Control engineering september 2015 by Aso de Ingeniería Química

www.controleng.com

Au T to hin m k at A io llie n d & f Co or nt ro l

APR15 A&C Snipe (CE)_Layout 1 3/13/15 2:33 PM Page 1

, BIG features

Precise built-in data logging Up to 32GB of information can be stored and accessed locally via micro SD or remotely accessed with the built-in web server.

eal-time data on temperature and analog modules

Get the RIGHT information . . . RIGHT now! Wiring diagrams, spec sheets and assembly instructions are available simply by scanning drop-down QR code tab on all I/O modules.

See for yourself!

Scan the QR code below.

FREE fully functional programming software

Productivity Suite software was developed and is supported , GA headquarters. Designed to work easily and efficiently, it has been industry-proven reliable by our customers for years.

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P2-550 CPU FEATURES: •

AutomationDirect

CPU and I/O Comparison

• •

High-resolution 4 line by 10 character OLED diagnostic display 50MB built-in memory Removable micro SD slot

• • • •

USB programming port RS-232 port RS-485 port 10/100 Ethernet port

•

10/100 Ethernet port

•

Three industry-standard communications protocols

Up to 32GB of data storage per card

MULTIPURPOSE

Allen-Bradley

Productivity2000

CompactLogix

Base (if required)

$69.00

N/A

Power Supply

$69.00

$414.50

CPU

$255.00

$3,160.00

16 AC Inputs

$105.00

$286.00

16 24VDC Inputs

$69.00

$244.00

8 Relay Outputs

$51.00

$301.50

8 Analog Input Channels (mA)

$199.00 P2-08AD-1

1769-IF8

ASCII Comm Module

$0.00

$737.00

Modbus RTU Comm Module

$0.00

$701.00

Total System Price with USB, Ethernet and Serial

$817.00

$6557.50

P2-04B

P2-01AC

P2-550

P2-16NA

P2-16NE3

P2-08TRS

Built in to CPU

N/A

1769-PA4

1769-L33ER

1769-IA16

1769-IQ16

1769-OW8I

$713.50

1769-ASCII

1769-SM2

All prices are U.S. published prices. AutomationDirect prices as of 6/5/2015. Allen-Bradley retail prices taken from www.plccenter.com 5/12/2015.

Plus the Productivity2000 features: • Effortless PID loops • Flexible tag name programming • Auto-discovered I/O

• Hot-swappable modules • Simple VFD conﬁguration • Built-in data logging • Web server functionality

REMOTE I/O GS DRIVES only

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input #1 at www.controleng.com/information

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Productivity2000 - small size Shown at actual size: power supply, CPU and seven I/O modules in only 10-1/2”

Rea

FR ETHERNET

micro SD

USB

RS-232

RS-485

Don’t let the small size fool you, the Productivity2000 is a robust controller that includes many impressive features in its compact design. From tag name programming, to auto-discovered hardware including VFD’s, to web capabiltiy and mobile device access. There is really no way to discuss them all, so head on over to our website, www.Productivity2000.com to get the full story. Hardware that is built to last Engineered here in the USA, the Productivity2000’s rugged design and quality-tested build is ready for ﬁeld duty. We stand behind its performance with a 2 year warranty. Not only can the P2000 handle adverse conditions, but the 50MB of user memory also ensures that it has enough processing power to accommodate any future expansions you may need. A small investment today can grow with your application needs tomorrow. input #2 at www.controleng.com/information

Our P at our Atlanta,

input #3 at www.controleng.com/information

SEPTEMBER 2015

Vol. 62 Number 9

® C OV E R I N G C O N T R O L , I N S T R U M E N TAT I O N , A N D A U TO M AT I O N S YS T E M S W O R L D W I D E

25 Features 25 26 28 30 33 34 36 35

26 Cover photo courtesy: Bosch Rexroth

Flexible packaging-machine design Cover story on packaging automation: All industries need control-system flexibility, code re-use, scaling, and lower cost.

Pneumatic valve technology Packaging automation: Select manifold valves with a compact, lightweight design and digital electronics for easy integration into automation controls platforms and maximum value. See more online.

Servos improve packaging machines Packaging automation: Upgrade your next machine design with servo motors to decrease downtime, decrease footprint, increase throughout, and two other key reasons. See more images online.

Managing the risk of IoT Internet of Things (IoT) is growing rapidly. More devices are going online. Security is required to protect devices and users. Industrial network design and best practices help, including six steps for IoT risk mitigation. See more advice in the Digital Edition.

Hybrid machines, standard CNC Additive manufacturing: As the era of additive and subtractive machine tools emerges, today’s controls are well suited to handle the challenges, says a provider of CNCs and training. See related Digital Edition Exclusive.

Engineering Leaders Under 40 These 2015 award-winning Leaders, a dedicated group of engineers, give hope to manufacturing’s future.

Digital Edition Exclusives, www.controleng.com/DigitalEdition: Nine articles: Metal for 3D printing; SOFTWARE: Specification documents; Gateways; IIot software delivery; Legacy software; PLANT-WIDE ETHERNET: Ethernet network health; 40% capacity increase; Networks for Industry 4.0; IoT risk

CONTROL ENGINEERING (ISSN 0010-8049, Vol. 62, No. 9, GST #123397457) is published 12x per year, Monthly by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. CONTROL ENGINEERING copyright 2015 by CFE Media, LLC. All rights reserved. CONTROL ENGINEERING is a registered trademark of CFE Media, LLC used under license. Periodicals postage paid at Oak Brook, IL 60523 and additional mailing offices. Circulation records are maintained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. E-mail: customerservice@cfemedia. com. Postmaster: send address changes to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: customerservice@cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA, $150/yr; Canada/Mexico, $180/yr (includes 7% GST, GST#123397457); International air delivery $325/yr. Except for special issues where price changes are indicated, single copies are available for $30.00 US and $35.00 foreign. Please address all subscription mail to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.

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SEPTEMBER 2015 CONTROL ENGINEERING ● www.controleng.com

䴀愀渀愀最攀夀漀甀爀匀洀愀爀琀䘀愀挀琀漀爀礀ᤠ猀一攀琀眀漀爀欀

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input #4 at www.controleng.com/information

Re-Route Your Temperature Measurements Around Potential Roadblocks The new THZ3/TDZ3 Dual Input Smart HARTÂŽ temperature transmitters can help you avoid costly process interruptions and maintenance delays by ensuring your measurements always make it safely to your control system. Our Sensor Backup and Failover protection feature means you will never miss those critical readings - even if something goes wrong with one of the sensors. Plus, with Device Intelligence, a series of new and advanced features that enable smarter control and monitoring, the THZ3/TDZ3 gives you the conď&#x192;&#x17E;dence that your temperature measurements will get from Point A to Point B despite any potential roadblocks.

Demand Moore Reliability

input #5 at www.controleng.com/information

To learn more about our Dual Input p Temperature p www.miinet.com/THZ3TDZ3 Transmitter, go to: 900 Or call 800-999-2900

SEPTEMBER 2015

C OV E R I N G C O N T R O L , I N S T R U M E N TAT I O N , A N D A U TO M AT I O N S YS T E M S W O R L D W I D E INSIDE PROCESS appears after page 45; If not, see the Digital edition: www.controleng.com/DigitalEdition

P1 How to update an HMI

Upgrading human-machine interface (HMI) hardware, software, and applications can be an efficient process with limited required development time if these recommendations are followed.

P8 A better way to install automation in classified areas

Instead of employing protection methods, it’s often better to move automation systems to less hazardous areas and to use components rated for use in these locations.

PRODUCT EXCLUSIVE

departments

news

8 Think Again Cyber-physical systems, saving children, 5G

Giving robots a more nimble grasp

Control panel standards are changing soon; Industry 4.0 group looking to expand

Standards group on counterfeit pharmaceutical packaging

Events, Online news

10 Apps for Engineers Control methods

12 Products Exclusive All-in-one compact PLC controller PRODUCTS

14 Research Workforce development: Unskilled workforce struggle

products

16 Control Engineering International

China’s Industry 4.0 implementation

64 Back to Basics

Software integrates remote I/O capability; Industrial router for remote machine connection, commissioning; Surge protection devices for industrial applications

WLAN design basics, considerations

www.controleng.com

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CONTROL ENGINEERING SEPTEMBER 2015 ● 5

More resources posted daily at:

SEPTEMBER

Trending

www.controleng.com

New Products

Control Systems

Process Manufacturing Discrete Manufacturing

System Integration

Networking & Security

Info Management

Education & Training

2015 Industrial Internet of Things (IIoT) webcast series Control Engineering’s webcast series continues in September and covers several topics on the Industrial Internet of Things. Learn more about these upcoming webcasts here www.controleng.com/ media-library/webcast-archive.html: lloT webcast two: Operations Thursday, Sept. 17, 2015, at 11 a.m. PDT/1 p.m. CDT/2 p.m. EDT IIoT webcast three: Integration considerations

IIoT video: See on-machine sensor values in real time via Apple iPad There’s a lot more to read online. Go to www.controleng.com/news to read Control Engineering’s exclusive web content: Career advice for an engineering student Security for wireless instrumentation WLAN design basics and wireless network consideration Time for OT, IT to align priorities Prevalence of IoT may leave networks vulnerable to attacks Join the conversation online at www.linkedin.com/groups?gid=1967039: Various types of PLC Thinking of a project in automation or industrial robotics for my final year... any suggestions? Why you need NO timers, other than ON DELAY!

System Integration Keep up with the latest industry news by subscribing to Control Engineering’s 14 newsletters at www.controleng.com/newsletters. SI advice includes: Project management tips for system integration Creative teamwork Gateways for the Industrial Internet of Things

Point, click, watch DIGITAL FITNESS: Tips & Tools for Trimming the Digital Fat in 2015: Steve Krull Marketing to Engineers: The digital landscape is constantly changing with new strategies emerging all the time. Join Steve Krull of Be Found Online for what promises to be an entertaining session covering some of the things you can do to get your site, content and campaigns in tip top shape for 2015, and increase your business. www.youtube.com/user/ControlEngineeringTV.

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SEPTEMBER 2015 CONTROL ENGINEERING ● www.controleng.com

Tuesday, November 3, 2015, at 11 a.m. PDT/1 p.m. CDT/2 p.m. EDT Other webcasts are archived, including cyber security, project management, Ethernet, and wireless.

Oil & Gas Engineering August issue Oil & Gas Engineering helps to maximize uptime and increase productivity with industry best practices and new innovations, increase efficiency from the wellhead to the refinery with automation and monitoring strategies, and maintain and improve safety. At www.oilandgaseng.com: Operational technology to information technology in the oil and gas industry The Internet of Things (IoT) in the oil and gas industry

Engineering career advice from the 2015 Control Engineering salary survey Think again: Many subscribers taking the 2015 Control Engineering salary survey provided write-in advice about engineering careers. Keep learning and mentoring and learn effective project management and communications, including the benefits of automation and controls engineering, are among tips and reminders. Get some advice at www.controleng.com/ce-research.

Unbeatable Control,

Precision, and Flexibility

Lowering cost, increasing productivity, and shortening design times are just some of the challenges industrial engineers face. The graphical system design approach combines productive software and reconfigurable I/O (RIO) hardware to help you meet these challenges. This off-the-shelf platform, customizable to solve any control and monitoring application, integrates motion, vision, and I/O with a single software development environment to build complex industrial systems faster.

>> Accelerate your productivity at ni.com/industrial-control-platform

800 453 6202 ÂŠ2013 National Instruments. All rights reserved. LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. 12125

input #6 at www.controleng.com/information

NI LabVIEW system design software offers ultimate flexibility through FPGA programming, simplifies code reuse, and helps you program the way you thinkâ&#x20AC;&#x201C;graphically.

editorial

THINK AGAIN

1111 W. 22nd St. Suite 250, Oak Brook, IL 60523 630-571-4070, Fax 630-214-4504

Content Specialists/Editorial

Cyber-physical systems, saving children, 5G

Automation, controls, and instrumentation are used for cyber-physical integration, saving children, and developing technologies for 5G wireless communications. Get inspired.

t’s hard not to be inspired about engineering after viewing demonstrations of the cyber-physical worlds that could help manufacturers and machine designers to be more efficient, a heart pump that’s saved more than 800 children since U.S. Food and Drug Administration (FDA) approval, and 5G wireless data transfer technologies under development shown to move 10 GB per second. These were among on-stage keynote demonstrations at the NIWeek conference in August 2015 in Austin, Texas. With data collection, “more channels and faster sampling are the trend driving more data. More data provides more opportunity to drive improvements and business results, but we cannot just connect sensors to the cloud and use the information. Innovation is required in-between. Edge analytics are needed to put control right next to measurement,” explained Eric Starkloff, executive vice president of global sales and marketing, National Instruments (NI). Ride the technology wave

“Moore’s Law wasn’t a law, it was a selffulfilling goal,” Starkloff said. Companies need to take advantage of the next incredible wave of technology, he said, and many are. An Industrial Internet of Things (IIoT) demonstration used a mountain bike fitted with sensors and instrumentation. Software from ThingWorx, a PTC business, showed how an operator might see an industrial machine’s metrics in real time by looking through a mobile human-machine interface (HMI) or wearable HMI, such as a headmounted, hands-free display. Berlin Heart Inc. created a heart assist device for children, which can assist heart pumping until the child can get a transplant or heal. Before use, testing simulates a heart to verify electrical and pressure settings for proper calibration. An automated sod-harvesting machine from Firefly Equipment, the ProSlab 155, has 8

●

an advanced design and control system, 40 hydraulic control valves, 5 axes of motion, and more than 150 I/O channels for more accuracy and less maintenance, securely. A security enhanced Linux kernel (being applied in the Airbus factory of the future with more robotics, smart tools, and coordinated interfaces), in cooperation with system integrator Leccionne, requires specific calls to the kernel to ensure that certain operations are from a secured source. Big data: Noting that companies only analyze 5% of data collected, Jaguar increased the amount of data it examines from less than 10% to more than 95%, to decrease time to market and maintain quality. Nokia, in testing for 5G cellular service under development, proved millimeter wave spectrum as viable for use, in a 2x2 multiple input multiple output (MIMO) link at 10 Gbps, more than four times better than last year. Samsung is working on full-dimension MIMO (FD MIMO) to increase capacity 3x to 5x, with 3-D waving forming to point the signal where needed. A vector signal transceiver was used by Noffz and Harmon to speed testing and decrease emergency response time to an automobile wireless notification system by 40%. Too busy to travel? Think again: Conferences deliver inspiration and information. ce

More advice Share inspiration from a conference by using the comment feature of this posted article. See 10 photos and more details, with insights from NI co-founders. Link to a robotic exoskeleton from Hyundai Motor Group. Browse events, www.controleng.com, upper right.

Mark T. Hoske, Content Manager 630-571-4070, x2214, MHoske@CFEMedia.com Peter Welander, Content Manager PWelander@CFEMedia.com Amanda Pelliccione, Director of Research 630-571-4070, x2209, APelliccione@CFEMedia.com Joy Chang, Digital Project Manager 630-571-4070 x2225, JChang@CFEMedia.com Chris Vavra, Production Editor CVavra@CFEMedia.com Eric R. Eissler, Oil & Gas Engineering, Editor-in-Chief 630-571-4070 x2224, EEissler@CFEMedia.com

Contributing Content Specialists Frank J. Bartos, P.E., braunbart@sbcglobal.net Jeanine Katzel, jkatzel@sbcglobal.net Vance VanDoren, Ph.D., P.E., controleng@msn.com Suzanne Gill, European Editor suzanne.gill@imlgroup.co.uk Ekaterina Kosareva, Control Engineering Russia ekaterina.kosareva@fsmedia.ru Marek Kalman, Poland Editor-in-Chief marek.kalman@utrzymanieruchu.pl Lukáš Smelík, Czech Editor-in-Chief lukas.smelik@trademedia.us Aileen Jin, Control Engineering China aileenjin@cechina.cn

Publication Services Jim Langhenry, Co-Founder/Publisher, CFE Media 630-571-4070, x2203; JLanghenry@CFEMedia.com Steve Rourke, Co-Founder, CFE Media 630-571-4070, x2204, SRourke@CFEMedia.com Trudy Kelly, Executive Assistant, 630-571-4070, x2205, TKelly@CFEMedia.com Elena Moeller-Younger, Marketing Manager 773-815-3795, EMYounger@CFEMedia.com Kristen Nimmo, Marketing Manager 630-571-4070, x2215, KNimmo@CFEMedia.com Brian Gross, Marketing Consultant, Global SI Database 630-571-4070, x2217, BGross@CFEMedia.com Michael Smith, Creative Director 630-779-8910, MSmith@CFEMedia.com Paul Brouch, Director of Operations 630-571-4070, x2208, PBrouch@CFEMedia.com Michael Rotz, Print Production Manager 717-766-0211 x4207, Fax: 717-506-7238 mike.rotz@frycomm.com Maria Bartell, Account Director Infogroup Targeting Solutions 847-378-2275, maria.bartell@infogroup.com Rick Ellis, Audience Management Director 303-246-1250, REllis@CFEMedia.com Letters to the editor: Please e-mail us your opinions to MHoske@CFEMedia.com or fax us at 630-214-4504. Letters should include name, company, and address, and may be edited for space and clarity. Information: For a Media Kit or Editorial Calendar, email Trudy Kelly at TKelly@CFEMedia.com.

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SEPTEMBER 2015 CONTROL ENGINEERING ● www.controleng.com

630-571-4070, x2221 Stuart Smith, International Tel. +44 208 464 5577

MHatcher@CFEMedia.com stuart.smith@ssm.co.uk

It’s About (up)Time.

Upgrade to More Uptime. When you choose a PROFINET network, the comprehensive diagnostics are ‘baked in’ the protocol. PROFINET diagnostics uniquely help prevent and reduce unplanned downtime. Scalable network redundancy is as easy as running the cable. Because it’s about time.

Welcome to The PROFINET of Things...We’ve Been Waiting for You. input #7 at www.controleng.com/information

apps for

ENGINEERS

www.controleng.com/appsforengineers

Automation Solutions for End of Line Packaging & Food Processing Industries

Control methods CFE Media’s Apps for Engineers is an interactive directory of engineering-related applications for Apple iOS and Android operating systems from various companies. We’ve categorized apps by category, company, and type. These energy management and savings applications are listed in the app as of September 2015.

EZ-RMC iOS 6.0 +, Android 4.0.3 + Cost: $25.99 Company: EZAutomation Website: www.ezautomation.net

EZ-RMC allows users to remotely connect to selected EZAutomation humanmachine interfaces (HMIs) and view and operate the currently displayed screen on the remote HMI. Currently supported HMIs: - SoftHMI ver i.12.4 or later - EZWindowsHMI ver i.12.4 or later - EZ-CE HMI ver i.12.15 or later

ISWvis Mobile Android 2.3.3+

Cost: Free Company: ISW Website: www.iswvis-mobile.at/en ISWvis Mobile is graphical software for visualization and control, or supervisory control and data acquisition (SCADA/HMI), for Simatic S7 (S7-1200, S7-300, and S7-400) and the Siemens Logo controls for Android. Use the PC Editor to create and transmit visualizations on an Android smartphone or tablet to ISWvis Mobile. See and operate control(s) over wireless local area network (WLAN) and virtual private network (VPN).

JUMPFLEX-ToGo Android 2.2+ Cost: Free Company: Wago Website: www.wago.us

Visit us at Booth #6104 South Hall

Jumpflex-ToGo brings the power of PC-based configuration software to a mobile device. Configure input and output parameters via a smartphone or tablet PC on an Android OS via a finger swipe for 857 Series transducers. View configuration data and the actual measured value. The Wago 750-921 Bluetooth adapter will communicate between a smart phone and transducer.

Lutron Home Varies with device

Cost: $19.99 Company: Lutron Website: www.lutron.com

Global manufacturer of process control and factory automation solutions input #8 at www.controleng.com/information

Control lights, shades, temperature, keypads, and more from anywhere. Set a comfortable temperature when returning from a trip, ensure lights aren’t left on, and shades aren’t left open while you’re away. Manage multiple RadioRA 2, HomeWorks QS, and HomeWorks Illumination systems in the same app.

For more information: Call: 1-800-Go-Festo 1-800-463-3786 www.festo.us/packaging

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SEPTEMBER 2015 CONTROL ENGINEERING ● www.controleng.com

Reliable Detection For Your Application

You can’t afford not to know. See it all at thinkallied.com/sensors

1.800.433.5700 © Allied Electronics, Inc 2015. ‘Allied Electronics’ and the Allied Electronics logo are trademarks of Allied Electronics, Inc.

input #9 at www.controleng.com/information

An Electrocomponents Company.

EXCLUSIVES

product

All-in-one compact PLC controller Unitronics’ Vision700 is an all-in-one compact programmable logic controller (PLC) with an expansive 7-in. color touchscreen with a variety of input/output (I/O) modules and expansion options and can use both snap-in I/O modules that plug directly into the unit and DIN-rail mounted I/O expansion units.

nitronics’ Vision700 is an all-in-one compact programmable logic controller (PLC) with an expansive 7-in. color touchscreen with a variety of input/output (I/O) modules and expansion options. The PLC offers a wide range of I/O configurations that can include digital, high-speed, and analog I/Os modules, as well as PT100/thermocouple and weight/pressure measurement. It can use snap-in I/O modules that plug directly into the unit and DIN-rail mounted I/O expansion units. Expansion modules enable 1,000 I/O points locally or remotely at distances of up to 1,000 m. Communication options include Ethernet, cellular, and industrial protocols such as Modbus, DF1 slave, BACnet, J1939, CANopen, and others. Each unit comes supplied with an Ethernet card and USB programming port; an additional RS232/RS485 port can be added for Profibus and CANbus communications. It features the “Protocol” utility, which allows it to communicate via almost any ASCII protocol. The PLC can be accessed

“I want safety straight out of the box”

via the programming port or remotely accessed using GPRS/ GSM/CDMA and other IP networks for data acquisition and program download. It can notify supervisors of critical information via e-mail and short-message service (SMS), enabling real-time remote management. It uses intuitive, all-in-one VisiLogic software, designed to enable hardware configuration, PLC, and HMI application programming. The software has a full library of drag and drop function blocks for complex automation control tasks. ce Unitronics, www.unitronics.com Input #200 at www.controleng.com/information

Go Online www.controleng.com/products has more products. Also see the product section in the September 2015 print/digital edition. Interested in introducing a product to the world here? Contact Mark T. Hoske, mhoske@cfemedia.com.

Introducing the One Series Safety Transmitter Now plant safety pros get simple setup and faster, safer performance, right from the start — all at a more affordable price. Instead of a costly, overcomplicated process transmitter that must be adapted for safety use, the One Series Safety Transmitter is the first SIL-certified transmitter designed solely for safety system applications. Only the One Series Safety Transmitter comes with an internal high-speed switch for the fastest emergency shutdown. And that simple design means fewer nuisance trips — for greater safety, productivity and throughput. Drop in the One Series Safety Transmitter and your safety work is done!

