Control, Instrumentation and Automation in the Process and Manufacturing Industries October 2019
www.controlengeurope.com
Bionicman and his super hand!
Tools to help deliver a digital future
Flow measurement: getting it right
Data gathering from disparate PLCs
CONTENTS Taking the next steps towards Industry 4.0
Editor Suzanne Gill suzanne.gill@imlgroup.co.uk Sales Manager Adam Yates adam.yates@imlgroup.co.uk Production Holly Reed holly.reed@imlgroup.co.uk Dan Jago David May G and C Media
Group Publisher Production Manager Studio Design
I was interested to see the response to my call for comments when I asked the question ‘Industry 4.0: are we there yet? And what’s the next step?’ It seems there is now a good understanding about how to make Industry 4.0 a reality – the downside is that there does appear to still be some way to go. Industry needs to accept that it is not possible to simply apply new technology to existing machines and business models. There also needs to be investment in the adoption of new business models – for both end-users of technology and for the machine builders and systems integrators who are providing the technology. In this issue we look at all aspects associated with the continuing move towards digitalised plants and the tools that will be needed to make it successful. Next stop for the Control Engineering Europe team is the SPS – smart production solutions event, which takes place in Nuremberg from 26-28 November. If anyone exhibiting at the show would like us to report on the highlights on their booth, please do get in touch so that we can arrange a meeting. We hope to see many of you there! Suzanne Gill Editor – Control Engineering Europe suzanne.gill@imlgroup.co.uk
INDUSTRY REPORT
SCADA & HMI
5
20 Find out how a medical appliance manufacturer solved its data gathering headaches in a factory full of multiple-branded devices
FITS on course for end-of-year release; Is industry ready for 5G?
EDITOR’S CHOICE 6
Wireless condition monitoring for pump systems; Tablet PC for hazardous areas
REMOTE MONITORING 10 Overcoming challenges to reach your remote monitoring goals
CALIBRATION 20 We look at what’s involved in getting flow measurement right and the potential hazards of getting it wrong
TEMPERATURE & PRESSURE CONTROL 24 Automating dome-loaded pressure controllers 26 Avoiding the risks associated with chemical injections in the oil and gas industry
SPECIAL FOCUS: INDUSTRY 4.0 10 Looking at the tools which will help deliver a digital future
INDUSTRIAL COMMUNICATIONS
12 Now is the time to take the next steps on the Industry 4.0 journey 16 All change to reap the full potential of Industry 4.0
COLLABORATIVE OPERATION 17 Overcoming the challenges of greater collaboration between man and machinery
SERVITISATION
28 We take a closer look at time-sensitive networking (TSN) and the advantages it will offer for industrial communications
FINAL WORD 30 Jason Urso, chief technology officer at Honeywell Process Solutions, discusses the changes in control system design
18 Could servitisation transform every aspect of modern manufacturing? Control Engineering Europe is a controlled circulation journal published eight times per year by IML Group plc under license from CFE Media LLC. Copyright in the contents of Control Engineering Europe is the property of the publisher. ISSN 1741-4237 IML Group plc Blair House, High Street, Tonbridge, Kent TN9 1BQ UK Tel: +44 (0) 1732 359990 Fax: +44 (0) 1732 770049
Control Engineering Europe
Control Engineering (USA) Frank Bartos, Mark Hoske, Renee Robbins, Vance VanDoren, Peter Welander Circulation Tel: +44 (0)1732 359990 Email: subscription@imlgroup.co.uk Completed print or on line registration forms will be considered for free supply of printed issues, web site access and on line services.
www.controlengeurope.com
Qualified applicants in Europe must complete the registration form at http://imlrenewals.managemyaccountonline.net to receive Control Engineering Europe free of charge. Paid subscriptions for non-qualifying applicants are available for £113 (U.K.), £145 (Europe), £204 (rest of world); single copies £19.
October 2019
3
INDUSTRY REPORTS
5G: is industry ready? Recent research shows that 50% of industry professionals are positive about 5G in manufacturing and see it as a way to obtain universal connectivity. HMS Networks surveyed 50 international industry professionals in spring 2019 to inquire about the positioning of wireless communication in their companies and to see how they are getting ready for the launch of 5G. The findings of this research have been published in a whitepaper document entitled ‘5G: Is the Industry ready?’ providing an interesting insight into the current situation in the manufacturing industry in terms of 5G preparedness. The document also looks at the use of wireless technologies in industry today and possible future directions. Key findings highlighted in the document include the fact that more than half of the interviewees indicated that they use wireless communication solutions for remote monitoring and remote operation of assets. One-third of the respondents stated that
their companies were using wireless communication for different kinds of Industrial Internet of Things (IIoT). Almost half (48%) of respondents were positive about 5G in manufacturing – they mostly appreciated that the technology will replace cables, Wi-Fi, and the many industrial standards in use today. However, for the majority (58%) of respondents, the reliability and robustness of wireless systems plays a decisive role in whether to adopt 5G or not, and this was voiced equally by representatives from both the operations technology (OT) and
information technology (IT) domains. Low latency was mentioned as being important by 26% of respondents. “The survey clearly shows that industry is becoming increasingly aware of 5G benefits for industrial communication. What the industry really needs is technical information and practical examples,” said Marcela Alzin, program manager at HMS Labs at HMS Networks, who conducted the research. To download a complimentary copy of the whitepaper please visit: www. hms-networks.com/industrial-iotsolutions/5G/ready
Control Engineering 2019 Motor Drives Study results Respondents to the Control Engineering 2019 Motor Drives study identified five key findings related to the purchase and specification of variable-speed, servo/stepper and medium-voltage drives: 1. Usage: 80% of respondents use or expect to use variable speed drives (VSDs) within the next 12 months; 46% use/plan to use servo and/or stepper drives and 17% use/plan to use medium voltage (MV) drives. 2. Applications: When specifying VSDs, 89% of applications are new, 74% are retrofit and 71% are
4
October 2019
replacement. The breakdown for servo/stepper drives is 87% new, 67% retrofit and 64% replacement. For MV drives: 89% new, 81% retrofit and 78% replacement. 3. Purchasing: 36% of respondents prefer to buy motors and related VSDs separately; 22% prefer matched units. Regarding servo/ stepper drives, only 12% prefer separate, and 60% look for matched units. For MV drives and above NEMA motors: 30% prefer separate, and 19% favour matched units. 4. Expenditures: Over the past 12
www.controlengeurope.com
months, respondents estimated an average of $139,000 having been spent on VSDs. For the same time frame, respondents also estimated average values of $94,000 for servo/ stepper drives and $620,000 for MV drives. 5. Important factors: The most critical qualities respondents look for when choosing a motor drive are frequent start/stop tolerance for VSDs (83%), accurate positioning for servo/stepper drives (97%) and frequent start/stop tolerance for MV drives (83%). Control Engineering Europe
INDUSTRY REPORTS
FITS on course for end-of-year release A final review of the emerging FDT 3.0 technology platform, known as the FDT IIoT Server (FITS) standard, has been completed by the FDT Group and, according to Lee Lane, chairman of the FDT Board of Directors, the FITS specification remains on schedule for an end of year release. Because industrial solutions tend to stay in service for such long periods of time, FDT leadership defined use cases to investments for the future – this includes platform independence, a comprehensive security solution, OPC UA integration, mobile device management, and a repository for DTMs. While there are a host of other important features included, all these requested use cases have taken shape within the emerging
FITS platform. Within a FITS architecture, the FDT Server becomes the pivotal IIoT hub empowering the intelligent enterprise. The Server boasts a web services portal allowing access from authenticated mobile devices or any major browser along with an OPC UA interface for IT/OT convergence and enterprise access. Additionally, rich control features will allow any industrial communication protocol or vendor device to be seamlessly integrated, supporting smart manufacturing practices for the process, hybrid and discrete industries. Developed from the ground up with security at its core and an operating system agnostic environment, an FDT Server is fully deployable in the cloud,
on-premise, edge or in a desktop environment. With more than 10 million DTMs and several hundred thousand FDT/FRAME-enabled applications currently deployed and in use it was vital to preserve the FDT legacy installed base investment and as the vendor community advances its FDT-enabled applications and system offerings all legacy DTMs will function in a single user Microsoft FDT Desktop environment updated to the FITS standard. It will be possible to freely mix FDT 1.2.x, 2.0, 2.1 and 3.0 DTMs within a desktop application. Users planning to continue to use a desktop application are advised to check with their system providers about their update plans for that application.
Open Industry 4.0 Alliance gains a new member Successful scaling and implementation of new business models have traditionally been hampered by the heterogeneity of industrial components and systems. The Open Industry 4.0 Alliance was created to help establish an open ecosystem and framework for interoperability between vendors. The Alliance enables IT and OT vendors to engage in open dialogue and generate common customer value. The latest member of the Alliance is Software AG. The company will position itself in the segments of IoT
Control Engineering Europe
Connectivity, Open Edge Computing and as a Hybrid Integration Operator. The positive effects of the digital transformation on production and logistics processes across companies and the establishment of the first digital business models have already been successfully tried and tested in the process industry and in discrete manufacturing. But the variety of different protocols, standards and frameworks is a hindrance to platform-based scaling and monetisation approaches. In response IT and OT organisations such as ifm electronic, Beckhoff, SAP, KUKA,
www.controlengeurope.com
Hilscher, Endress+Hauser and Multivac have partnered to drive cross-vendor standardisation of digitalisation projects in production and logistics. Their proviso is ‘One and Open’. More than 21 manufacturing and software companies now belong to the Open Industry 4.0 Alliance. Together, they are developing open, compatible and standardised solutions for industrial customers.
October 2019
5
EDITOR’S CHOICE
Wireless condition monitoring for pump systems Sulzer has introduced the Sense wireless IoT condition monitoring system which includes wireless sensors that can be attached to a pump, agitator, motor or any rotating equipment. The sensors measure temperature and vibration and send this data to the cloud to allow the operating status of the equipment to be remotely monitored 24 hours a day, seven days a week. Sulzer Sense devices are battery powered and operate in a wireless mesh network, making them costefficient to deploy and operate. The condition monitoring
feature identifies changes in condition parameters and indicates potential faults at an early stage helping engineers to detect possible imbalance, misalignment, looseness and bearing wear.
Smart plastics make maintenance intelligent igus’ smart plastics are now able to monitor the health of energy chains, cables and bearings. It does this via the addition of sensors at the pin/ bore connection between the links of energy chains to measure abrasion and wear status. By networking with the igus communication module (icom.plus), these sensors can be integrated into the IT infrastructure; production management systems, such as SCADA and MES; or online into
cloud solutions. igus performs 10 billion annual test cycles of energy chains and cables and the results are incorporated into a free service life calculator. In this way, it is possible to predict how long an e-chain will work reliably in the respective machine application. With isense components, the service life is continually updated as each update takes into account the current ambient conditions of the application.
