” not. You don’t have to have someone out
in the field watching.”
Where to Begin? the rich flow of data available from Among the additional investments
Even users who are aware of the your HART devices. plants might need to consider are:
untapped riches locked in HART- “Would you put in a massive pro- HART interfaces: An interface such
capable instruments might be at a loss gram to acquire information from sump as the HIM HART Loop Interface and
about where to begin taking advantage pumps?” says Oddo, whose DuPont Monitor from Moore Industries strips
of this resource. Here are some steps facility in Pass Christian, Miss., was last digital HART data from the instrument
to consider: year’s HART Communication Founda- for use in the control system or in appli-
Identify your HART instruments: tion Plant of the Year. “Probably not. cations based on other platforms such
The first step in many plants – particu- But would you do it to gain more infor- as a PC. For example, smart HART
larly large operations that might have mation on critical reactor temperatures? multivariable mass flow transmitters
thousands of instruments – is to deter- Yes, you probably would. In situations sense three process variables (pressure,
mine which installed instruments are where you might have temperature temperature, and differential pressure or
HART-capable. In many cases, this upsets that could cause you to go criti- raw flow). Using these data, they per-
is simply a matter of consulting the cal, you could be risking explosions and form an internal calculation to derive
plant’s asset management system fatalities, so when you start assessing mass flow, which is transmitted as a
and/or instrument documentation. A those situations, using HART is pretty 4-20 mA signal to the control system.
general rule is that any smart instru- much a no-brainer.” “Unfortunately, unless you have a

HART03_19_20_START.qxd 9/15/03 2:08 PM Page S-20
“HART may not give you everything you want,

but it could get you 85 to 90% of the way.”
HART-based control system, there is plexers enable users to save on wiring HART commands from the host com-
no way to continuously monitor the to field instruments by serving as a field puter to the field devices. A multiplexer
non-primary variables used to make interface to multiple HART-enabled also can be an integral part of the con-
the calculation,” says Steve Todd, Moore field devices. Typically, a PC acts as the trol system as a third-party I/O. As an
Industries’ marketing director. “By read- host, providing the human-machine I/O system, the multiplexer can include
ing the HART digital data on the sec- interface and performing other high- intrinsically safe barriers and other fil-
ondary variables and transmitting them level functions. The multiplexer contin- tering capabilities and provide services
as an analog signal, these variables can uously monitors the field devices, to the field device, such as galvanic iso-
be obtained in an older control system.” reports the current readings and instru- lation or power. For this type of instal-
HART multiplexers: HART multi- ment status to the host, and passes lation, no additional terminations or
space are required.
About the HART Communication Foundation HART PC modems: Users of desk-
top or laptop PCs can equip their com-
The HART Communication Foundation (HCF) is an independent, not-for- puters with modems that enable
profit organization that provides worldwide support for the HART technology. two-way communications with HART
Established in 1993, HCF is the technology owner and standards-setting body instruments. Among the leading manu-
for the HART protocol. HCF manages the protocol standards, ensures that facturers of such devices is MACTek.
the technology is openly available, and educates users through training and The devices are available for serial and
support for application of the protocol. USB ports as well as for laptop comput-
ers’ PCMCIA card slots. “Our modems
Memberships work with just about every HART com-
HCF memberships are open to any company interested in the use of HART munication software package that I
technology—suppliers, systems integrators, end users, and others. HCF know of,” says Tom Holmes, founder
membership provides many benefits including the ability to vote on matters and president of MACTek.
influencing future direction of the protocol, participation on HCF working While a PC equipped with a HART
groups/committees, access to HCF technology and tools for HART devel- modem can perform many of the same
opment, use of the HART logo, and participation in HCF-sponsored promo- tasks as a handheld communicator—
tion activities. downloading configuration information
to a field instrument, for example—PCs
HART Training Workshops generally have far more memory than
HCF workshops educate users on HART communication. Workshop sessions such communicators and are capable of
are scheduled quarterly in Austin, Texas, and Basel, Switzerland: more sophisticated tasks.
• HART Applications: This special on-site workshop provides a basic overview Protocol converters—Converters can
of HART communication and the capabilities of HART-enabled devices. The deliver HART data to control systems,
benefits and options for real-time integration with plant automation/asset asset management systems, and other
management systems also are discussed. platforms via other digital protocols. For
• HART Protocol Fundamentals: The HART protocol is relatively easy to imple- example, Smar last year introduced a
ment, but there is a learning curve. This intensive, three-day, developer-ori- converter to deliver HART data via a
ented workshop provides all the information and tools necessary to efficiently Foundation fieldbus network. Moore
develop a HART-based field device or system interface. Industries’ HART Interface Module,
• Writing Device Descriptions (DDs): This four-day consultative training ses- mentioned above, also has a HART-to-
sion covers all aspects of the Device Description Language (DDL) and how Modbus option that converts the digital
to use DDL to write the DD for a specific field device. Students leave the signal from a smart HART instrument to
workshop with a working prototype DD for their HART device. a standard Modbus RTU protocol output.
As DuPont’s Jake Oddo puts it:
HART Communication Foundation “Right now, your plant might be about
9390 Research Blvd., Suite I-350, Austin, TX 78759 10% of the way towards where you want
Telephone: 512/794-0369; Fax: 512/794-3904 it. HART may not give you everything
Email: [email protected] Web: www.hartcomm.org you want, but it could get you 85 to 90%
of the way.” ◊

HART03_23_26_POTY.qxd 9/8/03 5:40 PM Page S-23
HART Plant of the Year

The Detroit Water and Sewerage Dept. (DWSD) Uses HART Technology to Eliminate
Metering Disputes, Improve System Reliability, and Streamline Operations.
T he old adage “numbers don’t

lie” may be true in some cases,
but when buyers and sellers
rely on different sets of figures, the sit-
uation is ripe for dispute.
ing pits throughout the system. Measure-
ment devices include a variety of flow
and pressure meters manufactured by
Smar, Endress+Hauser, and ABB.
Prior to implementation of the
tem (Figure 1), which was successfully
piloted from 1996 to 1997 and is being
expanded as a $10 million piece of a
major infrastructure upgrade project.
That’s the situation the Detroit AMR/SCADA project, data was Watershed Objectives
Water and Sewerage Dept. (DWSD) recorded via chart recorders and To create the system it needed, DWSD
decided to rectify in its dealings with similar paper-producing methods. and its consultants set five goals:
suburban municipality customers Because the meters inform the utility • System dependability: Failure of any
across Southeast Michigan. Many of how much water is being used and single component could not disrupt
customers had measuring devices by which customers, DWSD’s direc- system performance, the flow of data,
operating in parallel with DWSD’s tor and its head water system engineer or the calibration work of the meter
older equipment. Invariably, the two refer to the meters as the utility’s technicians.
systems disagreed and the customer “cash register.” • Preservation of metering data: There
always argued for the lower-cost However, by the mid-1990s, many can be no discrepancies between data
reading. DWSD was forever in battles of the customers were using cash anywhere in the system, and there
to show the legitimacy of its meter registers of their own, says Head Engi- must be opportunities to recover data
readings. neer Dennis Green. The parties dis- when failures occurred.
In response, DWSD developed and agreed over consumption data and • Standardization of equipment and
implemented an extraordinary Auto- that’s where problems arose. control of versions of software.
matic Meter Reading/Supervisory Con- In response, the department approved • Minimal reliance on paper documents.
trol and Data Acquisition (AMR/ development of the AMR/SCADA sys- • Incorporation of software aids into
SCADA) system that relies on the
power of the HART communication Figure 1: Extraordinary Meter Reading
protocol to deliver consistent, reliable
data on system performance directly to
customers as well as to the utility. DWSD’s Water Board Building DWSD’s Central Services Facility
Citing the utility’s innovative RADIO RADIO

approach to real-time use of the HART
PC on
protocol, its aggressive plans to expand PC on
LAN/WAN
Oracle
database
SCADA
Master
SCADA
Master
Oracle LAN/WAN
database
its use of HART technology, and the Metering site Office of customer’s water department
typical of 276 sites typical of 85 sites
results it is achieving, the HART Com- Mobile headend for
meter calibration crew
Above-ground control cabinet
munication Foundation selected the
RADIO
Detroit Water and Sewerage Dept. as RADIO RADIO
Oracle database
its HART Plant of the Year for 2003. PLC/
RTU Community SCADA
Master PC
Oracle database
P DP P
Water, Water Management T T

Pumping stations & water treatment plants
typical of 27 sites
Everywhere Underground
meter vault
DWSD’s services extend far beyond RADIO
Detroit’s city limits to an area of more

Distributed
than 1,000 square miles including controller of DCS
approximately 40% of Michigan’s popu-

lation. Water flow and pressure are con-
trolled and measured through instruments The new SCADA and automatic meter reading system is being expanded as a
housed in nearly 300 underground meter- $10 million segment of a major infrastructure improvement program.

“HART is a stable protocol posing a low

compatibility risk for planned expansions.”
The Power of HART gence built into HART instruments

enabled them to perform calculations,
Through the use of HART, the Detroit Water and Sewerage Dept. freeing computing power in higher-
integrated a vast array of diverse field devices and technologies on a single level platforms for other tasks.
networked system that takes full advantage of HART’s digital communica- For example, the differential pressure
tion capabilities. The result is a common odometer total display throughout cells used in the system are capable of
the system that can be read via the LCDs on the HART meters just like the self-monitoring and on-board totaliza-
odometers of the mechanical meters while the PLC/RTU collects total and tion, says Dan Lacy, sales executive
instantaneous rate of flow readings to control switching between the large for Greenwood, Ind.-based Endress+
and small venturi meters using standard and extended HART commands. Hauser. E+H transmitters are used
In addition to stemming billing disputes with its customers, the throughout the water system to report
AMR/SCADA system is delivering the following benefits to the utility and pressures in DWSD’s mains and the pres-
its customer communities: sures delivered to customers, which can
• Increased ability to quickly detect and repair troubles in the distribution confirm proper operation of the commu-
system. nity’s pressure-reducing valves and avoid
• Improved safety through HART-enabled remote monitoring, calibration, telephone calls to DWSD’s Systems
and validation. Performing these tasks remotely enabled DWSD to Control Center.
reduce field crews’ need to enter potentially hazardous meter pits. In addition to approximately 750
• Greatly enhanced value from existing instrumentation without having to instruments in nearly 300 metering pits
rely on communications technologies that are not as well field-proven throughout DWSD’s service area,
as HART and that require steep investment and risk. the system consists of a PLC/RTU
• Greater accuracy in readings throughout the water-distribution system, located at each meter pit. Each PLC/
largely due to HART’s ability to preserve the full accuracy of the mea- RTU is connected to the pit’s instrumen-
suring element in a digital format. tation and is equipped with radio teleme-
• Range switching and totalization with a single instrument through HART’s try and a battery backup. The two DWSD
digital transmission of multiple variables. SCADA head-ends feature dual histori-
• The ability to drive computational functions to the field device (e.g., total- ans, each capable of maintaining up to 10
ization), which frees the higher-level PLC/RTU for tasks such as moni- years of data for recovery and analysis.
toring equipment health. Other components of the system
• Fault tolerance through the ability of HART instruments to retain a his- include 35 laptop computers that serve
tory of their readings. In addition, the system’s packet radio network as mobile SCADA masters for field cal-
reroutes signals in case of a node failure. ibration and are used to set and down-
• Creation of a computer-based historian, which facilitates analysis and load instrument parameters. DWSD also
reduces paper records. supplied its customers with approxi-
mately 90 PCs that serve as SCADA
monitoring stations, thus giving cus-
the SCADA system for maintenance, The Answer Is HART tomers access to the same data that
calibration, performance monitoring, DWSD determined that HART pro- DWSD is receiving. All laptop and desk-
and other functions. vided the best solution for several rea- top PCs run iFIX software and Oracle
At the core of the new system are sons. First, HART minimized the relational database management soft-
the existing flow and pressure trans- additional investment DWSD had to ware and can operate independently of
mitters and flowmeters. Among the make, since most of the existing the DWSD SCADA headends.
issues DWSD faced were identifica- instrumentation was HART-capable “Every PLC/RTU runs the identical
tion and adoption of a digital means and could use existing wiring. In copy of software developed for DWSD
of measuring and transmitting data addition, HART is a stable protocol by Control Microsystems and EDS,”
that would work with the variety of posing a low compatibility risk says Cliff Montgomery of Rhythm
measurement technologies already for planned expansions. Furthermore, Technologies, a Michigan consulting
in use (e.g., mechanical meters, HART enabled DWSD to digitally firm that helped design and implement
venturis, orifice systems, magnetic extract secondary variables and diag- the network. “We download parameters
flowmeters, etc.). nostic information, and the intelli- from a laptop PC running GE Fanuc iFIX

“I know these newer fieldbus technologies are the hot thing

right now, but it could have cost us twice as much money.”
software to configure the PLC/RTU for PLC/RTU calculating a volume by scan- quantify the payback on the project.
monitoring and operating a particular ning instantaneous flow rate values from “The continuing controversies over the
meter, and we upload those operating the HART loop,” says Green. “In addi- accuracy of our meters can be bottom-
parameters each day and store them in tion, the HART instrument/meter inte- less pits in terms of time and money,”
the historian, along with the HART grates far more frequent readings than says Green. “With the new system,
device serial numbers and communica- DWSD is seeking an end to those dis-
tion statistics. That way, we know the Figure 2: Took a Load Off putes. Estimated bills that err in favor
configuration of the system each day of the protesting customer have been
and when it changes.” reduced substantially.”
The AMR/SCADA system is designed Other networking technologies such
to accept readings from up to four as Foundation fieldbus and Profibus
flowmeters and four pressure devices have matured considerably since 1996,
at each metering point, each of which when DWSD began piloting its sys-
is capable of measuring and digitally tem. Nevertheless, Green says that he
transmitting multiple variables. In would still use HART, even if the pro-
keeping with the goal of fault-toler- ject were beginning today. “I know
ance, the devices, although connected HART-enabled devices allow DWSD these newer fieldbus technologies are
in a common loop, are wired to the to distribute total flow computation the hot thing right now, but it could
PLC/RTUs in a star topology, so if a responsibilities to the processors of the have cost us twice as much money,”
single device or instrument cable fails, differential pressure transmitters and he says. “HART does the job for us,
it can be taken out of the loop at the the magnetic flowmeters in the vaults, and it’s done on our standard equip-
aboveground PLC/RTU. reducing the load on the PLC/RTUs. ment that was already installed – you
The fault-tolerant philosophy extends don’t pay extra for it. It certainly was
to the PLC/RTUs and the packet radio the PLC/RTU, so the values are much ideal for what we wanted to do.”
network as well. “The system operates more accurate. This freed up the Looking ahead, Green noted that
like the Internet,” says Green. “The mes- PLC/RTU to do all the instrument health DWSD is building a SCADA system
sages going back and forth are like e- monitoring and store 31 days of 5-min. for controlling its treated water trans-
mail. Each radio acts as a repeater for its meter readings.” mission system and wastewater collec-
neighbors and automatically reroutes As part of that monitoring, HART tion system, which includes new sewer
messages around a radio that fails or that allows the PLC/RTUs to detect the types meters. “Once our customers are sat-
is suffering interference.” and brands of instruments on the network isfied with the water meters of the dis-
The customers feel better about all this. and collect their serial numbers each day tribution system, we want to integrate
“The municipalities that purchase water for a permanent record of equipment that our 54 sewer meters into the SCADA
from DWSD receive the data from their can be used in billing disputes and to system. Much of the equipment on the
meters directly rather than from the quickly identify faulty equipment. process control SCADA system also is
DWSD head end,” adds Montgomery. HART-capable, so we definitely want
“This assures customers that DWSD is So Far, So Good to bring them in,” says Green.
not adjusting or manipulating the data.” Overall, the utility is happy with the For more information on this appli-
Cesar Cassiolato, manager of pressure new system, but it hasn’t attempted to cation, go to www.hartcomm.org. ◊
transmitters for Smar, notes that his com-
pany’s differential pressure transmitters How DWSD Won
(Figure 2) are designed to retain totaliza-
tion, even in the event of a power loss. The HART Plant of the Year Award is an annual award presented to compa-
“There’s no reset upon loss of power. nies that use the real-time communication power of their HART devices.
When the power returns, you can con- The HART Communication Foundation asked its members and CONTROL
tinue to totalize correctly,” he says. magazine readers to nominate plants that are using the power of HART tech-
That meant DWSD could rely on nology. A panel of HART Communication Foundation officials and
HART. “So we decided to have the CONTROL editors reviewed the submissions, interviewed the finalists, and
HART instrument perform the integra- selected the 2003 HART Plant of the Year.
tion of rate to volume, rather than the

