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Control, Instrumentation and Automation in the Process and Manufacturing Industries May 2020

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CONTENTS A digitalisation wake-up call?

Editor Suzanne Gill suzanne.gill@imlgroup.co.uk Sales Manager Adam Yates adam.yates@imlgroup.co.uk Group Publisher Iain McLean iain.mclean@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

There can be no doubt that we have all been negatively affected, in some way, by the current global pandemic. We conducted a small survey to find out more and were heartened to find that readers of Control Engineering Europe are not letting the pandemic change their digitalisation plans – albeit projects may be postponed until the crisis is under control. The good news is that the current situation appears to have made more enterprises consider digitalisation projects to ensure they have greater visibility into their plants and supply chains in the future to allow them to meet the rapidly changing customer demands that many are seeing today. In this issue we have focussed on technology developments that enable and simplify digitalisation. We hope that it offers some food for thought so that when we emerge from the current crisis there are more firm plans in place to ensure that plants will be in better shape to cope with disruptive or unexpected events in the future. Suzanne Gill Editor – Control Engineering Europe suzanne.gill@imlgroup.co.uk

INDUSTRY REPORT

FLOW & LEVEL CONTROL

24 A cost-effective solution to prevent tank overfill

Smart factory investment is at a critical stage

EDITOR’S CHOICE

CYBERSECURITY

26 Cybersecurity should be your indispensable digital transformation co-pilot

Polarisation helps to reveal often hidden details; Ethernet communication for Ex areas

OT/IT CONVERGENCE

MACHINE CONTROL

10 Where technology convergence leads, organisations must follow. We find out more about the impact that this will have on the role of the control engineer

28 Protecting PLC systems from security threats

SINGLE PAIR ETHERNET 14 With SPE technology advancing rapidly we find out what this could mean for the adoption of Ethernet technology at field level

FINAL WORD 30 Jan Zhang reports that COVID-19 is forcing manufacturers to rely more on automation and digitalisation for long-term operations to reduce the financial impact

HART COMMUNICATION TECHNOLOGY 18 HART: Evolution in action 20 Staying in the loop! 21 Moving towards digitalisation with HART technology 22 Taking critical plant floor data to higher levels

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

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May 2020

INDUSTRY REPORTS

Ethernet/IP enhancements ODVA has provided details about the latest enhancements to the EtherNet/IP Specification which will provide improved network diagnostics, new methods to lower bandwidth and resource requirements for devices, and the addition of IIoT building block infrastructure. New tools have been introduced to manage the network, removing roadblocks to adding EtherNet/IP to the simplest of devices, and preparing for TSN with the Link Layer Discovery Protocol (LLDP), a vendor-neutral link layer protocol based on IEEE 802 technology. In addition to the recent enhancements to EtherNet/IP, to allow users to obtain device diagnostics pursuant to the NE107 standard, ODVA

has enhanced EtherNet/IP further to provide overall system diagnostics. The additional EtherNet/IP system diagnostics are said to enable a better understanding of the number of connections, resource usage, the number of Ethernet errors, missed packets, and overall CPU utilisation. A common, scalable network diagnostic assembly definition for diagnostic connection points defined by other objects will enable these new statistics to help assist in network troubleshooting. Additionally, new provisions for aggregation of multiple I/O connections will provide a mechanism to multiplex many individual connections into one, which will reduce network bandwidth. Runtime reconfiguration will be seamless and

efficiency will be improved across the board, especially in instances where IO-Link or HART translation or modular I/O is utilised. Updates to allow for constrained devices running on EtherNet/IP will enable UDP-only device communication with the goal of lowering resource and hardware requirements. Constrained devices are anticipated to significantly lower the cost barrier thereby further strengthening the business case to add EtherNet/IP to in-cabinet, small sensors, and other simple devices. Ethernet will be possible all the way to edge devices, including use of Single Pair Ethernet (10BASE-T1S), enabling end to end IIoT communication. EtherNet/IP, including CIP Security, has been enhanced to include constrained device definitions.

HART-IP developer kit launched for process automation instrument suppliers FieldComm Group has announced the availability of a software, hardware and services development platform for HART-IP enabled instruments. HART embraced Internet Protocol (IP) in 2009, shortly after the release of the WirelessHART protocol. Now, as low-cost, twowire, Ethernet enabled solutions for field instrumentation get ready to enter the market, FieldComm Group believes the time is right for HART-IP enabled wired instruments. Based on the Raspberry PI (3B+) system and using GitHub repositories, the HART-IP Developer Kit provides a path for process instrumentation manufacturers to prototype and demonstrate high speed HARTIP instruments with minimal engineering effort. Initially configured to work with Power-over-Ethernet (PoE) solutions, the developer kit features a replaceable Ethernet module

May 2020

that will be upgraded to support 2-wire Ethernet-APL as components become available in the future. Planned upgrades also include incorporation of FieldComm Group’s OPC UA-centric Process Automation Device Information Model (PA-DIM), for interoperability with OPC UA based enterprise applications, as well as support for JSON and XML based DeviceInfo files for use with lightweight IIoT edge gateway solutions. “FieldComm Group is committed to continued support of the installed base of HART devices and the enhancement of the HART protocol to migrate these assets in the age of digitalisation, said Ted Masters, president and CEO of FieldComm Group. “Over 375 FieldComm Group members, representing major suppliers to the process industry, can now leverage this development to build upon the value from field

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devices by extracting more data at the speed of internet. We are excited to show users a path that will lead them to an ethernet-based solution while protecting their investment and not impacting their reliability. Device integration and seamless plant floor to cloud data transfer is a requirement for digital transformation since the ultimate goal is to provide data in a standard way across all suppliers and protocols. Combined with other technologies, such as Field Device Integration (FDI), JSON and Process Automation Device Information Model (PADIM), these technologies offer suppliers and users a well-defined path to realize this vision.” The HART-IP Developer Kit includes hardware, software access to a HARTIP server, HARTIP client and a sample EDD as well as instructions and four hours of technical support from FieldComm Group technical staff. Control Engineering Europe

INDUSTRY REPORTS

SMART FACTORY INVESTMENT AT CRITICAL STAGE

A research paper, entitled Industry 4.0: Rising to the Challenge, has been published by Siemens Financial Services (SFS) as the first of a series on the investment challenges faced by manufacturers migrating their businesses to Industry 4.0 technologies. The report highlights the fact that investment in digital transformation now constitutes the difference between surviving and thriving for companies, even more so in the light of recent economic uncertainty that comes with the current Covid-19 pandemic. SFS has developed a model which conservatively estimates the size of the investment challenge faced by the manufacturing industry as it seeks to implement smart factory technology during the five-year period 2020-2024. Previous research from the company found that the ‘tipping point’ for investment, at which half of manufacturers will have substantially migrated to Industry 4.0 production platforms, will occur within the next five to seven years. New financing models to enable Industry 4.0 investment are often aligned to business outcomes, to integrate financing closely with

the expected rate of return-oninvestment delivered through the benefits of digitalised technologies. “Given the twin pressures of growing competition in domestic and export markets for European manufacturers, investment in digital transformation is at a critical point,” said Brian Foster, head of industry finance at Siemens Financial Services. “Smart

finance enables sustainable ways to invest that facilitate clearly identified desired business outcomes for the manufacturer, all achieved through access to the right technology and services with support from a knowledgeable specialist financier. This is especially supportive given the likely economic impact of the current global healthcare crisis.”

