Ce 17 11

MAY17 AC Branding Snipe - New Size (CE).qxp_Lay

www.controleng.com

thinkallied.com

At AutomationDirect.com we have the PLCs y need at the prices you want.

Regardless of your project or system needs, AutomationDirect has a PLC to match your specs and your budget. So whether you’re building a simple process or a complex machine, you can count on us for affordable PLCs you can rely on.

R

MasTer your

conTrol challenge wiTh The power oF do-More!

The Beginner’s BesT Friend

CLICK PLCs Basic PLC Unit starting at

$69

Do-more PLCs sta

Free Programming Software & Tech Support for Life!

The CLICK PLC family offers extreme value for everyday applications. The compact size and easy programming make CLICK great for small applications and beginner projects.

Free Programming Softwa

The Do-more PLC family is d programming powerhouse ha instruction sets in the market allow it to stand strong against a

Adva Con

Simple Control

(Fixed memo

Basic Analog

Ethernet

Discrete

Serial

Research, price, buy at:

www.CLICKPLCs.com

Analog

Ethernet

Discrete

Serial

Built-in High Speed

USB

Embedded Help Videos

Custom Comm Slot

Research, p

www.Do-m 1-800-633-0405

www.AutomationDirect.com input #38 at www.controleng.com/information

you Break Free FroM a-B!

Productivity Series CPU starting at

$255

Free Programming Software & Tech Support for Life!

arting at

$199

are & Tech Support for Life!

determined to get it done. This as one of the most advanced t and many other features that any challenge.

Are you still paying the price for your Allen-Bradley controller?

Are you tired of the never-ending software and support expense?

Has the unbearable cost of ownership taken you by surprise?

Well now you can break FREE with Productivity. The Productivity Series PLCs are high-performance tag name based controllers with expansive built-in communication options and other features you’ll love at an awesome price. And with Productivity you’ll never get hit with extra fees since our software, manuals, tech support, and access to online resources are all completely FREE!

Advanced Control

anced ntrol

(Tag name based)

ory addressing)

Motion PID PWM Outputs

price, buy at:

orePLCs.com

Analog

Ethernet

Motion

Data Logging

Discrete

Serial

PID

Mobile Access

High Speed

USB

Module Data Displays

Web Server

Hot Swappable I/O

Built-in Expansion Ports

Data Logging Data File Management PLC Simulator Integrated Security

Research, price, buy at:

50MB User Memory

www.Productivity2000.com

PLCs with a purpose... ...to exceed your needs while saving you money!

Productivity PLCs

Do-more PLCs

CPU starting at:

$255.00

starting at:

$199.00

(P2-550)

(BX-DM1-10AR-D)

R

CLICK PLC Units starting at:

$69.00

(C0-00DD1-D)

We have the PLC for you...

Your industrial automation needs can vary from the smallest simplest machine to a complex plant-wide operation, and we want the opportunity to serve each and every one.

N

To meet the unique challenges of each application while at the same time guaranteeing the utmost satisfaction, yout 1 4/13/17 we’ve 11:34 AM Page 1 with three well-respected companies (Host partnered Engineering, FACTS Engineering and Koyo Electronics) to develop three distinct, quality PLC product lines. Each PLC family comes with FREE software and life-long support, with new features added continually to not only meet ever-changing industry demands but also exceed your expectations.

So, if you’ve never considered AutomationDirect for your controller needs, let us show you how price and performance can work hand-in-hand for a better overall experience.

Order Today, Ships Today! * See our Web site for details and restrictions. © Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved.

input #1 at www.controleng.com/information

get more than you paid for...

1-800-633-0405

the #1 value in automation

When things just work, work gets done.

Kepware’s industrial connectivity software provides secure and reliable data from the shop floor to the top floor, so you can focus on productivity.

Learn more at kepware.com/CE

input #2 at www.controleng.com/information

Build Your Own Industrial IoT Connectivity Solution With Moxa's ThingsPro gateway and software, you can easily bring Industrial IoT connectivity to a large number of industrial sites or customers. Linux-based and completely programmable, it includes built-in functions to connect Modbus devices directly to enterprise and SCADA cloud services.

• Open Linux platform with easy migration from Raspberry Pi • Built-in integration with Amazon AWS, Ignition SCADA • Designed and certified for industrial use • Optional 4G LTE module with Verizon and AT&T certification Learn more at www.moxa.com/thingspro.

Vol. 64 Number 11

®

NOVEMBER 2017

17 |

18 | Maximizing ROI with an integrated approach to control systems

18

05 |

20 | Micro-controllers versus PLCs: Which belongs in your plant?

Voltage monitor

COVER: Cybersecurity and reliable communications are two issues important for industrial installations of automation and controls, including with petrochemical applications.

Cover image courtesy: Honeywell INSET (p. 24): Diagram shows the general structure of a power supply system for use in space vehicles.

Courtesy: Voronezh State Technical University, Russia

ANSWERS

Voltage regulators

Solar batteries

22 | Maximizing a control system’s lifecycle

Main and filters

Currentt control C t

Voltage converters

High voltage sources

Current contro control

24 | Multi-alternative power supply control 25 | Magnetostrictive sensors’ benefits for wind turbines

Charging and discharging devices

Accumulator batteries

Current control

26 | Renewable energy opportunities

24

INSIDE PROCESS

P1 | Turning safety into profitability

INSIGHTS

P2 | Your questions answered: Choosing sensors for the application

06 | 2017 IIoT for Engineers Report: Five key findings on IIoT, Industrie 4.0 37 |

08 | Accelerate IIoT with hardware, software 10 | Rewire the process industry with IIoT

NEW PRODUCTS

32 | ESD knobs; Process control system; Vibration sensors

NEWS

13 | IIoT analytics framework report published; ‘Father of the PLC’ remembered; Online articles

33 | Incremental and absolute encoders; Rocker switches for harsh environments

14 | Think Again Get credit for your learning CFE Edu: https://cfeedu.cfemedia.com/catalog (PLCs, IIoT, arc flash and more) Webcasts: www.controleng.com/webcasts (Sensors, IIoT, and more)

CFE

Edu

INNOVATIONS

TM

46 | Four-axis SCARA robot for pick-andplace assembly, medical processes; Advanced connection system for underground cables BACK TO BASICS

48 | Six traits for excellent engineers

CONTROL ENGINEERING (ISSN 0010-8049, Vol. 64, No. 11, GST #123397457) is published 12x per year, Monthly by CFE Media, LLC, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. 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 Downers Grove, IL 60515 and additional mailing offices. Circulation records are maintained at 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Telephone: 630/571-4070.

E-mail: customerservice@cfemedia.com. Postmaster: send address changes to CONTROL ENGINEERING, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Publications Mail Agreement No. 40685520.

Return undeliverable Canadian addresses to: 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. 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 US and $35 foreign.

Please address all subscription mail to CONTROL ENGINEERING, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. 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.

www.controleng.com

CONTROL ENGINEERING

November 2017

•

3

Keep Your Instrument Processes Locked Down Tight.

Instrumentation that Keeps Danger at Bay

SFY Functional Safety Frequency-to-DC Transmitter

Put a fortress of protection around your process with FS Functional Safety Series instrumentation from Moore Industries. You can be conďŹ dent that it will safeguard your processes when you need it the most.

Our STA, SSX, SST, SRM, STZ and the NEW SFY Functional Safety Frequency-to-DC Transmitter have been designed and built to strict IEC 61508 standards, ensuring safe and reliable function – particularly in environments where hazardous or emergency situations are likely to occur.

Demand Moore Reliability To learn more about our Functional Safety y Series,, call (800) 999-2900, or go to: www.miinet.com/safetyseries input #3 at www.controleng.com/information

INSIGHTS ®

RESEARCH

6

2017 IIoT for Engineers Report: Five key findings

TECHNOLOGY UPDATE

10

Digitalization can offer process industries increased process optimization. Industrial Internet of Things (IIoT) adds efficiency.

Respondents to the 2017 IIoT for Engineers study identified five key findings on Industrial Internet of Things (IIoT) framework and Industrie 4.0 platform.

8

CONTROL ENGINEERING CHINA

Accelerate IIoT

NEWS

13

More intelligent manufacturing is possible more quickly by choosing products that help with Industrial Internet of Things (IIoT) architectures.

Get a topical newsletter, free

Rewire the process industry with IIoT

IIoT analytics framework report published; ‘Father of the PLC’ remembered; Online articles THINK AGAIN

14

See newsletters and sign up www.controleng.com/e-newsletters

What’s needed for wireless control?

Wireless control in 6 easy steps: Technologies can enable wireless control and mobility applications.

What are you waiting for?

JOIN THE NEXT INDUSTRIAL REVOLUTION WITH NAPCON Napconize your operations: understand your big data, optimize production, reach new tops in performance, and train your operators like never before.

Learn more at napconsuite.com

input #4 at www.controleng.com/information

INSIGHTS

Purchasing HMI software, hardware

RESEARCH

Not restricted

Don't know

6%

2017 IIoT FOR ENGINEERS REPORT:

Five key findings on IIoT, Industrie 4.0

R

espondents to the 2017 IIoT for Engineers study identified five key findings regarding their familiarity and implementation of the Industrial Internet of Things (IIoT) framework and Industrie 4.0 platform: 1. Technologies: Sensing technology (77%), connectivity platforms (74%), and data analytics (73%) are the top technologies that engineering/IT staff and corporate entities/local executive management are interested in exploring or pursuing based on recent advances with IIoT. Corporate entities or local executive management personnel are more interested in pursuing data analytics (76%) features.

2. Increasing productivity: Based on IIoT advances, six in 10 respondents expect productivity gains for wired or wireless networking, device bus, Fieldbus networks, I/O modules, etc. and HMIs, SCADA, historian, alarm management, and data acquisition systems.

3. IIoT budget: Respondents estimate an annual budget of $328,160 for their companies’ investment in IIoT and

other areas associated with digital manufacturing; 18% estimated an investment of more than $500,000.

4. Anticipated benefits: Three in five respondents expect IIoT to benefit connections between people, data, and machines, as well as improving operations decision making/increasing agility.

5. Challenges: Data security concerns are the biggest challenge (49%) when it comes to planning and executing IIoT projects, followed by insufficient staffing skills (45%) and lack of budget (43%). ce At www.controleng.com/2017IIoTStudy, view more information. Amanda Pelliccione is the research director for CFE Media, apelliccione@cfemedia.com.

M More RESEARCH

Control Engineering covers several research topics each year.

All reports are available at www.controleng.com/ce-research

Equipping solutions to be ‘smart’ products Don't know

Yes

No

13%

34%

60%

Bound to existing agreements or standards

Only 34% of end users are bound to existing agreements or standards when purchasing HMI/ SCADA software or hardware.

Source: Control Engineering 2017 HMI Software & Hardware Study

49%:

Average percentage of a company that uses mobile devices for work. Source: Control Engineering 2016 Mobility, Ethernet, and Wireless Study

27%

of end users expect their bonus compensation to increase this year. Source: Control Engineering 2017 Career & Salary Survey

8 in 10

end users agree that motor sizing and tuning software are important when evaluating servo and/or stepper drives. Source: Control Engineering 2017 Motor Drives Study

10% 30%

47%

More research Sometimes Companies are more often than not offering solutions equipped for in-service product data acquisition or to be “smart” products. Source: CFE Media LLC

6

•

November 2017

CONTROL ENGINEERING

Control Engineering covers several research topics each year.

All reports are available at www.controleng.com/ce-research.

www.controleng.com

Allied Delivers Innovative, and Industry-Proven Control Solutions Reliable, easy-to-install products for both inside and outside the cabinet.

Find This & More

thinkallied.com •1.800.433.5700 input #5 at www.controleng.com/information

Š Allied Electronics, Inc 2017.

INSIGHTS

CONTROL ENGINEERING CHINA Stone Shi, Control Engineering China

Accelerate IIoT; here’s how More intelligent manufacturing is possible more quickly by choosing hardware and software that help with Industrial Internet of Things (IIoT) architectures.

T

Cui Peng is the marketing manager of Internet of Things at National Instruments (NI) China. Courtesy: Control Engineering China

Yi Xilu is the technical market engineer of Internet of Things at NI China.

Courtesy: Control Engineering China

8

•

he Industrial Internet of Things (IIoT) has developed into a key means to help realize the smart factory and intelligent manufacturing concurrent with development of the internet of everything. Control Engineering China asked National Instruments (NI) Corp. China executives, Cui Peng, marketing manager, and Yi Xilu, technical market engineer of Internet of Things (IoT), how to accelerate IIoT implementations.

IIoT platform architecture

Collection and analysis of Big Data runs through IIoT processes, from front-end data acquisition, transmission, transfer to the cloud, and to a decision-making terminal. Data acquisition and analysis are core to NI offerings, an advantage for those seeking an IIoT platform architecture.