Leverage Your Assets
HART Communication:
It's Not Just for Configuration Anymore
W ant to run your plant

more efficiently? Would
you like to set up a better,
more automated maintenance manage-
ment program? Are you trying to obtain
More Than Maintenance
Maintenance technicians appreciate
HART because it makes their jobs eas-
ier. Techs can interrogate devices
directly from the control room, elimi-
The Gainesville Regional Utility,
Gainesville, Fla., uses HART Commu-
nication to diagnose instrumentation
problems and reduce unnecessary
trips to the field. The data is fed to
asset management information from nating many unnecessary trips out into asset management system software
your plant instrumentation? the plant. from Emerson Process Management.
Maybe you’d like to avoid process
disruptions. Or keep your plant from Figure 1: Powerful Intelligence
catching fire and blowing up.
A level transmitter at a Midwest
refinery was short-circuited by conden-
sation and created an erroneous 4-20
mA signal. The operator was suspi-
cious, but no one could find a problem
until the tank overfilled and shut the
entire plant down. The process disrup-
tion cost $300,000.
If the system and level transmitter had
been HART-enabled, the erroneous sig-
nal could have been detected and the
operator would have been alerted to the
problem before it shut down the plant.
You can create those kinds of capa-
bilities in your plant. You may already
have much of what you need to HART diagnostics mean technicians at the John R. Kelley Generating
get started, particularly if you pur- Station, Gainesville, Fla., make far fewer futile trips up the seven-story heat
chased new smart field instrumenta- recovery generator to check out questionable field devices.
tion in the past 10 years. That’s
because just about every smart field What you may not realize is that Operators at its John R. Kelley Gener-
instrument built these days is capable simplifying maintenance and calibra- ating Station (Figure 1) can check
of HART Communication. tion tasks is just the tip of the iceberg. many process problems by examining
And if you have devices with Your HART devices also have the asset management data from a PC.
HART Communication, you also have power to push your existing plant For example, if an operator suspects
a good start on what you need to run instrumentation and control systems a transmitter is not zeroing out, he can
your plant more efficiently. You’re into the 21st Century. check the asset management system
ready to begin an asset management You can use HART technology to historical data. If there’s a difference
program, obtain early alarms on pro- get started in asset management, for of 5% or more between the process
cess upsets, and increase the reliability example. HART devices have all the signal and the HART data, the opera-
of your processes. information you need to determine tor knows a problem exists, and some-
What’s more, it won’t be a device status, health, and the need for one must physically check the transmit-
major investment to obtain the infor- field maintenance. HART devices can ter and associated equipment. More
mation you need, because it’s already also determine the health of other pro- often than not, the utility will report the
there, ready to be accessed via HART cess equipment, such as control and problem is a leaking valve, found
Communication. safety shutdown valves. long before the consequences become
XI
“After nearly a year of working with HART, our reliance on
the asset management software continues to grow.”
serious and cause a system breakdown. tains the basic flow, temperature, inputs for a Triconex triple-modular
“After nearly a year of working with level, or pressure signal, the digital redundant system used for safety
the HART-capable instrumentation HART data superimposed upon the 4- and emergency shutdowns. “When
installed as part of a re-powered 110 20 mA signal contains much more the same signal needs to go to our
MW combined-cycle generating plant, information. Depending on the device, control system and the Triconex
our reliance on the unit’s asset man- the digital signal can contain 40 or safety system, we use a signal split-
agement software package continues more data items. ter/isolator from Moore Industries,”
to grow,” says Terry Gordon, instru- After a HART-enabled device is says Bart Propst, process control
mentation supervisor. “It enables us to commissioned and installed in a plant, engineer. “The Moore device
do a lot more things a lot quicker, with it provides those data items 24 hours a receives a 4-20 mA signal from a
fewer personnel than we could by fol- day, continuously. All you have to do HART instrument and sends 4-20
lowing conventional instrument main- is communicate with the device. mA outputs to the control system
tenance procedures.” and another 4-20 mA signal created
One of the finalists for this year’s The HART of the Matter from the HART data to the safety
HART Plant of the Year Award, a What can you do with all that data? system.” This lets them use the same
Solutia plant in Chocolate Bayou, Here are a few ideas: 4-20 mA sensor for control, safety,
Texas, that started up in 2000, has lots • Asset management: HART instru- and shutdown, and still maintain
of HART-enabled instrumentation. ments contain data on the health and signal isolation.
All the HART data is logged to an status of field assets, plus additional • Improve product quality: HART
AspenTech data historian and to an process variables. Software is avail- data can be used to improve pro-
asset management system. “Our able from several vendors to acquire cess dynamics and product quality.
design decision was to use as much data directly from the HART field The Solutia plant in Chocolate
smart instrumentation as possible,” devices to track calibration and con- Bayou acquires process data from
says John Forbis, Engineering Fellow figuration changes, and keep records multivariable HART transmitters.
at Solutia’s Integrated Nylon Div., St. on instrument changes for compli- Forbis says they use Valvelink
Louis. “Ninety-nine percent of all ance purposes. Asset management software to do advanced testing
instruments are HART-enabled. The systems can use the additional pro- and trim key valves to improve
only non-HART instruments are on cess variables to directly read flow, process performance.
OEM systems, such as chillers and air • Manage maintenance: At the Air
compressors. We tried another com-
Top 10 HART Apps Products and Chemicals plant in
munication technology, and it just did 1. Configuration Baytown, Texas, the asset manage-
not work for us.” 2. Commissioning ment system keeps track of 1,000
A British Petroleum ethylene plant 3. Calibration transmitters and 150 valves using
in Cologne, Germany, has about 2,000 4. Diagnostics HART data. “Plant personnel use
HART-enabled instruments and about 5. Multivariable process data asset management for routine trou-
800 HART-enabled control valves 6. Process/device alarms bleshooting of process issues, recal-
integrated with its DCS. “We plan to 7. Signal verification ibration, and verifying valve opera-
use condition-based preventive main- 8. Redundant signals tion relative to the original valve
tenance implemented via the Foxboro 9. Data for SCADA applications signatures,” says Mark Lusignia,
DCS and HART to reduce downtime,” 10. OPC-compliant data instrument engineer.
says Helmut Schult, DCS site man- • Real-time diagnostics: When prob-
ager. “Specifically, we are configur- level, pressure, and temperature data lems arise with a field instrument,
ing the system to automatically send to be used for compensation, envi- the array of diagnostic information
e-mails describing impending prob- ronmental check, or other purposes. available in HART devices makes it
lems to our maintenance department.” • Acquire process data: HART allows possible to diagnose many problems
HART Communication is being control and other systems to obtain from a PC screen. In some plants, half
used by many companies to acquire digital process data directly from of the times an instrument tech is
data for SCADA systems and DCSs. field devices. For example, the Solu- asked to go out into the plant to check
Although the traditional 4-20 mA out- tia plant at Chocolate Bayou uses an instrument, the result is “no prob-
put from each HART transmitter con- HART technology to acquire analog lem found.” Being able to diagnose
XII
“HART data showed that the calibration cycle could be
at least doubled to every six months.”
instrument problems remotely saves calibration for 122 critical devices and enjoy the benefits of HART
time and improves worker safety. from once every three months to Communication from the beginning.
For example, the Gainesville something less often. It takes four HART will simplify installation,
Regional Utility uses HART com- hours to calibrate each device, and startup, calibration, and maintenance,
munication to verify the condition four times per year seemed to be too and provide a cost-effective low-risk
and operational status of instruments frequent, but they had no way of foundation for an intelligent instru-
on top of a seven-story heat-recov- knowing how often calibrations were ment network for the entire plant.
ery generator and other inaccessible really necessary. For companies that already have
points. “It would take a technician The plant used HART data to col- existing plants with legacy instrumen-
up to an hour to go out into the lect device information and run tation, the upgrade path is different.
plant and check a single instrument,” online diagnostics. “After a year- First, take an inventory of all the
says Gordon. and-a-half evaluation period, HART HART-enabled instrumentation in
• Diagnostic alarms: When a control data showed that the calibration your plant. You probably will be sur-
system depends on a 4-20 mA signal cycle could be at least doubled to prised to find out how many installed
alone, an operator has no way to every six months,” says Ian Allen, HART instruments you have.
check the accuracy or validity of data instrument engineer. “We also got Second, map out an upgrade strat-
when a problem is suspected. With more accurate information as to egy. Non-smart field instruments have
HART-enabled systems, software can when a device actually did fail, as to be upgraded and replaced periodi-
be set up to automatically look for a opposed to waiting for the next cal- cally, so make sure that new instru-
device status problem or a perfor- ibration, so it could be repaired or ments are HART-enabled. Such an
mance problem and sound alarms replaced immediately.” upgrade path is quite easy, because
long before a problem can be detected nearly every legacy 4-20 mA instru-
in the 4-20 mA loop current. Where Do You Go From Here? ment can be directly replaced with a
• Minimize scheduled downtime: GSK For companies building new green- HART device. What’s more, the
Pharmaceuticals in Irvine, Scotland, field plants, the choice might be sim- replacement device will require no
also a HART Plant of the Year final- ple: buy only HART-enabled field change to your existing control system,
ist, wanted to reduce the frequency of instruments and system components because the HART device’s 4-20 mA
output connects to the same terminals
Finding Problems as the legacy device.
When you map out the upgrade
HART communication enables intelligent I/O systems to identify and diag- strategy, you may find that a particu-
nose process problems such as: lar process unit needs only one or two
• Loop fault: With a standard 4-20 mA signal, I/O systems can detect a prob- instruments to become an all-HART
lem only if the signal is outside the 4-20 mA range, and only if it is con- system. In such a case, you may want
stant; they can easily miss intermittent problems. A HART system can peri- to speed up the upgrade on that
odically check the 4-20 mA signal to ensure its agreement with the field unit or swap some HART instrumen-
I/O device. It detects intermittent problems and performs loop tests when- tation into the system from elsewhere
ever needed. in the plant.
• Device failure: With ordinary transmitters, I/O can detect catastrophic Third, review the migration strate-
device failure only if the 4-20 mA signal is outside the normal operating gies we show on pages S-12 and
range. With HART, internal diagnostics can communicate the status of field S-13, and see how your plant might
devices in real time, provide early notification of problems, and help you take advantage of its HART instru-
take action to prevent a process disruption. ments. Then obtain a HART server,
• Incorrect reading: When the accuracy of the 4-20 mA signal is impaired HART-capable multiplexers, HART-
by, for example, a bad connection or deteriorating sensor, the host sys- enabled I/O, or a similar HART-
tem can detect the incongruities between the 4-20 mA signal and the addi- based system from your instrument
tional process variables communicated by the HART protocol. Early detec- supplier and begin implementing an
tion and analysis of these incongruities can focus maintenance operations asset management, automated main-
and prevent shutdowns. tenance, device diagnostics, or device
status alarm application.
XIII
Unleash the P
Critical Facts About HART
• Traditional 4-20 mA analog signal is
used for control and/or monitoring.
• Digital signal carries additional infor- Point-to-Point Strategy
mation on the same wiring. • Part-time connection
• Single device
Migration Strategies for HA
• All HART smart devices continu-
HART-
ously provide process data for plant • Rem
operation—24/7. • Cen
• Off
• HART provides access to all device Analog DCS/PLC
data while the 4-20 mA analog signal Asset m
is being used for control. HART for device configuration
• Information about the status (health)
of the field device and quality of the
4-20 mA signal is in every message. HART-to-Analog Strategy
• The Process or Primary Variable • Real-time process variable data
• Device diagnostics conversion
(PV) is transmitted as a 4-20 mA sig-
nal and also as a digital value. To analog control system
• Many devices have measured or cal- Signal extracter
culated process variables in addition Existing system I/0
to the PV.
• The more you communicate with
HART devices, the more value you
receive from your investment.
HART process data
HART Device Data Analog + HART converted to 4-20 mA
Every HART device, regardless of
the supplier, comes standard with the
ability to communicate 35-40 data
items you can use to improve your HART value More HART value
operations. These data items include:
• Process Variable Values
Primary, secondary, and other values
Loop current value in milliamps
• Device Status & Diagnostic Alerts A Choice of Migration Strategies in commissioning and maintenance.
Device malfunction There are many ways to benefit from Connecting to the 4-20 mA wires, you
Configuration change the power of HART communication can interrogate a device from remote
Variable out of limits and leverage the intelligence in your locations for diagnostic information.
Primary variable output fixed smart field devices. The figures show • HART-to-Analog Strategy: Signal
or saturated several simple and cost-effective extractors communicate with HART
• Device Identification migration strategies to get more from devices in real time to convert the
Instrument tag, device type, etc. currently installed HART equipment intelligent information in these
• Calibration Information • Point-to-Point Strategy: This is the devices into 4-20 mA signals for
Date of last calibration most common way HART is used. input into an existing analog control
Upper & lower range value The communication capability of system. Add this capability one
PV damping HART-enabled devices allows them device at a time to get more of the
Loop current transfer function & to be configured and set-up for spe- power of HART.
alarm action cific applications, reducing spares • HART-Plus-Analog Strategy: New
Write protect status inventory and saving time and money HART multiplexer packaging solu-
XIV
ower of HART
Serve HART to Plant Networks
The HART Communication Founda-
tion has developed the HART Server
HART-enabled DCS/PLC/PAS
Full HART Implementation Strategy Tool to facilitate serving HART data to
RT Integration • Real-time and integrated data
• HART data part of DCS
plant networks and other high-level
• Full HART data access OPC-compliant applications. The tool
-Plus-Analog Strategy provides easy access to HART device
ote device access a data anywhere on a plant network.
HART-enabled I/0
dat
tralized device diagnostics
• Allows several applications to
T
f-line data access

HAR
simultaneously access data in a

anagement system
HART device.
• Enables popular HMI and trending
packages to access HART data.
• Connect to one or a thousand devices
using common HART I/O systems
HART-to-Plant-Network Strategy
HART data • HART data to LAN and interfaces.
• OPC-compliant HART OPC Ethernet • Cost-effective and easy to set-up
I/O with mux • Enterprise-wide access
and use.
SCADA Historical trending SPC/SQC MIS/ERP
OPC clients • Can put HART data on your desk
top, PDA, e-mail system, etc.
• Created and supported by the HART
Ethernet-TCP/IP
data Communication Foundation.
HART HART OPC server
RS-232 interface What to Do?

I/O with mux
HART-enabled I/O HART communication technology is
simple, easy to use, low-risk, and cost-
effective. As with any journey, taking
the first step is important. Here’s how
Maximum HART value to get started:
• Visualize one or more of the many
ways HART communications could
improve operations in your plant.
• Identify your installed HART
tions make it easy to communicate continuously put HART data directly devices to confirm that key measure-
with HART devices by replacing your into your control system. Continuous ments are included. If not, map
existing I/O termination panels. Your communication between the field out a plan to make all devices
analog control signal continues on to device and control system allows HART-capable.
the control system but the HART data automatic detection of problems • Provide HART technology training
is sent to a device management sys- so corrective action can be taken to your staff.
tem providing valuable diagnostics before there is negative impact to the • Explore HART solutions with your
information 24/7. Although the con- process operation. suppliers to determine your best
trol system is not aware of the HART • HART-to-Plant-Network Strategy: migration strategy.
data, this solution provides access to HART OPC server software tools • Contact the HART Communication
device diagnostics for asset manage- provide a simple, cost-effective Foundation or visit the Foundation
ment and process improvements. means of passing HART data onto web site, www.hartcomm.org, for
• Full HART Integration Strategy: your plant Ethernet network to OPC- more information and for specific
Upgrading your field or remote I/O compliant applications anywhere in cost-effective solutions you can use
system provides an integrated path to the plant. to Unleash the Power of HART.
XV
Powerful Connections
New Products Seamlessly Connect
HART Field Devices to Any Control System
I n essence, HART’s value proposi-

tion is moving more data from the
process into the control system with
an infrastructure you already own, then
leveraging that information to increase
the control system and higher-level sys-
tems. While the several-second latencies
of other approaches are usually quite
acceptable in process applications, con-
trol systems optimized for HART Com-
“HART instruments are connected to
the Industrial IT I/O system,” explains
Martina Walzer, marketing manager
of fieldbus technologies for ABB.
“HART information is then tunneled
plant efficiency. A range of connection munication can reduce latency times to to the controller via Profibus.” HART
options make it relatively easy. about 0.4 sec. per point, depending on Communications is also available
If your plant has a DCS connected the network configuration. on ABB’s legacy control systems
to a large number of HART-enabled Honeywell’s Experion PKS control including Advant, Symphony, and
instruments and field devices, the system offers eight-channel HART ana- Freelance 2000.
HART signal superimposed on the log-input and analog-output modules. HART devices can communicate
4-20 mA wiring is readily available and Both modules scan the standard 4-20 with Siemens’ systems through its
contains a wealth of useful process and mA analog signal and the HART digi- compatible remote I/O, HART modem,
device diagnostics information. tal signal. The HART digital data is HART interface, or HART multiplexer
made available to the control system products, and a HART I/O module
Control Systems Get HART over ControlNet. is offered as part of the APACS+
Most of the major DCS and control sys- “HART device information is control system.
tem vendors already have HART Com- scanned from each device and made Emerson Process Management deliv-
munication capability in their newer available for display, logic, control, or ers its DeltaV automation systems with
systems, and many have upgrade paths trending,” says Joe Serafin, Experion HART as a standard. “We feel so
for older systems. For example, in May
the Foxboro division of Invensys Figure 1: Multiplexers Link HART to Any PC
announced new I/A Series HART mod-
ules. Each module can accept up to eight
4-20 mA inputs and fully integrates
HART Communication.
The Foxboro upgrade has already
been used to implement asset manage-
ment and preventive maintenance at a
British Petroleum ethylene plant in
Cologne, Germany. The plant has
about 2,000 HART-enabled instru-
ments and about 800 HART-enabled
control valves. “We purchased new
input and output modules and installed
the newest version of the Foxboro I/A
software,” says Helmut Schult, BP’s
DCS site manager at the Cologne plant.
“We then installed the modules, and DIN rail-mounted multiplexers can be interconnected to provide communica-
configured the I/A system to recognize tion with as many as 7,905 HART devices.
the modules.” There was no need to
change field devices since they were PKS product manager for Honeywell strongly that HART is a good protocol
already HART-capable. Industry Solutions. for those not considering Foundation
This kind of system offers full-time, ABB supports the HART protocol fieldbus that the DeltaV automation
real-time HART data integration with through its Industrial IT controllers. system analog I/O is only sold with
XVI
“Signal extractors can access portions of HART data from a
device and send it to your plant control systems.”
HART capability,” says Ron Eddie, process variable values, the status and connection scheme combining master
vice president of technology for Fisher- diagnostic alerts, and the device identi- and slave multiplexers (Figure 1) can
Rosemount Systems. fication information contained in the connect as many as 7,905 HART field
HART functionality is also available HART data. devices to a PC.
on Westinghouse Ovation systems and Many control systems already have
on Provox and RS3 systems. On older the capability to communicate via a OPC Serves It Up
generations of Provox it is only neces- digital fieldbus or an OPC interface. A more versatile and powerful method
sary to upgrade the I/O terminal strip A low-cost way to connect HART of connecting HART instruments and
and the analog I/O card. For the older instruments and control valves to these control valves to existing control sys-
generations of RS3 systems, it is neces- control systems is through a commu- tems is through the OPC-compatible
sary only to upgrade the I/O electronics. nications gateway. Multiplexers, RS- HART Server Tool (Figure 2). Inex-
232 interfaces, and gateways that con- pensive and simple to implement, all
Clever Devices Fill Gaps nect HART to Ethernet, Modbus, and that is required is a PC, OPC server
If your existing DCS is not HART- Profibus are widely available. software from the HART Communica-
enabled, and if immediate plans do not The Viator HART PC modem from tion Foundation, and a multiplexer or
call for a new DCS or an upgrade to MACTek, for example, attaches to serial modem.
your DCS to make it HART-capable, a PC serial port and allows the PC The PC can be anything that runs
there are many other options. Signal to communicate with HART devices. Windows 95/98/NT/2000, from a full-
extractors can access portions of HART The modem is a good interface for blown desktop machine to a rack-
data from a device and send it to Siemens’ Simatic PDM and other asset mounted device. The PC does not
your plant control system via 4-20 mA management software. require a keyboard or a display to run
signals and/or discrete outputs. Pepperl+Fuchs has a choice of the HART Server Tool software pro-
The 2002 HART Plant of the Year HART multiplexers that convert gram, so it can be very compact, indus-
(page S-21) makes extensive use of HART data to RS-485. This serial data trially hardened, and designed for low
power consumption.
Figure 2: At Your Service The HART Server Tool software
communicates with the HART devices,
SCADA Historical trending SPC/SQC MIS/ERP and converts HART data to OPC data.
OPC clients This OPC data can then be communi-
cated to any software package with OPC
client communications.
Ethernet-TCP/IP Virtually all HMI, asset management,
HART OPC server
and soft logic software has a built-in
data
HART OPC client interface, so the HART
Server Tool can be used to connect just
RS-232 interface
I/O with mux about any application to HART field
HART-enabled I/O devices. The HART server also allows
several systems to access data from a
HART device at the same time, and it
can even be used to transmit data to
handheld wireless devices such as PDAs.
Whether starting small by extracting
The HART OPC server provides a standard interface between HART devices HART data on a limited basis for a spe-
and any OPC client. cific purpose or diving in with a fully
HART-capable DCS, using the informa-
Moore Industries’ SPA loop monitor can be recognized by a number of PC- tion you already have available from
and alarm. Signal extractors like the based software programs including your installed base of HART field
SPA extract the HART data superim- AMS from Emerson, Cornerstone from devices is a powerful, cost-effective way
posed on a 4-20 mA signal and retrans- Applied Systems Technologies, and to leverage your plant’s assets into the
mit virtually any combination of the Pepperl+Fuchs’ PACTware. A typical 21st Century.
XVII
HART Plant of the Year
DuPont Uses HART Data to Satisfy Safety Interlock
System Valve Test Requirements
F or its recognized success with