WHILE OTHERS THINK ABOUT THE IIOT … we are already there. Networks and computers for a smarter industry. Powerful computers designed for your needs Secure and reliable networks – anywhere, anytime Vertical intergration from SCADA to field device Moxa. In the middle. www.moxa.com

EDITOR’S CHOICE

Ultrasonic transducer offers enhanced flowmeter performance Emerson has added the Daniel T-200, a titanium-housed transducer, to its gas ultrasonic flowmeter product line. This product is the first to use metal 3D printing to enhance the acoustic performance in custody transfer applications. The robust design of the flowmeter provides increased reliability, uptime and safety while achieving high gas measurement accuracy. In an ultrasonic flowmeter, transducers generate acoustic signals that are sent back and forth across the fluid stream. The difference in the transit times of these signals is used to determine the

fluid flow velocity. Signal quality and strength are critical to measurement accuracy, which is paramount in custody transfer applications. An error of only 0.1% can equate to hundreds of thousands of euros annually in a large diameter high pressure pipeline. The all-metal housing is said to provide a barrier from corrosive hydrocarbon fluids and wet gas, extending the life of transducer components. The T-200 can also be safely extracted while the meter is under pressure without special high-pressure extraction tools, which reduces the possibility of greenhouse gas emissions during

extraction. The capsule, which contains the piezoelectric crystal used to produce ultrasonic sound waves, is retractable as a single piece for simplicity and ease of use. The new design is rated for a wide range of operating conditions, including pressures from 1 barg to 255 barg and temperatures from -50 to 125°C.

Polarisation helps to reveal often hidden details IDS has added 5 megapixel polarisation cameras to its product portfolio with the addition of the Sony IMX250MZR 5 MP polarisation sensor, with integrated on-pixel polarisers, its uEye CP camera family. The models are said to offer better object detection in cases of low contrast or light reflections. They also provide a convenient way of detecting fine scratches on surfaces or the stress

distribution within transparent objects. Both USB3 Vision and GigE Vision are available as interfaces. Using polarisation filters, the sensor generates an image with four polarisation directions in a single image. Based on the intensity of each directional polarisation, the polarisation angle and the degree of polarisation can be determined. This offers versatility – for example, for checking residues on surfaces before

further processing or for removing reflections for traffic monitoring.

Ethernet communication for Ex areas Turck has introduced the first Zone 2 Ethernet gateway for its excom I/O system. This allows process data from hazardous areas to reach IT systems for analysis and evaluation at sufficient speeds and safely, via a parallel data channel – a fast and easy way of implementing condition monitoring and predictive maintenance. The new GEN-3G multiprotocol device operates at high data rates in Profinet, Ethernet/IP or Modbus TCP networks without the need for manual intervention. The integrated gateway switch enables the implementation of linear

May 2020

topologies which can be connected easily in the network to form a ring. In addition to hardware redundancies for power supply units and gateways, excom also supports redundancy concepts such as S2 system redundancy to ensure maximum availability. excom can also provide special solutions for protocols that do not specify any native standards for redundancy. The I/O system thus offers

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a standard redundancy landscape for operators – irrespective of the protocol used at the particular site or plant section. Regardless of whether excom is used for Zone 1, 2 or for a safe area, users can rely on the same DTM, EDS or GSDML and the same operator logic. This reduces the training required and ensures flexible use by specialist personnel in different plant sections. Control Engineering Europe

INTELLECTUAL CAPITAL

sponsored article

Cross-industry and cross-application alliance for Single Pair Ethernet technology The technology partnership between Phoenix Contact, Weidmüller, Reichle & DeMassari (R&M), Fluke Networks, and Telegärtner for the Single Pair Ethernet (SPE) has progressed to create the SPE System Alliance. Find out more about this collaboration.

he newly formed SPE System Alliance consists of leading technology companies from various industries and fields of application who have come together to bundle their respective SPE expertise and ensure the target-oriented exchange of this knowledge. The partners in this group are pursuing the goal of driving the development of SPE further forward for the Industrial Internet of Things (IIoT) and may branch out to other areas as well. The System Alliance has most recently been joined by Datwyler, Kyland, Microchip Technology, Rosenberger, SICK, O-Ring, Draka/Prysmian Group, and University 4 Industry.

Synergies in the SPE System Alliance The network aims to collaborate on the technological challenges faced when implementing SPE in IIoT applications. The goal of the companies is to accelerate their own development of expertise in SPE technology and to allow it to be implemented faster and more reliably in their products. Through this orientation toward a cross-industry and cross-application exchange platform, companies from all future SPE ecosystems are coming together. The focus is not, however, on individual aspects such as connection technology. Instead, the focus is on questions and challenges that continue to exist with many market participants in connection with SPE. Rule exchange formats and collaborative project activities provide the freedom for close cooperation. The members are already working together in the first subcommunities, in the fields of connection technology, standardisation, SPE useControl Engineering Europe

case reports, and even for cable solutions, among others. Commenting on the alliance, Torsten Janwlecke, President Business Area Device Connectors at Phoenix Contact, said: “SPE is one of the mega trends in industrial data processing for end-toend IP-based networking from the sensor to the cloud. The Single Pair Ethernet technology therefore not only includes all infrastructure components of industrial network technology, such as connectors, cables, PHYs, sensors, switches and other devices, but will find its application in many different areas. This is exactly where the SPE System Alliance comes in. The exchange of members takes place across industries and applications and is not limited to one aspect, such as connection technology. All participating companies can contribute their expertise in the various working groups and thus also benefit from the exchange. The contribution of Phoenix Contact in the Alliance refers in particular to the part of connection technology and infrastructure components, such as switches. Here, we contribute, among other things, findings on the newly developed M8 SPE connector, which is highly relevant for the connection of sensors and thus for the implementation of IIoT and SPE.” Thanks to its broad lineup, the SPE System Alliance already covers a large range of applications and fields of application: For example, within the automotive industry Ethernet systems are increasingly being employed

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within vehicles. Meanwhile, for the passive industrial cabling field of connectivity SPE can provide consistent IP communication from the field level right through to the corporate level, and therefore from the sensor through to the cloud. Further, in sensor technology, in addition to their use in classic automation technology, sensors are increasingly being integrated as intelligent data suppliers into IIoT applications via Ethernet networks. Due to the miniaturisation of the connection technology that has become possible with SPE, smaller sensors can also be connected to Ethernet networks. Combining SPE with the power supply over the data line means that additional plug connections to the voltage supply are no longer needed. Moreover, the use of SPE as the standard interface allows device manufacturers to provide an optimised range of devices with fewer versions. The SPE System Alliance is an open platform for companies that want to further advance SPE technology on the market. Details and options for contacting the System Alliance are available on the website ! www.singlepairethernet.com. May 2020

SINGLE PAIR ETHERNET

MAKING THE IIoT REAL

With SPE technology advancing rapidly Control Engineering Europe finds out what this could mean for the adoption of Ethernet technology at field level.