Tablet PC for hazardous areas Endress+Hauser has introduced Field Xpert SMT77, a rugged tablet PC tool for commissioning and maintenance staff to manage field instruments and document the work progress. The tablet comes preinstalled with device configuration software and device library. The device enables plant asset management in Class 1 Div 1 hazardous areas. Like the Field Xpert SMT70 (Class 1 Div 2 rated), the Field Xpert SMT77 supports HART, PROFIBUS DP/ PA, Foundation Fieldbus, Modbus, CDI and Endress+Hauser service interfaces. It features a device library of over 2,700 pre-installed device and communication
6
October 2019
drivers, allowing it to work with many different instruments from a wide variety of vendors. It can connect to field instrumentation devices directly via a USB or Bluetooth wireless modem, or via a gateway, remote I/O or multiplexer to a bus system.
www.controlengeurope.com
DIN wireless gateway supports network connectivity for sensors
The DIN Gateway V2 is a 900 mHz wireless gateway, from SignalFire Wireless Telemetry, with an integrated I/O capability for easy network connectivity of wireless and wired sensors, integrated Ethernet and built-in automation. Featuring two digital inputs, two digital outputs, three analogue inputs and an optional gateway output module with eight analogue and two digital outputs. The three analogue inputs can be used for any measurement or control device while the digital outputs are useable for annunciation or basic on/off applications. This enhanced gateway – designed for Class 1 Division 2 Groups C and D locations – supports wireless configuration of up to 240 remote nodes at 3+ mile typical range and interfaces via RS-232 Modbus RTU or Modbus-TCP (Ethernet). This gateway enables wireless configuration of remote nodes and HART devices via PACTware or Radar Master and automatically configures as a star or mesh network. It also features low power consumption, integrated high-gain 5dB omnidirectional antenna and 500 mW radio operating at 902-928 MHz license-free ISM band. The optional expansion output module provides an additional 8 analogue outputs and 2 digital outputs. Control Engineering Europe
ComBricks: PROCENTEC’s solution for permanent PROFIBUS monitoring and diagnostics
Infrastructure and design are not able to allow for every unforeseen factor. Human error, environmental conditions, poor physical maintenance, integral components not upgraded alongside system upgrades, new parts fitted etc. While the list of possible causes is endless, the result is always the same. Network disputation and downtime. PROCENTEC is a specialist in the field of PROFIBUS, PROFINET and Industrial Ethernet networks offering products that measure, signalize and connect the different parts of an installation and ensure that it operates effectively to limit unplanned downtime to a minimum. We present the customer with an opportunity to fix or exchange a failing component before the network collapses, or at least shut the system down in a controlled manner. They have the peace of mind that our diagnostic tools will allow them quickly to identify the problem; and should they need it, the knowledge that our experts are at the end of the phone 24/7, eager to help find a solution as fast as possible. Our biggest frustration when designing and implementing new systems, is to see companies unwilling to invest adequately in technologic insurances and back-ups ready to react to an imminent or actual network failure. They believe the new system will never fail. A very daring risk to take. Our ComBricks platform, designed specifically to tackle this issue, is rapidly becoming the network component of choice for applications that require integrated capabilities for remote monitoring and asset management. With ComBricks, it would be possible to perform online monitoring over a web browser and SCADA systems 24/7, receive alerts over e-mail, and make historical recordings of events happening. If a device, such as a flow meter, would start to fail by sending repeats to the PLC, it is detected before it could interfere with the industrial network and shut down production. Instead of reacting to a problem, the team would become proactive in their maintenance and troubleshooting with the help of ComBricks.
Train to gain and maintain PROFIciency And of course, there’s also the PROCENTEC Academy, which has certified over 4,000 engineers from all over the globe to gain qualifications to be able to maintain their PROFIBUS and PROFINET networks to the highest standards. Although PROFIBUS and PROFINET are well-established and easy to use technologies, training is essential for engineers making use of today’s advanced automation technology. PROCENTEC’s new international training calendar features trainings in English at our headquarters in the Netherlands as well as courses around the globe and in-company courses. Ultimately, the right training is both a short- and long-term investment to ensure that operations run well without unexpected downtime. Discover PROCENTEC’s powerful solutions for your PROFIBUS, PROFINET and Industrial Ethernet networks, and view our available courses at www.procentec.com/training/.
www.procentec.co.uk | info@procentec.com
COVER STORY
sponsored article
The super hand! Bionicman is a different kind of superhero. His futuristic prosthetic hand lends him superhuman powers. He uses these powers to give children with disabilities more confidence – and cool, 3D-printed hands.
W
hen Michel Fornasier dons his sparkling blue cape, he ceases to be a normal human with everyday problems and limitations. He transforms into his alter ego ¬– Bionicman – who has unlimited powers, is able to fly, and can even turn back time. “The costume creates this special kind of magic. When I’m standing in front of school kids, they actually believe that they’re looking at the real Bionicman. That’s just an amazing feeling,” said Fornasier. However, Fornasier isn’t wearing his superhero costume just to make himself feel good. He’s on a mission. He works to strengthen the confidence of children and show them that having a physical disability does not make them better or worse than other children. Fornasier was born without a right hand and knows what he is talking about. He never let things slow him down, learned early how to tie his shoelaces, and has even run a marathon. After all, why not?
was born. Fornasier contacted the artist David Boller, who had worked for Marvel and DC in the USA and had even drawn Spider-Man comics in the past. Together, they created the first stories about Bionicman, who comes to people’s aid in various situations. Physical handicaps play a role in many stories. “What I want to do is to point out in a playful way that there are people with disabilities, and that they would like to be treated just like anyone else,” said Fornasier. The first comic anthology is out now. A second volume is planned for late 2019. While Bionicman provides the moral support, Fornasier helps out with state-of-the-art technology. In 2016, he started the charity organisation ‘Give Children a Hand,’ to which he devotes a lot of energy. A cooperation with ETH Zurich and the Wyss Institute has been set up to develop affordable prosthetic hands whose components come from a 3D printer. Currently, 25 children are wearing prototypes and continually
provide feedback for improvements. “To children, the look is often more important than the functionality,” said Fornasier. “First and foremost, the prosthesis has to look cool!”
Ambassador of the Cybathlon There is still a lot to do: Engineers have to keep developing prosthetics, and society needs to treat people with disabilities as equals. This is what Bionicman fights for. These goals are also shared by the Cybathlon event, which will take place again in 2020 in Zurich. In the Cybathlon, people with physical disabilities compete against each other in obstacle races – supported by stateof-the-art technical assistance systems. It comes as no surprise that Fornasier is an ambassador of the Cybathlon. “I mainly try out new tasks for the prosthetic hand race and provide feedback to the organisers to find out what is difficult and what could be improved. It’s a great event, because it’s about people, not about disabilities.” !
From Spider-Man to Bionicman Fornasier has been using a myoelectric hand prosthesis made by Touch Bionics, a high-tech device with six integrated maxon motors that provides 25 motion patterns. He said: “This prosthesis has made my life much easier in many respects. I can use it to ride a bicycle or scooter and am able to type on a keyboard using both hands. Also, simply being able to hold a smartphone in my right hand feels great.” Children used to ask whether the hand gives him superpowers? Initially, Fornasier said no. However, after a while he began to say: ‘Who knows?’ and that is how the idea of Bionicman
8
October 2019
©maxon: Fornasier has been using a myoelectric hand prosthesis made by Touch Bionics, a high-tech device with six integrated maxon motors that provides 25 motion patterns.
www.controlengeurope.com
Control Engineering Europe
Change the world with a reliable partner maxon is supporting the Cybathlon 2020 in Zurich as a Presenting Partner – because we believe that extraordinary engineers and technicians are changing the world for the better. What can we do for you? www.maxongroup.com
Precision Drive Systems
INDUSTRY 4.0 FOCUS
Tools to help deliver a digital future Industry 4.0 has now moved well beyond the concept stage although there is still a long way to go. The next generation 5G wireless networks and the use of Artificial Intelligence (AI) will be crucial elements to enable Industry 4.0 to be wholly implemented, according to Steve Sands.
C
onnectivity is critical to Industry 4.0 and the rollout of the emerging next generation 5G wireless networks is expected to accelerate adoption. Manufacturers demand speed, secured communications and low latency, and for the first time industrial automation companies have been involved in the development of the new telephony standard from the outset – ensuring that these characteristics will be provided. The 5G Alliance for Connected Industries and Automation was established to serve as a central global forum and members jointly strive to make sure that the particular
interests of the industrial domain are adequately considered in 5G standardisation and regulation. Further, the 3GPP (Third Generation Partnership Project), the industry body tasked with developing global standards for mobile communications, is working to develop the necessary radio technologies and architectural components that will be able to support Industry 4.0 requirements for vast connectivity, ultra-reliability and ultra-low latency. One of the main differences between 5G and previous generations of mobile networks lies in its strong focus on machine-type communication and IoT. 5G supports three essential types of communication which are
all key requirements from smart factories. These include ultra-reliable low-latency communications (URLLC) which facilitates highly critical applications with very demanding requirements in terms of end-toend (E2E) latency (down to the millisecond level <1 ms), reliability and availability; massive machinetype communication (mMTC) which provides wide-area coverage and deep indoor penetration for hundreds of thousands of IoT devices per square kilometre and is designed to provide ubiquitous connectivity with low software and hardware requirements from the devices, and will support battery-saving, low-energy operation; and enhanced mobile broadband
Where AI takes place.
10
October 2019
www.controlengeurope.com
Control Engineering Europe
INDUSTRY 4.0 FOCUS (eMBB) which provides high data rates and offers coverage well beyond that of 4G. Security concerns are also being addressed with 5G which can be characterised as a modular communication system, with inbuilt privacy and security based upon the cloud approach. It can be flexibly configured to meet different service requirements and it includes strong E2E security. In particular, mutual authentication between the device and the network is supported. All transmitted data is encrypted between the device and the network. 5G also supports a flexible authentication framework with the Extensible Authentication Protocol (EAP) and strong encryption, while meeting strict latency requirements. While the standards are not expected to be ready until 2020, projects are already underway exploring ways to increase productivity using robotics, big data
analytics and augmented reality with 5G in a manufacturing setting. 5G is likely to support various Industrial Ethernet and Time Sensitive Networking (TSN) features, thereby enabling it to be integrated easily into the existing (wired) infrastructure and, in turn, enabling applications to exploit the full potential of 5G with ease.
need arises. The data produced from the manufacturing process is analysed and actioned through AI to create dynamic self-learning production environments that are able to provide increasingly higher levels of productivity, operating with higher quality in a safer working environment.
Artificial intelligence
Manufacturing production and the digital world are merging, making factory automation more flexible, increasing energy efficiency, linking logistics processes more closely and optimising the value chain. 5G networks and the emergence of AI will be key enablers for the digital future and will offer manufacturers the chance to build smart, digital factories using Industry 4.0 principles !
AI is also expected to accelerate and enhance the implementation of Industry 4.0, and connectivity is vital for AI to succeed. AI can be defined as the concept of improvement and gaining insights through smart analytics and modelling. Machinery will become increasingly autonomous and it is expected that they will use AI to organise cooperation among themselves, sharing data with the supply/ delivery chains and with users: creating ad-hoc networks as the
Conclusion
Steve Sands is product management and marketing manager at Festo UK & Ireland.
INDUSTRY 4.0 FOCUS
TIME TO TAKE THE NEXT STEPS ON THE INDUSTRY 4.0 JOURNEY According to automation vendors there is still some way to go before industry starts to reap the benefits promised by Industry 4.0. The next step is the adoption of a variety of enabling technologies.
O
ne noticeable effect of the move towards digitisation is the impact it is having on the sensors and devices employed across the plant. Obviously, device connectivity is improving – from 4-20mA current loops, digital I/O lines and proprietary serial protocols to standardised solutions like industrial Ethernet or the IO-Link protocol. In addition, today’s sensors are getting smarter as they need to be able to offer a lot more than just measurement values. They are now also required to provide information relating to their identity and the condition of the application they are monitoring. Data coming from these smart devices can now be deployed to control units and IT systems in real-time. Data is no longer locked in the sensor and can be used for condition monitoring or predictive maintenance tasks which can help reduce downtimes or improve OEE. “This is all good news,” said Benedikt Rauscher, head of global IoT projects at Pepperl+Fuchs. “However, there are still challenges facing the control engineer if there is no common language that all components understand. A great deal of manual engineering work still required to integrate devices from different manufacturers into machines and plants. Because through-engineering across the entire value chain is one of the characteristics of Industry 4.0, a unified vocabulary and semantic has to be established.” According to Rauscher the solution is to add an asset administration shell to the physical product to build an Industry 4.0 component. This shell will contain all the data and information
12
October 2019
relating to the asset. Its general structure is already defined and several initiatives are now working on sub models for specific domains as the next important step towards Industry 4.0. “An important next task for automation vendors is to provide asset administration shells for their products and to establish structures for linking the physical products to their shells,” continued Rauscher. “The components have to be marked with unique machine-readable identification labels or tags. During operation the identification data is also available through the component’s interface, so the asset administration shell is available always and everywhere. A good example of how the asset administration shell in the internet creates value is when it is accessed with mobile devices during maintenance and service tasks. Those can very often be carried out much more effective when device specific information is directly available for the worker.”
www.controlengeurope.com
Bandwidth Eckard Eberle, chief executive officer of Siemens Process Automation unit, believes that the growing quantity of data, brought about by the digital transformation of industry, is opening up new productivity potential and new business models. He said: “The main drivers of this trend are future technologies such as AI; edge computing; autonomous handling systems; industrial communication with 5G; and IT security. A comprehensive communication infrastructure is a precondition for wide-area Industry 4.0 applications and to achieve this, Industry 4.0 needs greater bandwidth and very short transmission times with maximum availability.” Eberle went on to explain that Siemens is conducting its own industrial 5G research projects and is building a 5G Interoperability Test Center under real conditions. This includes evaluation and testing of the industry standards currently available, such as OPC UA, Control Engineering Europe
> p14
Make your life easier. Use the zenon Software Platform to automate your Smart Factory: ` Instant reporting and analytics ` Ergonomic visualization and control ` Comprehensive data acquisition and management ` Quick application engineering and maintenance www.copadata.com/zenon
visit us: SPS IPC Drives | Nürnberg November 26–28, 2019 | Hall 7, Booth 590
Plan more flexibly, achieve goals faster with Configure to Order for assembled products Let’s connect. On-call orders? Tight deadlines? Last minute design changes? To ensure that despite increasing complexity your panel building runs productively and cost-effectively, our Weidmüller Configurator supports you with new Configure to Order services. Thanks to full data consistency you benefit from quotations within minutes, flexible made-to-order production and binding delivery times for the individual assembly of rails and enclosures. To enable you to process smaller projects economically as well, you can even place orders for quantities of one. Sales: 0845 094 2006 Tech: 0845 094 2007 Email: marketing@weidmuller.co.uk Email: www.weidmueller.com/cto
INDUSTRY 4.0 FOCUS
Profinet, and TSN. “Also, from an automation side, as manufacturers, Siemens has completely re-thought the actual technology of process control systems. The result is our fully web-based process control system Simatic PCS neo which provides direct and secure access to all the information required, regardless of location or time, and by using all standard devices, including mobile ones.”