HART-enabled instrumentation,
as well as its commitment to
future system enhancements using
HART technology, the DuPont chlo-
Fail-Safe System Relies on HART Communication
Most safety interlocking at the DeLisle plant is implemented through a
dedicated DCS controller, but certain processes must be equipped with a hard-
wired relay safety shutdown system. Many of these processes use HART-
ride-processing facility in DeLisle, enabled pressure and temperature transmitters. Each of these transmitters
Miss., has been selected the 2002 sends a 4-20 mA process variable signal to a Moore Industries SPA loop mon-
HART Plant of the Year. itor that decodes the HART data superimposed on the 4-20 mA signal.
The HART Communication Founda- The SPA then sends a process variable signal derived from the HART data
tion asked CONTROL readers and its to the DCS, and it also sends fail-safe alarm contacts to the hard-wired relay
members to tell us about plants that are safety shutdown system. These alarm contacts are set to indicate high-level,
leading the way in using the power of low-level, and the presence or absence of the HART signal.
HART technology. Many worthy nom- HART-enabled instruments allow DuPont to operate the plant in a safe and
inations were received. A panel of Foun- efficient manner. “HART and the SPAs provide a solution that unlocks a wealth
dation officials and CONTROL editors of diagnostic and process information in the positioners and transmitters,”says
reviewed the submissions, interviewed DuPont project manager Joe Moffet. “This information is used to increase reli-
the candidates, and selected the HART ability and minimize the duration of required plant shutdowns.”
Plant of the Year.
Three main factors led the judges to
select this DuPont application as this
year’s winner. First, the plant uses the
power of HART even though it does not
have a HART-enabled control system.
Second, HART Communication is used
full-time in daily operations. Finally, the
plant is migrating to using HART infor-
mation for additional cost-effective solu-
tions that deliver significant benefits to DuPont is using this highly efficient TiO2 processing site as a benchmark
the enterprise today and into the future. for other facilities because of its outstanding compliance with safety, health,
The DeLisle plant produces DuPont’s and environmental requirements. DuPont plans to fully exploit the available
proprietary R-104 Ti-Pure titanium HART data with an asset management system that will provide automated par-
dioxide (TiO2). TiO2 is a white pigment tial valve-stroke testing, predictive maintenance alerts, and comprehensive
used in paint, plastics, and products management of the plant instrumentation system.
where color retention is desired. TiO2
absorbs ultra-violet light energy and it processes was with HART-enabled the safety interlock system and as an
also possesses light-scattering proper- instrumentation,” says Joe Moffet, pro- input to the control system. Like most
ties that enhance whiteness, brightness, ject manager with DuPont. “Virtually all other users, DeLisle personnel use hand-
and opacity. of the plant instrumentation is HART- held HART communicators for config-
TiO2 production requires a sophisti- enabled, and this includes instruments uration, calibration, and troubleshoot-
cated manufacturing process that used to monitor and control temperature, ing. And as we’ll see, future plans call
includes chemical reduction, purifica- pressure, level, and flow.” for HART data as a key input to an asset
tion, precipitation, washing, and calci- The DeLisle plant control and instru- management system.
nation of titanium, iron, and other metal mentation system uses the HART com- Normal plant operations are con-
sulfates. “DuPont determined that the munications protocol in a variety of trolled by a Honeywell TDC-3000
best way to control and monitor these ways. HART data is used as an input to distributed control system (DCS), and
XXIV
“Virtually all of the plant instrumentation is
HART-enabled...temperature, pressure, level, and flow.”
the DCS is also used with a hard-wired connected to the DCS via a 4-20 mA ation without HART Communication,”
relay system to control safety shutdown signal sent from the DCS to control the observes Moffet.
systems. Although future generations of valve position. HART data is superim-
Honeywell DCSs will be able to directly posed on the 4-20 mA connection, and Online Tests Reduce Outages
receive and transmit HART data, the the SPA loop monitor and alarm extracts DuPont has plans to take valve testing
present DCS does not have HART com- the valve-stem position from the HART to another level—a level that will
munications capability. data. The SPA then sends the actual reduce the number and lengths of out-
DuPont needed to add intermediate valve-stem position data to the DCS via ages required for safety interlock test-
instrumentation to extract relevant data an additional 4-20 mA connection. ing. Certain valve testing requirements
for safety interlock systems can be met
Major Benefits of HART Communication for DuPont
with partial valve-stroke testing of
1. Expedites testing of safety interlock valves, shortening plant shutdowns. emergency shutdown valves during
2. Provides fail-safe inputs to the hard-wired relay safety interlock system. normal operations. Performing those
3. Allows remote configuration and ranging of virtually all instrumentation. tests during normal operations means
4. Reduces the number and duration of shutdowns by using partial fewer shutdowns are required, and the
valve-stroke testing. required tests take less time so the shut-
5. Establishes the foundation for an asset management system. downs can be shorter.
Partial valve-stroke testing during
from the plant’s HART instruments, The DCS compares the valve control normal operations is a procedure,
and Moore Industries’ SPA HART output signal to the HART valve-stem either manual or automated, used to
loop monitor and alarm is used for position data to ensure proper position- stroke a valve over a small percentage
this purpose. ing. This data is used to verify correct of the valve’s total travel range. For
One of the main reasons DuPont functioning of the valve in normal oper- example, a safety interlock valve
selected the SPA instrument is that ations, and to test the valve when might be fully closed during normal
Moore Industries submitted the SPA to DuPont performs periodically required operations. Partial valve-stroke testing
an independent third party for failure plant shutdowns to verify operation of could be used to move the valve to a
modes, effects, and diagnostic analysis the safety shutdown system. slightly open position. This would ver-
(FMEDA). “FMEDA is a detailed cir- The HART data allows DuPont to ify valve operation without affecting
cuit and performance evaluation that test valve safety interlock operation normal operations.
estimates the failure rates, failure from the control room. Control room The present system could be used to
modes, and diagnostic capabilities of a operators place the appropriate DCS undertake manual partial valve-stroke
device,” explains Bud Adler, director of output in manual mode and adjust the testing, or an upgraded system could be
business development with Moore 4-20 mA control valve output signal to used to implement automated partial
Industries. “Using the reliability data open and close the valve. The SPA valve-stroke testing.
from the SPA’s FMEDA report, DuPont sends a 4-20 mA signal derived from “We are currently evaluating device
is able to verify that required safety the HART data back to the DCS to ver- management system that would be able
integrity levels (SILs) are attained.” ify valve position. to directly accept data from all of our
Consider the alternative: If the valve- HART instruments,” Moffet says, “and
HART Increases Uptime stem position data was not available at the system could be used to implement
TiO2 production involves many critical the DCS through HART and the SPA, automated partial valve-stroke testing.”
and potentially hazardous processes, so DuPont would have to station an instru- Other plans call for using additional
reliable operation of the safety shut- ment technician at each valve to SPA capabilities to monitor the diagnos-
down systems is of paramount concern. observe valve operation. The technician tic status of the valve-stem positioners,
DuPont uses HART to provide key would have to observe valve travel, and to provide alarm on low valve-operating
safety interlock inputs to the DCS and communicate this information to con- air pressure, and to provide relay con-
to the hard-wired relay system. trol room personnel. “There are over tacts for open and closed valve position.
The safety interlock system has a 100 control valves equipped with For more critical applications, one-out-
number of on/off control valves, each Moore SPA loop monitors, so valve of-two (1oo2) and two-out-of-three
equipped with a HART-enabled valve- safety interlock testing would be a (2oo3) configurations can be used to
stem positioner. Each control valve is labor-intensive and cumbersome oper- increase availability and reliability.
XXV
Use the Power of HART
Your Wish Is HART’s Command
L ook under your nose.

Though rarely in the
news, HART has the
largest installed base
of all digital field communications
protocols in the process industries. A
significant percentage of the field
devices in your plant are probably
means of capturing information that
can improve the operation and finan-
cial results of their plants.
Highly visible discussions have
promoted fieldbus capabilities and
the value of additional information
from remote communications. But
access to information is one thing—
users and suppliers/members on the
value of full-time HART communi-
cation. The HCF web site, www.hart-
comm.org, has been redesigned to
make it more user-friendly as well as
to provide more user-application and
user-oriented information.
HART-enabled, and you almost cer- the ability to get it full-time and with- What to Do
tainly are or will soon be under pres- out pain is another. Take another look at HART as it
sure to bring more information from Over the past 10 years, companies applies to your company’s needs.
those devices to your control, asset of all sizes have created HART-capa- Review your installed base of instru-
management, and enterprise systems. ble devices that operate in a hybrid mentation and your current buying
But many end users haven’t made fashion. These devices offer a power- requirements as they are likely to show
the connection. HART can do much ful bridge between the analog and you have a significant investment in
more than serve as an occasional digital worlds by using the 4-20 mA and potential to harness HART.
information bridge for device config- signal to feed the control system as Talk with your suppliers about how
uration and troubleshooting. In many initially designed, and simultaneously their products support the full power
applications it can serve as the pri- carry digital HART information— of HART. If they don’t, ask why. Dis-
mary means of two-way communica- which in most cases is free—with cuss your current installation with
tions for system integration. additional process variables, enhanced your suppliers to ascertain the degree
Using the power of HART commu- alarms and diagnostics information. of HART compatibility of your sys-
nication is like letting the genie out HART Communication Foundation tem. Then map out a plan to use your
of the bottle. (HCF) members around the globe assets to the fullest.
have created a cadre of instrumen- There is a growing need to use intel-
Resources Are Rising tation that collectively provides all the ligent data from the field to address
When HART technology was intro- pieces of the puzzle needed to address enterprise improvements such as per-
duced in the early 1990s, control engi- the many needs of process control. formance, quality, safety, reliability,
neers realized information from intel- And the HART protocol continues to profitability, maintenance, and man-
ligent devices was valuable, but at the evolve as a global standard. Members agement. No one bus or communica-
time there was no easy or clean way recently approved new HART 6 spec- tion technology is perfect for all
to integrate this data into control sys- ifications that expands communica- applications, but HART may be the
tems. For years, valuable information tions capabilities and is compatible simple, cost-effective, low-risk, high-
in these devices has languished in with existing instrumentation. value solution you need for improved
parts of subsystems, in limited appli- In addition, the HCF has initiated process control—and odds are you’ve
cations such as maintenance and loop a significant program to educate both already got it. ❖
check-out tools, or ignored altogether.
Meanwhile, the business situation
in the process industries has changed
dramatically, creating the need to
maximize any and all investments
and assets. Reduced manpower, bud- Ron Helson, Director
get cuts, higher profit requirements, HART Communication Foundation
and increased global competition 512/794-0369
have users looking at all possible [email protected]
I
Call for Information HART Delivers Process Data to SCADA, ERP, and Asset Management Systems
M ost users were attracted to HART

for instrument calibration and main-
tenance, but many don’t realize the
protocol has the power to be the
main digital communication bus for applications such
as SCADA, ERP, and asset management. HART provides
a wealth of the type of data required by these high-
level applications.
Automation gas chromatographs and calculates com-
pressibility constants using AGA8 calculations. This
information is downloaded to the HART-compatible
Rosemount 3095FT flow transmitters via the HtNode
every three hours. Production data is also acquired from
Daniels 2500 flow computers and RTUs,” adds Tandy.
The HtNode is a protocol translator that allows HART
devices to communicate via Modbus.
Corporations have spent billions of dollars over the past The 3095FT flow transmitter was chosen by Calumet
few years installing ERP and asset management systems. because it provides high accuracy, is physically smaller
A tremendous amount of pressure is now being applied to than most flow computers, and has a competitive price.
process plant managers and engineers to provide data to It provides differential pressure, absolute pressure, and
these systems. SCADA systems must also be upgraded to temperature inputs on the same transmitter. The HART
improve performance and reduce costs. protocol is used for communication of process variables
Existing HART instruments can accomplish these tasks
in a cost-effective and low-risk manner. Figure 1: Get Connected
SCADA Can Do More With HART

The market for SCADA applications continues to grow.
According to Russ Novak, director of consulting for the
ARC Advisory Group, Dedham, Mass., “The worldwide
SCADA systems market for the oil & gas and water &
wastewater industries exceeded $650 million in 2000. This
market will reach almost $780 million by the end of 2005,
growing at an annual rate of 3.5%.” HART devices can
be expected to play a significant role in this growth. HART-enabled field devices like the ones in this safety system
Periodic instrument adjustment is a necessity in pro- offer both a conventional analog signal (for control) and a
cess plants, but continuous monitoring can be a require- digital signal (for information).
ment for certain applications. One of these applications
is a SCADA natural gas metering system designed by and for the acquisition of device-specific historical and
Arcom Control Systems, Kansas City, Mo., for the Tejas configuration data.
Calumet gas plant in Louisiana (Tejas is an affiliate of Accurate measurement of gas flow with the flow trans-
Royal Dutch Shell). mitters is only possible with continuous composition feed-
The Calumet gas plant receives raw natural gas from back. “The gas chromatographs yield information with
offshore pipelines and separates out liquids such as respect to gas composition. The SCADA system uses this
propane, ethane, and methane. The plant consumes natu- data to continuously calculate correct parameters for the
ral gas in the process and is charged for the energy usage flow transmitters. These parameters are sent to the flow
by its suppliers. “Our firm designed a gas flow measure- transmitters via the HtNode so that that the flow calcula-
ment system for Calumet to internally verify the amount tions are adjusted dynamically based on composition of
of energy used in various parts of the process. Calumet the natural gas,” Tandy says.
needed to provide check metering for gas usage,” says Jon Another SCADA application makes use of HART’s
Tandy, a project engineer for Arcom. capability to simultaneously transmit both 4-20 mA and
The gas flow measurement system uses a combination digital signals. “HART devices were the best choice for
of protocols to gather and process data. “Our SCADA a safety shutdown system installed in a process plant.
system acquires gas composition data from Applied Two independent control systems were required because
II
“Tests validate the condition of the field device
and often eliminate unnecessary trips to the field.”
digital fieldbus protocols have not been approved by the The AMR system uses spread-spectrum radio and
standards organizations for shutdown applications,” satellite communication to extend the HART network
observes James Gray, director of I/A systems marketing beyond the traditional 10,000-ft. distance limitation.
for Invensys Process Systems, Foxboro, Mass. Spread-spectrum radios from Freewave Technologies pro-
In this application (Figure 1), each field device must vide the wireless link between the gateway and the HART
have the capability to transmit a signal to each of the two instruments. “The radios allow great flexibility in network
independent control systems. “A Foxboro I/A system is architecture through multipoint and repeater configura-
the DCS and a PLC was used for the safety shutdown tions, as well as providing reliable data transmission
system. In the I/A system, the fieldbus module interfaces of the HART messages,” Tandy adds. “With the use of
to the HART digital communication signal from the field repeaters, HART units can be brought into a single multi-
device. The PLC uses the 4-20 mA signal from the field plexer from a radius of 80 miles or more.”
device for its analog I/O as the primary input of the safety By implementing the HART-based AMR system, the
shutdown system,” continues Gray. pipeline company was able to realize cost savings in sev-
The DCS analyzes the HART signal information and eral ways. The paper chart recorders previously had to be
distributes this information throughout the control sys- collected and tabulated manually for each monthly billing.
tem. “The HART protocol is used for diagnostic infor-
mation from the field device. This information can pro- Figure 2: HART Works With Wireless
vide an active status word to the system and alert the
operator of a device fault before it impacts the perfor-
mance of the process. The status word is integrated into
the analog input block of the control system and propa-
gated throughout the control strategy if an error or device
fault is detected,” adds Gray.
If an error is found, the DCS can interact with an oper-
ator to correct the problem. “Once an error in the field
devices is detected, the operator or technician can inter-
rogate the field device from the console. Using the tools
of the I/A system’s Technician’s Workbench, a poll com-
mand is sent from the operator console to the field device
to read or perform a series of diagnostics,” Gray says.
“These tests validate the condition of the field device and
often eliminate unnecessary trips to the field.”
HART capabilities can also be extended to wireless A gateway/multiplexer in this gas metering application acts as a
SCADA applications. A major Midwest gas pipeline com- HART master and publishes data using TCP/IP.
pany planned to replace paper chart recorders on its natu-
ral gas pipeline with an automated meter reading (AMR) This is now done automatically with ongoing savings
system. The AMR system would have to be capable of estimated at $1.25 million per year. Because the HART
acquiring data from devices within a radius of up to signal is transferred over the radio link, there is no need
80 miles, publishing this field data from locations through- for a separate remote terminal unit (RTU) or multiplexer
out the Midwest to a central host in Tulsa, and integrating at each meter site. One multiplexer serves as a master to
the data with an existing measurement system. 32 HART meters and allows data consolidation.
The system architecture diagram (Figure 2) illustrates Wireless communication avoids costly cable runs to
the design of the wireless SCADA system. Multivariable each HART meter. The multivariable flow transmitters
flow transmitters provide flow measurement and data effectively combine a traditional flowmeter and three dis-
logging capabilities. These transmitters communicate crete instruments into a single instrument, yielding hard-
via HART over a wireless radio link to a network gateway/ ware cost savings of almost 30% per site. TCP/IP com-
multiplexer from Arcom. “Our Director gateway satisfied munications allow remote diagnostics and configuration,
all the requirements for the project,” says Tandy. “The reducing the need for on-site technical support. HART
Director uses HART to acquire real-time and historical provides the communication tool to create an extended
information. Data is then published to a central host via meter-reading network via spread-spectrum radio and
satellite.” satellite communication.
III
“The status and diagnostic information available from each HART
device can be used to automatically verify proper operation.”
ERP Needs HART Initial device configuration establishes a baseline for

ERP and e-business systems from vendors such as SAP, each instrument that can be compared to later readings
Baan, and Oracle cannot perform as designed without to create a history for the instrument. The baseline
extensive information from plant-floor control systems. includes not only calibration information, but also device
This information is often available through existing information such as a user-designated tag number, a
HART devices. Plant engineers can extract data from user-defined descriptor, and manufacturer’s information.
these existing devices and provide it to ERP systems. The “One specific issue in calibration management that is
expenses of purchasing and installing new devices often addressed by the HART protocol is the ability to posi-
can be avoided. tively confirm the identity of the device being calibrated.
Many food and pharmaceutical processes require exten- Prior to smart devices, there was no inherent method
sive recordkeeping with respect to batch parameters. available to confirm the unique device identification,
These parameters can include process variables such as which is obviously required to validate the calibration
pressure, temperature, and level. The multivariable capa- history,” observes Alexander.
bilities of HART devices can be exploited to extract these This observation is seconded by Aventis. “Using Cor-
secondary variables from existing devices. nerstone with the HART interface has helped us tremen-
Batch records should also indicate if each field device dously in getting new instruments configured and cali-
is operating properly. The status and diagnostic informa- brated quickly,” adds Humphreys. “Cornerstone also has
tion available from each HART device can be used to
automatically verify proper operation. The only alterna- Figure 3: Manage Change
tive in most cases is to have a field technician check and
verify device operation.
HART Helps Manage Assets