thernet networks have traditionally prevailed from the company level via the operation and process level right up to the control level. The field level, however has mostly been connected via various bus systems due to the huge number of devices here, which has made the use of Ethernet cost-prohibitive. This looks set to change as Single Pair Ethernet (SPE) technology starts to take shape. In addition to data transmission via Ethernet, SPE also enables a simultaneous power supply of terminal devices via Power over Data Line (PODL) over a single pair of copper wires, opening up new possibilities and fields of application for industrial Ethernet. Recently, the international standard for Single Pair Ethernet (SPE) interfaces in industrial applications has been published within IEC 63171-6 which is incorporated into current SPE cabling standards of the ISO/IEC 11801-x series of standards for structured cabling. The implementation of SPE in the ISO/IEC 11801 documents is important because it describes the cabling channels with all necessary parameters – length, number of connections, bandwidth and the complete set of transmission parameters

May 2020

– in relation to the environment so can be metrologically verified after installation. To find out more, Control Engineering Europe posed the following questions to SPE Industrial Partner Network members: Q: How and where is SPE expected to offer an alternative to existing industrial ethernet infrastructure in process and manufacturing plants and what impact do you expect it to have on the growth of IIoT? Jonas Diekmann, technical editor at Harting (JD): SPE will not replace the existing 8-wire multi-pair Ethernet cabling, which is ubiquitous in office and control equipment today. Instead, it has the potential to replace the jumble of fieldbus protocols employed at field level with one communication standard – Ethernet. Trends such as IIoT bring with them predictive maintenance capabilities, which requires a large number of additional sensors to provide the data. Ethernet is the right standard and SPE is the right infrastructure to implement this idea in a space, financial and resource-saving manner. In short, SPE

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will provide the infrastructure for the IIoT. Nigel Broad, UK director PMM Cable PMM Connectivity at Lutze (NB): While Ethernet, and especially Industrial Ethernet, has become more accepted for time-critical applications in industrial automation, alternative technologies are often still used to connect sensors and actuators. This means that there is a break between the Ethernet-based control level and the field level. In most cases fieldbus systems or even analogue systems are still used here and this is where SPE comes into play and convinces with a variety of advantages. For example, the transition from the control level, based on Ethernet with 4-paired cables, to the field level does not require any change in the content of the Ethernet packets. A simple media converter makes the conversion to SPE possible. This transparency – from the point of view of communication protocols and other software – makes it possible to configure a sensor via a laptop, regardless of its geographical location. Even complex sensors with update options can be integrated with little effort, and error diagnosis is also easier and more accurate.

Control Engineering Europe

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SINGLE PAIR ETHERNET Uwe Widman, technology & standardization at Belden Deutschland (UW): Existing Ethernet network infrastructures enable point-to-point communication with shielded twisted pair Ethernet cables up to 100m with bandwidths of typically 100 MHz (CAT 5) or 500 MHz (CAT 6A). The limited transmission distances and the high costs of Ethernet ports and components have been a barrier to adoption of Ethernet at field level. SPE, as part of IEEE 802.3cg with bandwidths of 20 MHz and transmission distances of up to 1,000m and the ability to transmit data and power according to IEEE 802.3bu (PODL) now enables Ethernet access for the process industry in hazardous areas. SPE, in combination with PODL, has the ability to replace existing fieldbus infrastructures in the process industry. Additionally, IEEE 802.3cg makes it possible to implement cost-effective point-to-point connections up to 25m with unshielded twisted pair cables. The process industry is, however, only one area where SPE can replace existing fieldbus systems – with a transmission rate of 10 Mb/sec it can replace many fieldbus systems with data rates 9.6kb/sec to 10 Mb/sec, with distances exceeding 100m. The IO-Link standard – which is widely used in the automation market – is currently limited to data rates of 230 Kb/sec and a transmission distance of 20m. However, it is now being evaluated in a concept study for SPE integration to bring the advantages of both technologies into IO-Link specification. With the ongoing digitalisation in industry, a variety of new application fields are appearing. New field devices, with higher functionality, simpler fast connection technologies for cables & connectors; progress in miniaturisation, a cost-effective component infrastructure; and in combination with the TSN technology, SPE fulfills the requirements to create successful IIoT model in the process and automation sectors.

May 2020

Q: What are the barriers to adoption of the technology in existing plants, which will often have a great deal of legacy systems? JD: In the future field-level equipment will need to be equipped with new interfaces, magnetics and chips. Since this process of renewal can be carried out gradually, there is no requirement to change everything at once. Devices and subscribers can be gradually converted and connected to Ethernet. Implementation will most likely, therefore, take place within the usual renewal processes of structures. When you consider that fieldbus systems still account for a market share of about 40% today and that these could be replaced by SPE in the future, the potential becomes clear. It will still take up to two years before a significant number of applications go into production. Good market penetration is expected to take place within about five years and it could be 10 years before SPE becomes the dominant standard at the field level. NB: The introduction of SPE technology in the industrial field together with TSN gives the industrial sector an opportunity to make a leap forward in both precision and accuracy. The biggest obstacle will be that components will have to be changed and the entire active and usually also passive infrastructure will need to be adapted. The true benefits will not become accessible until network products, hardware and software are all available. However, it should not be too long before these barriers are removed. UW: With the publication of the IEEE 802.3 SPE standards and the future IEC standards for generic cabling, cables and connectors, SPE has set the basis for success. There will be a fast breakthrough into existing legacy systems with the relevant fieldbus systems if the interfaces between the new SPE technology and existing ‘legacy technologies’ are made available. Vital elements for success include miniaturisation; weight reduction and simple connection technologies.

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Q: What advice can you offer control engineers considering converting their field level to SPE? JD: For the first time, SPE – as a new physical layer – offers the possibility of bringing Ethernet to every sensor at the field level in a space- and cost-efficient manner. Using the TCP/IP protocol, all participants can be identified and the TSN protocol, which can also be used with SPE, allows sensors to deliver data in real-time. It is important that engineers start to plan now for this change. NB: The present technology break between the control and field level makes the operation and administration of such a network unnecessarily complicated. A complete review of the field level is the place to start. The APL (Advanced Physical Layer) working group considers the 10 Base-T1L standard to be ideally suited for extending Profinet or Ethernet/IP to the field level. These are common networks within the automation and control arena. Due to the physical requirements for the cables, Ethernet was previously unsuitable for use in hazardous areas. The use of SPE technology, in conjunction with singlepair cables, will enable a transmission rate of 10 Mbit/sec with segment lengths of up to 1,000m. As SPE allows PODL this means that it is possible to power sensors from the network. UW: The network system philosophy is important. Consider everything from the field level, through the edge to the cloud. Belden considers SPE as a further element of the Ethernet infrastructure. SPE technology will be further developed by IEEE 802.3 and international standardisation organisations and user organisations will include this technology in their specifications. With APL technology, a first IEEE 802.3 SPE standard for the process level is already available. Do consider SPE in a future network infrastructure and utilise it in brownfield expansions where interfaces to legacy technology are available. ! Control Engineering Europe