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Baldor•Dodge® Quantis Ultra Kleen® and Tigear-2® Ultra Kleen stainless steel gear reducers are the ultimate choice for poultry and meat processing applications. Completely sealed and made of premium stainless steel, each gear reducer features long-life gear construction, maintenance-free operation and IP69K rated protection against high pressure and high temperature washdown environments. You can count on Quantis Ultra Kleen and Tigear-2 Ultra Kleen stainless steel gear reducers for the superior reliability it takes to survive harsh washdown applications…day after day after day.

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Ethernet technology budget allocations Products, software Don't know

research

26%

2015 WORKFORCE DEVELOPMENT STUDY:

Five findings on the unskilled workforce struggle

espondents to the CFE Media 2015 Workforce Development Study identified five high-level findings impacting the manufacturing industries today: 1. Workforce shortage: The average manufacturing facility today has 5% of jobs currently unfilled, down from 7% in 2014. Despite the decrease, 64% of respondents still believe that their facility’s workforce shortage will increase over the next 3 to 5 years. 2. Causes: When asked about the primary causes of the workforce shortage, 56% of respondents said there aren’t enough skilled applicants to fill the roles of the growing number of retirees, and another 34% agree that their hiring rates aren’t keeping up with manufacturing’s rapid expansion. 3. Unskilled workforce: According to respondents, the younger workforce most lacks problem solving (57%), instrumentation (55%), project management (51%), and electrical knowledge (50%); but they remain proficient in computer knowledge (60%) and other basic skills (31%).

4. Actions taken: In an effort to combat the workforce shortage, 44% of facilities have taken to online recruitment and job postings, 40% have instituted or increased in-house training, and 35% have reached out to local technical schools for assistance. Nine in 10 respondents believe that their facilities still need to increase internal education/training programs and provide clear career paths for each new employee in order to better appeal to the younger workforce. 5. Manufacturing’s image: More than half of respondents still don’t believe that manufacturing is portrayed as a positive career choice in the U.S. Sixty-three percent agree that offering apprenticeship programs would help to improve manufacturing’s image, and another 57% think introducing this career choice at an earlier education level—as well as improving salaries, benefits, and job security—are key action items. View more information at

www.controleng.com/2015WorkforceDevelopment. Amanda Pelliccione is research director at CFE Media, apelliccione@cfemedia.com.

Outsourced functions as result of workforce shortages 40% 4

Maintenance e

2 28%

Engineering

1 17%

T Manufacturing IT Human resources

1 10%

Otherr

1 10%

e None

2 27%

Maintenance and controls and automation are the most outsourced functions. Graphics courtesy: Control Engineering, CFE Media.

www.controleng.com/ce-research FOR MORE RESEARCH INFORMATION ●

45%

16%

About the same

S i Services

64%

of survey respondents perceive their control system cyber security threat level as low to moderate. Source: Control Engineering 2015 Cyber Security Study

7 in10

end users expect their base annual salary to increase this year; average increase expected is 3%. Source: Control Engineering 2015 Career Survey

66%

of survey respondents claim that the lack of available skilled workers has not kept their facilities from expanding operations. Source: CFE Media 2015 Workforce Development Study

3 37%

Controls, automation

13%

SEPTEMBER 2015 CONTROL ENGINEERING ● www.controleng.com

More research Control Engineering surveys its audience on five topics each year: cyber security; career survey; system integration; information integration; and mobility, Ethernet, and wireless. All reports are available at www.controleng.com/ce-research.

input #12 at www.controleng.com/information

INTERNATIONAL

Made in China 2025:

Chinese government aims at Industry 4.0 implementation The “Made in China 2025” plan, known as the Chinese version of “Industry 4.0,” proposes four specific measurements to assess industry’s Industry 4.0 maturity.

T Aileen Jin

Editor-in-chief, Control Engineering China

he “Made in China 2025” plan, known as the Chinese version of “Industry 4.0,” was printed and distributed by the State Council in 2015, symbolizing progress from the proposal of the concept to the implementation of the plan. The Made in China 2025 proposes a target of becoming a manufacturing giant within 10 years. During these 10 years, companies should achieve significant improvement in overall manufacturing quality, enhancement of creativity and productivity, and the integration of industrialization and information. The plan stipulates that the percentage of research and development (R&D) funds of large manufacturing companies should increase from 0.95% in 2015 to 1.68% by 2025, and the valueadding ratio of the manufacturing sector should increase by 4%. Use of computer numerical controls (CNC) should increase 30%, and the energy consumption of manufacturers should fall 34%. The plan also proposes nine strategic missions, five key projects, and 10 breakthroughs in key sectors with respect to the implementation of the greater plan of transitioning from a manufac-

turing country to a manufacturing giant. The five key projects include the construction of manufacturing innovation centers, smart manufacturing projects, manufacturing base strengthening projects, green manufacturing projects, and high-end equipment innovation projects. Recently, the Chinese Ministry of Industry and Information Technology (MIIT) released the 2015 smart manufacturing projects, including 94 projects covering scientific research institutions and enterprises incorporated into the list, symbolizing the start of the smart manufacturing project in the Made in China 2025 plan. ce - Aileen Jin, editor-in-chief, Control Engineering China. Edited by Joy Chang, digital project manager, Control Engineering, jchang@cfemedia.com.

Go Online Read this online for more details. This was translated and edited for Control Engineering from Control Engineering China. www.cechina.cn See other international coverage. www.controleng.com/international

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The Control Room of the Future—Today. The Experion® Orion Console increases operator effectiveness over a greater scope of responsibility, boosting situational awareness for faster response to changing conditions. Ultra-high definition screens with pan & zoom, flexible display layouts, and operating limits and targets directly integrated into overview displays guide more profitable operation. Experion Collaboration Station displays secure control and business network information, efficiently establishing communication and collaboration among team members from diverse locations. Discover how relevant information in a common view leads to better decision-making.

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NEWS

Giving robots a more nimble grasp Most robots on a factory floor are fairly ham-handed: Equipped with large pinchers or claws, they are designed to perform simple maneuvers, such as grabbing an object and placing it somewhere in an assembly line. More complex movements, such as adjusting the grasp on an object, are still out of reach for many industrial robots. Engineers at MIT have now hit upon a way to impart more dexterity to simple robotic grippers, by using the environment as a helping hand. The team, led by Alberto Rodriguez, an assistant professor of mechanical engineering, and graduate student Nikhil Chavan-Dafle have developed a model that predicts the force with which a robotic gripper needs to The robot pivots the rod push against various fixtures in between its fingers by pushing the environment in order to adjust against a bookend. Courtesy: Alberto Rodriguez, Nikhil Chaits grasp on an object. If a robotic gripper aims to van-Dafle, MIT/MIT News pick up a pencil at its midpoint, but instead grabs hold of the eraser end, it could use the environment to adjust its grasp. Instead of releasing the pencil and trying again, Rodriguez’s model enables a robot to loosen its grip slightly and push the pencil against a wall, just enough to slide the robot’s gripper closer to the pencil’s midpoint. Rodriguez calls these improvements “extrinsic dexterity”— as opposed to the intrinsic dexterity of, say, the human hand. To adjust one’s grip on a pencil in a similar fashion, a person, using one hand, could simply spider-crawl her fingers towards the center of the pencil. But programming such intrinsic dexterity in a robotic hand is tricky and raises a robot’s cost. With Rodriguez’s approach, existing robots in manufacturing, medicine, disaster response, and other gripper-based applications may interact with the environment to perform more complex maneuvers cost-effectively. “Chasing the human hand is still a very valid direction [in robotics],” Rodriguez said. “But if you cannot afford having a $100,000 hand that is very complex to use, this [method] brings some dexterity to very simple grippers.” Rodriguez and Chavan-Dafle will discuss the new approach this month at the International Conference on Intelligent Robotics and Systems. Giving robotics a push

Visit omega.com/ omb-daq-2416 input #15 at www.controleng.com/information 1-888-826-6342 omega.com ©©COPYRIGHT INCALL ALLRIGHTS RIGHTSRESERVED RESERVED COPYRIGHT 2015 2011 OMEGA OMEGA ENGINEERING, ENGINEERING, INC.

The team is seeking ways a robot might use gravity to toss and catch an object, as well as how surfaces like a tabletop may help a robot roll an object between its fingers. Research was supported, in part, by the National Science Foundation. This article online has more details: www.controleng.com. - Edited from an MIT News Office story by Jennifer Chu by Chris Vavra, production editor, Control Engineering, cvavra@cfemedia.com.

Prices listed are those in effect at the time of publication and are subject to change without notice. Please contact OMEGA’s sales department for current prices. Note: Models with wireless option are approved for use in the U.S., Canada and Europe only.

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SEPTEMBER 2015 CONTROL ENGINEERING

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NEWS

industry

Control panel standards are changing soon There’s a transition underway regarding UL 508 of which customers and control panel builders should be aware: UL 508 will soon be phased out and replaced by UL 60947-4-1. This change is the result of more than 10 years of work by the UL, National Electrical Manufac-

turers Association (NEMA), and others. The purpose is to harmonize international standards from UL and its counterparts such as the Canadian Standards Association (CSA) and the International Electrotechnical Commission (IEC) in Europe. The UL 508 standard is more than 200 pages long, and the committee that was formed to update this standard went through each page, paragraph by para-

graph, to find differences between IEC and UL test protocols. The end result is a phase-in of a new series of standards, UL 60947-4. UL 60947-4-1 most closely resembles UL 508. Phase-in dates vary. See article online for details. After Jan. 27, 2017, all products must meet UL 60947-4. The committee worked on harmonizing the UL and IEC standards, but there are intrinsic differences in voltages used around the world that affect testing. Within those parameters, the committee worked on normalizing the standards so manufacturers will have an easier time testing their products against the various iterations. - Tom Fowler, staff product specialist, Schneider Electric. Edited by Chris Vavra, production editor, Control Engineering, cvavra@cfemedia.com.

Industry 4.0 group looking to expand Platform Industrie 4.0 seeks to broaden the understanding that Industry 4.0 needs to be understood as a project for society. The group is planning to create close alliances with associations in the public and private sector and in the general populous, to bring greater awareness of what the digital economy can do for Germany. Industry 4.0 represents the fourth industrial revolution with the use of cyber-physical systems. The goal of Industry 4.0 is to facilitate the emergence of the intelligent factory, characterized by adaptability, resource efficiency, ergonomics, and integration of customers and business partners in business and value processes. It was adopted in the Action Plan for “High-Tech Strategy 2020” in November 2011 by the German federal government. Platform Industrie 4.0 aims to serve as a moderator and catalyst for the exchange of information among groups. - Chris Vavra is production editor, Control Engineering, cvavra@cfemedia.com.

Go Online

input #17 at www.controleng.com/information

Learn more about Platform Industrie 4.0: www.plattform-i40.de/ CFE Media is hosting a webcast series on Industry 4.0 and the Industrial Internet of Things (IIoT). www.controleng.com/webcasts 20

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SEPTEMBER 2015 CONTROL ENGINEERING

See more news daily at www.controleng.com/news

Standards group on counterfeit pharmaceutical packaging The Steering Committee of the Open Serialization Communication Standard Working Group (Open-SCS) announced the accelerated development of an industrial interoperability standard and associated requirements templates by year-end 2015 to focus on health care packaging serialization interoperability across a plant’s equipment and systems and between the supply chain systems. Since the 2012 patent cliff, generic products now make up 80% of the global health care market and are a primary counterfeiting target where counterfeit drugs flood the market and generate about $75 billion revenue annually; The counterfeit industry is estimated to grow 20% annually; Counterfeit drugs constitute as much as 70% of total drug supply in some countries. McKinsey & Company said, “Global standards could enable substantial patient safety benefits and enable total health care cost reduction of $40 to 100 billion.” In September 2014, Open-SCS founding members first gathered in Frankfurt, Germany, as the Open Architecture for Track & Trace Group to address these issue. More than 80 health care manufacturers, solution providers, suppliers, and consulting companies contributed to develop inter-plant serialization solutions to improve deployment efficiency and high cost of compliance to the aggressive regulations. Interoperability standards, such as OPC-UA, ISA-95/88/B2MML, EPCIS, PackML, and others, cover most requirements, but there are gaps, suggested Charlie Gifford, executive director of the Open-SCS Group. “A single standard interoperability implementation will sufficiently cover the entire requirement for health care serialization compliance,” Gifford said. Serialization legislation from many countries dealing with the global health care counterfeiting crisis requires immediate serialization and aggregation of products from the manufacturer to the patient. Production floor and warehouse equipment and systems should exchange information with the manufacturers’ supply chains and the patients’ support systems. Open-SCS said data exchanges can: 1) Define and simplify the base roles for each actor in CONTROL ENGINEERING SEPTEMBER 2015 ● 21

the data flow to supply chain; 2) Define the communication protocols used for each connection point; 3) Enable greater flexibility of the serialization architecture available to the industry; and 4) Substantially reduce integration cost and product delays from different vendors. With input from health care pro-

viders and vendors, Open-SCS plans to release standard and implementation specifications by year-end 2015. - Edited from an OPC Foundation press release by Chris Vavra, production editor, Control Engineering, cvavra@cfemedia.com.

input #18 at www.controleng.com/information

industry

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NEWS

HEADLINES ONLINE See www.controleng.com/news for daily coverage including items below. Industry events At www.controleng.com, on the right side, click into the events box and scroll by month to see related industry events including: Tips for automation system integration project management, RCEP Webcast for PDH credit: Automation system integration project management, when done right from project inception, can mean the difference between a successful implementation that adds value and one that doesn’t. Sept. 10, archived thereafter. www.controleng.com/webcasts Pack Expo Las Vegas, Las Vegas, Nev., Sept. 28-30 www.packexpolasvegas.com/ Emerson Global Users Exchange, Denver, Colo., Oct. 12-16 www.emersonexchange.org/americas/ ODVA Industry Conference, Annual Meeting, Frisco, Tex., Oct. 13-15 www.odva.org/ AnyLogic Conference 2015, Philadelphia, Pa., Nov. 4-5 www.anylogic.com/conference 2015 Process Control & Safety Symposium, Houston, Tex., Nov. 9-12 www.isa.org/pcs2015/

www.lasertech.com/ce 877.696.2584 input #19 at www.controleng.com/information

Top 5 Control Engineering articles July 27 to Aug. 2: Most visited articles included: SCADA cyber security, Industrial priorities, Automated machine tending, Robotic trends, and SIS. Career advice for an engineering student Ask Control Engineering blog offers advice links to resources to help with engineering career advice. Declining oil and gas prices to impact world generators market IHS says declining generator sales into the oil and gas industry in 2015 will burden suppliers that will look to other industries for growth.

Power sources for highest performance in harsh environment.

Prevalence of IoT may leave networks vulnerable to attacks Internet of Things (IoT) devices are prevalent in highly regulated industries, and the infrastructure supporting those devices is vulnerable to security flaws, according to a recent study. Founder of first robotics company honored on 90th birthday Joseph F. Engelberger, a World War II veteran, engineer, and entrepreneur created the first robotics company, Unimation, and turned 90 years of age on July 26. Robotics market in North America off to strong start in 2015 The Robotic Industries Association (RIA) reported that $840 million worth of robots were ordered by North American companies in firsthalf 2015, setting a new record high in sales.

input #20 at www.controleng.com/information

The new age of disruptive innovation The Industrial Internet of Things (IIoT) has created a lot of buzz in the manufacturing space, along with confusion and misinformation. PMI hits 52.7% in July; outlook positive Growth slips as oil prices and global economic uncertainty linger, though the overall outlook among manufacturers is trending positive.

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CFE Mediaâ&#x20AC;&#x2122;s Global System Integrator Database is an interactive community of global end-users and system integrators hosted by Control Engineering, Plant Engineering, and our global partners in Asia and Europe. Through this database you will be able to connect with System Integrators by searching their corporate profiles which highlight: industries served, engineering specialties, product experience, geography, and other pertinent data. Find and connect with the most suitable service provider for your unique application.

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cover story - packaging automation

Packaging machine design Control system flexibility, a need across all industries, means easy re-use of code from one controller to the next, scaling from two-axis machine to a high-axis coordinated motion system with the same software, reducing hardware costs, training time, and troubleshooting.

n the packaging industry, companies need flexibility to meet evolving demands of the market–different product looks, quantities, and sizes. This requires a range of machine speeds to produce different product sizes and shapes with the same quality. It introduces the need for automatic changeover procedures to accommodate different packaging material or fill product types. Important elements in control system flexibility include software and controlKey ler hardware. Users should easily re-use concepts code from one controller to the next. Scalability is a common need across Machine designs can be simplified with control all industries to keep costs low. The system flexibility. same software should economically serve a simple two-axis machine and a Scalable software and hardware and reusable high-axis coordinated motion system. code help. Scaling along a product line of controllers reduces hardware costs, training Compatible automation components also ease time, and troubleshooting efforts.

added to the system by modifying the existing chain of servos machine design time and already on the machine. This maintenance. Pre-made tools also allows for the same control Another need is finding pre-made cabinet across multiple families tools for their industry requirements. It is difficult to of machines and frees the cabinet design from the design a system for a packaging machine with a con- needs of the machine itself. troller that’s designed for the process industry. The There are packaging OEMs that manufacture original equipment manufacturer (OEM) needs solu- four or five lines of packaging equipment, and tions from providers who understand their industry, each one of those product lines have multiple know the needs of the machine, and have software machine sizes. By using a cabinet-free servo drive tools pre-built to accommodate those needs. solution, they are able to standardize the control The design of the control cabinet also is impor- cabinet across all machines. Each control cabinet tant in flexible design. Using an integrated motor is the same size, and the components are largely and servo drive system, with the drives mount- the same, even across the different product lines. ed out of the cabinet and on the frame of the This reduces costs significantly because the bill of machine, addresses this need. If an OEM wants to materials is roughly the same for all machines. design a control system for low axis count but use that same control cabinet for a system with dozens Less inventory Design flexibility also reduces the need to of axes, adding more drives to the control cabinet for additional motion axes means more cabinet maintain inventory of parts. When assembly and space, more parts, and more time to build, along field technicians are accustomed to building and working with the same system, assembly time is with multiple design iterations. With some systems, it also means adding less and errors are fewer. Familiarity also helps unnecessary components like back-planes and field service technicians to quickly find problems extra slots that may or may not be used, to add if they arise. ce - Allen Tubbs is product manager, electric flexibility to the design, but at a much higher cost. An integrated motor and drive system allows for drives and controls, Bosch Rexroth Corp. Edited additional servos without changing the design of by Mark T. Hoske, content manager, CFE Media, the control cabinet. Additional servo drives can be Control Engineering, mhoske@cfemedia.com. www.controleng.com

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Having a low-cost controls solution for a simple two-axis machine and an economical solution for a machine with a high-axis coordinated motion system that runs on the same control software is important to keep costs down. Cover photo courtesy: Bosch Rexroth

Go Online See another photo with this article online with links to more design tips, mechanical resonance, and Industry 4.0 advances. If reading the digital edition, click through the headline or search on the headline atop www.controleng.com.

CONTROL ENGINEERING SEPTEMBER 2015 ● 25

packaging automation

Pneumatic valve technology Select manifold valves with a compact, lightweight design and digital electronics for easy integration into automation controls platforms and maximum value. See more online. Key concepts Cost of ownership, high speeds, easy integration, and reliability make pneumatics attractive for machine builders. New pneumatic valve designs help packaging machine builders. Diagnostics, pressure control, and safety capabilities will help extend pneumatic applications.

neumatics is widely used in many packaging machines to drive motion and actuate machine sequences. It is a clean, reliable, compact, and lightweight technology that provides costeffective control and actuation to help packaging machine designers create innovative systems while staying competitive. Manifold valve technology plays a central role in the performance and effectiveness of pneumatic systems. Recent developments in this technology have increased pneumatic flexibility, modularity, and ability to integrate with and be controlled by the advanced communication bus architectures preferred by leading packaging machine original equipment manufacturers (OEMs) and end users, enhancing the application that value pneumatics technology supplies.

Pneumatics-driven packaging applications

Go Online More on flow control, valve design, valve intelligence, pressure control, safety. Link to additional pneumatic articles in the online version of this article, including pneumatic energy savings, pneumatics for pick and place, and when to apply pneumatic actuation. If reading the digital edition, click through the headline, or search on the headline atop www.controleng.com.

Consider this... When considering new machine designs, examine new packaging automation technologies, including pneumatics. 26

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Pneumatics can be particularly effective for machine motion that combines or includes highspeed, point-to-point movement of the types of products that have the weight and size dimensions typically found in packaging machines. This includes indexing, sorting, and pick-andplace functions. It is also used for suction cups or noncontact transfer devices. For example, on cartoning machines pneumatics can drive multiple functions: indexing the infeed of blank cartons onto the process line, driving machine components that help form the folds then close the carton folds, and moving glue guns or other sealing devices. In form fill and seal machines, its common to have pneumatics-driven clamping devices and heat sealers, as well as tension controllers on rollers discharging the plastic film that forms the bags being sealed. Four factors continue to make pneumatics broadly appealing to machine builders. 1. Cost of ownership: Most pneumatics components are relatively low-cost, and systems are relatively easy to maintain and repair without special training or outside specialists, which can add to operating costs. 2. High speeds: Pneumatic-driven systems move products through machine sequences at high speeds—typical systems support motion sequences of up to 5 m/sec (16 ft/sec), and higher-

SEPTEMBER 2015 CONTROL ENGINEERING ● www.controleng.com

Latest generation manifold pneumatic valves, such as the Aventics AV03 valve, integrates intelligent electronics and bus interfaces for easy use in packaging machine controls. Courtesy: Aventics

end cylinders support 11 m/sec (36 ft/sec); these rates satisfy a significant percentage of throughput rates found in many packaging machine applications, such as pick-and-place systems. 3. Easy integration: Pneumatic technology is easy to integrate into larger machine designs, highly modular, lightweight, and compact enough to be installed on moving machine elements such as linear modules. 4. Reliability: Pneumatic-driven systems can offer the kind of long-lasting reliability expected from today’s automation technologies. For example, one pneumatics suppliers’ valve series has been tested to operate, without device failure, through 140 million duty cycles. Manifold valves: Control the flow

All pneumatics systems work on the same basic principle: One air source provides all air pressure needed for the different components, and it is the valve system that controls the distribution and sequencing of the air to drive individual actuators. When selecting a valve system, the main criteria to use are the valve’s flow rate, the weight and space constraints associated with fitting it into a machine design, and valve functionality. See more advice in the online version. ce - Erl Campbell is industry sector manager— food and beverage, Aventics. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.