Recordkeeping also extends to instrument calibration
activities. Asset management programs can use HART
capabilities to automate much of the calibration and record-
keeping required for critical processes.
One provider of Windows-based instrument asset man-
agement software is Applied Systems Technologies, Fort
Lauderdale, Fla. Its Cornerstone software is a family of
Microsoft Windows-based process instrument mainte- Instrument maintenance management software can use HART
nance management tools. data to track calibration and configuration changes.
Aventis Crop Science uses Cornerstone software at
its plant in Institute, W.Va., to configure and manage a database that is password protected and that automati-
its HART-compatible instruments (Figure 3). “Each cally documents every change that takes place at our site.”
instrument is configured and trimmed in the Aventis Aventis uses the software in conjunction with HART
instrument shop prior to putting the device into service,” instruments to provide complete management of instru-
says Brad Alexander, Applied Systems president. “The ment calibration and maintenance. Alexander says, “The
HART protocol makes it easy for the device to be auto- Cornerstone HART maintenance station makes it possi-
matically added to the Cornerstone database when the ble to confirm existing configurations, to automatically
first connection is accomplished.” detect any configuration changes introduced in the field,
Three of the instrument shops at the site use Cornerstone, to prepare configuration edits for download to an instru-
and Aventis plans to convert the rest of the shops in the near ment upon next connection, and to reconcile any variances
future. “We use the HART interface with Cornerstone to between the instrument database records and the devices.”
configure the instruments for our use and to track any The software can also be used to provide remote diag-
changes that are made to these instruments,” says Denny nostics by periodically polling each instrument to access
Humphreys, an instrument/electrical technician with the device status. This information can then be used to alert
equipment reliability group at Aventis. “These changes the instrument shop and generate repair orders. “We use
might be made in the field through a documenting cali- the Cornerstone monitor feature with our HART Instru-
brator, in the field though a field communicator, or ment. This allows us to quickly spot any problems with an
through Cornerstone itself.” instrument including signal spiking, ground loops, or a
IV
“The HART interface is not proprietary so
we are not tied to one instrument vendor.”
problem with the primary element,” continues Humphreys. process uptime can be increased by delivering field-based
The HART protocol and maintenance management data directly to an EAM. When AMS is integrated with
software allow Aventis to use instruments from many an EAM system, early predictive maintenance warnings
different vendors. “The HART interface is not propri- can be provided about potential equipment problems.
etary so we are not tied to one instrument vendor or one Trial-and-error preventive maintenance can be
type of documenting calibrator. Cornerstone is also able replaced by prioritized work orders based on actual evi-
to handle many vendors through the use of model dence that a repair or replacement is required. Rather
libraries and calibrator libraries that can be used any- than scheduling field devices for maintenance based on
where on the LAN,” Humphreys says. “I have been com- the calendar, the EAM system receives notification from
pletely sold on the HART interface for years, but it was AMS that service is necessary and a work order to that
not until I discovered Cornerstone that the benefits effect is generated.
became so very apparent.” Integration of an online AMS with an EAM system
lowers overall maintenance costs and increases process
Application Optimizes HART uptime by providing advanced warning about potential
Condition and diagnostic information generated by field equipment failures. By combining these important
instruments can be captured from control networks by maintenance tools, companies can establish a predictive
online applications and integrated with an enterprise asset maintenance environment to keep plants running at
management (EAM) or computerized maintenance man- higher efficiency with less technician involvement.
Potential problems can be corrected before serious
Figure 4: Leverage Assets damage occurs, and the cost of maintenance can be
significantly reduced.
Syncrude Canada, Calgary, Alberta, is using HART and
the AMS system at its oil refinery in Fort McMurray,
Alberta. “During the design of our most recent
process unit, a 305,000 barrel-per-day vacuum distillation
unit, we decided to install all HART smart instruments
and hook them up to the AMS through a Honeywell DCS,”
says Gil Hurtubise, process automation specialist with
Syncrude in Calgary.
The AMS system works with HART devices to
improve plant efficiency. “The largest economic payback
is the maintenance efficiency gained by being able to
access the equipment diagnostics in order to make our
Bringing data from HART instruments into enterprise asset maintenance more predictive,” adds Hurtubise. “Equip-
management (EAM) systems allows automatic generation of ment diagnostics also allow us to keep a history of con-
work orders based on actual device conditions. trol valve signatures. This becomes a very valuable tool
as the equipment ages and also assists in planning which
agement system (CMMS). equipment must come out for maintenance during a
One such online application is Asset Management Solu- planned process unit outage. It is important, however,
tions (AMS) software from Emerson Process Management, that this tool [AMS] be set up as a working system ini-
Austin, Texas. AMS provides the interface between tially and later supported on a dedicated basis through
fieldbus devices and maintenance management systems organizational structure.”
(Figure 4). This allows automatic generation of work Another benefit of HART was realized during plant
orders based on actual device conditions. startup. “Using the HART component of the signal
The online asset management software gathers data allows you to be much more efficient during final con-
from HART instruments and stores it in a device-oriented struction checks, commissioning loop checks, and
database. The data is then processed, organized, and startup,” adds Hurtubise. “It allows you to forgo many
presented in graphic displays. The information can be used of the point-to-point wiring checks that you would nor-
to speed unit startups, streamline routine maintenance, and mally make with analog instruments, by making use of
provide early warning alerts of component failure. the digital network to prove the integrity of the wiring
Overall maintenance costs can be further reduced and instantly for the entire loop.” ❖
V
Hidden in HART Field Devices Offer Much More Than the Process Variable
M ost users know HART provides for limited accuracy for storage tank weighing systems. These
communication of multiple data systems often measure weights up to 200,000 lbs. and
items between field devices and require high precision to resolve the total weight to an
a host controller or computer. acceptable level.
Many also know that integrating additional field device
system performance.
Many existing and most new HART devices have mul-
data into control or maintenance strategies can improve tivariable measurement capabilities. This is true of many
pressure and temperature devices; most flow, level, and
What most HART users don’t know is there is an analytical devices; and all valve positioners and valve con-
incredible amount of data that can be communicated trollers. Table I lists common types of multivariable
between their existing HART devices and control systems. devices and typical outputs available from these devices.
Typical user estimates of available data items range from Up to three secondary process variables in addition to
three to 10 values in addition to the process variable. The the primary process variable (total of four) can be simul-
actual number is 35 to 40 values depending on the type of taneously transmitted from a HART device to a host in a
HART device (see sidebar, “Data Items Available for single message. This multivariable capability can be
Communication Between HART Devices and a Host”). exploited in a number of ways.
There is tremendous value in the data available from
HART devices. “Many users have little or no idea of the Multivariables Provide Multi-Benefits
measurement and process improvements that can be imple- Multivariable transmitters with a digital HART interface
mented through HART devices,” says Warren Meyer, prin- offer tremendous functionality and application diversity
cipal marketing specialist with The Foxboro Co., Foxboro, compared to instruments with only a 4-20 mA output.
Mass. “These improvements typically require minimal Unfortunately, the average user of HART devices only
engineering and can be imple-
mented quickly and at very low Table I: Common Multivariable Devices
cost. These HART devices are Device Primary and Secondary Process Variables*
like icebergs—we only see Pressure transmitter Pressure, temperature, differential pressure
about 20% of the functionality pH transmitter Electrode output, compensation temperature, sensor impedance
and 80% is hidden from view.” Coriolis meter Mass flow, density, temperature, totalized flow
The most important data items Valve positioner Target stem position, actual stem position, actuator pressure,
available from HART devices output signal to actuator
are the process variables. The Temperature transmitter Temperature, cold junction compensation value
primary process variable is con- DP level transmitter Level, pressure at cell 1, pressure at cell 2,
tinuously transmitted in two temperature of capillary fluid
formats: 4-20 mA analog and *HART supports up to 256 process variables in a device. However, only four of them
digital as part of the HART pro- can be transmitted in a single HART message.
tocol. The primary process vari-

able is also transmitted as a percent of range. Finally, the scratches the surface in terms of using the information
loop current in milliamps can also be accessed. The loop available from them.
current reading can be used to validate the signal being One of the best ways to improve plant profitability is
received by the controller. to use the on-board temperature sensor located in virtu-
The primary process variable digital value is expressed ally all HART devices. This sensor measures the internal
as an IEEE floating-point number with up to 32-bit preci- temperature inside the field device, not the ambient or
sion. This far exceeds the standard 12-bit precision offered process temperature. The manufacturer uses internal
with most PLC and DCS analog input modules. device temperature to characterize the output during wide
High precision can be especially useful in weighing and temperature fluctuations, thereby eliminating most of the
scaling applications. Twelve-bit resolution yields very temperature-related error of the device. A user can also
VI
“One client…saved over $300,000/year since 1989 using the
‘free temperature measurement’ for alarming.”
digitally transmit the on-board device temperature to the Management, formerly Fisher-Rosemount.
control system using the HART protocol. Multivariable instruments often can use multiple vari-
“Our clients often use the on-board temperature sensor ables to calculate process information. A differential pres-
for freeze protection alarming,” says Meyer. “During the sure flowmeter, for example, uses pressure taps upstream
winter months in cold climates, every process plant has and downstream of an orifice plate, and the square root of
some type of freeze protection on various production lines. the differential pressure is proportional to the flow. A mul-
The protection can be electric heaters, steam, or just insu- tivariable transmitter could transmit the flow value, the
lation to keep the process fluid from freezing.” upstream pressure, and the downstream pressure. Calcu-
The conventional solution is to purchase and install a lations performed at the instrument level can provide
temperature sensor inside the freeze-protection housing. better accuracy and can off-load central controllers from
This can be very expensive and may not be cost-effective these math-intensive tasks.
for many applications. “When our clients use the internal
temperature measurement already available over the Valves Vie for Attention
HART interface, all that is required is a software change The multivariable features of HART are used extensively
to set alarm points,” adds Meyer. “One client in northern for valve control. “The management of final control ele-
Canada with approximately 2,000 microprocessor-based ments through digital communication offers significant
transmitters estimates they have saved over $300,000 each advantages,” says James Gray, director of I/A systems
year since 1989 using the ‘free temperature measurement’ marketing, Invensys Process Systems, Foxboro, Mass.
for alarming as compared to the previous installation with “Intelligent valve positioners provide real-time feedback
4-20 mA transmitters.” of valve position, measurement of pneumatic supply pres-
Another use of the internal instrument temperature is sure, and measurement of the positioner’s output signal
for ambient temperature error compensation on a dual-seal to the actuator.” Operators can use the secondary variable
level transmitter. The ambient temperature error of the dif-
ferential pressure transmitter is virtually eliminated with Figure 1: Bring Full Closure
factory compensation using the internal temperature sen-
sors. The problem is that the compensation is done before
the dual seals are installed on a vessel, and this installa-
tion can introduce temperature errors.
The temperature errors of the dual seals tend to offset
each other because the error on one side is canceled by a
similar error on the other side. But there still is one error
that is not compensated: a shift in the output caused by a
temperature-driven change in the density of the fluid
inside the capillary between the two seals. As the ambi-
ent capillary temperature changes, the change in the fluid
density creates an error.
The low-cost solution is to take the on-board tempera-
ture inside the basic differential pressure transmitter as a A smart HART loop monitor used with a HART communicating
good approximation of the seal fill fluid temperature. A valve positioner provides a reliable and cost-effective alternative
user can then program a software compensation block with for online emergency shutdown valve testing.
a table of the fill fluid density vs. temperature. A few basic
math calculations using the distance between the seals, the information to perform remote diagnostics on valves.
span of the level measurement, and the density vs. temper- HART valve positioners can monitor actuator pressure
ature chart greatly enhance level measurement accuracy. (Figure 1). “Excess friction in a control valve often leads
A hydrostatic tank gauging system can be configured to surging conditions that can result in dangerous process
using pressure transmitters with a temperature secondary upsets,” says Bud Adler, director of professional devel-
variable. “We multi-drop two or three pressure transmit- opment for Moore Industries, North Hills, Calif. “Our
ters, each with secondary temperature variables, to create HART loop monitor can be configured to alarm on loss
a tank level measurement system. This system is marketed of actuator pressure (a secondary variable) that often
as our Hydrostatic Interface Unit,” says Jim Cobb, mar- results from a clogged air filter or a torn diaphragm.”
keting manager for Austin, Texas-based Emerson Process Emergency shutdown valves can use the multivariable
VII
“The management of final control elements through
digital communication offers significant advantages.”
capabilities of a HART valve positioner. “Potentially “A prudent strategy is to upgrade the valve with a smart
catastrophic results can occur when an emergency shut- HART positioner and a HART loop monitor,” says Adler.
down valve does not close when triggered by a dangerous “With this combination, the presence of adequate air sup-
process upset,” Adler says. “These critical valves often go ply can be verified and the valve can be partially stroked
for months or even years without being stroked to assure on a regular basis to ensure its ability to move off of the
proper operation.” seat.” The loop monitor reads the HART secondary vari-
Users do not stroke these valves because partial valve able and provides stem position feedback to ensure that
actuation without position monitoring can be hazardous. the valve is only partially stroked.
Data Items Available for Communication Between HART Devices and a Host
Process Variable Values1 Status and Diagnostic Alerts2 Calibration Information for 4-20 mA
Primary Process Variable (analog) Device Malfunction Transmission of Primary Process Variable
4-20 mA current signal continuously Indicates device self-diagnostic has Date
transmitted to host detected a problem in device operation Date of last calibration, set by user
Primary Process Variable (digital) Configuration Changed Upper Range Value
Digital value in engineering units, IEEE Indicates device configuration has Primary variable value in engineering
floating point, up to 24-bit resolution been changed units for 20 mA point, set by user
Percent Range Cold Start Lower Range Value
Primary process variable expressed as Indicates device has gone through Primary variable value in engineering
percent of calibrated range power cycle units for 4 mA point, set by user
Loop Current More Status Available Upper Sensor Limit
Loop current value in milliamps Indicates additional devices status Set by manufacturer
Secondary Process Variable 1 data available Lower Sensor Limit
Digital value in engineering units Primary Variable Analog Output Fixed Set by manufacturer
available from multivariable devices Indicates device in fixed current mode Sensor Minimum Span
Secondary Process Variable 2 Primary Variable Analog Output Saturated Set by manufacturer
Digital value in engineering units Indicates 4-20 mA signal is saturated PV Damping
available from multivariable devices Secondary Variable Out of Limits Primary process variable damping
Secondary Process Variable 3 Indicates secondary variable value out- factor, set by user
Digital value in engineering units side the sensor limits Message
available from multivariable devices Primary Variable Out of Limits Scratch pad message area
Indicates primary variable value outside (32 characters), set by user
Commands From Host to Device the sensor limits Loop Current Transfer Function
Set Primary Variable Units Relationship between primary variable
Device Identification digital value and 4-20 mA current signal
Set Upper Range
Instrument Tag Loop Current Alarm Action
Set Lower Range
User defined, up to eight characters3 Loop current action on device failure
Set Damping Value (upscale/downscale)
Descriptor
Set Message Write Protect Status
User defined, up to 16 characters
Set Tag Device write-protect indicator
Manufacturer Name (Code)
Set Date Code established by HCF and set
Set Descriptor by manufacturer 1. Quality indicators for process
Device Type and Revision variable data added with HART 6.
Perform Loop Test
Force loop current to specific value Set by manufacturer 2. On/off values, eight bits, always
Device Serial Number defined as shown. Set by device self-
Initiate Self Test
Set by manufacturer diagnostics. Device status alerts
Start device self test
increased to 16 bits with HART 6.
Get More Status Available Information Sensor Serial Number
Set by manufacturer 3. Additional tag with up to 32
Codes vary by manufacturer/device
international characters added
with HART 6.
VIII
“This strategy provides differentiation between a sensor
problem and potentially dangerous process condition.”
The inherent capability of HART valve positioners to Handheld communicators can access this information
provide diagnostic and preventive maintenance informa- when connected to the instrument loop, but most appli-
tion has proven invaluable in an installation at the Ayles- cations would benefit from continuous monitoring of
ford Newsprint manufacturing mill in Aylesford, England. these status bits.
The mill recently constructed a new de-inking and pump- This monitoring function is provided with some DCS
ing plant and installed a modern newsprint machine. and HMI software packages, but not all control and mon-
The mill uses the Smart Adviser plant health monitor itoring systems have this functionality. “Moore Industries
from Thermo Measurement, Winchester, England, to
enhance the existing process monitoring and control sys- Plenty of Devices
tem and to provide significant benefits in three areas: Device Category1 No. of Companies No. of Devices
valve maintenance, valve failure, and multiplexing. “A Actuator 3 4
large number of valve positioners with HART communi- Analytical 12 58
cation are in operation at the mill,” reports Peter Vincent, Analyzer 1 8
sales and marketing director for Thermo Measurement.
Cabling 1 9
“Some are installed on minor applications but many per-
Calibrator 3 3
form critical safety tasks.”
The advantage of using HART-capable devices is their Control 4 6
ability to communicate digitally on top of the traditional DCS 2 2

4-20 mA line and transmit a wealth of data rather than Density 7 19
only one process variable. Additional parameters that can Flow 24 78
be monitored by a HART-capable valve positioner include Gateway 1 1
requested valve position, actual valve position, tempera- Handheld 6 6
ture, and actuator pressure.
I/O system 9 23
During normal operation, HART communication
Interconnect 1 9
provides a cost-effective and time-saving method for iden-
tifying problematic valves and valve positioners. Instru- Interface 9 9
ment performance is monitored by extrapolating the digital IS barrier 6 44

data readings related to the requested valve position and IS isolator 1 6
the actual valve position and comparing the two readings Isolator 3 16
(Figure 2). Level 31 60
The software analyzes valve positioner performance Modem 6 8
and alarms when an abnormal condition occurs. “If the
Modem IC 1 2
difference between the two readings falls outside of the
Monitor 4 5
normal tolerance of the valve (i.e. valve deviation), Smart
Adviser logs it as a fault,” Vincent says. “The dead band Positioner 18 28
or hysteresis facility is used to determine the normal delta Pressure 32 66

and this is adjustable up to 25% of span to cover nearly Services 5 15
all conditions.” Software 17 19
In addition, should the valve deviation exceed the pro- Temperature 26 41
grammed alarm point, the critical alarm mode provides Tools 5 15
instantaneous indication of valve failure. When the main-
Total 2382 560
tenance schedule is drawn up, the log is studied to see
1. per HART Communication Foundation web site
which valves are frequently working outside of normal
tolerances. Smart Adviser can also function as a multiplexer, 2. 111 different companies
collecting up to 24 channels of field data from smart valve