ONLINE TRAINING AND LEARNING SERVICES HELP MANUFACTURERS THROUGH COVID-19 PANDEMIC

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ake UK has expanded its online training and learning services to ensure that manufacturers are able to pivot their business to operating through the Covid-19 crisis and, in particular, to safeguard the future of their workforces. As well as operating a Coronavirus hub, which gives companies access to the official Government advice and support schemes, Make UK has transferred its HR & Legal, Health & Safety and Apprentice Training online, while continuing to introduce new services to help companies such as remote cyber security protection for individuals working from home. Make UK is now training a record number of almost 2,000 apprentices online. The interactive training is being delivered with a smart assessor to support online assessment while mentoring and coaching is also available to students. Make UK’s HR & Legal team has also been providing help to companies on issues ranging from the Government’s Job Retention Scheme to staff wellbeing advice. The organisation is also offering virtual online classrooms for its Health & Safety courses. To enable companies to address the threat to cybersecurity due to the increased numbers of people working from home, Make UK has also teamed up with Assured Cyber Protection (ACP) to help protect business operations and mitigate against risk. To find out more about these online services go to: www.makeuk.org/ Make UK is also urging engineering and manufacturing employers not to delay their apprentice recruitment plans. Stephen Mitchell, director of apprentices and technical training at Make UK’s Technology Hub in Birmingham, said: “We completely understand that these are testing times for all employers, but apprentices are resilient and full of drive, they help to provide fresh ideas and are vital for business growth. During this time of unprecedented change, you still need to look at the future of your business, and apprentices play a key part in this. “Even if employers are not in a position to take on apprentices immediately, we would encourage them to start the conversations now. We are constantly holding telephone interviews, and our streamlined recruitment process means employers can access applications and candidates with minimal fuss and delay.” For more information on apprenticeships with Make UK, call 0808 168 5874 or email asrecruitment@makeuk.org Control Engineering UK

May 2020

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ENGINEERING SKILLS

CLOSING THE SKILLS GAP THROUGH INVESTMENT IN PEOPLE AND TECHNOLOGY To tackle the skills gap the UK engineering sector needs to invest in both people and technology says Graeme Wright, chief digital officer, Manufacturing, Utilities and Services at Fujitsu UK.

he skills gap could cost our economy an estimated £120 billion by 2030. With a new digital age – where engineering organisations, products and services will increasingly rely on connected technologies – just around the corner, this gap must be addressed. In the UK today 44% of organisation leaders say they have not planned radically enough for the future. And of the same respondents, 37% see the most necessary change for the future as being training and reskilling of employees. To overcome this, it’s important for organisations to attract and retain the right employees. A key element of this is breaking down existing barriers and shattering pre-conceived ideas of a career in engineering. Organisations should consider partnerships with Government and educational institutions, for instance, as a means of finding staff with the right skillset. Partnerships can enable the creation of virtual engineering worlds and provide role models from an engineering background to meet with, and be shadowed by, students. This collaboration is key to showcase the excitement an engineering career can offer a young person, encouraging children to explore the different career options in the industry that might be available to them. Young people are digital natives and will provide a wealth of knowledge to allow organisations to innovate. It’s important to invest in them to keep up with the digital disruption that is changing business landscapes faster and more significantly than ever before. Jobs are constantly evolving, and as a result continuous learning should be

UK2

May 2020

encouraged and put in place. There is a skills pipeline needed to fuel this technological disruption and it is important that employers can keep up so that their employees can too. With the market moving so quickly, organisations must ensure the workforce have the right skills in place to build upon as times change. For example, many organisations are moving away from the ‘traditional’ factory. This means factories need to be managed as part of a ‘smart factory’, using technologies like IoT (the internet of things) as well as the better use of data in existing industrial control systems. The skills needed to use certain equipment will need to change, so engineers in this space will have to be educated in the skills needed to accommodate this, such as analytics, AI and cyber security.

The power of technology The good news is that technology can go some way to bridging the skills gap. Organisations can look at utilising emerging technologies – such as virtual and augmented reality (VR/AR), for example. It has the potential to change the way education and skills are delivered to people of any age. It creates engaging training that can be deployed anywhere, enabling learners to experience all types of workplace

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environments without having to leave the office, university, college or classroom. Not only can organisations use technology to educate, it’s also a way for them to bridge beyond more than the skills gap. By applying technologies like robotic process automation, drones and automation, employees can be freed up to solve the complex issues which machines cannot. As a result, the jobs that are often dangerous can be left to machines while employees perform higher value, lower risk tasks. Ultimately, education and technology are the powerful tools engineering organisations should be investing in sooner rather than later. For engineering organisations to grow and embrace the opportunity that technology has provided, as well as keep pace in the age of digital disruption, they must ensure there is a future pipeline of talent and continuous investment in the talent of today. ! Control Engineering UK

Game Changer Two Steps Ahead

ctrlX Automation from Rexroth: The most open automation system on the market Enter the future today with ctrlX Automation, a system with endless possibilities. This 360 solution is uncompromisingly open, with no proprietary systems or interfaces, free choice of programming language and ready for future standards. Flexible, with straight forward start up and nonstop performance, ctrlX keeps you entirely connected to almost everything. ctrlX, the revolution in engineering. Two Steps Ahead.

NEW PRODUCTS

PLC plays it safe A safety module option is now available for Mitsubishi Electric’s MELSEC iQ-R PLC which is said to provide the performance and integrity of a separate safety PLC but without the added cabinet space. The iQ-R is suited to use in many demanding, mission-critical applications, in addition to more conventional process control applications. To deliver safe and robust operation in both low and high-risk applications controllers must address some specific safety requirements. In addition to managing advanced control tasks, the PLC can offer combined safety control to drive functional and process safety. This offers

the ability to create applications that are compliant with ISO 13849-1 PL e and IEC 61508 SIL 3 standards. The combination of process and safety control in a single unit helps machine builders, integrators, and endusers benefit from a scalable control management strategy, while also optimising equipment footprint, reducing wiring requirement and lowering capital investment. These benefits are further enhanced by the option of using a common CC-Link IE Field Gigabit Ethernet network for

both process and safety control communications. Operational control functionality is programmed using a single platform – GX Works3. As a result, it is possible to create and execute integrated process and safety control programmes via a single CPU module, reducing the time and cost associated with setting up two separate controllers.

RFID antenna, evaluation electronics and fieldbus interface in a single module With a long user-adjustable operating range and a choice of fieldbus interfaces, HF RFID systems, which form part of the DTE60x range from ifm electronic, are said to be suited to use in a range of production line applications. The new units provide RFID antenna, evaluation electronics and fieldbus interface in a single compact IP67 rated module. All versions of the range

incorporate an integrated web server for ease of configuration and they provide access to diagnostic and monitoring functionality. Integration of the systems into automation systems is straightforward as function blocks are available for many brands of programmable controller. Data from the units can also be accessed directly via the process image.

Manual flow control option for ball valves In addition to electric or pneumatic actuation, Bonomi (UK) can now offer a manual flow control device for use in conjunction with many of its Valpres V-Notch ball valve range. The new manual stainless-steel device is said to offer an alternative to pneumatic or electric actuators. It employs a simply calibrated method, which allows precise and accurate flow control to be achieved. The manual flow control device is compatible with most of the Valpres range of V-Notch ball valves, including 2-piece and 3-piece ball valves, wafer pattern ball valves and split body flanged ball valves.