“As for IIoT, we will help customers build a basic architecture, emancipate them from data acquisition, and allow greater focus on data analysis,” said Peng.

“In the past, the customers spent 80% of their time to carry out the front-end system architecture and data acquisition, with 20% left for data analysis.” A platform of hardware and software can help customers to speed up IIoT deployment, Peng suggested.

Elements to help with IIoT deployment include embedded industrial controllers, systems on modules, machine vision, motion control, industrial touch screens, data acquisition and control platforms, and cloud-based data management and analysis software.

Xilu added, “The basic architecture of IIoT as produced by NI can realize the intelligent test and protocol test, as well as monitor equipment in the industrial field. In such cases, early design verification and later mass production will be monitored online in real time to enable predictive maintenance, protect stable operation of assets, help customers enhance production efficiency, and shorten the production period.”

As IIoT develops into a comprehensive systemic engineering architecture, a cooperative ecosystem helps. Companies that offer open-ended platforms of integrated hardware and software also help.

Peng said, “Another extension of the NI platform concept lies in the industry development, jointly promoted by cooperative partners under the assistance of the ecosphere. Generally, we will provide a platform offering to satisfy customer-defined demands.” To supply customer solutions, Peng continued, “We will adopt two methods. First, we will join with local or

November 2017

CONTROL ENGINEERING

global professional partners to build the solution suitable for the specific field. Second, we cooperate with end customers to develop the specified system.”

In the U.S., NI joined with Cisco, Intel, and other industrial companies to build an IIoT Lab at NI’s Austin headquarters, focusing on the micro-grid control and communications, advanced manufacturing control, heavy equipment asset monitoring, and other fields. NI also is among companies working on and promoting the IEEE Time-Sensitive Networking (TSN) standard. IIoT Lab members are producing TSN-based controllers and multi-slot Ethernet-based compact controllers that can support TSN standards.

Smarter manufacturing

In China, starting in 2016, NI began cooperating with Industrie 4.0-Intelligent Factory Laboratory under Tongji University to co-build an NI Industrial Internet Laboratory. Cyberinsight, an NI partner in prognostics and health management (PHM), can use the NI platform to customize and develop an end-to-end IIoT product for customers. Applying the industrial intelligent algorithm engine enables platform and data analysis services to help Chinese industrial customers with real-time asset health management and predictive maintenance. Peng said NI seeks more companies in China engaged in Big Data analysis and data mining to provide IIoT hardware and software across industries. IIoT has progressed beyond theoretical concepts. IIoT platforms have been implemented in China and abroad, especially for machine state monitoring and controls, to which Big Data analytics brings unprecedented value. ce

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

M More INSIGHTS

KEYWORDS: IIoT, Big Data IIoT implementations are accelerated with an integrated platform.

IEEE Time Sensitive Networking and other cooperative industry efforts enable IIoT architectures for machine monitoring, controls, and Big Data analytics. www.controleng.com/international www.controleng.com

Technology Elevated to the Cloud.

Grounded by Honeywell’s Dependability.

Introducing Experion® Elevate: real-time process SCADA delivered as a secure

Time to Elevate Your Thinking.

and scalable service—for predictable costs, easy upgrades, and continual support. We call it Elevate because it takes SCADA to a higher level.

Go to www.hwll.co/SCADA to vote for Experion Elevate.

Connected Industrial Connected Plant

For more information, please visit www.honeywellprocess.com/elevate. © 2017 Honeywell International Inc.

input #6 at www.controleng.com/information

Connected Worker

INSIGHTS

TECHNOLOGY UPDATE Amit Chadha, L&T Technology Services Ltd.

IIoT can rewire the process industry Digitalization can offer process industries increased process optimization and plant efficiency. Industrial Internet of Things (IIoT) adds predictive maintenance, asset information management, and open device configurability.

D

igitalization can offer many advantages to process industries, such as new opportunities in process optimization and increases in plant efficiency.

The Industrial Internet of Things (IIoT) offers predictive maintenance, asset information management, and open device configurability to a vertical that is just beginning to embrace Industrie 4.0.

Process plants are built around myriad of moving parts, and increasing age brings inefficiencies. While utility prices rise, legacy plant equipment incrementally adds to upkeep costs. Legacy plants waste approximately 30% of the energy they consume.

The convergence of information technology (IT) and operations technology (OT) data helps factory operations. This is where the buzz around IIoT starts making sense. As sensors and Internet-protocol-enabled devices proliferate, IIoT ultimately will dominate the factory floor. With more effective information analysis manufacturers will be able to create leaner processes, streamline operations, and drive cost efficienKEYWORDS: cies. In a connected ecosystem, machines can Digalitization, IIoT send alerts that communicate their status, enabling production detours without disrupDigitalization increases efficiency. tion. Imagine the possibilities across multiple sites connected by a cloud-based enterprise Sensors and monitoring will move maintenance from resource planning (ERP) system. Intelligence reactive to proactive. and best practices established in one model Artificial intelligence will plant could be seamlessly exported and impleincrease optimization. mented across every connected facility.

M More INSIGHTS

CONSIDER THIS

How can greater digitalization expand optimization?

CE RESEARCH IIoT research: 3 in 5 respondents expect IIoT to benefit connections among people, data, and machines, as well as improving operations decision making/ increasing agility.

10

•

November 2017

Efficiency increase: 82%

If reports are to be believed, manufacturing plants experience an 82% efficiency increase with digitized processes. Addressing utility costs, a major Japanese chemical producer embedded 148 steam traps with sensors, leading to a 7% reduction in the cost of steam.

With IIoT, plant operators can access more asset-related data. As IIoT links edge sensors and analytics, it will provide benefits by: CONTROL ENGINEERING

Industrial manufacturing systems, advanced distributed computing, low-cost sensors, and IIoT are transforming the value chain.

Courtesy: L&T Technology Services Ltd.

• Cost-effectively collecting data using wireless, low-energy sensors • Developing data-driven, strategic, actionable operational intelligence • Presenting this information to plant managers at the right time • Delivering performance improvements once corrective actions have been taken.

Going by present standards, operators have been leveraging this information to transition from reactive maintenance activities to a more efficient predictive maintenance framework. Implementing efficient maintenance prioritization across multiple sites is a major hurdle that remains.

Maintenance, AI, optimization

Combining computerized maintenance management system software and data gathered through IIoT, maintenance personnel can monitor asset groups, specifying parameters for triggering alerts, automating responses, and work order generation by directly interfacing with cloud ERP. The process industries will find advantages in using artificial intelligence (AI). To increase plant safety, operators have been reducing manual intervention on the factory floor. Manufacturing systems that have capitalized on machine learning and predictive data analytics reportedly have improved production capacity by 20%, while lowering resource use by 4%.

Human faculty for reasoning and logic are essential to manufacturing. As machines begin to think like we do, AI will become the central nervous system of the connected plant ecosystem, and using intelligence derived from to squeeze the maximum value out of every dollar spent. ce

Amit Chadha is president of sales and business development and is a member of the board at L&T Technology Services Ltd., a CFE Media Content Partner. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. www.controleng.com

— ABB Ability™ Smart Sensor

motors that let you know when it’s time for a service.

ABB’s new condition monitoring solution revolutionizes maintenance for low voltage motors. ABB Ability™ Smart Sensor monitors key parameters and sends the data to a secure server for analysis. Users can access detailed status reports from their smartphone or PC. The solution enables proper maintenance planning for longer motor lifetimes, lower energy consumption and big reductions in downtime. www.abb.com/motors&generators input #7 at www.controleng.com/information

INSIGHTS

Digital edition? Click on headlines for more details.

See news daily at www.controleng.com/news

NEWS

IIoT analytics framework technical report published The Industrial Internet Consortium (IIC) has published the IIC Industrial IoT Analytics Framework Technical Report (IIAF). It is a technical document that includes a complete set of instructions that Industrial Internet of Things (IIoT) system architects and business leaders can use to deploy industrial analytics systems in their organizations. IIAF can help system architects and designers map analytics to the IIoT applications and ensure that business leaders can realize the potential of analytics to enable more-informed decision-making.

When analytics, applied to machine and process data, help optimize decision-making and enable intelligent operations. New insights and intelligence can be applied across the enterprise in any industry if the appropriate data can be collected and curated with appropriate analytics.

“In transforming machine raw data into actionable information, industrial ana-

lytics plays a crucial role in the industrial internet just like refineries that turn crude oil into high energy fuel. The actionable information from the analytics is the fuel that drives the optimization of industrial operations and production, the creation of

new revenue streams and the enablement of new business models,” said Shi-wan Lin, IIC technology working group chair and CEO and co-founder, Thingswise LLC. Edited from an IIC press release by CFE Media.

Headlines online Top five Control Engineering articles Oct. 16-22 most visited articles: wireless tank level monitoring, welders and robots, valves, HMIs, and machine control demands.

Eight reasons why consolidating software improves engineering processes Consolidating software can provide benefits: data quality, efficiency, and lower costs.

Dick Morley remembered as ‘Father of the PLC’ Electrical engineer best known for his work on the programmable logic controller (PLC) died at 84. Image courtesy: Schneider Electric Sharp decrease in OSHA workplace violations, 2017 Reported OSHA workplace safety violations decreased 14%.

Manufacturing is booming: PMI hits 13-year high Oil and gas software company acquired Emerson agreed to acquire Paradigm, a provider of oil and gas industry software.

Sensors, IIoT device implementation Sensors and networks are important to Industrial Internet of Things implementations, said experts at Sensors Midwest conference.

November 2017

•

13

input #9 at www.controleng.com/information

INSIGHTS

THINK AGAIN

®

3010 Highland Parkway, Suite 325, Downers Grove, IL 60515. 630-571-4070, Fax 630-214-4504

Content Specialists/Editorial

What’s needed for wireless control?

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

Wireless control in six easy steps: Technologies can enable wireless control and mobility applications. What are you waiting for?

I

f you weren’t among the early adopters of wireless control and mobile technology applications, I get it: If something goes wrong, they’re calling you, not me. I’m just the person saying wireless control has been done reliably and can be done because enabling technologies have been readily available.

wouldn’t have been considered previously because of wired communication costs. Batteries last longer in applications without line power.

3. Software can help design, configure, and operate wireless connections. It isn’t as difficult as it used to be. Ask someone you trust for a demo.

Wireless control: 6 steps

4. Mobile hardware (tablets, smartphones, industrial-enabled rugged mobile human-machine 1. Reliable and secure wireinterfaces) can use enabled softless communication designs ware to provide a view into Mark T. Hoske, connect the wireless portion (or Content Manager controls, automation, and instruall) of the control loop, dependmentation. The latest software selfing on the implementation. Relioptimizes to fit the screen size, so able signals need to go from sensors to the redesigning HMI screens for mobility may logic device, from the logic device to the not be needed. actuator, the actuator can provide feed5. Connections to higher-level systems back, and the measurement device measures again, to optimize the loop. If it’s an (perhaps wirelessly) provide additional, someopen loop, a human gets a notification or times cloud-enabled intelligent applications alarm (perhaps wirelessly) and confirms or for analysis, providing smarter and faster enables the next step in the loop. Closed- decisions more easily to help decision-makers. loop control is fully automated, alarm6. Information justifying investments ing only if there’s a setpoint violation or fault that might not be fixed as part of the in wireless control and mobility help those automation. Reliable and redundant wire- involved look forward to rapid returns on less communications exist, ensuring signal investment, resulting in hero status for the integrity, using standards and/or using pro- advocate and a showcase of reliable wireless capabilities that look like something engiprietary technologies. neering-minded youth want to be a part of.

2. Wireless hardware can be appropri- Or perhaps you’ll get a hearty handshake, a ately and rapidly installed to enable wire- pat on the back, and the satisfaction of havless communications for control and mobile ing time to do the next six things. monitoring applications. Wireless networks and enabling devices are many, often at a Either way, think again about wireless: price point that enables applications that Don’t automatically specify wires and cable because you don’t think wireless is ready for prime time. Contact your automation vendor or an appropriate system integrator for insights. ce What do wireless control and mobility applications need?

M More INSIGHTS

Vote now on wireless-related products among Control Engineering Engineers’ Choice Finalists.

See wireless and mobility products at: www.controleng.com/EngineersChoice.

14

•

November 2017

Mark T. Hoske is content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.

CONTROL ENGINEERING

Emily Guenther, Associate Content Manager eguenther@cfemedia.com Amanda Pelliccione, Director of Research 978-302-3463, APelliccione@CFEMedia.com Joy Chang, Digital Project Manager JChang@CFEMedia.com Chris Vavra, Production Editor CVavra@CFEMedia.com

Contributing Content Specialists Frank J. Bartos, P.E., braunbart@sbcglobal.net 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

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

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

CFE Media Contributor Guidelines Overview Content For Engineers. That’s what CFE Media stands for, and what CFE Media is all about – engineers sharing with their peers. We welcome content submissions for all interested parties in engineering. We will use those materials online, on our website, in print and in newsletters to keep engineers informed about the products, solutions and industry trends. www.controleng.com/contribute explains how to submit press releases, products, images and graphics, bylined feature articles, case studies, white papers, and other media. * Content should focus on helping engineers solve problems. Articles that are commercial or are critical of other products or organizations will be rejected.

