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with 10 built-in discrete I/O

The BRX PLC family offers: • Advanced motion control • Robust data logging • Onboard serial and Ethernet ports • Discrete, high-speed and analog I/O • Expansion capabilities • Interchangeable communications port • Free programming software (with simulator) • Integrated video help • Free technical support • Much, much more...

CPU and I/O Comparison PLC Unit (with Ethernet)

(28) 24VDC Inputs

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FC6A

$814.00

$490.50

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Built-in

$433.00

$85.00

(16-pt DC IN module + 14 DC IN on PLC unit)

(8-pt DC IN module + 20 DC IN on PLC unit)

$433.00

$125.00

(16-pt DC OUT module + 10 DC OUT on PLC unit)

(8-pt DC OUT module + 16 DC OUT on PLC unit)

$330.00

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(4IN/2OUT Analog combination module)

(4IN/2OUT Analog combination module)

2080-LC50-48QVB

BX-08ND3

$45.00

(28 DC IN on PLC unit)

Built-in

BX-08TD1

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6ES7 214-1AG31-0XB0

6ES7 221-1BH30-0XB0

6ES7 222-1BH30-0XB0

Built-in

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6ES7 234-4HE30-0XB0

(2 Analog OUT on PLC unit)

2080-OF2

$556.00

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(4 Analog IN on PLC unit)

(2) Analog Outputs

IDEC

S7-1200

$642.00

BX-DM1E-36ED13-D

(8-pt DC OUT module + 16 DC OUT on PLC unit)

(4) Analog Inputs

Siemens

$473.00

(8-pt DC IN module + 20 DC IN on PLC unit)

(20) 24VDC Outputs

Allen-Bradley

BRX PLC

2080-IF4

FC6A-C40K1CE

FC6A-N08B1

FC6A-T08K1

FC6A-L06A1

$1,020.50

All prices are U.S. published prices. AutomationDirect prices as of 2/20/2017. Allen-Bradley, Siemens and IDEC prices taken from www.radwell.com 1/27/2017.

Research, price, buy at:

www.BRXPLC.com

Order Today, Ships Today! * See our Web site for details and restrictions. © Copyright 2017 AutomationDirect, Cumming, GA USA. All rights reserved.

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input #2 at www.controleng.com/information

JULY 2017 Vol. 64 Number 7

Features 30 Controller embeds programming efficiency Cover Story: PLC programming: Selecting the right controller and accompanying programming software adds efficiency to the controller programming process.

34 PLC programming tips, benefits for engineers

8,10, 30, 34 COVER IMAGES COURTESY: From top, AutomationDirect, p. 30; CFE EDU PLC training; PLC tutorial from Automation Primer with related coverage, p. 34; EZAutomation PLC, p.10.

Cover story: Get help for programmable logic controller (PLC) programming from Control Engineering editorial advisory board member Frank Lamb, covering ladder logic and scanning, binary-coded decimals, and reusable codes.

36 Safety over industrial communication networks Industrial Ethernet is becoming easier to use for industrial safety applications. Standards, trends, and technologies are helping with industrial Ethernet-based safety systems.

38 Industrial fail-safe, node-to-node communication CIP Safety, for functional safety applications on EtherNet/IP and DeviceNet networks, provides fail-safe communication between nodes.

36

40 Safety layer on top of networks Safety network: PI North America, the organization for Profinet and Profibus, explains use of the ProfiSafe safety network on top of industrial Ethernet, Profinet, and device-level Profibus networks.

42 Thermal management requirements for edge computing Edge computing requires several variables to be considered and an advanced climate control solution.

44 Transfer switches: Which configuration is right for your system?

When it comes to picking the right transfer switch for a facility, engineers need to consider many aspects such as system installation, operation modes, and switching mechanisms to help prevent downtime in the event of a power outage.

57 Digital Edition Exclusives Specifying enclosures for machine vision systems IT/OT convergence needs conflict resolution from both sides Link online: Digitalization trends in the automotive industry Link online: Industrie 4.0 and smart services Link online: Robotics for the oil and gas industry.

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CONTROL ENGINEERING

42 CONTROL ENGINEERING (ISSN 0010-8049, Vol. 64, No. 7, 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 2017 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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Simplify Your Work

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JULY 2017

Safety lifecycle model Conceptual Process Design

PHA Process Hazard Analysis & Risk Assessment

LOPA Apply Non-SIS Protection Layers to Prevent Identified Hazards or Reduce Risk

Vol. 64 Number 7

SIS Required?

SRS Develop Safety Requirement Specification

Define Target SIL

SPECIFICATIONS

SIL CALCS Perform SIS Conceptual Design and Verify it Meets SRS

Perform SIS Detail Design

DESIGN

SIS Installation, Commissioning, & Pre-Startup SAT

INSTALL

?

SIS Start-up, Operation, Maintenance, Periodic Functional Testing

Changes

O&M

P1

Inside Process Appears after page 46; Also, see the Digital Edition: www.controleng.com/DigitalEdition

P1 Determine safety integrity level for a process application Safety instrumented systems (SIS) are installed in process plants to mitigate process hazards and they must be assigned a target safety integrity level (SIL) during the process to determine what needs to be done next.

18

P6 Three ways to increase efficiency at a spirit manufacturing plant Manufacturers at a spirit manufacturing plant can increase production and efficiency by setting realistic expectations, simplify their model, and asking for a third-party’s input with an overall equipment effectiveness (OEE) analysis.

Departments 8 Think Again Ease of use: Programmable controllers

10 New Products for Engineers Chlorine analysis sensor systems; Rugged rack-style PLC

Products

59 Permanent magnet motor with integrated speed control; Motor series for positioning, velocity control; RIGHT: IoT edge device; BELOW: Piezo stages for 3-D positioning accuracy; BELOW, RIGHT: Integrated hybrid servomotor; Permanent magnet motor

12 Research In-house system integrators

Control Engineering international 14 Expansion in instrumentation with software, technology updates 16 Industrie 4.0 optimizes safety

Technology Update 18 PC-based controls: Expanding plant-floor architectures from the edge to IIoT 20 The benefits of robotics process automation

64 Back to Basics Seven ways to integrate worker health and safety

60 Power supply series; Extensometer for safety applications; BELOW, RIGHT: Miniaturized MEMS accelerometer; HMI for machine components; BELOW, LEFT: Real-time SCADA for IT, OT applications

News 22 23 24 25

Robots for logistics and transportation; manufacturer expands Cybersecurity workforce education; process instrumentation growth GE leader led the largest company acquistion; online headlines Video use in data collection is increasing, survey says

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CONTROL ENGINEERING

JULY 2017

| 5

More resources posted daily at:

JULY

IIoT

www.controleng.com

New Products

Control Systems

Process Manufacturing Discrete Manufacturing

System Integration

The impact of robotics technology on urbanization There’s a lot more to read online. Go to www.controleng.com/news to read Control Engineering’s exclusive Web content.

Digitization trends to leave large footprint on automotive industry Benefits of equipment life optimization programs Real-world HMI design considerations for improved safety Conference focuses on IIoT for process, oil and gas industries.

Networking & Security

Info Management

Education & Training

On-demand webcasts: Couldn’t catch a recent webcast? See it ondemand at www.controleng.com/webcasts.

Webcasts

June 13: Leave My Things Alone – Getting Ready for IIoT June 8: IIoT Webcast Two: Sensing and control at the edge: Microcontroller kits May 25: Cloud ERP Streamlines Operations in an Era of IIoT Data April 13: IIoT Webcast One: Get your head into the cloud.

Control Engineering provides unique automation research: See more on the HMI software and hardware survey in this issue. Read other research summaries and sign up to download the full reports at www.controleng.com/ce-research.

NEWSLETTER: PROCESS INSTRUMENTATION & SENSORS

Hydrocarbon chemistry transforms a century, and still going Keep up with the latest industry news by subscribing to Control Engineering’s 16 newsletters at www.controleng.com/newsletters: Control Engineering Salary and Career Survey, 2017 Technology drives performance of presence sensor range and accuracy

Oil & Gas Engineering June issue Oil & Gas Engineering provides industryspecific solutions designed to maximize uptime and increase productivity through the use of industry best practices and new innovations, increase efficiency from the wellhead to the refinery by implementing automation and monitoring strategies, and maintain and improve safety for workers and the work environment. Read the digital edition at www.oilandgaseng.com.

Temperature manufacturing facilities opened in Indiana, Michigan.

Point, click, watch GAMS 2016: Robotics: Rise of the Machines The 2016 Global Automation and Manufacturing Summit (GAMS), presented by CFE Media, will bring together experts from all areas of the Industrial Internet of Things (lloT) to look at not just the current state of lloT but also at the potential benefits of deployment for the manufacturing industry. www.youtube.com/user/controlengineeringtv.

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Digital Edition The tablet and digital editions of this publication have unique content for our digital subscribers.

This month has digital exclusives on: Specifying enclosures for machine vision systems; Why IT/ OT convergence needs conflict resolution from both sides.

MAY17 AC Branding Snipe - New Size (CE).qxp_Layout 1 4/13/17 11:34 AM Page 1

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

Ease of use: Programmable controllers Standard programming has abstracted into configuration, wizards are more intelligent, and libraries of code are embedded into intuitive objects. Controllers touts modularity, flexibility, and connectivity.

P

Programming

someday may consist entirely of humans talking to computers, but since humans often misunderstand humans, this may take awhile. For now, many simple programs or common goals can be achieved through the use of abstraction, wizards, libraries of objects, and other intuitive tools, avoiding programming for simple functions. This comes as programmable controller hardware—whether in something that looks like a traditional programmable logic controller (PLC) or another form factor—becomes more powerful, more economical, and easier to integrate. This seems to apply for devices using standards, such as IEC 61131-3 programming languages, IT-familiar languages, or both.

Easier productivity

With programming, ease-of-use conventions help those with less formal computer education increase industrial productivity, even as with shortages of those with appropriate skills in science, technology, engineering, and math (STEM) fields. Smarter software makes contextualized help, documentation, and training available when and where needed, avoiding online searches, help desk calls, or, worse, paging through a paper manual.

The progression is natural. Jeff Kodosky, a National Instruments (NI) founder and business and technology fellow, and father of NI LabVIEW software, noted at 2017 NIWeek that when engineers draw something, it usually includes boxes and arrows. Software that uses those conventions naturally is more intuitive. For years, the NI software platform has

MORE

ADVICE GO ONLINE www.controleng.com keyword: Controller Webcasts on IIoT: www.controleng.com/webcasts Research on IIoT: www.controleng.com/ce-research PLC training: www.controleng.com/cfe-edu Digital edition: click the headline for more info online, photos, and links.

8

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CONTROL ENGINEERING

encapsulated code inside object that can then be grouped into larger objects. The latest version was demonstrated in about four minutes, producing results without programming.

In addition, Kodosky said, the new platform refreshes a 30-year-old code base that will enable NI programmers to innovate more quickly (CE, June, p.28).

Another industrial control platform, Ignition, has rapidly expanded, according to Inductive Automation’s founder and CEO, Steve Hechtman, at the 2016 Ignition conference in September. One reason for double-digit annual growth, Hechtman said, is having industrial software that empowers customers to swiftly turn great ideas into reality by removing technological and economic obstacles. The software is said to install in four minutes, is scalable from a Raspberry Pi board-level controller to enterprise servers, is more intuitive, and has a fixed (simpler, economical) pricing structure.

Automation benefits

These examples, while significant, are not unique. For more on these topics in this issue, see pages 10, 18, 30, and 34, as you think again about how programmable controllers are adapting for ease of use, greater flexibility, modularity, easier upgrades, greater safety and security, with wider and simpler interconnections to legacy and IT systems. The benefits of optimal automation and controls have become the mantra of Industrial Internet of Things (IIoT) and Industrie 4.0 platforms.

As we’ve said for years, don’t wait until it’s too late to integrate automation, controls, and instrumentation. Evaluate new technologies’ capabilities, redesign processes, and implement opportunities to augment better decisions, higher productivity, and more. ce

Content Specialists/Editorial

Mark T. Hoske, Content Manager 847-830-3215, MHoske@CFEMedia.com Jack Smith, Content Manager 630-907-1622, JSmith@CFEMedia.com Kevin Parker, Senior Contributing Editor, IIoT, OGE 630-890-9682, KParker@CFEMedia.com Emily Guenther, Associate Content Manager 630-571-4070 x2220, eguenther@cfemedia.com Amanda Pelliccione, Director of Research 978-302-3463, APelliccione@CFEMedia.com Joy Chang, Digital Project Manager 630-571-4070 x2225, JChang@CFEMedia.com Chris Vavra, Production Editor 630-571-4070 x2219, CVavra@CFEMedia.com

Contributing Content Specialists Frank J. Bartos, P.E., braunbart@sbcglobal.net Peter Welander, PWelander@CFEMedia.com Vance VanDoren, Ph.D., P.E., controleng@msn.com Suzanne Gill, Control Engineering Europe suzanne.gill@imlgroup.co.uk Ekaterina Kosareva, Control Engineering Russia ekaterina.kosareva@fsmedia.ru Wojciech Stasiak, Control Engineering Poland wojciech.stasiak@trademedia.us Lukáš Smelík, Control Engineering Czech Republic 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 630-214-4504. Letters should include name, company, and address, and may be edited.

Information: For a Media Kit or Editorial Calendar, email Trudy Kelly at TKelly@CFEMedia.com.

Marketing consultants: See ad index.

Custom reprints, electronic: Brett Petillo Wright’s Media, 281-419-5725, bpetillo@wrightsmedia.com

Editorial Advisory Board www.controleng.com/EAB Doug Bell, president, InterConnecting Automation, www.interconnectingautomation.com David Bishop, president and a founder Matrix Technologies, www.matrixti.com Daniel E. Capano, president, Diversified Technical Services Inc. of Stamford, CT, www.linkedin.com/in/daniel-capano-7b886bb0

Mark T. Hoske, Content Manager MHoske@CFEMedia.com

Frank Lamb, founder and owner Automation Consulting LLC, www.automationllc.com Joe Martin, president and founder Martin Control Systems, www.martincsi.com Rick Pierro, president and co-founder Superior Controls, www.superiorcontrols.com Mark Voigtmann, partner, automation practice lead Faegre Baker Daniels, www.FaegreBD.com

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Cabinet Confidence Powerful output means system reliability Phoenix Contact’s expertise and commitment to innovation across a wide range of industries enable you to build your control cabinet with confidence. QUINT Power supplies are the most powerful and flexible choice for your industrial environment.

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input #5 at www.controleng.com/information

PRODUCTS New Products for Engineers

Chlorine analysis sensor systems Endress+Hauser’s chlorine analysis systems are designed to eliminate the need for costly reagents and accompanying required maintenance. It’s panel-mounted and includes a chlorine sensor, pH probe in an integrated flow assembly, sensor cables, and a transmitter.

E

Endress+Hauser’s chlorine analysis systems are designed to eliminate the need for costly reagents and accompanying required maintenance. They are designed for applications where water is disinfected using chlorine such as, industrial water, power, and wastewater. Each turnkey system is panelmounted with an amperometric free chlorine sensor and a pH probe mounted in an integrated flow assembly, sensor cables, and an Endress+Hauser Liquiline transmitter. An integral flow switch mounted in the flow assembly monitors for proper system flow, and provides an alarm at the transmitter if flow is interrupted. A lead-free regulator sets system pressure to 15 psi.

System tubing is ⅜-in. stainless steel and all components are installed on a 20 x 20-in. stainless steel panel prepared with ⅜in. ID mounting holes for secure mounting to a vertical surface. Stainless steel inlet and outlet shut off valves, with ½-in. female National Pipe Thread (NPT) fittings, allow for system isolation during routine sensor maintenance. The pH-

compensated measurement ensures accurate N,N-diethyl-P-phenylenediamine (DPD) verification, and a separate ¼-in. sample valve allows a DPD verification test for residual chlorine to be performed without interrupting system measurement. The independent DPD verification test capability also ensures compliance with EPA requirements. A built-in needle valve in the flow assembly provides flow control between 30 and 120 L/hour, and an inductive low-flow alarm switch indicates when flow is too low for proper measurement. ce Endress+Hauser www.us.endress.com

Input #200 at www.controleng.com/information

MORE

PRODUCTS GO ONLINE More New Products for Engineers: www.controleng.com/NP4E.

Rugged rack-style PLC The EZAutomation EZLogix programmable logic controller is a low-cost, rugged, modular rack-styled PLC ready for Industrial Internet of Things (IIoT) applications. Ladder logic, advanced function blocks, and a built-in simulator are just a few features that come with free programming software.

E

EZLogix from EZAutomation, a U.S. manufacturer and online distributor, is a rugged rack-style, din-rail mounted programmable logic controller (PLC) said to offer high-performance specifications at extremely cost-effective price points. It includes free software and manuals with simple ladder logic programming, advanced function blocks, a built-in simulator to test logic where no additional hardware is needed, and a built-in data logger.

The controllers are said to be ready for Industrial Internet of Things (IIoT) applications. With an integrated message queuing telemetry transport (MQTT) protocol, direct connectivity to external devices (such as sensors, resistance temperature detectors (RTDs), analog inputs, etc.), and easyto-setup secure communication with other networks (such as Modbus TCP/IP), the EZLogix is designed to be a PLC, and a low-cost edge-gateway computer/controller. The EZLogix line is designed to be a “bridge” between existing operational technology within a plant, such as factory machines and plant 10

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CONTROL ENGINEERING

database networks, so valuable data can be shared reliably and securely to improve plant productivity and efficiency.

Data collection is integrated, up to 64 GB. Break point ladder debugging is included along with automatic input/output (I/O) point configuration, automatic proportional-integralderivative (PID) tuning, and a wide variety of digital and analog I/O. Integrated communications include USB, Ethernet, RS232/422/485, and micro USB. For a typical 50-60 I/O mid-sized machine PLC, with CPU, power supply, modular I/Os, and software, total cost is less than one-tenth that of another industry offering.