UK4

May 2020

Equally suitable for liquids and gases, Bonomi’s V-Notch solutions make it possible to transform from an on-off

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ball valve, into a regulation/control one, with flow rate regulation ratios ranging up to 500:1. Control Engineering UK

SMART CAMERA

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Putting the power of deep learning at your fingertips The In-Sight D900 is a smart camera from Cognex powered by In-Sight ViDi software designed specifically to run deep learning applications.

his embedded solution helps factory automation customers easily solve challenging industrial OCR, assembly verification, and random defect detection applications anywhere on the line that have gone uninspected because they are often too difficult to program with traditional, rulebased machine vision tools. In-Sight ViDi applications are deployed on the In-Sight D900 smart camera without the need for a PC, making deep learning technology accessible to nonprogrammers. It uses the familiar and easy-to-use In-Sight spreadsheet platform which simplifies application development and factory integration.

Fast and accurate assembly verification The In-Sight D900 uses artificial intelligence to reliably detect complex features and objects and verifies parts and kits are assembled correctly based on their location within a pre-defined layout. The In-Sight ViDi Check tool can be trained to create an extensive library of components, which can be located in the image even if they appear at different angles or vary in size.

Analyse complex defect detection tasks The In-Sight ViDi Detect Tool learns from images of good parts in order to identify defective parts. ViDi Detect is ideal for finding anomalies on complex parts and surfaces, even in situations where defects can be unpredictable in their appearance.

Guided application development

Quickly decode challenging OCR applications The In-Sight D900 deciphers badly deformed, skewed, and poorly etched codes using optical character recognition (OCR). The In-Sight ViDi Read tool works right out of the box, dramatically reducing development time, thanks to the deep learning pretrained font library. Simply define the region of interest and set the character size. In situations where new characters are introduced, without vision expertise, this robust tool can be retrained to read application-specific codes that traditional OCR tools are not able to decode. Control Engineering Europe

In-Sight ViDi takes advantage of the intuitive In-Sight spreadsheet interface to quickly set up and run deep learning applications without programming. The In-Sight spreadsheet simplifies application development and streamlines factory integration with a full I/O and communications function set. It also enables the ability to combine traditional Cognex rules-based vision tools (like PatMax Redline) and deep learning tools in the same project, leading to quicker deployments and faster cycle times. Since In-Sight ViDi requires vastly smaller image sets and shorter training and validation periods, deep learning applications are quick and easy to set up, teach, and deploy. In-Sight ViDi applications on the InSight D900 can be deployed without a PC. This highly-modular, IP67-rated deep

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learning vision system includes fieldchangeable lighting, lenses, filters, and covers that can be customised to match your exact application requirements. It also includes an embedded inference engine that is specifically designed to solve complex deep learning applications at production line speeds.

Web-based HMI The In-Sight D900 vision system offers mobile, platform independent visualization for accessing HMIs (human machine interfaces) through In-Sight ViDi software. A simple point-and-click interface allows customers to build highly interactive, web-based HMIs remotely accessible via a web browser over the network. Combining power, accessibility and ease of use, the In-Sight D900 inspects the previously uninspectable, ensuring: • Quicker deployments and a faster time to value • Consistent and accurate inspection results at scale • Better quality products by catching more potential issues For more information: www.cognex.com or call +44 121 296 5163 May 2020

HART COMMUNIC ATION TECHNOLOGY

HART: Evolution in action Wally Pratt, director of HART technology at FieldComm Group, brings us up to date of developments of the HART Communication Protocol.

ne of the key reasons that HART continues to dominate today is a constant focus on enhancing the technology in response to evolving market requirements. FieldComm Group’s HART technology working group will release Revision 7.7 of the standard this summer. It will include both clarifications and corrections along with enhancements to add targeted useful features. Major improvements to HART-IP are included in this release. Since its inception HART-IP has supported both field devices and I/O Systems (Remote I/O and WirelessHART Gateways). HART-IP enabled products have been shipping since 2009. With the emergence of initiatives like IIoT, Industry 4.0, and the NAMUR open architecture, interest in high-speed Ethernet to the plant floor is increasing. Ethernet-APL, a 2-wire, 10Mbs, intrinsically safe physical layer is in development with products expected to be available in the next 18 months. Naturally, Ethernet-APL has driven growing interest in HART-IP enabled field devices. But like any ethernet protocol, security must be present and reliable. Notable among the enhancements included in Revision 7.7 are improvements to HART-IP security.

Security improvements With revision 7.7, requirements for specific, minimum security suites are now specified. There are three legs to security specified – communication security, audit logs and syslogging. Communication security requires that new devices support the industry standard Internet Protocol (IP) Transport Layer Security (TLS) and Datagram Transport Layer Security (DTLS) suites. Since TLS and DTLS both have many options and choices, their application

May 2020

to HART-IP are tailored and clarified in HART-IP requirements. In addition, HART Commands have been added to simplify security deployment. Additional diagnostics and forensic requirements are also included. Devices are required to capture ‘Audit Logs’ that summarise communications activities. There are general security status and records for each client session (up to 128). Client session records include: client identification, connection start/stop times, whether the device configuration was changed in that session, etc. Audit Logs are useful in determining (for example) who and when an inadvertent change to the device was made. HART-IP devices must also support ‘syslogging’. Syslogs are an industry standard means of publishing device events (to a network’s Security Information and Event Management (SIEM) system. All HART-IP devices must support network time (using either NTP or PTP). Consequently, all syslog messages from all network devices are time synchronised, enabling forensics on network-wide behaviour and activities. Combining communication security, audit logs and syslogging results in robust security for HART-IP enabled products.

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Developer kit As low-cost, 2-wire, Ethernet enabled solutions for field instrumentation near market availability, FieldComm Group is releasing a developer kit to enable field instrument manufacturers to learn about migrating from 4-20mA + HART to HART-IP. Based on the Raspberry PI (3B+) system, and using GitHub repositories, the HART-IP developer kit provides a path for process instrumentation manufacturers to prototype and demonstrate high speed HART-IP instruments with minimal engineering effort. Initially configured to work with power-over-ethernet solutions, the developer kit features a replaceable Ethernet module that will be upgraded to support 2-wire Ethernet-APL as components become available.

Quality assurance Finally, for developers, new releases of the HART and WirelessHART Tests systems are available. Two new features include easier to use burst message testing and elimination of the need for commercial gateways when testing WirelessHART devices. For users, this means improved operation of registered HART and WIrelessHART instruments. ! Control Engineering Europe

PROComSol Process Communications Solutions

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HART COMMUNICATION PROTOCOL

STAYING IN THE LOOP! You just received one of the new technology HART communicators that use your smart phone. You connect the modem to your HART instrument, launch the App and… nothing happens… ‘error connecting to device’. What’s going on? ProComSol offers some advice.

he problem being encountered is that the loop is missing a vital element of HART – the loop resistor which, according to HART specifications, is an essential component. The resistor serves two purposes – it is needed to convert the current-based HART signal to a voltage signal and it prevents the loop power supply from cancelling out the HART signal.