Digital twinning The essence of Industry 4.0 is the digitalisation of assets and processes, which can be incorporated into the concept of digital twinning. Digital twins can be defined as a set of models that provide useful information to develop, validate and optimise an asset or a process in a digital environment. Digital twins are based on data collected by sensors installed on physical objects (things) to provide real-time insights about status, functioning, position and other parameters. “There are many advantages that can be brought about by digital twins,” said Giuseppe Surace, chief product & marketing officer at Eurotech. “Among them, the availability of a digital model of an asset or a product will significantly reduce prototyping and development phases, increasing product quality and speeding up interactions and feedbacks by final customers at the same time.” This concept becomes even more
14
October 2019
relevant because the digital data coming from a production plant allows the monitoring of every process – from raw material treatment to assembling to finalisation – monitoring can also be extended to logistics and power consumption which is extremely useful to optimise production and logistic processes to maximise return-oninvestment (ROI) and efficiency. “Thanks to cloud computing all the data collected by sensors in the field can now be transferred to IT systems for analytics and integration with enterprise resource planning (ERP) and other applications. Eurotech offers an edge-to-cloud platform – Everyware IoT – designed to simplify and accelerate the development of end-to-end IoT applications from data collection in the field to data analytics in the cloud or on premises. “Assets and products are therefore connected, thanks to IoT technologies, which enables new and innovative business models that could help enterprises to optimise their processes and maximise efficiencies while improving daily-life activities. “The continuous collection of data generates a ‘data lake’ that contains a great deal of information. Todays applications only use very small percentage of those data, for example to provide predictive maintenance or other Industry 4.0-related applications. The interesting part is that we do not
www.controlengeurope.com
know yet how to use the rest of the data,” continued Surace. “The next step would be for data to be used by machines to perform tasks autonomously: we are entering into the era of Artificial Intelligence (AI), Machine learning (ML) and Deep Learning (DL). These three concepts are interrelated, but we could define ML and DL as branch applications of AI. AI can be defined as the ability of machines to perform autonomous tasks without human intervention: with Machine Learning, operators provide machines with data and algorithms – usually trained in the data center or in the cloud – to perform those tasks. Deep Learning is an even more advanced phase: machines are trained directly by computers and do not need human intervention to work autonomously. This requires a lot of computing and processing power and companies like Eurotech are able to help by delivering products that move the paradigm of data center processing capabilities from the Cloud to the Edge.
Security Another challenge facing process engineers today, as they implement IoT solutions and Industry 4.0 applications, is security. This is true not only when introducing cloud platforms but also for the integration of automation networks and IT systems on premises. Another prerequisite for this type of implementation is the need for interoperability between the various disparate devices and applications. OPC UA (Unified Architecture) is an interoperability standard addressing these challenges. It is increasingly accepted and adopted globally, including the major players in the automation as well as the IT industry. OPC UA leverages security standards, which have been proven in the IT world and defines ways to integrate these standards flexibly in IoT solutions. Recently NAMUR – the standardisation association for measurement and control in chemical industries – has approved the use of OPC UA technology for Control Engineering Europe
INDUSTRY 4.0 FOCUS data exchange and has defined the NAMUR Open Architecture (NOA) model addressing the need for standardised Industry 4.0 application in the process industry. “The outcome of these activities includes a specific OPC UA Companion Standard as well as the introduction of a so-called ‘NOA diode’ as a system architecture component, for security reasons enforcing strict readonly access to data from field devices and PLCs,” said a spokesperson at Softing Industrial Automation. The spokesperson went on to explain that, in Germany, the interest group for sets of engineering rules (Interessengemeinschaft Regelwerke Technik) represents approximately 30 companies from the chemical and pharmaceutical industries and its service providers. One of its tasks is to promote digitisation in the process industry. As part of this task, the group initiated the development of an NOA model test facility providing complex processes with all types of process and diagnostic data from the various operating and failure states under real conditions for testing purposes. “Bilfinger Maintenance was contracted to build this test facility, which consists of two containers and their automation, representing the procedural aspect of the facility together with measuring instruments transmitting machine diagnosis data to the automation system. It offers a dedicated internet line including various firewalls and security protections and can be connected to one or more clouds,” continued the Softing spokesperson. “As a result, the test facility can be adapted flexibly to different requirements allowing to be used easily and without a complicated approval procedure by participating companies. This provides a way to produce realistic fault conditions in a reproducible manner to address undesired operating states in the process and failures in the device technology.” Softing’s dataFEED Secure Integration Server was included in the test facility Control Engineering Europe
Bilfinger maintenance was contracted to build a NAMUR Open Architecture (NOA) model test facility.
to guarantee the NOA diode behaviour and to provide the full set of security aspects based on OPC UA in one central component. For example, it allows different access rights to be specified or different applications and users and to restrict access to individual data to specific applications. Thus, access to the data in the field devices and PLCs can be defined as read-only.
Quality management Digital technologies for quality management (Quality 4.0) can also create substantial added value. However implementation is anything but easy according to consulting firm BCG and the German Society for Quality (DGQ) , who surveyed 221 companies from manufacturing industries worldwide on their quality management strategies. Nearly two-thirds of the survey participants believe that the application of Industry 4.0 technologies to enhance quality will significantly affect their operations in the coming years. The greatest advantage cited was the reduction in defect rates, and consequently in costs. However, there are still many challenges to
www.controlengeurope.com
overcome including a shortage of necessary skills, and in many companies a lack of willingness to implement the technologies and a reluctance to formulate clear quality goals.
Conclusion Today engineers are facing very different requirements and challenges than they were just a few short years ago. This has been acknowledged by Deutsche Messe, organisers of the Hannover Messe in April 2020, which will focus on the many changes that are currently taking place in industry, as it moves towards Industry 4.0 under a lead theme of ‘Industrial transformation.’ “The world is embarking on a period of change, the likes of which we haven’t seen for a long time,” said Dr Jochen Köckler, managing board chairman at Deutsche Messe. The challenge for industry now is to take control and actively shape this transformation process, and that means investment in areas like Industry 4.0, Logistics 4.0, artificial intelligence, and 5G. It is vital that engineers seek inspiration and adopt fresh ideas for the ongoing changes they need to make in their operations. ! October 2019
15
INDUSTRY 4.0 FOCUS
All change to reap the full potential of Industry 4.0 Philipp Jauch believes that change to both machinery and business models are needed to allow us to really see the full potential of Industry 4.0.
Y
ear after year the manufacturing industry is observing changes that relate to the move towards Industry 4.0, IIoT, cyberphysical systems and also the relationship between operational technology (OT) and information technology (IT) environments. Before we reach Industry 4.0 significant change is still needed, but it cannot be expected or effected by simply applying technical evolutions to existing machines and business models. Significant change will occur only when industry starts to invest in new business models. Today, machine builders earn money by building automated machines that focus on reducing costs and optimal productivity thanks to overall equipment effectiveness (OEE). It is equally important to ensure machines continue to run smoothly and this could potentially create an opportunity for machine builders to offer service contracts. Take this idea one step further and you could argue that producers or plant owners do not have to be the ones to own the machines! This would provide another new business model for machine builders. Many manufacturing companies are still producing in developing countries where, traditionally, they have benefitted from lower production costs. However, today consumers are taking more notice of the impact of production on the environment and on the local workforce. Products manufactured in a fair way are gaining more traction in the market. Additionally, these manufacturing practices â&#x20AC;&#x201C; which employ a large workforce but a low grade of
16
October 2019
automation â&#x20AC;&#x201C; are not really suited to the move towards more flexible, adaptive production.
Paving the way What would it take to pave the way for adaptive production? Could it actually take place in countries with traditionally higher production costs, such as Germany, by reducing costs and increasing flexibility with the help of advanced automation? What would it require? For example, it could include production lines that are easily accessible and cost effective, to allow smaller companies to rent them for test and batch runs. Production lines would thus need to be set up with flexibility in mind and would need to allow for easy adjustment, fast switchover times and a payment model for the actual production times. One key factor would certainly be the time it takes to implement these changes. Today, most factories are typically set up using unalterable constructs. Large automation companies protect their domain with proprietary systems and protocols. Plant owners want production running with minimal downtimes and combining multiple automation systems is high risk with big efforts in harmonisation. What if machine builders would choose their favorite automation solution based solely on the best technical and cost-effective solution? Having the guarantee that this machine will have truly standardised
www.controlengeurope.com
ways of interoperability would result in every possible type of adjacent machine collaborating together. It would eventually result in factories making giant leaps in changing into manufacturing places capable of fast idea adaption and production. Machine builders are historically strong in mechanics, drive and control automation and now their IT capabilities are constantly growing and evolving. There is an opportunity to apply IT capabilities to existing machines, but also to design new machines with IT benefits at their core. Technologies such as OPC UA, TSN, MQTT, industrial hardened embedded PCs, and sophisticated and flexible cybersecurity are key elements to make this vision a reality and identifying and embracing these tools and devices will be the driving factor to create new business models for manufacturing. It is up to new players entering the ring to challenge the industry with smart, new approaches. The game is still on â&#x20AC;&#x201C; and it stays exciting! ! Philipp Jauch is business development manager for Factory Automation at Moxa Europe. Control Engineering Europe
UK INDUSTRY NEWS
IS JARGON HOLDING BACK MANUFACTURING GROWTH? Research from Wyelands Bank has shown that over two-thirds of mid-sized manufacturers say there is too much jargon in the finance industry and this has resulted in missed business opportunities. 51% of survey respondents said that jargon has stopped them from getting the financial services they need and more than half said that confusing financial terminology has probably led to missed opportunities. The research, of mid-sized manufacturers turning over £10m-£300m, showed that an inconsistent use of terminology causes real confusion. What’s more, this confusion has stopped businesses from accessing the finance they need to unlock growth. Nearly three-quarters feel that different banks use the same terminology for different products and services. Conversely, a similar proportion (71%) feel that identical products are called different things by different banks.
Commenting on the research findings, Iain Hunter, CEO of Wyelands Bank, said: “Business finance does not need so much jargon. It is confusing and makes it harder for customers to understand what they are looking for or to make the right decisions about what finance they need. “Making it easy for firms to raise funds to unlock growth goes to the heart of the productivity debate in the UK. Anything that gets in the way can be detrimental to those firms and to the UK economy.” The Wyelands Bank research also shows that more than two-thirds of mid-sized manufacturers think that there is more jargon in the financial industry than in other business areas. A similar number believe that banks hide behind financial jargon and, as a result, some 60% would rather speak to someone outside of their bank about
financing options. The difficulties raising finance meant that these companies have missed out on an average of £20 million in revenues and an average of 11 new contracts which would have enabled each firm to create an average of ten new jobs.