(Technology discussions and comparative tables may be accepted if non-promotional and if contributor corroborates information with sources cited.) * If the content meets criteria noted in guidelines, expect to see it first on our Websites. Content for our e-newsletters comes from content already available on our Websites. All content for print also will be online.

All content that appears in our print magazines will appear as space permits, and we will indicate in print if more content from that article is available online. * Deadlines for feature articles intended for the print magazines are at least two months in advance of the publication date. Again, it is best to discuss all feature articles with the appropriate content manager prior to submission.

Learn more at: www.controleng.com/contribute

www.controlengineering.com

The

Leading

MRO & Automation Solution Radwell.com - Reduce facility downtime - Reduce operating costs - Industrial Electronic Repair - Radwell Certified PreOwned - Radwell Verified Substitutes - Brand New - Asset Recovery / Buy Back - Engineering

800.332.4336

sales@radwell.com

input #10 at www.controleng.com/information

Disclaimer: Layout, design, and compilations on this site, are Copyright © 2017 Radwell International, Inc.. All rights are reserved. PLCCenter is a Division of Radwell International, Inc.. Radwell International, Inc.. sells new and surplus products and develops channels to purchase such product. This website is not sanctioned or approved by any manufacturer or tradename listed. Radwell / Radwell.com is not an authorized distributor, affiliate, or representative for the listed manufacturers unless explicitly stated otherwise. Designated trademarks, brand names and brands appearing herein are the property of their respective owners.

Securely use removable media across industrial control networks.

Connected Industrial Connected Plant

Protect against current and emerging USB-borne threats with Secure Media Exchange.

Secure Media Exchange (SMX) reduces cyber security risk and limits operational disruptions by monitoring, protecting, and logging use of removable media throughout industrial facilities.

Vote for Secure Media Exchange (SMX) at www.hwll.co/VoteSMX

Connected Worker Cyber Security Solutions

For more information, visit www.hwll.co/SMX Š2017 Honeywell International Inc.

input #11 at www.controleng.com/information

ANSWERS FEATURE ARTICLES

®

24

Multi-alternative power supply control

Space vehicles, among the most challenging and varied operating environments, require alternative energy sources with a multi-level control structure to exclude the risk of failures and ensure uninterrupted power supply in various flight modes.

25

Magnetostrictive sensors’ benefits for wind turbines

Magnetostrictive linear position sensors are designed for advanced motion control implementations and, when used with a CANopen interface, are useful in wind turbine applications.

COVER STORIES

18

Maximize ROI with an integrated approach to control systems

Programmable logic controllers (PLCs) combining integration, cybersecurity, and OPC UA bring greater productivity and reliability.

20

Micro-controllers versus PLCs: Which one belongs in your plant?

Single-board computers and micro-controllers offer opportunities for automation applications, but they may not be the best option for critical production applications.

22

26

Diversity of projects are available to be automated.

M More ANSWERS More Inside Process online www.controleng.com Related topics are available under the “Process Manufacturing” pull-down menu.

INSIDE PROCESS

P1

More

M ANSWERS Check out the PLC digital report: www.controleng.com

www.controleng.com

Turning safety into profitability

Companies need to view safety as more than a cost and see it as an opportunity to improve overall performance and effectiveness. Doing that requires a culture change and being able to focus on safety risks in real time.

Maximizing a control system’s lifecycle

Extending the lifecycle of a control system requires proper maintenance and effective lifecycle management practices.

Renewable energy opportunities

P2

Your questions answered: Choosing sensors for the application

The Aug. 22, 2017, Control Engineering “Choosing sensors for the application” webcast presenters addressed questions not covered during the live event.

CONTROL ENGINEERING

November 2017

•

17

ANSWERS

COVER: RELIABILITY Swapnil Adkar, Honeywell

Integrated controls boost ROI Programmable logic controllers (PLCs) combining integration, cybersecurity, and OPC UA bring greater productivity and reliability.

I

ndustrial organizations want to maximize return on investment (ROI) by ensuring that automation assets are secure, future-proof, adhere to open standards, and integrate to existing assets—avoiding having to “rip and replace” current infrastructure. When it comes to programmable logic controllers (PLCs), advancements in embedded cybersecurity, increased integration to site-wide systems, and compliance to communication standards are increasing productivity and reliability.

Increased cybersecurity

Security breaches in control systems can lead to significant damages and harm to plant personnel and the public; damage to plant assets and equipment, causing lost production with unplanned downtime; and fines due to regulatory compliance issues, and damage to a company’s reputation, resulting in a loss of customer and investor confidence.

These concerns drive manufacturers to seek products that adhere to strict cyberKEYWORD: security guidelines. Designing for ISASeProgrammable logic cure Embedded Device Security Assurance controller (PLC) certification ensures PLC integrity and its KEY CONCEPTS development lifecycle, and includes rigThe benefits of an integrated orous communication robustness testing, approach for control systems functional security assessment, and softHow to simplify process ware development security assessment. operations A secure boot can provide a physical layer Using the OPC UA of security on the central processing unit architecture.

M More ANSWERS

Cybersecurity and reliable communications are two issues important for industrial installations of automation and controls, including with petrochemical applications. Cover image courtesy: Honeywell

18

•

November 2017

CONTROL ENGINEERING

(CPU) that prevents changes to and the loading of unauthorized software. A built-in firewall can include embedded cybersecurity technology to help reduce exposure to denial of service attacks and message flooding at the control level. This protects the controller and network from unwanted traffic.

OPC UA reliability, integrated controls

A new breed of PLC provides an Industrial Internet of Things (IIoT)-ready open platform for better leveraging data across the plant infrastructure. The OPC Unified Architecture (UA) specification offers secure integration of a wide range of instruments, equipment, and software throughout an industrial enterprise. Interoperable multi-level and multiplatform open communication also supports flexibility and standardization with less hardware.

PLC programmers can link information from controllers to other devices, systems, and business enterprise applications. PLC platforms embedded with OPC UA help make digitization a reality by using open-computing industry standards and streamlining an integrated plant architecture with communications to enterprise systems.

Combining control systems from the same vendor can make coordination easier with fewer teams and direct access to system knowledge, resulting in faster setup, testing, and troubleshooting. Operational benefits can be achieved with a common human-machine interface across system applications. An integrated solution provides pre-built diagnostics, an integrated alarm summary, and history, trending and reporting on an automation infrastructure.

With distributed control system and PLC implementations, users can simplify process operations, deploy equipment with a common lifecycle. Integration provides lifecycle cost savings, less engineering, and higher reliability. IIoT, Industrie 4.0, and other initiatives employ communication as a key element.

Efficiency in combining intelligent systems, sensors, and actuators becomes more important. Controllers designed to be secure, IIoT-enabled edge devices provide an open platform that enables users to leverage data across assets to help reduce unplanned downtime and off-specification products. ce

Swapnil Adkar is a Honeywell global product marketing manager; edited by Emily Guenther, associate content manager, CFE Media, eguenther@cfemedia.com. www.controleng.com

Profit

Engineer

Turn industrial automation into the profit engine of your business.

Two views — one shared vision — enabled by EcoStruxure™ Foxboro DCS. Empower your workforce to control operational efficiency, reliability, safety, and profitability together — in real time. Only EcoStruxure Foxboro DCS provides measurable operational profitability improvements and a future-proof architecture, enabling 100% ROI in less than one year.

Ignite your profit engine today by downloading our whitepaper.

schneider-electric.com/smartoperations input #12 at www.controleng.com/information

ANSWERS

COVER: AUTOMATION RELIABILITY Bill Dehner and Tim Wheeler, AutomationDirect

Micro-controllers versus PLCs

Single-board computers and micro-controllers offer opportunities for automation

applications, but they may not be the best option for critical production applications.

T

he variety of micro-controllers emerging has been growing rapidly, with no signs of abating. These devices offer many capabilities, along with whole ecosystems of accessories that are also cost-effective.

Consequently, interest in these products has moved from automation clubs and basement robot builders, to the point where some are considering their use in manufacturing. When an engineer seeks to solve a small industrial automation challenge, the traditional approach has been to use a programmable logic controller (PLC). While some engineers may consider a micro-controller, certain factors should be considered.

Open-source board-level products resulting from the do-it-yourself electronics industry (the maker world), other micro-controllers, field-programmable gate array boards, and single-board computers have varying capabilities and limits, and, for discussion here, will be lumped under the heading of micro-controllers.

Similarly, the characteristic attributions of PLCs and other industrial controllers do not apply to every model and manufacturer, although there is a high degree of consistency.

Industrial automation example

An engineer may be considering a small automated task involving two or three sensors, an actuator for the output, and a reporting function to the larger control system. It will require a basic program to make it operate.

KEYWORD: This is simple for many small PLCs Automation reliability, at a lower price, but there are factors that programmable logic controller should be considered first. A lower-cost KEY CONCEPTS small open-source board-level micro-conComparing PLCs with troller might be tempting to try. Regardmicro-controllers ing input/output (I/O) compatibility: does Factors to consider when using the prospective micro-controller offer the a PLC for industrial automation required I/Os? It isn’t difficult to find a applications. micro-controller with the correct number Reliability and broader cost issues working with of discrete and analog I/Os, but they may micro-controllers. not be the right type.

Some are relatively easy to convert, CONSIDER THIS such as a 4-20 mA current loop to a 0-5 ‘Other considerations’ are discussed in greater detail in the V voltage loop. Others are more difficult online version of this article. to convert, such as an analog output using For related links about PLCs, pulse-width modulation, common for read this article online. In the micro-controllers. Some signal convertdigital edition, click on the ers are available as standard products, but headline or search the headline they add to the overall cost. An engineer for www.controleng.com

M More SOLUTIONS

20

•

November 2017

CONTROL ENGINEERING

PLCs, like this AutomationDirect BRX, have been the workhorse in industrial automation applications for decades. Courtesy: AutomationDirect

insisting on a full do-it-yourself experience may try to create the converter internally, but that can require extensive development time.

PLCs are designed to work with industrial sensors and offer a wide range of I/O choices, so there should be little or no need for external conversion. Wiring directly to a PLC or I/O module will be easier since it is designed for this purpose. A PLC also will ensure a high degree of protection for the devices and circuits by building in isolation for relevant I/O points. An end user may be able to do the same, but this requires additional knowledge and increases complexity.

Mounting and housing a micro-controller is a consideration, since it likely will be a naked board with pins for connections. The end user also must supply power and create terminals to attach external devices.

Other considerations

Micro-controllers are bare-bones devices, and other considerations include lack of operating system software routines, applications, and software housekeeping functions; software and hardware watchdog functions; data verification and safe mode; environment considerations such as shock and vibration, electromagnetic noise, corrosion, limited temperature range, and related testing; generic versus branded boards; longevity and migration paths; technical support; as well as reliability and safety. ce

Bill Dehner is a technical marketing engineer and Tim Wheeler is a technical marketer and training developer, AutomationDirect. Edited by Emily Guenther, associate content manager, Control Engineering, eguenther@cfemedia.com. www.controleng.com

™ ™ NEW Full-color InView Full-color InView Industrial Message Display!

Through state-of-the-art LED innovation, we’ve created an industrial display with 3x the brightness and greater pixel density, while only requiring half the power of our legacy displays!

• • • • • • •

Bright 1800-nit LED’s NEMA 4 & NEMA 4X 6.25mm pixel pitch Up to 5 lines of text.

Modbus TCP/IP protocol support Bi-directional message scrolling Available in 40” or 70” wide models.

For more information, please visit us at www.spectrumcontrols.com, or contact your local Rockwell Automation distributor. input #13 at www.controleng.com/information +1 (425) 746-9481 www.spectrumcontrols.com spectrum@spectrumcontrols.com

ANSWERS

COVER: AUTOMATION RELIABILITY David Ward, Cross Company Integrated Systems

Control system lifecycle Extending the lifecycle of a control system requires proper maintenance and effective lifecycle management practices. Seven tips can help.

I

f a control system is at the end of its lifecycle and a company can’t afford the time or expense of an upgrade to the whole system, some things can be done in the interim to increase the longevity of an aging system, independent of the system’s age.

In most cases, a control system consists of much more than a few programmable logic controllers (PLCs). There are controllers, input/output (I/O) cards, a network infrastructure, gateways or interface devices to allow data to flow between systems, and human-machine interface (HMI) software applications or proprietary consoles.

To maximize the lifecycle of a system, it’s important to have good preventive maintenance plans, and a plan for managing the dependence on aging components and software, which are essential to operation.