The EZLogix is offered with free same-day shipping and free U.S.-based technical support from 6 a.m. to midnight and is made in EZAutomation’s Iowa plant. ce EZAutomation EZAutomation.net

Input #201 at www.controleng.com/information

www.controleng.com

LEAP™ for Operations Increases Operational Productivity and Throughput.

More Integrated.

More Synergies.

Less Work.

Now, use LEAP project methodology to optimize, simplfy, and run operations efficiently. Once an automation project is implemented, continue to use LEAP principles to squeeze more out of what you have and avoid major capital expansions.

For more information, please visit

Connected Industrial

www.honeywellprocess.com/LEAPforOperations Š 2017 Honeywell International Inc.

input #6 at www.controleng.com/information

Connected Plant

IIoT, Industrie 4.0 integration process Nearly 100%

1%

Perhaps 75%

Little or none

3%

research

21%

2016 SYSTEM INTEGRATION STUDY

46%

In-house system integrators

F

Four out of 10 respondents to the

Control Engineering 2016 System Integration Study perform all system integration projects in-house, as opposed to providing services to third parties or hiring system integrators. Below are five findings from this study as they relate to in-house system integrators: 1. System integration projects: On average, eight in-house system integration projects are performed per year; the average project size is $231,162.

2. Devices integrated: The top devices these companies integrate in-house are programmable logic controllers or programmable automation controllers (72%) and human machine interface hardware or equipment, operator interface, control panels, alarms, annunciators, data acquisition equipment, or data recorders or plotters (67%).

3. Project effectiveness: Forty-eight percent of in-house system integrators

29%

Perhaps 50%

report automation system integration to be highly effective in their projects, compared to 47% moderately effective, 2% somewhat ineffective, and 3% not effective.

4. Most recent project: Looking at their most recently completed system integration project, 62% of respondents indicated an on-time delivery, and 67% were able to adhere to the budget initially settled upon.

5. Challenges: These system integrators are challenged with finding/hiring engineering talent for system integration (50%) and for industry experience (41%), frequent changes to regulations/codes and standards (33%), and a lack of communication (33%). ce View more information online at www.controleng.com/2016SystemIntegration.

Amanda Pelliccione is the research director at CFE Media, apelliccione@cfemedia.com.

Perhaps 25%

Figure 1: Three-quarters of facilities are less than 25% of the way through the integration process of IIoT and/or Industrie 4.0. Source: Control Engineering 2016 Industrial Internet of Things & Industrie 4.0 Study

85%

of system integrators outsource up to 10 projects each year. Source: Control Engineering 2016 System Integration Study

46%

of end users have earned their Bachelor’s degree, and 20% have earned their Master’s. Source: Control Engineering 2017 Career & Salary Survey

Measuring project success In-house system integration projects 63%

Increased productivity levels

61%

Completed on time

57%

Completed on budget Operator adoption

41%

Return on investment

41%

Quality of information flow

35%

Figure 2: Six in 10 in-house system integrators consider a project successful if the project was completed on time and on budget, and resulted in increased productivity. Source: Control Engineering

35%

of survey respondents report spending $40,000 or more on HMI software and hardware in the past year. Source: Control Engineering 2017 HMI Software & Hardware Study

More research Control Engineering covers several research topics each year. All reports are available at www.controleng.com/ce-research.

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

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CONTROL ENGINEERING

www.controleng.com

Get Your Business Set For Growth.

To grow your business, you need to not only streamline operations and expand into new markets, but act on opportunities to enhance the customer experience.

Epicor provides industry-specific, tailored ERP solutions to get your business set for growth and scale with business demand, fast. Together, we are the Grow Getters.

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CONTROL ENGINEERING international

Expansion in instrumentation with software, technology updates Market update: Honeywell expands process automation and instrumentation products and channels to continue to augment growth in the next three years, according to Control Engineering China.

W

With the slowdown in global economic

growth, the growth rate of major new projects in the process automation market has decreased in recent years. To continue growth, various process automation manufacturers, including Honeywell Process Solutions (HPS), have made strategic adjustments.

Vision in instruments

At a recent conference, Asheesh Arora, vice president of HPS global channel marketing, said HPS would see breakthrough growth within three years. In 2016, the sales volume of flow measurement and control business reached $650 million, MORE fifth in the instrument field. By 2020, he said, HPS ADVICE expects to achieve sales of $1 billion in its flow measurement and control business, and rank among the KEY CONCEPTS Honeywell Process Solution top three, globally, in the instrument field. outlines growth plans.

Arora said HPS determined five ways to leverFlow measurement and control, inage and promote growth in 2016: follow areas of strumentation, channels, and products growth, implement breakthrough strategies, expand are growth areas. the channel network, focus on large project opporFull support for the natural gas tunities, and introduce new products. In 2017, HPS supply chain is offered with Elster will increase investment to continuously promote acquisition, integration. implementation. For 2015 HPS revenue, the serGO ONLINE vice business accounted for 39%, project business www.controleng.com/international accounted for 33%, products accounted for 17%, www.cechina.cn and Industrial Internet of Things (IIoT) accounted CONSIDER THIS for 11%. By 2020, HPS expects the proportion of its How do your supplier growth plans support your anticipated expansion? products business to increase to 30%, and project business will be 16%, and IIoT will be about the same.

As some manufacturers plan a shift from being mostly product providers to overall solution providers, HPS seems to emphasize breakthrough performance growth from product sales, with an increase in the product proportion from 17% to 30%.

Honeywell has prepared for growth in product innovations.

Asheesh Arora, vice president of Honeywell In 2015, Honeywell completed Process Solutions (HPS) global channel marketing, its biggest acquisition to date, expects significant growth for the company in the next $5.1 billion for the gas heating, three years, driven by product innovation and channel control, and metering system expansion. Courtesy: Control Engineering China, HPS company Elster. “We will

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continuously make investments to increase more target markets, and realize the increase from $5 billion at present to $10 billion in 2020,” said Arora.

With broader lines and more product introductions, watch for more software and products based on IIoT. HPS attaches an increasing amount of importance to offering services for small and medium-sized clients. In particular, with a continuous increase of product lines, channel partners become more important. Arora said that HPS owns more than 200 channel partners in Asia-Pacific region, including more than 50 channel partners in China.

In 2016, the channel business performance was better than the overall market. With year-on-year growth of 16% globally, channel business reached $248 million, and the Asia-Pacific region realized 14% growth. With strong growth in the second half of the year, personnel in the Asia-Pacific channel business manager team increased 50%.

Honeywell will provide the personnel support, tools, and software to “help distributors provide products for Chinese customers and carry out relationship management. Therefore, we expect that China’s channel business may surpass USA, and China will become the largest market globally in the next three years,” Arora suggested.

New growth: value chain

With the completion of Elster’s business integration, HPS has been able to provide service for the entire natural gas supply chain. Arora said he believes the natural gas industry has a rather long supply chain: upstream, midstream, and downstream. Even with different HPS products and solutions, the demand for Big Data is a common thread through the existing and future industrial environment, to make factories more intelligent. “We will further make more investments in the natural gas field, provide a safer, more effective and reliable solution to industrial applications of customers, and stimulate the growth.” Arora expects breakthrough growth within three years. ce

Stone Shi is executive editor-in-chief, Control Engineering China; edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com. www.controleng.com

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CONTROL ENGINEERING international

Industrie 4.0 optimizes safety

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Control Engineering Europe: Industrie 4.0 efforts include human interactions and safety.

Control, Instrumentation and Automation in the Process and Manufacturing Industries June 2017

www.controlengeurope.com

Welcome to the future of

Industrial Ethernet diagnostics

Putting big data into context Identifying your industrial cyber security gaps Special CC-Link IE supplement: Enabling Industry 4.0 with Open Gigabit Ethernet CEE_June_2017_3.indd 1

09/06/2017 14:52

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Many Industrie 4.0-compatible technologies have additional safety features built into them, rather than having to be added later.

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MORE

ADVICE KEY CONCEPTS Industrie 4.0 includes automation, people, and safety.

Flexible reconfiguration can pose a safety challenge.

Risk assessments are key.

GO ONLINE www.controleng.com/international www.controlengeurope.com CONSIDER THIS How is safety related to your automation efforts?

This was from a June 5 Control Engineering Europe article, “How Industrie 4.0 can optimise safety.”

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is set to redefine the current working environment as a highly adaptable workspace that can respond to changing customer requirements almost instantly. Based on information generated and stored, individual production lines can help to transform operations.

Automation use is primarily associated with Industrie 4.0. Even so, one of the main beliefs of Industrie 4.0 is that people are the key players. Connectivity between humans and machine, with the integration of IT, is fundamental.

In a traditional production environment, with lines or cells frequently geared to the manufacture of one product, the safety of those working in the facility is generally straightforward to monitor. A risk assessment of all aspects of the operation— from individual components through to operator “touch points” with equipment—will create a guide, which, in theory, should remain valid until the use of that line changes or alterations are made to the equipment within it. Immediate hazards can be minimized and risks to operator safety averted, as long as correct procedures are followed.

Safety challenges in reconfiguration

An Industrie 4.0 plant can present different and a more intricate set of challenges. Reconfiguration of production areas at short notice, involving the rapid changes of tooling and the physical movement of equipment, can pose safety challenges, while the sheer number of configurations achievable to meet potential requirements may entail a separate risk assessment for each. Safety of personnel and data under a secure network cannot be ignored if compliance with local, national, and international regulations is to be maintained.

Technologies can help. Industrie 4.0 offers the opportunity to increase safety further with the ability to gather data in real time and then act upon it before a potential hazard becomes a real one.

A range of devices can be fitted onto equipment capable of detecting and reporting operator behavior that may pose a risk to safety. Among the most common forms are intelligent cameras which gather digital images or footage and pass these to a central control point, automatically highlighting any abnormal behaviors, such as restricted-area entry.

Many systems designers also opt to equip machines with safety sensing devices that immediately can detect if a human operator has moved into an unsafe area or positioned themselves too close to some plant equipment. A default response is to power down the machine or, with a collaborative

CONTROL ENGINEERING

robot, to slow down to a safe speed, allowing the individual time to move away from the hazard.

This type of feature also is beneficial when equipment has to be moved, for example, previously a machine would need to have all its guards in place and be completely switched off before any action could be taken. With the desire to avoid switching off machines to avoid additional warm-up times and quality issues with first-off components, this is a major advantage in the dynamic production environments associated with Industrie 4.0.

Many Industrie 4.0-compatible technologies have additional safety features integrated, rather than having to be added afterwards. One example is Industrie 4.0 compatible drives that can be used to create a machine protocol with a unique number, highlighting immediately a potential safety issue if a different protocol is used.

Safety networks, risk assessments

Safety networks are common in Industrie 4.0 environments. These include openSafety, Sercos, and Profinet (to name a few) with all common bus systems now having a safety version. All have been designed as an advance on older wire-based systems for powering down and enable a greater flow of information to ensure uptime is maximized and that equipment only powers down as a last resort.

An alternative is a safety zone module that checks wires and negates the need to invest in a separate safety bus system in certain applications.

Sound health and safety practices are needed; a risk assessment of every scenario likely to be encountered (effectively, any machine configuration which can be selected) must be undertaken, with operatives receiving the necessary training to work effectively in this more dynamic environment.

No effort should be spared in protecting personnel no matter the manufacturing processes adopted.

While individual system components may be considered to be “safe,” the story may differ when considering components’ use in combination. In an Industrie 4.0 environment, there may be an added requirement to program alternative routes for autonomous or robotic equipment that experiences an obstacle on its route around the facility. By working with component suppliers and safety-qualified engineers, achieving a Industrie 4.0 compliant production environment is practical. ce

Andrew Minturn is product manager at Bosch Rexroth. Edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com. www.controleng.com

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Critical Power: Generators and System Design

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TECHNOLOGY UPDATE on the edge

PC-based controls: Expanding plantfloor architectures from the edge to IIoT Edge devices facilitate data processing at the plant level, increasing security and using Industrial Internet of Things (IIoT) standards.

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Cloud computing is a hot topic in fac-

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ADVICE KEY CONCEPTS How smart edge devices facilitate data processing at the plant level.

Security measures for industrial Ethernet systems and edge devices.

How PC-based control technology benefits facilities.

GO ONLINE For related links about edge computing, including a recent webcast, read this article online. In the digital edition, click on the headline or search the headline for www.controleng.com and www.controleng.com/webcasts.

CONSIDER THIS Are built-in security features in industrial Ethernet systems and communication protocols enough to protect data processing?

tory automation circles, and while Industrial Internet of Things (IIoT) technologies can offer many benefits, not every company is fully onboard with moving operations to the cloud. This could be due to security concerns, corporate policies for data access, resource availability, among other reasons.

Edge computing, conversely, takes the data processing concept enabled by cloud service providers and moves it back down to the plant level, closer to the devices that create the data. This can alleviate some of the security concerns, as the data never leaves the facility, but also can serve as a stepping stone into a future cloud solution as business needs grow and change.

Smart edge devices for data processing

“Smart� edge devices facilitate data processing at the plant level. Several tasks must be accomplished before a device can be considered a smart edge device. The first task centers on data collection from the industrial process. Once data has been acquired and stored, the edge device then

Smart edge devices facilitate data processing at the plant level, enabling transmission of process data to and from the cloud. Courtesy: Beckhoff Automation

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accomplishes its primary task—data analysis based on preset goals or parameters. These tasks are carried out directly on the device, with the option to move the data vertically to the cloud or to other company databases for filling dashboards used by business and facilities managers.

Data can be transmitted at the edge and/ or to the cloud using recognized IoT and IIoT standards, such as object linking and embedding for process control unified architecture (OPC UA), message queuing telemetry transport (MQTT), and advanced message queuing protocol (AMQP). This creates a seamless migration path for future upgrades, and PC-based control systems are best-suited for these kinds of applications because of inherent openness to IT standards for hardware, software, and networking.

Another important point to consider with PCbased control is scalability in hardware. Controls engineers can start with small processors for very basic commands and protocol translation, then migrate to powerful multi-core industrial PCs and embedded PCs for advanced data processing and analytics at the edge. The more powerful industrial PCs also can pull double duty as complete machine or line controllers.

PC-based control architectures make it possible for the same hardware platform to be deployed everywhere on the manufacturing floor. For example, this type of automation hardware can serve as the programmable logic controller (PLC), motion controller, robot controller and/or as an IoT gateway device, and much more. Thinking higher level, the hardware components used to power the cloud are typically data center-level servers run by a large IT companies, or smaller servers that are purchased by a large end-user and run on-site as a private cloud application.

Using an intelligent edge device, such as a PCbased controller, can help users filter out important data from huge masses of raw data, whether this data stays in the facility or is sent to the cloud.

As part of a cloud services solution, smart edge devices can reduce the associated expenses, regardless of whether cloud service fees are based on the

www.controleng.com

Your Global Automation Partner

volume of data transmitted or the number EtherCAT does not require the use of of messages sent to the cloud. switches, there is little danger of outPC-based control technology makes side frames being inserted into the it possible to implement plant floor- control system in the first place, but to-cloud communication architectures if so, those frames would be destroyed that do not need expensive managed automatically. switches from a third-party IT venFor vertical integration, OPC UA dor. Machine builders and manufactur- provides built-in session encryption, ers can access some pre-integrated IoT message signing, sequenced packets (to and cloud-connected technologies. The block replay attacks), authentication, hardware involved is part of the stan- and more. MQTT and AMQP offer dard industrial PC and I/O hardware similar security and encryption meaoffering. sures for cloud communication. Further All the programming or configu- protections can be implemented with ration to establish the IoT connectiv- standard IT infrastructure planning ity is conducted in the for firewalls, providsame universal platform ing ample security for Future smart used to program a PLC, public cloud systems. motion control, robotIf preferred, end users devices must find ics, safety, and humancan consider a private machine interface. While a balance between cloud running entirely this won’t make a motion within the enterprise IT control programmer an system. When the right delivering highinstant “IoT expert,” it technology components performance and facilitates highly efficient are in place, users can programming among spefeel confident that data offering a compact is encrypted and procialized programmers and teams. This way, advanced tected from intrusion. footprint. analytics and filtering can In the future, smart be handled at the machine devices must find a balin a programming environment that’s very ance between delivering high-performance familiar across engineering teams. and offering a compact footprint. Despite the ultra-compact size, CPU options Security for smart edge devices are available up to a quad-core procesThe combination of a high-perfor- sor, so this interprocess communicamance industrial Ethernet system such tion (IPC) can be an overall machine as EtherCAT and a vertical communica- controller and/or an IoT gateway to tion protocol such as OPC UA provides push data to cloud services. IPCs can a variety of built-in security measures integrate industrial Ethernet protocols that do not require programming to such as EtherCAT and cloud commuimplement. At the plant floor and nication standards such as OPC UA machine to machine level, EtherCAT and MQTT with ease. has integrated security features that With the appropriate PC-based control block unwanted intrusion from out- software, the IPC hardware becomes whatside sources, and it does not require ever it is programmed to be. Advanced the use of IP addresses. By default, IoT and Industrie 4.0 concepts are changEtherCAT slave devices “destroy” ing by the minute, and it is this kind non-EtherCAT frames. This includes of flexibility and adaptability in hardinjected malware or viruses, since they ware and software that will help machine are not part of the control process. These builders and end-users stay ahead in the unexpected “bad” frames of data are industry. ce not forwarded by EtherCAT, so they are immediately stopped without losing Eric Reiner is industrial PC market speimportant process data. EtherCAT also cialist, Beckhoff Automation. Edited by preserves data tunneled through stan- Emily Guenther, associate content mandard TCP/IP devices that are connected ager, Control Engineering, CFE Media, as part of the system architecture. Since eguenther@cfemedia.com.

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CONTROL ENGINEERING

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TECHNOLOGY UPDATE intelligent robots

The benefits of robotics process automation Process automation enhances business development with a vast return on investment (ROI).