2015

input #22 at www.controleng.com/information

packaging automation

Servos improve packaging machines Upgrade your next machine design with servo motors to decrease downtime, decrease footprint, increase throughout, and two other key reasons. See more images online.

nnovations in automation are drastically changing the world of packaging. Here are five reasons to consider using servos in machine design: Servo motor advances 1. Less downtime for product changare driving machine es: Historically, packaging machines have been design capabilities. made with very intricate mechanical designs. Increased reliability, This allowed for precisely synchronized movemore throughput, smaller ment from motion technologies incapable of such footprint, higher torque, less wear, and easier precise movement. Intricate designs often came maintenance may result. with the burden of downtime for changing the mechanical system to accommodate a change in the product. With the precision of a servo system, these changes can be accomplished with the downloading of a new recipe or cam table when an operator touches a virtual button on a human-machine interface (HMI). This significantly reduces downtime and alleviates the need for services from a skilled mechanical technician for the changeover. 2. Smaller machine footprint with higher torque: Factory floor space is expensive. A smaller machine footprint can allow for more machines in the same space. Servos can provide a much higher torque-to-volume ratio than other technologies. This can allow for automation of processes that were previously impossible. Servos also are available in a wide variety of sizes. A thumb-sized servo motor can integrate an absolute encoder with a resolution of 131,072 pulses per revolution. 3. More throughput with less shock to the product: Sometimes the motion profile is just as important as the accuracy of the final position. Using methods of electronic camming, servos can provide very smooth accelerations and decelerations This graphic shows how sizes of Yaskawa with very fast moves. servo motors have decreased as performance This can provide more has increased. Appearing left to right are the Yasproduction per hour kawa Sigma-1, Sigma-2, Sigma-5, and Sigma-7. without stressing prodCourtesy: Yaskawa America Inc. uct being packaged. In

Key concepts

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SEPTEMBER 2015 CONTROL ENGINEERING â&#x2014;? www.controleng.com

some cases if a product is liquid or fragile, past automation technologies have limited the cycle rates or damaged the product. 4. Longer lasting machines: Just as less shock is better for the product, it is also better for the machine. Mechanical wear can be drastically reduced by using servos, providing a longer life for the machine and less costly repairs. They can also reduce the audible noise, giving the impression of a higher quality machine and helping to improve the production floor environment. More efficient servo technology runs at cooler temperatures, further increasing lifetime. 5. Less downtime with better diagnostic tools: The modern multi-axis servo system uses a network, and this architecture provides improved diagnostic capabilities over past solutions. This allows for high bandwidth information from the motor to the controller. This provides a superior method of detecting and resolving issues that arise. A servo system provides feedback on position, velocity, torque, and alarm codes that can represent excessive temperature, friction, and many other conditions that may occur. Trending and comparing these values to baseline values can detect issues long before they cause machine breakdown. These diagnostic tools are becoming web-based so that someone could log in and check the machine remotely. These machine design improvements can help machine builders, system integrators, machine builder customers, and final product consumers. ce - Jerry Tyson is the southeast regional motion engineer, and Michael Miller is the regional motion engineering manager, at Yaskawa America Inc. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.

Go Online This storyâ&#x20AC;&#x2122;s online version provides links to more information and additional images, which help explain these points. If reading the digital edition, click through the headline. If reading in print, search on the headline atop www.controleng.com.

Consider this... Which new motion technologies can best advance your machine capabilities?

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software upgrades

Software licenses, upgrades Industrial software users should use new features and innovations without costly annual software maintenance contracts or paying for each individual software version release. Key concepts Software licensing structures are changing. Licensing changes offer the ability to use runtime version free, buy only what’s needed, or associate the license with certain hardware provides flexibility. OEM intellectual property can be protected. Inside Process, P1, and Digital Edition have other articles on software upgrades.

oftware licensing models should be fair and flexible, offering the ability to update to the newest available release and implement new features. The distribution of software tools is vital to continued industrial growth. Also of critical importance is maintaining intellectual property (IP) and budgets to fund software development. If, for example, users bought an automation design and programming software license in 2000, they should be able to download the newest version or build off the software today and run it on the original license. Similarly, licenses from a 2010 software release should be valid for today’s version. Users should be able to take advantage of new features and innovations without having to subscribe to costly annual software maintenance contracts or pay for each software release. A useful feature is to give customers the ability to generate a free trial runtime license for seven days without restrictions. This license may be regenerated as often as needed, which, for exam-

Trial: Companies often provide trial licenses to allow prospective customers to test software before purchasing the full product. A unique feature in the industry, TwinCAT 3 enables customers to generate a free trial runtime license, which runs for 7 days without restrictions. Intellectual property is preserved: If a user bought a Beckhoff Automation TwinCAT 2 license in 2000, the user can download the newest version or build of the software in 2015 and run it on the original license. Licenses from the 2010 release of TwinCAT 3 are valid for today’s version. Licensing philosophy ensures that no production machine will be down because of a runtime licensing issue. Software module pricing depends on the IPC performance level and on software components used. Courtesy: Beckhoff Automation 30

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SEPTEMBER 2015 CONTROL ENGINEERING ● www.controleng.com

ple, enables engineering computers to run without a commercial license. Creating a model where engineering tools can be freely downloadable from the web and used without registration allows engineers to use the tools to complete projects and encourages machine development and innovation. Avoid licensing downtime

Production is the end goal for a controls vendor, original equipment manufacturer (OEM), or end user, and, to this point, programming software licensing philosophy should ensure that no production machine will ever be down because of a runtime licensing issue. Trial licenses can be generated in emergency situations for permanent or temporary controller replacement on the production line. Runtime licensing should be flexible based on the performance level of the industrial PC (IPC) platform and the software components used. Cost for software modules is based on the performance class of the central processing unit (CPU), allowing cost effective licenses. More runtime licenses can be added as needed, providing a simple path for upgrade, should company needs change. The built-in ability of a unified programming platform to run progammable logic controller (PLC) code without fees or licensing enables users to take machine control and test code offline from the production machine and perform the bulk of testing before running a line of code on the live machine. After testing, the necessary permanent license can be purchased, and tested and approved code can be implemented into the system. ce - Daymon Thompson is TwinCAT product specialist, Beckhoff Automation. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.

Go Online A recent poll at www.controleng.com asks about average controller age. To access links and information about other licensing options, click through the headline to the online version of this article when reading the digital edition or search on the headline at www.controleng.com.

Consider this... Do rigid software licensing rules restrict innovation and creativity?

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Cimation is an operations consulting company delivering secure technology solutions to the global energy industry. With experience in process automation, industrial IT, enterprise data, and ICS cyber security solutions and more than 200 employees in 7 global offices, we are ready to execute efficient strategies that converge IT and operations technology. Armed with diverse project experience, process knowledge, and technical expertise, we improve energy operations by engineering and integrating industrial technology. In our years, Cimation has executed thousands of reliable systems integration and engineering projects for oil and gas, refining, chemical, power, utilities, and storage businesses. We understand the processes and objectives that drive industrial operations and help companies improve safety and efficiency through holistic solutions customized to meet their business needs. Since opening our doors in 2009, we have grown by developing trusted partnerships with both clients and vendors. More than 300 customers in North America, South America, Europe, and Africa including independent companies, mid-size operators, and global super majors trust their operations technology infrastructure to Cimation. By tailoring our services to the unique needs and requirements, we help realize process efficiency and longterm cost-savings in spite of market volatility. Speak to one of our leading industry experts today to learn more!

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plantwide Ethernet

Managing the risk of IoT Internet of Things (IoT) is growing rapidly; more devices are going online. Security is required to protect devices and users. Industrial network design and best practices help. See six steps for IoT risk mitigation. Digital Edition Exclusive section has a 4-page version of this article.

he Internet of Things (IoT), or variations of the term, has saturated the media with stories of connected vehicles, networked wearables, home automation, and smart meters. With such significant conversation, one would think that this market was invented yesterday, but machineto-machine communication that typically interfaces with the physical world via networks has been with us for a long time. The less flashy devices known as industrial control systems have been running our electric grids, oil pipelines, and manufacturing plants for decades. Like cloud computing, which partly owes its lineage to the mainframe timesharing concepts of the 1960s and 1970s, IoT has been rebranded. The market for connected devices is shifting. Like cloud technology, IoT is massively larger in scale than its earlier generations and is growing fast. What makes it significant, and a little scary, is its sheer ubiquity, touching consumers and businesses alike. Use cases are expanding from narrowly focused to broad-based and life-critical health care and transportation applications. To understand the risk to IoT, definitions are needed. At its most basic level, IoT implies network connectivity, the use of embedded (or limited computing) devices, and, typically, involves some connection to the physical world, such as measuring temperature, blood pressure, or road vibrations. In essence, it implies network connectivity for everyday devices that traditionally were not considered computers; however, nearly every use of IoT also involves some traditional computer usage. Small, embedded devices usually report their status and receive instruction from a traditional computer workstation, server, laptop, or smartphone. It’s better to think of IoT as less a series of small devices and more of an ecosystem that requires multiple components to work correctly. The supporting components, while appearing to be normal computing devices, still need to be adjusted for the real-time nature of and massive data often associated with IoT. Computer networks need to be everywhere and optimized for the volume and velocity of the data flows. And the appropriate business logic needs to be devised for what are largely autonomous networks. But fundamentally, IoT is about the core components that interact with the physical world. They

typically include sensors to measure things like temperature, wind speed, or presence of an object. And they often include actuators that initiate actions like driving a car, turning off power, or injecting insulin. The supporting functions are often the place where the actions are determined, but for some largely autonomous devices, some of those decisions could be made independently based on the input the device receives. Six IoT risk mitigation steps

Take six actions regardless of risk or budget. 1. IoT owners should identify current IoT implementations in place, planned, or anticipated. This may include building management systems for heating and air conditioning or even the mechanisms used to run elevators if they’re networked. 2. Organizations should identify any security policies or procedures related to IoT. If none exist, companies should document high-level controls, such as locking the elevator machine room. 3. Within three months, organizations should ensure that device owners have applied the risk model and reviewed the results with management. 4. Organizations should identify mitigation steps and related costs to achieve the desired state. 5. In the next six months, organizations should identify IoT risks that they don’t control, but that affect the organization. 6. Organizations should also participate in industry groups to encourage development of security standards for the devices that most affect them. ce - Gib Sorebo is chief cyber security technologist at Leidos Engineering. Edited by Eric R. Eissler, editor-inchief, Oil & Gas Engineering, eeissler@cfemedia.com.

IoT software interacts with connected devices in a cycle, akin to a control engineering process. Courtesy: Leidos Engineering

Key concepts A basic understanding of IoT and implementing some basic steps can put any organization on the right track to managing its IoT risk. IoT is thought of as less a series of small devices and more of an ecosystem. Unlike traditional information technology components, IoT-connected devices are often more vulnerable.

Go Online Online link to other articles, including: Industrial Internet of Things needs data, clouds, and analytics. www.controleng.com

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CONTROL ENGINEERING SEPTEMBER 2015 ● 33

additive manufacturing

Hybrid machines, standard CNC As the era of additive and subtractive machine tools emerges, today’s controls are well suited to handle the challenges, says a provider of CNCs and training. Key concepts Computer numerical control (CNC) has the industry knowledge and power to serve hybrid machines with additive and subtractive machining capabilities. Additive manufacturing is creating parts made from titanium, stainless, or disparate powdered metals. CNC providers have prior experience integrating with robotic systems.

EDITOR’S NOTE: Some additive manufacturing shops have rows of additive machines, producing parts that may not require additional machining prior to use, depending on the application. Additive machining price competitiveness with subtractive machining depends on complexity, material(s), and number of parts in the job.

Go Online If reading the digital edition, click on this article, which is linked through the headline for more information, photos, and related articles. www.controleng.com/magazine

Consider this... Combining additive and subtractive technologies means sending a design to a machine and receiving a ready-to-use titanium or stainless steel part. 34

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ith the emergence of additive machining (use of 3D printing to create actual parts) more than a decade ago, it quickly became a prototyping marvel. As design changes were made, the result could be quickly visualized in a 3D solid part. Manufacturing also appreciated the tool, as it enabled them to see potential process problems in the actual cutting of the part. Modifications could be made on the fly without part functionality being compromised. Lastly, for the estimators, this tool allowed substantially better quote prepping. Then materials for 3D printing evolved at light speed, and the market quickly realized this technology had production potential. Making a short run of parts on such a machine became a reality. While 3D printing machines are 5 to 10 years away from being everyday shop production units, another development has seen the fusion of additive and subtractive technologies into a new generation of hybrid machines. Seemingly incompatible technologies such as laser metal deposition and chipcutting machines have emerged. This is fabrication and machining at its core. Existing and standard computer numerical control (CNC) technology has been implemented on these machines. Whether the parameters involve laser gases, powdered metal deposition, inert atmosphere vacuum, or fiveaxis rotation of a milling head or rotary table, the function of the control remains nearly identical. With CNC technology, one control can run two varying technologies for fabrication and chipcutting, either on a one-channel or a two-channel unit, often in tandem with a robot head or gantry for part articulations. At the 2014 International Manufacturing Technology Show (IMTS), this technology was introduced when running a lathe and a robot on the same CNC was already possible, without a secondary programmable logic controller (PLC) or unique robot language commands. A next logical step would be to create additive and subtractive technologies within the same machine. Parts made from titanium, stainless, or disparate powdered metals are being built up, joined, machined, or otherwise processed on machines today. Driven gears, for example, are now laser welded from machined and stamped components into one assembly.

SEPTEMBER 2015 CONTROL ENGINEERING ● www.controleng.com

Figure 1: Laser metal deposition for additive manufacturing meets conventional metal cutting, subtractive manufacturing on the same machine, running one CNC in an inert atmosphere. All figures courtesy: Siemens Industry Figure 2: A turbine housing made from titanium uses the machine and processes described here.

The CNC, when controlling radically different machine operations, uses a modified set of code but not a different language, as was previously necessary with robotic integration. Since advanced CNC units carry a secondary channel, the commands easily can be set up there, if not incorporated into the main channel. It depends on the complexity of the motion and total number of parameters being controlled. Simultaneous control and monitoring of laser metal deposition and fiveaxis milling functions present little challenge to the high-end CNCs on the market today. The next decade surely will be an exciting time in the machine tool and fabrication world. Just remember: CNC is in control. ce - Randy Pearson, is an international business development manager, Siemens Industry Inc., Drives Technologies, Motion Control-Machine Tool Business. Edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com. In the Digital Edition Exclusive section, see a related article about metals used in 3D printing.

digital edition

EXCLUSIVE

www.controleng.com/DigitalEdition

Control Engineering Digital Edition benefits:

Benefits of the Control Engineering Digital Edition include tablet-friendly viewing (HTML5), exclusive content in every issue (more than 20 extra pages here); headlines link to the longer version posted online; links are live where a URL is provided; and an email link arrives when ready.

DE-1 Industries using metal for 3D printing

Metal use for additive manufacturing is growing rapidly, and metals are being used for customized and mass production by a variety of industries, according to a report by IDTechEx. Metals in use or under investigation include titanium, nickel, aluminum, cobalt, and their alloys. SOFTWARE UPGRADES

DE-3 Do you really need a specification document?

A well-written design specification that has been thoroughly reviewed and discussed can greatly minimize startup headaches and number of design changes.

DE-7 Gateways for the Industrial Internet of Things: Trends Industrial Internet gateways help translate among competing, closed silos of closed, proprietary stacks. Integrated cloud services add device usefulness.

DE-13 Capitalizing on the Internet of Things: Revenue potential Manufacturers are in the fourth industrial revolution led by the Internet of Things (IoT). Smart objects help. See three ways to monetize IoT devices and 10 software considerations.

DE-17 Legacy software blues

Is the legacy software platform holding projects back? Virtualization can offer a safe and affordable path forward. PLANT-WIDE ETHERNET

DE-19 Ethernet networks add health, visibility to industry

A converged network approach and greater cross-team visibility of edge devices create reliable, industrial networks in step with Industrial Internet of Things (IIoT) and big data.

DE-23 Acadian Seaplants: Ethernet helps with 40% capacity increase

A new processing facility with Ethernet infrastructure allowed Acadian Seaplants to increase capacity with flexibility, visibility, and easier maintenance.

DE-26 What kind of fieldbus is needed for Industry 4.0?

High connectivity and powerful communication capacity are necessary between equipment and servers to realize the dream of connecting smart manufacturing with all things. Fieldbus organizations are seeking new ways to adapt the new needs of industry.

DE-27 Managing the risk of the Internet of Things

The Internet of Things (IoT) is growing rapidly. More devices are going online. Protect devices, systems, and users with smart industrial network design and cyber security best practices. See risk formula graphic and six steps for IoT risk mitigation. This expands on the p. 33 article. www.controleng.com

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CONTROL ENGINEERING SEPTEMBER 2015 â&#x2014;? 35

digital edition

EXCLUSIVE

3D printing with metal An IDTechEx report said that 3D printing with metal is growing rapidly and that metals are used for customized and mass production by a variety of industries. Additive manufacturing metals in use or in testing include titanium, nickel, aluminum, and cobalt. Key concepts Additive manufacturing is being used for mass production. 3D printing in metal is the fastest growing segment of 3D printing with the aerospace and medical industries using it for mass production. Some industries, like jewelry, are 3D printing in metal for custom projects.

D printing encompasses a variety of different printing processes and is primarily additive in nature. Each of the technologies is suitable for use with a different range of materials, which in turn defines the suitable applications of the printer. 3D printing may have started with form and fit testing for prototypes, but the technology has evolved in the past few years to encompass manufacturing products on a mass scale. With 3D printing, designs are not constrained by manufacturing limitations, and design complexity no longer adds cost. This opens up design avenues and enables the economic production of lighter components. This aspect is critical to the aerospace and automotive industries. 3D printing in metal is being used to manufacture parts in a wide variety of industries. Metals are the fastest growing segment of 3D printing, with printer sales growing at 48% and material sales growing at 32%, according to the IDTechEx report titled, “3D Printing of Metals 2015-2025.” Adoption by high-value, low-volume industries

Consider this... What other industries could rapidly scale up use 3D printing in metal for mass production, apart from the aerospace and medical industries? DE-1

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The IDTechEx report states that high-value, low-volume industries such as aerospace and biomedical have been the earliest adopters of 3D printing in metal because of the current speed. For example, GE Aviation has invested more than $3 billion to house 3D printers to print 100,000 fuel nozzles by 2020. In addition to titanium, the aerospace industry also is investing in cobalt, nickel, and aluminum alloys to be used in additive manufacturing. Arcam, which manufactures electron beam melting (EBM), has used 3D printers to manufacture more than 50,000 orthopedic implants for the medical industry. The report states that both industries have a strong need for titanium alloys and combine for a market share of 31% by volume. In addition to titanium, the aerospace industry also is investing in cobalt, nickel, and aluminum alloys to be used in additive manufacturing. 3D printing in metal objects also is being used in the dental industry. According to the report, dental supplier Argen Digital is produc-

SEPTEMBER 2015 CONTROL ENGINEERING ● www.controleng.com

ing metal substructures to make copings and bridges with the same properties as cast parts. 3D printing in metal is also used for more creative outlets as well as mass production. The report states that the jewelry industry is very invested in 3D printing metal objects. Jewelers were early adaptors of selective laser melting (SLM) technologies, which allow the designer to customize precious metals with relative ease. The jewelry industry is driving 3D printing in precious metals, with gold powder having a 49% market share by revenue. 3D printing is a natural extension for the jewelry industry because there are no qualifying standards for jewelry; designers are already good at computer-aided design (CAD); designers are skilled in finishing and polishing and are accustomed to making items; and designers crave artistic freedom and unusual designs. 3D printing’s profile is growing

Local Motors put 3D printing in metal in display at IMTS 2014 in Chicago with the demonstration of their 3D printed car. The printing process lasted the entire show, using carbon fiber as the material, and ended with the car driving around at the end of the event. Everything on the car that could be integrated into one piece (such as the exterior and the chassis) was printed. While it took several days for everything to come together, the concept alone is an example of where 3D printing is going. The technology is enduring growing pains as users continue to work out the bugs. IDTech’s report suggest that many industries see metal 3D printing in their future, and it will become a mainstay in mass production before people realize. ce - Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com.

Go Online Learn more about 3D printing in metal from the IDTechEx report here: www.IDTechEx.com/3dmetals Learn more about Local Motors’ 3D printed car and their plans for the future: https://localmotors.com/3d-printed-car/

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digital edition

EXCLUSIVE

Do you really need a specification document? A well-written design specification that has been thoroughly reviewed and discussed can greatly minimize startup headaches and number of design changes. Key concepts A specification is something that tells people what they should build. The detailed design specification is typically divided into two sections, hardware design and software design. Making changes after the project is configured is sometimes necessary, regardless of the planning, and adds time to the project.

he most common specification for a distributed control system (DCS) is an I/O list written on a paper napkin. That is an old joke, but it is truer than someone may realize. Many initial DCS requests for quote (RFQ) are based simply on an approximate input/output (I/O) list and the number of operator stations required. While this can result in a reasonable “ball park” first pass estimate, the accuracy of that first pass will depend on how close the initial I/O count was to the actual I/O required to complete the system. A specification is something that tells people what they should build. Without a specification they don’t know what to build. A well written design specification that has been thoroughly reviewed and discussed can greatly minimize startup headaches and number of design changes. Think back to the paper napkin specification. It is a pretty big risk for a company to venture into a complex project without a written understanding of the functional requirements, with results that could last 20 years. There is benefit and value to a specification for complex controls projects. In the controls world there are two basic types of specifications: Functional design specifications and detailed design specifications. These specifications help address two critical objectives of a project: setting and staying on budget and setting and maintaining the schedule.

Functional design specification

A functional design specification defines the overall design and functions that the system needs to perform the operations required to execute a successful project. It is typically used to help develop a budget plan for the project or plant. It describes how the plant or unit will operate and allows the user to obtain budgetary bids based on a more detailed set of criteria than just basing the bids purely on a list of inputs and outputs. If a specific platform has already been standardized, the initial development of a specification may be a bit easier to develop. It also narrows the number of system integrators from

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which to choose, provided that the list is of integrators who have demonstrated experience on the chosen platform. If there is no specific platform selected, having a functional design specification will help ensure that the process of selecting a platform is based on a defined set of criteria. When people request bids based on paper napkins, they will get a wide range of bids. Some may provide a “Cadillac” system, while others will quote an “economy car” and hope to upsell later on features that are actually needed. The functional design specification helps identify, in writing, the product being made, how someone should make it, the plant areas and units, if the process is batch or continuous, programmable logic controller (PLC) or a DCS, remote racks or a central rack room, reporting requirements, and if there’s need for remote viewing capabilities. In addition, the specification can help plan the actual testing methods and conversion strategy to include downtime requirements and critical components. By having these and other items listed in the specification, a team will create a solid basis to receive reasonably similar bids from the request for proposal (RFP) that accounts for all aspects of the project. Two comparison examples of customers’ experiences with functional specifications follow. Two case studies

A customer recently needed to upgrade a unit’s control system that has been in place since the mid-1980s. The company had been using the equivalent of EBay for a decade to keep the system running and several key personnel retired, taking with them a vast knowledge base that had kept the system running for the past 30 years. Most DCS systems are designed to be in place for 20 years, but are rarely designed to actually run for 30 years without major upgrades in technology. The customer decided to purchase a frontend engineering and design (FEED) study, which is another name for a functional design

study. This study was to help identify exactly what was needed on the new system and to develop a document that would allow personnel to meet vendors and obtain bids for the replacement system. For the FEED study, four companies spent a week on-site pouring through the original documentation for the system and going through the updates that had been made on the documentation, as well as walking the plant to assess the electrical and mechanical requirements for the new system. Fortunately, they had done a reasonably good job of updating the information, but as it was in paper form, there was no electronic documentation that could easily be pulled into a database. After the site visit, there was about a 2-3 week effort to produce the final FEED study document. The document allowed the customer to set a good budget for the project and make a realistic assessment of downtime and implementation time required to work with production for the upgrade. Another customer, several years back, was building a new plant with a completely new design. Those involved opted not to develop a functional design specification as they wanted to quickly get the plant up and running. By omitting this step they suffered. Neither of the two project objectives that were identified earlier were achieved. They ran over budget as they were designing the system on the fly and were constantly reworking configuration. This added cost to the project. Because of the lack of a clear design and the resulting tinkering, the project schedule slipped, and the personnel did not meet the startup date. In an effort to bring the project back on schedule, some shortcuts were taken and, while they did help the schedule, they caused support issues for the long term. In the end the customer had a working system, but it was over budget and completed late. This scenario could have easily been improved by simply taking the time and making an investment at the beginning of the project to develop a proper specification. The additional cost that the company incurred was substantially more than the cost of a design study. Detailed design specifications

The detailed design specification is typically divided into two sections, hardware design and software design. The hardware design incorporates elements like system architecture, cabinet requirements, cabinet distribution, cabinet design, PC requirements, fieldbus or traditional I/O devices, and

network requirements. The system architecture determines what level of redundancy should be used and whether a safety system is required or a basic process control system will suffice: n Cabinet designs should consider environmental requirements (indoor or outdoor) and whether they may need cooling to keep the equipment within required heat and humidity tolerances. n Cabinet distribution addresses if the plant will have centralized I/O using homerun cabling or a distributed I/O cabinet layout in which a bus is used between areas and shorter instrument wires are required.