Automation maintenance: 7 tips

Keeping up with control system releases and properly maintaining the system over its lifecycle is essential to ensuring its reliability and continuous operation. This exercise can thwart the demands of time, manufacturing, and production schedules.

distributed components. Variable frequency drives, valve banks, remote I/O, etc., are all reliant on a solid network. In most cases, it makes sense to make this as robust as possible. Users should explore layout topologies, distributing loads, and fault tolerance using multiple links and switches.

4. Stay up to date: Every control system has a life span. Computers should typically be replaced every five to six years and controllers/hardware should be replaced as needed (while still available). Keeping up-to-date can involve upgrading computers and the control software. Companies that follow the latest version of software supplied by the vendor probably will be upgrading PCs more often due to enhancements and functions offered on the newer operating systems, which usually don’t support older hardware.

5. Virtualize: In most cases, it’s possible to virtualize the old system, which would allow users to limp by until a final solution is in place. This works well if you have good control hardware and need an immediate solution to HMI PC replacement problems.

1. Control system power: Good, reliable, and clean 6.

M More ANSWERS

KEYWORD:

Computers typically should be replaced every five to six years.

Virtualization can maximize the life of a control system while providing needed flexibility for a plant manager.

Extending the lifecycle model of a control system requires proper maintenance and good management practices.

GO ONLINE Read this story online at www.controleng.com for more information about control systems and additional stories from Cross Company.

CONSIDER THIS What other methods can plant managers use to maximize a control system’s lifecycle?

22

•

November 2017

power is a must to maintain longevity. Use an uninterruptible power supply (UPS) and run the critical components from it.

2. Environment:

Keeping tabs on the environment means factoring in temperature, humidity, and dust. Controlling the temperature and humidity around the components in the control system is critical. The warmer the cabinet, the shorter the life of the components inside (above a threshold temperature). This applies to computers as well. Accumulated dust can act as an insulator, keeping the cooling air from properly removing heat.

3. Network updates: The network is the backbone of the control system yet it is often the part most overlooked. The data has to make it from the processors to the server/HMI so it can be controlled.

More and more systems are adopting Ethernet as the go-to choice for control of CONTROL ENGINEERING

Phased replacement: Replacement often consists of updating the HMI software to a package that works with the existing and new hardware. Users can replace hardware as part of a phased approach, running the new and old systems side-by-side on the new HMI software until the upgrade is complete and you have all-new hardware. This removes the vulnerability of the outdated computer hardware running legacy operating systems.

7. Plan ahead: Several years prior to when a control system is to be discontinued, users should begin the process of planning the next steps to ensure you minimize the potential for production outages. Most vendors offer migration paths. Using thin-clients is also a great way to help minimize the impact of replaced hardware because these are independent of operating systems. ce David Ward, integration/energy management engineer, Cross Company Integrated Systems. This article originally appeared on Cross Company’s website.

Cross Company is a CFE content partner. Edited by Hannah Cox, content specialist, CFE Media. www.controleng.com

Advantech EtherCAT Solutions • Real Time • Precision • Simplicity • Integration

Aligned with PC-based control to provide the latest in processors, flexibility and main stream Ethernet fieldbus, Advantech provides solutions to machine makers and system integrators. With the support of EtherCAT open standard protocol, users can leverage the fast cycle time for high performance synchronous motion control.

PCI-1203

2-Port EtherCAT Universal PCI Master Card

AMAX-3285

EtherCAT Pulse Command Module

www.advantech.com

AMAX-4800

Industrial EtherCAT Remote I/O Slave Module

ADAM-5000/ECAT 4-slot Distributed High Speed I/O System for EtherCAT

input #14 at www.controleng.com/information

ANSWERS

S.L. Podvalny and E.M. Vasiljev, Voronezh State Technical University, Russia

Multi-alternative power control Space vehicles require alternative energy sources with a multi-level control structure to exclude failure risk and ensure uninterrupted power supply in various modes.

C

hanging operating conditions in space creates difficulties for supplying reliable power to spacecraft. A property of biological systems, homeostasis, can resolve challenges by using multi-alternative principles: Multi-level structure and control, functions diversity and partition, and structure modularity.

For example, the power supply system (PSS) of an orbital station contains alternative energy sources with a multi-level control structure. To embody the principle of modularity and partitioned functions, the general control zone is divided into non-overlapping active control ranges. Partitioning of functions, modularity, and the structure’s hierarchy excludes the possibility of a cascading increase in system failures and ensures uninterrupted station power supply in various flight modes.

Reliable power for an orbital spacecraft is difficult due to significantly varying luminous flux densities, variable temperature, and shade on solar batteries, even when a PSS design has multiple redundancies.

Experience in designing and exploitation of a PSS shows the need for active reorganization of the operation modes and the interaction of its modules, depending on the current flight conditions. That is, better control is needed.

KEYWORDS PSS design needs to form common principles, Power supplies, power as well as build on successes achieved in creatcontrol ing autonomous PSSs using one methodological Multi-alternative control approach for resolving design problems. The conhelps with spacecraft power cept of a multi-alternative structure is proposed supply design. based on the functions of biological systems. LivMulti-levelness, ing communities can be sustained in a changing modularity, and partitioning functions all help. environment, a property of homeostasis.

The following comprise the concept: The prinGO ONLINE ciple of diversity, partitioned functions, the prinMore details, diagrams, ciple of multi-leveling, and modular design. The and eight references appear with this article online at PSS of the Russian segment of the International www.controleng.com.

Space Station is an example of the implementation of these principles. The results of applying matheCONSIDER THIS matical and simulation models of the main system How can multi-alternative design help your project? modules and examining the processes of applying

More

M ANSWERS

24

•

November 2017

CONTROL ENGINEERING

Solar batteries

Voltage regulators Currentt control C t

High voltage sources

Accumulator batteries

Voltage converters Current contro control

Main and filters

RELIABLE ENERGY EFFICIENCY

Voltage monitor

Charging and discharging devices Current control

Diagram shows the general structure of a power supply system for use in space vehicles.

Courtesy: Voronezh State Technical University

the multi-alternative principles in critical functional modes. The subsystems of the main PSS (see diagram) are: • Solar batteries, the primary source of energy • A high voltage source located on the apparatus external to the space station and playing the role of a secondary energy source • Electrochemical accumulator batteries, which accumulate energy if there is an excess in the system, and returning energy if there is a shortage.

Subsystems have automatic control circuits; interactions in operating modes are discussed online; eight graphics show subsystems and power controls.

Multi-alternative control

Analysis of the critical operating modes of the autonomous PSS of the space station shows that the survivability of the system under consideration is achieved as a result of application of the evolutionary principles of multi-alternative control.

• Multi-levelness creates the diversity of behavioral strategies of the system by transferring control and distributing the power supply functions between the subsystems and within each of them, depending on the present situation.

• Modularity reduces the possibility of cascade (technologically connected) development of an emergency situation and failure.

• Functions partition ensures high efficiency of organized control channels with narrow functional purposes.

On the basis of these principles, active redirection of the energy and information flows of the PSS and change in the strategy of how subsystems function in extreme situations are realized. ce

Semen L. Podvalny is head of the Department of Automated and Computing Systems, and Eugeny M. Vasiljev is associate professor of the Department of Automated and Computing Systems, at Voronezh State Technical University; edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com. www.controleng.com

ANSWERS

RENEWABLE ENERGY

CUSTOMAXIMIZED!

Moira Lise, MTS Sensors

Magnetostrictive sensor benefits

Sensor? Housing? Lens holder?

Plug orientation? It´s your choice!

The uEye LE USB 3.1 Gen 1 industrial cameras

Magnetostrictive linear position sensors, when used with a CANopen interface, are useful in wind turbine applications.

M

agnetostrictive linear position sensors are designed for advanced motion control implementations and can be integrated into many applications. The interface allows the simultaneous detection of four magnets using one sensor with a stroke length up to 20 m. The interface, signal transmission, and exact position measurement of magnetostrictive linear position sensors make them suitable alternatives to reed-chain based sensors or limit switches.

BOARDLEVEL VERSIONS

SINGLE-BOARD CAMERA

OPTION: PLUG ORIENTATION

MIC OPTION

USB TYPE-C

USB POWER DELIVERY

OPTION: LENS HOLDER

WIDE RANGE OF SENSORS

Wind industry sensing applications

Magnetostrictive sensors are used for position feedback in the closed-loop control for the pitch of rotor blades: they measure position with high accuracy under great aerodynamic forces and continuously changing wind conditions. To ensure the highest safety during maintenance, locking cylinders keep the rotor blades of wind turbine stationary and positioned precisely. The extending and retracting movement of the locking bolt makes the wind turbine lock and unlock. The detection of the locking/unlocking position can be monitored with sensors. They provide operation and functionality in difficult maintenance situations due to rotor height or in challenging offshore environments.

As wind velocity and direction change, the pitch control adjusts the angle of the rotor blades by a few degrees to maximize the output for all wind speeds. When the wind velocity exceeds the maximum permissible generator output, the blades are adjusted away from the optimum position to reduce the aerodynamic efficiency and maintain constant rotation. Blades are turned back into the wind when wind speed drops again.

Actively controlling the rotation speed enables peak efficiency, reduces the stress on the rotor and tower, and is the foundation for increased safety and longevity. ce Moira Lise, MTS Sensors. This article originally appeared on the CAN in Automation (CiA) website. CAN in Automation is a CFE Media content partner. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com.

Magnetostrictive linear position sensors with CANopen are designed for advanced motion control implementations. These are Temposonics R-Series sensor.

Courtesy: MTS Sensors/CAN in Automation CONTROL ENGINEERING

November 2017

•

®

www.ids-imaging.us/usb3.1 25

input #15 at www.controleng.com/information

ANSWERS

RENEWABLES

Mark T. Hoske, Control Engineering

Renewable energy opportunities Biofuels, hydrogen and fuel cells, solar, wave energy, wind, advanced vehicles, and others are among applications for automation, controls, and instrumentation.

Wind energy is among projects funded by the U.S. Dept. of Energy’s Office of Energy Efficiency and Renewable Energy (EERE). Courtesy: Mark T. Hoske, Control Engineering, CFE Media

R

enewable energy and energy efficiency are among industries where automation, controls, and instrumentation are being applied. These include biofuels, hydrogen and fuel cells, solar, wave energy, wind, and others supported by U.S. Dept. of Energy (DOE).

Below, see some recent DOE awards and announcements.

Project sampling

Eight projects were selected to negotiate for up to $15 million in DOE funding to optimize integrated biorefineries: Sept. 20.

DOE Fuel Cell Technologies Office and the U.S. Army’s Tank Automotive Research Development and Engineering Center announced plans to collaborate on jointly funded projects to advance progress in hydrogen and fuel cell technologies: Oct. 4.

A new high-performance computing initiative from DOE aims to help U.S. industry accelerate the development of new or improved materials for use in severe environments. Sept. 19.

DOE announced $46.2 million for 48 projects in its SunShot Initiative. These projects are intended to develop innovative, early-stage solar power technologies, which are aimed at lowering costs and improving reliability and efficiency: July 12.

DOE announced up to $12 million in in four new projects to advance marine and hydrokinetic energy technologies, which can harness energy from U.S. oceans and rivers: June 15.

DOE released three wind market reports: Aug. 8. ce

Mark T. Hoske is content manager, Control Engineering, mhoske@cfemedia.com.

M More ANSWERS

KEYWORDS: Renewable energy See more with this article online and learn more at DOE’s Office of Energy Efficiency and Renewable Energy, www.energy.gov. input #16 at www.controleng.com/information

26

•

November 2017

ANSWERS

INSIDE PROCESS | SAFETY Gregory Hale, ISSSource

Turning safety into profitability Companies need to view safety as more than a cost and see it as an opportunity to improve overall performance and effectiveness. Change the culture; refocus on real-time safety risks.

S

afety technology and the professionals behind it provide a solid assurance the process and facility remain safe and sound. That is a vital element of process automation, but there can be more.

An Aberdeen Group study on the three tiers of safety levels said the top tier is best in class with 90% overall equipment effectiveness (OEE), 0.2% repeat accident rate, 0.05% injury frequency rate, and 2% unscheduled asset downtime. The top tier represented 20% of the aggregate performance scorers. That compares to the laggard or third tier of performers that have a 76% OEE, 10% repeat accident rate, 3% injury frequency rate, and 14% unscheduled asset downtime.

This category had 30% of the aggregate performance scorers. The middle is filled out by the rest with an 85% OEE, 2.4% repeat accident rate, 0.9% injury frequency rate, and 6% unscheduled asset downtime.

Every 15 seconds a worker dies from a work-related accident or disease, said a report from the International Labour Organization. That adds up to 6,300 deaths per day or 2.3 million a year. In addition, every 15 seconds, 153 workers have a work-related accident.

It is easy to ask why don’t more manufacturers think safety first? The answer is not easy; companies see safety as a cost and not a business enabler that can boost profits. That thinking may soon change.