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In automation’s

60-year history, business executives and workers often hesitated to implement new technology before they supported its benefits. Robotics process automation (RPA) is the use of software with artificial intelligence (AI) and machine learning capabilities to accomplish repeatable tasks, previously requiring human interaction. Though there are jobs in nearly every industry that in time will no longer require human interaction due to automation, keeping RPA at arm’s length is a rejection of progress for businesses that want to develop and cultivate a competitive edge.

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While there might be routine maintenance, automation expenses are controlled by the desire to expand the business and employ additional

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automation capabilities to realize greater benefits.

Automation benefits

MORE

ADVICE KEY CONCEPTS The benefits of robotics process automation (RPA).

The challenges of implementing process automation.

How to maximize ROI with RPA. GO ONLINE For related links on automation, read this article online. In the digital edition, click on the headline or search the headline for www.controleng.com.

CONSIDER THIS What industries would benefit the most and receive the most ROI from process automation?

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Like any new technology or process, automation implementation does require upfront costs.

But the use of automation can result in increased return on investment (ROI) because automation reduces labor costs, allowing employees to focus on more business-critical tasks instead of focusing on repeatable processes. According to Information Services Group, automation’s returns have garnered double-digit productivity improvements over outsourcing, and cost reductions between 14% and 28% have been realized.

Automation can also streamline regulatory compliance that imposes fines by virtually eliminating human error. With the correct automation solution, the cost savings reverberate throughout an organization and the ROI impacts multiple budget lines.

Automation can be complicated, but the beauty of this technology is its ability to easily scale from simple to complex. The key to understanding what type of automation can work for a particular application is to rediscover every aspect of each process then realistically think through what can be streamlined or eliminated in each action. Keep in mind that many current everyday processes exist because of automation— from simple automated stamp machines to

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complicated medical procedures. Automation can be applied to every business when the right automation experts critically looks at an organization’s practices.

Customer-facing businesses setting themselves apart with personal touches and big smiles should not shy away from automation as a business enhancement. In fact, the opposite is true.

Automation implementation on the back-end processes can free up valuable time for employees to spend on more meaningful customer interactions – not less.

Business development, automation

Automation technology is ever-changing. But an update to automation technology will only need to change when processes or the business needs change. Unlike other business efficiency tools, it doesn’t require numerous software updates, renewals, or pricey upgrades. While there might be routine maintenance, automation expenses are controlled by the desire to expand the business and employ additional automation capabilities to realize greater benefits.

Automation is a sign of growth. It is a sign of efficiency and an investment that will pay off for years to come. Business owners frightened of RPA and what it stands for in regards to the future of the business should think of it as a natural step in expanding and keeping up with the needs of an ever-growing clientele.

While there are growing pains and staff realignments associated with many RPA implementations, current employees can use this opportunity to learn about automation and expand skillsets. Also, if an automation plan is inclusive, employees can contribute meaningful insights into the best ways for the automation to function and hence, support a more efficient RPA implementation.

If experts with a vast understanding of automation implementation and rethinking processes are put to use, automation can open the door to a new world in business development. ce

Deanna M. Murray is a content specialist at Disys. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com. www.controleng.com

CALLING ALL SYSTEM INTEGRATORS...

2018 System Integrator of the Year

call for entries

Entries are due August 18, 2017 Control Engineering and Plant Engineering’s annual

System Integrator of the Year Awards

2018

Questions?

Who should enter?

If you’re a system integrator with demonstrable industry success, Control Engineering and Plant Engineering urge you to enter the 2018 System Integrator of the Year competition. Past System Integrator of the Year winners—Class of 2017, Class of 2016, and Class of 2015—are not eligible to enter the 2018 System Integrator of the Year program.

Contact Bailey Rice Director of Business and Market Development CFE Media brice@cfemedia.com (630) 571-4070 x 2206 2017 System Integrators of the Year

15 | 2016 SI Giants 29

What’s in it for the winners?

The chosen System Integrator of the Year winners will receive worldwide recognition from Control Engineering and Plant Engineering. The winners also will be featured as the cover story of the Global System Integrator Report, distributed in December 2017.

How will the competition be judged?

Control Engineering and Plant Engineering’s panel of judges will conscientiously evaluate all entries. Three general criteria will be considered for the selection of the System Integrator of the Year: • Business skills • Technical competence • Customer satisfaction

Finding the right recipe People, processes are crucial to SI success story 23

A supplement to CONTROL ENGINEERING and PLANT ENGINEERING magazines

Tell us how you measure up in these three areas.

Get the application: www.controleng.com/SIYApplication

INDUSTRY NEWS and events

Robot use in logistics and transportation industries expected to grow The robotics market serving logistics and transportation companies is primed for rapid growth over the next five years.

Currently, around 80% of warehouses are operated manually, meaning they have no automation support.

That’s about to change in a big way.

In 2016, the logistics robotic market had a global market revenue of $1.9 billion. In 2021, a recent study predicts market revenue for the global sector to reach $22.4 billion. In the same amount of time, robot unit shipments will grow from 40,000 to 620,000 annually.

Amazon is known for automated distribution centers, but other logistics companies are turning to robotics for the safety, efficiency, and accuracy they provide.

Robotics applications in logistics and transportation

Distribution networks, across the entire global supply chain, require a high volume of varied and complicated tasks. This

presents challenges for automation, which is easiest and cheapest to implement where there are easy and repetitive tasks. But new technology is overcoming these logistical obstacles in a few distinct ways.

Container loading and unloading

Much of the goods consumed in America were at some point shipped in a standard container from overseas. Typically, these products aren’t palletized, meaning they’re stacked from floor to ceiling. The variation in products sizes and shapes has made automation of loading and unloading difficult until recently.

3-D laser vision, coupled with robotic software, can view different products in a container, determine the optimal loading or unloading sequence, and carry out this function with a high level of accuracy.

Stationary piece picking

In the warehouse, items are always being sorted. Often, it’s simply a matter of moving a product from one box to another. Historically, piece picking has been difficult because robots weren’t sure which items they were picking. Industrial robot arms, enabled by vision systems that can recognize which product is which, are able to handle this process in a stationary workcell. These robots boost efficiency and accuracy in the warehouse.

Custom packaging

Whether it’s a big sale or a bulk discount, many items need custom packaging before they hit retailers’ shelves.

This is very difficult for a robot since it means working with different sizes and shapes of products, but also because it requires work to be completed around humans as opposed to inside of a workcell. This is where collaborative robots, designed to work safely around humans, have played a role in logistics.

Collaborative robots (cobots) have no sharp edges and shut down when they bump into something. In logistics applications, some cobots even can be trained to do tasks by letting a human guide their arms once to learn the motion. This decreases inefficient programming time and speeds of the custom packaging process.

Robots are quickly making their way into the logistics and transportation sector. They’re providing safety, efficiency, and accuracy in a wide variety of applications, mostly involving work in the distribution center.

This article originally appeared on the Robotics Industries’ Association (RIA) Robotics Online Blog. The RIA is a part of the Association for Advancing Automation (A3), a CFE Media content partner.

Edited by Hannah Cox, content specialist, CFE Media, hcox@cfemedia.com.

Manufacturer relocates, expands

A Robots with increased intelligence and speed can help in palletizing or package transfer and other motion control applications. This Fanuc Robot moved boxes at the 2016 Pack Expo. Courtesy: Mark T. Hoske, Control Engineering

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manufacturer of custom universal joints and mechanical power transmission products, Belden Universal, announced its plans to move into a 40,000-sq-ft factory in Hillside, Ill., in close proximity to Belden’s current headquarters in Broadview. Relocation will proceed in staged phases this fall and is expected to conclude by late 2017.

The constructed factory will accommodate manufacturing technologies, Lean equipment layout and automated workflow for increased efficiency and better overall customer experience. Ergonomic design throughout the building will further enhance employee productivity and job satisfaction.

“We are extremely proud to move into our new building in the very near future. The larger, modern facility will allow us to continue delivering highly innovative products and quality service to our customers and provide an improved work environment to our employees,” says Perry Sainati, president of Belden Universal.

Edited from a Belden Universal press release by CFE Media.

www.controleng.com

Digital edition? Click on headlines for more details.

See news daily at www.controleng.com/news

Groups to collaborate on cybersecurity workforce education

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RC Advisory Group and SANS Institute have agreed to collaborate to further develop and nurture the global cybersecurity community. The two organizations will work together to support cybersecurity workforce education and development for industry, energy, utilities, government, academia, and infrastructure. They also will help address the pressing need to develop and propagate new cybersecurity solutions for the emerging smart cities, smart transportation, and Industrial Internet of Things (IIoT) initiatives. This includes performing joint research to provide a better understanding of the current state of cybersecurity awareness and preparedness.

ARC and SANS aim to foster an expanded and more aware security community through joint workshops and other activities at the 2018 ARC Industry Forum in Orlando, FL and upcoming SANS events, including the 2018 ICS Security Summit.

“By equipping the workforce with the cyber-awareness and technical training needed to help safeguard today’s connected and converged systems, we increase the effectiveness of our security operations,” said Doug Wylie, director at SANS Institute.

“Managing the security of industrial facilities, infrastructure, and smart cities is

a major challenge for ARC clients. Cybersecurity is also constraining broader adoption of emerging technologies that can improve performance, reliability, and safety,” said Sid Snitkin, vice president at ARC Advisory Group.

ARC and SANS plan to collaborate to provide enhanced cybersecurity content at the 2018 ARC Industry Forum.

Edited from an ARC Advisory Group press release by CFE Media.

Process growth The 2016 U.S. process instrumentation and automation (PI&A) market, valued at $11.7 billion, is projected to grow 3.6% by 2021 to a total of $14 billion according to the Measurement, Control & Automation Association (MCAA). The group’s 2017 annual market forecast report projects growth concentrated in five industries: Chemicals, electric utilities, oil refining, food and beverage, and pharmaceuticals with a cumulative market gain of $2.28 billion over the forecast period.

The report projects the chemicals industry market gain will be largest, about $850 million; the other four are projected to add over $1 billion in market gain during that time. Oil and gas spending, expected to be essentially flat in 2017, is expected to increase through 2021. See more online.

Edited from an MCAA press release.

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input #10 at www.controleng.com/information

INDUSTRY NEWS and events

Flannery named CEO of GE GE announced that John Flannery, current president and CEO of GE Healthcare, has been named CEO of the company by the GE Board of Directors effective Aug. 1, 2017, and Chairman and CEO effective January 1, 2018.

Flannery began his career at GE Capital in 1987 where he focused on evaluating risk for leveraged buy-outs. In 1997, he moved to Argentina and led GE’s Equity business in Latin America and the overall GE Capital business for Argentina

and Chile. In 2002, Mr. Flannery became the president and CEO of GE Equity. In 2005, he moved to Asia where he was responsible for the Asia Pacific region for GE Capital. In 2009, he moved to India to lead the country for GE. During his time in India, Mr. Flannery upgraded the leadership team, built the culture, and focused on the industrial side of the business, where he increased industrial sales by 50 percent in 2011.

In 2013, he was tapped to lead business development at GE Corporate where he focused on capital allocation for the company and led the acquisition of Alstom, the largest industrial acquisition in the company’s history.

Since joining GE Healthcare in 2014, Flannery expanded the division with a John Flannery, the president and CEO of GE Healthcare, has been named the CEO of GE effective Aug. 1, 2017, taking over for Jeff Immelt, who has been running the company since 2001. Courtesy: GE

Medical power supplies Very compact and efficient 40 and 65 Watt models in metal package or open frame are certified to ES 60601-1 3rd edition for 2 × MOPP.

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Flannery led the acquisition of Alstom, the largest industrial acquisition in company

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history.

focus on technology leadership in core imaging, created digital platforms and solutions, expanded life sciences through bioprocess solutions, and added key technology to its cell therapy systems business.

He also launched Sustainable Healthcare Solutions, which is focused on bringing disruptive technologies to healthcare providers across emerging markets.

Jeff Immelt, who was named CEO in 2001, changed the company into a digital industrial portfolio aligned to key markets—power, aviation, transportation, health care, and oil and gas. He will retire from the company on Dec. 31, 2017.

Edited from a GE press release by CFE Media.

Headlines online Industry events At www.controleng.com, industry events include: Process Expo 2017, Chicago, Sept. 19-22 www.myprocessexpo.com Pack Expo and Healthcare Packaging Expo, Las Vegas, Sept. 25-27 www.packexpolasvegas.com Fabtech, Chicago, Nov. 6-9 www.fabtechexpo.com/about A3 Business Forum, Orlando, Jan. 17-19, 2018 https://a3.a3automate.org/a3/businessforum

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ARC Industry Forum 2018, Orlando, Feb. 12-15 www.arcweb.com/events/rc-industry-forum-orlando

Top five Control Engineering articles

June 12-18: Most visited articles included NEC changes, control system automation errors, Salary and Career Survey, networking to improve a superconducting magnets, and integrator advice.

May PMI ticks up slightly as manufacturing remains solid Collaborative robots in the laboratory Cyber espionage the cause for most companies security breaches

Reliable. Available. Now.

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input #11 at www.controleng.com/information

Six questions about reliability vision companies need to answer

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Digital edition? Click on headlines for more details.

See news daily at www.controleng.com/news

Video use in data collection rising, according to survey

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survey conducted by HBM shows that video use is acceler The most common reason for using video in data collection ating in data collection. Almost half of the respondents (47%) is to gain additional input analyzing unexpected deviations (73%). already use video in data recording. In addition, 54% of the Other common reasons are decision finding (50%) and visualization respondents expect video use within their organization to increase of results to management (41%). in the next year.

Regular video (such as webcams) most commonly is used for Video cameras already are used in many industrial test and data collection. In the survey, 80% of respondents use this type. measurement applications in addition to data collection with tradiHigh-speed video is used by over one-third of the respondents tional tactile sensors. However, (36%), often in combination with until now, there has been very traditional video.

Video supports traditional sensor data little information on the level and Video in data collection is nature of this use. likely to increase substantially and is becoming a valuable source of “Based on the study there in the next several years. This is additional information. is no longer any question that indicated by both sides; by those recording video data in parallel already using video today and by to tactile sensors or digital bus signals is becoming more and more those who do not. In total, 54% of all the respondents expect video attractive to users,” said Christof Salcher, product manager instruuse in data collection within their organization to increase. Among mentation at HBM. “Video supports traditional sensor data and is non-users that amounts to 37%. becoming a valuable source of additional information, making the Use brings more use. Those already using video are more prone room for interpretation even narrower in testing.” The survey’s to increase their usage within the next years (76%). Of those 50 findings include: respondents expecting to increase their use of video in data, a majority Video is most commonly used in structural durability, fatigue (69%), predicts a substantial growth of 10-50%. None of those already testing (48%). Machine monitoring or general lab testing (30%) and using video expect the video usage to decrease in the next year. mobile data acquisition or road load data acquisitions (28%) are Edited from a Control Engineering Europe article by Chris Vavra, proalso relatively common areas of application. duction editor, Control Engineering, CFE Media, cvavra@cfemedia.com.

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Operator panels

X2 control

Integrated CODESYS control

X2 control panels are available in 4, 7, 10, 12, 15 and 21 inches.

X2 control panels combine industrial HMI and CODESYS IEC 61131-3 PLC functionality in the same compact hardware. Add standard I/Os and you’ll get an elegant and cost-effective solution.

X2 series. Strong. Stylish. Smart.

Learn more at beijerelectronics.com/x2control input #12 at www.controleng.com/information

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Project Certainty How 15 Companies Achieved Capital Project Success You have heard the stories — or you have told them yourself — about capital projects burdened by startup delays and excessive costs. Decades-old project methods are not helping anymore. Today, successful integrated project execution—whether a greenfield new build, a modernization, or a migration—requires all of us to go beyond traditional thinking.

The difference between whether projects are on-time and onbudget or late and over-budget often comes down to strategies.

Transforming capital project execution requires new strategies and taking best practices from successful projects. Early project decisions have a large impact on complexity. Technology can be a key lever to reducing complexity. Project management and remote collaboration can reduce complexity and save time on project schedules. Projects require flexibility and flexibility delivers big benefits to project schedule, even making up for project delays outside the automation scope and with tight project schedules.

Whether by eliminating unnecessary hardware, reducing wiring, or reducing project hours, these solutions all drive significant cost savings that add up to millions of dollars even on small projects, but many industries are unaware and remain burdened by project delays and cost overruns.

This interactive eBook showcases actual successful capital projects and how companies across countries and industries are combining best-in-class project strategies and automation technologies to transform capital project execution. These strategies have helped one company deliver 3 complex projects at once and another company save more than $10 million. Through 15 case histories, we’ve captured how companies spanning all industries and the globe leverages best practices, strategies, and technologies to deliver significant improvements on capital projects.

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Download the eBook: http://www3.emersonprocess.com/projectcertainty/capitalprojectsebook/ input #13 at www.controleng.com/information

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Redundant Power Supply Concepts Important Contribution to Uptime

Anja Moldehn | Phoenix Contact Electronics GmbH, Germany Mike Garrick | Phoenix Contact USA

To ensure business success in the industrial sector, machines and systems around the world require a high degree of reliability. Less downtime results in higher profits, and control cabinets that operate continuously are a key to keeping factories efficient. For this reason, many engineers are implementing redundant power supply concepts combined with redundancy modules.

Power supplies are configured redundantly anywhere that downtimes would have a negative impact. For example, for a device with a rated current of 20 A, the power supply system would consist of two power supplies, each with 20 A on the output side, connected in parallel. If one of the power supply units develops an internal fault or if the primary power supply fails, the second unit automatically takes over and supplies the load current. This means that the power supplies must be dimensioned so that one power supply unit can cover the complete power demand of the connected devices in all operating states.

To minimize the risk of a failure, the user should consider all potential fault sources. This paper demonstrates several examples of potential failures and offers suitable solutions for each situation.

Examples in the paper include: • Fault in one phase of the primary power supply • Break in the cable between the power supply unit and the redundancy module • Short circuit or break in the cable to the power supply or failure of one power supply unit • Break in the cable between the redundancy module and the load • Short circuit between the power supply and the redundancy module • Excessive load current caused either by a faulty load or subsequent increase through other devices • Internal defect in the redundancy module In sensitive applications, a redundant configuration of the automation solution ensures high system reliability.