positioners and sending it to the control system. provides loop monitors that are typically panel-mounted
and connected just like a handheld calibrator. When a
Available: Advanced Diagnostics HART status bit changes, the loop monitor provides both
HART devices provide eight diagnostic status bits (16 bits LED indication and a relay output,” says Adler.
with the new HART 6 enhancement). These status bits can The relay output can be connected to an existing con-
be used to provide early warning of device problems. trol and monitoring system, and the loop monitor can also
IX
“There are more than 30 diagnostic parameters
available to maintenance to determine the health of a valve.”
provide a 4-20 mA signal based on one of the HART pro- branches,” Hage says. “Windows-based software allows
cess variables. This allows a HART instrument to be inter- setup choices like input type and range, output zero
faced to a control system simply and quickly. and span, output damping, upscale/downscale drive, and
The performance of temperature transmitters can be display parameters to be easily viewed, selected, and
improved by using the status and diagnostic information downloaded to a HART instrument with a few clicks
provided by HART devices. “Most temperature transmit- of a mouse.”
ters incorporate sensor diagnostics to drive the 4-20 mA Configuration via a computer is especially advanta-
output either upscale or downscale upon sensor failure. In geous for multiple instruments with the same parameters.
a safety-critical application, this high or low action would
often trigger an expensive and perhaps unnecessary pro- Figure 2: Requested vs. Actual
cess shutdown,” says Adler.
Valve becomes
HART compatible temperature transmitters can be Accepted Delta/tolerance sticky or not fully
used to avoid a process shutdown. “A HART loop mon- (dead band/hysteresis) positioned
itor can be configured to use the status bits to provide a
relay output indicating sensor failure,” Adler adds.
“This strategy provides differentiation between a sen-
sor problem and potentially dangerous process condi- Time
tion. For more safety-critical applications, a dual non- Event is time and
voting scheme or a two-out-of-three scheme provides Delta between date stamped and
'requested' and 'actual' written to alarm
even more reliability.” valve position log, alarm is set
A transmitter can lock at a fixed output value if it is
placed in a manual mode for tests and not returned to auto- Valves can be monitored by comparing requested vs. actual
matic operation. HART’s Primary Variable Analog Out- position data via HART.
put Fixed status bit can be used to detect this condition
and alert an operator. “Another significant advantage of the PC over a handheld
Distributed control systems such as Foxboro’s I/A can is that once developed, a PC configuration can be stored
automatically detect and use HART diagnostic informa- to disk and downloaded to multiple transmitters. The more
tion. “HART status and diagnostic signals can be transmit- transmitters with the same or similar setup, the more time
ted in digital format and used by the control strategy and you save,” concludes Hage.
operator displays,” says Gray. “In addition, there are more Periodic instrument adjustment is a necessity for all
than 30 diagnostic parameters available to maintenance to processes, but continuous adjustment can be a require-
determine the health of a valve. These are available through ment for certain applications. These applications virtually
our Technician’s Workbench I/A system module.” necessitate a digital data interface to a smart instrument.
If the composition of the fluid or gas that is being mea-
Configuration Is Easy With a PC sured changes continuously and if this change in com-
Most HART users are aware that HART instruments can position affects setup parameters, then continuous recon-
be configured remotely from any point on the HART data figuration is required to maintain the accuracy of
highway. This can be performed with handheld calibra- process measurements.
tors or through a host computer. Smart instruments equipped with HART capability can
Calibration performed with a host computer offers enable continuous adjustment by receiving data from
many advantages over calibration via a handheld unit. instruments with respect to fluid or gas composition, using
“HART transmitters feature programming options that go these data to automatically calculate settings, and down-
far beyond relatively common universal input capabili- loading these settings to the affected instruments.
ties. The arrival of simple and highly functional Windows- Asset management software programs make extensive
based calibration and configuration software allows faster use of the device identification information available
set up and more precise settings than is possible with a through HART. This information is read by the asset
handheld communicator,” observes Joseph Hage, vice management program and stored in a database, allowing
president of engineering, Moore Industries. the program to automatically populate the database with
Setup is simplified and time is saved by using a host pertinent information related to each instrument’s tag
computer for calibration. “Handheld calibrators often number, manufacturer, device type, final assembly num-
require a user to scroll through lengthy configuration ber, and serial number. ❖
X
Put It to Work Take Advantage of HART Communications by Connecting Instruments
to Control Systems, Laptop PCs, or Wireless Networks
A s we saw in the article, “Call for Informa-

tion,” processing companies are using
HART information in SCADA, asset
management, optimization, and ERP
systems. In the article, “Hidden in HART,” we saw the
multitude of information available in field instruments, all
of which is available for the taking. Here’s how to access
all that valuable information.
HART-based smart instruments first appeared on the
scene. Back then, being able to work with a handheld ter-
minal to remotely change, calibrate, and diagnose a field
instrument was all the rage. Today, engineers and techni-
cians still use this capability out in the field, but now they
don’t have to. Instead of getting wet or huddling in an
instrument shed, engineers and operators can interrogate
and change parameters from the comfort of the plant’s
You will be happy to learn that not only is instrument control room, using software loaded on any Windows-
information readily available, it is downright easy to get. compatible PC. All they have to do is connect the PC to
What’s more, you don’t have to be a programmer. We’ll the HART device network, and install a simple software
walk you through the various options available, starting package that emulates a handheld terminal.
with handheld terminals and working up to the most com- Siemens and Emerson Process Management both offer
plex networking systems. software packages—Simatic PDM and AMS respec-
tively—that run on a PC. Both can connect directly via
Calibrating Field Devices RS-232 to a HART multiplexer (see below), and provide
Virtually everyone who owns HART instrumentation all the configuration, setup, calibration, and diagnostic
knows how to connect a handheld terminal to calibrate or functions of handheld terminals.
diagnose a field device. Essentially, you find any conve- At this point, Device Descriptions (DDs) enter the
nient location along the 4-20 mA signal line—between picture. While a handheld terminal or PC software pack-
the instrument and its termination in the control room or age has the ability to configure any HART device, DDs
remote data acquisition system—and clamp on an adapter. make the procedure much simpler, because they provide
The adapter is able to read the analog and embedded dig- the necessary parameter locations. Every vendor that
ital signal without affecting the signal in any way. makes a HART instrument also writes a DD that can be
Many of the handheld terminals are based on Emerson loaded into a handheld terminal. Typically, an end user
Process Management’s 275 HART device, which it sup- loads handheld terminals with DDs for all the field instru-
plies to many HART vendors as a house brand. It was mentation in the plant so engineers and technicians can
designed years ago, but it still works just fine. Newer work with anything.
handhelds from companies such as Smar are becoming Owners of the 275 HART terminals often send the unit
available with Palm user interfaces. According to Jonas off to the manufacturer to have the necessary DDs loaded.
Berge, manager of Smar Asia-Pacific Operations in This is much easier for some plants than loading DDs
Singapore, the Palm-based devices have a Windows-like locally. Fortunately, the latest handheld terminals and PC
user interface. “This comes in handy, as newer-generation software packages are able to load from CD-ROMs, disks,
HART devices have more diagnostics information than or Internet sources, simplifying the update process. At pre-
ever before,” says Berge. “Some information is better sent, there are more than 250 unique HART instruments
visualized graphically on a large screen than on just a text- from 70 vendors, all with individual DDs.
based screen like the older units.”
About 80% of all process controller and field instru- Getting Connected
ments have a HART interface these days, and practically For a simple connection, a HART modem interface from
every maintenance technician, operator, instrument engi- MACTek will connect your PC’s RS-232 port to a
neer and control engineer knows how to use a handheld HART field device. The modem connects to the 4-20 mA
HART terminal to change the zero and span, or check sta- signal line just like the handheld communicators, and
tus. In probably 99% of the process installations, this was provides an RS-232 signal containing all the digital
why HART devices were bought in the first place. HART information.
That was most definitely true 15 years ago, when If more than a few HART devices are involved, then
XVIII
The HART Server starts working immediately. Users can
start gathering HART data in a matter of minutes.
RS-485 multiplexers from companies such as Arcom, The HART Server is a plug-and-play device; that is, once
Elcon, MTL, Pepperl+Fuchs, Stahl, or Thermo Measure- it is connected to the HART network via a modem, it auto-
ment can be used (Figure 1). Up to 31 multiplexers can be matically recognizes and communicates with all HART
connected, each with 32 loops, for a maximum of 992 devices it can find on the network. This includes HART
devices. Some multiplexers support a multi-tier architec- devices directly connected via RS-232 as well as devices
ture that allows you to connect thousands of field devices connected through various control networks, multiplexers,
into a single virtual network. The point is, no matter how and I/O systems. Once it establishes communication, the
many HART devices you want to connect—from one to HART Server automatically retrieves device information.
thousands—the connection to your PC is simple and Each OPC client that connects to the HART Server can
straightforward. All you need is a modem and a cable. And request information at any rate desired. The client can
a server, of course. specify update frequency, dead band, and so on. The
The HART Communication Foundation (HCF) recently HART Server will update information as requested and
announced the availability of the HART to Enterprise send it to the client.
OPC server, or HART Server. Load this software into your To see how easy it is to use, download a free evaluation
PC, hook up to HART devices with a modem, and you version of the HART Server. Just go to www.hartcomm.
gain real-time access to all the process-related informa- org, select the End User Info box, then click on HART
Server. From there, you can request a demo evaluation kit
Figure 1: Serial Killers that allows you to download server and related software
modules on your PC and simulate the complete server
functionality, free of charge for 30 days. This kit includes:
❖ HART Server software
❖ Xmtr-mv instrument simulation software (Windows
NT only)
❖ GnHost diagnostic software
To use these modules, simply load the software into a
Windows NT, 98, or 2000 environment, associate and
jumper the correct COMM ports on your PC (for exam-
ple, COMM 1 for the server, COMM 2 for Xmtr-mv) and
Multiplexers can be used to bring a virtually unlimited number follow the instructions in the kit. You may also use your
of HART field devices into serial ports. own instruments in the simulation by connecting a HART
modem to the serial port.
tion available in HART devices. With HART Server soft-
ware and a $350 RS-232 link or a $2,000 Hooking Up a HART Multiplexer
multiplexer, you may have all the connective functionality If you have more than one HART device, connecting them
you’ll ever need. to your control system can be done in one of two ways.
The HART Server is OLE for Process Control (OPC)- The first is to run the HART signals to a HART I/O board
compliant, so it can obtain information from HART devices in your control system.
and pass it along to any OPC client applications, such as The second way to obtain HART data is to use a HART
SCADA/HMI software, an Internet web browser, an Excel multiplexer. This is ideal for end users with control sys-
spreadsheet, SQC and SPC software, and ERP systems. For tems that do not yet support HART digital data for con-
example, real-time flow transfer data obtained from a trol and monitoring purposes. Users with legacy control
HART device can be delivered to an Excel spreadsheet. systems also are in this situation.
No special skill or customized software is needed. David Hohenstein, manager of the hardware marketing
Using simple drop-down screens (Figure 2), fill-in-the- group at Pepperl+Fuchs, Twinsburg, Ohio, explains that
blanks functions, and tag names, the HART Server can be hooking up a HART multiplexer is easy. “Just run the
configured to automatically collect real-time information 4-20 mA signals from HART field devices into a HART
from any number of HART devices and deliver it to any multiplexer,” explains Hohenstein. “The multiplexer strips
OPC client application. Once configured, the HART off the digital HART data, then sends the 4-20 mA signal
Server starts working immediately. Users can start gath- on its way.”
ering HART data in a matter of minutes, rather than sev- The original 4-20 mA signal is unaffected, so it can con-
eral hours or days. nect to a normal analog input board at a control system.
XIX
“The multiplexer strips off the digital HART data,
then sends the 4-20 mA signal on its way.”
Meanwhile, the multiplexer sends the digital HART data ment information available to any OPC client device
to the control system via a serial link, typically (Figure 3). This includes web browsers, SCADA systems,
RS-232 or RS-485. ERP systems, and software that drives cell phones, hand-
The only trick to using a HART multiplexer is that it held computers, personal digital assistants (PDAs), and
must be compatible with the control system, says wireless equipment.
Hohenstein. “The connection to all HART instruments A control system designed and installed by SysInc
is standard, but every control system is different. You Engineering to support multiple plants, process areas, and
have to purchase a HART multiplexer with an I/O inter- loading facilities makes extensive use of HART devices.
face that works with your particular control system.” Pep- A Windows 2000 HART OPC Server at each plant is con-
perl+Fuchs has 40 different HART multiplexers, with nected directly to an Arcom 32-channel HART multi-
models ranging from 32 to 255 channels. plexer via an RS-485 serial port.
Once connected to the control system, the multiplexer Approximately 70 two-wire and four-wire HART
becomes a passive device, serving merely as a conduit of devices per plant are connected to the multiplexer. These
information. When asset management or HART Server devices include SAAB and Krohne radar level gauges, Inor
software in the control system wants data from a HART
instrument, it sends the device a HART command. The Figure 2: Drop-Dead Easy
command signal goes to the HART multiplexer which
embeds the digital signal into the 4-20 mA loop. The com-
mand arrives at the HART device where it is acted upon.
The HART device embeds the requested information into
the 4-20 mA signal, and the multiplexer strips out the dig-
ital data and sends it on to the control system.
Issues to be considered with HART multiplexers pri-
marily involve speed. A multiplexer with 255 channels
and a single modem operates much slower (on a channel-
by-channel basis) than does a 32-channel multiplexer with
one modem. If a control system needs faster access to data,
it can use smaller, eight or 16-channel multiplexers, or The HART Enterprise OPC server offers drop-down screens,
you can purchase multiplexers with multiple modems. fill-in-the-blanks functions, and tag names.
Getting More Complex and Smar temperature transmitters, Micro Motion mass
So far, we’ve only looked at HART networks that connect flowmeters, and Endress+Hauser volumetric flowmeters.
to a single PC. Much more capability is available for a Most of the HART devices are wired in a multi-drop
serious user. It’s possible to connect your HART instru- configuration and connected to the HART OPC Server.
ments into most major networks, the Internet, and even Other HART devices feed into four-channel ProLinx
into wireless systems. HART/Modbus gateways that in turn feed into the
Arcom, for example, sells a series of multiplexers that Modbus OPC server. The OPC server provides a clean
plug into Modbus networks. At Shell’s Tejas Calumet gas interface to custom as well as off-the-shelf SQL and
plant in Louisiana, data from Rosemount HART flowme- web-based applications.
ters is stored in Modbus registers in an Arcom HtNode Most of the devices are set up on multi-drop networks
multiplexer, allowing any Modbus host to access the and do not use the 4-20 mA signal available from each
information. A SCADA system in a PC accesses the flow device. The faster update time of a 4-20 mA signal took
data every five minutes by interrogating the HtNode a back seat to the accuracy of the HART digital signal for
device over Modbus. this application.
HART multiplexers are available that support Ethernet According to the system integrator, the client plans to
TCP/IP connections. Such a system could easily connect take advantage of many HART features. “Our client will
into the Internet, a plant intranet, OPC systems, or other use the multivariable, status and diagnostics, and remote
plant network schemes based on Ethernet. In such a case, calibration capabilities of the HART devices. The most crit-
a PC or workstation equipped with HART Server software ical capabilities for this application are multivariable and
can access HART instruments anywhere on the network. device status,” says Curtis Butt, electrical engineer, SysInc.
With a HART Server in your PC, you can make instru- “The long-term manageability of the system required us to
XX
“The HART protocol will help us achieve better
repeatability and higher accuracy.”
provide not only remote access to basic variables, but also Pat Moyer, product manager at A-B, explains that the
remote diagnostics and configuration.” system is supplied with preconfigured instructions that
The client and SysInc expect to see a significant support HART commands. “We provide several basic
improvement in the reliability of the data coming from HART commands, but a user is free to write additional
the devices. “The old system had only local displays at commands in ladder logic to perform whatever functions
each instrument,” says Butt. “Operators did not trust the are needed, such as data logging, alarm checking, or mon-
system and would often revert to manual operation. Part itoring device status.” Moyer says the HART module is a
of this was due to devices being in remote locations, big hit among certain A-B customers. “We have users in
which led to difficulties in calibration and verification of the food and oil and gas industries that use the module
proper operation.” extensively,” she says.
Yokogawa Corp. of America, Newnan, Ga., offers hard-
Figure 3: Opened to OPC ware and software that acquire HART data and make it
available to its Centum control systems. Bruce Jensen,
manager of systems marketing, explains that a Centum
can acquire data from a standard HART multiplexer or
from its own FIO 4-20 mA input modules. “The FIO
devices have a HART module that extracts the digital
HART data from the 4-20 mA signal and provides both
analog and digital data.” FIO devices are available in eight
or 16-channel versions.
Yokogawa’s Plant Resource Management software for-
mats the HART data and makes it available to the HMI and
controls software, where it can be monitored, trended,
logged, and displayed. Jensen says most customers use the
capability to automate instrument maintenance functions
The HART Server can make process data available to any because the software supports all the standard configura-
OPC-compliant device: web browser, SCADA system, ERP tion and calibration functions from an HMI screen.
system, cell phone, PDA, wireless, etc. “We have several users, mostly in the pharmaceutical
industry, who are starting to take advantage of HART data
Operators will now be able to remotely access devices for more sophisticated purposes,” says Jensen, “but most
and receive accurate information. “The new system will of our users are not familiar with all the capability avail-
provide complete access to all devices including status, able within HART.”
calibration, and configuration information,” Butt con- Virtually all major process control companies support
cludes. “Use of the HART protocol will help us achieve HART, so it should be relatively easy to connect your con-
better repeatability and higher accuracy, both in the pro- trol system to your own HART devices.
cess area and in the bulk storage/inventory area.” Dave Sheppard, vice president of I/A Systems at
You may never need such complex communication Foxboro/Invensys, Foxboro, Mass., says Foxboro has sup-
schemes, but it is comforting to know that HART instru- ported HART for maintenance purposes for years. “We
ments fit right in. support the connection of HART multiplexers from sev-
eral suppliers,” he explains, “and we bring the HART data
Connecting to Controls into a dedicated PC where third-party software can obtain
HART devices can connect directly to control systems and data for maintenance calibration and equipment configu-
devices, allowing users to make use of instrument data for ration functions.”
monitoring, alarming and control purposes. At ISA/2001 in Houston, Foxboro will unveil a new
Allen-Bradley, Wickliffe, Ohio, provides a HART eight-channel analog I/O board with a HART module that
interface module for its PLC 5 and SLC programmable splits out the digital signal and feeds it into standard equip-
controllers that allows a PLC to see HART data. Installed ment control block (ECB) modules. “The HART data will
as a remote I/O device, the module acquires data from a be made available to Foxboro’s HMI and process control
HART instrument, strips out the HART signals, and puts software like any other process variable, so it can be used
the data into a format that can be addressed by ladder for control, data logging, monitoring and so on,” says
logic programming. Sheppard. “We are taking orders now for delivery in the
XXI
“HART data will be available like any other process variable,
so it can be used for control, data logging, and monitoring.”
second quarter of 2002.” that is supported by all software packages that claim to be
Honeywell, Phoenix, is on a similar track. “We offer OPC clients or servers, such as HMI/SCADA systems.
standard HART multiplexers from Pepperl+Fuchs or When you get the HART system connected to the
MTL,” says Joe Serafin, product manager for Plantscape HART Server, simply go to the part of your HMI or
I/O. “The MUX connects to the serial port of a PC, which SCADA system that defines I/O points. You will be
runs Cornerstone or some other third-party HART soft- adding the HART instruments the same way you config-
ware for maintenance and instrument calibration.” ured your plant when you first installed the HMI/SCADA
Honeywell’s customers have been asking for additional system: that is, you’ll probably use a menu-based config-
HART capabilities, so Honeywell has a HART I/O card uration screen to define the path, device, tag name, and so
in the works, scheduled for introduction in the near future. on, and your HMI/SCADA system will lead you through
“The new card will strip off the HART digital data from the process.
the 4-20 mA signal and make it available to the control
environment,” says Serafin. Figure 4: Dig Out All the Data
Meanwhile, if you don’t want to wait for products to
become available, you can take matters into your own
hands and implement a system using the HART Server.
By the Numbers
Here’s a step-by-step procedure for getting started with
the HART Server. This should get you up and running in
a matter of just a few minutes:
1. Load and install the HART Server software on your PC.
You can download it from the Internet or load it from
a CD-ROM.
2. Configure your PC’s COM port to communicate with
the HART network. You need to tell the PC port if it Loop monitors can read all the data from HART field devices
will be seeing RS-232, RS-485, or RS-485 with an Eth- and convert it into additional signals for control systems.
ernet adapter. The HART Server configuration screens
help you do this. You will also be able to define how often you want each
3. Configure the HART Server to set up links between the parameter or groups of parameters updated, or “turned on.”
data sources and the data users (what programs want to When a group is turned on, the HART Server will publish
see what data?). Again, the HART Server configuration the data items (i.e., update, acquire, and send the group to
screens ask the right questions. the client). This allows processing packages from loop con-
4. Verify and test the HART Server using the GnHost diag- trollers to process historians to obtain instrument informa-
nostic software tool, supplied by the HART Foundation. tion from the field as often as necessary, simply by making
Most of the configuration menu screens are similar to the appropriate definitions in an OPC software package.
Windows Explorer. With a series of mouse clicks, you
should be able to complete the configuration quickly. The Using Specialty Devices
HART Server will automatically detect and learn the HART Several HART instrument vendors have developed spe-
devices connected to the port. At the end of the configura- cialty processors and loop monitors that perform unique
tion process, two-way communication between the HART diagnostic and analysis functions. In many cases, this
Server and the HART instruments will be fully established. allows you to take advantage of the information contained
The HART Server pass-through software lets OPC in your HART instruments without making a network con-
client applications send HART commands to HART nection or using PC software. In other words, you can
instruments. Therefore, any software such as configura- solve local problems without involving the plant’s main
tion or valve analysis packages that run on handheld ter- control system.
minals can run on a PC equipped with HART Server. An annoying problem in many plants involves sticking
Likewise, HMI and SCADA software can access data valves and worn-out positioners. Such problems are usu-
using standard OPC functions. The OPC client browses ally difficult to detect for most control engineers, mainte-
the data items available from the server and subscribes to nance technicians, and even the best process control and
the data items of interest. This is a standard OPC function SCADA systems. Most all these entities are usually at a loss
XXII
“We will be able to use [HART 6] for at least
10 or 15 more years, or even longer.”
to explain a valve’s bad behavior when it starts hunting, create three additional 4-20 mA analog signals from a
sticking, and performing poorly. The answer in most single HART message. The HART 4-20 mA signal goes
plants is to pull the valve out of the line for maintenance. to a control system flanked by three additional 4-20 mA
A HART-based smart valve positioner has all the infor- signals. This makes it possible to extract gross flow, net
mation you need to analyze valve performance. HART flow, mass flow, and process temperature from a Brooks
data can tell how many times the valve opens and closes, Instruments TRi-20 flowmeter; or valve position, actua-
how much the stem has traveled, if actuator pressure has tor pressure, controller process variable, and controller
changed, and a host of other variables that are available setpoint from Fisher, Masoneilan, Neles, Samson,
through HART, but are never monitored in most plants. Flowserve, and other valve actuators.
The positioner itself can perform its own analyses. For Multivariable devices such as these are becoming avail-
example, the Smar FY301 performs diagnostics, collects able to solve specific problems and help maintenance and
operational statistics, and stores information pertinent to operations engineers obtain the most information possible
the management of the valve and actuator. from their HART devices.
But how do you get to this data, and what do you do The best part is that all this diagnostic, status, and oper-
with it? You can install a HART loop monitor to moni- ations information has been available all this time, so it
tor any of these variables, and to sound an alarm if it sees requires no additional investment by end users. All they
a condition that could result in dangerous process upsets. have to do is go get it with handheld devices, multivari-
For example, excess friction in a valve can lead to surg- able loop monitors, or PCs and HART Servers.
ing conditions. Loss of actuator pressure from a clogged
air filter or torn diaphragm can cause a dangerous or HART Marches On
costly control offset. A loop monitor can be set to alarm Although HART has been available for 15 years, like Eth-
on any of these conditions. ernet it is showing no signs of getting old. The current ver-
Aylesford Newsprint in Aylesford, England, has many sion is HART 5, but HART 6 has recently been approved
HART-based smart valve positioners and it uses Smart by the foundation’s members.
Adviser from Thermo Measurement to check for faults “HART 6 is an augmentation of the existing standard
and problems. The module accepts data from up to 24 that allows the installed base to continue while incorpo-
valve positioners, performs a variety of calculations to rating new features,” says Ben Cianfrone, engineering
compare the requested position to the actual position, development manager, Fluke Corp., Everett, Wash. “We
compares it against a deadband, monitors pressure to the will be able to use this for at least 10 or 15 more years,
pneumatic actuator, and sounds an alarm if it detects a or even longer.”
fault. The module can also act as a HART multiplexer; The upgrade was necessary because HART instru-
that is, it can collect data from the valve positioners and ments are getting smarter all the time, incorporating
send it to a PC via an RS-232 link. more self-diagnostics, saving more operational history
Control systems that are not fitted with a HART data, and reporting on the quality of the data they obtain.
modem and HART Server cannot obtain any data other Someday, HART devices may even have other HART
than the 4-20 mA signal from HART instruments. Here, devices embedded within, such as flow computers and
loop monitors can serve as an intermediary. For exam- multi-channel temperature monitors. HART 6 makes all
ple, Moore Industries’ SPA monitor can read all the this possible, without making any previous HART
data from a HART device, extract digital data, and pro- instruments obsolete.
duce additional signals (Figure 4). It provides up to four Some of the new functions include Extended Device
independent relay outputs that can be used as alarms Status, which alerts users to situations such as, “device
when process conditions fall outside of user-selected needs maintenance;” Device Variable Status, which
high or low limits. It can also pick off any of the four allows field devices to self-validate and provide quality
dynamic (analog) variables from the HART data and indicators on process data (good, poor, bad, fixed); Long
transmit it to the control system as a 4-20 mA signal. Tags, which allows international characters and longer
For example, it could take the density value from a tag names; Configuration Change Counter, which deter-
Coriolis flowmeter, the stem position for a valve, or it mines if a field device configuration has been changed;
can calculate an analog variable as a function of two or and Block Data Transfer, which moves large blocks of
more other variables. data between masters and field devices. The new spec
Rosemount’s Tri-Loop monitor, for example, can should be available for all to review at the ISA Show
extract the remaining three process measurements and in September. ❖
XXIII
Get Started The HART Foundation Will Help You Extract Information From Your Field Instrumentation
T he preceeding articles have shown how HART