“There has to be a senior management commitment to viewing safety as more than a cost, but an opportunity to improve performance,” said Martin Turk, Schneider Electric’s director, downstream O&G global solutions architect. “There is a need for a belief—a commitment from the executive—to do something to improve performance.”

four times a day to find out what they are going to do to turn around profitability. To create a safety environment, there has to be a direct link between profitability and safety.”

That is where real-time safety and operational profitability come into play.

“What we are finding in most plants today is they are setting up their safety limit as a constant,” Martin said. “What if you can directly measure the safety risk and realize the plant’s normal safety threshold can be pushed a little because your equipment is in better shape? This way you can drive more profitability to the plant because of lower safety risk. By doing that, to a chief executive, you tied profitability to safety so there is a direct metric showing if you control and reduce safety risk you can drive more profitability. We believe that is the link to create a safety culture by mathematically showing how that can be done.”

The biggest barrier to linking safety and profitability is being able to measure safety risk in real time. To do that, Martin suggested users look at operational safety measurement, conditional safety measurement, and conditional measures around an asset. ce Gregory Hale is the editor and founder of Industrial Safety and Security Source, a news and information website covering safety and security issues in the manufacturing automation sector. This content originally appeared on www.ISSSource.com. ISSSource is a CFE Media content partner. Edited by Chris Vavra, production editor, CFE Media, cvavra@cfemedia.com, and Jack Smith, content manager, Control Engineering, CFE Media, jsmith@cfemedia.com.

M More ANSWERS

KEYWORD:

Process safety

GO ONLINE Read this story online at www.controleng.com for more information on process safety, as well as related stories from ISSSource.

KEY CONCEPTS When the message has to come from the top, safety often ends up slighted because of profitability issues.

Measure safety risk in real time to link safety and profitability.

Clamp down on safety where it’s needed.

CONSIDER THIS Is it possible to turn safety into profitability? See more details with this article online.

Focus on profits

Safety often ends up slighted when chief executives are responsible; not that they don’t believe in safety, but they have profitability issues to focus on.

“Working in a publicly traded company, the pressure (on chief executives) for profitability is so enormous and so short term, even if somebody wants to focus on safety, they are in survival mode because they have to show results next week or they are out of a job,” said Peter Martin, vice president, business value solutions at Schneider Electric. “That culture is a terrible culture. I know some senior level managers that are really top-notch talent that would love to have a safety environment, but they are called into meetings

www.controleng.com

Respondents to the Plant Engineering 2016 Safety Study identified seven high-level findings impacting the manufacturing industries today. Source: Plant Engineering CONTROL ENGINEERING

November 2017

•

P1

ANSWERS

INSIDE PROCESS | SENSORS Frank Lamb, Automation Consulting LLC, and Christopher Thompson, Matrix Technologies Inc.

Choosing sensors for an application The Aug. 22, 2017, Control Engineering “Choosing sensors for the application” webcast presenters addressed questions not covered during the live event.

E M More ANSWERS

The New Products for Engineers Database has sensor-related product categories. www.controleng.com/NP4E www.controleng.com/ webcasts

xperts provided advice about how to choose sensors for automation and control applications; important implementation details regarding proper sensor selection; methods, technologies, and considerations for sensor applications; fundamentals of specifying process sensors; and process sensor technologies and their applications.

Presenters Frank Lamb, founder, owner, and manufacturing and automation business consultant, Automation Consulting LLC, and a Control Engineering Editorial Advisory Board member; and Christopher J. Thompson, PE, department manager, process engineering, Process Solutions Dept., Matrix Technologies Inc. (Matrix Technologies Inc. was named System Integrator of the Year by Control Engineering magazine multiple times), responded to questions not answered during the live “Choosing sensors for the application” webcast.

Q: Can you discuss application of radar and ultrasonic sensors and transmitters?

Christopher Thompson: Radar sensors are typically associated with measurement of liquid or bulk level in some type of container (such as a tank, vessel, silo, or hopper). The sensor emits a microwave pulse that is either directed down a fixed probe (guided wave) or into the open area of the container (noncontact). In both cases, the transmitter then detects the reflection time of the microwave pulse as it bounces back from the fluid or build solid level in the container. A guided wave also can detect interface levels in liquid-liquid applications, and its measurement is largely independent of the property changes that occur at various operating conditions. Noncontact radar sensors can be inhibited by use with some solids, fluids with low dielectric, substantial surface turbulence,

MONITOR VISCOSITY SIMPLY SENSE MIXER MOTOR HORSEPOWER WITH UNIVERSAL POWER CELL EASY INSTALLATION • No holes in tanks or pipes • Away from sensitive processes VERSATILE • One size adjusts to motors, from small up to 150hp • Works on 3 phase, fixed or variable frequency, DC and single phase power SENSITIVE • 10 times more sensitive than just sensing amps CONVENIENT OUTPUTS • For meters, controllers, computers 4-20 milliamps 0-10 volts

PROFILING A PROCESS

24

• Power changes reflect viscosity changes • Good batches will fit the normal “profile” for that product POWER DECREASE SHOWS BATCH IS DONE

22 20 18

POWER SENSOR

16 14 12 10 8

DRY MIX HIGH SPEED

ADD LIQUID LOW SPEED

MIXER MOTOR BEGIN HIGH SPEED MIX

6 4 2 0

BATCH 1

BATCH 2

BATCH 3

CALL NOW FOR YOUR FREE 30-DAY TRIAL 888-600-3247 WWW.LOADCONTROLS.COM input #17 at www.controleng.com/information

NETWORKED VALVE CONTROL. COMPACT. FLEXIBLE.

OL NTR

E CO V L VA

IN '(

12 ( ,Ǭ2

7+

WAGO-I/O-SYSTEM 750 750-632 Proportional Valve I/O Module r Compact, 12 mm wide module r Control two valves up to 24V and 1.6A each r Integrate with a variety of networks and I/O modules www.wago.us/valve-control

input #18 at www.controleng.com/information

ANSWERS

INSIDE PROCESS | SENSORS

DPM-COUNTERS-TIMERS UPM

BARGRAPHS NTM

condensing vapor environments, and echoes from container walls or internals.

Ultrasonic sensors operate on a similar principal as the radar, with the sensor measuring time-of-travel or reflection time of the ultrasonic pulse emitted. The sensor correlates this time to the liquid or bulk solid level in a container, or flow through a pipe. The flow sensor is typically used with liquids and gases, and the emitted ultrasound must be capable of penetrating through or being reflected from the material being sensed. Ultrasonic level sensors are fixed, but flowmeters can be either fixed or portable, inline, or clamp-on.

Ultrasonic level sensors can be inhibited by use with some solids, foaming, interference, or echoes from container walls or internal, smoke and/or dust, and heavy vapors. Flow sensor applications depend highly on the fluid being metered. If there are any questions or uncertainties regarding the sensor, inquire into possible vendor testing, instrument trials or rentals, or an application warranty.

Q: Can you discuss sensor use in hazardous areas?

COMMON FEATURES (ALL SERIES)

LOOP/SIGNAL/UNIVERSAL POWER INPUT SIGNAL FAIL ALARM ISOLATED RS485-USB-ETHERNET DAS-SCADA-CYBER SECURITY READY MIL-NUCLEAR-INDUSTRIAL GRADES AND CUSTOMS REMOTE DISPLAY/CONTROLLER ISOLATED 4-20mA/VDC & RELAYS OUT >50 ANALOG INPUT SIGNALS 15 DIGITAL INPUT SIGNALS 1-4 ISOLATED CHANNELS >40 MODELS! LIFETIME WARRANTY/>25 YEAR MTBF SINCE 1974

520-748-7900

MADE IN THE USA

www.otekcorp.com

input #19 at www.controleng.com/information

Frank Lamb: To prevent explosions and combustion in hazardous areas, sensors are housed in an explosion-proof enclosure or intrinsically safe “NAMUR” rated sensors are used. These sensors operate on less than 8 V dc to prevent sparking and often are connected through an intrinsic safety barrier.

Q: Can you discuss accuracy considerations for gas flowmeters?

Thompson: With most gas flowmeters, accuracy will depend on the material being sensed, the process conditions encountered, the installation location, operating range, and the technology selected. Condensing vapors are a challenge for most applications, so operating in a range that will minimize the likelihood of liquid droplets forming is important. Depending on the technology, turndown could impact not only the accuracy but ability to use the meter (e.g., vortex, turbine, or differential pressure).

Particulate-laden gases also can pose a challenge for some meters, depending on the type and concentration of particulates.

Proper temperature/pressure corrections

P4

•

November 2017

as well as proper flow distribution into the meter itself (e.g., sufficient conditioning or upstream/downstream straight runs) will impact differential pressure flowmeter accuracy, while thermal mass meters will struggle with streams containing variable composition, aerosols, droplets, etc. Flowmeter accuracy issues can be addressed by having an accurate description of the stream being sensed, a clear definition of the operating parameters, and an understanding of the potential technology limitations prior to sensor selection.

Q: Can you discuss best questions to ask stakeholders when selecting sensors?

Thompson: In general, many of the components of the sensor specification itself may come from the stakeholders, such as process conditions, stream composition, accuracy requirements, etc., and buy-in should be obtained that the values specified are accurate.

Some additional questions include: 1) What’s the history with this application and sensors that have been used in the past? 2) Are there any lessons learned to incorporate into our design considerations? 3) Is there a preferred technology or make/ model that has been identified at the facility or elsewhere throughout the organization? 4) What are the accuracy, reliability, and range requirements for the sensor?

5) Are there any access or operating limitations based on the installation location (e.g., internal interferences, maintenance accessibility)? 6) What is the required sensor redundancy and what is the frequency of planned calibration? 7) Have all stream components been considered and accurately characterized opposite the proposed materials of construction? 8) If it is a replacement due to failure, has the root cause been determined and mitigated? 9) What type of local or remote indication is necessary for process control, and is there latency experienced from the instrument location opposite the control point? 10) Into what environment will the sensor and transmitter be installed (such as electrically classified hazardous locations, temperature extremes)? ce Edited by Mark T. Hoske, content manager, mhoske@cfemedia.com, and Jack Smith, content manager, Control Engineering, CFE Media, jsmith@cfemedia.com.

CONTROL ENGINEERING

advertisement

Update To The NFPA 70E Standard The National Fire Protection Association (NFPA) is a trade association that develops and maintains various standards and codes designed to prevent injury and economic loss caused by fire and electrical related hazards. The organization published NFPA 70E, the Standard for Electrical Safety in the Workplace and updates the standard every three years.

One change in the latest version, NFPA 70E 2018, includes new language in Article 120.5 (7) about absence of voltage verification. This white paper examines the new NFPA 70E options for absence of voltage testing, reviews the advantages and limitations of various voltage testing and voltage indicator products, and explains how the VeriSafe™ Absence of Voltage Tester (AVT) complies with the new NFPA 70E requirements.

Prior to NFPA 70E 2018, the process electrical workers would use to verify the absence of voltage in a panel or other electrical equipment required the use of an “…adequately rated test instrument…”, which was typically interpreted as a hand-held voltage tester. NFPA 70E, Article 120.5, Process for Establishing and Verifying an Electrically Safe Work Condition, has always contained a step to verify he absence of voltage. The 2018 edition includes an exception, also known as an approved alternative, to using a handheld test instrument.

The new exception describes an absence of voltage tester (AVT). Part of the motivation for including this exception was to stimulate original solutions and development of new technology for safety applications and make testing for an absence of voltage safer and more efficient.

For example, when performing the traditional method of using a hand-held voltage tester to check for an absence of voltage in a control panel, the door must be open to conduct the test. This exposes the electrical worker to potentially lethal voltages. However, implementing AVT devices allows the worker to verify the absence of voltage prior to opening the panel which reduces the risk of an electrical incident as well as reducing the complexity of testing with a hand-held tester. cs@panduit.com • www.panduit.com/verisafe

Register to download the paper: https://pages.panduit.com/verisafe2-controlengineering.html input #20 at www.controleng.com/information

INNOVATIONS

NEW PRODUCTS FOR ENGINEERS Process control system for future-oriented digitalization Siemens’ Simatic PCS 7 V9.0 is a process control system designed to supporting future-oriented digitalization down to the field level. It supports Profinet with two distributed input/output (I/O) lines for greater digitalization right down to the field level, as well as extensive new software functionality. Plant operators benefit from greater flexibility, convenience, future-proofing, and wide-ranging compatibility with legacy installations. The new I/O line is designed for high availability and can be used in the field up to Ex zone 2.

Electrostatic discharge fluted grip knobs Elesa ESD fluted grip knobs, leveling element bases, and bridge handles in special conductive technopolymer prevent the accumulation of electrostatic charge, protecting electronic components that would otherwise be damaged by a build-up and consequent destructive discharge. Grip knobs for clamping, plus plastic bridge handles for pull operation, varied leveling feet, non-slip pads, and floor fixing points.