Depending on the application, operators can choose between solutions without decoupling or with decoupling by means of diodes or a MOSFET. Register to download the paper at: www.phoenixcontact.com/powersupplywhitepaper info@phoenixcon.com • www.phoenixcontact.com input #14 at www.controleng.com/information

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How to Modernize Your Factory on Your Terms Jim Wilmot | Controls Product Manager, Siemens Underperforming automation systems can compromise productivity and profits Downtime is a plantâ&#x20AC;&#x2122;s #1 enemy. Thus, many manufacturers are contending with outdated or insufficient automation systems and components that are compromising productivity. The time to modernize is now! But manufacturers may still hesitate to invest in their automation systems because they fear downtime during changeover, the need for more staff training, having to convert existing code or taking a hit to their budgets.

To avoid these challenges, manufacturers should seek automation solutions that have integrated functionality and are engineered to migrate seamlessly into future technologies to lower their total cost of ownership. These solutions should be based on a single engineering framework that seamlessly integrates controllers, distributed I/O, HMI, drives, motion control and motor management using a common database as well as integrated security, safety and diagnostics.

Is staying with your current vendor the best choice?

While it may seem like the least painful route is to upgrade components from a current vendor, it may not be the best option for manufacturers. Many vendors have dead-ended or are phasing out legacy hardware, and no spare parts are available.

Some vendors may offer more advanced versions of obsolete parts, but manufacturers may still need to convert their code to new programming software.

A total systems approach or individual component replacement?

Manufacturers have two options when deciding to modernize their production: a total systems approach or individual component replacement. A total systems approach is best for manufacturers that want the full benefits of totally integrated automation â&#x20AC;&#x201D; a necessary step to integrating your entire value chain, from design and engineering, to sales, production and service. When total replacement is not feasible, manufacturers should seek advanced automation components that can easily integrate with existing systems while providing additional functionality.

Doing nothing can compromise your competitiveness When it comes to modernizing, manufacturers have installation options to match their production and budget requirements â&#x20AC;&#x201C; enabling more informed decisions for greater flexibility and competitiveness.

James.Wilmot@Siemens.com www.usa.siemens.com/modernize Register to download the paper at:

www.industry.usa.siemens.com/topics/us/en/modernization/resources/Pages/Modernize-White-Paper.aspx input #15 at www.controleng.com/information

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How to Balance Cable Properties with Thermal Performance in Industrial Applications Alex Terpe | Product Management, Lapp Group Control cables increasingly have to withstand temperature extremes in applications such as food and beverage machines, industrial ovens, furnaces, foundries and industrial process equipment. These applications can subject the cable to continuous-use temperatures as low as -50ºC and as high as 180ºC. For these environmental conditions, customers have to think about cables with jacket materials other than PVC. You could buy very expensive specialty cables that can withstand even hotter or colder temperatures, or you could try to use a more traditional PVC control cable, whose lifecycle starts to fall dramatically in hot or cold environments.

A growing class of control cables occupies a middle ground between over-engineered specialty cables and commodity PVC cables. Based on silicone or cross-linked polyolefin copolymers, these cables can take over in thermal environments that would cause PVC cables to fail prematurely. Improving the thermal performance of a control cable can be a balancing act. Some of the changes to cable construction that widen the operating temperature range can compromise the cable’s electrical or mechanical properties. Silicone and cross-linked polyolefins do a good job striking that balance.

For a closer look at these cables, and in particular, how they balance thermal performance against other desirable cable properties, register to download the paper here: landing.lappusa.com/heatcable_WP_PE. ce201707_whitePprHLF_lapp.indd 1

input #16 at www.controleng.com/information

Webcasts

www.controleng.com/webcast

sales@lappusa.com www.lappusa.com 6/14/2017 12:10:13 PM

Control Engineering Webcasts help you obtain educational information on specific topics and learn about the latest industry trends.

Check out some of our Webcasts on topics like: • Choosing sensors for the application • lloT series: Get your head into the cloud • lloT series: Sensing and control at the edge: Microcontroller kits • lloT series: lloT transforms predictive maintenance • System Integration case studies • lloT series: Preventive maintenance: Technologies, applications and business models • Motors and drives • Human-machine interface hardware, software

COVER STORY programming for PLCs

Controller embeds programming efficiency Selecting the right controller and accompanying programming software adds efficiency to the controller programming process.

A

MORE

ADVICE KEY CONCEPTS PLC architecture can ease programming.

Top-down configuration and devicecentric programming help with PLC programming.

Various devices can be programmed similarly.

GO ONLINE See more details and links to other programming advice by clicking on the headline in the digital edition or searching on the headline at www.controleng.com.

CONSIDER THIS Would decreased programming and less configuration help with your next project?

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programmable logic controller (PLC) or other controller is selected based on its application, but choice should take into consideration the capabilities of the accompanying controller programming software platform, as this will have a great effect on quick and efficient coding.

It’s possible to start up the development platform, create a new project, and start writing ladder code from scratch with just about any controller programming software package, but this method requires configuration-on-the-fly and is not as efficient as other methods. However, some controller programming software platforms have built-in efficiencies. By design, these platforms lead the developer along the right path, reducing the effort needed to complete a program.

One approach combines two methods for more efficient programming: top-down configuration and device-centric concepts (Figure 1).

Top-down configuration provides a clear path for the programmer by showing what is and isn’t needed when configuring a PLC project, all based on menu-driven selections. Device-centric concepts let devices handle common functions “behind the scenes,” freeing the programmer from these tasks.

Examples and explanations of top-down configuration and device-centric programming can improve programming efficiency.

Top-down configuration

For some controllers, configuration is simplified using a top-down method (see Table). In the table, the order of the tasks is by precedence, with each item in the list depending on the item or items above it. For example, everything below CPU configuration depends on how the CPU is configured. Serial port, port type, Ethernet input/output (I/O) master options and server options such as Modbus/TCP and EtherNet/IP explicit messaging are configuration selections typically available during CPU configuration.

(EtherNet/IP is an industrial Ethernet protocol from ODVA.) These selections add necessary

CONTROL ENGINEERING

parameters to some or all the items below CPU configuration.

Table: Top-down configuration steps 1. CPU configuration 2. I/O configuration 3. Module configuration 4. Device configuration 5. I/O mappings 6. Memory configuration

Configuring the controller in the proper order helps everything below it fall into place, simplifying and automating some software development. Configuring a CPU as a Modbus RTU client only, for example, affects the items below by only exposing the appropriate parameter options, simplifying subsequent steps.

Device-centric concepts

The development efficiencies realized by an orderly configuration lead directly to devicecentric concepts. With these concepts, ladder code talks to a device in the middle, not directly to the hardware itself (Figure 2). A device is similar to a printer driver on a PC, where the driver (device) handles all the low-level details so a programmer can send data to a printer, without worrying about printer programming.

A programmer likely thinks of a device as a sensor, encoder, I/O module, variable frequency drive (VFD), EtherNet/IP module, remote rack, or a similar piece of hardware. In a device-centric controller, the devices are instead pieces of code between the program and the hardware.

Using this concept, the device is configured, and it handles the details for control of the hardware by the controller, such as establishing communication protocols, handshaking, and defining memory requirements. Much of the hardware details are handled via configuration of each device, not with controller programming. www.controleng.com

Figure 1: Some controllers, such as AutomationDirect’s Do-more BRX Micro PLC family, provide top-down configuration and a device-centric approach for more efficient programming. All figures courtesy: AutomationDirect

After configuration

Once a device is configured, the program instruction talks to the device, not directly to the hardware. The instruction uses the defined memory, handshaking bits, and memory flags created during configuration of the device. The instruction also can talk directly to and from memory using bits and integers to make logic decisions. The instruction also can perform math functions and place the floating-point result back in memory, for example.

A device, such as a serial port, talks directly to memory as well. As data flows to or from a serial port, the device handles buffering and status flags in memory. The device handling the behind-thescenes details is what makes the programming device-centric, with everything revolving around the device.

A server can be thought of as a device as well.

It runs in the background, talks directly to the hardware, and moves data between the hardware and memory. Modbus TCP is an example of a server. It functions for the most part outside of the controller program, but can be accessed by it.

Put efficiency into action with devices

Regardless of the complexity of the hardware selected, the device provides a clean, uniform interface between the hardware and controller program. Each device is set up the same way, for example a Modbus/RTU or a general-purpose serial port, by following top-down configuration www.controleng.com

‘

If the controller lacks on-board highspeed inputs, a high-speed counter module can be used to count encoder

’

quadrature pulses.

steps, which require selecting features and filling in a few blanks.

A typical application, like a box diverter, contains several pieces of hardware that must be controlled. The application may include an encoder to synchronize the diverter gate to different box lengths, a motor controlled by a VFD, and a barcode reader to scan a conveyed box to determine its destination. Input and outputs also will be needed to monitor sensors for box detection, and to control pneumatic actuators, such as a lift.

As this box diverter application demonstrates, it’s not unusual to have several different pieces of automation hardware connected to a PLC, with each hardware component and its required connections defining the devices.

However, in this instance, a controller with a top-down configuration and device-centric concepts is quickly configured, with much of this effort performed automatically.

If the controller lacks on-board high-speed inputs, a high-speed counter module can be used to count encoder quadrature pulses. This module is not a part of the CPU configuration, CONTROL ENGINEERING

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COVER STORY programming for PLCs

Figure 2: Using a devicecentric approach, where the device handles the low-level details of the hardware interfaces, can simplify programming. AutomationDirect’s Do-more Designer controller programming software platform has a device-centric approach.

but it is automatically discovered in the second step, I/O configuration.

The third step, module configuration, will then autofill the needed parameters with default values for the discovered module. Any edits to the configuration required can be made here during this step. The PLC will automatically handle the I/O mapping for the added module, and create the needed image register addresses.

The controller’s Ethernet port communicates to the VFD. Starting at the top of the configuration list, the Ethernet I/O Master is enabled as part of the CPU configuration step. This creates an entry in the I/O configuration, allowing IP configuration and other communication options. Nothing more is typically needed for this device’s configuration since the other parameters, like I/O mapping, all are done automatically.

The controller’s serial port is used to communicate with the barcode scanner using simple ASCII text strings. The port is recognized during the CPU configuration step where a general-purpose serial port is configured, including settings such as baud rate and hardware protocols such as RS-232.

I/O and module configuration are not needed, and the device configuration is created automatically, providing a pre-configured interface with access to system resources. The memory configuration step automatically allocates memory for the device.

Multi-point discrete input and output modules are used to monitor and control the sensors and pneumatics. These modules are configured in a similar fashion. Some of these devices are easy to set up and some more complicated, but all use the same methodology. Configuration starts at the top of the table list and works downward, filling in only the parameters not automatically defined in prior steps.

Efficient instructions

As shown in Figure 2, a top-down and device-centric controller programming platform is quickly configured. Controllers with this type of programming software typically also provide more efficient instructions, such as proportionalintegral-derivative (PID) loop and motion control blocks.

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‘

Newer, advanced controllers are simplifying programming by enforcing a more top-down approach and using device-centric

’

concepts.

There are thousands of uses for PID loops, so there is no one-size-fits-all solution. Some controllers have limited options, but others have improved PID instructions to increase efficiency by providing independent, modular, interchangeable, and run-time configurable methods to meet application needs.

Part of this improved efficiency is the result of breaking down the PID loop into smaller pieces. Instead of embedding all the PID parameters, such as filters, scaling, ramp-soak tables and alarm handlers, in one PID instruction, separate instructions are used to access the parameters individually to simplify customization of these control algorithms. These instructions also can include trend views for display to help with understanding of the control loop response, and to assist with initial tuning and troubleshooting.

Motion control instructions can follow a similar path, broken down into different levels of instruction complexity. Simple motion instructions allow quick application of basic move commands with minimal required configuration.

Intermediate-level motion instructions provide more user-defined parameters. Advanced instructions enable selection or creation of custom move profiles, often through a simple configuration process.

Newer, advanced controllers are simplifying programming by enforcing a more top-down approach and using device-centric concepts.

With proper configuration, much of the device interface between the controller software program and the hardware happens automatically and efficiently without the need to write code.

Quicker configuration leads to fast programming, and this is enhanced with the wider variety of available instructions. ce Bill Dehner is technical marketing engineer at AutomationDirect; edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. www.controleng.com

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COVER STORY programming for PLCs

PLC programming tips, benefits for engineers Get help for programmable logic controller (PLC) programming, covering common topics in ladder logic.

L

adder logic and programmable logic controller (PLC) scanning, binary coded decimals, and reusable codes are among PLC programming tips offered by Control Engineering editorial advisory board member Frank Lamb, the founder of Automation Consulting Services Inc., a Control Engineering content partner.

Featured below are tips on PLC programming from three different viewpoints.

Ladder logic, PLC scanning

MORE

ADVICE KEY CONCEPTS There are different types of registers for PLC scanning that are updated to an output table, which will be used to drive physical devices connected to the PLC. Binary-coded decimals (BCDs) are a class of binary encodings represented by four or eight bits.

Many platforms allow reusable code to create powerful programs quickly, but each has its own method.

GO ONLINE Visit cfeedu.cfemedia.com for “Introduction to PLCs,” a five-part comprehensive series on PLC programming and its history by Control Engineering editorial advisory board member Doug Bell.

Read the full versions of these stories online at www.controleng.com with additional images and other articles by Frank Lamb about PLC programming.

CONSIDER THIS What other programming methods can be used for PLCs and what benefits do they provide for engineers?

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Almost all PLCs worldwide handle scanning in the same way. First, the CPU reads the physical inputs into a memory table, usually called the “input table.” This table is then used as the program is evaluated. There are different types of registers that are used in different platforms; these registers are updated as the logic is processed left to right on each rung and top to bottom within each routine.

This includes updating an output table, which will later be used to drive the physical devices connected to the PLC. The program might call different subroutines for different purposes, and it can be important in what order routines are called. Depending on where memory registers and output tables are updated, the physical outputs could be delayed by up to two scans. In either case, the program meanders through the different routines as they are called before returning to wherever they were called from and eventually ends up at the end of the original cyclic routine. Most programs use an initial cyclic routine that is used to call all of the other routines.

Some programs, however, run on a periodic basis instead of a continuous program. This is uncommon, though. Most programs use a continuous program configuration that runs as fast as it can. After executing all of the code, evaluating the logic, and updating all of the tables (except for the input tables, which were written at the beginning of the scan), the resulting output table or register contents are written to the physical outputs.

How long does this take? That depends on the platform (speed of the processor), how much code there is in the program, and the types of instructions used. Sometimes programmers will use loops

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in the program or make repetitive calls to the same routines. All of this has an effect on the total scan time. There is usually documentation available indicating the execution time for different instructions, but there’s no point in trying to add up all of the code to make an estimate on length. It simply is available for reference.

Scan time can take as long as 80 ms. If the scan time is longer than about 50 ms (for a machine control project) then the user should seek a more powerful processor or ways to make the code more efficient. Beyond 50 ms, the effect on output reaction for a machine control project can be noticeable; for a process control project this may not matter.

Binary-coded decimals and PLCs

Binary-coded decimals (BCDs) are a class of binary encodings (usually represented by four or eight bits). Humans need to add up those individual bits in our registers to convert them to base 10 because that’s the way we’re programmed to think.

Back in the days before touchscreens, 7-segment displays and thumbwheel switches were used as a numerical interface between humans and PLCs. Even before the PLC, these devices were the only graphical way to interface with circuits numerically.

Users could move plugs around like in the days of ENIAC (the first electronic general purpose computer), but it was a lot easier to view and adjust decimal numbers with these devices. The problem was, they were very input/output (I/O) intensive.

Each thumbwheel segment required four inputs (+ power), while each 7-segment display required four outputs (+2 power connections). Still, it was easier to interface with signed or unsigned integers in decimals than use pushbuttons and pilot lights.

A common complaint is the math; every data type has to be explicitly declared on the platform, and converted if data types are not equivalent. Not only that, but the standard timer and counter data types incorporate BCD into their data structures.

This is because the structures go all the way back to when people had to deal with things like these thumbwheels and seven-segment displays. In fact, the timer setpoints are still entered as “S5T#3S” for a 3-second setpoint. The timer uses three BCD www.controleng.com

Binary code ABCD 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1

0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1

0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1

Decimal number

0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

BCD code B5 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1

0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0

0 0 0 0 1 1 1 1 0 0 0 0 0 0 1 1

0 0 1 1 0 0 1 1 0 0 0 0 1 1 0 0

0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1

Binary-coded decimal (BCD) is a class of binary encodings of decimal numbers where each decimal is represented by a fixed number of bits, usually four or eight, which goes against the way humans compute data. This disconnect can cause problems for programmable logic controller (PLC) users.

Graphics courtesy: Frank Lamb, Automation Primer

digits (12-bits) and two extra bits for the time base.

This is also true for the counters, meaning that they only count from -999 to +999.

Each four-digit section can only carry bit values from 0000 to 1001; for the next value, rather than indexing to 1010, (“10” in signed or unsigned decimal or “A” in hexadecimal), the next bit gets bumped to the next section of bits. This means that the last six combinations of bits (A-F) are effectively wasted—not possible in the BCD structure.

The BCD structure or base also is still usable in many of the newer touchscreens, but most programmers tend to choose an integer base to express decimal numbers. BCD is sort of like DOS; engineering schools still touch on it, but people really don’t know where it comes from. Referring to old thumbwheels and seven-segment displays may help clear up some of the mystery and “why” of BCD. Advantages of reusable code for PLCs

Many programmers base their knowledge and abilities on experiences with Allen-Bradley products from Rockwell Automation since much of the installed base in manufacturing consists of A-B PLCs. Rockwell Automation’s ControlLogix family was a huge jump in PLC capabilities with enhancements such as being tag-based, allowing the use of user-defined data types (UDTs), and add-on instructions (AOIs). Tags could also be local to each program, allowing them to be duplicated for re-use.