is much more than just a way to calibrate
flowmeters. It provides an enormous amount of
plant-floor information not obtainable through
any other means, and you don’t need a complicated field-
bus system to get to that data. In fact, since most of your
instruments, valves, and controllers already have a HART
interface, obtaining real-time process information is not
that time, HCF left all the end user promotion to the mar-
ketplace while it concentrated on helping the vendors
design and develop new instruments, software, interfaces,
calibrators, and similar devices. All of HCF’s educational
efforts and training classes have been designed for ven-
dors, and all of its efforts toward standardization have
been aimed at solidifying and enhancing HART products.
It’s accomplished that, in spades. Today, HCF has
only easy, it is very inexpensive. All you need to do is more than 130 vendor members all over the world that
learn how to use it. offer a large number and variety of HART-compliant
When it comes to calibration and diagnostics with hand- products (Figure 1). Virtually every process instrument
held terminals, HART technology is so easy to learn that built today has a HART interface. In spite of all the pub-
vendors often teach their customers over the telephone. licity garnered by the various fieldbuses, the fact remains
Bud Adler, director of professional development at Moore that HART has the largest installed base in the industry,
Industries, North Hills, Calif., says he often walks people and it is growing every day. This is in part because many
through a quick course. “It is fairly easy to lead someone
through a procedure over the phone,” says Adler. “The Figure 1: A Global Standard
technology is simple and the procedures are straightfor-
ward. We do it all the time.”
Jon Tandy, sales engineer at Arcom Control Systems, North America
46% (65)
Kansas City, Mo., agrees. “I’m the one who usually Europe
44% (62)
deals with HART customers from sales through tech
support, and I generally educate them over the phone,” he
explains. “Often, they have some basic understanding of
Australia
HART already.” 0.7% (1) Asia
When you need to go beyond handheld terminals, it gets 9.3% (14) Total companies: 142
a bit more difficult. Moore Industries’ Adler travels around
the country giving HART seminars at trade shows and There are HART Communication Foundation member companies
“Lunch-and-Learn” sessions, where employees from a almost everywhere you’d want to go.
chemical or process plant get a sandwich and a seminar on
HART. “We get everyone from instrument engineers to fieldbus-compatible instruments and devices also have a
maintenance technicians,” says Adler, “and most are HART interface. Fieldbus users may discover they actually
amazed to find out what the instruments already installed have two plant networks built into their devices: fieldbus
in their plant are capable of providing.” and HART.
Some companies conduct on-site training during instal- The HCF realizes its future lies in educating, enlight-
lation. Thermo Measurement’s signal conditioning ening, and engaging users, so it has launched an End
product manager, for example, trained people at Ayles- User Program. This program will teach users about the
ford Newsprint on-site. benefits of HART, establish a training curriculum, bring
All this vendor activity is useful and helpful, but what end users into the HCF, and involve them in the HART
the industry really needs is a better and more consistent interface for everyone’s benefit.
way to teach end users about HART.
Educational Support
Regarding Users in a New Light Learning more about networking and HART Servers is a
The HART Communication Foundation (HCF) has been little bit beyond a five-minute phone call from the rep.
strictly a vendor group since its founding in 1993. During You need training and non-vendor technical literature.
XXVI
The HCF realizes its future lies in educating, enlightening,
and engaging users, so it has launched an End User Program.
HART Communication Foundation HCF understands. Here’s what they have in store for you:
❖ The Complete HART Guide on CD-ROM: This is an
The HART Communication Foundation (HCF) is an independent, excellent way to learn how HART works, in a format
non-profit organization that provides worldwide support for the that is easy to pass on to fellow workers and bosses.
HART protocol. Established in 1993, HCF is the technology owner The CD-ROM was recently completely revised to
and standards-setting body for the HART protocol. HCF manages include new topics such as HART 6, asset management,
the protocol standards, ensures the technology is openly avail- and the HART Server. The new CD-ROM is available
able for the benefit of the industry, and educates users by pro- for free from HCF, and you should be able to get a copy
viding training and support for application of the HART protocol. at the HART Foundation booth at the ISA or Interkama
shows this year. To obtain a free copy via the Internet,
HART Workshops go to the HCF web site (see next bullet). You can also
Workshops are an excellent value since an engineer can often call the HCF office in Austin, Texas.
spend weeks of valuable development time overcoming the learn- ❖ Web site: The HCF web site at www.hartcomm.org has
ing curve of the protocol. A workshop provides all the needed been completely updated to include a new end user focus
information in a two or three-day session. Workshops include: on applications, education, downloads, Q/A forums, and
❖ HART End User Workshops: During the latter part of 2001, a newsletter. An end user can pick up a large amount of
the HCF will begin training courses for end users. technical, product, and application information by simply
❖ HART Fundamentals Workshop: The HART protocol is browsing through the web site and following the links.
relatively easy to implement, but can have a steep learning ❖ End user training: The HCF plans to offer a comprehen-
curve. This provides all the information and tools to efficiently sive two-day HART technology education class, start-
develop a HART-based device. ing in 2002. Two pilot classes will be held in 2001. The
❖ Writing Device Descriptions (DDs) Workshop: The Device classes will be taught by HCF staff and will cover the
Description Language (DDL) provides significant benefits to slave technology, using DDs, applications, device configura-
developers, end users, and host manufacturers. This workshop tions, communications, and using the HART Server.
explains how to use DDL to write DDs for a product. Participants To find out more about specific dates and times, con-
leave the workshop with a prototype DD for a HART device. tact HCF or visit the web site.
After HCF runs the pilot classes, it plans to finalize
Memberships the training materials so that users will be able to con-
HART Communication Foundation memberships are open to sup- duct classes themselves. This will put training out in
pliers, system integrators, end users, and others interested in the the field, closer to end users.
use of the HART protocol. Regular/associate and sponsor mem-
berships are structured for corporate members. Information-only Coming on Board
memberships are available for non-profit educational institutions, The HCF also realizes that end users will determine the
research institutes, and government agencies. End user compa- future of HART. Already, many experienced users are
nies can join as a regular/associate member, and individual con- asking for additional capability and functions. Although
trol engineers may join as information-only members. HART has been available for 10 years for field commu-
Members are able to attend foundation meetings; participate nications, it is just now entering the early adopter step in
on committees; obtain free specification updates; get 100 free its lifecycle as a networking system. At this point in
copies of the quarterly newsletter; access engineering support HART development, user input is critical.
services; and receive discounts on workshops, development tools, The HART Foundation is considering forming an end
protocol licenses, and device description registrations. user core group to provide it with input on key issues such
A membership application form is available on the web site. as HCF activities, technology issues, applications, prod-
uct needs, and other ideas. If you are interested in partici-
Contact Information pating, contact HCF.
HART Communication Foundation While fieldbus efforts are struggling to deal with a
9390 Research Blvd., Suite I-350 large number of unrelated and incompatible networks,
Austin, TX 78759 HART offers an excellent alternative. The HCF and its
Tel: 512/794-0369; Fax: 512/794-3904 vendor members have built a technology that works, but
Web site: www.hartcomm.org end users are needed now to make sure that HART con-
E-mail: [email protected] tinues to meet all the information and network needs of
the process industry. ❖
XXVII
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The HIM converts HART
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Control System
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HART CONTENTS/INDEX
8 Wireless HART™—
Information Unchained
WirelessHART™ releases the informa-
12 What Wireless HART™
Can Do For You
When facing new operational chal-
24 How to Get Unchained
with Wireless HART™
WirelessHART™ offers several ad-
tion trapped in your field devices by lenges, innovative companies find vantages over other wireless alterna-
offering 100% backward-compatibility solutions using wireless technologies. tives. Here’s how to get started.
with your installed HART devices.
ADVERTISERS Moore Industries . . . . . . . . . . . . . . . . . . . . . .4

ABB Instrumentation . . . . . . . . . . . . . . . . . .27 ProComSol. . . . . . . . . . . . . . . . . . . . . . . . . .26
Emerson Process Mgt/Plantweb. . . . . . 14, 15 Siemens AG . . . . . . . . . . . . . . . . . . . . . . . .2, 3
Hart Communication Foundation . . . . . . . .28 Invensys/Foxboro. . . . . . . . . . . . . . . . . . . . .19
Honeywell Field Solutions . . . . . . . . . . . . . .16 Turck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
MACTek . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Yokogawa . . . . . . . . . . . . . . . . . . . . . . . . . .6, 7
Expanding the Possibilities

By Ron Helson, Executive Director, HART Communication Foundation
A
s the technology owner and standards- capability that can benefit both your existing wired ap-
setting body for the HART Protocol, the plications and new monitoring and control applications.
HART Communication Foundation was in a Why wireless? Wireless provides a cost-effective ad-
unique position to develop a wireless communication ditional communication path for many legacy control
standard for process measurement and control applica- systems, enabling access to the intelligent information
tions. We were able to draw on the technical resources in field devices. And new measurement and control
and expertise of more than 200 member companies to devices can be quickly and easily deployed without the
create a new technology that expands the capabilities of physical limitation and expense of signal wire.
the HART Protocol while protecting the global installed Soon suppliers will introduce HART 7-enabled devices
base of 24+ million HART devices. that will provide a new way to monitor, manage,
WirelessHART™ Communication is a new and diagnose existing and new measurement and
capability defined in the HART 7 specifications control instrumentation—allowing your intel-
that establishes the first open and interoperable ligent field instruments to communicate valuable
wireless communication standard for the process information to provide significant operational
automation industry. WirelessHART™ focuses on cost reductions, enable process improvements,
the needs of the industry by providing a simple, and facilitate regulatory compliance.
reliable, and secure technology for wireless transmission of HART Communication is stronger than ever. Mil-
process and diagnostic data from intelligent field devices. lions of HART-enabled devices are purchased and
This new wireless standard builds on established and installed each year. The HART protocol continues to
field-proven technologies, including the HART protocol, be the technology of choice for smart instrumenta-
IEEE 802.15.4 radios, frequency-hopping, and mesh tion. WirelessHART™ is yet another example of how
networking. These standards allowed us to create a the Foundation continues to strengthen and enhance
solution that is easily deployed by instrumentation pro- the technology to ensure that it supports your needs
fessionals—preserving the HART-enabled devices, tools, and protects your investment.
training, and work procedures used today. The following articles provide an overview of the new
WirelessHART™ is fully backward-compatible with enhancements to the HART Protocol standard. You will
existing instrumentation, extending the value of installed learn what WirelessHART™ is, where it can be used, how
HART-enabled devices. It complements, but does not it expands the benefits of HART technology, and what
replace, wired HART technology, providing an additional you need to know to start expanding the possibilities!
For more information on WirelessHART™, go to www.controlglobal.com/articles/2007/184.html.
HART® and WirelessHART™ are trademarks of the HART Communication Foundation.
CT0709_Hart.indd 5 8/23/07 10:51:17 AM

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WirelessHART™—
Information Unchained
WirelessHart™ releases the information trapped in your field devices with
100% backward-compatibility with your installed HART devices.
O
f the 24 million-plus HART-enabled de- • WirelessHART™ using IEEE STD 802.15.4-
vices currently installed around the globe, 2006-compatible physical layer and MAC PDU
only about 10 percent are delivering their to produce both mesh and point-to-point wire-
full diagnostic potential, a state of affairs that less networks;
is poised for change,” says Ron Helson, HART • Worldwide appeal using 2.4 GHz frequency-
Communication Foundation (HCF) Executive hopping, spread-spectrum technology;
Director. “Development of the WirelessHART,™ • Enhanced data publishing modes, including one-
standard, along with the new enhanced DDL way publishing of process and control values;
capabilities, opens the door to the untapped func- spontaneous notification by exception; ad hoc
tions in HART devices and simplifies the task of request/response; and auto-segmented block
integrating instrumentation from multiple vendors transfers of large data sets;
into plant asset optimization systems.” • Dedicated bandwidth for high priority and peri-
odic communications;
Enhancing HART • Shared bandwidth to provide elasticity for event
Since 1990, millions of HART devices have been traffic and ad hoc request/response maintenance
installed, and most remain in service today. Pro- and diagnostic messages;
tecting that installed base was paramount when • Time-stamped data gathered at time of mea-
the HART Foundation, with the assistance of end surements in order to provide improved signal
users and ABB, Adaptive Instruments, Coronis, processing and control;
Dust Networks, Elpro, Emerson Process Manage- • Time-triggered actions/measurements for syn-
ment, Endress+Hauser, Flowserve, Honeywell, chronized operation across multiple devices (e.g.,
MACTek, Omnex, Pepperl+Fuchs, Phoenix Con- vibration sensors);
tact, Siemens, Smar, and Yokogawa, defined the • Highly secure communications using AES-128
requirements for WirelessHART.™ bit encryption with individual Join and Session
Emerson Process Management’s director of HART Keys and Data Link Level Network Keys;
and Fieldbus Technology, Marty Zielinski, says, “The • QoS messaging applied to all messages to ensure
WirelessHART™ standard effort has produced a fully complete and prioritized delivery;
digital protocol that uses consolidated mechanisms • Clear Channel Assessment channel-hopping,
to reduce communications overhead and adds im- blacklisting, and adjustable transmit power
portant capabilities to the HART standard, including support to maximize coexistence between
alarms, alerts, status with measurements, and time WirelessHART™ networks and other ISM-band
synchronization, just to name a few.” equipment;
The results are seen in the key technical fea- • Multiple sequential data points of the same pro-
tures of the recently released HART Protocol cess variable in a single data packet;
Revision 7 (HART 7) standard: • Command aggregation for embedded multiple
S- Advertising supplement to CONTROL
CT0709_Hart.indd 8 8/22/07 2:00:52 PM

read commands in a single transaction, giving primary process measurement – flow, pressure,
faster configuration uploads; temperature, etc. Simultaneously riding on that
• Backward-compatibility for the 24-plus million same pair of wires is an all-digital signal that
installed HART devices; contains HART device information – secondary
• Multiple power options capable of using long measurement values, device health, and other
life batteries, solar, loop, or line power sources. process and diagnostic information.
The release of the HART 7 standard added
HART FOR PROFIT: USING THE DATA WirelessHART™ as an additional means of com-
From its very beginning, the HART protocol has municating the all-digital HART diagnostic and
provided far more capabilities than configuring multivariable device information and even the
field devices. First, it provides real-time device basic process variable, if required.
diagnostics as well as multivariable device infor- “While developing the WirelessHART™ stan-
mation. When effectively used, HART information dard, the committee remained vigilant of two
has repeatedly enabled companies to lower operat- key requirements,” says Wally Pratt, the HART
ing cost and increase plant availability and reli- Communication Foundation’s chief engineer. “It
ability, thereby improving plant competitiveness. must be easy to deploy, and it must be easy to use.
“Yes, we’re going to move into WirelessHART,™ There should be no need for users to learn about
says Rob Brooks, process control supervisor, radio technologies, communication linking or
PPG Industries, Lake Charles, La., who has been become antenna experts.”
experimenting with wireless for three years. “We With the help of experts in process applications,
already have an AMS system. Ease-of-use-wise wireless technologies and the HART protocol, the
and cost-wise, wireless is the way to go.” HCF thoroughly investigated wireless technolo-
In a traditional hardwired HART installation, a gies, assembled the best elements, and added them
pair of wires connects the HART field instrument to the popular HART specification. The result is
with a host system. On that pair of wires are two that WirelessHART™ complements wired HART;
signals, a 4-20mA analog signal that carries the it does not replace it.
WirelessHART™
Existing HART Device
Wireless Access to
HART Device Device Wireless
Information Gateway
Wireless
Adaptor HART Data
Easy Access to Intelligent
Device Information
Enabled by
Wireless Adapter Device
PV Data Management
Device Status, Diagnostics, 4-20 mA Application
Configuration and more Analog Legacy
Signal DCS
Only I/O
CT0709_Hart.indd 9 8/22/07 2:01:24 PM