‘

Software design also becomes a test document that can be used

n Cabinet design deals with how the equipment is laid out within the cabinet, as well as power distribution, and defines typical wiring for different types of inputs and outputs.

during the factory

n PC requirements address the need for standard or industrially hardened PCs. Would a thick client architecture be necessary in which each operator and engineering station is a full PC with its own locally residing licenses or a virtualized system, using thin clients at each location?

confirm that the

acceptance testing as a checklist to system performs

’

as intended.

Software design deals with how the process will work. It defines how individual elements in the process act and react. The software document will define the device and functions of each specific device and each area of the plant. The devices are defined as control modules (CM). The functions are defined as equipment modules (EM). Developing and signing off on the software design before beginning the software configuration provide a system integrator with a solid basis from which to configure the system. This should eliminate confusion on how the system is designed to operate. The software design also becomes a test document that can be used during the factory acceptance testing as a checklist to confirm that the system performs as intended. Sometimes multiple departments in the same facility do not agree on the actual procedure the plant is currently using on a particular application. The process of going through the discussions to create the design specifications forces the plant production, management, maintenance, and engineering to realize discrepancies in their understanding of plant operation www.controleng.com

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CONTROL ENGINEERING SEPTEMBER 2015 ● DE-4

digital edition

EXCLUSIVE

Go Online See a Control Engineering webcast on “Tips for automation system integration project management” at www.controleng.com/webcasts. For more on specification documents, read “Specification documents: Pay now or pay later” at www.controleng.com.

Consider this... Looking back at the beginning of this article, do you really want to start with the paper napkin approach?

so they can discuss and agree on how to handle particular operations. In a current DCS system configuration scenario, a customer is building a new plant that is an entirely new facility near an existing plant. Working with the customer, a software design specification (SDS) was developed. Their engineering team had never built a plant from scratch, which presented some issues as they determined what new technologies to use and what strategies to keep from the existing plant. They decided that, even though the customer perfected the process in the existing plant, they did not want to simply copy it exactly without taking advantage of new technologies. In deciding to use new technologies, there was a need to accurately communicate to system integrator engineers how the plant should operate. This is a medium-sized DCS, and lot of time was spent jointly developing the software design specification. The software design has been a key part of the project and has helped to reduce confusion on how specific elements of the system operate. Some initial ideas on how elements would work have changed during the life of the project. Making changes after the project is configured is sometimes necessary regardless of the

planning and adds time to the project. In this case, the SDS is in place, which helped to quickly identify what the ripple effect of the required changes would be on the entire system, thus allowing the customer to determine whether the changes were worth the additional time. The SDS document acted as a test document during hardware and software checkout and will remain as a major part of the system documentation after the project is complete. Avoid the paper napkin

Most control systems will be in place for more than 20 years, and it is best not to risk a mistake on the front end that everyone will live with for a generation. For a nominal investment at the beginning of a project, individual engineers and their companies can realize significant savings on the project budget and on the lifecycle cost of the system. ce - John Walker is an account manager with the Cross Company, Integrated Systems Group. Edited by Joy Chang, digital project manager, CFE Media, Control Engineering, jchang@cfemedia.com

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digital edition

EXCLUSIVE

Gateways for the Industrial Internet of Things: Emerging trends Industrial Internet gateways help translate among competing, closed silos of proprietary stacks that provide vertical integration between the “things” in the field and the integrated cloud services that make them useful. Key concepts The IIoT trend toward fragmentation is at odds with the needs of system integrators and manufacturers. Software portability significantly improves the development speed and cost of connected systems.

emote connections and new software licensing structures can create opportunities for incremental upgrades in control and automation software, advancing efficiency, improving information flow, and bringing greater optimization. The confluence of ubiquitous, open standard-based Internet connectivity and powerful, low-cost embedded devices has led to the emergence of the Internet of Things (IoT). A projected 25-billion IoT-connected devices are expected to be online by 2020. This trend disrupts the established control and

instrumentation field, opening it up to a new range of possibilities referred to as the Industrial Internet of Things (IIoT). The development of the Internet itself has been characterized by collaboration, interoperability, and conformance to open standards in contrast to the foundational ethos of the Internet. In a manner foreshadowed by proprietary mobile phone ecosystems, the IoT/ IIoT space is emerging as a new “wild west” in which competing, closed silos have emerged. Each silo is vying to lock in a maximal share of the expected huge market by providing a

Figure 1: The FieldServer BACnet Router from Sierra Monitor Corp. is used by system integrators to interconnect BACnet networks using different media, such as RS485 field networks and IP networks, typically to connect the devices to a building management system. While BACnet routing is a standardized, low-level function, the FieldServer IIoT gateway architecture, on which the BACnet Router is based, affords it the ability to host application-level functions that add value for system integrators, removing the need for other tools to verify that all expected devices can be reached and identified. Images and graphics courtesy: Sierra Monitor Corp. DE-7

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full, closed, proprietary stack providing full vertical integration between the “things” in the field and the integrated cloud services that make them useful. The IIoT trend toward fragmentation is at odds with the needs of system integrators and manufacturers in control, instrumentation, building management, and energy management fields. Over the past two decades, these fields have been characterized by Figure 2: The FieldServer EZ-Gateway from Sierra Monitor Corp. illustrates a standardized industrywide collaboration in the approach to field device virtualization. In this example, a system integrator creates a profile that creation of open standards that configures data items to be read from a Modbus device and mapped into a BACnet data model, have exposed suppliers to more which allows the user to enrich the data model with: object name, object type, units, and descripdirect competition, while at the tion fields. Each profile can then be used to create multiple DeviceProxy instances correspondsame time expanding their mar- ing to multiple Modbus devices in the field. The image below shows four DeviceProxy instances ket reach. The result has created being instantiated and mapped into virtual BACnet devices. significant benefits to the industry as a whole. The convenience, added value, and efficiency of this approach is under threat from the new silos. In reaction to this danger, a number of vendors have formed the Industrial Internet Consortium (IIC, www.iiconsortium.org) to work toward establishing a consensus around interoperability. To this end, the IIC has published the “Industrial Internet Reference Architecture Technical Report” (IIRA), which sets out an architectural framework intended to guide the development of Industrial Internet Systems (IIS). The IIRA explores architectural concerns from business, usage, functional, and implementation Figure 3: A portable data format by which device profiles that have been manually configured viewpoints. The implementation on a gateway can be exported and shared with users via a profile sharing website hosted by the viewpoint discusses the technol- gateway vendor. A publicly available library of labor-saving profiles are indexed by a field device ogy and communication schemes model can be uploaded and instantiated on compatible gateways by any system integrator. required by the reference architecture and is of special interest for the topic at hand. ations, and analytics) via an access network, The IIRA outlines a number architecture which provides for data and control flows to be patterns that largely depend on the presence of exchanged. Figure 7-2 from the IIRA illustrates gateway devices, such as: this pattern. Three-tier architecture pattern with edge, platform, and enterprise tiers This pattern uses a gateway to connect the edge tier (containing field devices or edge nodes linked by a proximity network) to the platform tier (containing data transforms, oper-

Gateway-mediated edge connectivity and management architecture pattern Here an edge gateway provides the link between a local area network (LAN) of edge devices and a wide area network (WAN) linking to higher level services. The edge gateway may www.controleng.com

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EXCLUSIVE the system against the countless different data structures encountered in the field. Similarly, field device functions can be wrapped and presented in a coherent manner. For example, a gateway can render a collection of very diverse energy meters in an abstract representation that is consistent across an IIS, thus, insulating higher tiers of the system from often unavoidable variations in the field. Network management

Gateways are often ideally located to host field network management functions, removing the need for third-party network management tools.

Network discovery, self-configuration Figure 4: Growth in devices connected to the Internet disrupts the established control and instrumentation field, opening it up to a new range of possibilities referred to as the Industrial Internet of Things (IIoT).

itself act as the provider of local connectivity by acting as a hub. It serves to insulate the edge devices from the WAN and can contain some data processing, analytics, control logic, and application entities. As the widespread acceptance of modern, open-field protocol standards has reduced the need for traditional gateways in the field, the IIoT has created a need for a new breed of intelligent gateways that unlock the full potential of interoperability among diverse real-world devices and industrial Internet systems. Data management

Industrial and building automation gateways have moved far beyond the simple message translation paradigm of the classical definition of gateways. Gateways can now occupy all levels of the open systems interconnection (OSI) networking model. By supporting application layer entities, modern gateways can actively read, write, and manipulate data, as well as implement intelligent data caching, data logging, and controller functions. Store-and-forward techniques allow for the maintenance of continuous historical records where Internet connectivity is unreliable or intermittent.

Virtualization, abstraction

Beyond caching and mirroring data, gateways are becoming important providers of data abstraction. By modeling diverse field devices in consistent, self-documenting, virtual-device models, gateways insulate the higher tiers of

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Taking the network management concern a step further, IIoT gateways are becoming capable of zero-configuration deployment. Once such a gateway has been installed in a field network, it is able to detect field devices autonomously and consolidate data and functions into an integral interface.

Crowdsourcing

The enormous fragmentation and diversity of the existing, installed base of products can make some degree of human interaction unavoidable. Many legacy field protocols have no means of describing the data they present, forcing vendors to supply separate documentation of the data maps for each device model. These in turn need to be manually translated into gateway configurations for the data to become presentable in a more integral virtualdevice model. In a new development, a gateway vendor has created a portable data format by which device profiles that have been manually configured on a gateway can be exported and shared with the broader user community via a profile sharing website hosted by the gateway vendor. This is giving rise to a growing, publicly available library of labor-saving profiles that are indexed by a field device model and can be uploaded and instantiated on compatible gateways by any system integrator.

Application hosting

Multi-tier architectures often require a range of functions to be available to local operators even while the site is disconnected from the Internet, or perhaps in instances where a given deployment remains isolated. Additionally, a robust system design might require certain monitoring and control functions to be located locally to maintain uninterrupted operations where Internet connectivity is intermittent.

Figure 5: Industrial Internet Consortium (IIC) published the “Industrial Internet Reference Architecture Technical Report,” intended to guide the development of Industrial Internet Systems (IIS). This IIRA Figure 7-2 from the report shows a three-tier architecture pattern with edge, platform, and enterprise tiers. The pattern uses a gateway to connect the edge tier (containing field devices or edge nodes linked by a proximity network) to the platform tier (containing data transforms, operations, and analytics) via an access network, which provides for data and control flows to be exchanged.

Remote access

Gateways are able to host remote access servers, providing secure tunneling access to remote users of applications hosted on the gateway. This minimizes the functionality required of the cloud infrastructure and extends the usability of locally hosted applications.

Gateway architecture developments

The expanded scope of gateway functionality places enormous demands on the productivity and flexibility of the supporting technologies. Where gateways might traditionally have succeeded as monolithic embedded applications programmed in C or C++, the functional diversity and flexibility required today necessitate platforms that allow the desired combination of services to be assembled from a range of custom, purpose-built components and third-party, proprietary, or open-source components. The growing convergence between traditional server environments and embedded environments is creating important opportunities to expand the capabilities of gateways.

Portable software platforms

Software portability significantly improves the development speed and cost of connected systems by enabling communications or application code to be reused on multiple platforms. Two factors have emerged that have enabled

code sharing between edge and cloud platforms: compatible virtual machines (VMs) and portable operating systems. Compatible virtual machines

For the past two decades Java has made code portable by providing compatible VM implementations for platforms of various sizes. While making comparatively heavy performance demands, today’s edge devices are well able to run full-featured Java VMs and can draw on an enormous code base. Scripting languages, such as Perl, Python, PHP, and more recently, JavaScript, lend themselves to portable implementations because only the interpreter needs to be ported to any new platform. JavaScript is already the world’s most popular programming language, and the rapidly developing Node. js ecosystem offers a very promising portable platform that allows code to be shared between embedded devices, servers, and web browsers. The asynchronous, event-driven nature of JavaScript code makes it well suited to developing I/O-intensive, transaction-driven systems. In addition, npm, an open source package management system (npmjs.com), is delivering unprecedented growth in the number and scope of small, focused, and high-quality modules supporting a vast range of popular protocols, services, application programming interface (API) clients, and database clients and servers. www.controleng.com

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EXCLUSIVE

Table: Modbus data map Data address

Data value (available via Modbus)

Description (not available via Modbus)

30000

Inside temperature in Fahrenheit

30001

Outside temperature in Fahrenheit

Humidity in % relative humidity

<more values> 31000 <last value> 31001

Portable operating systems

Intruding on the historical preserve of proprietary embedded multitasking operating systems, Linux has emerged as a popular option for embedded devices. Through the RT-Preempt patch, the Linux kernel supports soft, real-time systems and is typically sufficient for field protocols with millisecond-scale timing requirements. Historically, edge devices have used custom, lightweight Linux distributions that were often different from desktop or server counterparts. Canonical’s Ubuntu is a coherent Linux offering covering IIoT operating system needs from edge to cloud through the addition of Snappy Ubuntu Core. Snappy provides a robust, secure, and modular update and a rollback mechanism for embedded devices and clouddeployed servers alike.

Interoperable, composable software modules

Go Online More information and images on this topic are in the online version. If reading the digital edition, click through the headline; if reading print version, search the headline at www.controleng.com.

Consider this... As IIoT/IoT develops, many companies are going to try to grab as many dollars as they can by making proprietary software, resembling prior technology wars, such as Betamax vs. VHS and Blu-ray vs. HD DVD. DE-11

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Apart from the use of portable operating systems and virtual machines, architectural flexibility is enhanced by software design practices that encapsulate functional modules in interoperable and composable ways. This generates more options for system designers to decide whether to locate application, monitoring, or control code on an edge gateway or in the cloud, and it maximizes efficiencies through code reuse. In addition to offering internal and downstream abstractions, differences between various upstream cloud-tier providers can be abstracted and wrapped in standard component interfaces, enabling a given gateway implementation to be integrated into a variety of systems with minimal effort.

Rich, self-describing data models

Beginning with XML, and increasingly through the more compact and browser-friendly JSON, gateways can present data and APIs in formats that make sense by themselves, that are

SEPTEMBER 2015 CONTROL ENGINEERING ● www.controleng.com

inherently extensible, and that can be integrated and interpreted by many systems. For example, a traditional Modbus data map would contain large number, 16-bit data registers that are identified by numerical addresses. Such a map would typically be hard-coded into a device, and the only possibility of extending the map would be through appending new values at the end of the map. (See Modbus data map table) All this information can be expressed in one JSON object, which can be extended without breaking compatibility with existing implementations by simply adding fields, as shown by the highlighted added field, Setpoint, which could simply be inserted without affecting the integrity of the communications. The object is transmitted as a text string and is intelligible on its own. While there is a price to be paid in that the JSON format is much more verbose than Modbus, the advantages greatly outweigh the costs in most cases. JSON Data Object { “Inside Temperature”:{ “Units”:”Fahrenheit”, “Value”:65, “Setpoint”:63 }, “Outside Temperature”:{ “Units”:”Fahrenheit”, “Value”:59 }, “Humidity”:{ “Units”:”%RH”, “Value”:80 } } Consolidation, maturation

The IIoT ecosystem is at an early stage, and a lot of consolidation and maturation lie ahead. The emerging breed of IIoT gateways will contribute toward containing uncertainty and preserving the value of existing investments by providing rapidly adaptable capabilities for keeping up with a changing environment. In their new guise, as envisaged by the industrial Internet architectures set out in the IIRA, IIoT gateways will remain an indispensable part of the industrial Internet for the foreseeable future. ce - Varun Nagaraj is the CEO of Sierra Monitor Corp. Jens Eggers is a software engineer at Sierra Monitor Corp. Edited by Eric R. Eissler, editor-in-chief, Oil & Gas Engineering, eeissler@cfemedia.com.

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digital edition

EXCLUSIVE

Capitalizing on the Industrial Internet of Things: Revenue potential Hardware manufacturers are in the midst of the fourth industrial revolution led by the Internet of Things (IoT). To keep up with new technological advances, they must move towards “smart” objects. See three ways to monetize Internet-connected devices and 10 software-centric business considerations. Key concepts Hardware manufacturers must consider using licensing and entitlement management. A connected product with such as system would make it easy for the device manufacturer to generate new revenue. Software lets manufacturers personalize offerings without manufacturing multiple models.

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o profit from a software business model transformation, device makers must have the systems in place to monetize the full potential of software investments and protect those investments in intellectual property. Hardware manufacturers must rethink their traditional business models and consider the role that licensing and entitlement management play in maximizing revenue potential. What would a software-centric business model look like?

Connected systems, software-centric approach

Taking a software-centric approach means manufacturers must re-design products from fixed-function, disconnected devices to flexible, seamlessly connected systems. A software-centric approach streamlines all aspects of the supply chain, from manufacturing to monetization. For instance, let’s say a telecommunications company has developed a “connected” commercial video surveillance camera with 10 features. Using the software-licensing-driven model, the telecommunications company need only manufacture one physical model. Using software and the power of licensing, the device maker then simply turns on features one through three to sell as the “basic” model. It could then turn on features one through six and sell that model as the “premium” model or turn on remaining features and sell it as the “platinum” model. Three models which previously required three manufacturing supply chains are now reduced to one. Moreover, this software-centric model adds flexibility and nimbleness making it easy for manufacturers to quickly configure products to take advantage of emerging market trends, without having to alter their physical supply chain.

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For instance, if software features one, four, five, and nine are popular with Chinese customers, a quick licensing reconfiguration results in a model optimized for the Chinese market. A connected product with a back-end, entitlement-management system also would make it easy for the device manufacturer to generate new revenue streams for the camera. For instance, the user of the “basic” camera could sign on to the device’s portal and purchase a 30-day trial for the “premium” model. Once the credit card data is provided, the system will unlock the premium features in the camera and without so much as a delay, the user has an upgraded device, and the manufacturer has generated a new revenue stream from the additional purchase. Depending on how the trial was set up, at the end of 30 days, the full upgrade charge may be debited, and the camera is fully upgraded. Or, through the entitlement-management system, the camera would automatically revert back to the basic model. Software-centric, with security

The same principles apply to IoT manufacturers across the spectrum of industry. Markets as varied as building automation, telecommunications, and gaming could benefit from adopting a software-centric business model, as could oil and gas equipment makers, test and measurement device manufacturers, and medical equipment manufacturers. Although building and creating these devices is a major part of the device manufacturer’s job, installing the software to allow these devices to connect and perform is crucial. The important thing when designing a connected device is to install security measures from the start. In this sense, manufacturers must ensure that applica-

Connected systems and a software-centric approach will benefit manufacturers. Courtesy: Flexera Software

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Software allows for flexible product configurations, manufacturers can quickly, easily, and inexpensively package and price devices to uniquely address new, emerging,

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or niche markets.

tions use tamper-resistant licensing codes to help reduce hacks. Companies need to invest the time to reverse-engineer embedded software on the device and make changes at the machine level if necessary to strengthen protection. This type of embedded licensing model has been successfully used in many devices: mobile phones with unlockable GPS functionality, routers sold in tiers based on number of supported ports, and cameras with different signal-processing algorithms based on available licenses. Three ways to monetize Internetconnected devices

Using automated licensing and entitlementmanagement systems to monetize Internet-connected devices offers many benefits, including: 1. Reduced manufacturing and distribution costs: Internet-connected devices controlled by embedded software significantly reduce manufacturing costs. Companies reduce the number of models they must manufacture by controlling features, capacity, configurations, and throughput via software, licensing, and entitlement management, allowing them to build once and “package” functionality multiple formats. Configuration of the products can be postponed until the exact requirements of the customer are determined. This manufacturing flexibility means that producers, distributors, and resellers require fewer inventories, greatly streamlining the supply chain.

2. New markets and revenue streams: IoT enables the creation of entirely new revenue streams as well as opportunities to grow the customer base. Using a software-licensing model for instance, manufacturers can easily offer product enhancements through software updates and charge for the enhanced functionality based on a software maintenance and update model. There are opportunities to charge for new levels of software support while simultaneously delivering a better customer experience. And because software allows for flexible product configurations, manufacturers can quickly, easily, and inexpensively package and price devices to uniquely address new, emerging, or niche markets that would previously have been impractical or prohibitive due to costs. The additional data generated by intelligent, connected devices also can be turned into intelligence and used to identify new potential markets and opportunities. 3. Product life extension: Licensing and entitlement management extends the life of the manufactured device. Much of the functionality of devices is managed and controlled using software, instead of being hard-coded into the device’s physical components. As a result, product upgrades and enhancements can be delivered using software commands communicated to the device over the Internet. This enables the customer to derive more value from the device over a longer period of www.controleng.com

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EXCLUSIVE

Licensing and entitlement management software helps manufacturers create connected devices that unlock new revenue streams, protect intellectual property, and implement configure-to-order manufacturing.

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time with minimal disruption. It’s good for the manufacturer too because it offers more up-sell opportunities for new functionality at minimal expense and effort.

4. Understand the difference between delivering hardware and digital goods—the distribution mechanisms should be coordinated, but can be unique.

Licensing is the enabler

5. Understand the software value lifecycle—as opposed to a one-off hardware transaction; it is an ongoing process and is increasingly subscription-based.