Those capabilities, except for being tag-based, already existed years before that on other platforms.

International Electrotechnical Commission (IEC) www.controleng.com

EN

B4 B3 B2 B1

Reusable code block

EN 0

Variable 1

Word1 in

Word1 out

Variable 3

Constant

Word2 in

Bit1 out

Variable 4

Variable 2

Bit1 in

61131 for programming languages has existed since 1993 or so, and other PLCs leveraged that early on.

An important difference between the older, registeronly based systems and more modern ones is the ability to build re-usable code blocks. Supporting platforms must have three features:

1. Local vs. global variables. Re-usable code must have variables that apply to each instance of the code; ideally only formatting the data once for the original code. What this means is that a list of tags or symbols should not have to be re-named for each instance or call. Duplicating a subroutine several times and iterating the addresses inside of it, though it saves time, isn’t really re-usable code.

Reusable code for programmable logic controllers (PLCs) provides users with flexibility and allows structures to be built that can be exported from one application to another.

2. UDTs. Creating UDTs allows structures to be built that can be exported from one application to another. They allow components to be described using generic terms such as “Speed,” “Start,” and “Reject.” UDTs don’t require tag-based systems, but they do require an advanced use of symbols.

3. Protectable self-contained blocks. It is important that the code be contained in a block that allows variables to be passed in and out, and protected so that users can’t change a specific instance of it. This requires a password or software key.

These are just some requirements. Other features like being able to write code in other IEC-compliant PLC languages also help make platforms much more powerful and “rapid code development” friendly.

Regardless of whether the platform uses subroutines with local variables or customizable instructions, reusable code is a critical part of creating powerful programs quickly. Many platforms allow reusable code, and each has its own methods. ce Frank Lamb, a Control Engineering Editorial Advisory Board member, is the founder of Automation Consulting Services Inc. This material originally appeared on the Automation Primer blog. Automation Primer is a CFE Media content partner. Edited

by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com.

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SAFETY networks

Safety over industrial communication networks Industrial Ethernet is becoming easier to use for industrial safety applications. Standards, trends, and technologies are helping with industrial Ethernet-based safety systems.

I

mplementation of an industrial safety network using Ethernet can be simpler with more standard configuration tools that are easier to program and use, reducing cost and complexity.

Standards for safety-rated protocols

MORE

ADVICE KEY CONCEPTS The requirements for modern digital safety systems.

Standards for transmitting safetyrated protocols.

Advanced technology for safety programming tools.

GO ONLINE For related links, read this article online. In the digital edition, click on the headline or search the headline at www.controleng.com. Also search “SIL3” for more safety coverage and search “safety” in the New Products for Engineers Database, www.controleng.com/NP4E. CONSIDER THIS Since safety systems could be networked instead of hard wired, what savings have you realized?

The majority of the standards for transmitting safety-rated protocols via Ethernet have been around for more than 15 years. The major specifications that define the requirements of modern digital safety systems are contained in the following standards, International Electrotechnical Commission (IEC) 61508 Functional Safety of Electrical/Electronic/Programmable Safety-Related Systems and IEC 61784-3 Industrial Communication Networks - Profiles - Part 3: Functional Safety Fieldbuses - General rules and profile definitions. (Safety-over-EtherCAT protocol is referred to as functional safety communication profile [FSCP 12] in the IEC 617843 specification.) The first digital safety systems were dedicated controllers with separate, proprietary communication buses. This was a step forward for safety implementation, but required additional hardware, programming software, licenses, and an additional fieldbus for the machine designer and end users.

The availability of fast and efficient industrial Ethernet systems such as EtherCAT made it possible to use the “black channel” approach

Table: Safety function commands for drives Safe torque off (STO): Shuts off power to the motor without disconnecting power to the drive. STO is used for emergency stop situations and to prevent unexpected motor movements.

Safe stop: Uses a controlled ramp-down (deceleration) to safely stop the motor, and then activates the STO function.

Safe position: This function transfers the safe position actual values of the drive to the higher-level controller. This function can be used to implement a reliable range positional travel for specific axes. If the safe position is out of range the axis will STO to prevent motion.

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recommended in IEC 61784-3. However, this was accompanied by the important recommendation that the safety data channel not exceed 1% of the maximum failure probability of the target safety integrity level (SIL) safety rating for which the safety profile is designed.

This enables safety protocol containers to be “tunneled” inside the fieldbus system, considerably simplifying the hardware and software for safety systems. Most devices for EtherCAT functional safety over EtherCAT (FSoE) are rated for SIL3.

Trends for FSoE

The trends for FSoE have been the acceptance of safety logic controllers and safety input/output (I/O) devices from multiple vendors. There are 27 companies making products that complement a FSoE system. This falls in line with the multivendor acceptance of EtherCAT in general, which has 200 master controller vendors, 105 I/O vendors, and 160 drive vendors.

Additionally, the availability of servo drives with safe motion functions onboard has streamlined automation design for vendors and users of motion control products because the motion controller can issue safety function commands directly to drives for safe stop, safe torque, and safe position (see Table). In addition, there is no longer a need to power down the drives, which was always a point of debate when considering whether a freewheeling flywheel, for example, actually established the safest conditions following an E-stop button push.

The benefits of advanced technologies

Configuration tools for FSoE have become more standardized over time. Users no longer have to maintain separate safety programming tools or licenses for each vendor’s products.

Configuration and programming tools are available for free from multiple EtherCAT hardware and software vendors, and these can configure any vendor’s FSoE devices, eliminating the need for additional programming tools, training for www.controleng.com

Through next-generation communication protocols such as EtherCAT, modern safety concepts still can be connected with legacy fieldbus systems.

Courtesy: Beckhoff Automation

‘

Users no longer have to maintain separate safety

additional software platforms and programming languages, and the need to purchase and maintain additional licenses. This enables the FSoE user to easily implement a SIL3-based safety system while reducing cost and complexity. In addition to the budgetary benefits, users also will be able to implement more

safety technology in more places as a result of these savings. ce Joey Stubbs is a North American representative at EtherCAT Technology Group. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com.

input #17 at www.controleng.com/information

programming tools or licenses for each vendor’s

’

products.

SAFETY networks

Industrial fail-safe, node-to-node communication CIP Safety, for functional safety applications on EtherNet/IP and DeviceNet networks, provides fail-safe communication between nodes.

F

‘

To better meet application needs, users also can design a network architecture with or without a safety PLC.

’

or safety applications, nodes may be safety I/O blocks, safety interlock switches, safety light curtains, and safety programmable logic controllers (PLCs) in safety applications up to Safety Integrity Level (SIL) 3, pursuant to International Electrotechnical Commission (IEC) 61508 standards and as certified by TÜV Rheinland. Since 2005 Common Industrial Protocol (CIP) Safety devices have been working in the field. CIP Safety has been adopted

by Sercos International as the only safety protocol for Sercos III networks, in addition to use in EtherNet/IP (the ODVA Ethernet protocol) and DeviceNet (ODVA device communication).

The capability eases integration and increases flexibility, because with CIP’s safety application coverage, applications can mix safety devices and standard devices on the same network or wire.

Single channel (non-redundant) hardware can be used for the data link communication interface because the safety application layer extensions do not rely on the integrity of the underlying standard CIP services and data link layers. This same partitioning of functionality allows standard routers to route safety data.

Data integrity at the end device

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ADVICE KEY CONCEPTS CIP’s safety application coverage The benefits of CIP safety on EtherNet/IP CIP safety technology requirements.

GO ONLINE For related links about CIP safety, read this article online. In the digital edition, click on the headline or search the headline for www.controleng.com. Also search ODVA and Sercos.

CONSIDER THIS In addition to networked motion applications, how is safety technology growing to address safety concerns?

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Because the end device is responsible for ensuring the integrity of the data, routing safety messages is possible. The end device will detect the failure and take appropriate action if an error occurs in data transmission or in the intermediate router. Without gateways, but by incorporating safety functionality into each device, safety devices from multiple manufacturers can communicate across EtherNet/IP or DeviceNet networks.

To better meet application needs, users also can design a network architecture with or without a safety PLC. This routing capability allows the creation of CIP Safety cells with quick reaction times on one network, such as DeviceNet, to be interconnected with other cells via other networks, such as EtherNet/IP. Only the safety data that is needed is routed to the required cell, which reduces the individual bandwidth require-

CONTROL ENGINEERING

ments. The combination of fast-responding local safety cells and the inter-cell routing of safety data allows users to create significant safety applications with fast response times.

Protocol for control, safety, energy, more

CIP, an object-based protocol, encompasses a comprehensive suite of messages and services for the collection of industrial automation applications—control, safety, energy, synchronization and motion, information and network management—and allows users to integrate these applications with enterprise-level Ethernet networks and the internet. EtherNet/IP—the adaptation of CIP on standard Ethernet technology Institute of Electrical and Electronic Engineers (IEEE) 802.3: Standard for Ethernet combined with the transmission control protocol (TCP)/internet protocol (IP) suite)—provides users with the network tools to deploy industrial automation applications while enabling internet and enterprise connectivity, resulting in data anytime and anywhere.

Because CIP Safety devices have CIP functionality, CIP Safety is connected through a CIP object: the safety validator object. This object is the interface between link layer connections and safety application objects, and it ensures the integrity of safety data transfers. CIP Safety does not prevent communication errors from occurring. Instead, the safety validator object detects communication errors and allows devices to take appropriate actions while ensuring transmission integrity.

CIP Safety uses safety cyclic redundancy checks (CRCs), data cross-checking, and timestamps to ensure the integrity of the safety information. These measures detect the possible corruption and/or delay of safety data that is transmitted. In addition, the use of end-to-end safety CRCs eliminates certification requirements for intermediate devices, allowing the safety protocol to be independent of the network technology. While individual link CRCs are not relied on for safety, they still provide an additional level of protection and noise immunity by allowing data retransmission for transient errors at the local link. www.controleng.com

With networked motion applications growing as a critical area for safety technology, ODVA, the organization that manages the CIP Safety technology, expanded application coverage of CIP Safety to include safe motion. Using the safety functions defined in IEC 61800-5-2: (Adjustable Speed Electrical Power Drive System – Part 5-2: Safety Requirements – Functional as a framework, ODVA defined the requirements to use safe motion in systems deploying CIP Safety, allowing users to deploy networked motion control systems using EtherNet/IP and Sercos III in applications requiring safe motion functions, such as safe torque off and safety limited positions. The resulting CIP Safety services for safe motion include support for drives on EtherNet/ IP and Sercos III. Devices that succeed in meeting the requirements for ODVA’s CIP Safety conformance test and are certified by an authorized competent body for full compliance with IEC 61508 will receive a Declaration of Conformity from ODVA indicating compliance with the CIP Safety specification.

ODVA’s conformance testing process provides the general industry with the vendorindependent assurance that products built to

‘

The resulting CIP Safety services for safe motion include support for drives on

’

EtherNet/IP and Sercos III.

the CIP Network specifications comply with those specifications. Products built to CIP Safety are required to hold a Declaration of Conformity from ODVA to demonstrate to the industry that the device has been successfully exercised against tests designed to help ensure compliance with the specification and with interoperability with other products. Due to demand, ODVA has expanded the number of test service providers it has authorized to test CIP Safety devices. Vendors can now submit products to multiple labs in Germany and in the United States to receive a Declaration of Conformity for CIP Safety. ce Katherine Voss is ODVA’s president and executive director. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com.

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According to the study, the top situations in which end users purchase new HMI software and/or hardware are an automation upgrade (28%), a new installation (20%), and an operations/engineering upgrade (11%). In addition; over the past 12 months, the average respondent’s company was estimated to have been spent $127,000 on HMI software and hardware; and an average of $123,000 is expected to be spent in the next year on these products.

Access the 2017 HMI Software & Hardware report with additional findings and insights. www.controleng.com/2017HMIReport

SAFETY networks

Safety layer for networks PI North America, the organization for Profinet and Profibus, explains use of the ProfiSafe safety network on top of industrial Ethernet, Profinet, and device-level Profibus networks.

N

etworked safety for PI North America involves using ProfiSafe, an additional software layer used on top of Profinet (industrial Ethernet) and Profibus (device-level) networks.

According to PI North America, ProfiSafe: Adds functional safety to an existing automation network, running on the same cables.

Compared to wired circuits, requires less engineering, less cable, faster commissioning, and easier maintenance.

Has been available since 2001 with nearly 7 million ProfiSafe devices in operation in 2016.

Can be used with wireless (such as WLAN and Bluetooth) and with open Ethernet backbones.

Works by reducing error probabilities in

MORE

GO ONLINE See an application story about how ProfiSafe was used with the Boeing 787 Dreamliner, as integrated by Advanced Integration Technology (AIT).

Link to more from PI North America. http://us.profinet.com/technology/profinet/ CONSIDER THIS If you’re hardwiring safety, have you considered savings available by implementing a safety network?

JULY 2017

Can be used for safety applications up to SIL3 according to IEC 61508/IEC 62061, or Category 4 according to EN 954-1, or PL “e” according to ISO 13849-1.

To implement ProfiSafe, one must first assess risks, determine a mitigation strategy (including controls, guarding, signage, etc.), use a ProfiSafe controller and input and output devices, and finally, reassess periodically. ProfiSafe also can integrate AS-i Safety at Work, said Michael Bowne, PI North America, executive director, citing ProfiSafe training materials. ce Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.

78%

Control systems

KEY CONCEPTS A safety network has been available to use with Profinet and Profibus.

ProfiSafe safety network is more flexible and less costly than hardwired safety.

Use of ProfiSafe has been carefully documented and help is available from the PI North America organization.

|

Operates without interference, avoiding impact on connected standard bus protocols and automation systems.

Which technology or service do you buy or specify that use, connect with, or support mobility, Ethernet, or wireless technologies?

ADVICE

40

transmitted data between certified devices and controllers and includes safety checks.

Wired or wireless networking I/O and systems

64% 62%

HMIs, SCADA, historian, etc.

PCs, IPCs, mobile devices, embedded, etc.

50% 49%

Motors, drives, and actuators Process/discrete sensors, vision systems, power supplies Power distribution systems, power protection, enclosure systems

42% 39% 38%

Pumps, valves, positioners Analytical instruments, test, or calibration equipment

36% 31%

Safety for process or machine systems

30%

Motion control systems and robotics Design, analytics, PLM, ERP, MES, batch, scheduling, SCM, IoT

17%

Controllers, networking equipment, and operator interface software are the most used technologies to support mobility, Ethernet, or wireless technologies. Safety devices were used by 31% of respondents for networking. Courtesy: Control Engineering 2016 Mobility, Ethernet, Wireless Report

CONTROL ENGINEERING

www.controleng.com

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Register for the IIoT series today at www.controleng.com/lloT

ENCLOSURES for automation

Thermal management requirements for edge computing Edge computing requires several variables to be considered and an advanced climate control solution.

E MORE

ADVICE KEY CONCEPTS Requirements to consider for edge computing Defining edge computing and its benefits How to protect equipment with proper thermal management.

GO ONLINE For related links about edge computing, read this article online.

In the digital edition, click on the headline or search the headline for www.controleng.com Read more online about protecting equipment with thermal management and the criteria to consider in edge computing.

CONSIDER THIS What benefits would more efficient enclosure cooling offer beyond energy savings?

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dge computing houses data processing capability at or near the “edge” of a network facility. Usually servers are contained in a micro data center, with as few as one or two enclosures. Data which is mission-critical, such as a component malfunction or a software defect, is captured and available in real-time on-site. Edge computing is valuable in capturing bandwidth-intensive and latency-sensitive data for analysis, lowering operating costs and improving energy efficiency. Lower-priority data can be sent to the cloud or to a remote data center.

Companies are recognizing the importance of incorporating edge computing into their processes. However, a basic rack-mounted enclosure is still a challenge. In edge computing, server rack density and small footprints are key components to provide the near-user computing data.

However, power consumption of a server rack is converted to heat which is deadly to IT systems.

And the smaller the space, the more the temperature rises. Thus, thermal safety is a paramount priority.

Checklist requirements for edge cooling

To determine the correct cooling solution for an edge computing microcenter, and prepare a plan that allows for correct sizing of the center, assess the distinct obstacles for edge computing.

Of all the concerns for an edge data center, cooling capacity consistently rates as a primary focus. A requirements checklist includes: Select a climate control system that is well-matched to the heat output of the edge data center Provide adequate airflow to each server rack Assure operational reliability of the cooling and redundancy system Maintain constant acceptable levels of temperature and humidity

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Have options for scalability at the rack level and at the edge data center as a whole.

Evaluating the variables in edge computing

Heat dissipation and the inherent heat problems in edge computing require modular climate control systems. An energy-efficient and advanced climate control and cooling concept for edge computing takes these variables into account: Temperature Humidity The velocity and pressure of airflows Heat losses of the installed components.

Consider these fundamental criteria and variants in the design phase: What type of liquid cooling package (LCP) cooling system should be installed? Whether or not a water- or refrigerant-based system is used can depend on the environment and the availability of a water supply.

Will the amount of racks and enclosures require hot and cold aisles? Cold aisle containment usually requires a raised floor.

What average temperatures should be maintained in the racks? It is still widely accepted that racks should be maintained at a cooler temperature, no more than 68 ° to 72 °F. The setpoint temperature required depends in part on the heat output calculations for the rack enclosure. With densely-populated edge centers, additional cooling power may be needed to offset the higher heat loads.

What is the volumetric flow rate of cooled air required? Calculating the airflow requirement for each center depends on the rack requirements to design an efficient airflow strategy. www.controleng.com

What are the ambient conditions? Temperature extremes in either direction will affect the energy required to maintain an acceptable environment for the racks. The degree to which ambient temperature may assist or hinder cooling may depend on the efficiency of the system and the density of the racks.

Where will the airflow be directed? Directing the cooler airflow to the front of the racks is desirable, but how will the heated air be discharged?

Do load fluctuations exist and what impact do these have on the cooling response times?