Resistance value The HART specification defines the loop resistor value to be in the range of 230 ohms to 600 ohms. Typically, 250 ohms is used. This value provides an easy conversion from a current value to a voltage value used in some control systems. In this case 4mA through a 250 ohm resistor is 1Vdc and 20mA is 5 Vdc. So, where should you put the resistor? It could be anywhere in series in the loop. An obvious and convenient place is in the PLC I/O card itself. If the PLC does not have a built-in resistor, then it could be placed into the marshalling cabinet. Often, cable is run from the control room to the plant floor to a marshalling cabinet. The worse option for loops in service because it means the loop must be

interrupted – is to place the resistor at the HART instrument. Simply lift one of the loop connections from the instrument, connect a resistor in its place and the other end of resistor connects to the cable lead. There may be enough room in the instrument enclosure so you can refasten the cover, keeping the resistor in the loop for the next time you need to connect. When working with a HART device in the lab, more options are available. The first option is to simply connect a resistor to one of the instrument loop connections. Then connect the power supply to the instrument and to the other end of the resistor. Modern HART modems now have the ability to power an instrument and often also contain a built-in loop resistor. This makes powering a device and communicating with it very simple. While the loop resistor is a HART specification requirement, loops with long cable runs may have enough loop resistance for HART communications to occur. The likelihood of successful HART communications in low resistance loops is increased when your HART modem output and sensitivity exceeds the HART specs. This means the modem can receive lower voltage signals and can transmit at higher voltage levels. Long cable runs will

likely provide enough wire resistance so that a dedicated loop resistor is not necessary. However, modems with more sensitive inputs are more susceptible to noise which will reduce communication reliability.

Common mistakes As simple as the loop resistor requirement is, connection mistakes still occur. A common one is put the modem connection in series with the loop. Another mistake is to put the resistor across the terminals of the instrument. This removes the instrument from the loop and creates a fixed current output. HART is always going to require a loop resistor. PSK (Phased Shift Keying, or high-speed HART) will still need a loop resistor as there is no difference in the wiring between FSK (Frequency Shift Keying, or standard HART) and PSK. The loop resistor is a HART requirement. While some loops may work without it, the tradeoff will be reliability. Noise will be more prevalent and command retries will occur more often, slowing down communications. So, install that loop resistor into the loop on your next shutdown. Or better still, install it the design phase! !

Loop resistor placement in the loop.

May 2020

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Control Engineering Europe

HART COMMUNICATION PROTOCOL

Moving towards digitalisation with HART technology Fabricio de Andrade explains the role that HART can play in helping plants reap the benefits of digitalisation.

any brownfield plants will already have huge installed bases of HART devices which are able to offer the same level of information as most new modern networks. All HART field devices can provide intelligent device management (IDM), just like you find in other digital devices. Further, digital systems like Netilion can access HART device data, opening the door to all the benefits of digital services. HART gateways, such as Fieldgate SFG250 from Endress+Hauser, provide a solution that can pull all HART information to an IIoT cloud service. Also,

with the installation of a WirelessHART adapter in parallel to the analogue system, it is possible to gather the digital data wirelessly through the gateway without affecting the analogue signal to the control system. Both solutions provide access to IDM, and connect to the gateway to make the leap from the field to the cloud, providing secure connectivity. With the devices connected, the next step is to sign up to Netilion Services to take advantage of the digitalisation of the system. New field devices often come with two digital protocols, the standard communication, such as HART, and Bluetooth. Bluetooth

allows you to check all your data using an app or by connecting to a Bluetooth gateway. The FieldEdge SGC200 has a direct connection to the cloud, so the Netilion Health service can apply to the connected field devices making it possible to access the information anywhere. The retrofit of the plant can be simple, because the HART protocol provides all the information needed for digital communication. You don’t have to switch everything straight away, but you do need access to your data remotely. Start now, start small and scale up as you need. ! Fabricio de Andrade is digital marketing manager at Endress+Hauser Digital Solutions.

HART COMMUNICATION PROTOCOL

BRIDGING THE GAP Taking critical plant floor data from smart HART field devices and sharing it with higher level control and information systems no longer has to be difficult or expensive, according to Tina Todd.

he rapid growth of industrial Ethernet and wireless networks in process manufacturing plants and automation facilities has resulted in data exchange within a facility and even throughout global corporate networks becoming commonplace. The separate information hierarchy levels, outlined in the ISA 95 model – related to process data exchange within a manufacturing facility – have started to coalesce. Traditionally, data and information that needed to be exchanged between the lowest plant floor levels 0-2 and the upper ERP level 4 required MES products or custom coding; and often both. This free flow of information has introduced a new set of ubiquitous terms, standards and phrases such as IIoT, Smart Factory, Cloud Automation and Industry 4.0. The typical process control model that involves decision making for the process at the local or centralised level by PLCs or BPCS (Basic Process Control System) is changing. These systems were never

intended to deal with the amount of data they would have access to in the near future. Streamlining of costs and overheads has left many manufacturers with just enough personnel to keep the plant running, so there is not the time, personnel or resources to analyse data. For this reason third-party companies, and even some of the larger process control vendors, are offering leasing or annual agreements that involve collecting, storing, and analysing process data. The challenge remains: how do existing and new manufacturing facilities find a cost-effective way to get critical plant floor data up to higher level information systems? The answer is to take advantage of the digital HART data that is already in many installed instruments. HART continues to get updated revisions that enhance data exchange capacity, speed, number of devices on a network, support over Ethernet, and wireless capability. It gives end

A HART interface device like the HES HART to Ethernet Gateway connects to the 4-20mA process signal and extracts HART process and diagnostic variables and makes them accessible via Ethernet.

May 2020

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users unfettered access to process and diagnostic data that can be shared with all areas of the new Smart Factory that supports IIoT endeavors. In many cases, HART instruments were installed simply because they could be configured and diagnosed easily with a HART handheld communicator (HHC). However, the HART digital signal often contains additional process measurements and other variables that may include instrument status, diagnostic data, alarms, calibration values and alert messages. A simple and cost-effective solution for gathering HART information is to use a HART interface device which makes acquiring data a fairly simple proposition. This HART data can then be made available to the control system, asset manager or plant Ethernet backbone where it can then be shared with higher level systems.

Interface options There are several ways to interface with HART smart field devices to acquire the digital process and diagnostic information. They vary from HART enabled 4-20mA input cards, HART multiplexer (Mux) systems, slide-in PLC gateway cards, custom coded software interfaces for asset management and MES/ERP systems and standalone gateways that typically convert the HART data to some other proprietary or open industry format. Many PLC and BPCS cards installed in legacy systems don’t have the capability to read the HART data that is superimposed on the 4-20mA signal. However, each vendor usually has an alternative card that is more expensive or offers a full upgrade path to input cards that read HART. HART multiplexers are common and typically their interface is a custom RS-422, RS-485 or RS-232 serial Control Engineering Europe

HART COMMUNICATION PROTOCOL connection which is custom configured for a particular vendor’s hardware interface, asset management system or control system. Some PLC and BPCS companies offer slide-in chassis type gateway cards that read the HART data and offer a proprietary backend communication connection to the system. Usually each of these options is costly and so is often avoided. The most expensive but also most specific HART interface to have is one written by a programmer which can then be customised to exact user and hardware specifications. Lastly, there are standalone HART gateways which provide an economical pathway to extracting HART data from field devices and making the data available to higher level systems. These products usually offer one to four channels or ports that allow several HART devices to be multidropped for maximum data concentration .