Industry urged to boost cyber defence investment Over half of UK manufacturers have been the victim of cyber-crime, and one-third of those have suffered some financial loss or disruption to business as a result, according to a recently published report from Make UK. The manufacturing sector is the fifth most targeted for attack in 2019, behind government systems and finance. Despite this, it remains among the least protected sector against cyber-crime in Britain. The new report, ‘Cyber-Security and Manufacturing – A Briefing for Manufacturers by Make UK’, has revealed the full extent of the threat across the sector from loss of data, theft of capital and intellectual property along with disruption to business. Expert opinion points to the fact that many more attacks will have gone Control Engineering UK
undetected, with businesses woefully unprepared to protect themselves against this threat or to detect a breach after the event. Cyber threat is increasingly a businesscritical issue, with 41% of manufacturers reporting that they have already been asked by a customer to demonstrate or guarantee the robustness of their cyber security processes. Yet, when asked if they would be able to do this successfully, 31% of businesses said they would be unable to give those guarantees of cyber safety if asked. Investment in the latest digital technologies is also being hampered, with many companies holding back from implementing the latest innovations for fear of increased exposure to cyber-attack. Some 35% of businesses admitted they are currently
www.controlengeurope.com
not fully investing in new digital processes even when not doing so will leave them unable to compete in an ever-changing and developing global marketplace. A cyber-attack recently brought a Norwegian aluminium producer to a standstill. NC Hydro was forced to switch to manual operation when its digital systems were infiltrated and it became subject to a ransomware attack. The company eventually had to halt production completely while the virus was isolated. Some factories were forced to use printed order lists as they could not access data digitally and it is believed that a ransomware virus known as LockerGoga was used which encrypts data and then demands a ransom to decrypt the files. The cost to the business was estimated at £32 million. October 2019
UK1
FOOD & BEVERAGE SECTOR FOCUS
PREDICTING THE END OF UNPLANNED DOWNTIMES Any unscheduled downtime will cause a major headache for engineers in the food and beverage manufacturing sector. John Rowley believes that predictive maintenance can offer a solution.
W
ith food manufacturers being continually squeezed on price by retailers and asked to fulfil orders for supply that can seem, at best, challenging, improving productivity is a priority. Tight timescales mean many lines are already running on a near 24/7 basis, leaving little leeway even for scheduled maintenance, let alone an unexpected breakdown. This can lead to overcautious service and maintenance regimes, which are expensive to support, but are preferable to unscheduled downtime. Most production line failures are not characterised by a sudden fault that results in immediate line stoppage. It is often a gradual degradation that impacts on product output. Before the line eventually stops, it might have spent a considerable period producing inconsistent goods – that add to the bottom-line cost of the issue, due to waste. So both unscheduled downtime and the developing causes of that downtime will directly impact productivity. The good news is that random equipment failure does not have to be a fact of life. Modern condition monitoring sensor technology can be retrofitted to rotating plant and equipment, while many of today’s plant and machine controllers will have monitoring and diagnostics functions built in, ready to use. Taking advantage of these technologies can take companies into the realm of predictive maintenance, where advanced warning of impending equipment failure gives
UK2
October 2019
engineers enough time to plan repairs during scheduled maintenance periods.
A leap forwards A conceptual and technological leap forwards from preventative maintenance, intelligent predictive maintenance ensures an asset is serviced only when needed. Predictive maintenance spots equipment problems as they emerge and develop, giving a warning of impending failure and so helping to maximise asset availability. Importantly, these predictive maintenance solutions are not complex; frequently they are simple and cost-effective to implement, and often they can be built from functions that already exist within the plant’s
control equipment. Take, for example, the add-on sensors that have been developed to monitor the increases in operating temperature, excessive current draw, changes in vibration characteristics and significant shifts in other operating parameters that can all be indicative of impending problems in rotating machines. Today these sensors come with embedded ‘smart’ functionality, revolutionising condition monitoring. A simple add-on to pumps, motors, gearboxes, fans and more, these sensors use a simple traffic light system of red, amber and green lights to provide at-a-glance monitoring of the condition of the machine. They can also be connected into wider factory automation networks using
Muntons Malt is reaping the benefits of a smart condition monitoring solution to protect fans and motors vital to its production process. [Source: Mitsubishi Electric Europe B.V.]
www.controlengeurope.com
Control Engineering UK
FOOD & BEVERAGE SECTOR FOCUS Ethernet and a managing PLC for a smarter solution.
From traffic lights to telemetry In isolation sensors can offer a starting point to implementing preventative maintenance strategies, but there are limitations to the traffic light warning system. While it indicates that a problem is developing, it gives no real clue as to what the problem might be or how serious it is; it offers no practical recommendations as to how the problem should be addressed; and while it shows problems developing on individual machines, it fails to provide an overview on the asset health of the plant. It is these limitations that Mitsubishi Electric has addressed with the Smart Condition Monitoring (SCM) solution which provides an integrated approach to monitoring the condition of individual assets and enables a holistic approach to be taken to monitoring the asset health of the whole plant. Individual sensors retain the traffic light system for local warning indication at the machine, but at the same time information from multiple sensors is transferred over Ethernet to a PLC for in-depth monitoring and more detailed analysis. The SCM kit provides a plug-andplay solution for machine condition monitoring. Sensors can be added to machines as and where required, with a teach function allowing the sensor and controller to learn the normal operating state of the machine, generating a memory map of key parameters. Once set up, the SCM provides 24/7 monitoring of each asset, with functions including bearing defect detection, imbalance detection, misalignment detection, temperature measurement, cavitation detection, phase failure recognition and resonance frequency detection. Linking multiple sensors into the control system enables the controller to analyse patterns of operation that Control Engineering UK
are outside the norm, with a series of alarm conditions that can provide alerts when attention is needed. The SCM analysis provides detailed diagnostics, offers suggestions for where additional measurements should be taken, and provides maintenance staff with precise error identification. It can even make recommendations as to what rectification actions should be taken, with clear text messages presented to personnel. This information can also be networked to higher-level systems for ongoing trend analysis across all the assets around the plant.
A practical example Looking at a practical example of the technology in action, Muntons Malt, a producer of malted barley is reaping the benefits of this solution to protect fans and motors vital to its large-scale and sensitive production process. The operation team had previously experienced issues with difficult-to-reach bearings inside a large fan housing, realising too late that a problem existed, and was forced to make an unscheduled stop to one of the lines to make repairs. Determined to learn from this, the company installed the smart condition monitoring system on two large 315kW fan sets and a single 90kW fan set, referencing the electric motor, power transmission coupling and main fan shaft bearing on each. The company is now acutely aware of the health of the fan sets and has a clear picture of any necessary maintenance well in advance of needing to make physical changes. Remote monitoring and fast diagnosis of any issues has also made the company very responsive should the operating parameters that have been set, even be approached. Live information and any alarms are displayed on a HMI mounted in the control enclosure and the system can work autonomously of any other automation, with multiple sensors located and recognised by unique IP addresses. However, at Muntons Malt
www.controlengeurope.com
the visual information, as well as the alerts, were connected into the existing automation software platform. This ease of connectivity illustrates further benefits of todayâ&#x20AC;&#x2122;s condition monitoring technologies, which can provide immediate, visible alarms anywhere in the world on smart devices. For multi-site businesses, this can help in quickly changing over production schedules from one plant to another to fulfil the most pressing orders or can alert remote maintenance teams of the need to perform more detailed diagnostics. This information isnâ&#x20AC;&#x2122;t just coming from external sensors. Modern drives, PLCs, SCADA systems and other automation products have comprehensive diagnostics capabilities inbuilt, monitoring not only their internal workings but also parameters such as current draw, voltage and temperature in connected motors, pumps, fans and compressors. All of this helps to build a detailed picture of the health of plant assets. And, with a simple plant network backbone, this information can be shared around the plant and beyond. Indeed, this sort of functionality is a key aspect of Industry 4.0 and is at the heart of the benefits of the digitalisation of production. We can see, then, that predictive maintenance strategies can offer comprehensive analysis on the health of individual machines as well as a holistic overview on the health of the wider plant. The result is vastly improved scheduled maintenance and optimised asset lifecycle management. With maintenance able to be planned in-advance, there is far less unscheduled downtime and significant reductions in the loss of service at short notice. Also, when assets are serviced only when needed, food and beverage producers can benefit from increased productivity and efficiency, with a very real impact on the bottom line. ! John Rowley is the food and beverage sector specialist at Mitsubishi Electric. October 2019
UK3
FOOD & BEVERAGE SECTOR FOCUS
MOVING TOWARDS INDUSTRY 4.0 WITH A FACTORY FULL OF AGEING ASSETS Suzanne Gill visits British Salt to find out more about the plant’s Industry 4.0 aspirations.
O
ver 50% of the salt used in the UK is produced at the British Salt factory in Middlewich, taken from the Cheshire Plain salt reserves – which are expected to last for the next 300 years. Since the British Salt factory was opened in Middlewich in 1969 it has produced over 30 million tonnes of high purity dried vacuum salt along with millions of tons of industrial and technical salt grades. When brine arrives at the plant, by pipeline, from the nearby brine field operation, the first step of the production process is purification, where unwanted impurities are removed from the brine solution. The purified brine then moves on to the evaporator hall where it goes through a series of evaporators that drive off the water to create a slurry. The final stage of dewatering process uses centrifuges to further reduce the water content. The salt is then further dried, moving through a series of fluid bed driers to drive out the last 2% of moisture. The next step is grading and then it either leaves the site in a bulk load on a road tanker or is sent on to the bagging plant, where around eight million bags, sized from a minimum of 10kg upwards, are processed each year.
considerations when specifying new equipment. “We employ a number of exotic materials across the plant,” explained Stephen Crabb, head of operations at British Salt. “Everything from conventional 304L and 316L stainless steel through to some real super high corrosion resistant alloys in the evaporator tray. We undertake constant maintenance around the plant, continually checking for points of corrosion,” continued Crabb. “Some of the plant is 50 years old – a time when control was mostly achieved manually. Technology moves quickly and we have, of course, added varying degrees of automaton to our processes over the years and we continue to do so.” When it comes to moving the plant towards Industry 4.0 there are many challenges as Crabb explained further: “One of the biggest challenges for us is that the factory runs 24/7 for 365 days of the year so we cannot stop the plant for any length of time to add new systems. We have made the decision to move carefully
towards Industry 4.0 via a series of mini projects where we are able to add cost-effective off-the-shelf automation solutions.