If the operation of the data center will see variations in energy use, a selected cooling system should be adaptable to the variations in power needs.

Should the system be scalable for future expansion? Having a system that can adapt to baying or can support additional rack cooling over the existing needs will eliminate costs if additional computing power is needed.

Cooling the edge computing microcenter can be approached most effectively via a liquid cooling system, either inline-based, rack-based, or a combination of both. There are two heat transfer media (water and refrigerant) that can work with these systems. Water offers exceptional cooling properties, well-suited to the high heat output of an edge system.

Refrigerant-based cooling is well-suited to small or medium edge enclosures, especially when a water supply is not readily available. Refrigerant cooling often operates with a smaller footprint, efficient in microcenters. In both cases, energy efficiency is a consideration. The energy-efficient, IT climate control system considers: Dimensioning of the cooling systems to match the actual power requirements Separation of cooling for server racks and room air conditioning by partitioning of aisles Use of energy-efficient components, such as electronically commutated (EC) fans that include power regulation of the cooling compressors Keeping the cooling water and room temperatures as high as possible Controlling all subsystems and continuous adaptation to the actual cooling power requirements.

Liquid cooling for thermal management

As data centers concentrate high-power servers in smaller footprints, the challenge of www.controleng.com

cooling these systems is greater. The power density of these server racks has increased from 2-8 kW per enclosure to more than 100 kW. Providing a liquid cooling package (LCP) for an enclosure (suite-based or rack-based) can efficiently dissipate heat from IT racks. Applications may include aisle containment or closed-loop cooling of single- or dual-IT-rack enclosures.

LCPs are a reliable, cost-effective cooling means to provide cooling capacity of 3 kW, up to as high as 60 kW. LCP devices support ITcompatible cooling and can achieving up to 50% energy savings using intelligent control, free cooling, and additional fans that keep a steady volumetric flow and a constant cooling output.

In IT data centers confined in small spaces, such as edge computing, heat build-up is rapid, and an LCP matched to the enclosure can provide efficient closed-loop cooling. With highperformance EC fan technology, refrigerant cooled air is targeted to the racks. Servers are cooled independently from the ambient air, easily adapted to one enclosure or a modular series.

Certain LCPs are designed for a bayed enclosure suite. Hot air from the room or hot aisle at the rear of the device is efficiently chilled by the high-capacity variable speed compressor and the refrigerated air is directed back into the room or cold aisle after cooling. Other attributes of an LCP may include air path control, small footprint, a design that augments fan life, redundant fan design, and efficient cool-air flows.

With the ever-increasing densities and demands for more capacity, the protection of vital IT data from edge applications to large legacy data centers requires the reliability and selection of thermal management products. Energy efficient design lowers operating costs, while IT components work at capacity. ce

Closed-loop cooling ensures edge data centers are protected from environments that have uncontrolled and fluctuating temperatures.

See this article online for a diagram showing thermal flow inside an enclosure. Courtesy: Rittal

Hans Baumann is a product manager at Rittal Corp. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com.

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POWER QUALITY electrical distribution

Transfer switches: Which configuration is best?

When it comes to picking the right transfer switch for a facility, engineers need to consider many aspects such as system installation, operation modes, and switching mechanisms to help prevent downtime in the event of a power outage.

M

any commercial and industrial facilities require continuous uptime to maintain business continuity in the event of a power outage. For this reason, these facilities rely on electrical distribution equipment such as transfer switches to safely transition electrical power between normal and emergency power sources.

Not all transfer switches are alike, however. The sheer number of available options and configuration modes can be daunting for an engineer while designing a system. Because of that, engineers need to understand the configurations available to determine what is correct for the application’s needs when implementing transfer switch technology.

Common system installation types

Engineers first need to understand their system installation type to determine the best transfer switch. The National Electrical Code (NEC) defines four categories for transfer switches: emergency systems, legally-required systems, critical operations power systems, and optional standby systems.

MORE

ADVICE KEY CONCEPTS Engineers need to understand what is correct for their unique needs when implementing transfer switch technology.

Factors engineers need to consider include system installation, transition types, switching mechanisms, and operation modes.

Picking the right transfer switch technology will keep a facility up and running in the event of an outage or power loss.

GO ONLINE Read this article online at www.controleng.com for more stories about transfer switches.

CONSIDER THIS What other factors should be considered when selecting a transfer switch for a facility?

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Emergency systems Emergency systems supply, automatically distribute, and control electricity used by systems essential to life safety during fires and similar disasters. They include fire detectors, alarms, emergency lights, elevators, public safety communication systems, and ventilation systems. They are often found in hotels, theaters, arenas, and hospitals. And they are regulated by a municipal, state, federal, or other government agency. They require the transfer of power from the normal to emergency power source to be completed within 10 seconds.

Legally required systems Like emergency systems, legally-required systems are government-regulated, but they are designed to automatically supply power to a selected set of regulated tools that are not classified as emergency systems. These systems serve functions such as critical heating, refrigeration, communication, ventilation, and lighting that could cre-

CONTROL ENGINEERING

ate hazards or interfere with rescue or firefighting operations if electrical power is unavailable. Power transfers between normal and emergency sources must be complete within 60 seconds.

Critical operations power systems (COPS) These systems supply, distribute, and control electricity in designated control areas when a normal power source fails. These include HVAC, fire alarm, security, communication, signaling, and other services that the authority having jurisdiction (sometimes a government agency) has deemed important to national security, the economy, or public health and safety.

Optional standby systems Operational standby systems are not required to function automatically during power failures.

They supply power to loads with no direct impact on health or life safety. These systems are most common in commercial buildings, farms, and residences.

Understanding transition types

There are two basic ways transfer switches can transition loads between normal and emergency power sources: open or closed. The specific functions performed by a given load and the importance of those functions to safety or security play an important role in determining which kind of transition is required.

Open transition An open transition is a “break before make” transfer, meaning the transfer switch breaks its connection to one power source before making a connection to the other. For some time between disconnection and connection, neither the normal power source nor the emergency source is providing electricity to downstream loads. There are two kinds of open transition: open delayed and open in-phase.

Open delayed transition In an open delayed transition, the transfer switch pauses in-between disconnecting from one www.controleng.com

power source and connecting to the other. That delay typically lasts either a specific, pre-set amount of time, or however long it takes the load voltage to drop below a pre-specified level.

Open in-phase transition With open in-phase transitions, an automatic controller uses built-in intelligence to execute an open transition at the precise moment it expects the normal and emergency power sources to be synchronized in phase, voltage, and frequency. If synchronization doesn’t occur within that time span, some transfer switches have the ability to default automatically to a delayed transition that serves as a failsafe.

Closed transition A closed transition is a “make before break” transfer, meaning the transfer switch makes a connection to the new power source before breaking its connection to the old one. Because there is no gap between disconnection and connection, downstream loads receive continuous power throughout the transfer process.

Switches configured for closed transitions usually transfer power automatically as soon as both power sources are closely synchronized in phase, voltage, and frequency. The overlap period during which both sources are simultaneously connected, or “paralleled,” usually lasts no more than 100 ms to comply with local utility interconnect requirements.

Switching mechanisms

The switching mechanism is the part of a transfer switch that is physically responsible for carrying the rated electrical current and shifting the load connection from one power source to another. Low-voltage switching mechanism technology comes in two basic varieties: contactor type and circuit breaker type. Circuit breaker switching mechanisms can be further divided into two sub-types: molded case and power case.

Contractor switching mechanisms Contractor switching mechanisms are the most common and affordable. These mechanisms often are constructed as a double-throw switch where an electrical operator opens one set of power contacts while closing a second set. In an open transition design, a mechanical interlock often is employed to prevent simultaneous closure of both contact sets.

In a closed transition design, the mechanical interlock is absent. Contactor switching mechanisms are designed to support all three transition types: open delayed, open in-phase, and closed. These mechanisms don’t include integral overcurrent protection, www.controleng.com

so the power contacts are not self-protecting.

Molded case switching mechanisms Molded case switching mechanisms are used routinely for closing and interrupting a circuit under both normal and abnormal conditions.

They are capable of supporting a mechanically operated, over-center toggle or a motor operator.

When configured for use in a transfer switch, a pair of molded case switches are operated through an interlocking mechanical linkage, which can be driven manually or automatically. These mechanisms provide a compact, cost-effective and service entrance-rated solution, as they eliminate the need for additional upstream protective devices.

Power case mechanisms Power case mechanisms are larger, faster, and more powerful than molded case mechanisms.

The two-step stored energy technology they use can be operated mechanically and electrically, and some models feature integral overcurrent protection similar to what typically is found in molded case designs. Their high interrupt rating also makes power case mechanisms a good fit for applications vulnerable to large fault currents.

Operation modes

Power transfers involve two processes: initiation and operation. Initiation is what starts the transfer, while operation is what completes it. Most transfer switches can support multiple operation modes through the addition of configurable options.

Transfer switches can be configured in multiple ways to meet specific application needs.

Courtesy: Eaton

‘

High interrupt rating also makes power case mechanisms a good fit for applications vulnerable to large fault

’

currents.

Manual mode In manual, initiation and operation are performed manually, usually by pushing a button or moving a handle, giving the operator maximum control of the transfer. An advantage CONTROL ENGINEERING

JULY 2017

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POWER QUALITY electrical distribution

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For repairs, a technician can bypass power ...to ensure that critical loads

.

remain powered without

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interruption.

CFE Media’s

of manual operation is, with molded case or power case designs, transfers can occur under load as a failsafe if the automatic controller sustains damage or becomes inoperable.

Non-automatic mode In non-automatic mode, the operator manually initiates a transfer by pressing a button or rotating a switch that causes an internal electromechanical device to electrically operate the switching mechanism. This device allows transitions to be completed more rapidly than they would with manual mode.

Automatic mode Automatic mode involves the transfer switch controller completely managing initiation and operation, which can reduce delay time compared to manual and non-automatic mode. Initiation is triggered when the automatic controller senses an unavailability or loss of source power and operation typically is performed by an electric solenoid or motor. While this mode completes the transfer in the shortest time and isn’t dependent upon a human operator, automatic transfer switches tend to cost more than devices that operate only in manual or non-automatic mode.

Bypass isolation mode Bypass isolation mode allows users to service transfer switches safely without compromising availability. Traditional transfer switches feature one switching mechanism, but bypass isolation transfer switches include dual-switching mechanisms that provide redundancy for critical applications.

The primary switching mechanism handles dayto-day distribution of electrical power to the load, while the secondary switching mechanism provides backup. During repair or maintenance, a technician can bypass power around the primary mechanism through the secondary mechanism to ensure that critical loads remain powered without interruption.

Determine the right configuration

Transfer switches support multiple operation modes and transition types, and feature a range of different switching mechanisms. By understanding the configurations and choosing the right switch, control engineers can help keep a facility running in the event of an outage or power loss, to help the business’ bottom line. ce

Charlie Hume is Eaton product line manager, automatic transfer switches; edited by Chris Vavra, production editor, Control Engineering, cvavra@cfemedia.com.

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INSIDE PROCESS safety integrity

Safety integrity level for a process application Safety instrumented systems (SIS) are installed in process plants to mitigate process hazards, and they must be assigned a target safety integrity level (SIL) during the process to determine what needs to be done next.

S

afety instrumented systems (SIS) are installed in process plants to mitigate process hazards by taking the process to a “safe state” when predetermined set points have been exceeded or when safe operating conditions have been transgressed.

The SIS is one protection layer in a multilayered safety approach since no single safety measure alone can eliminate risk. A layer of protection analysis (LOPA) is a method whereby all known process hazards and all known layers of protection are scrutinized closely. For each process hazard where a LOPA study concludes that existing protection cannot reduce risk to an acceptable or tolerable level, an SIS is required. Not all process hazards will require the use of an SIS. Each hazard that requires the use of an SIS must be assigned a target safety integrity level (SIL).

What are SIL levels?

SILs come from two voluntary standards used by plant owners/operators to quantify safety performance requirements for hazardous operations: IEC 61508: Functional Safety of Electrical/ Electronic/Programmable Electronic Safety-Related Systems IEC 61511: Safety Instrumented Systems for the Process Industry Sector.

As defined in the International Electrotechnical Commission (IEC) standards, there are four SILs (1-4). A higher SIL means a greater process hazard and a higher level of protection required from the SIS. SIL is a function of hazard frequency and hazard severity. Hazards that can occur more frequently or that have more severe consequences will have higher SILs. To determine SIL of process hazards, it is helpful to understand the safety lifecycle. www.controleng.com

Safety lifecycle

The IEC standards define a concept known as the safety lifecycle, which provides a repeatable framework whereby all process hazards are identified and analyzed to understand which hazards require the use of an SIS for mitigation. By design, this is a cyclical process. Any changes in process design, operating conditions, or equipment require cycling back to the beginning to ensure any changes are implemented properly.

There are many steps to follow to determine SIL. The process starts with performing a process hazard analysis (PHA).

A PHA is a systematic assessment of all potential hazards associated with an industrial process. It is necessary to analyze all potential causes and consequences of: Fires Explosions Releases of toxic, hazardous, or flammable materials, etc.

MORE

Focus on anything that might impact the process including: Equipment failures Instrumentation failures or calibration issues Loss of utilities (power, cooling water, instrument air, etc.)

Human errors or actions External factors such as storms or earthquakes.

Both the frequency and severity of each process hazard must be analyzed: How often could it happen? Tank spills could happen any time there’s a manual fill operation (multiple times a year) How severe is the result? Localized damage, fire, explosion, toxic gas release, death.

ADVICE KEY CONCEPTS Safety instrumented systems (SIS) are designed to mitigate process hazards by taking the process to a “safe state.”

A process hazard analysis (PHA) is used to determine a plant’s safety integrity level (SIL) The overall failure probability of a given safety instrumented function (SIF) is determined by performing SIL calculations (SIL calcs).

GO ONLINE Read this story online at www.controleng.com and see additional stories from Cross Company in the “System Integration and Process Control” blog.

CONSIDER THIS What particular process plants benefit the most from SIL and why?

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JULY 2017

| P1

INSIDE PROCESS safety integrity Safety lifecycle model LOPA Apply Non-SIS Protection Layers to Prevent Identified Hazards or Reduce Risk

PHA Process Hazard Analysis & Risk Assessment

Conceptual Process Design

SIS Required?

Define Target SIL

SRS Develop Safety Requirement Specification

SPECIFICATIONS

SIL CALCS Perform SIS Conceptual Design and Verify it Meets SRS

Perform SIS Detail Design

DESIGN Example of a safety lifecycle model. Courtesy: Cross Company, adapted from IEC 61511

SIS Installation, Commissioning, & Pre-Startup SAT

INSTALL

JULY 2017

O&M For every process hazard identified in the PHA: List all available non-SIS safety measures Assign each layer its own hazard risk reduction factor Calculate an effective hazard frequency with protection layers applied.

A hazard which necessitates basic First Aid intervention could be considered “acceptable” if it happens only once a year An explosion and fire due to a tank rupture could have an “acceptable” frequency of once in 10,000 years.

Example: A tank fill operation that happens 250 times per year “could” experience an overfill event 250 times per year.

Fire suppression systems Leak containment systems (dikes or double walls) Pressure relief valves Gas detection/warning systems.

|

?

Changes

Core to the PHA analysis is the fact that things can and do go wrong. Forget whether it will happen and instead consider when it will happen. Each identified hazard is assigned an “acceptable” frequency. You cannot assume a hazard will “never” happen.

The end result of the PHA is a list of all possible process hazards with each one assigned an acceptable frequency of occurrence. The next step in the safety lifecycle is the layer of protection analysis.

No single safety measure alone can eliminate risk. For this reason, an effective safety system must consist of protective layers.

This way if one protection layer fails, successive layers will take the process to a safe state. As the number of protection layers and their reliabilities increase, the safety of the overall process increases.

It is important to understand that each layer must function independently from the others in case one or more layers fails.

Some specific examples of protection layers include:

P2

SIS Start-up, Operation, Maintenance, Periodic Functional Testing

CONTROL ENGINEERING

A protection layer in the form of a proper vent/drain system could reduce the danger by a (risk reduction) factor of 100 The hazard resulting from tank overfill would have an effective frequency of 250/100 = 2.5 times per year.

After the effective hazard frequency of each hazard is known, the key question to ask is: “With non-SIS protection layers applied, is the effective frequency lower than the acceptable frequency?”

Once all process hazards are identified and protection layers assigned, if the PHA/LOPA study concludes that existing protection cannot reduce risk to an acceptable or tolerable level, an SIS will be required. Not every process hazard, however, actually requires the use of an SIS. Safety instrumented systems, functions

The purpose of an SIS is to take a process to a “safe state” when predetermined set points have been exceeded or when safe operating conditions have been transgressed.

The role of the SIS is to reduce risk by implementing safety instrumented functions (SIFs). www.controleng.com

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INSIDE PROCESS safety integrity

‘

Each safety instrumented function serves as a protection layer to bring the effective hazard frequency down below the acceptable hazard frequency.

’

Two examples of SIFs include:

Hazard: Tank overfill. SIF: The SIS stops the fill pumps at a predetermined safe level Hazard: High temperature. SIF: The SIS opens a relay to cut power to a heater circuit at a predetermined safe temperature.

In any case, an SIF is a safety function implemented by the SIS to achieve or maintain a safe state. An SIF’s sensors, logic solver, and final elements act in concert to detect a hazard and bring the process to a safe state.

Each SIF serves as a protection layer to bring the effective hazard frequency down below the acceptable hazard frequency. To do this, each SIF must have a minimum risk reduction factor.

Target SIL level of the SIF

With the tank overfill example, it was determined that after applying non-SIS protection layers there was an effective frequency of 2.5 times per year. If the acceptable hazard frequency is once in 10 years, then the SIF must have a risk reduction factor (RRF) of at least 25.

Minimum RRF of SIF = Effective frequency without SIS/Acceptable frequency = 2.5/0.1 = 25.

The minimum required RRF of each SIF is used to determine the target SIL level of the SIF.