Licensing and entitlement management software is the enabling technology that helps intelligent device manufacturers to make their products Internet-readyand personalize offerings without having to manufacture multiple models. Simple changes to the software in the device enables manufacturers to customize the product based on customer needs by managing how it behaves—for example, by activating or deactivating features, setting device capacity, and otherwise controlling the behavior of the product. This greatly simplifies product lifecycle management and facilitates supply chain management.

Big data provides more insight

The usage data provided by the softwarecontrolled device also can offer insight into how customers are using hardware, what software they use most often, and new services that could potentially be created. Furthermore, product usage information enables manufacturers to make conscious choices pertaining to trade-offs between cost and value of service when packaging products and services for customers and markets.

10 software-centric business considerations

There are 10 key points intelligent device manufacturers should consider when making the leap to a software-centric model. Device manufacturers should: 1. Secure business buy-in for the transformation—this is broader than just engineering or product management and requires coordination across business groups. 2. Understand the traditional software licensing methodology and its proven approaches that can be leveraged in the intelligent device context. 3. Determine the appropriate software license compliance policies and enforcement mechanisms among a wide spectrum of available options, anticipating the flexibility needed to make changes later as business conditions change.

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6. Create business processes to support the value cycle of the software. 7. Implement a customer self-service portal—it can reduce operational costs and increase customer acceptance of software. 8. Define and execute a product management and go-to-market strategy. 9. Implement sales training and compensation policies—selling is not about selling numbers of hardware pieces, but about selling “value.” 10. Continuously fine-tune strategies for product development, delivery, and execution to optimize revenue and margins. By using licensing and entitlement management, manufacturers create connected devices that unlock new revenue streams, protect intellectual property, and implement configure-toorder manufacturing—dramatically reducing inventory while facilitating greater responsiveness to changing market conditions. ce - Steven Schmidt is the vice president of corporate development at Flexera Software. Edited by Eric R. Eissler, editor-in-chief, Oil & Gas Engineering, eeissler@cfemedia.com.

Go Online See links to other IoT articles with this article posted online. If reading the digital edition, click through the headline or search on the headline at www.controleng.com.

Consider this... By applying pay-to-unlock-features to physical objects, manufacturers can streamline production, increase margin levels, and quickly add revenue with the swipe of the user’s credit card.

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digital edition

EXCLUSIVE

Legacy software blues Is the legacy software platform holding projects back? Virtualization can offer a safe and affordable path forward. Key concepts When software upgrades have gone too long, maintenance, downtime, and other risks can increase. Virtualization may provide a temporary fix and flexibility while budget and support are gathered for a full upgrade.

hen system integrators do a really good job, they sometimes give clients a false sense of permanence. The delivered system may perform so well there’s never a need to think about it, much less consider upgrading. Why consider an upgrade when the current system works, operators are familiar with it, and it’s paid for? But as the years add up, important dates come and go. First, the software maker’s window of support closes. Support for the operating system (OS) is the next thing to expire. Before long, the client is counting on obsolete software running on an aging server to keep the plant going. There’s a time bomb sitting on the server rack, and it’s not a matter of if it will go off, it’s when.

Due for an upgrade, uncommitted

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This was the scenario presented recently by a long-time customer. Many years ago, two redundant human-machine interface (HMI) servers had been installed. Both were running RSView32 from Rockwell Automation on Microsoft Installing two host servers would Windows Server maintain the failover redundancy, 2000 (SP2), and the give plenty of room to virtualize other cracks were starting to show. HMI climachines over time, and provide a ents were freezing platform for a new HMI system. up mysteriously, and the customer could see its venerable system was on its last legs. The servers were due for an upgrade, but the customer wasn’t ready to commit. That scope of work wasn’t in the budget, and the client needed an immediate fix. The challenge was to craft a solution that would meet immediate needs and position the system for future upgrades. Virtualization provided the client with flexibility for future development while allowing Go Online virtual machine copies of the existing servers At www.controleng.com/blogs, to safely remain on the network. Installing two read more about system integration from Maverick Technologies’ host servers would maintain the failover redundancy, give plenty of room to virtualize other blog, Real World Engineering machines over time, and provide a platform for Creative teamwork a new HMI system. Safety instrumented systems: The plan was to deliver freshly installed Tips from the trenches Timekeeping protocols for con- virtual instances of the Microsoft Server 2000 trol systems: What time is it? machines on the new host servers, but make

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clones of the originals to have for reference offsite. Ideally, these clones would be taken without interrupting production at the plant through a process called hot-cloning, but the OS didn’t make that process easy. Microsoft Server 2000 was the last server OS Microsoft released before adding Volume Shadow Copy Service (VSS), which is what most physical-to-virtual (P2V) conversion software packages use to make clones. One of the most popular packages is VMWare vCenter Converter, and its most current version is 6.0. The last version to support Microsoft Server 2000 was VMWare Converter 3.0.3 Build 89816, which can’t be downloaded directly because that version is no longer supported. Thankfully, a quick Google search helped. Converter 3.0.3 has two versions. The hotclone version requires an installation on the machine that should be cloned. The cold-clone version is a bootable disc that will allow cloning without a software footprint, but it’s necessary to take the server out of production to make the clone. With either version, a simple wizard guides the process and gathers relevant parameters like destination and machine name. When considering cloning to an external USB drive, remember there is a limit on the size of the discs recognized by Microsoft Server 2000 that varies depending on the Service Pack level in use. When the cloning process is done, the result will be a .VMDK file with a (hopefully) working copy of the cloned machine. The process described is specifically for a Server 2000 machine. When cloning anything with a newer OS, find the most up-to-date conversion tool that will support it. Newer versions yield better results. Timely upgrades are always best, but virtualization can help squeeze that last bit of life from legacy software while laying the groundwork for system upgrades. It’s a powerful tool that provides many valuable options, now and for the future. ce - Tim Gentry is an engineer at Maverick Technologies, an automation solutions provider offering industrial automation, and a CFE Media content partner. Edited by Chris Vavra, production editor, Control Engineering, cvavra@cfemedia.com.

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digital edition

EXCLUSIVE

How Ethernet networks can add health, visibility to industrial applications As the number of devices increase in automation networks, management and issue diagnostics become more challenging for automation and information technology (IT) professionals. A converged network approach and greater cross-team visibility of edge devices create reliable, industrial networks in step with Industrial Internet of Things (IIoT) and big data initiatives. Key concepts Industrial Internet of Things (IIoT) requires Ethernet. Ethernet visibility and diagnostics are needed for reliability. Smart switches improve reliability.

s Ethernet continues to upgrade for industrial networks, companies also seek to deepen the integration between industrial automation systems and enterprise applications. What efficiencies can unfold with assembly fault data analysis occurring in a back-end information technology (IT) process, or what golden business intelligence can be discovered in materials’ waste data linked to material vendor invoicing? Networking flexibility opens business implications in ways upper management cannot ignore, even in 2015. IIoT requires Ethernet

Industrial Internet of Things (IIoT) innovations in sensor technology, wireless connectivity, energy harvesting, big data, and cloud computing are part of the seamless exchange of information among devices, systems, and people, paving the way for improved performance, flexibility, and responsiveness throughout the enterprise value chain. This points back to the Ethernet; the industrial Ethernet network needs to deliver the data so big data analytics can deliver results. Considering the Ethernet requirement for more high-speed processes, as well as more data gathering, factories will need a redundant network; one that easily resolves network issues in the control layer. Radiating out, full network visibility would be implemented to ensure a dependable network to edge devices. Fortunately, a host of available layer 3 router and layer 2 managed switches can provide core network needs. What about layer 2 unmanaged (edge) switch requirements that must stretch to incorporate such characteristics as port status visibility at the IP address level and employ port quality of service (QoS) to ensure a work-

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ing model for the enterprise needs as much as the automation network? This is a switch’s role usually reserved for robust, managed switches, but the drawback is that such switches deployed on the edge can be costly and require a lengthy ramp-up time to implement. Lower-cost managed switches

On this topic, IHS’s John Morse predicted that “the introduction of lower cost, lower functionality layer 2 switches will economically serve the need of users as networks are expanded to meet the degree of connectivity required to join the industrial IoT revolution.” Also in a 2014 report on the market for industrial Ethernet infrastructure components, IHS said: “This trend may, in the longer term, see the demise of the unmanaged switch as the prices converge, much in the way the hub has become all but extinct.” To allow port status visibility for automation and IT software, the layer 2 unmanaged switch acting as the edge switch must support Modbus/ TCP and simple network management protocol (SNMP) communications. This allows supervisory control and data acquisition (SCADA), human-machine interface (HMI) software, and IT network management system (NMS) software to monitor the switch device status in real time.

Ethernet reliability

As more programmable logic controllers (PLCs), input/output (I/O) devices, terminal computers, and HMI become more Ethernetconnected, Ethernet will increasingly require the “always-available” adjective. It becomes an exponential resource drain for automation teams that continue without an update that provides visibility to the network’s edge. As edge devic-

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Supervisory control and data acquisition (SCADA), humanmachine interface (HMI) software, and IT network management system (NMS) software can monitor Ethernet switch device status in real time.

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Figure 1: The industrial Ethernet network built to handle big data initiatives will provide device layer visibility for the central IT layer. Advantech ProView switches enable convergence management to meet IIoT and big data scale network upgrades. The ProView switch series supports Modbus/TCP and SNMP protocols, allowing SCADA/HMI software and IT NMS software to monitor the switch device status in real time. Figures courtesy: Advantech

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As more programmable logic controllers (PLCs), input/ output (I/O) devices, terminal computers, and HMI become more Ethernetconnected, Ethernet will need to be always available.

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Figure 2: A network diagnosis model supports real-time, port-status viewing on SCADA/HMI and NMS used by central IT. Advantech ProView series of switches allow IT to control or perform certain configuration capabilities, such as setting device location, device IP mode, device IP, device netmask, default gateway, and read/write community name. The switches can provide statistical information including count on unicast, multicast, and broadcast packet for each Ethernet port. The switches support SNMP traps, which automatically notify the SNMP server during events. www.controleng.com

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EXCLUSIVE

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Temperature sensor data might be important for the factory engineer for process analysis and for the IT department for cloud cold storage and business process analysis; either team could be enabled to send or receive alerts if data loss becomes apparent.

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Go Online Click through the headline in the digital edition to read this article online for related links, or search on the headline using the search box atop www.controleng.com.

es multiply, and the data gathering functions increase, the personnel needed to check buggy switches would be less available, translating into lost data and lost revenue if the connection serves an automated process. Greater network visibility expedites troubleshooting for automation and IT teams. Edge switch technology that supports Modbus/TCP and SNMP protocols will be the enabler for this. In this model of converged networking, teams can work towards resolution of network issues fast. Data from a factory temperature sensor might be important for the factory engineer for process analysis and for the IT department for cloud cold storage and business process analysis; either team could be enabled to send or receive alerts if data loss becomes apparent. Enabling diagnostics

However, the next step is more powerful: Either team can diagnose that there is a disconnected Ethernet line to port 5 of the edge switch I/O input hosting the temperature sensor and inform on the necessary fix. This is made possible with an edge switch that has onboard agents for Modbus/TCP and SNMP protocols.

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The more intelligent edge switch provides detailed statistical information on each port including speed, linkup counter, count on the multicast packet, count on unicast packet, and count on error. With the edge switch also supporting SNMP it will allow the IT team’s network management system or station software to perform status monitoring in tandem. The fix is employed and data restored at the speed of today’s more business-minded automation networks. Ethernet network transformations like these will take place to keep up with the growing number of devices and the variety of data demands. An Ethernet network can be easily viewable from the device layer to control layer to the central office. ce - Ken Kao is product manager for Advantech’s industrial networking team. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.

Consider this... Perhaps smarter switches can add to your Ethernet network intelligence.

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digital edition

EXCLUSIVE

Acadian Seaplants: Ethernet connections help with 40% capacity increase New seaweed-processing facility with Ethernet infrastructure and integrated motor control centers allowed Acadian Seaplants to increase capacity by 40% and provide flexibility, visibility, and improve maintenance without production disruption. Key concepts Hard-wired networking discourages upgrades and optimization. Ethernet facilitates easier expansion, changes. Easier maintenance, less downtime, and increased visibility are among other Ethernet benefits.

seaweed producer switched from hardwired controls to use of Ethernet to facilitate a 40% increase in production without downtime, while improving maintenance via remote support, increasing visibility, and providing flexibility to make production changes as needed at a lower cost. Seaweed’s natural nutritional and healing powers have been known for millennia: The Romans applied marine plants to help heal wounds and rashes, and the Japanese made it a dietary staple. Today, processed seaweed is a key ingredient in everything from human

Before and during expansion into the Dr. James S. Craigie Research Center in Cornwallis, Nova Scotia, Canada, Acadian Seaplants found that the TechConnectSM service from Rockwell Automation, with 24/7 phone support, helped the engineering team solve issues quickly, especially in the early stages of plant automation. The engineering team installed three EtherNet/ IP-enabled CompactLogix PACs to manage system functions. The team easily set up and configured the MCCs using the same software as the PACs, Rockwell Software Studio 5000 Automation Engineering and Design Environment. IntelliCenter software that monitors the MCC also can send the motor control device information directly to Studio 5000 software. Images courtesy: Rockwell Automation DE-23

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nutritional supplements to animal feed. Acadian Seaplants, based in Dartmouth, Nova Scotia, Canada, cultivates and processes seaweed for a variety of products in this international industry. One of those products is crop biostimulants, derived from a species of seaweed called Ascophyllum nodosum, used to improve the health and growth of plants. Hardwired inflexibility

Acadian Seaplants produces crop biostimulants in liquid and powder formats at its facility in Cornwallis, Nova Scotia, Canada, and ships branded products to more than 80 countries. Its proprietary production process starts with locally and sustainably harvested seaweed. Then various bio-active compounds are extracted, clarified, filtered, and concentrated. Finally, the compounds are tested for quality, preserved, and packaged. This complex manufacturing process requires a high degree of process control. Before 2006, motor controls and facility communications were hardwired. If the company wanted to change or add a step in the production process, rewiring areas in the facility would be required. Between 2006 and 2008, the company began automating the Cornwallis facility. Modernization wasn’t enough to meet growing demand. In the last decade, the use of natural biostimulants in agriculture and horticulture increased substantially, and Acadian Seaplants needed to grow and upgrade its biostimulant production facility in response. The company decided to build onto its existing plant to add capacity and automate the new equipment to increase process control and manufacturing efficiency.

Easier integration with Ethernet

Electrical supplier, Graybar, knew Acadian Seaplants was already using Ethernet-enabled programmable automation controllers (PACs)

from Rockwell Automation. To help Acadian Seaplants expand without adding hardwiring for motor controls, Graybar proposed using motor control centers (MCCs) also enabled by EtherNet/IP (an Ethernet protocol from ODVA), so the MCCs could easily integrate with controllers in the existing system. Acadian Seaplants continued to automate existing processes and increased production capacity by about 50% between 2008 and 2009. But by 2011, the company needed to expand again and decided to build a much larger plant across the street. The proven technology in the existing space needed to be implemented on a larger scale. Downtime during expansion would have made it difficult to continue to meet orders. In the new facility, Acadian Seaplants also wanted to expand its recently implemented integrated MCCs and controllers and enable remote support to reduce maintenance time. Three-year expansion

Over three years, the Acadian Seaplants engineering team moved existing processes and equipment into a new facility, the Deveau Center. The plant science division gained three times more manufacturing space, meaning they needed more equipment. Experiences from the 2009 expansion were applied to help Acadian Seaplants implement a similar MCC implementation at a facility five times the size of the original operation. With counsel from Graybar, the Acadian Seaplants engineering team designed an integrated plantwide infrastructure for system monitoring and motor control over EtherNet/IP. The network became critical when the Acadian Seaplants team worked in stages to move existing processes to the new site. To start, the team built a piping system over land and under the street to move liquid product between the two facilities. As the team installed new equipment, they connected it via EtherNet/IP to the existing equipment on the other side of the street. Acadian Seaplants subscribed to remote maintenance services for many years, providing 24/7 phone support to help the engineering team resolve issues quickly, especially in the early stages of plant automation. The engineering team installed three PACs to manage system functions. The PACs seamlessly connected with other system components via an EtherNet/IP network. System information was fed to a desktop computer on-site, where staff could monitor operations in real time.

Centerline MCCs from Rockwell Automation provide precise motor control and power. Electrical supplier, Graybar, knew Acadian Seaplants was already using Allen-Bradley CompactLogix PACs from Rockwell Automation. To help Acadian Seaplants expand without adding hardwiring for motor controls, Graybar proposed using Allen-Bradley Centerline MCCs with IntelliCenter technology.

The Acadian Seaplants team moved the existing MCCs and installed additional ones to provide precise motor control and power in the seaweed-processing facility. The team easily set up and configured the MCCs using the same engineering and design programming software environment. Related software that monitors the MCC also could send the motor control device Bulletin 1606-XLP Compact Switched Mode information directly to Power Supplies from Rockwell Automation the design and program- are EtherNet/IP-enabled. The Rockwell Softming software, which ware Studio 5000 software recognizes the recognized the intelligent intelligent components in the MCCs, including components in the MCCs, variable speed drives and full-voltage startincluding variable speed ers. The add-on profiles immediately provide drives and full-voltage parameters for each component for faster starters. Libraries of soft- configuration. ware objects (blocks of code) immediately provided parameters for each component for faster configuration. No downtime, demand met

The new seaweed-processing facility was completed in 2014 without downtime, and Acadian Seaplants gained the production capacity necessary to meet immediate crop biostimulant demand. Already, the facility is operating at 40% higher capacity than the previous facility. www.controleng.com

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EXCLUSIVE

With its EtherNet/IP-based design, the facility could grow to 250% the prior output. The facility isn’t static. Acadian Seaplants may need to change functions one day, do improvements the next, or add processes. With the controls connected via EtherNet/IP, wires are virtual, and the company can make changes a With the Ethernet connections, lot faster at a lower cost.

in case of any issues, engineers can gain remote access securely, helping to immediately reduce downtime compared to previously required on-site visits.

Improved access

With integrated MCCs and controllers, Acadian Seaplants gained a more connected, reliable, and continuous facility. Information is now shared more seamlessly between processes and operators. In case of any issues, engineers can remotely access the desktop computer, helping to immediately reduce downtime compared to previously required on-site visits. Issues automatically appear on the operator screen, a human-machine interface (HMI), making them more visible to operators than the previous mechanical blinking lights.

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Based on the success of Acadian Seaplants’ expansion, the company is considering similar changes at other facilities. The engineering team has begun to automate processes with PACs at the food science division’s land-based cultivation facility and would like to move to EtherNet/IPenabled MCCs at the animal science division’s facilities in the next few years. ce - Wade Hazel is engineering manager for Acadian Seaplants. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.

Go Online If reading the digital edition, click through the headline to reach article links with more photos and links to related information on Ethernet protocols, Ethernet use in process control, and EtherNet/IP implementation tips. Or search on the headline atop www.controleng.com. www.acadianseaplants.com

Consider this... When doing a cost-benefit analysis of an upgrade that includes Ethernet, are lost opportunity costs part of the calculation?

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digital edition

What kind of fieldbus is needed for Industry 4.0? High connectivity and powerful communication capacity are necessary between equipment and servers to realize the dream of connecting smart manufacturing with all things. Fieldbus organizations are seeking new ways to adapt the new needs of industry.

egardless of Industry 4.0 in the era of Industry 4.0 and IoT. or the Industrial Internet ETG and OPC aim to apply proof Things (IIoT), high tocol to the real-time communiconnectivity and powercation between controllers at the ful communication capacity are equipment layer and slave stanecessary between equipment and tions; use the Extensible Authenservers to realize the manufacturtication Protocol (EAP) for the ing world’s dream of connecting communication between horismart factories with all things. zontal controllers and controllers High-speed, efficient, and safe in the field; and apply OPC UA fieldbus provides the basic guarto the vertical communication to antee to smart factories. Martin Rostan is execu- connect non-EtherCAT systems to “Traditional Ethernet has three tive director of EtherCAT meet all communications required problems in real-time communi- Technology Group for the vertical and horizontal cation, including low utilization (ETG). Courtesy: Conintegration of Industry 4.0. of broadband, stacking, and lag of trol Engineering China Future of a fieldbus exchanger,” said Martin Rostan, organization executive director of EtherCAT As a nonprofit organization, ETG does not Technology Group (ETG). Right now, the fastest industrial Ether- collect membership fees from its members, net technology can take only 30 µs to update and members also are provided free access to 1,000 input/output (I/O) devices; one Ethernet protocol stacking, sample codes, evaluation frame can process 1,486 bytes of process data toolkits, and implemented support and other exchange, at most, and communicate with 100 services at a lower price. This is the reason servo axes per 100 µs, while providing nanosec- why EtherCAT may be well accepted. From February 2014 to February 2015, 412 members ond synchronization. joined the ETG. ce Transition to Industry 4.0

If there is one ideal to summarize the hottest topic Industry 4.0, Martin Rostan believes that it is the integration of automation and information. For seamless connection with all enterprise information, the data transmission should be implemented from the equipment and control layers to the manufacturing execution system (MES) and enterprise resources planning (ERP) layers. The future fieldbus will be closely connected with enterprise-level networks and even the cloud. Based on such a vision, ETG and OPC signed a memorandum of understanding (MOU) at the Hanover Exhibition held in April 2015, declaring that both organizations will develop a common interface to better meet users’ needs

Key concepts High connectivity and powerful communication capacity are necessary between equipment and servers for Industry 4.0. The fastest industrial Ethernet technology can take only 30 µs to update 1,000 I/O devices. Data transmission should be implemented from the equipment and control layers to the MES and ERP layers.

- Aileen Jin is editor-in-chief, Control Engineering China. Edited by Joy Chang, digital project manager, Control Engineering, jchang@cfemedia.com.

Go Online This was translated and edited for Control Engineering from Control Engineering China. www.cechina.cn See other international coverage at www.controleng.com/international. www.ethercat.org Online linked to: Meeting the requirements of Industry 4.0 www.controleng.com

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Consider this... Is the fieldbus technology you are using ready for the Industry 4.0 transformation?

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Managing the risk of the Internet of Things Internet of Things (IoT) is growing rapidly, and more devices are going online. Protect the devices, systems, and users with smart industrial network design and cyber security best practices. See risk formula graphic (third page) and six steps for IoT risk mitigation. This is a Digital Edition Exclusive full-length version of the paper-edition article on p. 33. Key concepts A basic understanding of IoT and implementing some basic steps can put any organization on the right track to managing its IoT risk. IoT is thought of as less a series of small devices and more of an ecosystem. Unlike traditional information technology components, IoT-connected devices are often more vulnerable.