UNCHAIN YOUR DATA!
Field Powered
Wireless Access to
Additional Process Wireless
Measurements Gateway
+ PV + HART
– Data
Wireless Gateway
Connection to Plant Systems
Solar Host
Minimal Installation Powered Applications
Cost - No Wires
Battery, Solar or Field

Powered Devices Battery
Powered
HOW IT WORKS WirelessHART™ uses the IEEE-defined media

Hesh Kagan, Invensys’ director of technol- access control (MAC) header, further ensuring
ogy, explains, “WirelessHART™ and SP100 use robust, reliable co-existence with neighboring
the same radio and mesh networking stacks. wireless networks.
Though WirelessHART™ has some underlying • Fully redundant mesh networking − Wire-
differences, it could certainly be run as one of lessHART™ permits each device to transmit its
SP100’s protocols.” own data and relay information from other
WirelessHART™ technology is based on devices in the network, giving highly reliable
the international radio technology standard, end-to-end data communication. Each transmit-
IEEE802.15.4 2.4GHz. These are low-power ting device has two routes to send data to the
radios, making them ideal for industrial environ- network gateway. The alternate (self-healing)
ments, and they are cost-effective and available route is automatically established anytime a por-
from multiple sources. Conforming to interna- tion of the primary route is temporarily blocked
tional regulations, a +10dBm amplifier is used either physically or by electrical interference.
that allows a device-to-device communication • Enhanced security – WirelessHART™ employs
range of approximately 650 ft. (200m). All robust, industry-standard authentication security
WirelessHART™ field devices are required to be techniques that help ensure that both the net-
capable of routing messages from one device to work and its data are protected at all times. This
another, effectively increasing the reach of a net- includes message confidentiality (end-to-end
work beyond a single transmission link. encryption), message integrity checking, authen-
Major features of the WirelessHART™ proto- tication (message and device), and secure proce-
col include: dures for devices requesting to join a network.
• Time Division Multiple Access (TDMA) – This Thomas Holmes, president of MACTek de-
technique provides scheduled transmissions over scribes the potential of WirelessHART,™ saying,
the network in a series of 10ms time slots. This “It expands the possibilities for users to gain
coordinates data transmissions, reduces power access to valuable device information already sit-
consumption, and eliminates data collisions ting in their installed field devices. Access to this
within the network, effectively using bandwidth information provides the key to lowering operat-
and reducing communication latency. ing costs while remaining competitive. In many
• Frequency-Hopping – These techniques continu- cases, WirelessHART™ will allow users to have
ally switch transmissions among different bands. access to critical diagnostics and alarm informa-
This prevents potentially disruptive radio signals tion that would not be available using traditional
from blocking WirelessHART™ transmissions. wired HART technology.”
CT0709_Hart.indd 10 8/22/07 2:01:42 PM

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TUPA-168 TU-0907-25 Remote IO Ad1 1 8/22/07 12:43:04 PM

Wireless Cuts the ChAIns
What WirelessHART™
Can Do For You
When facing new operational challenges, innovative companies
find solutions using wireless technologies.
W
irelessHART™ is not just another piece diagnosing and troubleshooting instrumentation,
of manufacturing bling—the equivalent speedier commissioning, monitoring of critical
of the newest “must have” cell phone data, or even supervisory process control, wired−
or MP3 player that, in reality, consumers can do and now WirelessHART™− is able to meet each
just fine without. Rather, it extends the power of and every one of those requirements.
wired HART and has the potential to become an
essential part of your process plant’s communica- The Way it could be
tions network. It opens up new possibilities for Some major industrial users, such as BP and PPG,
measurement, testing, quality control, asset man- are installing prototype projects. Both companies
agement, and safety. What follows is an explora- have installed Emerson’s wireless systems, that
tion of some of these potential uses. company spokespersons have said are intended to
be pre-standard WirelessHART™ devices that can
Not just “part-time” help easily be upgraded once the standard is completely
The truth is, and always has been, that HART released and certified devices are available. Other
communication does aid device commissioning vendors, such as ABB, Honeywell, and Yokogawa,
and troubleshooting, but it is a “full-time” re- have also had beta test sites.
source, providing multivariable process data as But because WirelessHART™ is so new, real-
well as device status and health information. And world examples are not available. So to explore
now, with the introduction of WirelessHART,™ the benefits of WirelessHART,™ we have provided
each and every one of those features and benefits four fictitious companies with real problems
are easier than ever to collect. found in real process operations and that demon-
Gareth Johnston, a Fieldbus communication strate the kinds of solutions WirelessHART™ can
specialist with ABB, says “The low cost of install- provide. Here are the real-world challenges faced
ing WirelessHART™ will result in the end user by these fictitious companies.
being able to install short-term or ad hoc process • Everyday Chemicals wants to expand its prod-
measurements to improve the view of the process, uct offerings and quickly learns that it also needs
perhaps to solve quality issues.” better visibility into its processes.
Marty Zielinski, Emerson Process Management’s • Faced with aging instrumentation, no visibility
director of HART and fieldbus technology, concurs. about instrumentation health and performance,
“WirelessHART™ can also be used to add new and ever-increasing customer demands for water,
wireless measurement points at up to 90 percent Mega-Metropolis Water Treatment needs a reli-
lower installed cost than conventional wired points.” able, cost-effective solution that can be updated
Whether you need additional monitoring, easier over time and will reuse as much of its existing
ways to calibrate field instruments, better records instrumentation infrastructure as possible.
of instrument configuration changes and calibra- • When Really Cool Colored Inks hires a new
tion records, online insight into instrumentation plant manager away from a competitor, it learns
status, health and performance, assistance in why its competitor is more efficient, agile, and
CT0709_Hart.indd 12 8/22/07 2:02:04 PM

Pipes-Wireless_Horiz_FullPg.qxd:Control Spread 8/20/07 5:21 PM Page 1
Rosemount Flow
Measurement
Rosemount Level Rosemount
Measurement Pressure
Measurement
Wireless
1420 Gateway
AMS Suite:
Rosemount Temperature Intelligent
Measurement Device Manager
Start bouncing signals today. SmartPack™ starter kit

Call 1-800-999-9307 or go online to EmersonProcess.com/SmartPack
The Emerson logo is a trademark and a service mark of Emerson Electric Co. ©2007 Emerson Electric Company
CTHart_FPA.indd 14 8/21/07 9:43:39 AM

A wireless signal has no way through obstacles.
It will just bounce around.
At least the smart one will.
Introducing Emerson’s Smart Wireless – the secure, robust, self-organizing wireless network
that’s as easy to use as it is smart. With Smart Wireless, all the devices in the network can
communicate with each other. Whether it meets a permanent obstacle or a temporary barrier,
the self-organizing network automatically routes the signal around it. Smart Wireless is not
just flexible, it’s dependable – proven to deliver greater than 99% data reliability. To find why you should rely
on Smart Wireless from Emerson go to EmersonProcess.com/SmartWireless.

going the distance
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Control_0907_Hon_IMC_Lifetime_Tr1 1 7/3/2007 11:07:42 AM

Host Application
Network
Field Devices
Host Application
Gateway
Handheld
Network
Manager
Process Automation
Existing HART
Controller
Devices
Gateway
Adaptor
profitable: It’s using asset management software to process measurements can be provided easily
access process and instrumentation information. and cost-effectively.
Really Cool wants to move in the same direction. For example, Everyday Chemicals will replace
• Giganto Refining wants to extend the interval several single-measurement temperature transmit-
between planned maintenance shutdowns, but to ters with dual-measurement tools. For each new
do so and remain OSHA (Occupational Safety transmitter, the original (primary) temperature
& Health Agency)-compliant, it needs a way to measurement used the existing wiring and I/O
extend the full proof-testing intervals of its safety channel and appeared on the operator’s graphic
instrumented systems (SIS). exactly like the old temperature measurement. The
new (secondary) temperature measurement will be
AD HOC MEASUREMENTS collected and reported via WirelessHART™ com-
Sometimes the addition of new measurement points munication. Because of the ease of installation,
can help improve product quality, process reli- Everyday Chemicals will be able to replace the
ability or plant safety. Many modern analytical old transmitters with new ones while the process
instruments provide multiple variables that are remains operational.
accessible via WirelessHART.™ By replacing When Everyday analyzes the cost savings of not
obsolete, single-purpose instrumentation with having to add long runs of conduit and wire, not
HART-aware devices and adding self-powered having to shut down the process, not having to
WirelessHART™ adapters, new and/or secondary re-do control system upgrades and configuration,
CT0709_Hart.indd 17 8/22/07 2:02:23 PM

and not having to retrain operators, it will be able an upgrade plan that can be accomplished within
to add several WirelessHART™ process measure- existing budget constraints.
ment points that increase process visibility. Armed Mega-Metropolis will develop a three-year plan
with new process insights, the operators will be to replace aging, but critical existing instruments
able to significantly improve Everyday Chemicals’ with new HART instruments, each fitted with
product quality. WirelessHART™ adapters.
Less critical instruments will be placed in the
Aging instrumentation “replace-on-failure-pay-out-of-maintenance”
When you read articles in trade publications or at- category. Anytime one of these instruments fails
tend conferences and user group events, it’s easy to or otherwise qualifies for replacement, Mega-Me-
forget that not everyone has installed cutting-edge tropolis will purchase a HART instrument with
digital fieldbus. In fact, there are still many plants a WirelessHART™ adapter and pay for it using
with decades-old pneumatic instrumentation. money from its maintenance budget.
A significant number of process control instal- Because this plan uses existing wiring, instru-
lations have yet to make it to the 4-20mA analog ment replacements will be easy to install, calibrate,
electronic era, and there are boatloads of pre- and commission. After a minor upgrade to existing
HART 4-20mA instruments and another boatload handheld configuration devices, Mega-
of HART instruments that are under-utilized Metropolis also will be able to configure the new
throughout the world. WirelessHART™ parameters. With rare exceptions,
Because WirelessHART™ is fully backward- a measurement will be offline for less than one
compatible, it opens up all sorts of opportunities hour. Armed with new process information, Mega-
to use those thousands of miles of existing wire to Metropolis Water Treatment will find it can im-
ease replacement of aging instrumentation as well prove filter efficiency and thus filter maintenance,
as begin using HART information to improve pro- thereby maximizing chlorine effectiveness. The
cess reliability, availability, and plant utilization. ability to analyze HART information also will en-
Like many utilities and municipalities, Mega- able Mega-Metropolis to reduce filter maintenance
Metropolis Water Treatment cannot justify a frequency, thereby freeing up more maintenance
rate increase to cover the cost of upgrading to dollars to purchase additional HART instruments.
digital fieldbus technologies. However, it also
cannot afford to maintain the status quo; it Managing assets
needs a reliable, cost-effective solution that can The efficient management of a business’s assets
be updated over time and reuse as much of the is really what CEOs are expected to do, and how
existing instrumentation infrastructure as pos- well they do it is what Wall Street analysts use to
sible. Enter WirelessHART.™ reward or punish a company’s stock.
By conducting an in-depth instrumentation Asset management information is a critical
audit, Mega-Metropolis will be able to develop predictive maintenance component, but that’s only
one of its benefits. It can also capture important
Safety Expert Weighs In institutional knowledge.
When asked about the benefits of using HART process and Like an increasing number of companies, Really
device information to extend safety system proof-testing Cool Inks specializes in producing “designer prod-
intervals, exida founder and recognized safety instrument- ucts”; that is, products designed to meet specific
ed system expert, William Goble, said, “I believe that the customer and/or niche markets. The upside of de-
use of HART in SIS for purposes of performing proof-testing signer products is the potential for greater profits;
or semi-automatic proof-testing could be very valuable. the downside is that frequently a significant amount
I see an increasing number of SIS manufacturers adding of time elapses between production batches, and
HART AI/AO input modules. The downside of HART is that product formulations aren’t well-documented or
configuration variables can be accessed and changed via universally understood by operators.
handheld communicators. Some safety transmitters require Really Cool Ink’s new plant manager understands
that HART be disconnected during safety operation, as the that in order to capitalize on the upside of designer
devices’ software and hardware do not provide specific products, his plant needs to minimize the downside
protection against that possibility.” impacts, and that means establishing a robust asset
CT0709_Hart.indd 18 8/22/07 2:02:35 PM

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11:07:42 AM

management infrastructure that can capture the Safety instrumented systems

deep process knowledge that resides in experienced During the past couple of years, process indus-
operators, maintenance technicians, and senior try safety standard IEC 61511/ANSI/ISA 84.0.1
automation engineers. and its related safety instrumented systems (SIS)
Using a similar, but a more aggressive approach have been grabbing more and more headlines. At
than Mega-Metropolis Water Treatment, Re- the same time, ever-increasing energy demands
ally Cool Ink’s plan includes using the control are forcing companies like Giganto Refining to
system and a robust process-variable historian to seek ways to extend the interval between planned
identify the “gold production standard” for each maintenance shutdowns (outages) while remaining
product, with full recognition that because some OSHA regulation-compliant.
products are so infrequently produced, it will While examining what will be required to
take years to develop the entire gold-standard extend the interval between planned outages, one
library. Nevertheless, Really Cool Ink’s initiative of the problems Giganto engineers have identified
isn’t about quick profits; this asset management is the safety criteria used to design its SISs. Unless
endeavor is viewed by the entire company as Giganto’s engineers can find a way to extend the
strategic to its long-term success. Therefore, the interval between when the SIS is fully proof-tested
chief executives are committed to the tactical – a complex test that requires the process to be
implementation of the plan. shut down – it will not be possible to extend the
To ensure that as much in-process information interval between planned outages.
as possible is captured, Really Cool Inks is identi- Consistent with good engineering practices,
fying the critical measurements and replacing all Giganto uses hardwired instruments as SIS inputs.
the non-HART instruments with HART-enabled To facilitate commissioning and calibration ef-
and WirelessHART™ devices and adapters. During forts, HART instruments have been purchased and
the initial instrumentation audit, Really Cool Inks installed. Though Giganto’s engineers are aware
has been pleasantly surprised to find that many of the process and device diagnostics available in
of its instruments are already HART-capable, but HART devices, efforts to collect and analyze the
because they had been installed to help simplify information have yet to be undertaken.
commissioning and calibration, device diagnostic Now, with an urgency to extend the interval
and process information has not been collected between full proof-testing, Giganto’s engineers are
from a single instrument. taking a hard look at HART information, espe-
Really Cool Ink is still in the early stages of cially clause 3 of the IEC 61511 standard.
its plan to capture exactly what is required to Clause 3 defines, among other things, the safe
become more efficient, agile, and profitable in the failure fraction (SFF): the fraction of safe failures
delivery of designer products. However, it knows and dangerous detected failures in relation to the
one thing for sure; WirelessHART™ is one of the total failures. After consulting with safety system
critical components to its success. consultants, Giganto’s engineers are convinced
that by adding asset management software and
Mix & Match? No Problem WirelessHART™ adapters to its existing SIS
Few, if any, process plants use only one instrument com- HART devices, they will be able to use the HART
munication means. Older plants still have miles and miles process and device diagnostics to improve the
of wire. Plants using digital fieldbus communications (i.e., system’s SFF and thereby extend the time be-
DeviceNET, Foundation, Profibus, etc.) likely have installed tween full proof-testing.
different communication protocols to meet different What makes the WirelessHART™ adapters espe-
requirements. The result is often a plant with a little-of- cially attractive is that each can be added anywhere
this and a little-of-that, which when examined as a whole, along the transmitter wires, and the new devices do
produces the simple question, “Is there an easy way to get not introduce any common-cause faults.
information from these multiple communication protocols To minimize the possibility that the HART con-
into one collector (repository) device?” figuration variables of the safety system transmit-
Now, with the introduction of industrial wireless, the ters might be inadvertently changed via a handheld
answer has become much simpler; You bet there is and communicator, Giganto engineers will place each
WirelessHART™ is part of that solution! safety system transmitter in a double-locked instru-
CT0709_Hart.indd 20 8/22/07 2:02:50 PM

ment enclosure and place one key under the control and completely wirelessly makes these measure-
of the maintenance shop foreman and the second ments possible after all.
under that of the operations supervisor.
Through the use of WirelessHART,™ asset Steam traps
management software and some clever physical As energy prices rise, it becomes increasingly
transmitter configuration security plans, Giganto important to limit the amount of energy wasted.
Refining will be able to improve the SFF of its Plants often have many steam traps, and these
safety systems, thereby extending the interval be- can be easily monitored for unusual steam flows,
tween full proof-testing and, in turn, extending the allowing notification of a need for correction of
interval between planned maintenance shutdowns faulty operation that might otherwise go unno-
(outages), all while remaining OSHA regulation- ticed for some time.
and IEC 61511- conformant. “We’re doing some temperature profiling on a
stagnant steam line that is out in the middle be-
Additional wireless opportunities tween two major parts of the plant,” says PPG’s
Though early deployments of WirelessHART™ are Rob Brooks, “where there aren’t even junction
expected to be adaptors installed on hardwired boxes.” WirelessHART™-enabled sensors can
devices, the HART 7 standard does provide for save thousands of dollars in steam costs for
fully wireless HART deployments. very little outlay.
Beyond process monitoring, wireless is a natural
fit to provide a cost-effective means for health, safety, Safety showers
and environmental monitoring in such areas as area In the United States, OSHA’s First Alert Response
gas detectors, water effluent, gas emissions, relief guidelines require that plant operators be alerted
devices, steam traps, and safety showers. within 10 seconds of an activated safety shower.
Many remote safety showers are located in haz-
Area gas detectors ardous locations with no existing signal wiring. A
Many process plants require numerous gas detec- self-powered WirelessHART™ pressure transmit-
tors throughout the plant to ensure that the air is ter could be used and would only be required to
safe to breathe and to work in. Wireless detectors switch on its radio when the safety shower is oper-
will not only provide an efficient means of provid- ated or for remote diagnostic checking.
ing an alert to operators, but also to monitor the
operational status of the devices. Proceed with confidence
WirelessHART™ is an extension of the well-
Water effluent, gas emissions, known, widely accepted and proven-in-use
and relief devices HART Communication Protocol that has helped
The quality of any liquid or gas leaving a pro- improve thousands of process control facilities
cess facility is vitally important to maintaining worldwide. You already have the instruments;
environmental quality. Regulations are requiring now you can unchain the data in them. By updat-
more measurements at more frequent intervals ing the device description file, the same tools you
to ensure compliance and decrease the num- already use become suitable for use with Wire-
ber of fugitive emissions. Specifically, Wire- lessHART™ devices. WirelessHART™ devices can
lessHART™ devices could be used to monitor be configured wirelessly too. WirelessHART™
the opening of relief valves or the condition of uses the experience and knowledge gained using
rupture disks. By connecting the wireless data HART to minimize training and simplify mainte-
to the environmental monitoring software for nance and support activities.
the plant, WirelessHART™ devices can provide With WirelessHART™ you are assured of the
an easy, cost-effective way to audit the required same attention to interoperability and robustness
measurements without extensive modifications you’ve come to expect of wired HART. You get to
to existing control systems and plant wiring. use the same instruments in the same way, and you
Since many effluents aren’t located conveniently get the extra benefits. Like its wired counterpart,
close to the center of the plant, the ability of WirelessHART™ technology ensures your invest-
WirelessHART™ devices to operate on batteries ment will be protected well into the future.
CT0709_Hart.indd 21 8/23/07 9:56:57 AM