Siemens, www.siemens.com,

Input #201 at www.controleng.com/information

Vibration sensors: drives, rotating shafts

Elesa (UK) Ltd., www.elesa.com

Hansford Sensors’ HS-100 Series of vibration sensors is designed for drives and rotating shafts, such as pumps, fans, motors, gearboxes, and compressors, for condition monitoring, predictive maintenance, and plant management system applications. They are sealed to IP68 protection rating and are mountable for different options. The frequency response has been improved, to between 0.8 and 15 kHz, while the resonant frequency has been increased to between 26 and 34 kHz. The shift in frequency response represents a significant enhancement, allowing greater separation between the resonant frequency point of the piezoelectric sensing mechanism and the vibration frequencies of the application.

Input #200 at www.controleng.com/information

Hansford Sensors, www.hansfordsensors.com,

Input #202 at www.controleng.com/information

No application left behind.

Unidrive M AC Drives Simple set-up. Flawlessly functional.

No matter what your motor-driven challenge, there’s a Unidrive M drive with the exact levels of functionality you need.

Easy to apply. Built to last. Flexible. Scalable. Economical.

Free drive programming software and application consultation.

Find your solution at NidecUnidriveM.com

Now driving the world’s #1 brand of motors. And yours.

M100

M200

M300

M400

©2017 All Rights Reserved. Control Techniques is a trademark of Nidec Corporation.

input #21 at www.controleng.com/information

See more New Products for Engineers. www.controleng.com/NP4E

PE

Incremental and absolute encoders

AutomationDirect expanded its Koyo encoder product line to include more incremental encoder output options and higher resolutions for absolute encoders.

The TRD-S series of 6 mm solid shaft and TRD-SH series of 8 mm hollow shaft incremental encoders now have 5 to 12 V dc open collector output versions. These incremental encoders have an IP40 environmental rating with resolutions available from 100 pulses per revolution (ppr) to 2500 ppr and up to a 200 kHz maximum response frequency. Koyo light-duty encoders are cost-effective for applications with light loads on the shaft and perfect for industrial environments with good mounting conditions and flexible shaft couplings. The TRDNA series medium-duty absolute encoders are available in resolutions up to 2048 ppr. They feature a 50 mm diameter body with 35 mm depth and have a splash-proof IP65 protection rating. The absolute encoders are suitable for applications with moderate shaft loading and flexible shaft couplings and are used where position data must be retained through power cycles.

AutomationDirect www.automationdirect.com

input #22 at www.controleng.com/information

Input #203 at www.controleng.com/information

Low noise 3 & 5 Watt DC/DC converters in metal package.

Rocker switches for harsh environments

Apem’s KH series of rocker switches are shielded against accidental actuation with a protection guard and are designed for harsh environments such as agriculture, off-road vehicles, material handling, and automotive. The protection guards are designed to prevent accidental actuations, which can occur in harsh environments. The KH series features IP69K front-panel sealing and is available illuminated and non-illuminated, with numerous symbols and rocker colors to meet individual user requirements.

Apem Inc., www.apem.com

Reliable. Available. Now.

Input #204 at www.controleng.com/information

November 2017

•

TVN 3 and TVN 5WI Series • Ultra low ripple and noise 10 mVp-p typ.

• Singe and dual output models, fully regulated, isolated, no minimum load required • Input filter to meet EN 55032 class B without external components • Operating temperature range –40 °C to +85 °C • Wide input voltage ranges up to 75 VDC includes the low voltage range 4.5–13.2 VDC • Trim and remote control functions

33

www.tracopower.com

input #23 at www.controleng.com/information

UK_en_TVN3_5_CE_Third_4.5x4.625inch.indd 1

17.10.17 15:23

Sawmill Conveyor Lines: ABB Drives deliver reliable process control and a 5% increase in production efficiency Summary: At the Westas sawmill the production process is very long and conveyor intensive. The size and weight of materials varies greatly, starting with heavy logs and then transitioning to a range of smaller pieces. To keep the sequence of production processes running smoothly it is crucial that the speed and feeding of the conveyors adapt to the various products. A stop in some part of the process can affect things all the way to the beginning.

Challenge: Upgrade the conveyors that carry materials of varying sizes/weights through the long production processes, to gain greater speed control and performance efficiency without rebuilding the whole system.

Solution: Retrofit the existing conveyors with ABBs ACS580 general purpose variable speed drives.

Result: Achieve the desired results with a relatively small expenditure and a far better return on investment than complete machinery replacements: • Improved production efficiency by 5% : Better quality products, less waste, less energy usage and greater profits; • Reliable process control: Highly precise speed increases of 5 to 20% without using PLCs; • Easy commissioning and operation.

Instead of rebuilding the whole production line, Westas opted to invest in an automation upgrade to improve production efficiency. The upgrade included the log feeding, log metering and saw-line angle metering machines. The conveyors for each were retrofitted with ABBs ACS580 general purpose variable speed drives.

The addition of the drives allowed the speed of the conveyors to be adjusted as required to accommodate the varying loads and to sync with the production processes.

The ACS580s also improved production efficiency by approximately 5%, with a far better return on investment than completely replacing the conveyor lines.

In a sawmill the efficient use of raw materials is the key, but energy is also a major variable cost. Utilizing ABB drives, Westas was able to achieve savings on both material and energy consumption, adding directly to the bottom line.

ABB, Inc., Drives and Controls Phone: 800-752-0696 Read the full Case Study: http://new.abb.com/drives/media/case-westas-group input #24 at www.controleng.com/information

How Innovative Process Automation Quickly Doubled Production Summary: To meet growing market demand, International Foods purchased a brownfield site of a closed Ford Motor Company plant in St. Louis. Partnering with EPIC Process Systems, they built a new facility and expanded production for both liquid and powder food product lines.

Challenge: International Food Company needed a rapid expansion of their process and packaging lines due to increased customer demand.

A new brownfield facility was acquired, creating a project with an accelerated schedule and several challenging sanitary requirements.

Solution: A series of sanitary systems were built off-site (modular construction) and automated under controlled conditions, allowing field construction to occur simultaneously.

Modular engineering methods ensured high quality construction, system validation, and full startup before the target date.

EPIC ensured that all process and packaging equipment complied with stringent food and beverage sanitary requirements Title 21 CFR, Part 110 cGMP guidelines.

Site and plant construction was simultaneously underway while system programming and fabrication was occurring at EPIC’s sanitary facility. Allen-Bradley PLC’s were integrated on all equipment, with a custom batch tracking software developed by EPIC for recipe management and formula tracking.

Finished modules were shipped to the International Food Company plant, followed by a fast start up within three days of arrival. Each sanitary batching and blending system went through in-house, Factory Acceptance Testing (FAT) to ensure trouble free startup during installation.

A team of EPIC’s in-house automation engineers were on site throughout installation and commissioning. Their presence helped ensure the process and packaging systems were running at specified parameters. They also assisted in training plant personnel on all new operating systems associated with the new plant equipment. The collaborative project resulted in successful startup, allowing International Foods to increase production, meeting demand for their growing product lines.

Result: The Allen Bradley PLC platform and custom batching system nearly doubled production capacity and product offerings, while also improving product tracking and quality control.

Read the complete case study: http://bit.ly/2l5exOy EPIC Process Systems EPIC Industrial Automation

314-207-4261 www.epicmodularprocess.com 314-207-4261 www.epicindustrialautomation.com

input #25 at www.controleng.com/information

FASTechnology Group: Systems Integrator adds UPC Verification to Bagging Machines in Packaging Industry Summary: In the Consumer Packaged Goods industry, a simple mismatch of pre-printed package to product can quickly spiral into a safety concern for consumers, not to mention countless dollars lost on wasted products, recalls, and downtime. For example, a packaging line cannot have peanuts going into a potato chip bag. The risks of only checking the spool of film prior to running the line doesn’t always cut it. When FASTechnology Group was tasked with modifying existing production lines to verify the UPC of each and every bag, the company was able to use the latest in industrial controls across a wide array of technologies to deliver a solution to the customer.

Challenge:

Using the latest in PLC controls, HMI, and machine vision technology, as well as custom software and database development, FASTechnology Group created a system to read, compare and verify the UPC barcode of each and every product made against the plant’s ERP system.

The system combines an industrial logic controller, a machine vision barcode reader, and custom server-side software to cross-reference the physical UPC with the one in the Plant Management Software. As one of FASTech’s customers states: “Using this system, we are able to limit the pulling of jobs down from the plant management system to only those scheduled for the current shift. This keeps the user interface out on the plant floor clean, simple to use, and efficient.”

Result:

See more information on this and other related applications @ http://fastechgroup.com/services/cpg/

Supplement existing machines with an efficient, robust system to verify the correct pre-printed packaging is used for the product being packaged, 100% of thetime.

Solution:

A system that integrates seamlessly with the existing production lines, monitoring the necessary aspects to improve line consistency and make mismatching of product to packaging a thing of the past.

sales@fastechgroup.com Tel: 866-327-8324 www.fastechgroup.com input #26 at www.controleng.com/information

Power facility generates an automatic advantage with the Fluke 729 Automatic Pressure Calibrator Summary: Safe and efficient coal-fired power generation requires that all process transmitters and pressure switches be regularly calibrated to ensure that accurate pressure measurements are being fed back into the control system.

So when an instrument supervisor at a U.S. coal-fired power generation plant recently needed to replace a pressure calibrator, he chose the Fluke 729 Automatic Pressure Calibrator. He chose the 729 for its: • Built-in automatic pressure pump that generates and controls pressure up to 300 psi • Ability to document applied pressure, measured mA, and % error for multiple test points in one set up

Challenge: An instrumentation supervisor at a coal-fired power generation plant needed to replace an old failed pressure calibrator used to maintain and troubleshoot several hundred process instruments.

Solution: He purchased a Fluke 729 Automatic Pressure Calibrator with a built in electric pump that automatically generates and regulates pressure up to 300 psi and includes HART communication.

Result: Now, the company’s instrumentation technicians need only carry one tool to quickly and accurately test multiple pressure points on switches and transmitters, rather than up to four tools required previously.

This is projected to enable them to calibrate approximately 20% more instruments per route.

• Capacity to save measurements to the instrument.

His technicians just type in the pressure range, set the % error, and hit the start button. The 729 automatically regulates the pressure.

It even compensates for small leaks using stored compressed air and miniature air valves. This saves time and reduces the number of pressure calibration tools that instrumentation technicians have to carry, from four to one.

The instrumentation supervisor estimates that using the Fluke 729, allows his technicians to calibrate approximately 20% more instruments per route. This increased efficiency saves a significant amount of troubleshooting and preventive maintenance time, and reduces the amount of time an instrument is offline for testing.

Fluke-info@fluke.com 1-800-44-FLUKE www.fluke.com input #27 at www.controleng.com/information

`

Honeywell Implements Low-cost Cloud-based Oil and Gas SCADA System in Less than One Month Summary: In 2016, an oil and gas company acquired a gas field with over 300 producing wells. The goal: bring these wells online within one month. The company needed a vendor with deep SCADA knowledge, proven SCADA solutions and a cloud-based system allowing flexibility for changing assets and speed of implementation. Experion® Elevate fit the requirements to offload higher up-front, long-term costs typical to traditional SCADA solutions.

Challenge: The goal was to bring newly purchased wells online within one month, with a cloud-based system allowing change flexibility, speed of implementation, and a low-cost approach.

Solution: Experion® Elevate provided cyber secure communications and instantaneous data for field decision-making. Historical data was transferred into the existing production accounting system.

The client application was delivered via desktop or mobile tablet.

Result: Honeywell successfully completed system configuration on schedule, and commissioned the first wells within 2 weeks. The customer began monitoring and operating the new assets much sooner than planned, with increased production and efficiency and more predictable costs. The solution has performed with approximately 99.99% uptime.

The system provided communications to existing EFMs, instantaneous data for field decision-making, and a custom interface to transfer archived historical data into the existing production accounting system for reporting. Digital cellular networks provided the primary backbone. Experion® Station allowed access via a full desktop or mobile tablet. Embedded cyber security with all required firewalls and VPN gateways provided secure, private and encrypted data pathways.

Honeywell successfully completed system configuration on schedule, and commissioned the first few wells within 2 weeks. Meter templates and the communication infrastructure allowed the customer to begin monitoring and operating the new assets much sooner than originally planned.

The customer increased production and efficiency very quickly, and now has more predictable costs. The solution has performed with approximately 99.99% uptime of the Experion Elevate servers and virtual network. Expansion opportunities are being discussed to bring additional wells, compressor stations, and processing facilities into the system.

www.honeywellprocess.com/Elevate input #28 at www.controleng.com/information

Teel Plastics Reduces Downtime and Increases Efficiency with IoT Gateway for KEPServerEX® Summary: The Teel Plastics facility has ten manufacturing lines that produce different products throughout the day.