Target SIL Level is determined directly from the RRF by using the table below. Note the relationship between SIL and RRF. SIL1 has a minimum RRF of 101, SIL2 has a minimum RRF of 102, and so on.

Table1: Required risk reduction factor (RRF)

P4

|

SIL

Required risk reduction factor (RRF)

1

10 to 100 (101 to 102)

2

100 to 1,000 (102 to 103)

3

1,000 to 10,000 (103 to 104)

4

10,000 to 100,000 (104 to 105)

JULY 2017

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For the tank overfill example, the minimum RRF is 25, the target SIL of the SIF is SIL1 and this is, therefore, an SIL1 hazard.

For each hazard identified by the PHA and LOPA that requires an SIF, a target SIL is assigned using the same methodology. Note that it is likely you will have various target SIL. The next step in the process is to design an SIS capable of implementing the required SIFs and reaching the target SIL. Achievable SIL of the SIF

The SIS is a system comprised of numerous components such as: Sensors for signal input Input signal interfacing and processing Logic solver with power and communications Output signal processing, interfacing, and power Actuators (valves, switching devices) for final control function.

An example SIF that consists of the SIS deenergizing a relay to open a heater circuit upon high temperature could have any or all of the following loop components: Thermocouple Transmitter Input signal conditioner or barrier Analog input card Communication card(s) CPU Discrete output card Output signal conditioner or barrier Heater circuit relay.

One must assume that a hazard will occur at some point. You cannot assume a hazard will never happen. Similarly, one must assume that any of the components of the SIF could fail to act upon demand.

One very common failure would be an isolation valve that remains open under normal process conditions. If this valve is required to close to achieve a particular SIF, it is possible that the valve could stick in the open position and not close upon demand. For this reason, one must know the failure probability the SIF. The overall failure probability of a given SIF is determined by performing SIL calculations (SIL calcs). SIL calcs are somewhat complex, but essentially, the process is to gather failure rate data for the SIF components and account for factors such as test frequency, redundancy, voting arrangements, etc. The end result is that www.controleng.com

for each SIF, you have an overall probability of failure on demand (PFD).

Failure rate data for the numerous pieces of equipment that make up SIF loops are published by equipment manufacturers. Companies frequently contract with consultants to determine failure rate values.

It is failure rate data that is required as an input to perform SIL calcs for an SIF, not SIL data. There is no such thing as an SIL-rated device. You can’t buy SIL-rated transmitters or SIL-rated control systems.

Once the PFD of the SIF is known, then its RRF is simply the inverse of PFD (RRF = 1/ PFD). You can then compare the SIF’s RRF to the minimum required RRF. If the SIF’s RRF is greater than the minimum RRF, then the SIF is sufficient to reduce the overall hazard level below the acceptable level.

Returning to our tank overfill example, let’s assume the SIL calcs prove the SIF has an RRF of 300. Since this is greater than 25, the SIF is sufficient. If the SIL calcs had found an RRF of less than 25, then changing or rearranging the SIF components would be necessary.

One way to increase the RRF is to install redundant transmitters in a voting arrangement

Table 2: Probability of failure on demand (PFD) SIL

PFD

RRF

1

1 in 10 - 1 in 100

10 to 100

2

1 in 100 - 1 in 1,000

100 to 1,000

3

1 in 1,000 - 1 in 10,000

1,000 to 10,000

4

1 in 10,000 - 1 in 100,000

10,000 to 100,000

or to purchase transmitters with lower published failure rates.

The relationship between SIL level, PFD, and RRF is demonstrated in Table 2.

Going back to the tank fill example, there was a minimum RRF of 25 (SIL1) with an SIF RRF of 300. The achievable SIL level of the SIF is SIL2. This means there’s an SIL2-capable SIF being used to protect an SIL1 hazard. This is perfectly acceptable and is not unusual. ce David Yoset is a project manager with Cross Company. This article originally appeared on Cross Company’s Integrated Systems blog. Cross Company is a CFE Media content partner. Edited

by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com.

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INSIDE PROCESS overall equipment effectiveness

Three ways to increase efficiency at a spirit manufacturing plant Spirit manufacturing plants can increase production and efficiency by setting realistic expectations, simplifying their models, and having third-parties perform an overall equipment effectiveness (OEE) analysis.

B

MORE

ADVICE KEY CONCEPTS Set realistic expectations and benchmarks with an overall equipment effectiveness (OEE) analysis.

Consider switching from a specialized bottle to a standard bottle.

Have a third-party designer conduct an OEE analysis.

GO ONLINE Read this story online at www.controleng.com for more information on spirit manufacturing and overall equipment effectiveness.

CONSIDER THIS What overall equipment effectiveness are you getting from your most critical processes?

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JULY 2017

ottling is one of the biggest challenges in spirit manufacturing. For spirit manufacturers, it’s not usually a question of: “Can we make this product?” but rather: “Can we get it into a bottle fast enough to fulfill all our orders?”

How you get your product into its bottle can easily bottleneck your entire operation. If your company is wondering why you’re experiencing inefficiency problems, you might want to look at your equipment, bottle types, and/or overall processing lines. Consider these three tips for ramping up production and boosting efficiency.

not just equipment—and compares your current operations to what your potential, ideal output could be. For example, a simulation may determine your equipment is capable of producing 1,000 bottles in a minute, but an OEE analysis can reveal how this will actually play out given your current processing and setup.

A variety of factors can affect your plant’s efficiency, whether it’s cumbersome changeovers or an unproductive number of meetings.

Simple revisions to your facility’s everyday activities often can boost efficiency without the need to buy new equipment.

1. Set realistic expectations and benchmarks with an overall equipment effectiveness (OEE) analysis

2. Consider switching from a specialized bottle to a standard bottle

Processors sometimes question why their equipment is underperforming, asking, for example, “We bought a machine that can produce 500 bottles a minute, so why won’t it?” Of course, the reason could involve a host of variables, but it’s easy to first blame the machine.

Though sometimes increasing throughput is a matter of buying more equipment, you have to establish realistic key performance indicators (KPIs) before you invest in new technology, Don’t design for the impossible.

Don’t expect that 500-bottles-per-minute machine to produce 500 bottles per minute if you haven’t looked at overall OEE. New equipment alone won’t make up for problems in an OEE. The first step in improving efficiency is understanding your baseline and establishing realistic goals. One of the best ways to do that is through an OEE analysis, which incorporates a virtual simulation to study your plant’s existing processes and packaging.

This type of analysis factors in all the variables that determine how your plant operates—

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One of the most unique elements of spirit manufacturing is the packaging. When it comes to liquor, the bottles themselves often are elaborate marketing tools.

However, producing a variety of SKUs means packaging lines have to be designed to handle changeovers for a number of these specialized bottles.

If you’re producing multiple products and considering OEE, ask these questions: How fast are current changeovers?

How many bottles actually stay on the line?

How fast can the equipment function with a specialized bottle versus a standard bottle?

If efficient output is a concern, consider switching to a standard bottle type. Designing a packaging line around a standard bottle will decrease changeovers and make stocking easier. While marketing is crucial in spirit manufacturing, standardizing the bottle type may be even more important if it’s the difference between inefficiency and an optimized, profitmaximizing throughput. www.controleng.com

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INSIDE PROCESS safety integrity 3. Have a third-party designer conduct an OEE analysis

If you feel like you’ve hit a plateau in manufacturing, a third-party designer may help you get your processing on track: Start by understanding your equipment: What are its capabilities? How old is it?

Then analyze how your plant is operating: What’s going wrong? What’s being done right? What are your output numbers?

You’ll need this information when researching a partner for an OEE analysis, but how do you know if it’s worth your time? Here are some basic signs that it’s time to call a designer: Lower than expected production rates from equipment Lower than expected plant production rates overall Excessive changeovers A multitude of floor problems on the lines Extensive bottle breakage Extensive shutdowns Extensive downtime.

‘

Simple revisions to your facility’s everyday activities often can boost efficiency without the need

’

to buy new equipment.

These red flags usually are easy to spot, but many times they will go unaddressed or accepted as the norm. Spirit manufacturing is a unique niche with unique needs. Before approving the purchase of major equipment or other significant changes, do your research to understand where you should invest your money to get the best ROI. ce Scott Baesler is a senior project manager at Stellar. This article originally appeared on Stellar Food for Thought. Stellar is a CFE Media content partner. Edited by Jack Smith, content manager, Control Engineering, CFE Media, jsmith@cfemedia.com.

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CFE Media’s

Global System Integrator Database CFE Media’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.

The newest version of the online database is even easier to use.

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More resources posted daily at:

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digital edition Exclusives, Online Extras: Benefits of the Control Engineering Digital Edition include tablet-friendly viewing (HTML5), exclusive content in every issue; headlines link to the longer version posted online; links are live where a URL is provided; and an email link arrives when ready. In addition, link to additional “Online Extra” articles.

DIGITAL EDITION EXCLUSIVES

DE1 Specifying enclosures for machine vision systems

Machine vision enclosure manufacturers aim to better understand and meet their customers’ specific needs for safe, fully integrated solutions, including solutions for use in harsh and dangerous conditions.

DE3 IT/OT convergence needs conflict resolution from both sides

Information technology (IT) and operations technology (OT) are very different organizations that have begun to converge, and they must start resolving their issues. Three tips for reducing potential conflict are highlighted.

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(Click on the headlines or search www.controleng.com.)

Digitization trends to leave large footprint on automotive industry A rise in average vehicle life, shift in repair opportunities and sales outlets, and emerging online sales have all created an opportunity for major growth in the automotive aftermarket industry that will likely continue to grow in the future.

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JULY 2017

| 57

DIGITAL EDITION exclusive

Specifying enclosures for machine vision systems Machine vision enclosure manufacturers aim to better understand and meet their customers’ specific needs for safe, fully integrated solutions, including solutions for use in harsh and dangerous conditions.

W

henever machine vision systems operate in a harsh environment, the systems require an enclosure that protects the investment within. However, an enclosure on an automotive inspection line will have different specifications and regulatory compliance requirements than an enclosure for process monitoring in a corrosive environment like a petrochemical plant. With this in mind, machine vision enclosure manufacturers are listening closely to the specific needs of customers as they relate to protective enclosures, and delivering solutions that are safe, robust, cost-effective, and fully-integrated.

Protection on the factory floor

MORE

ADVICE KEY CONCEPTS Machine vision enclosure companies are trying to make their products safe and useful for customized applications and harsh conditions.

Thermal imaging, which is used in remote condition monitoring and process control of critical industrial assets, is a major field for enclosures.

Companies are also developing enclosures for potentially explosive environments.

GO ONLINE Read this story online at www.controleng.com for more information about machine vision systems and enclosures.

CONSIDER THIS In what other dangerous or unsafe environments could enclosures be useful?

DE1

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JULY 2017

A food and beverage manufacturing facility may be more hygienic than hazardous, but can still take a beating due to the high-temperature, high-pressure washdowns with harsh cleaners needed to keep food-preparation areas safe.

Machine vision enclosures for food processing applications typically are made of type 316 stainless steel, which offers increased corrosion resistance and strength at elevated temperatures.

The enclosures also must have food contact-rated gaskets and must be designed to eliminate moisture traps where liquids might collect. What’s more, enclosures must be built without glass since it could shatter on impact, creating the risk of shards falling onto the food processing line.

Nearly all industrial enclosures are designed to an ingress protection (IP) rating. Enclosures in food preparation and packaging applications require IP65, IP66, and IP66K ratings to withstand water jets of increasing pressure.

Allison Park Group Inc. (APG) specializes in industrial enclosures for machine vision systems.

According to APG president Chris McGeary, more manufacturers are asking for even higher-rated enclosures. “Most food lines are sterilized regularly with a high-temperature pressure washer with

CONTROL ENGINEERING

some type of cleaning fluid in the spray,” McGeary said. “[Today], companies with food processing lines are selecting IP69K rating, and that will cover anything that they throw at it.”

The IP69K rating test method specifies a spray nozzle dispensing 176 °F water at 1,160 to 1,450 psi at a flow rate of 4 gallons per minute (GPM).

The nozzle is placed within 4- to 6-in. of the tested device, which rotates once every 12 seconds.

APG modifies its off-the-shelf enclosures according to the needs of the application. “We’ve made enclosures with acrylic viewports, but it turns out that on some food lines, the chemical used in the cleaning process attacks the acrylic, so you put in a polycarbonate window instead,” McGeary said. “In some cases it might be a hot environment, so we need to add a provision for cooling in the enclosure.”

In another instance, a food application operating amid potentially explosive gases or dust would require a custom product that includes an off-the-shelf explosion-proof housing as well as a pressurization system that keeps positive pressure within the enclosure.

The “get tough” trend is also being adopted by other manufacturing industries, such as automotive. Instead of choosing machine vision enclosures that only meet the NEMA 12 standard for designs that keep dust and dripping water at bay, customers are specifying IP65 because it stands up to the pressure of a garden hose, McGeary said.

The harsh and the hazardous

As a general rule, thermal imaging applications can pose the greatest challenge to the engineers tasked with protecting sensitive machine vision technology. “Most thermal cameras are inherently in rough industrial environments with a lot of heat exposure, or they might be in hazardous locations requiring explosion-proof installations,” said Markus Tarin, president and CEO of Movitherm. www.controleng.com

Thermal imaging is commonly used in remote condition monitoring and process control of critical industrial assets where a temperature anomaly could signal a dangerous situation.

For example, infrared cameras can remotely monitor flare stacks, which burn off gas waste in harsh and hazardous industrial locations like petroleum refineries and gas processing plants.

Thermal cameras also are exposed to a lot of heat in industries such as steel, requiring that enclosures be cooled via air or liquid.

Because enclosures for thermal cameras have a unique set of operational requirements, Tarin said customers should use a turnkey machine vision enclosure solution. “On the surface, designing an enclosure seems fairly straightforward, but many people do not understand all the technical intricacies required,” Tarin said.

“It can be a daunting task to get the camera integrated properly into an enclosure.”

Movitherm calibrates thermal cameras to account for transmission losses on the viewing glass, as well as performs thermal calculations to determine the correct type of cooling (and engineering those options in-house when applicable).

On the other hand, some enclosures require a heating element. “We have designed special highpowered heating systems for applications in Alaska, where conditions can be below the camera’s minimum operating temperature,” Tarin said.

“We’ve also done heaters to make sure the viewing glass doesn’t fog up or freeze over.”

Thermal camera enclosure manufacturers often offer other add-ons appropriate to the application. These include a sunshield for enclosures with direct exposure to sunlight, an automated windshield wiper that cleans the viewing window of dust and debris, and an air barrier surrounding the viewing glass that blows a steady stream of compressed air to prevent particles from settling.

Explosion containment and prevention

Thermal cameras operating in explosive atmospheres represent another challenging area that a qualified integrator can help navigate. Industry standards and regulations such as Europe’s ATEX directive and UL FM in the U.S. mandate that equipment be designed to minimize the occurrence and severity of accidental explosions. This can be accomplished with explosion-proof (“exproof ”) enclosures, which prevent any explosion transmission from the inside of the protection system to the outside. Another method, explosion prevention, uses a purge and pressurization www.controleng.com

system to ensure that hazardous particles or gases have been eliminated from the enclosure.

“Customers can’t just buy an ex-proof enclosure and put their own camera in it,” Tarin said.

“You need to be certified to integrate these things. The user is not allowed to ever open up that enclosure because as soon as they do, they lose the certification for that application.”

To meet growing demand for condition monitoring in explosion-hazard environments with extreme climate conditions, Automation Technology GmbH (AT) recently added several fea-

‘

Companies with food processing lines are selecting IP69K rating, and that will cover

’

anything that they throw at it. tures to its ex-proof enclosure. The product, which integrates an infrared camera, heater, and interface controller and is ATEX certified, accommodates cameras with an extended operating temperature range of -40 to 60 °C. AT also enlarged the protection window and added a sensor to measure the viewport’s temperature.

The complete package

According to Tarin, buying trends in the enclosure sector act as a microcosm of how U.S. customers currently specify their entire vision system: They’re looking for a one-stop shop.

“They really don’t care about the individual components so much as what the end solution can do for them,” he said.

Companies still care about cost and lead time, though. “We see customers who, if they can’t get something off-the-shelf, they would rather not do it at all and wait it out for another year or two to see if somebody comes up with something,” Tarin said. “They don’t want to pay custom engineering charges for enclosure projects. But they want a complete turnkey solution at an off-the-shelf price.” ce

Winn Hardin is contributing editor, AIA. This article originally appeared on the AIA website.

The AIA is a part of the Association for Advancing Automation (A3). A3 is a CFE Media content partner. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com.

CONTROL ENGINEERING

JULY 2017

| DE2

DIGITAL EDITION exclusive

IT/OT convergence needs conflict resolution from both sides Information technology (IT) and operations technology (OT) are very different organizations that have begun to converge and they must start resolving their issues. Three tips for reducing potential conflict are highlighted.

I MORE

ADVICE KEY CONCEPTS Information technology (IT) and operations technology (OT) have different goals and agenda, but they need to work together in today’s modern environment.

IT’s main priority is protecting data and company assets and OT’s main priority is making sure work processes are not hampered or slowed.

Strategic alignment, a joint task force, and pilot projects are three ways to get the two sides to work together and resolve potential conflicts.

GO ONLINE Read this story online at www. controleng.com for more information about IT and OT and additional stories from ISSSource.

CONSIDER THIS What other methods/strategies could be used to get the IT and OT to work together?

DE3

|

JULY 2017

nformation technology (IT) and operations technology (OT) are both responsible for resolving potential cybersecurity risks. However, both groups have different approaches and mindsets on the topic that are incompatible when they are brought together, which can led to conflict.

Pre-internet, the line between IT and OT was clear. The line has been blurred as technology has brought connectivity to nearly every device on the plant floor and in field locations. That enhanced connectivity is connecting IT and OT in new ways and, as a result, they are starting to converge.

Instead of conflicting with one another, which has been the standard mindset, they must start resolving their issues for their sake and the sake of the company as a whole.