Utopia “Utopia for us would be to have realtime information from across the plant displayed at a single point but this is a huge challenge for 1960’s designed factory such as ours,” said Crabb. “We would first need to role the DCS out further into the factory and this would allow us to employ artificial intelligence (AI) technology. If we can put in place more control loops that can monitor and control themselves then the plant would become more reliable. This is why we want to take the approach of having a single control solution across the plant. Today we still rely on a human to react to the information provided by the data. “Employing AI technology could also help improve the plant’s overall energy efficiency. Today we rely on operators to make informed decisions. In the future we hope to see this process
Specialised solutions Because salt is such a corrosive and erosive product many of the assets in the British Salt facility need to be specialised. The environment will, for example, result in mild steel corroding seven times faster than in a normal environment. Materials of construction is one of the biggest
UK4
October 2019
Stephen Crabb with members of British Salt’s control electrical team.
www.controlengeurope.com
Control Engineering UK
> UK6
You you Youprobably probably think You probablythink thinkyou you knowwhat what SMC -- the know theworld world know what SMC - the world leaderin in pneumatics pneumatics and leader and leader in pneumatics and automation solutions solutions --isis automation automation solutions - is allabout: about: actuators, actuators, valves all valves all actuators, valves andabout: fittings, right? and fittings, right? and fittings, right? They're the products that SMC has built its success
They're the products that SMC has built its success onforforover over 60 years. But But they are just part onThey're 60 years. they arehas justbuilt partof how the products that SMC itsofhow success wecan can help you. weon help you. for over 60 years. But they are just part of how we can help you. Didyou youknow knowthat thatwe we can can also Did also supply supplycustomer customer specific control systems and engineered specials specific control systems and engineered specials Did you know that we can also supply customer whether you need just one, or one hundred. - whether you need just one, or one hundred. specific control systems and engineered specials
-Some whether you need justalso one, oron one hundred. our customers Some ofofour customers also rely rely onus usfor forinnovative innovative productstotohelp helpsuppress suppress vibration, products vibration,totoeliminate eliminate Some our customers also rely on us for innovative staticororof provide precise fluid static totoprovide precise fluidtemperature temperaturecontrol. control. products to help suppress vibration, to eliminate static or to provide precise fluid temperature control. Forexample, example, takeour our new compact For take new compactand andlightweight lightweight HRS-R thermo chiller. HRS-R thermo chiller. For example, take our new compact and lightweight Developed for use in the Food Industry, this IP54 HRS-R thermo chiller. Developed for use in the Food Industry, this IP54 rated chiller delivers outstanding temperature rated chiller delivers outstanding temperature stability and for long lifeincycle performance. Developed the Food Industry, this IP54 stability and longuse life cycle performance. rated chiller delivers outstanding temperature With IP67 internal electronics and stainless steel stability longelectronics life cycle performance. With IP67 and internal and stainless steel construction this chiller has been specifically construction this chiller has been specifically designed to withstand the challenges of working in With IP67tointernal electronics and stainless steelin designed withstand the challenges of working harsh environments. harsh environments. construction this chiller has been specifically designed withstand the challenges of working in For moreto information on our HRS-R For more information on our HRS-R harsh environments. chiller contact us on 01908 563888 or
chiller contact us on 01908 563888 or check out our web site. check out our web site.on our HRS-R For more information chiller contact us on 01908 563888 or SMC - more than check out our web site. SMC - more than
just pneumatics just pneumatics SMC - more than just pneumatics
www.smc.uk www.smc.uk
www.smc.uk Follow us on
Follow us on
Follow us on
FOOD & BEVERAGE SECTOR FOCUS being undertaken using AI technology, using real-time data to ensure the plant is always run at optimum efficiency.” Recent automation technology investment at the plant has been focussed on the end-of-line processes. A new packing line was installed in October 2018 and another new line is due to be installed imminently, with yet another on order. The packing area is one of the newer parts of the facility and so is currently the most automated. “In this area we are already able to collect real-time information about packing rates – mostly using off the shelf technology solutions. Other equipment is so specific to us that a bespoke solution is needed,’ said Crabb. “Our current strategy is to automate locally,” said Crabb. “We have a top level control layer, provided by Metso, which monitors and controls the entire factory and this works very well. To enable us to benefit from the use of predictive maintenance technologies we also need to focus on specific assets. In a factory such as ours the pumps and valves are all of differing ages, with some even being obsolete, so we either need to add automation as and when we replace assets or we need to employ retrofittable solutions. Of course, with a strategy such as this is connectivity is a key enabler. We need to get data from a wide variety of disparate sensors and systems to a central point and this is not an easy task!”
Automation projects Three senior members of British Salt’s control electrical team have been tasked with working on these siloed automation projects. For example, they are looking at how to integrate the new pack lines into the existing control system. At the micro scale they are also working on projects to find out how to best monitor and capture data from factory assets using retrofittable sensor technology. One of the automation projects is
UK6
October 2019
focused on one of the plants main circulating pumps – if this pump isn’t working efficiently it could increase energy costs by up to 10%. “We are in the process of fitting monitoring sensors to this pump. The control system to monitor the pump is already in place and this gives us some very basic data. However, we will need to replace the pump to fit the new sensors to ensure that the pump has all the correct fittings, explained Crabb. “We cannot take this step until the next planned plant shutdown. When it is all up and running this new pump control and monitoring system will link directly to our DCS system.” British Salt is also currently trialling an ABB Smart Sensor on a flue gas compressor drive. “We capture C02 from flue gas emissions for use in the purification process. This system has no standby drive so it is important that we know in good time about any motor deterioration,” said Crabb. While the Smart Sensor is wireless the team does still need to download information locally, using a Bluetooth tablet. The sensor holds data for up to 40 days so the engineering team is currently collecting data on a monthly basis. “If this data proves useful our next step will be to install more of these sensors across the site on other motors and to install a
www.controlengeurope.com
Bluetooth infrastructure which flows automatically onto the ABB cloud to send us a warning if an asset exceeds its defined pre-set specifications.” A number of other manually gathered condition monitoring operations are being undertaken by the engineering team – including vibration analysis. In conclusion, Crabb admitted that funding for new technology to help steer the factory towards Industry 4.0 is always going to be a challenge. “In an 24/7 50-year old plant there is always a need to replace existing assets so adding new technology has to compete for financing with these vital asset replacements and repairs. “There will also always be a level of uncertainly when it comes to making Industry 4.0 technology decisions and it does require a leap of faith. No one knows how quickly technology will change or whether a better solution might become available in the near future,” he said. Despite this the engineering team at British Salt is already starting to make these difficult decisions in a bid to ensure that the plant continues to run at optimum levels of productivity and efficiency. “As digitisation technology reduces in price then some of these futureproofing decisions will become much easier to make,” concluded Crabb. ! Control Engineering UK
Forward-thinking solutions. sdrawkcaB .ytilibitapmoc
Like you, we understand the vital importance of interoperability with legacy systems. That’s why the forward-thinking range of industry-leading automation solutions we’ve been supplying to the UK for over 35 years now, are all backwards compatible. Our PLCs, HMIs, Inverter Drives, Industrial Robots, Switchgear, Servo / Motion Controllers and Software solutions are all designed to address the requirements of end users, systems integrators and OEM businesses to help improve productivity, efficiency and quality. So don’t hold back in seeing what the future could bring for your company contact us on automation@meuk.mee.com or call 01707 276100. gb3a.mitsubishielectric.com
@meukautomation
mitsubishielectric-automationsystemsuk
■
Robots
■
Advanced HMIs
■
Programmable Controllers
■
Variable Speed Drives
■
Servos & Motion Systems
■
Low Voltage Switchgear
■
Software Solutions
NEW PRODUCTS
Lightweight delta robots Mitsubishi Electric has extended its MELFA articulated arm and SCARA robot offering to include a range of delta robots which combine its servo technology with the latest mechanicals from e-F@ctory Alliance partner Codian Robotics. Codian Robotics has driven the use of materials such as carbon fibre, titanium and anodised aluminium, stainless steel and plastics to deliver solutions that offer optimum strength-to-weight ratios. These lighter weight parts benefit speed while corrosion resistant options can meet the needs of more hygiene sensitive applications. The combination of Codian’s interchangeable structural
components with Mitsubishi Electric’s servo motion packages provides a scalable solution that is easy and costeffective to integrate with different formats of control platform. Machine builders can choose to
build a delta robot solution around either MELSEC PLCs or MELFA robot controllers. Solutions can be based around the Codian D2 or D4 ranges of robots. D2 robots are offered in either two- or three-axes, with maximum speeds of 250 picks-perminute, payloads up to 100kg and a maximum working envelope of 1500 x 430mm. They are said to be well suited to high-speed pickand-place applications. To meet high performance and versatile pick-and-place needs Codian D4 robots are offered in either three- or four-axes, with maximum speeds of 200 picks-per-minute, payloads up to 35kg and a working envelope of up to 1600 x 350mm.
Infrared spark detector StuvEx has launched the PSD3-D infrared spark detector which can detect the infrared energy created by embers, sparks and flames in pipelines and other parts of a process system. On detection of a problem the system is able to activate isolation equipment, such as fast-closing valves, and or extinguishing systems. The principle advantage of the
PSD3-D is that it does not require a separate control unit. It can either be used in isolation, to shut the process down, or as part of a larger factory explosion protection system. The ATEX-certified system is designed to be installed within pneumatic and mechanical conveying systems, dryers, mills, filters and cyclones.
Safe radar system solution for protection zone monitoring Pilz has added what it believes to be the world’s first safe complete radar solution for protection zone monitoring to its safe sensor technology portfolio. The new solution comprises the LBK System safe radar system from Inxpect and the PNOZmulti 2 configurable small controller. Because radar technology is insensitive to external influences such as dust, rain, light, sparks or even shock,
UK8
October 2019
it provides safe, economical monitoring even in rugged environments where optoelectronic sensors and technologies cannot guarantee availability. Comprising up to six radar sensors – depending on the application – and one control unit, with the PNOZmulti 2 compact configurable safe controller responsible for safety in the system, the solution can be used up to SIL 2, PL d, Category 2.
www.controlengeurope.com
Each sensor protection zone is flexible and varies, depending on installation height and sensor inclination. It can be set up as wide (110°/30°) or narrow (50°/15°) with maximum depth of 4m. The layout of the total protection zone and system is also flexible and can be configured up to a maximum 15 x 4 m using six sensors in series to create a linear barrier. Control Engineering UK
COLLABORATIVE OPERATION
MAN AND MACHINE WORKING COLLABORATIVELY Josep Lario comments on how industry is overcoming the challenges associated with the move towards greater collaboration between man and machine.
M
anufacturing production lines are beginning to change as industry evolves. Greater flexibility is vital in order to cope with demands for shorter production runs, tighter deadlines and greater product variation. These challenges are being addressed with interconnected, intelligent and more advanced systems that are able to be programmed to handle a wide range of tasks. This has brought new challenges, such as how to program all these devices without needing to learn many different systems and programming languages. Luckily, there are tools available that offer integrated development environments (IDE) for configuration, programming, monitoring and 3D simulations. These IDE tools integrate configuration, programming, simulation, and monitoring in a simple interface that allows engineers to manage vision, motion, control, safety, and robotics in one system.
Relationships Even today, production lines are made up of many different machines – each designed to perform a specific task or set of tasks before the product under construction moves to the next stage in the process. Each of these machines has its own control system for programming and operation, with different manufacturers having their preferred communications and operating protocols. So getting these machines to talk to each other is already a challenge. The good news is that there is a number of existing standards. For example, the OPC-UA communication protocol, defined by the OPC Foundation provides a cross-platform unified architecture for industrial automation. In Control Engineering Europe
addition, automation vendors, such as Omron, are building more communications functionality into their devices to allow them to communicate with each other, transferring data in real-time to keep production lines running optimally and bringing increased flexibility and efficiency to modern production lines.
Teamwork collaboration With all the machines on a line now online, this provides opportunities for increased flexibility. New instructions can be downloaded to a line to change the production, software can be updated remotely, and bugs fixes rolled out to all connected devices just like updating the software on computers or apps on smart devices. This still presents some challenges – while the communications may be standardised, the machines themselves may still use their own operating languages and control systems. Some integrated development systems have overcome this by providing a standardised and seamless interface that allows programmers to program a complete manufacturing or production line. Integrated platforms give programmers easy access to all aspects of process management. Taking this a step further, some are incorporating the popular Git – a free and open source distributed version-control system – which ensures efficient project management and easy comparison of different versions. This boosts productivity by supporting cooperative and efficient co-development by teams from different sites. Any number of development teams in different locations can work on the same project simultaneously.
www.controlengeurope.com
The version-control system allows engineers to work on a local version of a project with full control over the project source code. Improvements and modifications made to the code on the team’s version can then be merged with a remote server, so other teams can access the code. Thus, projects are fully traceable, and comparison and management of machines and projects is simple. Changes to code can be identified so engineers do not waste time solving a problem already solved by another team. A further aspect of collaborative operation is how easy it is for operators to perform process monitoring and control. Machines need to be intuitive and easy to operate. User interfaces need to be simple consistent and intuitive to use, so that even less skilled operators can become familiar with controls quickly.
Many hands make light work Or so the saying goes! The increase of collaborative work, whether this is between operators and machines, remote teams or the machines alone, can deliver substantial benefits for manufacturing lines and production. Benefits such as improved collaboration to boost efficiency, reducing work for programmers, helping to avoid costs from downtime and improved communication when processing information. ! Josep Lario is EMEA product marketing manager, Software, at Omron October 2019
17
SERVITISATION
MOVING TOWARDS PAY-AS-YOU-GO PRODUCTION Paul Hingley believes that servitisation is set to transform every aspect of modern manufacturing.