IoT defined

To understand the risk to IoT, definitions are needed. Clearly, IoT is a somewhat fluid term and owes its name more to media hype rather than to a multi-year standards process. Consequently, it has the “know it when you see it” quality. At its most basic level, IoT implies network connectivity, the use of embedded (or limited computing) devices, and, typically, involves some connection to the physical world, such as measuring temperature, blood pressure, or road vibrations. In essence, it implies network connectivity for everyday devices that traditionally were not considered computers; however, nearly every use of IoT also involves some traditional com-

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puter usage. For example, these small, embedded devices usually report their status and receive instruction from a traditional computer workstation, server, laptop, or smartphone. A typical IoT architecture might look similar to what is shown in Figure 1. It’s better to think of IoT as less a series of small devices and more of an ecosystem that requires multiple components to work correctly. The supporting components, while appearing to be normal computing devices, still need to be adjusted for the real-time nature of and massive data often associated with IoT. Computer networks need to be everywhere and optimized for the volume and velocity of the data flows. And the appropriate business logic needs to be devised for what are largely autonomous networks. But fundamentally, IoT is about the core components that interact with the physical world. They typically include sensors to measure things like temperature, wind speed, or presence of an object. And they often include actuators that initiate actions like driving a car, turning off power, or injecting insulin. The supporting functions are often the place where the actions are determined, but for some largely autonomous devices, some of those decisions could be made independently based on the input the device receives. While IoT is still a relatively new concept, core components have had populated industrial networks for decades, and they foretell some of the risks that could potentially be faced. Industrial networks have frequently been the subject of cyber attacks. Unlike traditional information technology components, they are often more vulnerable because many industrial networks were never designed to connect to networks that were linked to a hostile Internet. Instead, those closed networks assumed physical attacks were the threats to guard against. In addition to interconnectivity challenges, the core industrial devices, such as program-

mable logic controllers (PLCs), had basic communication protocols that could crash if they received any unexpected data. Moreover, PLCs were essentially designed to process commands from whoever sent them, sometimes with little or no authentication. That meant that if the industrial networks were not sufficiently isolated or properly defended, compromise was more likely with real physical consequences. IoT threats are real

Threats have through IoT:

been

executed

Nearly two decades ago, a disgruntled former employee used network access to remotely release sewage. In 2007, researchers demonstrated that a generator could be destroyed by remotely opening and closing circuit breakers rapidly. In 2014, hackers broke into the industrial network of a German steel mill and prevented a blast furnace from shutting down. With respect to the more modern IoT devices, a researcher hacked his insulin pump, others managed to compromise smart meters, and, in a segment aired on “60 Minutes,” Defense Advanced Research Projects Agency (DARPA) scientists remotely controlled automobile brakes. These examples show how securing billions more of IoT devices, deploying them on a wide variety networks, and connecting some of them directly to the Internet will continue to pose great challenges. Even with better network stacks and more rigorous cyber-security controls, the nature of many of these devices means that the robust controls that exist on typical workstations, laptops, servers, or even smartphones are unlikely to be implemented in the devices’ design. Controls need to be evaluated and implemented in a different way. Moreover, these devices are incredibly diverse in application, location, and architecture. Some rely on centralized con-

trol, while others have their own intelligence and often operate autonomously. By definition, they are connected with other networked components, which means they are at risk of being compromised, have the potential to spread infections, and serve as a platform for hackers to attack other parts of the ecosystem. That is why the risks posed by IoT are significant, because, normally, there is a level of trust that pervades the network where these live. It is the network and its scalability offer the greatest promise and the greatest risk for IoT.

Figure 1 shows the cycle of how IoT software interacts with connected devices, akin to a control engineering process. Courtesy: Leidos Engineering

Approaches to IoT risk

So given the wide variety of devices and their influence on the future world, what’s the best way to reduce risk? Traditional risk management may point in many directions. Trying to understand the kinds of future threats and devising controls to address them are likely to be overwhelming with the proliferation of new devices and continual acceleration of related threats. Also, the traditional strategy depends on how devices are used. Another method would focus on the impacts and prioritize efforts around those with the most devastating consequences. This is a common www.controleng.com

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EXCLUSIVE or control system computer banks), whether the devices will interact with existing technology, and any assumptions that are made about the infrastructure that should already be in place. All business objectives should be noted, because one of the tasks for a risk analysis is to determine the consequences of those objectives not being met due to hacking or some other device failure. It is also important that a use case be created for each variation. For example, connecting a smart meter that merely measures and reports energy usage has very different implications than one that also supports the ability to remotely disconnect power. The details matter. Deciding how detailed the use case should be is often a judgment call. Prioritize vulnerabilities

Figure 2 shows the risk formula for the Internet of Things. Courtesy: Leidos Engineering

method used by many government approaches, where the bulk of the focus is on impact and not how vulnerable a particular device is to a given threat. While impact is important, it is more important to first appreciate what exactly IoT devices are intended to do. Starting with a use case analysis also demonstrates what the intended business purpose is. If a device later gets used for something else, the risk team can point to the original analysis to remind management that a new risk analysis is warranted. Building a risk model

To evaluate IoT risk, first define the use case. How will the devices and the supporting infrastructure be used? While technical descriptions are useful, the focus should be on the relevant business processes and expected outcomes. How exactly will this produce operational, business, or personal value? Given that nearly all projects must be approved with similar justification, this information shouldn’t be hard to find. Unlike broad-based budgeting that seeks a general goal, but doesn’t touch on the how, these use cases should be very specific and should include details. The kind of data involved should include whether humans will interact directly with these devices in a physical sense (such as health monitoring devices, self-driving vehicles,

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Once impacts are known, the potential vulnerabilities are easier to identify and prioritize. Identification of vulnerabilities usually starts with examining all interfaces and potential attack surfaces, both logical and physical. Because the number is often quite large, it may be necessary to focus on likely and sufficiently impactful threats. For example, it’s unlikely that a nation state is interested in gathering information on someone’s power usage unless it was the power usage for a key military base. In essence, vulnerabilities, to some extent, need to be informed by the current threat environment. Finally, the exercise goes beyond the standard risk analysis to recognize that IoT will not stand still. By its very nature, it will grow and mutate to satisfy demands. Technologies like road sensors and smart meters are not designed to be replaced frequently, so software updates and network changes will need to use the installed hardware. That also means that considerations like upgradeability and extensibility, while not largely cyber security considerations, become bigger issues with IoT. Consequently, future use and misuse cases should be identified. Similarly, the consequences of expanding the network of devices, and how that could lead to an overreliance on the core installation, need to be considered. For example, handling the security of a few self-driving cars may be manageable with one person manually doing occasional oversight. However, once the few cars grow to several thousands, just hiring more people won’t

work, as the amount of data and attack surfaces increase exponentially. In that case, the only cyber-security solution to greater degrees of scale and automation is by using cyber-security automation that is then overseen by people. Harm to other stakeholders, or externalities, also needs to be part of the equation. The result is the extrapolated risk that a given IoT device or set of devices poses, as depicted in Figure 2. Mitigating risks

Of course, identifying risks is only part of the equation and is often a trivial exercise. IoT phenomenon has fostered a cottage industry pointing to all the ways devices can be hacked. While the potential consequences of these attacks are not always fully appreciated, it’s clear that adequately addressing the vulnerabilities will be a big job. Perhaps the most important consideration is that the device be identified for a particular purpose and if that purpose changes, the risk analysis and potential compensating controls would also change for the manufacturer and the end user. For example, a networked drone could be sold as only appropriate for agriculture and oil drilling observations in unpopulated areas. Enforcing these parameters could be a challenge, even if manufacturers disclaim liability for unspecified uses. Vendors have every incentive to find new uses for products. Moreover, when a device is designated for only a particular purpose, the manufacturer actually may incur more liability as any failure or harm it caused could be viewed as foreseeable, an important consideration in determining negligence. At the very least, some assumptions should be highlighted, and any limitations should be noted. For individuals or businesses purchasing these devices, mitigation and proper use starts with a well-defined use case development process. For businesses, that should mean policies specifically permitting or excluding a device’s use in a particular environment or for a particular purpose. Where personally identifiable information is involved, there should be clear data collection and retention policies. And specific people should be assigned responsibility for each device, as well as for the larger system involved, where relevant. Companies, in particular, need to review insurance for coverage of device damage and the harm that could result if the device is misused. Where possible and relevant, some sort of ongoing security monitoring should be implemented.

Finally, device owners need to understand that one security review is not enough. They need to schedule ongoing reviews as device use expands, as major changes are made to any backend infrastructure that communicates with these devices, and as new types of data are collected. The risk management model then needs to be revised with every change in scope. Six IoT risk mitigation steps

For those currently involved with IoT, which includes nearly everyone, six basic actions should be taken regardless of the risk involved or the dollar amount being spent on the program. 1. Beginning right away, IoT ownPersonally ers should identify current IoT impleidentifiable mentations that are in place, planned, or anticipated. This may include buildinformation ing management systems for heating requires clear and air conditioning or even the mechadata collection nisms used to run the elevators if they’re networked. and retention 2. Next, organizations should identify policies; assign any security policies or procedures related to IoT. If none exist, companies should at specific people least document some high-level controls responsibility for that should be in place, such as locking the elevator machine room. each device and 3. Within three months, organizations larger system. should ensure that device owners have applied the risk model described above and reviewed the results with management. 4. Organizations should also identify mitigation steps and associated costs to achieve the desired state. 5. And in the next six months, organizations should identify IoT risks that they don’t control, but that affect their organization. 6. Organizations should also participate in industry groups to encourage development of security standards for the devices that most affect them. ce

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- Gib Sorebo is chief cyber security technologist at Leidos Engineering. Edited by Eric R. Eissler, editor-in-chief, Oil & Gas Engineering, eeissler@cfemedia.com.

Consider this... As IoT spreads to almost every object in the future, how can we protect ourselves from hacked devices, or even the hacking of our homes? The question is should there be objects that are not connected for our own safety?

Go Online Industrial Internet of Things needs data, clouds, and analytics Linked to this article online: Industrial Internet of Things needs data, clouds, and analytics. www.controleng.com

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Daniel Ackmann ...........37

Amanda Pelliccione, Project Manager and Director of Research

Chad Albert...................37 Corey Arrick..................37 Joseph Bastone ...........37 James Couto ................38 Dave Denison ...............38 Stephen Dora...............38 Jesse Dorn ...................38 Alfredo Flores ..............39 Michael Gagne.............39 Cassy Gardner .............39 Miguel Gutierrez ..........39 Bryant Jackson ............40 Robert Jardel ...............40 Jayesh Jariwala ...........40 Scott Lawless ...............40 Hunter Longshore ........41 Sean Mascarenhas ......41 Abid Munawar ..............41 Justin Nielsen ..............41 Jayson Pestow ............42 Jeff Poirier ....................42 Justin Robinson ...........42 Carl-Johan Roos .........42 Kori Shane ...................43 Lee Smith......................43 Bret Van Wyk ...............43 Chris Vitale ...................43 Nathan Wingate ...........44 David Ziskind................44

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The 2015 Engineering Leaders Under 40 are a dedicated group of engineers that give hope to the future of manufacturing.

With the future of manufactur-

ing heavily relying on the younger workforce, Control Engineering and Plant Engineering are honored to present the 2015 Engineering Leaders Under 40. These 30 individuals are involved in a variety of industries and responsibilities that force them to sharpen their multi-tasking and management skills daily. The majority—70%—serve the engineering and system integration (SI) sectors, while instrumentation and measurement (57%), consulting (50%), and food, beverage, and tobacco (50%) round out the top four segments in which they are involved. Here is a quick look at this year’s Leaders: Education: 90% of the Leaders have earned their bachelor’s degrees, 20% master’s degrees, and 7% associate’s degrees. Job function: 23% are primarily involved in SI roles, 17% control engineering, 10% general/corporate management, 10% consulting, 7% product design, 7% manufacturing engineering, and 6% plant management/engineering.

SEPTEMBER 2015 CONTROL ENGINEERING ● www.controleng.com

SI or engineering services: 79% provide SI or engineering services to manufacturing organizations. Products or systems: The top five products or systems purchased or specified by this year’s Leaders are industrial control equipment or systems (57%), software (53%), I/O products or systems (53%), instrumentation (53%), and programmable logic controllers (53%). Machines for resale: 37% design, build, or install machines for resale to other companies; 47% design, build, or install machines for use within their companies. The 2015 Engineering Leaders Under 40 are featured in the following section and with more information online at www.controleng.com, and will be honored at the 2016 Engineering Awards in Manufacturing dinner hosted by Control Engineering and Plant Engineering on Monday, March 21, 2016, in downtown Chicago. For information on how to nominate for 2016, visit www.controleng.com/EngineeringLeaders.

Daniel Ackmann, CEM, LEED AP BD+C, 28

Chad Albert, 30

Project Manager; Energy Engineer; Enviro-Management & Research Inc.; Springfield, Va.

Engineering Manager; Bluff Manufacturing; Fort Worth, Texas

BS Civil Engineering, Purdue University

BS Civil Engineering, Western Michigan University

ckmann enjoys the nonroutine nature of working with multiple federal agencies, of helping find out-of-the-box solutions to save energy and money, and of having a considerable indirect impact on so many people. He has consulted for federal agencies looking to optimize performance—including the U.S. Dept. of Defense, where he assisted in achieving federally mandated energy and greenhouse gas (GHG) reduction goals, developed and maintained GHG inventories, analyzed utility bills and rate structures for opportunities to lower costs, and identified energy conservation capital investments and lower cost opportunities. In response to the American Energy Manufacturing Technical Corrections Act of 2012, Ackmann was the lead writer and researcher in identifying advanced meter best practices in federal facilities, buildings, and equipment for the U.S. Dept. of Energy. Ackmann manages the development and operation of the Architect of the Capitol’s utility metering enterprise system and bill verification system to ensure that all U.S. Capitol facilities effectively manage energy use and retain data to establish near- and long-term utility budget goals. Ackmann has authored federal guidance for procuring public utility and energy management services through area wide and utility energy service contracts for the General Services Administration. Recently, he and his wife vacationed in Iceland to enjoy the people, geology, and beauty of the country.

Corey Arrick, 38

Joseph Bastone, 37

Engineering Manager, BAE Companies, Philadelphia

Marketing Manager; Honeywell; Fort Washington, Pa.

BS Agricultural & Biological Engineering, Purdue University

BS Chemical Engineering, Rensselaer Polytechnic Institute

rrick has broad experience as a process engineer and project manager working in the food, pharmaceutical, and health/personal care industries. He has worked as a design and construction engineer for various clients, ranging from Godiva Chocolatier to GlaxoSmithKline. He also has worked in plant operations and as a quality specialist in the meat industry. Recently, Arrick managed the operations team and acted as the start-up engineer at a meat import and processing facility. He manages the quality department for the company’s products, achieving U.S. Dept. of Agriculture import and domestic status and leading the facility to Safe Quality Food certification. In 2001, Arrick received an Operational Achievement Award at Godiva Chocolatier for the installation and start-up of a caramel-cooking process, and in 2012 he received a PRIDE Award—Professionals Recognizing Individuals who Demonstrate Excellence—at Barry-Wehmiller Design Group. Arrick has five U.S. patents and two European patents for hot-beverage products. Arrick is a motorcycle enthusiast and enjoys experimenting with foods and drink by brewing his own beer, wine, and ciders and making his own yogurt and cheese.

lbert brings his advanced skills in creating automation systems for the engineering team at Bluff Manufacturing. As an innovator, Albert drives new product development and redesigns existing products for greater manufacturing efficiency. He consistently leads his team to deliver solutions and value to their customers, increasing revenue for his company. Albert has transformed the way Bluff’s products are created with his process development framework designed for the engineering department. He also has created automated tools to streamline the customer ordering process and systematize products, resulting in decreased ordering cycles. In the engineering industry, Albert has been the Bluff member representative of the Loading Dock Equipment Manufacturers group of the Material Handling Institute, which reviews, discusses, and revises the standards for the design, performance, and proper operation of loading dock equipment. Outside of work, Albert enjoys spending time with his 2and 4-year-old sons. He is involved with community service, including mission trips to Central America and helping with Hurricane Katrina cleanup in Alabama. Albert volunteers for his church through community cleanup projects and assisting the homeless in Fort Worth.

astone uses his strong analytical capabilities to consistently prioritize tasks for effective commercialization of prominent developments at Honeywell in Fort Washington, Pa. He manages the Experion PKS Control and I/O portfolio, which includes five product manager direct reports who represent more than 100 years of experience. Starting as an application engineer, Bastone spent his first 8 years with Honeywell in the field with key customers. He later joined the product marketing team as the product manager for Experion controllers and was selected to launch derivatives of Experion PKS, for which he received a Corporate Marketing award in 2012. Bastone is now the marketing manager for this product, and he recently launched the Universal I/O for Experion. He is also a key contributor for the LEAP initiative at Honeywell Process Solutions, challenging how automation projects are implemented and deployed. For this, he also won a Corporate Marketing award in 2015. Bastone always has been drawn to technology and the path it offers: exposure to new, high technologies while managing a business. At home, he does time-lapse photography with his two children, along with a student robotics platform.

www.controleng.com

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CONTROL ENGINEERING SEPTEMBER 2015 ● 37

James Couto, 32

Dave Denison, 39

Project Manager; Autopro Automation Consultants Ltd.; Calgary, Alberta

Director, DeltaV Product Marketing; Emerson Process Management; Round Rock, Texas

BS Electrical Engineering, Lakehead University; MBA, University of Calgary

BS Computer Engineering, Iowa State University; MBA, St. Edward’s University

outo is currently the youngest project manager contracted at Autopro Automation Consultants. Couto also manages his own company, Couto Consulting, and a separate software-as-a-service business. He is recognized at Autopro as a strong leader and an effective team builder, and he is always looking for ways to improve processes and drive efficiency in projects. Couto’s broad range of skills and experience, including an excellent balance of people and technical skills, contributes to his tremendous ability to mentor others, even staff members more senior than he is. In the past year, Couto successfully completed his MBA at the University of Calgary, an achievement that consumed all of his spare time. The desire to broaden his experience and move away from a pure technical focus to one that includes the business perspective prompted him to pursue the degree independent of financial support from the company. Off the clock, Couto volunteers with Engineers Without Borders and works on the corporate engagement team to establish awareness of the organization. He participated in the 2012 Enbridge Ride to Conquer Cancer and raised more than $5,000 for the Alberta Cancer Foundation.

Stephen Dora, 33

Jesse Dorn, 32

Engineering Specialist, Plant Planning; Toyota Motor Engineering & Manufacturing North America Inc. (TEMA); Erlanger, Ky.

Project/Maintenance Manager, Manufacturing; Victaulic; Easton, Pa.

ver the past 16 years at Emerson Process Management, Denison collaborates cross-functionally to create a compelling product and technology vision based on customer needs and new innovations. He contributed to the DeltaV distributed control system (DCS) as a software engineer, software development manager, and director of software applications and is a DeltaV product marketing director. Denison wrote real-time software responsible for running control logic and interfacing to multiple I/O technologies within the DeltaV controller. Denison led the effort to design and certify the DeltaV SIS with the Electronic Marshalling product. Denison is a recognized innovator and has been awarded seven patents associated with DeltaV. Denison planned and directed multiple programs within the product areas of operations environment, engineering clients and servers, virtualization, and remote monitoring. Denison’s move into product marketing has increased his responsibilities and ownership of the DeltaV product lifecycle. During free time, Denison plays softball, basketball, and golf, and coaches his daughter’s youth basketball team.

BS Electrical Engineering, Rose-Hulman Institute of Technology

AAS Tool Making Technology & BS Manufacturing Engineering, Pennsylvania College of Technology

ora demonstrates leadership in his role as project leader for the TEMA Plant Planning Section for specification, design, construction, and handover as the owner for Toyota manufacturing plants in North America. At Toyota Motor Manufacturing Kentucky he exhibited continued growth in leadership roles for plant expansion to bring the Lexus brand to the U.S. Dora has advanced from his background of electrical engineering through building components and systems, including civil/structural, mechanical and piping, and electrical power and distribution. He has brought and led innovative cost-effective design and construction improvements while Toyota budgets and schedules have compressed. He participates in seminars and conventions to continue professional development. Dora is a leader for Toyota projects primary commitment to construction safety by obtaining his Occupational Safety and Health Administration 30-hour credentials as well as participating in all Toyota electrical safety and lockout training. He has authored several Toyota training courses on power distribution and electrical systems. Dora married in July 2015, and he and his wife enjoy running 5 and 10k races, traveling, and yard saling.

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orn’s intelligence, self-motivation, and professionalism has allowed him to be successful in multiple roles within Victaulic, including his present position as the project/maintenance manager in manufacturing. Dorn began his career at Victaulic in 2007 in the rotational engineering program and has rapidly advanced while undertaking various leadership roles. He has served as a cost reduction team leader and municipal operations facility manager to his current position. With a strong understanding of U.S. operations, Dorn has been instrumental in implementing effective process improvements that have enabled Victaulic to achieve major savings while boosting productivity, improving manufacturing output, and enhancing on-time product delivery for customers. Dorn is skilled in process improvement, including finding ways to secure local efficiency gains and manufacture products close to customers. He has a strong passion for locomotives, specifically fixing and performing maintenance on steam trains. He volunteers at several tourist railroads. When not working on trains, Dorn likes spending time with his wife, two children, and other family; out on the river in his kayak; or riding dirt bikes and four wheelers with friends.

SEPTEMBER 2015 CONTROL ENGINEERING ● www.controleng.com

Alfredo Flores, 31

Michael Gagne, 28

Senior Controls Engineer; RedViking; Plymouth, Mich.

Senior Software Engineer; Kepware Technologies; Portland, Maine BS Electrical & Computer Engineering, University of Maine

BS Mechatronic Engineering, Monterrey Institute of Technology and Higher Education, Querétaro (ITESM)

lores is a detail-oriented leader in implementing standards that unify RedViking’s processes across diverse business units. From his origins in mechanical design, Flores has shown aptitude for quickly acquiring new skills and leads in electrical engineering, controls engineering, and project management for the manufacturing execution systems (MES) and manufacturing and assembly solutions teams. At age 25, Flores took over a factory information systems launch project with great success. At 27, he managed a staff of eight engineers to successfully implement a complete tracking and error proofing system (EPS) in a new plant, before conveyors were installed. Flores’ EPS worked flawlessly upon launch without time for the normal debugging process. He recently designed a unique controls architecture for RedViking’s battery-free inductively powered automated guided vehicle system, Wingspan. Flores is the new knowledge leader and has designed a new approach to make the AGVs “controls-agnostic.” In his free time, Flores is studying for his Master’s degree in engineering management and enjoys playing outdoor sports with his two young children.

agne’s extremely versatile skill set allows him to lead projects in all of Kepware’s major markets. He is well respected among his peers, serving as a mentor to new hires and contributing to key decisions behind Kepware’s major product releases. In 2009, Gagne was one of the first recipients of Kepware’s Scholarship for Excellence in Engineering. This recognition led to an internship with the company followed by his graduation in 2010. From there, he quickly advanced his career, moving from software engineer to senior software engineer. Gagne played a major role in the design and development of the Scheduler, a data optimization tool integrated within the company’s flagship product, KEPServerEX. As lead engineer of the project, he ensured the technology maintained its core purpose and functionality from inception to release. His ability to contribute across many areas of the business makes him an invaluable asset to the company and enables him to lead future initiatives. Currently, Gagne is spearheading the development of Kepware’s OPC Unified Architecture implementation. Gagne also promotes science, technology, engineering, and mathematics (STEM) education by volunteering in local career fairs, encouraging students with his own story to pursue careers in technical industries.When he’s not overseeing engineering projects, Gagne spends free time homebrewing his own craft beers, having recently joined the American Homebrewers Association.