Each line requires a custom recipe for every product— and employees had to memorize multiple recipes during a single shift. Teel needed a solution that would control all recipe complexities electronically, in order to reduce downtime and product flaws caused by human error.

Teel found that Kepware’s IoT Gateway for KEPServerEX was the only product that provided a seamless, reliable, and scalable solution for controlling all the essential recipe components through a single web interface.

Challenge: Teel Plastics employees memorized and applied multiple complex, changing recipes during a single shift. But even a minuscule recipe mistake caused downtime and reduced product quality. Teel needed to control all recipes electronically, in order to reduce human error and its downstream impact.

Solution: Kepware’s IoT Gateway for KEPServerEX was the only solution that could address all of Teel’s needs. Kepware’s IoT Gateway also had the interoperability to connect to Teel’s entire range of diverse PLCs.

Result: Teel has reduced set-up times by 30 percent, all but eliminated human error, increased process efficiency, improved product quality, and increased visibility across the enterprise.

With the IoT Gateway providing device interconnectivity to multiple PLCs—including Allen-Bradley and Siemens—Teel drastically reduced human error, downtime, and product flaws. Efficiency was also increased in many ways— for example, processes that previously required 40 clicks now take one single click.

With in-depth plant floor data from the IoT Gateway, Teel engineers have also made their recipes much more efficient. Seamlessly aggregated data enables operators to perform predictive maintenance and leadership to make more informed decisions on recipes—so Teel can produce greater output at a much higher quality. For example, prior to the IoT Gateway, one line was completing 18 units a minute. Now, it is outputting 35 units a minute—nearly doubling its capacity.

sales@kepware.com +1.888.537.9273 x354 www.kepware.com input #29 at www.controleng.com/information

Calculation Management with Confidence: Creating Robust, Auditable Processes in the Mining Industry Summary: Companies invest much time and effort in their products’ designs, techniques, and intellectual property. These are managed across an organization with careful thought and attention. There’s a fundamental process behind these assets that is often overlooked, and its lack is responsible for pains that engineers face on a regular basis: calculation management, a process that treats calculations as vital, valuable company assets.

Diavik Diamond Mine, Canada’s largest diamond mine, recognized this challenge and decided to invest in Diavik Diamond Mine calculation management processes, creating tools and worksheets that offered powerful insights previously unavailable. Using Maple, from Maplesoft, enabled them to perform Challenge: complex calculations quickly At Diavik Diamond Mine, accurate and easily, while moving towards forecasting of diamond production transparent, auditable calculais critical. A deep understanding of tions that give company-wide plant processes requires reliable, insight into technical processes. validated techniques that predict outcomes and allow continuous improvements.

Solution: Diavik decided to invest in their calculation management processes. Maple enabled them to perform complex calculations quickly and easily, while moving towards transparent, auditable calculations that give company-wide insight into technical processes.

Result: After a few months, Diavik has noted time savings by moving process calculations from spreadsheets into Maple. They’ve gained deeper insight and are making steady progress in developing processes that will deliver consistent results with less risk.

At Diavik these processes are regularly analyzed for a more precise understanding of future yields, and to find efficiencies.

Traditionally they’ve relied on spreadsheet tools, but were experiencing limitations. This led to the use of Maple which now provides better insights for management and employees, increased efficiency and optimized operations.

In a few short months, Diavik has noted the time savings. The current pace of technical projects requires the company to proactively approach calculation management to eliminate redundancies and downtimes associated with outdated techniques. They’ve gained deeper insights and are making steady progress in developing robust, validated processes that will deliver consistent results with less risk.

View the complete case study online: http://bit.ly/2yz4kgu info@maplesoft.com • 519-747-2373 www.maplesoft.com input #30 at www.controleng.com/information

S88 Batch Control Upgrade Improves Coffee Creamer Plant Performance with Minimal Downtime and Retraining Summary: Our customer’s changing business needs required a dynamic system which would allow ongoing recipe and process modifications without lost production. The system controlled key processes at several locations in the plant. The new batch system needed to integrate reliably with the existing HMI. Access to batch data was desired to assist with improving product quality and plant efficiency.

Challenge: A global leader in the food industry was faced with replacing an unsupportable legacy batch control system at a powdered coffee creamer plant.

Solution: McEnery Automation implemented a new S88 batch control system integrating Rockwell Automation’s FactoryTalk Batch with the plant’s existing ArchestrA Graphics HMI. Enhanced reports were created using FactoryTalk Batch Reporting, Microsoft SQL Server and SQL Server Reporting Services (SSRS).

Result: The new batch control system increased the plant’s efficiency and provided an easy, reliable way for plant employees to implement and maintain recipe and process changes, allowing our customer to remain a leader in their marketplace.

One FactoryTalk Batch server was used to control multiple process areas including wet mixing, dry mixing and CIP. Redundant servers with warm backup capability increased the system’s reliability; Campaign Manager allowed automatic initiation of repetitive batches. Batch Archiver and Batch Reporting provided access to production data throughout the enterprise.

Phase logic was implemented in three ControlLogix controllers. HMI graphics maintained the same look and feel to reduce retraining. Script function libraries and API calls created a seamless interface between the HMI and batch server.

Because of extensive testing and simulation, a cutover period of just a few hours was required for each process area, with no lost production and operators trained in one shift.

The solution increased the plant’s efficiency in several ways: Increased system reliability reduced production outages; Improved reporting assisted in identifying and eliminating inefficiencies in existing processes; Use of more precise control strategies ensured that additions were within tolerance, reducing waste and re-work.

Read the complete case study on our website: http://www.mceneryautomation.com/fb-batch-automation.html

Tel: 636-717-1400 CustomerService@McEneryAutomation.com www.McEneryAutomation.com input #31 at www.controleng.com/information

Heater Differential Temperature Monitoring and Alarming Using Associated IS Summary: The customer needed to measure inlet and outlet temperature of a process heater using existing three-wire RTDs and provide a 4-20mA process variable signal, representing the differential temperature across the heater, to the BPCS controller. The measurements are in a hazardous area and plant standards require a certified IS system.

Utilizing the associated IS and dual RTD input capability of the THZ3 temperature transmitter, the heater’s differential temperature 4-20mA signal was wired in series to a local alarm trip and host BPCS.

Challenge: Measure inlet and outlet temperature of a process heater using existing three-wire RTDs and provide a 4-20mA process variable signal, representing the differential temperature across the heater, to the Basic Process Control System (BPCS).

The measurements are in a hazardous area and plant standards require the use of a certified IS system.

Solution: The THZ3-DIN Dual Input Temperature Transmitter with the Associated IS (AIS) option, and SPA2 Alarm Trip with self diagnostics capability and local display/alarm status indicators.

Result:

The process side alarm trip provided visual and audible heater failure warning and indication while the host BPCS maintained primary control and master alarming capability. Additionally the HART diagnostics from the THZ3 allowed the BPCS to constantly monitor key parameters such as RTD drift, broken sensors and critical transmitter diagnostics.

Providing a local process side alarm trip substantially saved wiring and operation costs since new signal wires (RTD and alarm) didn’t have to be pulled to support the newly desired local alarms, two IS barriers were not needed for the RTD wires back at the BPCS location, sensor diagnostics continuously monitored by the BPCS and local differential temperature calculation and indication can now be done in the field.

Successful measurements to the BPCS of inlet and outlet temperature, temperature differential, sensor diagnostics, transmitter diagnostics using HART to the BPCS.

800-999-2900 info@miinet.com www.miinet.com input #32 at www.controleng.com/information

Phased-in Control System Modernization Helps Dow Corning Upgrade with Minimal Cost and Downtime Summary: The increasing speed of business is pushing many industrial assets harder, inching them closer and closer to their thresholds of reliability and safety. To forestall any potential failure that might have resulted as systems at its Carrollton, Kentucky facility approached end of life, Dow Corning implemented a control system upgrade in collaboration with Schneider Electric.

Challenge: • Control potential operational safety and reliability risks by upgrading legacy system • Execute the project at low cost, low risk with reduced time to production • Provide seamless transition to new technology for Dow Corning Operations team

Solution: • Phased-in migration that kept wiring and nose cone infrastructure intact • Schneider Electric EcoStruxure Foxboro DCS automation system and Schneider Electric Modernization Services

Result: • Reduced project risk and cost by preserving infrastructure • Kept all existing nose cones and field wiring • Job executed 50% faster than expected • Reduced CAPEX by 50% • Added two extra days of production, leading to a faster time to profit

Initially fearing that they would have to rip and replace their existing system, Dow Corning was pleased to find that the Schneider Electric services and solutions, including the EcoStruxure™ Foxboro DCS, enabled them to phase the upgrade in without having to shut down all systems and cease production for an extended time.

Keeping the legacy infrastructure intact decreased the estimated time-to-completion by 50%, giving back two extra days of production and a faster time-to-profit.

The project itself was also cost effective.

Preserving the existing nose cones and wiring infrastructure, for example, reduced CAPEX by 50%.

Dow Corning now enjoys a new, more powerful automation system and is well-poised to gain measurable operational profitability improvements, safely.

Learn more: http://bit.ly/2gDM558

mary.costain@schneider-electric.com +1 (508) 549 4970 input #33 at www.controleng.com/information

WebPort Remote Access Optimizes Manpower and Chemical Usage in Water Features Summary:

Challenge: Optimize the manpower spent to control, monitor and manage large water features.

Solution: Install a WebPort remote access unit with cellular modem for: secure remote access to the system’s controller, event notifications to quickly notify personnel of chemical imbalances and easy data access to review meaningful data and optimize decision making.

Result: After installing WebPort, the chemistry of the water features is more consistent and the need for manual testing has declined.

Data is now displayed using dashboards to monitor the health of the overall system which has improved trouble shooting and the ability to foresee future maintenance needs.

An OEM was responsible for managing a large volume water feature through daily testing and the use of chemical controller more commonly known as an Oxidation-Reduction Potential (ORP) controller. Due to the complicated chemistry, environmental factors and inherent challenges with large volume systems, daily testing was required.

Unfortunately, testing often returned poor results and indicated inconsistent chemical usage. Depending on treatment, odor problems, algae growth and excess chemical costs were all potential outcomes if not managed with additional manpower.

Thus, a better system for monitoring and managing the water feature was needed.

Spectrum Controls worked closely with the OEM to understand their needs and deliver a solution that has improved their management of large volume water features. By integrating a WebPort remote access unit, the OEM can now remotely access their system using a cellular or Ethernet connection and download data without being on-site.

Dashboards are also being delivered to personnel, allowing data to be reviewed quickly so chemical adjustments can be made to maintain an ideal water treatment program. The ability to collect data and monitor the system has further led to improved trouble shooting and the ability to foresee future maintenance needs. Today, the water feature has stabilized, and decreases in chemical usage and manual testing has returned significant savings.

425-746-9481 • spectrum@spectrumcontrols.com • https://goo.gl/9TTQhZ input #34 at www.controleng.com/information

MEDIA SHOWCASE FOR ENGINEERS Your place for new products, literature, Apps, Videos, Case Studies and White Papers.

MULTI-CONTACT

connectors

With Silver-Nickel Butt-Style Contacts for Maximum Performance & Durability

FEATURES AVAILABLE 7 to 37 contacts 4mA to 150A per contact Easy-to-wire contact terminals meltric.com 800.433.7642

CE one sixth November Blue.ai 1 10/23/2017 12:02:13 PM

Input #100 at controlengineering.hotims.com

Input #101 at controlengineering.hotims.com

Input #102 at controlengineering.hotims.com

O&GEng-CE 2017-06_TRGuide_MediaShowcase2x4_MII.indd5/17/2017 1 2:23:54 PM

Industrial DIN-rail power supplies.

C

M

Y

CM

MY

TIB series

CY

The reliable basic product line

CMY

Build Your Own Industrial IoT Connectivity Solution

K

Learn more at www.moxa.com/thingspro

Reliable. Available. Now. www.tracopower.com Input #103 at controlengineering.hotims.com

www.controleng.com

Input #104 at controlengineering.hotims.com

Input #105 at controlengineering.hotims.com

CONTROL ENGINEERING

November 2017

•

45

INNOVATIONS

NEW PRODUCTS FOR ENGINEERS

See more New Products for Engineers. www.controleng.com/NP4E

PE

Four-axis SCARA robot for pick-and-place assembly, medical processes

Denso Robotics’ HSR Series four-axis SCARA robot uses advanced vibration control, a rigid lightweight arm, and improved heat dissipation in the base unit to achieve new levels of continuous high-speed performance and repeatability. The HSR’s reduced shaft whip and settling time, along with a lighter-weight arm and an optimized arm structure, enable it to accelerate faster than previous models, run continuously at its maximum rated speed, and stop more precisely. Standard cycle time (with a 2-kg weight) is from 0.28 to 0.31 sec. and repeatability is from ±0.01 to ±0.12 mm. Maximum payload capacity is 8 kg, with available reaches of 480, 550, and 650 mm. Applications for the HSR series include high-speed, high-precision pick and place assembly processes, as well as packaging processes in the food, medical device, and pharmaceutical sectors.