O
ne of the main themes running through the Siemens Digital Talks conference earlier this year in the UK was how the concept of servitisation was permeating through many layers of the manufacturing sector. Driven by the power of increasing digitalisation, servitisation is based around the idea of moving from a one-off transactional relationship to an ongoing service-based one. For example, a traditional machine builder would build and deliver a machine to order. Beyond some fairly basic maintenance support, the commercial relationship would usually end there. Potentially 20 years later and the client may want a replacement or an upgrade, but by then they could also require a different specification or a new configuration which might see them go to a competitor. In other words, engagement with the core customer base is primarily time-limited, with no guarantee of any repeat business or any meaningful additional income coming from them.
of predictive maintenance, energy efficiencies, increased throughput, improved logistics and other productivity benefits. An example of this machineas-a-service (MaaS) approach was demonstrated at the Digital Talks event by TrakRap, a UK-based secondary packaging business. The company demonstrated how it is now able to sell a ‘pay-per-wrap’ solution to end-users based on them having access to powerful production data via Siemens’ Mindsphere cloud-based operating system. This is possible without TrakRap needing to wrestle with terabytes of raw, unqualified information. Instead it can utilise data which has already been processed on the factory floor via Edge processing before being uploaded to Mindsphere for analysis. The move from machine maker to machine manager has had
a transformational impact on TrakRap’s business model. Through remote diagnostics and predictive maintenance it can reduce call-out times by over 50%. In terms of the cost to its clients, this equates to a reduction of 70% in downtime. This means that TrakRap is no longer in the machine selling-business; it is now a service provider that is remunerated each month by clients who are happy to enter into a pay-asyou-go arrangement linked to agreed KPIs and efficiency targets. Servitisation now also determines how TrakRap finances its business. Working with Siemens Financial Services, Siemens provides investment in advance, based on a five-year period, which is repaid via TrakRap’s new servitisation business model. This arrangement is not unique to TrakRap, and servitisation as the basis for a different approach to financial
A quiet revolution Digitalisation and the advent of the digital twin in particular is quietly revolutionising this business model. Machine builders are now empowered to supply machinery bundled with an ongoing service offer which is linked to continuous improvement, ongoing optimisation and tangible KPIs. This process sees ‘machine maker’ evolve into ‘machine manager’, with the end-user customers generating significant savings through the use
18
October 2019
TrakRap is now able to sell a ‘pay-per-wrap’ solution to end-users based on them having access to powerful production data via a cloud-based operating system.
www.controlengeurope.com
Control Engineering Europe
SERVITISATION investment and capital expenditure within manufacturing is another emerging trend. For example, Siemens has been tasked by Pilkington PLC to look into cutting its energy costs. We calculated that to deliver the efficiencies demanded would cost several millions. Pilkington was not minded to invest in such a large sum up front at that time, so Siemens agreed to provide the technology on the guarantee that Pilkington would pay a fee each year based on the outcome of achieving the energy savings it was seeking.
30th international exhibition for industrial automation Nuremberg, Germany 26 – 28 November 2019 sps-exhibition.com
Elegantly simple It is an elegantly simple solution – the energy savings Pilkington made from our interventions translates into financial savings, which, in turn, is used to pay us back in annual instalments. Admittedly we were taking a risk, but we were confident that the energy recovery and digitalised solutions being deployed on behalf of Pilkington would generate the energy efficiencies we were being targeted on. Siemens took a similar approach to a recent contract secured with malt manufacturer, Boortmalt, which tasked it with reducing production costs by up to 30% by optimising utility consumption, raw material usage, machine performance and general production processes. Like Pilkington, Siemens has agreed to work towards a range of outcomes, and the deal was underpinned by a commercial model which sees us being rewarded for the outcomes or performance metrics we achieve and not simply for the hardware and software we install. Peter Nallen, chief operating officer from Boortmalt, described this arrangement as a “de-risked financing capital investment model” for the business which would “achieve Boortmalt’s sustainability strategy with confidence”. So, from TrakRap moving from being a machine builder specialising in packaging machines to a ‘pay-perwrap’ vendor, and the likes of Boortmalt and Pilkington remunerating us annually based on performance and not on the cost of equipment, you start to see how the evolution of Industry 4.0 technologies and the concept of servitisation are inextricably linked. Siemens welcomes this disruptive business model. We envisage entire pay-as-you-go factories on the horizon, and more manufacturers migrating to a service-based model through the power of digital twins, Edge processing and secure cloud-based analytics. In addition, we believe that ‘service’, in all its forms, will emerge as one of the most powerful drivers with regards to increasing a manufacturer’s competitiveness, and that servitisation will very soon become the new normal within all manufacturing disciplines. !
Bringing Automation to Life
Hands-on. Visionary. Personal. Find answers to your current needs on-site, as well as possible solutions for the challenges of tomorrow. Register now and get
30% off with the discount code: SPS19BESV12 sps-exhibition.com/tickets
Paul Hingley is data services business manager at Siemens Digital Industries. Control Engineering Europe
October 2018
19
SCADA & HMI
DATA GATHERING FROM DISPARATE PLCs Find out how a medical appliance manufacturer cost-effectively solved its data gathering headache within a factory full of multiple branded devices.
A
move into new premises and upgrades to network architecture and server, resulted in Welland Medical’s existing data capture system no longer functioning. The company, which specialises in the design, development and manufacture of stoma care appliances and accessories, sought quotes to obtain a replacement/upgrade of this its data capture system which proved to be prohibitively expensive. So, the company set out to find a new data capture system for its factory production machines to monitor and record production key performance indicators (KPIs) and synchronise this to a database that could be queried to produce live data and historical operational and management reporting. Welland Medical’s installed factory production machines have a variety of brands of PLCs at their heart, all of which reside on an automation Ethernet network along with various human machine interfaces (HMIs) and other devices. It can be a challenge to gather meaningful production data from multiple brand devices.
A faceless HMI solution Lamonde Automation was able to offer a solution with the Weintek cMT Server, a faceless HMI. The cost of the unit was a small, one-off hardware cost, plus installation and configuration by Lamonde, but there are no ongoing costs as no licence is required. Compared to a traditional approach to this kind of problem, which would require multiple OPC server licences to communicate with the installed PLCs and devices, the cMT Server offers
20
October 2019
a cost-effective solution, costing just a small percentage of the price for a single OPC server. The specific unit recommended and installed by Lamond Automation was the Weintek cMT-SVR-100 which provides all the interface and datalogging capability that would be reasonably expected of an HMI, but without taking up precious panel real-estate or providing an unnecessary additional touch screen. While primarily the cMT is acting as a data-concentrator/communication gateway, the HMI application has been developed to make it a useful shop-floor diagnostic tool accessible by Android/IOS devices using Wi-Fi, as well as via a PC running the Weintek cMT Viewer app. Using bit-triggered data sampling, each PLC presents a snapshot of the production data: product code, an ASCII string, and four 32bit registers providing current, real-time parts per hour, batch count and a downtime reason code, and a spare register for future use. Captured data is written to an SD card installed in the cMT-SVR-100 in real-time on a rolling 31-day FiFo (first in first out) cycle and periodically synchronised to a MySQL Database residing on the Welland Medical server.
Providing resilience Resilience is provided by the 31 days of storage on the SD card so, should there be a temporary issue with the server, the data will be available to resync once the server issue is resolved. Further integrity is provided by
www.controlengeurope.com
the front-end, developed by a thirdparty. By synchronising the captured database with a second database, a further layer of data integrity is provided so any erroneous writes or table dropping calamity (it happens!) affects only a mirror of the real machine data. All the data is displayed on monitors at the end of the production line and in the staff canteen, providing highly visible business-rich information – far more than Welland Medical had on its old system. Commenting on the project, James Jeffery, senior projects engineer at Welland Medical, said: “We were looking for a method to move data from various production lines into our MySQL server. This would feed a frontend program and provide live OEE type data on large screens on the shop floor, but our machines have many different brands of PLCs fitted. “We found the solution offered by Lamond Automation easy to use and it can extract data from the majority of makes of PLCs for a very small cost. Lamond wrote the program for this and provided training on site for our engineers. A front end was programmed by an external SQL server expert. The few problems we did suffer were very quickly resolved.” ! Control Engineering Europe
SCADA & HMI
Connectivity solution for different types of field devices Connext is a communication server from Progea which is aimed at companies investing in automation platform compatibility and data processing. Said to be more than just an ordinary server, Connext offers connectivity for different types of field devices as well as providing data recording tools. It is an open, flexible and modular l/O server solution based on OPC UA technology. Its ability to obtain real-time data via machine to machine (M2M) communications allows users to build systems that boost efficiency and improve competitiveness. A key feature is its ability to connect to
any field device, as it supports many standard communication protocols, plus IloT communications via the cloud. The solution enables different protocols to be applied and used simultaneously which allows Connext to provide a flexible, universal tool that can help engineers to ensure higher levels of plant connectivity and interoperability. Functionality is enhanced by interfacing with existing devices and systems. Acting as a gateway between field information and other local or remote systems, Connext can serve a range of industrial information systems including SCADA, HMIs,
MES and ERP platforms. From a programming point of view, in addition to its own set of drivers and function modules, .NET developers can benefit from the software development kit (SOK) to integrate their own suite of customised protocols and expand the existing library of drivers available. The Connext OPC UA server was designed to support the Data Access (DA), Alarm & Conditions (A&C) and Historical Access (HA) OPC UA specifications so, in addition to its server functions, the solution also offers the ability to manage alarm notifications and record the data transferred in a database, either onpremise or in the cloud.
OVER 35 YEARS OF INTEGRATIVE AUTOMATION SOLUTIONS
cMT-G SERIES IIoT GATEWAYS
cMT-G01 - Ethernet | cMT-G02 - Ethernet & WiFi | cMT-G03 - Serial Bridge | cMT-G04 - Ethernet Bridge
www.lamonde.com
020 3026 2670
sales@lamonde.com
CALIBRATION
FLOW MEASUREMENT: GETTING IT RIGHT
Understanding, monitoring and controlling flow rate, as part of industrial processes, are essential elements to the viable operation of production systems. Brendan Robson discusses what is involved in getting such measurements right and the hazards of getting it wrong.
F
undamentally, the selection of appropriate measurement technology and its cost, accuracy and proper use will affect the measurement result. For example, a recent BBC report estimated that the UK exported 1.2 billion bottles of Scotch whisky in one year, which equates to approximately £4.36 billion in sales (and associate tax revenue, of course). A measurement uncertainty of 0.5% on volume across this industry would result in a financial exposure of around £21.8 million. A recent measurement audit of an alcohol bottling plant found that classic manual procedures were in place for both sampling and for offline measurement of density, subsequently used to infer the Alcohol By Volume (ABV) of the product. Unknown to the plant operators, the expensive Coriolis meters being used to measure flow rate were also capable of measuring density. Using these Coriolis meters to measure both flow and density would allow for immediate online monitoring of alcohol content along with prompt action and enhanced product control. The reluctance to change is a powerful barrier throughout industry. However, this should be balanced with an understanding of the available technology, including the importance of flow measurement, and its assessment in a cost-benefit analysis according to requirements. When operating a process that relies on measurement systems for monitoring productivity, control, or safety, the ability to prove the
22
October 2019
accuracy of the measurement system The traceability chain is vital. This requires an understanding As we move up the traceability of measurement uncertainty, chain towards a given measurement calibration and traceability, as standard, the uncertainty in well as a management system that measurement reduces (becomes more incorporates a measurement policy accurate). However, to achieve lower and a maintenance schedule. This leads uncertainty it is necessary to invest to confidence in the measurement more money in the system by way process and the final result. of increased capital, maintenance To achieve the target accuracy, costs and experienced staff. This is which is so critical to trade and important to consider, as the most commerce, most countries have a accurate system is not always the dedicated regulatory framework which correct solution for a given application. supports the national measurement Owing to the cost penalty associated infrastructure and is designed with achieving and maintaining to facilitate and regulate good low uncertainty, the requirements measurement practice. In the UK, this for a given application need to be system is known as the National Measurement THE TRACEABILITY CHAIN System (NMS), which is delivered through the UK Government’s Department 0.05% National Standards Laboratory for Business, Energy & Industrial Strategy (BEIS). Metrology traceability, including 0.1% Calibration laboratory flow determination, plays a vital role in national infrastructure since accurate results and confidence in 0.5% Company “Master” instrument measurement are impossible to achieve without it. Traceability is the technical proof that a 1% Production instrument measurement device has the appropriate pedigree, normally through calibration records, 5% End product referenced back to a national standard.
www.controlengeurope.com
Control Engineering Europe
CALIBRATION
considered prior to system design and component selection. Despite the work that is invested in maintaining and regulating the NMS, when performing a measurement audit, a common finding relates to instruments that are not installed or operated in accordance with the requirements, or in some instances are no longer traceable to the appropriate standard. Furthermore, it is not uncommon to find flow meters in service where the operator has no record of when the device was calibrated and no planned maintenance for the system. So, what is restricting industry from investing in such powerful diagnostic tools and traceability? A key factor is the required level of measurement uncertainty. If we consider the oil and gas petrochemical industries, the needs are usually well established. These organisations typically have dedicated metering departments to support the measurement of flow for hydrocarbonbased products of high value, where even small uncertainties can lead to large financial exposure over short
timescales. Another key factor is that these industries are regulated much more tightly than others, due to the fiscal value of the metered product. The same degree of stringent regulation does not often apply to flow measurements in other industrial environments. So, companies in sectors such as food and beverage, power or chemical may rarely undertake complete flow measurement audits and instrumentation is often underutilised. Conversely, the development and application in medical and pharmaceutical areas are potentially a matter of life or death.