Cassy Gardner, 24

Miguel Gutierrez, 35

Engineer; Banks Integration Group; Vacaville, Calif.

Project Manager; Maverick Technologies; Santa Ana, Calif.

BS Biological Systems Engineering, University of California, Davis

BS History, California State University, Fullerton

hough Gardner is in an entrylevel position at Banks Integration Group, she has significantly impacted her company and continues to help reshape its direction and culture. Gardner is actively involved in creating a positive environment at Banks; she has taken the lead role in Bright Ideas, one of Banks’ management’s initiatives aimed at improving employee engagement. In this role, Gardner has engaged and collaborated with employees of all levels within her company. Gardner has developed the infrastructure to help employees make a positive impact and influence the direction of the company through this iniative. In addition to her contributions at Banks, Gardner enjoys working with children to foster interest in the science, technology, engineering, and mathematics fields. She recently participated as a mentor in the Women in Science and Engineering program at UC Davis and helped execute and coordinate an outreach presentation at the local Boys & Girls Club of America. She actively participates in the local International Society for Pharmaceutical Engineering (ISPE) chapter planning and organizing events and also has spoken at the local student chapter of ISPE about controls engineering.

utierrez combines many first-rate skills to make him an effective engineering leader at Maverick Technologies. He quickly learned the necessary technical skills early in his career and still demonstrates an ongoing personal drive to always know more. He engages with customers to understand their needs and with coworkers to encourage, help, and train them. Gutierrez knows what it takes to execute a project right the first time with the highest quality, keeping the team focused so that the customer is delighted and Maverick is the preferred choice for customers and employees. A liberal arts background forms the foundation of Gutierrez’s experiences. However, as he worked through school he acquired database programming experience that quickly transitioned him into the automation industry where he found an aptitude for human-machine interface and programmable logic controller development. He has consistently gained skills and executed increasingly complex projects through his career, pushing himself to excel in each task. He is a regular contributor to company blog posts that promote excellent work skills. When he’s not working, Gutierrez can be found at the paintball park with friends or preparing for his next Zombie Run or dragon boat race.

www.controleng.com

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CONTROL ENGINEERING SEPTEMBER 2015 ● 39

Bryant Jackson, 28

Robert Jardel, 30

Systems Engineer/Task Manager; Leidos Engineering; Walled Lake, Mich.

Controls Engineer; Airline Hydraulics; Bensalem, Pa.

BS Electrical Engineering Technology, Michigan Technological University

AAS Mechanical Engineering, Camden County College

Jayesh Jariwala, PE, 39

Scott Lawless, 35

Project Manager; Applied Control Engineering Inc. (ACE); Owings Mills, Md.

Project Manager; Leidos Engineering; Walled Lake, Mich.

BS Chemical Engineering, University of Delaware

BS Electrical Engineering & Computer Engineering, Kettering University

ackson is an eager, capable young professional who has quickly risen at Leidos because of his outstanding talent and aptitude. His ambition is apparent to all that work with him. Jackson enjoys a challenge and volunteers for new and difficult responsibilities, resulting in him quickly becoming a leader within Leidos as a systems engineer and project manager. He is willing to tackle any task, running straight toward a problem to find the solution. Jackson was hired at Leidos immediately following his graduation from college in 2010. He took on additional responsibilities, even outside the expectations of his managers. He is most proud of his work at a casting facility in Toluca, Mexico—a very difficult project that he encountered in his career. He started as the lead project engineer, responsible for the design, implementation, and commissioning of a new utility control system to be tied into an energy management system. He is currently the main point of contact for the majority of this customer’s projects.Jackson spends his time away from work with his wife and their 5-month-old daughter. He also volunteers for philanthropic walks and is active in other similar events.

ariwala possesses expertise in classic control systems including human-machine interfaces and programmable logic controllers. Jariwala differentiates himself with a breadth of knowledge on plant historians, database schemas, reporting applications, and custom programming applications. Strengths include designing systems to capture critical process data and developing dynamic Web-based reports for a variety of users. He has also worked with customers to bring plant floor data into manufacturing execution systems and enterprise systems. Since graduating from the University of Delaware, Jariwala has enjoyed a career as a process control engineer at ACE. He began his career in ACE’s Newark, Del., office and then transitioned to be a senior technical resource for ACE’s Chesapeake Region office in 2010. Throughout his career at ACE, he has been a highly soughtafter resource internally and to ACE’s customers. Jariwala is also the FIRST chair of the Baltimore/Washington D.C. section of the International Society of Automation (ISA). For the past 5 years, he has volunteered as a mentor for the FIRST Robotics Competition. Jariwala mentors an all-girls robotics team from Western High School in Baltimore, providing programming training and troubleshooting support.

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ardel is the type of person who can pick up a book or manual, read it, and retain all the knowledge inside. He is self-motivated, hardworking, and is always willing to go above and beyond to help and teach others in his spare time. Jardel quickly expanded his skill set when he started with Cryovation LLC in 2013, which resulted in company growth. He was quick to put his acquired skills to use, helping to develop new processes for the company; this led to the release of two new products that Jardel designed. Jardel also took leadership roles in a number of startups, interfacing with multiple engineering disciplines, salesmen, as well as the customer. Currently, Jardel is employed with Airline Hydraulics where he hopes to once again develop and implement innovative solutions for a growing industry. At home, Jardel has set up a programmable logic controller (PLC) test station with human-machine interfaces, PLCs, and other automation controls in order to develop his skills and discover new techniques for his profession. Even though his work finds its way home every night he never misses an opportunity to spend quality time with his fiancée, Katie, and daughter, Caylen.

awless is a project manager and engineer who consistently performs and completes projects successfully, gaining him the trust, confidence, and respect of his clients. Lawless has developed profitable programs for major customers at Leidos Engineering and is a leader in his part of the company. Lawless’ strengths lie with implementing system integration program solutions and teaching young engineers within Leidos. His team is currently working on a fan array air handling system program that is developing a standard control system design to meet the requirements of his clients, Ford Motor Co. and General Motors. His team is in the process of designing a modular chilled-water control system that can be assembled and tested before shipment to the client’s site. Lawless is a certified energy manager through the Association of Energy Engineers and a project management professional through the Project Management Institute. Within the company he is a go-to person for system controls/integration questions and assistance. Lawless is close with his family and friends, well connected, and respected in the community. He has been involved with multiple kickball tournament fundraisers and local charities and has a great camaraderie with his coworkers.

SEPTEMBER 2015 CONTROL ENGINEERING ● www.controleng.com

Hunter Longshore, 33

Sean Mascarenhas, 33

R&D Professional—Control Systems Engineer; Sandvik Mining; Alachua, Fla.

Senior Engineer; Autopro Automation Consultants Ltd.; Calgary, Alberta

BS Electrical Engineering, University of Florida

B.Eng. Electrical Engineering, McMaster University

Abid Munawar, 33

Justin Nielsen, 37

Central Engineering Lead; Intech Process Automation; Houston

Manager—Control Systems & Instrumentation; Excel Engineering; St. Paul, Minn.

ongshore is a talented, detailoriented, and hands-on control systems engineer at Sandvik Mining. Having taken a system lead role at the Sandvik Automation Modules (SAM) product line, he has responsibility for upgrades, rollouts, investigating issues, providing hot fixes, and other primary tasks related to SAM. Additionally, he has undertaken mine visits where he engages the end user to suggest new features and capabilities as well as conducting troubleshooting and training sessions. Longshore has led several training classes within the Sandvik factory in Florida to educate shop floor personnel whenever new features are released and on testing. While studying at the University of Florida, Longshore found a genuine interest in mechatronics and dedicated one of his senior projects to developing closed-loop control motor driver boards for a three-axis computerized numerical control machine. Additionally, during his college career, he spent a couple of summers in South Africa working at a robotics lab where he was introduced to machine controls. Aside from work, Longshore is also an avid cyclist and runner, often training with his co-workers for off-road cycling events and half marathons.

BS Mechatronics Engineering, National University of Sciences and Technology; MBA, Virtual University of Pakistan

ascarenhas has progressed very quickly since graduating from McMaster University. He was responsible for major projects very early in his career—within his first 5 years he led a large distributed control system upgrade project, including a successful shutdown and turnaround. When Autopro opened its location in Pune, India, Mascarenhas was one of the first people sent to train and mentor new technical staff, working long hours to orientate them and get them ready to work on Autopro’s projects. More recently, he was electrical lead on a large greenfield project for a major petrochemical producer, the largest project in Autopro’s 25-year history. This involved managing a team of more than 20 technical staff, in addition to interfacing with the client and subcontractors, and ensuring that quality standards were met on all electrical deliverables. There was a great deal of complexity in the number of engaged vendors, number of Autopro branches that provided project staff, and new technologies that were deployed on the project. For the past 6 years, Mascarenhas has volunteered as a high school football coach. He loves football and sharing his passion for the game to develop leadership skills with youth.

BS Chemical Engineering, Clarkson University

unawar has demonstrated leadership skills required at a management level to achieve his career goals and to contribute in achieving company targets. He is continually striving to enhance his professional skills so that his team can improve as a whole. Munawar’s main contribution has been in establishing a central engineering lead function and managing a large pool of project resources. He has developed and successfully run batches of trainee engineers to harvest resources for meeting Intech’s future needs. Munawar has established an effective performance management mechanism to not only evaluate performance periodically but to chalk out a career road map and provide mentorship to younger engineers so they can achieve their objectives. For this, he formulated a new competency framework for his business unit by using his analytical skills and mapped the existing competencies of the resources of his department on the new framework for gap analysis. Munawar has led a volunteer group that planted and cared for more than 3,000 trees in Lahore, Pakistan. He recently relocated to Australia and is looking forward to contributing to its automation and control society.

ielsen has provided a fresh perspective to broaden the services provided by Excel’s Control Systems group, as well as the client base that Excel Engineering serves. He is able to understand what the client needs, ensure that the individuals performing the work are performing optimally, and provide quality services to Excel’s clients. He has a vested interest in sharing his knowledge with the engineers who work with him and helping them succeed in their careers. Nielsen has been involved in controls and automation engineering since 1999 and has a strong background in the pharmaceutical, chemical, and power generation industries. Nielsen has been the lead for control system engineering on several multi-million dollar controls system upgrade projects for key clients. Nielsen’s functions include developing new business relationships, mentoring junior level engineers, and continuing to broaden the services that engineers can provide. Nielsen is an International Society of Automation (ISA) member and an ISA-certified automation professional. Nielsen is a dedicated father of two boys, who are 7 and 9 years of age. He enjoys coaching their baseball and basketball teams and participating in activities that capture his sons’ interests.

www.controleng.com

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CONTROL ENGINEERING SEPTEMBER 2015 ● 41

Jayson Pestow, 31

Jeff Poirier, 39

Senior Controls Engineer, Functional Safety Engineer (TÜV Rheinland); Frakes Engineering; Indianapolis

Senior Controls Engineer; RedViking; Plymouth, Mich.

BS Automation & Control Engineering, Indiana State University

estow is very passionate about machine safety and works hard to help customers achieve a safer facility. While in high school, Pestow participated in a 2-year technical program for machine tool technology and was inducted into the National Vocational-Technical Honor Society. After graduating college, Pestow maintained his commitment to the constant learning curve in engineering and technology. As a young engineer, he earned his Six Sigma Green Belt and used those tools to lead Lean initiatives for several years. Working as an engineer comes with inherent risk, and being a witness to two nonfatal industrial accidents propelled him into the concentration of machine safety. Frakes Engineering shares his commitment to safety and presented him the opportunity to pursue a certification as a functional safety engineer through TÜV Rheinland, a certification that fewer than 100 engineers nationwide receive each year. Pestow has been a competitive runner and triathlete for 6 years. In 2012, he proposed to his now-wife, Tara, at the finish line of his first marathon. This past May he was a top-500 finisher in the Indy 500 Mini-Marathon, a large U.S. half-marathon.

Justin Robinson, PE, CAP, 30 Performance Excellence Specialist; Maverick Technologies; Columbia, Ill. BS Chemical Engineering, Auburn University

obinson has experience working in an array of industrial manufacturing industries, on various distributed control system (DCS) platforms, and in multiple roles on Maverick project teams. Robinson has led significant DCS and human-machine interface migration projects. He also supports coaching and mentoring of team members, and he is the subjectmatter expert of high-performance graphics within Maverick, supporting the technical leadership of projects. Robinson started his career with Maverick as a process control engineer. He has since been promoted from engineer I, engineer II, and senior engineer to a principal engineer within 7 years due to his technical expertise, leadership, and customer support dedication. Robinson was most recently promoted to a new role as a performance excellence specialist. Robinson says that learning new things is the most fulfilling aspect of this career. Professionally, he enjoys learning coding, languages, processes, controls platforms, or work processes. When he is not working, Robinson enjoys playing guitar with his church’s worship band as well as expanding his cooking and “handyman” skill sets.

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BS Electrical Engineering, University of Michigan

oirier designed first-of-its-kind helicopter transmission flexible testing software at RedViking that enables motors to switch roles during and between tests to accommodate highly complex test profiles on one test stand. The challenge of configuring four 3,000-hp motors to change roles was unprecedented. In an example of a typical helicopter test stand, Motor A might always control speed with Motor B slaved or geared to follow it with balanced torque. Motor C creates load, and Motor D absorbs load and syncs to the first two motors. And all of these have to be synced and balanced. Poirier has built software to allow the test operator to change the system at the push of a button, so that the speed is now controlled by Motor C and torque is controlled by Motors A and D. In the same test or in the next test speed can be controlled by Motor B and torque by Motors A and D. Poirier’s software creates previously impossible flexibility in helicopter powertrain testing and provides outstanding cost savings. Poirier is an avid mountain biker; while on his honeymoon in Hawaii, he and his wife rented road bikes and used them to climb to the top of the Haleakalā volcano, an 83-mi ride with 10,700 ft of climb.

Carl-Johan Roos, 34 Functional Safety Officer; Emerson Process Management, Rosemount Division; Shakopee, Minn. M.Sc. Electrical & Computer Engineering, Chalmers University of Technology; MS Electrical & Electronics Engineering, Georgia Institute of Technology; MBA, University of Gothenburg

oos was one of the driving forces behind a new standard for overfill prevention that has been a major safety contribution to the oil industry. Roos has built-up a global overfill prevention business with unique competency based on thousands of installations. This know-how is now used in a customer-centric approach where Emerson provides the global process industry with the equipment, solutions, and lifecycle services compliant with functional safety standard IEC 61511 to minimize the overfill risk. Roos has led the extension of modern level measurement technologies into safety-critical applications. He has contributed significantly to product achievements at his company, including taking safety to the next level by introducing the world’s first SIL 3 radar level gauge, reducing installation costs considerably through a patented two-in-one radar level gauge, and introducing new proof-testing technologies, such as verification reflectors. Outside of work, Roos is a fanatic floorball player, which can be described as hockey but without the ice and the skates. He and his wife have two sons, ages 9 months and 3 years old.

SEPTEMBER 2015 CONTROL ENGINEERING ● www.controleng.com

Kori Shane, 38

Lee Smith, 30

Safety and Environmental Manager; Schneider Electric; Cedar Rapids, Iowa

Lead Software Engineer; Mettler Toledo Safeline Ltd.; Manchester, England

BS Environmental Health, Illinois State University

MS Software Engineering, The University of Manchester (UMIST)

Bret Van Wyk, 32

Chris Vitale, 38

Program Manager; Interstates Control Systems Inc.; Sioux Center, Iowa

Director of Marketing; Turck; Plymouth, Minn.

BS Computer Science & Systems Administration, Dordt College

BS Electrical Engineering, Minnesota State University—Mankato; MBA, University of Phoenix

hane is an integral part of the management team in the Schneider Electric Cedar Rapids facility, providing leadership in the location’s direction beyond her primary function of leading safety and environmental activities. She is the leader of the plant safety committee at her facility and a member of the plant emergency response team. Shane has led the campaign for safety-improvement ideas as well as developed and implemented the plant’s behavioral safety audits. She was responsible for implementing the use of active release technique in her facility; a technique that proactively treats injuries to prevent them from becoming serious. She is also leading the development of the facility’s business continuity plan—an action plan that actively anticipates the impact that a crisis or disaster could have on a plant. Shane is the North American representative to the GlobES Phase II Steering Committee, which integrates the global processes for safe chemical management. Beyond the plant walls, Shane drives to take safety and environmental aspects into her home. She has a passion and dedication to her children and works to raise them in a safe and healthy environment.

an Wyk is a key resource in working with Interstates’ customers to find solutions for supervisory control and data acquisition (SCADA) computer systems, industrial networks, and hosted virtualization platforms. Van Wyk is a leader in the company’s manufacturing information technology (MIT) services group, and his primary responsibility is in the quality of project delivery. Van Wyk began his career with Interstates as an MIT systems analyst and has assumed additional responsibilities over the past several years. He has been heavily involved in developing an industrial patching solution for a Fortune 500 company that services all plant floor PCs. This process includes analyzing the software on the system and offering approved Microsoft patches accordingly. Van Wyk is now an Interstates program manager. In this position, he is responsible for all projects within MIT, as well as developing internal work processes for his team. Van Wyk is driven to find ways to continually improve his work. Because of Van Wyk’s push, the MIT team has made progress in documentation, efficiency, and work accuracy. Outside of work, Van Wyk enjoys learning how to use his new meat smoker. He enjoys spending time with family and playing with his kids.

mith is a lead software engineer for Mettler Toledo’s metaldetection business. Based in Manchester, England, he has strategic and technical ownership of the connectivity and machine-integration capabilities for all metal-detection products. In addition, he has responsibility at a divisional level to define a harmonized approach to connectivity and machine integration across all of Mettler Toledo’s product-inspection systems. Smith is one of Mettler Toledo’s Organization for Machine Automation and Control (OMAC) representatives and is also a member of the PackML Technical Advisory Board. He holds a master’s degree in software engineering from UMIST and is an elected Chartered Engineer on the UK Engineering Council. Smith recently presented at the OMAC PackML workshop in Chicago where he provided a case study of Mettler Toledo’s PackML implementation as well as examples of how to use PackML in combination with various industry standard protocols to offer customers a true end-to-end integration solution. Smith and his wife spend free time with their three young sons, including a recent visit to the Chill Factore indoor snow park—a new experience since the U.K. doesn’t get much snow.

uring his 15 years with Turck, Vitale has demonstrated a deep understanding of how their products work and make a difference in the field. He has a passion for educating others about Turck technology and how it can be applied. He is constantly searching for ways to evolve this skill, most recently transitioning from a role as product manager of Turck’s network and interface division to serve as director of marketing. Vitale is skilled at connecting and creating conversations between end users and engineers, and he continues this tradition in his current position. Vitale has helped guide many products from concept to installation in customer applications, including Turck’s Multiprotocol Ethernet technology platform. After 6 years in the division, Vitale transitioned to lead the marketing department as its director in December 2014. He saw this as an opportunity to apply his product knowledge and engineering mindset to the creative design and marketing skills of the team. Outside of work, Vitale spends as much time as possible being outdoors and with his family. His hobbies include hunting and fishing, working out, family bike rides, and playing sports like Wallyball and basketball.

www.controleng.com

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CONTROL ENGINEERING SEPTEMBER 2015 ● 43

Nathan Wingate, 26

David Ziskind, PE, 33

Utilitiesand Technology Manager; Cooper River Partners; Goose Creek, S.C.

Automation Engineer; The Dennis Group LLC; Duluth, Ga.

BS Mechanical Engineering, University of North Carolina—Charlotte

BS Electrical Engineering, Georgia Institute of Technology

ingate exhibits the technical and analytical skills of a competent engineer and positive character and moral foundation apparent to all who work with him. He has a logical sense of what is required of engineered systems, the analytical engineering knowledge to test his intuition, the curiosity to delve into working details, and the engineer’s fulfillment of accomplishment when his involvement has resulted in a more efficient and safer plant operation. Wingate began his career as a maintenance engineer and advanced to utilities and technology manager, which includes management of all operational utilities, process control systems, and information technology. Wingate’s diligence have contributed to an overall utility uptime of 99.97% for three successive years in a facility that operates round the clock. Wingate applies analysis skills to guide problem solving and drive corrective action through the maintenance department and capital projects. Wingate understands that his professional and family responsibilities are intertwined. He is a leader in his community and church with a deep interest in promoting missions to help underprivileged people.

eyond his direct automation and electrical engineering responsibilities, Ziskind leads recruiting efforts for The Dennis Group’s Atlanta office, which has seen personnel growth of more than 60% over the past 2 years. Part of this strategy includes building relationships with more than eight colleges, universities, and trade schools. Additionally, Ziskind has built a co-operative program from the ground up, a program which now has more than 10 co-op participants performing engineering work for the company. Ziskind started in the industry as a co-op at Polytron in 2001. Six years later, he managed the company’s design group, including rolling out Autodesk’s AutoCAD Electrical throughout the organization and leading the effort to outsource modular design work. Ziskind led the electrical and startup effort for a major revamp of a cold-fill beverage line for a Fortune 500 company, successfully leading to the product’s market debut. Ziskind enjoys traveling, having visited South America and hiking the Inca Trail with friends in 2009. Ziskind and his wife, Miriam, reside in Atlanta with their two sons.

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inside process

How to update an

HMI

Upgrading human-machine interface (HMI) hardware, software, and applications can be an efficient process with limited required development time if these recommendations are followed.

ost manufacturing facilities use PC-based human-machine interfaces (HMIs) to operate and monitor automated equipment. Unfortunately, just about every one of these facilities has HMI software or hardware that is, or soon will be, obsolete (see Figure 1). Advice is available for how to efficiently upgrading from one PC-based HMI operating system to the next, from one version of HMI software to the next, or from one HMI software supplier to another—all while minimizing rework of the existing HMI graphics, programming, and configuration. The dreaded operating system upgrade

Typically triggered by a PC hardware failure, upgrading the operating system (OS) on a PC-based HMI can be difficult for a variety of reasons. To perform this type of an upgrade, the issues listed in Table 1 must be evaluated and addressed. Usually, the first step is consulting the HMI software vendor to verify what HMI versions are compatible with the new OS. However, as technology evolves, many HMI vendors are tempted to create new products and disregard compatibility with legacy operating systems. More often than not, the HMI software originally used to design the application has been discontinued, and to support the new OS, it must be migrated to different HMI software—not just a newer version of the same software. If migration is necessary, the application must typically be re-designed, either partially or entirely, which results in high costs related to engineering and downtime. These costs can be reduced or even avoided when purchasing HMI software

from a supplier committed to adopting technological evolution while maintaining compatibility with applications created in previous software versions. Communication protocols that implement a proprietary physical layer, such as Data Highway Plus (DH+), Profibus DP, and others, require a physical adapter to connect a PC to the proprietary network. Such adapters require custom device drivers so the OS can recognize them. Migrating to a new OS usually requires an updated version of these device drivers. In the long term, the best approach to avoid or minimize the risks and costs associated with this migration is to replace, when feasible, protocols and networks based on proprietary physical layers with protocols supporting communication through standard Ethernet-based networks. Ethernet has grown as a standard physical network in automation systems. HMI software that provides a layer of abstraction or separation between the communication interface and the tags database will facilitate the new configuration, and it will also aid and simplify future upgrades. The impact on the HMI software project will depend on the level of isolation that HMI software provides between the communication interface

Figure 1: When an HMI gets that rusty old car look, it’s a good time to consider upgrading the operating system and HMI software or to select a new HMI software vendor. Images and tables courtesy: Wonderware InduSoft

Key concepts Making an operating system upgrade to a PC-based HMI can cause platform problems. If a change is necessary, upgrading to a new HMI can provide a variety of benefits. Automatic mechanisms can make an upgrade easier by retaining key functionality.