Using the data Once HART data is extracted from field devices it is essential that the information is made available in an open and easy-to-interface manner. Now that Ethernet backbones have become the standard for in-plant communication links, it seems only reasonable that any interface device that gathers and holds enormous amounts of data should include an Ethernet port. Likewise, these same devices should support open protocols that run seamlessly over Ethernet networks. Employing HART data for process monitoring, control, predictive maintenance, and process optimisation requires that open and vendor neutral industrial protocols be supported. This allows the HART device data to freely flow to most any control, SCADA and monitoring system from any vendor. Now that HART supports Ethernet with HART-IP, it seems logical that any device supporting the HART protocol with an Ethernet port would support HART-IP devices which typically allow for any HART field device data to be mapped to a number of Device Variables locations Control Engineering Europe

for reading by a HART-IP host. One of the most installed and supported industrial Ethernet protocols is MODBUS/TCP which takes MODBUS data packets and wraps them in a TCP header utilising IP addressing. This makes implementation by HART to Ethernet Gateways offer a quick and economical way of sharing both host computer critical HART data with higher level systems. and field device manufacturers quick and abundant. site data and property. At a minimum, Additionally, Ethernet devices can offer a two layer protection scheme should web pages to view the collected HART be put in place for the device that process and diagnostic data on any includes software and physical hardware PC or mobile device. However, efforts restricted access. should be made by device vendors to lay Traditionally, end users have had the information out in a table format to deal with custom and proprietary with easy-to-understand headers and configuration packages from vendors address locations (for other supported for advanced capability devices. This protocols) so that additional hosts can be typically requires several custom configured more easily. software packages that users have to learn, become familiar with and Cybersecurity considerations get IT support and permission. Most IIoT, cloud storage, big data and a host IIoT capable devices are not simple of other interconnecting methods and field instruments and therefore small strategies has led to production and handheld configurators are not efficiency increases. However, this convenient for setup and configuration. has also led to cybersecurity issues. It Indeed, many HART protocol gateways is therefore important that Ethernetrequire complex database mapping and based devices include safeguards within programming software. When sourcing their products to ensure that network or specifying an IIoT device, investigate bandwidth is protected, viruses or what the programming interface will malware cannot be loaded, unwanted be. There are several open standards access is not granted, unauthorised and software packages that vendors reconfiguration of device is not allowed, have access to that prevent the need for and unauthorised writes to memory custom and sometimes even expensive locations are not accepted by the programming software utilities. device. In addition, physical security of With the acceptance of industrial such devices must also be restricted to Ethernet backbones and wireless authorised personnel only and process networks, IIoT HART interface devices data should be read only – unless the with built-in security measures, device is required to perform control. open industry protocols and ease of It is important that the entire product programming, provides a quick and lifecycle, including design, build and test, seamless way to share process data with must adhere to tight process and quality the entire corporate infrastructure. ! assurance requirements. Additionally, post installation considerations should Tina Todd is director of engineering at be taken to assist onsite protection of Moore Industries-International, Inc.

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May 2020

FLOW & LEVEL CONTROL

A COST-EFFECTIVE SOLUTION TO PREVENT TANK OVERFILL AnnCharlott Enberg, functional safety manager at Emerson, explains how radar gauges with innovative 2-in-1 technology can provide two independent layers of protection against spills, in compliance with the relevant safety standards.

hen process vessels or storage tanks contain hazardous, flammable or explosive materials, overfills can have catastrophic consequences, including injuries or even death to personnel, as well as significant asset damage, extensive environmental harm, and the blighting of an organisation’s reputation. For these reasons it is essential to invest in a robust safety instrumented system (SIS) that complies with the relevant industry standards. There are two key global standards for overfill prevention. These are: • The International Electrotechnical Commission’s IEC 61511 standard, which outlines best safety practices for implementing a modern SIS within the process industry. IEC 61511 is an industry-specific adaptation of IEC 61508, which is an industryindependent standard for functional safety. • The American Petroleum Institute’s API 2350 standard. This provides minimum requirements to comply with modern best practices in the specific application of non-pressurised above-ground large petroleum storage tanks. Organisations rely on accurate and reliable level measurement instrumentation in both their SIS and their basic process control systems (BPCS). The technology of choice for SIS sensors has historically been mechanical point-level switches. Although this type of sensor has a lower initial purchasing cost than continuous level measurement technology, it does not provide any

May 2020

online measurement, so it is virtually impossible to know whether it is functioning correctly. These switches consequently require frequent ontank proof-tests, resulting in tank (and possibly process) downtime and risking the safety of personnel who need to climb tanks to perform the tests. For this reason many organisations now use modern continuous level gauges instead. The dominant level measurement technology for BPCS is non-contacting radar. Radar technology provides good levels of accuracy, which is crucial because even a small inaccuracy in level measurement can equate to thousands of gallons of volume uncertainty. It is also extremely reliable, has minimal maintenance requirements, and provides availability close to 100% during the long lifespan of a device.

Diverse and identical separation There is a common misconception that the key standards for overfill prevention require the level measurement technology used for the SIS to be of a different type to that used for the BPCS. This requirement is typically referred to as diverse separation and is one reason why some organisations still use less sophisticated technologies such as pointlevel sensors, servo gauges and floatand-tape gauges for their SIS. However, it is confirmed within IEC 61511-2 that it is legitimate to use the same technology for both the SIS and the BPCS. This is known as identical separation, and IEC 61511 states that this method ‘may have some advantages

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Bulk liquid storage facilities require accurate and reliable level measurement instrumentation within both their basic process control systems and their safety instrumented systems.

in design and maintenance because it reduces the likelihood of maintenance errors’. Diverse and identical separation are both valid options. However, diverse separation introduces extra complexity and makes human error more likely, because personnel would need to learn about installing, configuring, prooftesting and maintaining two different technologies rather than just one. There is an increasing realisation that reducing maintenance and similar ‘handling errors’ is critical – by some estimates, 75% of industrial accidents are traceable to organisational and human factors. In this context, the Buncefield oil storage terminal fire of 2005 provides a case in point. Buncefield had redundant and diverse technology for overfill prevention, but the level measurement device acting as the high-level alarm was inoperable because of human error. It Control Engineering Europe

FLOW & LEVEL CONTROL had been taken offline for testing and had been reinstalled incorrectly, and was therefore not functioning.

tanks by replacing a single existing BPCS or SIS sensor with two continuous level measurements with a minimum of tank modifications. Often, a radar level gauge with 2-in-1 technology fits the antenna of earlier generations of devices and therefore requires no tank modifications.