Key considerations Regardless of the industry in question, a key consideration is: Do you understand the uncertainty in the measurement systems that you require for your business? And can you prove it? Furthermore, how does your measurement system perform over time? How frequently do you calibrate? And do you have any past performance data that would allow you to improve the performance or establish an optimal
calibration period? Crucially, are these points recognised in your quality system? Traceable and good measurement practice is critical in achieving accurate and repeatable flow measurement. However, selecting the appropriate solution depends upon understanding the operation and the measurement uncertainty required for a given application. This requires a fundamental understanding of metrology as well as the process to which it is applied. Additionally, given the sophistication and capability of modern flow measurement technology, such systems may not simply measure flow rate but also provide powerful diagnostic capability and valuable data. This can provide insight into both the efficiency of the measurement system and the effectiveness of the process, which has the potential to yield substantial commercial benefits including improved monitoring and performance. ! Brendan Robson is a project engineer at TĂ&#x153;V SĂ&#x153;D National Engineering Laboratory.
Cost and time saving solution for tank and silo calibration Replacing time-consuming and cumbersome test-weight, flow-meter or material-substitution methods, Mettler Toledoâ&#x20AC;&#x2122;s RapidCal tank scale calibration system instead applies downward force with hydraulic equipment that mimics tank-scale loading during normal operation. According to the company doing the calibration this way accounts for piping- and understructure-influences and offers greater calibration accuracy. The new method is said to save up to 80% working time when compared with traditional methods. It also avoids waste of deionized water that is typically used for flowmeter calibration. The RapidCal reference system promises 0.1% accuracy. Reference load cells provide traceability to applicable standards. RapidCal also avoids the need for tankemptying and cleaning of material substitution, which in turn eliminates contamination risk and disposal costs. The effective downtime is limited to a few hours per calibration.
Control Engineering Europe
www.controlengeurope.com
October 2019
23
TEMPERATURE & PRESSURE CONTROL
Automating dome-loaded pressure controllers Dome loaded back pressure regulators are often used in processes where constant pressure is needed in a chemical reactor. Electronic pressure controllers can offer an effective solution to automate such processes.
T
he process pressure of dome loaded back pressure regulators is set by applying the required pressure to the reference side of the controller at a one-to-one ratio. Traditionally they use springs to set the upstream pressure. However, The change in the spring force as it is compressed is a major source of error or overpressure. Pressure Control Solutions offers the Equilibar back pressure regulator, which is designed to maintain upstream pressure at its own inlet to enable high precision and stability in controlling the pressure in chemical processes. It is said to be particularly suitable for use in low flow, extreme temperature, mixed phase fluids, corrosive media and sanitary process conditions. “Until recently we used single-valve electronic controllers to get the right pressure levels for our dome loaded back pressure controllers, then to reduce pressure, we added artificial leaks. Although this solution worked very well in practice, the downside was that it required us to continuously use inert, high-pressure gas,” said Armand Bergsma, owner of Pressure Control Solutions. “This configuration is fine for low-pressure applications using a compressed air network, or highpressure applications where the customer provides a centralised highpressure network,” continued Bergsma. “However, it can be a problem if such facilities are not available. “If there is no centralised highpressure network, it is possible to use 200 or 300 bar gas cylinders. The
24
October 2019
reactors used to test catalysts usually only need a pressure of 150 to 180 bar, so no more than 50 to 20 bar respectively should be used from a 200-bar nitrogen cylinder in order to maintain maximum process pressure. For extended periods another another way to limit the consumption of dome gas will be required.”
Reducing gas consumption
The Bronkhorst PPC does not just reduce gas consumption, it also offers stability. Because it employs clean pure gases, processes that combine an Equilibar precision dome-loaded pressure controller and the PPC are able to control pressure stability at a rate better than 0.1%. The process side of the dome loaded pressure controller is often used to process aggressive reactants and by-products at high temperatures. For these severe applications, the Equilibar can be manufactured from chemically inert materials such as SS316, Hastelloy, Zirconium and Monel. The multiple-orifice design is capable of controlling gases and liquids as well as multi-phase flows. !
Together with Bronkhorst Nederland the company looked for a solution to reduce the consumption of dome gas. The solution was found by combining Pressure Control Solution’s Equilibar dome-loaded back pressure controller with the new Bronkhorst EL-PRESS Process Pressure Controller (PPC). This device features an integrated PID controller, which makes it possible to regulate two control valves, greatly reducing the consumption of dome gas. The pressure controller opens the control valve located upstream of the pressure sensor. Meanwhile, the downstream valve remains closed, which causes the reference pressure to increase. Gas consumption during the pressure build-up is negligible. The control valve, located downstream of the pressure sensor, is only opened once the pressure is lowered. “Naturally, the upstream valve remains closed when this happens,” continued Bergsma. “By choosing the right valve (orifice size) and PID settings, it is possible to either quickly or slowly increase This application example demonstrates the Equilibar and/or reduce the dome pressure, dome loaded controller combined with a PPC. Image courtesy of Zeton, NL. depending on our requirements.”
www.controlengeurope.com
Control Engineering Europe
DIGITAL RETROFIT?
Digital Retrofit - Your path to Industry 4.0 success Digitalise existing equipment and machinery and give them the capabilities to capture, store, process and communicate data with HARTING’s MICA (Modular Industry Computing Architecture). Why Digital Retrofit with MICA? Create a smarter, more efficient business Extend the life of existing and old machinery Program in a language you know Save costs by upgrading existing machinery to increase efficiencies Communicate with legacy machines and different protocols
www.harting-mica.com/en
TEMPERATURE & PRESSURE CONTROL
PUTTING PRESSURE ON PRODUCTIVITY Carefully selected measurement instrumentation and a suitable inventory management system can help avoid the health and safety risks associated with chemical injections in the oil and gas industry. It can also help reduce costs.
I
n oilfield services chemicals are often used to coat the side of a wellbore to improve stability. In pipelines they prevent build-up and keep the infrastructure healthy. So, in the oil and gas industry chemicals are regularly injected, in many different forms, into process lines and fluids. They protect the infrastructure, optimise processes, assure flow and in general improve productivity. Unfortunately, their use is not without risk – too little chemicals may lead to downtimes or process fluid clogging, while too much chemicals may damage the infrastructure and lead to empty supply tanks or may complicate the regeneration process. Measuring the correct density and the correct blending of multiple chemicals is vital. If too much pressure is used for the injection, production may need to shut down which can be very costly. Plant operations typically involve interaction and coordination between different stakeholders, each looking after their own responsibilities and targets but sharing a common goal – to improve operations and to make them safer. Maintenance managers have to take single systems out of line for periodic maintenance checks, quality managers check the implementation of new safety rules, well managers seek to reduce chemicals density to prevent damage to the well and operations managers often want to use more viscous materials to minimise the risk of build-up. To align all of these demands requires a clear automation concept which offers a future-proofed solution. Inventory management systems support the operator by improving regeneration processes and assisting with optimal fluid orderings. This leads to additional cost-savings and answers the demands of different stakeholders.
26
October 2019
But how does it work? Take, for example, the injection skids for the oil and gas production and for the pipeline infrastructure. Every injection line is typically equipped with a flow meter – usually mass flowmeters – a pressure transmitter, temperature control and a pressure regulator to control the pressure of the injection. An inventory management system compares the tank level measurement of the skid with the main inventory measurement, derives trends and optimises the just-in-time principle of inventory management. Future requirements can be matched with current inventories and supplies are ordered in good time to avoid running out of chemicals to inject. By processing injection rates and level measurements in one system, operators are able to detect differences in measurements. When comparing in mass, the sum of injections should be equal to the levels measured in the tanks. In case of discrepancies, system connections need to be checked for leaks or erroneous injections. Measuring the individual tank level and the injection rate also helps optimise blending volumes. A backup or safety system ensures the correct blending, based on the density or tank level compared to plan. During pressurisation and flow injections the infrastructure is facing a higher risk of damage. Reliable pressure and flow measurement instruments are crucial to optimise injection performances and contribute to resource conservation.
Selection Among the most important selection criteria are liquid compositions, temperature and pressure ranges, flow
www.controlengeurope.com
rates, the location of an installation and specific certificate requests. Weight is also important as chemical injection skids are often used on offshore platforms. Since the risk of over-pressurisation is minimal, a compact pressure transducer with a 4 to 20 mA analogue signal is generally a good choice for single line use. The signal goes to the system DCS, where the operator monitors the individual line pressures. Device data is provided via software interfaces and webserver technologies. It is crucial to ensure that the data is available to everyone who needs it for decision making. As data now is available in electronic form, the reconciliation between inventory management systems and ERP systems is becoming increasingly efficient. Going one step further: if data relating to the chemical inventories is shared between operators and suppliers, proactive resupply of raw materials is improved as part of an integrated supply chain management. With proper data monitoring about current product consumption and inventories, suppliers are enabled to plan just-in-time shipments, resulting in higher production continuity while keeping inventories to a minimum. ! Control Engineering Europe
Sensorik 4.0: Smart Sensors. Ideas beyond limits. Industry 4.0 starts with the sensor or field device. These provide the basic data for the digital networking of plants and production processes in an Internet of Things. With its innovative sensor and interface technologies, Pepperl+Fuchs already enables process and production units to interact intelligently. Be inspired at www.pepperl-fuchs.de/sensorik40
CEE Pepperl&Fuchs Half Page Ad.indd 1
BETTER PLANT
19/09/2019 19:59
|
BETTER PRODUCTIVITY
|
BETTER PROCESS
|
BETTER PEOPLE
Appetite for Engineering is a one-day educational and networking forum for senior engineering professionals. It has been created to provide the UK food and beverage manufacturing industry with a forum to network with peers and industry experts, and to learn about engineering developments and successful implementations. Join the discussion to find solutions to your current challenges, to identify opportunities and to create new solutions to tackle your production problems.
17th October 2019
Are you ready to join us? Register your interest online at
www.appetite4eng.co.uk Or contact Trevor Southerden T: 01732 359990 E: trevor.southerden@imlgroup.co.uk
Manufacturing Technology Centre
Ansty Park, Coventry Headline sponsor:
Sponsors: Group WHERE EXPERTISE FLOWS
INDUSTRIAL COMMUNICATIONS
TSN IN AUTOMATION Volker E. Goller discusses time-sensitive networking – why it is being developed and what advantages it will offer for industrial communications.