Getting Unchained
How to Get Unchained

with WirelessHART™
Deploying any industrial wireless network requires addressing physical
and security related issues, however WirelessHART™ offers several
advantages over other wireless alternatives.
“M
any control systems do not existing knowledge and software tools to support
provide access to HART data,” WirelessHART™ instruments and adapters.”
says Yokogawa’s Manager, Field
Instruments, Kaoru Sonoda, “and wireless technol- Flexibility by design
ogy can be a practical and cost-effective solution.” According to Guido Stephan, director technology
The solution is not to require control system and processes, automation, and drives, sensors
vendors to revise, or end users to rip and replace and communication, R&D technology & pro-
existing control systems, but rather to enable cesses, Siemens AG, “WirelessHART™ commu-
them to do an end run around the problem. But nication will not replace wired HART, but it will
increased demands on operators and maintenance offer access to diagnostic features of field devices
demand a simple, effective solution. and will allow additional applications not pos-
Enter wireless. sible with wired devices.”
“Wireless technology has now been tested,” Sono- WirelessHART,™ part of the new HART 7
da continues, “and we believe it is capable of meeting standard, provides four ways to acquire data from
the critical demands of the process industries.” field devices.
Gareth Johnston, fieldbus communication specialist The first two are the traditional wired methods,
with ABB, says, “WirelessHART™ has been designed with the primary physical variable on the 4-20
to simplify commissioning and lifetime support. The mADC loop, and the digital data (diagnostics,
specification team always had it in mind to keep it as secondary physical variables, alarms, etc.) carried
simple as 4-20mA. The result is that users can employ on the wire and pulled off at the control system or
by a handheld calibrator.
Mesh network architecture The two new ways are
1) Wireless adapters for existing field device,
2) WirelessHART™ field devices, with or
without wires.
The wireless adapter is designed to retrofit
any of the more than 24 million existing HART
devices and provides wireless access to both the
primary process variable and all the digital data
from the device. A WirelessHART™ field device
can be installed with or without 4-20 mA loop,
Figure 1. WirelessHART™’s mesh network architecture al- can operate on battery power, and provides the
lows relatively easy installation, often without an extensive same data access as the adapter. The wireless data
site survey. The self-organizing and self-repairing nature of a is transmitted to a gateway, which connects to the
mesh network is well-suited to the industrial environment. control or asset management system.
CT0709_Hart.indd 22 8/22/07 2:03:18 PM

As with all previous upgrades to HART standards,
HART 7 and WirelessHART™ are completely back- Mesh network architecture
ward compatible to any installed field device. 4-20mA
Now is probably a good time to reiterate that with HART 4-20mA
with HART
HART information – diagnostics, health, second- 4-20mA
Marshalling panel
ary variables, etc. – is communicated digitally with HART
on the same pair of wires as the 4-20mA pri- 4-20mA
with HART
mary measurement signal. Implementing Wire-
lessHART™ simply provides another means of Field
JB
accessing that same HART information and more.
WirelessHART™ technology is based on IEEE
802.15.4 2.4GHz radio technology. The low power WirelessHART
requirements of radios designed to this standard
make them inherently suitable for low- power mesh 4-20mA
networks, and because of international standards, with HART
these radios are cost-effective and available from

multiple sources. To ensure conformance to inter- Figure 2. Fully developed, a HART network uses Wire-
national regulations, each radio includes a +10dBm lessHART™ to unchain the valuable diagnostic and process
amplifier that supports a clear-path transmission data locked inside existing systems and provides for future
range of approximately 650 ft. (200m). Additionally, expansion with a choice of wired or wireless field devices.
to extend the reach of the wireless network, each
field device is required to communicate its own data even a few hundred feet. Beta testers have reported
messages, as well as being capable of passing on data that they have installed a gateway and carried a
messages received from neighboring devices. (See wireless instrument around to check location and
Figure 1.) The flexibility of WirelessHART™ provides quality of signal, rather than doing an extensive
multiple options for device placement to extend both survey. Typically process plants have both inter-
the reach and reliability of the network. mittent and permanent obstacles that are likely to
reduce, often times significantly, a user’s ability to
Planning establish wireless communication between field-
Though the underlying technology of Wire- mounted devices. WirelessHART™’s mesh network
lessHART™ all but eliminates the need to conduct simplifies this issue by providing multiple paths
complex site surveys, no one is so naïve as to around obstacles, including the ability to go point-
believe that network robustness, maintenance, to-point, not just mesh.
and ease of future expansion (scalability) can be Having the flexibility to locate HART wireless
achieved without some degree of up-front planning. adapters anywhere along the wire can simplify
To ensure a WirelessHART™ installation meets installation, maintenance, and security signifi-
performance expectations, users should examine cantly, as in the case of the wireless adapters inside
these four areas: a marshalling cabinet where distances are minimal
1) Physical layout, and intrinsic safety isn’t an issue (Figure 2). Like-
2) Reliability, security and coexistence, wise, a transmitter can be placed in an otherwise
3) Commissioning, inaccessible location, say, under a large reactor,
4) Operation and maintenance. and the adapter located in a location where clear-
path transmission is available. No other wireless
Physical layout methodology provides this flexibility.
When users begin planning an industrial wireless Once a physical WirelessHART™ device layout
network, a plant walk-through reveals the physical plan is developed, the next step is to examine reli-
difficulties of achieving clear-path transmissions of ability and security requirements.
CT0709_Hart.indd 23 8/22/07 2:03:47 PM

Getting Unchained
Getting Your Feet Wet
You may have 50 or 5000 HART-enabled devices in your plant,

and all of them are working, doing their jobs. You might not want
One of the beauties of the
to do anything to disturb them while they work until you have WirelessHART™ standard is
some more experience with the new WirelessHART™ technology.
that the wireless
So what to do?
You can gain experience with unchaining your HART data one adapter does not need to be
of two ways. First, you could find a place where you’d like to located at the transmitter.
monitor process variables, but because of the expense, you’ve
never been able to justify doing it before.
BP’s Cherry Point, Wash., refinery did that in the most publi-
cized beta test of Emerson’s SmartWireless system.
SmartWireless was designed as a WirelessHART™ precursor;
that is, the system was designed to take HART data wirelessly,
using hardware and firmware that approximated a best estimate
about the final standard. Emerson publicly stated at the time and
has reiterated since, that SmartWireless was capable of and in-
tended to be upgraded to WirelessHART™ as soon as the standard
was released and products were certified and available for sale.
Marty Gering, wireless data collection coordinator and wire-
less worker administrator for the refinery, was in charge of the
demonstration installation. Although Cherry Point is actually
the second-newest refinery in the U.S., there are many locations
where large bodies of uncaptured data exist.
"This data is valuable," Gering said at Emerson Exchange 2006
when he discussed the installation, "but we can't touch it because
of the expense of wiring and running conduit. Lube oil and bearing
This field device is installed at PPG Industries’ Lake Charles, temperatures, among other values, are just left out of the picture."
La., facility and transmits HART data entirely wirelessly. (Photo Gering is at work on another project now: the tank farm.
courtesy of Emerson Process Management) Cherry Point was built to be a 95,000 bbl/day refinery and
Reliability, Security & coexistence less network, tolerance means that receiver nodes
Understandably, reliability and security ranked tolerate interference caused by other nearby radio
high among end-user concerns during initial frequencies or the occasional mistake, doing what
discussions about deploying wireless technolo- is necessary to prevent data loss. WirelessHART™
gies within the process industry. To that end transmitters can also use a power turn-down fea-
WirelessHART™ addresses reliability and security ture to reduce the reach and/or range of the signal
concerns by using robust, well-proven, and highly to avoid network conflicts.
effective techniques. In fact, when combined with WirelessHART™’s robust security measures
built-in good neighbor/tolerant neighbor co- protect the network and its data at all times.
existence features, WirelessHART™’s use of fully They include message confidentiality (end-to-
proven mesh network routing techniques make end encryption), message integrity checking,
it highly reliable. message and device authentication, and secure
Like any good neighbor, WirelessHART™ de- procedures for devices joining the network.
vices try to avoid bad behaviors, such as talking Industry standard techniques are used to
(transmitting) too loudly, talking too often, talking provide authentication and encryption. Wire-
too long and/or using the entire frequency band, lessHART™ also gives users the flexibility to apply
that affect others. Tolerance is a second charac- their own network security strategy while prevent-
teristic of being a good neighbor. Within a wire- ing security from ever being disabled.
CT0709_Hart.indd 24 8/22/07 2:04:22 PM

To control
system
Asset
Management
Sysytem
HART data to
PC via OPC or
Control other protocol
Loop Controller
WirelessHART™
gateway
WirelessHART™ network
using adaptors for
existing instruments
has now become a 245,000 bbl/day refinery just by increasing In addition to the wireless field device Gering is using,
throughput and optimization. The tank farm was built with the second path to unchaining HART data is only now be-
only level and, in some cases, temperature sensors, and Gering coming available. One of the beauties of the WirelessHART™
wants to access that information wirelessly. standard is that the wireless adapter does not need to be
"We're beginning a new project to connect those tanks wire- located at the transmitter. It can be located anywhere along
lessly with backup level. We also have hundreds of valves that we'd the 4-20 mA current loop.
like to have positioner information on, as well as other pressures As soon as adaptors become certified for compliance, you’ll
and temperatures," Gering announced. "We have mixers with mo- be able to buy and try them out on existing wired HART instru-
tors we'd like to monitor current on, and lots of other things. We're ments where you already know you want the data inside them.
looking at 300 points. We want to finish the engineering this year This will require NO rewiring and will not require taking the
and have a big start on implementation by the end of 2007." instruments or control valves out of service at all.
As you prepare to install and then commission each one joins the network.
WirelessHART™ systems, remember that your expe- But first, the network manager, which may or
rience, training, and tools used for HART-enabled may not be hosted in the gateway device, must be
devices apply to WirelessHART.™ configured with the correct network ID and device
WirelessHART™ devices are configured and password(s). Once that is done, the network
installed in much the same way as they have manager will automatically adjust the network’s
been in the past, protecting your investment and schedule based on the requirements reported by
maintaining the HART experience of being easy each device as it joins the network.
to use. After the WirelessHART™ adapters are in- Because WirelessHART™ provides an additional
stalled, commissioning can begin. Actually there means of collecting HART information, the com-
are two parts of commissioning–network commissioning procedure is similar to that for wired
missioning and device commissioning. systems. Using existing HART configuration tools,
such as a HART handheld configurator or per-
NETWORK COMMISSIONING sonal computer (PC) application, users only need
Network commissioning begins when the gateway to configure three additional parameters–device
device is powered up and begins advertising. Being password(s), network ID and device refresh rate.
the first device in the network, the gateway estab- Existing handheld or PC applications can also
lishes its own schedule that synchronizes nodes as provide a status display of the joining process
CT0709_Hart.indd 25 8/22/07 2:04:41 PM

Getting Unchained
and will quickly help pinpoint any communica- log value of the primary variable (PV) is compared
tion issues. These devices also can provide access to the digital value being reported from the device.
to diagnostics and supporting device calibration For example, someone might have provided an
and maintenance operations. offset to the 4-20mA analog value that has not
been accounted for in the control system. Compar-
Device commissioning ing the digital value of the PV to the analog value
The final step to commissioning a Wire- verifies the entire loop is properly calibrated.
lessHART™ network is to complete device Consistent with wired HART, theWire-
verification and conduct a loop test of any wired lessHART™ specification allows wireless devices
devices. WirelessHART™ devices need no 4-20 and wired devices using adapters to simulate a
mA loop, and have a maintenance port for test- process value to accommodate loop testing, al-
ing. Commissioning and maintenance are done lowing verification of data across the network,
via standard commands or DDL. through the gateway, and into a host application.
When so specified on the purchase order, device A wireless device can be set to transmit a fixed
manufacturers put device tags and other identifi- value in order to conduct this important test.
cation and configuration data requested the user Many HART configurators provide easy ways of
into each field instrument prior to shipment. After collecting, archiving, and/or printing commissioned
installation, the instrument identification (tag and device information. Because WirelessHART™ uses
descriptor) can be verified in the host system using the same configurators as hardwired HART, existing
a configurator (handheld communicator or PC). procedures for collecting and recording “as-installed”
Some field devices provide information on their device configuration data, calibration records, and
physical configuration (e.g., wetted materials). These other device records remains essentially unchanged.
and other configuration data can also be verified, WirelessHART™ is the first open and interoper-
thereby ensuring the installed instrument is suitable able wireless communication standard designed to
for the application. Such verifications are important address the critical needs of process industry users.
for regulatory health, safety, and environmental con- It has been carefully designed and thoroughly
formance, as well as ISO quality requirements. tested to provide reliable, robust, and secure wire-
Loop integrity is important when commission- less communication in real-world industrial plants.
ing a device. For HART-enabled devices, analog WirelessHART™ provides new ways to gather
loop integrity can be checked using a loop test information on process parameters and monitor
feature, available in many HART devices. The the performance of plant assets in areas that have
loop test feature enables the analog signal from a previously been difficult to achieve either techni-
HART transmitter to be fixed at a specific value cally or cost-effectively. It extends the power of
so total loop integrity from device to indicators, HART into areas that were difficult to reach with
recorders, and operator displays is correct. conventional wired systems, and it provides low-
Additional integrity can be achieved if the ana- cost digital access to existing HART devices.
Affordable DD Based Configuration Using Your PC
ProComSol, Ltd designs and manufactures both the hardware and software needed
to perform complete HART device configuration and monitoring using your PC.
DevCom2000 software uses the registered DD’s from the HART Foundation, allowing
full access to all device parameters, including Methods. The HM-USB USB HART
modem and the HM-BT-BAT Bluetooth HART modem offer significant cost savings
and productivity benefits. Units meet industry standards for USB, Bluetooth, and
HART connectivity. Order this affordable solution online using our secure website.
ProComSol, Ltd
Process Communication Solutions
Tel. 216.221.1550 • Fax 216.221.1554 • www.procomsol.com • [email protected]
CT0709_Hart.indd 26 8/22/07 2:05:03 PM

Ever installed a dP backwards?
Eliminate rework with reversible polarity.
The innovative 364 dP transmitter.

Pulling out and reinstalling a reversed dP takes time
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High and Low side with the push of a button - regardless

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Visit us at www.abb.com/pressure to learn more about
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© Copyright 2007 ABB.
This side up_HART.indd 1 8/15/07 12:51:38 PM

4HE NEW INTEROPERABLE WIRELESS COMMUNICATION STANDARD
FOR THE PROCESS INDUSTRIES
WIRELESSHARTCOMMORG
(!24¤ AND 7IRELESS(!24 4- ARE TRADEMARKS OF THE (!24 #OMMUNICATION &OUNDATION

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Application Guide

Keep Your Plant Competitive

Get More from What You’ve Got

Unleash the Power – See What You Can Do

Realize the Potential

Unleash the Power – Your Wish is HART’s Command

WirelessHART™ Information Unchained

WirelessHART Overview Presentation by HCF Executive Director

The Complete HART Guide Sponsors

For additional information contact:

The HART Application Guide has been created by the HART

© 2003 HART Communication Foundation Page 1

Page 2 © 2003 HART Communication Foundation

© 2003 HART Communication Foundation Page 3

Frequency Shift Keying

Figure 1: Simultaneous Analog and Digital Communication

Page 4 © 2003 HART Communication Foundation

POINT-TO-POINT In point-to-point mode, the traditional 4–20 mA signal is used to

Note: Instrument power is provided by an interface or external power source

Figure 2: Point-to-Point Mode of Operation

© 2003 HART Communication Foundation Page 5

Control System or Other Host

Note: Instrument power is provided by an interface or external power source that is

Figure 3: Multidrop Mode of Operation

Page 6 © 2003 HART Communication Foundation

COMMON Common practice commands provide functions implemented by many, but

Table 1: HART Commands

Note: Table 1 is a partial list of HART commands. See Appendices B, C,

© 2003 HART Communication Foundation Page 7

Page 8 © 2003 HART Communication Foundation

Benefits of HART Communications

© 2003 HART Communication Foundation Page 9

Improved Plant Operations

Multivariable devices reduce the number of instruments, wiring, spare

Page 10 © 2003 HART Communication Foundation

Improved Plant Operations

Field Control Room

Figure 4: Examples of Device Parameters Sent to Control Room

© 2003 HART Communication Foundation Page 11

Improved Plant Operations

Page 12 © 2003 HART Communication Foundation

Primary Master: Power

Figure 5: Multimaster System

© 2003 HART Communication Foundation Page 13

Instrumentation Investment Protection

At the basic level, HART devices communicate with a handheld terminal

Page 14 © 2003 HART Communication Foundation

Benefits HART Instruments Digital Instruments

© 2003 HART Communication Foundation Page 15

Getting the Most out of HART Systems

Page 16 © 2003 HART Communication Foundation

Wiring and Installation

Cable Capacitance – pf/ft (pf/m)

No. Network 20 pf/ft 30 pf/ft 50 pf/ft 70 pf/ft

9,000 ft 6,500 ft 4,200 ft 3,200 ft

8,000 ft 5,900 ft 3,700 ft 2,900 ft

7,000 ft 5,200 ft 3,300 ft 2,500 ft

6,000 ft 4,600 ft 2,900 ft 2,300 ft

Table 3: Allowable cable lengths for 1.02 mm (#18 AWG)