Denso Robotics, www.densorobotics.com,

Input #205 at www.controleng.com/information

Advanced connection system for underground cable connections

Thomas & Betts’ Shear Bolt advanced connection system is designed to install with a standard wrench and without additional components to enable underground cable connections to be made more safely and quickly. Shear Bolt includes a head that snips off at the appropriate torque, which reduces the chance of human error and provides greater reliability. The Shear Bolt also features a selection of four sizes to accommodate wires from 2AWG to 1,250MCM, designed to simplifying choice for greater flexibility for tight space applications. Shear Bolt is also current-rated up to 900 amps for aluminum or copper conductors.

Thomas & Betts, www.tnb.com,

Input #206 at www.controleng.com/information

PRODUCT & LITERATURE SHOWCASE

Signal Conditioners & Ethernet I/O www.Acromag.com/CE

877-295-7057

We have the experience to help you solve your monitoring and control challenges.

Get your new product guide today 4-20mA Isolators & Splitters Ethernet, Modbus, Profibus I/O

Sensor Brackets and so much more...

Please request your...

Input #100 at controlengineering.hotims.com

eNewsletters

Subscribe today by visiting: www.controleng.com/newsletters

2D / 3D CAD Files Catalogs Stock & Customs

softnoze com

Input #102 at controlengineering.hotims.com

Mount | Apply | Position | Protect

InputL#103 WORLD EADERatINcontrolengineering.hotims.com SENSOR INTEGRATION COMPONENTS

46

•

November 2017

CONTROL ENGINEERING

TM

TM

www.controleng.com

Advertising Sales Offices ContentStream

Patrick Lynch, Director of Content Marketing Solutions 630-571-4070 x2210 PLynch@CFEMedia.com AL, FL, GA, MI, TN

®

ad index Company

Page#

RSN

Web

ABB Drives and Controls . . . . . . . .13 . . . . . . . . . 9. . . . . . . .www.new.abb.com/drives/us/acs580-campaign ABB Inc . . . . . . . . . . . . . . . . . . . . . .11 . . . . . . . . . 7. . . . . . . .www.abb.com/motors&generators

Aaron Maassen, Classified, Product Mart, Media Showcase 630-571-4070 x2216 AMaassen@CFEMedia.com AR, IL, IN, IA, KS, KY, LA, MN, MO, MS, NE, ND, OK, OH, SD, TX, WI, Central Canada

Bailey Rice (630) 571-4070 x2206 BRice@CFEMedia.com

ADVANTECH . . . . . . . . . . . . . . . . . .23 . . . . . . . . 14 . . . . . . .www.advantech.com Allied Electronics . . . . . . . . . . . . . .C1, 7 . . . . . . . 5. . . . . . . .www.alliedelec.com AutomationDirect . . . . . . . . . C2, IFG, OFG . . . 1, 38 . . . . . .www.automationdirect.com

AK, AZ, CA, CO, HI, ID, MT, NV, NM, OR, UT, WA, WY, Western Canada

Baldor Electric Company . . . . . . . .11 . . . . . . . . . 7. . . . . . . .www.baldor.com

Iris Seibert (858) 270-3753 ISeibert@CFEMedia.com

Beckhoff Automation LLC. . . . . . . .26 . . . . . . . . 16 . . . . . . .www.beckhoff.com EZAutomation . . . . . . . . . . . . . Bellyband . . . . . . . . . . . . . . .www.EZAutomation.net Fluke Corp . . . . . . . . . . . . . . . . . . . .12 . . . . . . . . . 8. . . . . . . .www.fluke.com/729calibrator

CT, DE, MD, ME, MA, NC, NH, NY, NJ, PA, RI, SC, VA, VT, WV, DC, Eastern Canada

Honeywell Inc . . . . . . . . . . . . . . . . .9 . . . . . . . . . . 6. . . . . . . .www.honeywellprocess.com/elevate

Julie Timbol (978) 929-9495 JTimbol@CFEMedia.com

Honeywell Inc . . . . . . . . . . . . . . . . .16 . . . . . . . . .11 . . . . . . .www.hwll.co/SMX IDS Imaging Development Systems . . . . . . . . . .25 . . . . . . . . 15 . . . . . . .www.ids-imaging.com

Internation (outside U.S., Candada)

Stuart Smith +44 208 464 5577 stuart.smith@ssm.co.uk

Kepware Technologies . . . . . . . . . .1 . . . . . . . . . . 2. . . . . . . .www.kepware.com/CE Moore Industries - Intl. Inc . . . . . . .4 . . . . . . . . . . 3. . . . . . . .www.miinet.com Moxa Technologies . . . . . . . . . . . . .2 . . . . . . . . . . . . . . . . . . .www.moxa.com

Publication Services

NAPCON . . . . . . . . . . . . . . . . . . . . .5 . . . . . . . . . . 4. . . . . . . .www.napconsuite.com

Jim Langhenry, Co-Founder/Publisher, CFE Media JLanghenry@CFEMedia.com

Nidec Industrial Automation USA, LLC . . . . . . . . . .32 . . . . . . . . 21 . . . . . . .www.NidecUnidriveM.com

Steve Rourke, Co-Founder, CFE Media SRourke@CFEMedia.com

Panduit. . . . . . . . . . . . . . . . . . . . . . .31 . . . . . . . . 20 . . . . . . .www.panduit.com

Trudy Kelly, Executive Assistant, 630-571-4070, x2205, TKelly@CFEMedia.com

RADWELL INTERNATIONAL, INC .15 . . . . . . . . 10 . . . . . . .www.Radwell.com

Elena Moeller-Younger, Marketing Manager 773-815-3795, EMYounger@CFEMedia.com

Schneider Electric . . . . . . . . . . . . . .19 . . . . . . . . 12 . . . . . . .www.schneider-electric.us

Kristen Nimmo, Marketing Manager KNimmo@CFEMedia.com

SEW-EURODRIVE, Inc. . . . . . . . . . .C4 . . . . . . . . 37 . . . . . . .www.seweurodrive.com

Brian Gross, Marketing Consultant, Global SI Database 630-571-4070, x2217, BGross@CFEMedia.com

SPECTRUM CONTROLS. . . . . . . . .21 . . . . . . . . 13 . . . . . . .www.spectrumcontrols.com

Michael Smith, Creative Director 630-779-8910, MSmith@CFEMedia.com

TRACO POWER . . . . . . . . . . . . . . . .33 . . . . . . . . 23 . . . . . . .www.tracopower.com

Paul Brouch, Director of Operations PBrouch@CFEMedia.com Michael Rotz, Print Production Manager 717-766-0211 x4207, Fax: 717-506-7238 mike.rotz@frycomm.com

Wilbrecht LEDCO, Inc. . . . . . . . . . .33 . . . . . . . . 22 . . . . . . .www.wilbrechtledco.com Yaskawa America, Inc. . . . . . . . . . .C3 . . . . . . . . 36 . . . . . . .www.yaskawa.com

Maria Bartell, Account Director, Infogroup Targeting Solutions 847-378-2275, maria.bartell@infogroup.com

Inside Process

Rick Ellis, Audience Management Director 303-246-1250, REllis@CFEMedia.com

Load Controls Inc.. . . . . . . . . . . . . .P2 . . . . . . . . 17 . . . . . . .WWW.LOADCONTROLS.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.

Otek Corporation . . . . . . . . . . . . . .P4 . . . . . . . . 19 . . . . . . .WWW.OTEKCORP.COM

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

WAGO Corp. . . . . . . . . . . . . . . . . . .P3 . . . . . . . . 18 . . . . . . .www.wago.us

Marketing consultants: See ad index.

REQUEST MORE INFORMATION about products and advertisers in this issue by using the http://controleng.com/information link and reader service number located near each.

If you’re reading the digital edition, the link will be live. When you contact a company directly, please let them know you read about them in Control Engineering. www.controleng.com

CONTROL ENGINEERING

November 2017

•

47

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

INNOVATIONS

BACK TO BASICS Jessica Potts, TopEngineer

Six traits for excellent engineers Engineers who aspire to be great have common traits such as good communication skills, a heightened curiosity about their profession, and good analytical and mathematical abilities.

G

reat engineers are competent, creative, yet logically practical, and incredibly influential on everyone’s daily lives. For some, the thought of being an engineer seems like an unattainable and distant goal that can never be achieved. Great engineers are a rare breed. Six traits make some engineers rise above the rest.

1. Natural curiousity

M More INNOVATIONS

KEYWORDS:

engineers, STEM Great engineers are rare, but those who develop their skills and become well-rounded can hope to become great.

Great engineers are detail-oriented and selforganized as well as constantly curious about the world around them.

It’s also important for an engineer to be good at communication, analysis, and mathematics.

GO ONLINE Read this story online at www.controleng.com for additional stories about engineers including a Control Engineering article from 2014 about the seven things noncontrol engineers should know about control engineers.

CONSIDER THIS What other skills or traits should a great engineer have?

48

•

Engineers must be able to observe a process, structure, machine, or system and determine how it works and how they can improve upon it. Curiosity is a beneficial quality in nearly every industry because it indicates interest and drives creativity. Engineers must have the energy and determination to research and understand problems and their solutions and it starts with that natural curiosity. Kids who grew up asking, “Why?” are good candidates for engineering programs, but those who excel at engineering are more often those who pursue “Why?” to “Oh, that’s why.” Asking questions isn’t enough for an engineer; they want to find out the answer and are willing to spend as much as time it takes until they reach a satisfying conclusion.

2. Self-organized

Engineering teams usually have managers tasked with keeping workers on course, but most engineers must be able to manage projects. Often, engineering projects last months or years, and ideas or discoveries made long ago must be readily available for application. By displaying project management skills, it is more likely to obtain raises and promotions. Selforganization is one of the few top engineering qualities that can be improved upon with concerted effort.

3. Detail-orientation

To succeed in engineering, the person needs to be able to parse details and organize them to create an effective machine—process, system, structure. This is part of an engineer’s daily responsibilities and such attention to detail allows engineers to analyze intricate problems and produce high-quality work.

4. Good analytical skills

There is a world of difference between something

November 2017

CONTROL ENGINEERING

working and something working well. Engineers are typically tasked with finding the most efficient solution to a problem, which requires being able to analyze the issue and all possible answers to identify the best course of action. Analytical ability comes in many shapes and forms; even English majors must be analytical in some sense. Engineers’ analytical minds are constantly running, revising plans to ensure the best possible outcomes. People who are able to logically pick problems apart and discover optimal solutions on the fly have the right stuff as a potential engineer.

5. Strong mathematical skills

Every engineering discipline, from computer engineering to petroleum engineering, works with numbers and equations. At its very core, engineering is the application of theoretical mathematics to the physical world to solve everyday problems. Engineering programs often are rigorous in mathematical studies, putting students through advanced calculus, statistics, trigonometry, and geometry. Students curious about engineering should be confident and comfortable in writing and using formulas to solve problems because it will be required after graduation.

6. Good communication skills

While engineers may seem to be asocial, numbers-focused professionals, they are far from hermits. Engineers almost always work in teams, which means communication between team members occurs on a regular basis. Communication failures within engineering result in low-quality machines, inefficient systems, and worse. So the ability to express thoughts and opinions must be finely honed. As with project management skills, engineers who prove themselves adept at communication often excel in management positions. Aboveaverage communications abilities will help with an advanced education to prepare for an accelerated career in engineering. ce

Jessica Potts is head of marketing at TopEngineer, a CFE Media content partner. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com. www.controleng.com

Critical Matters

Critical matters call for dependability. Doctors, nurses, patients, and loved ones all need the assurance everything will be running smoothly 24/7/365. Yaskawa can provide you with the urgent care you need for every drive challenge. Quality product. Easy programming. Quick order turnaround. A drive you can start up easily and never worry about. That’s what Yaskawa delivers for its customers.

Our Z1000, for example, is a variable frequency drive that is specifically designed for building automation applications such as fans, pumps, chillers, and cooling towers through 500 hp.

Available in bypass or redundant drive configurations, the Z1000 can be counted on for reliable, continuous operation when HVAC is needed most. The Z1000 is perfect for building automation applications that require reliable motor control.

Want to learn how Yaskawa benefits healthcare? Call us today.

input #36 at www.controleng.com/information For more info: http://go.yaskawa-america.com/1100 Yaskawa America, Inc.

Drives & Motion Division

1-800-YASKAWA

yaskawa.com

presence

The gift of global presents.

Thinking global, but acting local.

With 15 manufacturing facilities and locations in 52 countries, SEW-EURODRIVE is truly a global company. But, it’s the 17,000 employees providing the best in service that makes us a real local partner.

Whether you need inverter drives, motors, large industrial gear units, or smaller gear units, you can get the whole package from one source.

seweurodrive.com input #37 at www.controleng.com/information