F
or industrial communication applications guaranteed latency is vital, making classic Ethernet unsuitable. This, along with its other shortcomings in the industrial environment, has resulted in automation experts over the years developing their ownEthernet extensions. However, the paths taken have differed greatly. Protocols using Ethernet as a transport medium for a fieldbus claim complete control over the Ethernet medium for themselves. Classic TCP/IP communications are only possible in piggyback style via the fieldbus (EtherCAT and POWERLINK) or through a channel assigned by the
28
October 2019
fieldbus (Sercos). Bandwidth control is firmly in the hands of the fieldbus. There are also protocols which guarantee bandwidth reservation through a time slicing procedure on the Ethernet. PROFINET IRT should be mentioned here. IRT enables hard deterministic real-time data transmission on the same cable on which soft real-time or background traffic is operated. A precise timing model for the transmission paths is necessary for planning of the time slices. Finally, there are protocols based on sharing of the Ethernet cable. These protocols use quality-of-service (QoS) and are at home in factory and process
www.controlengeurope.com
automation applications. PROFINET RT and EtherNet/IP, for example. These protocols are limited to the range of soft real time (cycle time ≥ 1 ms). For these standards, special hardware support and, thus, special ASICs are needed. Because PROFINET RT and EtherNet/IP are also based on the embedded 2-port switch with cutthrough, they are also not exempt here. Flexible hardware-based multiprotocol solutions, such as Analog Devices’ fido5000, help solve the problem in an elegant manner.
Enter TSN With TSN, extensions for standard Ethernet in accordance with IEEE 802.1
Control Engineering Europe
INDUSTRIAL COMMUNICATIONS
that break free of past limitations have successfully been developed. There is now a standardised layer 2 in the ISO 7-layer model with upward compatibility to the previous Ethernet and hard real-time capability. With 802.1AS-rev, TSN also defines an interoperable, uniform method for synchronising distributed clocks in the network. Because best effort communication always takes place with TSN, the common use of a cable is possible for hard real-time applications, as well as all other applications (web server, SSH, etc.). TSN is not dissimilar to PROFINET IRT in that regard, and it also offers comparable performance. What is new with TSN is the need for more extensive network configuration. Centralised or decentralised configuration is possible. Both types of configuration are currently being discussed and implemented. Interoperability between the two configuration mechanisms is a future development goal. But, what are the practical advantages of TSN? The most common answer is that, with a larger market, less expensive network interfaces also appear on the market. After all, TSN will also be found in building automation and the automotive industry in the future. As a matter of fact, the market for embedded TSN solutions is expected to be significantly bigger than the current market for all industrial Ethernet solutions put together. The greatest technical advantage of TSN over previous industrial Ethernet methods is its scalability. Unlike current industrial networks, TSN was not defined for a specific transmission rate. TSN can be used for 100 Mbps just as for 1 Gbps, 10 Mbps, or 5 Gbps. It also enables topologies to be better optimised because now adapted data rates can be selected for various segments. Whether it’s Gbps, 100 Mbps, or 10 Mbps, a unified layer 2 – IEEE802.1/TS – is used. A uniform network infrastructure Control Engineering Europe
also helps personnel tasked with setting up and maintaining the network because, thanks to TSN, solutions can now be used in sectors other than automation: building, process, and factory automation and energy distribution alike. This brings us to the next advantage, the training factor. TSN is already a topic at many universities, mostly in the research stage. However, technical and vocational colleges are already showing interest in this topic. We can safely say that TSN will become basic knowledge for engineers, technicians, and skilled workers. Retraining for different fieldbuses will no longer be necessary. In nearly all TSN-related working groups there is a recurring theme – how to safeguard the transition to TSN and the supply to existing installations, such as Brownfield applications? On all sides, emphasis is being placed on making it possible for customers to smoothly transition to TSN. It can already be said today that the existing industrial Ethernet protocols are not just going to vanish overnight. On the contrary, anyone using PROFINET, EtherNet/IP, EtherCAT, or a similarly widespread industrial Ethernet protocol today can safely assume that he or she will also be able to operate networks with these protocols – and receive support and replacement parts – in 10 years’ time. All industrial Ethernet organisations provide models that describe how existing plants can cooperate with new TSN-based devices. The interface to the existing industrial network is made by a gateway (Sercos), with a coupler (EtherCAT), or without any special hardware (PROFINET RT). Especially PROFINET and EtherNet/IP plan to make their complete protocols available right on TSN as layer 2. This makes stepwise transition to TSN possible. In summary, TSN will be found everywhere in new installations as well as in the form of islands or segments introduced incrementally into existing
www.controlengeurope.com
installations. However, with TSN, there will be new players in the industrial Ethernet field. OPC UA, which, with the new transport protocol PUB/SUB, in conjunction with TSN, is already viewed as a competitor to the classic protocols. This means that in the future both the classic industrial Ethernet solutions, as well as TSN and the new players, will need to be supported.
TSN as an opportunity TSN makes it possible to create a uniform basis for all industrial communications. Once TSN is introduced, layers 1, 2, and 3 of the ISO 7-layer model will be unified in industry. This will make completely new levels of scalability and performance possible. Will communication on the upper layers also be standardised based on this? Will there be a unified OPC UA PUB/SUB? Possibly. With the fido5000 series, users are prepared for all scenarios.
TSN and Analog Devices Analog Devices acquired Innovasic, an industrial Ethernet leader, a little over one year ago and has now integrated it. Along with Innovasic, the fido5000 series of industrial 2-port switches was incorporated into the Analog Devices portfolio. The switches in the fido5000 series support all relevant industrial Ethernet protocols and are already TSN ready. With the fido5000, products that enable the transition to TSN and simultaneously meet today’s requirements, (PROFINET IRT, EtherCAT, POWERLINK, EtherNet/IP, etc.) can already be planned. OPC UA PUB/SUB will also be possible with the fido5000. The fido5000 series is undergoing continuous enhancement for this. New products for Gb applications will be offered, but the 10 Mb/100 Mb products will also be continued and adapted to customer requirements. ! Volker E. Goller is a systems applications engineer with Analog Devices. October 2019
29
FINAL WORD
SHIFTS IN CONTROL SYSTEM DESIGN Jason Urso explains how project execution using a process control system highly integrated virtual environment can meld software and networking to uncouple control applications from physical equipment, and controllers from physical I/O. This reduces capital cost, creates standardisation and eliminates some non-value-added work.
T
he world is changing at an unprecedented pace, and process control technologies have responded by adapting Lean project execution principles, software, and networking to decouple control applications from physical equipment, and controllers from physical input/output (I/O). Modular designs allow multiple controllers to form one virtual controller. Such technologies used in the connected global economy help business decisions to be agile and accurate. Processes must execute with speed and efficiency. Projects must be completed on time and within budget. Workers must react to changing circumstances with confidence based on available and precise data. Technology must enable success, not hinder it. Few technology environments are more complex than those required for
industrial control systems (ICSs). These environments must incorporate critical functions including cybersecurity, redundancy, high-speed networking and deterministic operations. This helps customers control safety-critical process manufacturing facilities with the highest levels of reliability. Process control systems (PCSs) have served the process industries for over 30 years. Many opportunities to harness the power of new technologies and make a step change in benefits remain. The process industry continues to have an opportunity to drive down capital cost by shifting from customisation to standardisation and eliminating significant amounts of non-value-added work. With installed systems, improved operations continue by converting data into knowledge and transforming knowledge into more precise action. Ultimately, the process industry has more opportunity to execute
projects in less time with lower risk while improving throughput, quality and operational reliability. Decades of implementations and customer collaborations provide first-hand knowledge of the pain points impeding project efficiencies and limiting customers from achieving and sustaining best operations. Helping customers overcome these roadblocks has resulted in a new approach to deploying and operating ICSs by integrating a virtual environment. Automation can be implemented effectively by applying Lean execution methods for automation projects. Such a strategy removes the traditional dependencies that used to force project flows to be sequential by combining universal I/O devices, virtualisation, virtual engineering and automated commissioning. Doing so separates physical from functional design, breaks down task dependencies, uses
Project execution with a new generation control system: Honeywell Experion PKS Honeywell Integrated Virtual Environment (HIVE) uses Lean project execution principles (the Honeywell LEAP process was introduced in 2014), software and networking to decouple control applications from physical equipment, and controllers from physical input/output (I/O) devices. Modular designs allow multiple controllers to form one virtual controller. PKS stands for process knowledge system. Image supplied by Honeywell Process Solutions.
30
October 2019
www.controlengeurope.com
Control Engineering Europe
FINAL WORD
standardised designs, and enables engineering to be done from anywhere in the world, resulting in significant risk and cost reductions.
Less complexity New generations of control system technologies use Lean project execution principles, software and networking to unchain control applications from physical equipment and controllers from physical I/O. This enables control systems to be engineered and implemented in less time, at lower cost and risk, and with simpler, modular builds. This transforms how control systems are maintained, shifting day-to-day management of servers to a centralised data center, where experts and established protocols mitigate cybersecurity risk, allowing plant engineers to focus more proactively on control system optimisation. Eliminating complexity, decoupling control from the physical platform and reducing information technology (IT) costs can remove roadblocks preventing simplified control system design, implementation and lifecycle management for project operations. Moving I/O to the field shifts the process control system closer to production units. Control centers are jammed with customised system cabinets along with massive amounts of wiring with little documentation. Distributing the control system closer to the process equipment achieves greater project savings with fewer wires and engineering hours in a smaller space. Some facilities have implemented remote I/O strategies to reduce project costs, but other opportunities are inherent such as modular and parallel project execution. To achieve the next generation of benefits, consider a high-speed Ethernet field I/O network that connects controllers to universal I/O mounted in the production areas. Such communications should be cybersecure with a built-in firewall and enhanced with encryption technologies where needed while providing the technology to accommodate an inevitable increase in the amount of sensed data.
Control Engineering Europe
Architecture advantages Benefits of such an architecture include: • Universal I/O discovery capability allows a controller to access any networked I/O module and channel. A traditional approach of controller to I/O communication requires a direct one-to-one physical connection between controller and I/O cabinet. Networked I/O eliminates a significant amount of planning and manual work. The system designer engineers the control strategy and assigns it to a controller and it will find its relevant I/O. This decreases project engineering planning and engineering. • Packaged control capability provides a simple software option to deliver redundant control with high-speed performance. As a process controller subset, these control capabilities are ideal for packaged equipment and provide regulatory, sequence and logic controls. This eliminates the need for complicated subsystem integration. • A universal wireless hotspot provides wired or wireless communication to field instruments and allows each field I/O box to be a wireless hotspot, if needed. This enables field workers to execute digital procedures with live access to control system data during commissioning and operations. • Modular commissioning provides the ability to commission field I/O cabinets independent of the control system. With this capability, controllers can run on a laptop, plug into the remote cabinet at a module yard and perform a set of commissioning activities as if connected to the rest of the control system. With this flexibility, modular builds spanning multiple yards becomes simple. These combined capabilities provide significant engineering, enabling projects to execute in less time with lower risk. For example, eliminating the risk and re-work inherent to late changes ensures automation does not
www.controlengeurope.com
become the critical path [bottleneck to completion]. Adding a new I/O as a result of change extends the control system network without requiring complicated changes to the control system. Traditional control engineering during a project requires meticulous planning since it is driven by a rigid hierarchical approach defined by a tightly bound physical relationships between controllers and I/O. Inefficiencies, re-work and risk materialise during seemingly inevitable late changes to I/O or controls that require a physical reconfiguration of the system. By allowing multiple physical controllers to appear as one virtual controller, the control architecture becomes a controller data center where process controls can be automatically load-balanced across the available controller computing resources. The advantages are powerful, especially when applied to the processing of late changes. It avoids the need to manually assign control strategies to specific controllers.
Cutting costs The virtualisation technology described reduces IT costs by eliminating the amount of physical IT nodes by as much as 80%. However, even with that effort, a large IT infrastructure remains onsite for reliability and scope of loss reasons. Lifecycle costs decrease by using virtualisation, which replicates virtual machine files from offsite to the onsite location. This fault-tolerant architecture enables operations from a central operations center or a regional data center. It has the same level of high reliability expected for critical process control. ! Jason Urso is vice president and chief technology officer, Honeywell Process Solutions. This article originally appeared in www.controleng.com
October 2019
31
THE NEW MUST HAVE FOR ROBOTS! POWERFUL EMBEDDED 3D CAMERA SYSTEM
The Ensenso XR 3D camera system
FLEX VIEW 2
www.ids-imaging.com
INTERFACE
INCREASED RESOLUTION
CMOS SENSOR
FLEXIBLE BASELINE
100 W PROJECTOR