Table 1: Considerations when upgrading operating systems and PCs Operating system incompatibility with existing HMI software Communication protocols Device driver changes Screen resolution Screen size factors Touchscreen operation Physical size and shape www.controleng.com

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CONTROL ENGINEERING SEPTEMBER 2015 ● P1

inside process

and other interfaces of the project, such as graphical display and scripts. More separation or isolation is better. Hardware migration issues

‘

Looking at extra space on an HMI screen from a new aspect ratio? Design one new screen that is always visible and shows critical alarms indicators to fill the gap. Don’t forget to consider mechanical changes.

When upgrading the PC display, changes in screen resolution can pose two common challenges. In the first scenario, a different screen resolution has the same aspect ratio (such as migrating from 800x600 to 1,024x768). Some products offer a native feature to scale the graphical interface automatically, so no modifications are necessary to the original application to fit a new resolution. Other alternatives would be off-line automated conversion and, in the worst-case, manual adjustment of the screens. In the second scenario, both the resolution and aspect ratio change simultaneously, as when migrating from 1,024x768 to 1,920x1,080 while upgrading to 16:9 wide-screen monitors and panels. A cost-effective method to mitigate this scenario is to use the automatic screen scaling capability of the HMI software development platform, if such is available. And, it’s also often helpful to design one new screen that is always visible and shows critical alarms indicators to fill the gap caused by the new aspect ratio.

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Often overlooked, mechanical changes must be completed in advance to support the physical size of the new PC, especially when the device must fit in a panel door. The touch screen operation may also change. The HMI software must be compatible with the input method of the new station such as touchscreen, physical keys, and/or mouse. Depending on the original software characteristics, configuration adjustments may be required for the application.

’

Upgrading from one HMI version to the next

There are many functional reasons to upgrade existing HMI software to a supplier’s newest version such as an improved user interface, added features, and improved communication. Another reason to upgrade is to maintain customer support from the software supplier, as most suppliers will be better at supporting their latest version as opposed to older offerings. A final reason to upgrade is to incorporate patches and fixes. Backward compatibility is a key factor in the cost versus benefit decision to upgrade the HMI software version. If the current HMI software supplier does not provide a smooth migration path, it may be an opportunity to switch to another supplier that does, since it can reduce engineering investment for future upgrades (see Table 2). It’s good practice to check the HMI software supplier’s release notes for newer versions. Look for potential issues that have been solved and find new features. New features may enable implementation of new functionality, such as support for multi-touch and gestures. A machine or process retrofit may involve the HMI and the controllers as well. In many cases, new controllers support tagbased communication rather than just memory addresses. In this case, upgrading the HMI to a version that supports tag integration with the controller will considerably reduce the time needed to adjust the application. It will also minimize configuration errors since the tags will be browsed and selected from the controller, instead of typing them manually. Newer versions of HMI software often include support for

Table 2: Considerations when migrating to new versions of HMI software n Backward compatibility n Incorporating new features and graphics

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n Tag integration n Traceability and authentication n New built-in drivers to replace older custom communication drivers n Connectivity n Security n Remote access P2

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SEPTEMBER 2015 CONTROL ENGINEERING

input #26 at www.controleng.com/information

inside process

importance and necessity of cyber security in automation systems. There is no silver bullet to prevent or mitigate cyber attacks, but keeping the latest version of the HMI software updated is an effective way to minimize or eliminate vulnerabilities from previous versions. Changing from one supplier to another

Figure 2: New HMI software, such as InduSoft Web Studio, can pay for itself with features such as remote access, tag integration, and improved cyber security.

trace ability and authentication, features that can ease compliance with regulations and also improve operations. New software versions improve communication

Connectivity or interoperability is a key factor in modern systems. New HMI versions may provide additional tools to exchange data with new devices—but also with ERP systems, databases, historians, cloud-based systems, and others. Many HMI software products were originally designed to display information only on the PC or other device where they are installed and running. However, most new products allow remote maintenance, troubleshooting, or even visualization of the application. This remote access, from a PC, tablet, or smartphone, improves productivity while minimizing downtime. The integration of cloud-based systems and wide area networks connecting geographically dispersed systems and Internet of Things (IoT) architectures have substantially increased the

Table 3: Considerations when changing HMI software suppliers n Import tools n Tag, ignore, import, replace, etc. n Screen graphics n Security n Communication configuration n Alarms n Recipes P4

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SEPTEMBER 2015 CONTROL ENGINEERING ● www.controleng.com

Some of the PC-based HMI software packages can import existing applications from installed PC-based HMIs, even those made by other suppliers, and can also include tag integration for a variety of drivers, making it easy to import HMI tags directly (see Table 3). Using these import tools can make it much easier to switch from one supplier to another, with the end result being a better HMI with improved capabilities (see Figure 2). Import tools can greatly reduce the cost to migrate HMI applications to different HMI software platforms that may offer better value or performance. Import tools automatically import tags from legacy systems and can even support merging legacy applications with existing ones. When migrating applications from HMI products not supported by native import tools, it’s often possible to copy the list of tags from an external list, in Microsoft Excel for example, and paste it into the application tags sheet. Import wizards can also import screen graphical components such as objects and pictures, along with their related properties and animations. Security settings are typically not imported automatically for two main reasons. One is to respect the confidentiality of authentication settings, primarily passwords. The second is the differences between revisions or different systems. The new upgraded software and related security system is likely to be substantially more sophisticated, and it also may use different configurations than legacy systems. Therefore, configuring the security settings of imported applications through the graphical user interface (GUI) of the end product is recommended. Communication settings for supported protocols should be automatically imported. This is possible in HMI applications with separation between the tags database and communication drivers, which also facilitates replacement of a legacy driver and protocol configuration with a new one. Alarm conditions and messages should also be imported automatically. This simplifies configuration of remote notification of alarms via e-mail or text message. The support for recipe data depends on the format configured in the legacy application. Consider HMI applications with native tools to import or support recipe data and trend history data in a variety of formats including text files

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inside process

(CSV, XML, TXT, etc.) or databases (MDB, SQL Server, etc.).

‘

Most new HMI software

packages allow remote

The HMI upgrade decision

maintenance, troubleshooting,

The decision to upgrade HMI software, or any other system for that matter, should be made on a cost-benefit analysis. Any system, whether hardware or software, will eventually become obsolete. As obsolescence approaches, downtime and safety risks increase. In other cases, even before an HMI software platform becomes obsolete, a new system can provide substantial benefits that justify the cost involved in the upgrade. Although migrating to a different supplier rather than to a newer version from an existing supplier may invoke higher cost in the short-term, it often provides significantly lower costs in the long run. Switching to an HMI supplier that promotes backward compatibility, openness, interoperability, support for standards, and reduced maintenance costs can make a change worth considering. Some hardware manufacturers design proprietary software that can lock users into their HMI hardware, controllers, and networks. On the other hand, HMI software from hardware-agnostic sup-

Go Online

For more info, see this article online and the Control Engineering HMI page, www.controleng.com/hmi

Consider this... When calculating the cost of doing an HMI software upgrade, do you add in the cost of lost productivity from not doing the upgrade yet?

or even visualization of the application. This remote access, from a PC, tablet, or smartphone, improves productivity while

’

minimizing downtime.

pliers provides a critical layer of separation from the hardware and OS. This provides a high level of flexibility and portability, which will represent great savings when deciding to upgrade the HMI system to a newer version. ce - Fabio Terezinho is director of consulting services at InduSoft and product manager at Wonderware by Schneider Electric. Edited by Peter Welander, Control Engineering contributing content specialist, pwelander@cfemedia.com.

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inside process

A better way to install automation in classified areas Instead of employing protection methods, it’s often better to move automation systems to less hazardous areas and to use components rated for use in these locations. Key concepts Automation equipment used in hazardous areas requires special protection to prevent fires and explosions. Protective measures necessary can be expensive or problematic. Locating equipment outside of the most strictly regulated areas can be far simpler.

lassified areas are often found in industrial plants due to the presence of hazardous gases and dust. When automation components are installed in these areas, certain rules, regulations, and design standards must be followed to ensure safety. Hazardous areas are classified according to either National Electrical Code (NEC) or the International Electrotechnical Commission (IEC). Table 1 shows a simplified version of this classification system, and much greater detail can be found within the detailed regulations, specifically NEC Article 500 and IEC 60079. Using the NEC standards for reference, Table 1 shows that Division 1 is more hazardous than Division 2 because hazards are more likely to be present. Therefore, automation components

Figure 1: Explosion-proof enclosures are much heavier and more expensive than their nonrated counterparts and typically require periodic inspections to ensure integrity. Courtesy: Vynckier P8

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SEPTEMBER 2015 CONTROL ENGINEERING ● www.controleng.com

installed in Division 1 require a higher level of protection than those installed in Division 2. Three main methods are used to implement levels of protection as required in classified areas: explosion proof, purging, and intrinsic safety. All these methods of protection require careful design—and often expensive components, installation, and maintenance. Examining these three protection methods provides context for an alternative way to install automation components in classified areas. Explosion-proof approaches

Explosion-proof enclosures and conduit systems protect automation components in hazardous areas through two methods. First, they are sealed to limit the amount of gas or dust that can enter the enclosure or conduit system. Second, they must have the structural integrity to contain an explosion so it doesn’t propagate throughout the classified area. These enclosures are typically used in Division 1 areas. Protection with enclosures has been used for many decades and is well understood by many engineers, designers, and plant maintenance personnel. Many suppliers provide explosion-proof enclosures and conduit systems, and the design standards for such systems are readily available. But compared to the standard National Electrical Manufacturers Association (NEMA) 4 enclosures, explosion-proof enclosures are very expensive, quite large, and very heavy (see Figure 1). Because these enclosures are sealed, the only practical method to dissipate heat is through the enclosure itself, limiting the type of components the enclosure can house, or requiring the enclosure to be oversized which further adds to costs. Any operator interface components must be rated for use in the area, which precludes the use of any type of graphical interface in a Division 1 area. Graphical interfaces can be mounted inside the enclosure and viewed through a window, but this limits visibility. Great care must be taken during installation of the enclosures and conduit systems to ensure proper sealing is preserved, and conduits must often be potted at transitions from Division 1 to Division 2 areas. Hot-work permits and accompanying precautionary measures are required to open explosion-proof enclosures, making servicing of the components inside the enclosure very expensive and difficult. Regular inspections of explosion-proof enclosures and conduit systems are required in some classified areas and strongly recommended in others. Inspections verify the integrity of the sealing systems and reveal the need for maintenance.

Figure 2: Purging enclosures with air or an inert gas can allow nonrated components to be used in hazardous areas, although the supply of air or gas has to be maintained constantly. Courtesy: Pepperl+Fuchs

next often require IS barriers, adding to the complexity of these systems. Avoid the hazard

As explained, all three of the leading protection methods require detailed design and often considerable expense

for system purchase and installation. The expense doesn’t stop with installation, because IEC 60079 requires initial inspections of components installed in classified areas and ongoing periodic inspections, typically done annually. The inspections often reveal areas requiring

Purging problems

Another method for installing automation components in hazardous areas is to purge enclosures with compressed air or an inert gas. Purge systems don’t allow hazardous gases or dusts to enter an enclosure because the interior is always under positive pressure. Depending on the type of purge system, this method allows standard enclosures and unrated automation components to be used in Division 1 and Division 2 areas. But purge systems can be quite expensive, particularly when they are used in Division 1 areas (see Figure 2). The cost doesn’t stop with installation, as purge systems require a constant supply of compressed air or an inert gas. This approach makes maintenance of the components within the enclosure problematic because the enclosure cannot be opened during normal operation.

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Intrinsically safe (IS) systems can be safely installed in Division 1 and 2 hazardous areas because the components and wiring systems cannot release sufficient energy to ignite gas or dust in the area. Unlike explosion-proof or purge systems, this method of protection permits many types of maintenance during normal operation. Because each component must be rated for use in the area, the range of items available for use is limited. Many common automation components, such as programmable logic controllers (PLCs) and motor drives, aren’t available with an IS rating. Even when IS-rated components are available, there is often an added charge from the supplier. The design of IS systems requires a high level of engineering expertise, adding to implementation time and expense. Transitions from one classified area to the SEPTEMBER 2015 ● P9

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inside process maintenance, further adding to expense. Realizing this, many suppliers began to introduce components within the past few years which can be safely installed and operated in Class 1, Division 2 (or Class I, Zone 1) classified areas. There is a significant difference between those two divisions even though they are in the same class, and the requirements for applicable devices and components also are significant. Location, location, location

Like real estate, when it comes to hazards, it’s all about location. Often the best approach for dealing with hazardous locations is staying out of them. Install as much of the automation equipment as possible outside of Class 1, Division 1 areas. Even moving to a Division 2 area makes a major difference. This isn’t as difficult as it may sound. In many industrial plants and facilities, relatively

Table 1: NEC Divisions and IEC Zones Frequency of Hazard Occurrence

NEC Classification

IEC Classification

Continuous hazard

Division 1

Zone 0

Intermittent or periodic hazard

Division 1

Zone 1

Abnormal condition hazard

Division 2

Zone 2

Table courtesy: Hoffman

few areas are classified as Division 1, and these areas are often quite small. Even when they have a large footprint, improvements can often be made to limit the amount of gases released to the atmosphere, thus reducing the footprint of areas classified as Division 1. Once Division 1 areas are reduced to a practical minimum, then all new automation components should be located in an adjacent Division 2, or even better, in unclassified areas unless there’s a compelling reason to do otherwise. In some cases, it may make sense to relocate existing automation components from Division 1 to Division 2 areas to avoid the related inspections and maintenance. For those few automation components that must be located in Division 1 areas, it’s often possible to use IS-rated components and connect to those components from Division 2 areas by way of IS barriers. Once all Division 1 areas have been minimized, and Division 2 and unclassified areas consequently increased, careful automation component selection can be made to use only those items rated for use in Division 2. Component selection and application

As recently as 20 years ago, there were very few automation components rated for use in Class

input #31 at www.controleng.com/information

Table 2: Automation components rated for use in Division 2 n Operator interface devices n PLCs and other controllers n I/O devices n Smart relays n Interface relays n HMIs n Variable frequency drives (VFDs) rated up to 100 hp n Pushbuttons n Pilot lights n Selector switches n Power supplies n LED flood lamps

I, Division 2 areas—and many of these were related to PLCs and relays. This situation has changed dramatically in the past few years, as the automation components listed in Table 2 indicate. And the list is steadily growing as suppliers respond to end-user demand. If a component is rated for use in Division 2, it can be installed in a standard enclosure and safe-

ly used without requiring any additional protection. Due to the wide availability of rated components, it’s now possible to assemble a complete control system with a human-machine interface (HMI), a PLC, an input/ output (I/O) device, a power supply, motor drives, and other required components—all rated for Class I, Division 2 use. This approach requires much less detailed design than the three main protection methods and costs less. No initial or periodic inspections are required, and maintenance is greatly reduced. When automation components suitable for Division 2 use were first introduced, they often carried a substantial price premium over nonrated counterparts. But this price premium has been greatly reduced in recent years, often eliminated completely (see Figure 3).

Figure 3: Many automation components are now available with Class I, Division 2 ratings at little or no extra cost. Courtesy: Idec

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inside process In many cases the product parts and materials have not been changed, just the inspection requirements for compliance. For example, in the case of an electromechanical switching compartment, the spark-producing components must be plastic sealed. The Division 2 rating assures that the sealed compartment will not leak over the component’s life. As a result, there is now a wide variety of electromechanical and solid-state relays rated for use in Class I, Division 2 areas. As LED lighting has become commonplace, new Class I, Division 1 and 2 lamps have become available and often are retrofitted in oil refineries and other facilities as they modernize lighting systems. Typical applications for automation components in Class I, Division 2 areas include but aren’t limited to: n Upstream oil and gas facilities for exploration and production n Midstream oil and gas pipelines and storage facilities

n Oil refineries n Petrochemical plants n Paint booths and paint mixing facilities n Water and wastewater treatment plants n Mining facilities n Pharmaceutical plants n Agriculture facilities such as grain silos n Food processing plants. Protection vs. location

The three main methods for protecting automation components installed in classified areas are explosion-proof enclosures, purged enclosures, and intrinsically safe systems. Depending on the specific application and automation components, each method can be effective. But each entails considerable upfront cost and ongoing care, service, and maintenance. A viable alternative in many cases is to install automation components and systems in Division 2 instead of Division 1 areas and to then use components rated for Division 2 use. This simplifies

design, cuts costs, and reduces operating and maintenance expenses. In response to user demands, suppliers have introduced many automation components suitable for use in hazardous areas, with more becoming available regularly. With careful components selection, most types of automation systems can be safely installed in Division 2 areas. ce - Steve Massie is a product manager responsible for relays, lighting, circuit breakers, terminal blocks, and hazardous location products for Idec. Edited by Peter Welander, Control Engineering contributing content specialist, pwelander@cfemedia.com.

Go Online For references and more, see this article online and the Control Engineering Process Safety page under the Process Manufacturing tab at: www.controleng.com. Standards organizations: www.necconnect.org www.iec.ch

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Patrick Lynch, Director of Content Marketing Solutions 630-571-4070 x2210 PLynch@CFEMedia.com

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Content For Engineers. That’s what CFE Media stands for, and what CFE Media is all about – engineers sharing with their peers. We welcome content submissions for all interested parties in engineering. We will use those materials online, on our website, in print and in newsletters to keep engineers informed about the products, solutions and industry trends. www.controleng.com/contribute explains how to submit press releases, products, images and graphics, bylined feature articles, case studies, white papers, and other media. * Content should focus on helping engineers solve problems. Articles that are commercial in nature or that are critical of other products or organizations will be rejected. (Technology discussions and comparative tables may be accepted if non-promotional and if contributor corroborates information with sources cited.) * If the content meets criteria noted in guidelines, expect to see it first on our Websites. Content for our e-newsletters comes from content already available on our Websites. All content for print also will be online. All content that appears in our print magazines will appear as space permits, and we will indicate in print if more content from that article is available online. * Deadlines for feature articles intended for the print magazines are at least two months in advance of the publication date. Again, it is best to discuss all feature articles with the appropriate content manager prior to submission. Learn more at: www.controleng.com/contribute

CONTROL ENGINEERING SEPTEMBER 2015 ● 63

back to

BASICS

WLAN design basics, considerations Rational planning and design, based on a thorough preliminary evaluation, can ensure that a wireless network will work the first time and easily expand without disruption. Key concepts Wireless is an unbounded medium, and the system design must facilitate efficient wireless signal propagation. Use rational planning and design to ensure that a WLAN will work and expand reliably. WLAN design considerations include capacity, access points, and facility type.

Consider this... When designing a WLAN, what is the one aspect you consider to be most crucial to its success? 64

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eing an unbounded medium, wireless system design must facilitate efficient propagation of radio frequency (RF, wireless) signals. This facilitates coverage and capacity, which are primary wireless local area network (WLAN) parameters. Where does the RF energy reach and how many clients can use it effectively before it becomes over utilized and slow? Rational planning and design, based on a thorough preliminary evaluation, can ensure that a WLAN will work the first time and allow ease of expansion without disruption. A well-designed WLAN will provide years of reliable service, and the return on investment (ROI) will be realized more quickly. For WLAN RF propagation, different types of antenna systems can shape the RF “beam” to service specific areas and exclude others also can modify coverage. In most cases, an access point (AP) will use an omnidirectional antenna theoretically propagating in all directions. For this discussion, assume this to be a circle with a 200-ft diameter line of sight at an output of 100 mW (20 dBm). This means that client devices within 100-ft of the AP will receive a good signal (> -80 dBm). Obstructions create signal attenuation depending on materials. Plywood and drywall do not present much attenuation, while concrete and steel greatly attenuate RF. So does the human body, which is made of more than 60% water. Groups of people can create more attenuation as an elevator shaft made of reinforced concrete. An AP cannot be placed in a convenient location and be expected to provide seamless and error-free network connectivity. The facility must be evaluated for wireless LAN suitability. This is called a survey and can be either a virtual survey, a predictive survey, or an on-site, physical survey. A survey can determine: Presence of neighboring WLANs and other sources of RF that could interfere Propagation pattern(s) of proposed AP(s) required to provide desired coverage Effect on propagation due to attenuation by walls and other architectural features Effect on propagation due to reflections and other behavior Location and type of wired network infrastructure (wiring closets, copper vs. fiber). Capacity is a primary issue to consider. Capac-

SEPTEMBER 2015 CONTROL ENGINEERING ● www.controleng.com

ity is not bandwidth or throughput, but the ability of the WLAN to provide reliable and available connectivity to clients in the coverage area. If a given client is served by four APs and everyone is out to lunch, plenty of bandwidth and throughput are available. What if the network becomes unusable when everyone returns and uses the network? Contention, transaction time

As more clients use the AP, there is increased contention for the medium. This requires more transaction time and can result in re-transmissions due to collisions. Only one client can be associated to an AP at a time. The transaction may last only a few milliseconds, and other clients are contending for AP use. Wait times and re-transmissions go up in proportion to the number of clients. Capacity cannot be accurately calculated in a predictive survey. Sophisticated algorithms will take contention into account, but nothing can predict how people or devices will use the network in real time; mobility of devices complicates this prediction. When a device is mobile, it can roam from one coverage area to another, creating increased contention on the new AP. Quality of service (QoS) algorithms and secure roaming will preempt lower priority traffic on the new AP and could cause further congestion. Mobile clients traveling to the extremes of the coverage area could also experience a loss of contact with other clients, resulting in collisions. All clients listen to all transmissions—if only the AP hears a client, then other clients will assume the medium is free. Adding more APs and operating them at lower power output usually can solve the capacity problem. Another technique essential for proper function of WLAN operation and device roaming is using multiple channels for the several APs installed in the facility. See more online. ce - Daniel E. Capano, owner and president, Diversified Technical Services Inc. of Stamford, Conn., is a certified wireless network administrator (CWNA). Edited by Chris Vavra, production editor, CFE Media, Control Engineering, cvavra@cfemedia.com.

Go Online www.controleng.com/blogs has more on this Capano wireless tutorial, including details about adding more APs and multiple channel use. Control Engineering has a wireless page. www.controleng.com/networking-security/wireless

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