Resisting convergence

IT and OT are resisting convergence happening all around them, said Luigi De Bernardini, chief executive of Autoware, a manufacturing execution system (MES) and smart manufacturing automation firm in Italy.

When working with clients in large manufacturing automation projects he found that, “Many manufacturers still see strong resistance to bringing information and operational technologies together, with mistrust coming from both sides.”

De Bernardini said that must change. “Continuing to operate separately not only slows the adoption of solutions based on technologies that fall outside of industrial control system (ICS) operations’ comfort zone, but also exposes companies to fault or security risks that could significantly impact production.”

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Different viewpoints

IT and OT are very different worlds with very different responsibilities. Fundamentally, IT secures data. An intentional or unintentional cyber threat could result in the loss of intellectual property, corporate financials, and employee or customer information—and the ripple effect can be costly, ranging from $200,000 to $4 million per incident.

In contrast, OT uses ICS logic to execute control processes, which produces a physical impact.

A cyber threat could have devastating physical consequences to critical infrastructure and services, employees, human life, and safety and the environment—as has been shown in numerous publicized incidents.

Different priorities

The different priorities of IT and OT are key to understanding why conflicts arise so easily between the two groups. IT’s top priority is to protect the data. OT’s priority is to protect the availability and integrity of the process, with security (confidentiality) coming last.

The security solutions each group might choose for the ICS operations environment may be different due to several variables such a regulatory and compliance requirements, network architectures, performance/production requirements, employee and environmental safety considerations, risk tolerance, and management and security goals.

Each group has a bias and a specific perspective when considering ICS cyber risks and consequences.

IT’s perspective

IT’s top priority is protecting data such as intellectual property, corporate financials, www.controleng.com

employee, or customer private data. They figuratively look across the demilitarized zone (DMZ) thinking of the many changes that could bring a stronger security posture to OT environments.

IT’s potential solutions include: Stronger network segmentation Access control lists to restrict and manage permissions and access to key resources Geographic or organizational groupings of data and assets Strong password hygiene Routine patching processes (automated and with much higher frequency) Security policies to apply everywhere.

OT’s perspective

OT’s top priorities revolve around availability. When considering suggestions from IT to secure ICS environments, OT will often invoke cybersecurity inertia to assure control processes and production yield are not placed at risk. Reasonable explanations for why ICS security cannot be implemented are: Fragile programmable logic controllers (PLCs) may not have enough memory to handle high traffic, such as a broadcast storm or unexpected function codes that cause a reboot.

Not all patches, even those released by ICS vendors, are required. It takes time to assess whether even the ICS-CERT advisories are appropriate for the devices in place.

Anti-virus or automatic patching is atypical and requires considerable testing, scheduling, and may even require vendor participation to assure warranties stay intact.

Flat network architectures are favored, with minimal or no subnets or secure zones to isolate unrelated systems and processes. In this way, OT can minimize performance latency that could disrupt timesensitive processes, and all resources are easily available to operators should they need to quickly pivot to manage another set of systems and processes. www.controleng.com

Shared credentials are common on many types of systems, new and legacy. This allows users to quickly gain access without strong password hygiene and frequent password changes that are difficult to keep everyone in sync.

Remote access is ideal for staff to connect from home or even vendors to connect from the internet to conduct maintenance or diagnostics on equipment.

‘

IT and OT each has a bias and a specific perspective when considering ICS cyber

’

risks and consequences.

Protecting information is important, but production losses translate into business losses.

Cyber threats that can disrupt production, cause damage, affect visibility and control, or jeopardize safety also could affect business profitability. Changes by IT are not appropriate or allowed.

Further, OT is still skeptical of the real risk to their ICS operations and control processes, believing the risks and consequences to be hype and rarities.

Conflict resolution

Rather than endure a major security breach that affects confidentiality or operations, companies should consider these three actions to reduce conflict and mistrust with IT and OT convergence while increasing ICS security at the same time.

1. Get strategic alignment at the highest levels.

De Bernardini said most of his clients, “Still have two strongly separated departments for operations and IT. They have different people, goals, policies, and projects.”

De Bernardini recommends starting with reorganizing IT and OT departments to be strategically aligned and unified. He suggests at least the chief information officer (CIO)/ chief information security officer (CISO), and chief operations officer (COO) should have, CONTROL ENGINEERING

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| DE4

DIGITAL EDITION exclusive “Partly common and overlapping goals and targets, which would force them to work cooperatively.”

The CIO/CISO must also accept complete responsibility for the cybersecurity of the ICS and for any safety incidents, reliability incidents, or equipment damage caused directly or indirectly by cyber incidents.

A member of the physical security department.

The task force should also consult: a site management/facility superintendent, a control system vendor and/or a system integrator and the CIO/CISO.

3. Develop pilot projects

‘

Pilot projects offer value with a low-risk benchmark to help the company train and progressively build a specific mix of shared

’

IT/OT skills.

2. Coordinate a joint task force.

NIST SP800-82r2 (Industrial Control Systems Security Guide) and De Bernardini recommend creating a joint task force as a cross-functional cybersecurity team to share varied domain knowledge and experience to evaluate and mitigate risk to the ICS. NIST goes so far as to specifically name titles that should be a part of this cybersecurity task force, which should include: A member of the IT staff A control engineer A control system operator A network and system security expert A member of the management staff

25%

of those taking the 2017 Control Engineering Salary and Career Survey said their level of understanding for Industrial Internet of Things (IIoT) was familiar and being incorporated into automation, controls, and other areas.

23%

more said they had heard of IIoT and are looking at how to incorporate it. www.controleng.com/ce-research

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and a governing structure.

One of the first things the joint cybersecurity task force can do is to identify pilot projects that both groups can work on together. The task force can compile a list of the most critical ICS assets that absolutely must be secured and begin to assess what needs to be done.

These pilot projects are designed to offer value with a low-risk benchmark to help the company train and progressively build a specific mix of shared IT/OT skills. This also will aid in determining how to jointly reduce conflict when deciding on steps toward improving ICS security.

De Bernardini said the joint cybersecurity team should have, “Joint governance and responsibility to execute projects, harmonize duplicated or overlapping systems and processes, and promote the development of the interdisciplinary skills that are now missing in most companies.”

Marathon, not a sprint

Mitigating the conflicts inherent in IT and OT convergence and improving ICS security doesn’t happen overnight.

Managers need to learn to share goals, jointly evaluate business risks and consequences, and train the broader group on shared skills, which will ultimately lead to appropriate ICS security products, processes, policies, and people.

The two collaborating and cooperating departments need to extend their skills to adapting the IT security project models for use in operations with consideration of all the differences inherent in their security priorities and risk biases.

While there are many cultural and structural challenges that come from bringing IT and OT together, the long-term benefits far outweigh any difficulties that might arise in the beginning. ce

Katherine Brocklehurst is with Belden’s Industrial IT group. This article originally appeared on ISSSource.com. ISSSource is a CFE Media content partner. Edited by Hannah Cox, content specialist, CFE Media, hcox@cfemedia.com. www.controleng.com

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NEW PRODUCTS and software See more New Products for Engineers at www.controleng.com/NP4E.

Piezo stages for 3-D positioning accuracy

IoT edge device for monitoring, controlling real-world processes Sealevel Systems’ SeaConnect 370 IoT edge device is designed to allow users to monitor and control real-world processes and trigger actions with SeaCloud, a cloud-based, built-in event engine. It can be used in applications such as asset management, data acquisition, environmental monitoring. The SeaConnect 370 features two Form C relays, four digital inputs (wet or dry contact), two 12-bit A/D converters, a 1-Wire bus interface and a microcontroller unit. It also features an optional demonstration kit for testing purposes. With integrated Wi-Fi capability, the SeaConnect 370 also can be configured with a cellular modem. For applications where geolocation is required, the SeaConnect 370 is available with an optional cellular and GPS module.

Sealevel Systems,

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Input #203 at www.controleng.com/information

Aerotech’s QNP3 series of XYZ piezo positioning stages combine sub-nanometer resolution, high dynamics, and geometric performance in a compact threedegree-of-freedom (DoF) package. They come with a 40 x 40 mm clear aperture with closed-loop travels up to 100 x 100 x 10 µm. Their design is ideal for optical and scanning probe microscopy or other inspection or manufacturing applications where two-sided part access is required with three-DoF manipulation. QNP3 piezo stages use a parallel-kinematic flexure and metrology design that ensure multi-axis accuracy, high stiffness, and long device life. The drive design minimizes X and Y yaw errors while still maintaining an Abbe-compliant metrology system. Z-axis actuators and capacitive sensors are designed to provide Abbe-compliant feedback in the vertical direction with minimal geometric errors. QNP3 stages are available with closed or open-loop feedback.

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Input #202 at www.controleng.com/information

Integrated hybrid servomotor QuickSilver Controls’ Inc. SilverMax X34 NEMA 34 integrated hybrid servo includes an internal and external clamp, a 20A RMS, 40A peak driver operating from 12 to 72V. The SilverMax X-series includes expanded command and register space as well as several commands and modes of operation. An improved driver design provides smooth motions over a wide speed range. The internal permanent magnet, high-pole count servo motor provides high efficiency and full power over a wide range of speeds. It has available torque up to 3200 in-oz./22.5 Nm for direct drive applications such as medical devices and industrial automation.

QuickSilver Controls Inc.,

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Input #204 at www.controleng.com/information

Motor series for positioning and velocity control Suited for scanning, pointing, measuring, and cutting, applications that require smooth velocity control and accurate positioning, the Agility series is designed to deliver torque ripple and zero cogging. Engineered with ZeroCog slotless motor technology, the effects of cogging torque, magnetic forces, flux harmonics, and phase balance and alignment are minimized to counteract the causes of torque ripple. The Agility series is offered in a wide range of low-profile form factors with a large through hole for convenient routing of cables, optics, sensing, technologies, and other system elements. Models are available in diameters from 12 to 300 mm, and with peak torques up to 41 Nm. All models are compatible with a wide range of controllers and drives.

Celera Motion,

www.celeramotion.com

Input #205 at www.controleng.com/information

Permanent magnet motor with integrated speed control electronics CI Takiron’s family of 12 mm OD micro slotless brushless permanent magnet (PM) motors are used in a wide range of applications such as battery-operated handheld power tools, miniature compressors, micropumps, and small robots. This four-member motor family provides stall or peak torque values ranging from 0.88 mNm (0.125 oz-in) to 1.14 mNm (0.161 oz-in). The C12C-XI-S and C12C-X2-S models use sleeve bearings and operate at 6480 and 7920 rpm, respectively. The ball bearing models, C12C-X2-S-B and C12C-X2-S, are used in applications that handle heavier application mechanical loads. All CI Takiron models have low current consumption (below 25 ma). The speed constant varies from 2.14 to 2.16 Krpm/volt for the C12C-XI models and 2.60 to 2.64 Krpm/volt for the C12C-X2 models. All four motors are energized at a low output of 3 volts dc.

CI Takiron,

www.takiron.co.jp/english

www.controleng.com

Input #206 at www.controleng.com/information

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NEW PRODUCTS and software See more New Products for Engineers at www.controleng.com/NP4E.

Real-time SCADA solution for OT, IT applications Honeywell Process Solutions’ (HPS) Experion Elevate is a real-time process supervisory control and data acquisition (SCADA) solution delivered as a secure and scalable service. Experion Elevate allows for predictable costs, easy upgrades, and continual support. It is a member of Honeywell’s suite of cloud-enabled solutions for operations technology and information technology (OT/IT). Experion Elevate is designed to allow industrial organizations to leverage operational expenditures over capital expenditures wherever possible. It also is designed to provide flexible and scalable SCADA options that are suitable for different operations. Experion Elevate provides a scalable, integrated multi-service system with a human-machine interface.

Honeywell Process Solutions (HPS),

www.honeywellprocess.com

Input #207 at www.controleng.com/information

Power supply series with industrial, medical safety approvals XP Power’s UCP225 series of 225 W ac/dc power supplies feature industrial and medical safety approvals in a small U-channel footprint. Seven single output voltage models are available ranging from 12 to 48 V dc, providing a wide variety of output voltage options to meet specific applications. The supplies provide up to 225 W of force-cooled or 150 W of convection-cooled power leading to very high power densities of 12.2W/in3 or 8.1W/in3. Operating temperature range when convection cooled is from -40 to 70 °C with full power available to 50 °C, making the product suitable for a wide range of applications. An additional 12 V dc, 500 mA fan supply is featured with all models to support force-cooled applications. The power supply contains two fuses for both line and neutral and has low leakage current as required by medical applications.

XP Power,

www.xppower.comInput

#208 at www.controleng.com/information

Extensometer for industrial and equipment safety applications

Miniaturized MEMS accelerometer

Vishay Precision Group’s Model 182 extensometer is a strain gage-based force sensor that is designed for industrial, EN15000 and EN280 compliant off-highway vehicle and equipment safety applications. The Model 182 extensometer accurately measures deformation, or changes in the length of a solid structural body, with a 500 μ full-scale sensing range and necessary redundancy for EN15000 and EN280 compliance in safety applications. Its design consists of a high-quality strain gage-sensing element, housed in a highly corrosion resistant coated alloy steel, with mounting via two bolt holes.

TDK Corporation’s Tronics AXO215 microelectromechanical system (MEMS) is designed to provide acceleration sensing performance for demanding applications such as precision instrumentation, unmanned vehicles, and avionics. The AXO215’s closed-loop configuration provides non-linearity that is less than 0.05%. Additionally, the hermetic J-lead package (12 x 12 mm) ensures reliable performance levels in harsh environments, while decoupling the mechanical stresses from the host system. Providing an in-plane linear acceleration measurement, the AXO215 has an input range of 15 g with ultra-low noise of 15 µg/√Hz. The 24-bit digital output is delivered with a bias instability of just 3 µg and an operating vibration resistance of 7.3 grms.

Vishay Precision Group,

TDK Corp.,

www.vpgsensors.com

Input #209 at www.controleng.com/information

www.tdk.com

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HMI for monitoring, controlling machine components Mitsubishi Electric Automation’s GT2107 wide series human-machine interface (HMI) is designed to monitor and control machine components with a graphical touchscreen that connects to equipment such as programmable logic controllers, variable frequency drives, and servos. This compact HMI features a 7-in. wide display with 800 x 480 resolution for clear image quality and is equipped with a remote connectivity option with an optional VNC server. The VNC server is designed to provide remote access to the HMI and connected equipment, allowing users to operate the system using tablets or personal computers to view data in real time.

The GT2107 also offers predictive maintenance information, giving plant managers the opportunity to proactively plan and manage equipment maintenance.

Mitsubishi Electric Automation Inc.,

http://us.mitsubishielectric.com/fa/en

Input #211 at www.controleng.com/information

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BACK TO BASICS worker safety

Seven ways to integrate worker health and safety Because of the great effect they have on each other, worker health and safety should be integrated rather than regulated separately for the benefit of the company and its employees.

W

When two functions

are so fundamentally connected to the condition of employees and the bottom line, how can they be motivated to collaborate?

A majority of companies maintain separate health and safety functions—one dedicated to employees’ well-being and another committed to their protection. These silos have been traditionally kept apart because of the specific expertise and processes required in each area. In addition, the Support a culture of U.S. regulatory environment reinforces the sepacontinuous learning; ration. Occupational Safety & Health Administration gain insights from leading (OSHA) oversees working behaviors and conditions conditions with no corresponding regulatory role and lagging indicators, for worker health.

The truth is, these two such as accidents. departments are intrinsically linked: unsafe working conditions can affect employee health while unhealthy employees are a safety risk at work.

Integrating these two functions can improve effectiveness and reduce costs. The Integrated Benefits Institute found poor employee health costs the U.S. economy $576 billion per year.

MORE More than 313 million workplace accidents ADVICE annually occur around the world, according to KEY CONCEPTS the International Labor Organization. AcciWorker health and safety are dents cost employers an estimated $2.2 trilintrinsically linked to one another and lion worldwide and result in more than 2.3 should be integrated by companies. million deaths per year. When two functions Companies need to be committed to are so fundamentally connected to the condithis plan and get everyone involved. tion of employees and the bottom line, how can Integrating health and safety helps uncover risks and promotes a culture they be convinced to collaborate? UL brought of prevention and well-being for together dozens of thought leaders to answer workers. this question. The group identified seven GO ONLINE actions organizations should take to integrate Read this article online at workplace health and safety. www.controleng.com and see ad1. Use a holistic approach. Treat health ditional stories from ISSSource. and safety as one function by designing initiaCONSIDER THIS tives—from wellness programs to reporting proWhat other actions can companies cesses—that incorporate health protection and take to integrate workplace health health promotion. and safety?

‘

’

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2. Make a commitment. Ensure health and safety activities are key contributors to an organization’s value system, not just a cost of doing business.

3. Present the business case. Express value in terms that senior executives understand.

They intuitively know healthy workers are more productive, but may need empirical evidence to justify investments.

4. Create an overarching management structure. Create lines of authority and reporting processes to encourage effective communications among all parties. While senior executives may have competing priorities, a collaborative structure helps open up the lines of communication from bottom up to top down, as well as across departments and functions.

5. Prepare for a new profession. Redefine professional roles and responsibilities to better meet current business, health, and safety management needs and trends.

6. Support a culture of continuous learning. Learn from behaviors and conditions that create risk (leading indicators), not just past accidents (lagging indicators). This continuum of insights helps employees and employers actively identify threats.

7. Get everyone involved. From participation in health and wellness initiatives to the formation of reporting and learning teams, involve the entire organization in order to foster a culture of health and safety.

While organizations may face challenges integrating their health and safety departments, the benefits of unifying the two functions are clear. Coordinated health and safety programs create greater transparency for uncovering risks and promote a culture of prevention and wellbeing, benefiting both organizations and their employees. ce Mark Ward is the general manager for UL-EHS sustainability. This article originally appeared on ISSSource.com. ISSSource is a CFE Media content partner. Edited by Carly Marchal, content specialist, CFE Media, cmarchal@cfemedia.com. www.controleng.com

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