2-in-1 technology Although many new installations use two radar level gauges for the BPCS and the SIS, some existing tanks have practical limitations that make it costprohibitive to install two separate level gauges. These include instances where only one tank opening is available, and where modifications would involve taking the tank out of service, resulting in additional costs. One solution to this problem is Emerson’s non-contacting Rosemount 5900S 2-in-1 radar level gauge, which has been verified by thirdparty assessor Exida as fulfilling the requirements of IEC 61511 to be used simultaneously as a BPCS sensor and as an independent SIS sensor. This device – which is also certified according to IEC 61508 – consists of two galvanically separated and independent electrical units and a common antenna. The gauge utilises frequency modulated continuous wave (FMCW) technology, and a shift in transmission frequency during measurements. Signals from the two units, which are transmitted

Conclusion

The Rosemount 5900S consists of two galvanically separated and independent electrical units and a common antenna, and therefore requires only a single tank opening.

via the common antenna, will remain independent of each other. Therefore, when connected with its cables separated in different cable trays and with separate power sources, a single level gauge can be used for both BPCS and separate SIS sensor measurements. The most obvious benefit of this configuration is that it requires only a single tank opening which allows for cost-efficient upgrades of existing

When selecting level measurement technology for use in the BPCS and SIS on bulk liquid storage tanks, technology diversification is not a requirement. Mixing technologies may even make the system less safe. It is more important to select a reliable technology with minimal maintenance requirements. This has led to many organisations installing two separate radar gauges to provide level measurement and independent overfill prevention on new tanks. For existing tanks, where an upgrade with two separate level gauges can be cost-prohibitive, 2-in-1 technology is a viable solution, enabling the simultaneous use of a single radar gauge as both a BPCS sensor and a separate and independent SIS sensor. ! AnnCharlott Enberg is functional safety manager at Emerson.

80 GHz radar transmitters Siemens has introduced the Sitrans LR100 series of 80 GHz radar transmitters with a narrow beam for flexible installation into existing vessel openings, or non-intrusive installation through plastic vessels. The 80 GHz high frequency delivers robust and reliable measurements even in challenging environments such as those with vapours, condensation, turbulence, or solids. The IP68-rated series consists of three products – Sitrans LR100 for basic measurement to 8m, Sitrans LR110 with communication and hazardous approvals options and range to Control Engineering Europe

15m, and Sitrans LR120 with communication and a range of up to 30m and optional submergence shield for flooding protection. 2-wire loop powered with HART or optional Modbus RTU connectivity consumes very low energy and fast start up. The dependable readings of these transmitters can help reduce engineers exposure to hazardous situations as

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there is no need to climb tanks, lean out over sumps, or crawl into confined spaces to maintain the instruments. Zero-meter blanking distance allows measurement right up to the sensor, avoiding costly overfilling. And 2mm accuracy enhances operational safety through precise measurement through the full range of the application. Simple commissioning is achieved via the Bluetooth interface and the Sitrans mobile IQ App or the Sitrans RD150 remote display. In remote areas connected to the Sitrans RTU3030C remote terminal unit, critical data can be transmitted and the units can be remotely serviced. May 2020

CYBERSECURITY

CYBERSECURITY: AN INDISPENSABLE DIGITAL TRANSFORMATION CO-PILOT To drive operational efficiencies, improve performance or to gain a competitive edge, digital transformation is being adopted in almost in every operational technology (OT) environment. This means that, to safely connect plants and sites – irrespective of whether it an on-premise or off-premise solution – cybersecurity is not optional, says Arun Veeramani.

he attack surface at a manufacturing plant has increased greatly as the number of OT assets that are connected to take advantage of Industrial Internet of Things (IIoT) grows. Almost every vendor is requesting remote access to the OT assets to provide predictive maintenance, asset performance management or to get data for analytics optimisation. These remote connections turn into potential vulnerabilities that need to be actively managed. These vulnerabilities are even more pronounced when legacy OT systems are not patched, or are so old that there are no patches or updates available. It is, therefore, critical to have a secure remote access solution with capabilities such as strong access controls, multifactor authentication, standardisation across the company, and a solution that also has capabilities for playback of sessions and an ability to audit.

Another challenge Visibility of processes and assets presents another challenge for manufacturers. Unlike enterprise IT assets, which are refreshed every few years, the assets at a plant can go decades before being refreshed. This means the inventory list of the different assets is only partial and often does not include critical information like firmware versions, software applications and security patches. With so many purpose-built hardware and multiple communication protocols, companies that are not able to identify

May 2020

their assets will not be able to protect them. Not so surprisingly, asset discovery and inventory is one of the top needs. With uptime and availability being a priority in the OT environment, the ability to discover assets through passive scanning of the network (passive asset discovery) is needed so as not to potentially interfere with the functioning of the asset. Active asset discovery, though more intrusive because of the selective probing, still plays an important role as it will discover assets that may not be communicating on the network as often for the passive asset discovery to work effectively. Honeywell Forge Cybersecurity Software has capabilities for both active and passive asset discovery capabilities, so that manufacturers can discover and inventory the assets and better manage the risks. As companies look at improving their cybersecurity maturity, many think that it takes a backseat to operational uptime and 24/7 critical operations. Small incremental cybersecurity gains over time really add up – performing vulnerability scanning, disabling unused

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features or updating passwords can be undertaken by marginally extending scheduled downtimes. A best practice to improve cybersecurity performance would be to embed it into the project management operation processes and procedures to ensure it is part of the concept, design and selection of OT assets. Recognising and leveraging all the opportunities during plant operations can go a long way in improving the cybersecurity posture of a company. One barrier to addressing cybersecurity challenges is the scarcity of cyber talent in the job market. According to ISC2 – an international nonprofit organisation specialising in Control Engineering Europe

CYBERSECURITY

cybersecurity training and certification, about 3.5 million positions will go unfulfilled by 2021. Turning to software platforms to automate and optimise some of the cybersecurity tasks will help cyber experts already on the team to be even more effective at managing cybersecurity performance. Additionally, OT managed security service and even outsourcing security operations center (SOC) capabilities can enable manufacturers to detect breaches and respond appropriately even in the face of the skills gap. For example, Honeywell offers Managed Security Services through which customers get 24/7 monitoring, patching and antivirus updates. Additionally, training the operators and engineers on basic cyber hygiene is essential so that it is not left only to the cyber staff to manage every little task. Training also mitigates a major threat vector – internal threats due to employee cyber inexperience

leading to bad actors gaining access to company systems. In addition to periodic training, effective policies and procedures, and access management needs to be in place as well.

An evolving threat It is important to be aware that, as technology evolves, so do malware and threats. There is no silver bullet or an end point for cybersecurity, rather it is an ongoing journey for a company to protect itself. Every site or plant needs to determine its cyber risk profile through an objective cybersecurity assessment and have a roadmap to address gaps and vulnerabilities. For a more cyber mature organisation, specialised assessments such as a network assessment or wireless assessment to address specific areas of their systems should be considered. Penetration testing is a more advanced technique to test out the defences of a mature organisation and is a way

to uncover both technical and nontechnical vulnerabilities. To address OT cybersecurity needs, a company that has a deep understanding of operational technologies and even has a hands-on experience with OT can bridge the mistrust that sometimes exists between the IT and the OT teams. The IT team can rest easy knowing that cybersecurity is being addressed while the operations director or plant manager can trust an OT cybersecurity company to understand challenges and criticalities of running a plant. To conclude, a holistic cybersecurity program needs to be in place to safely harness the power of IIoT while minimising downtimes due to cyberattacks. Consider cybersecurity as a co-pilot as you pilot your company on a safe digital transformation journey. ! Arun Veeramani is a senior offering manager with Honeywell’s Industrial Cyber Security team.

MACHINE CONTROL

PROTECTING YOUR PLC SYSTEMS FROM SECURITY THREATS While increasing connectivity can offer significant benefits it can also increase the cybersecurity risk to control. Steve Ward explains further.

yberattacks continue to evolve, becoming ever more complicated to detect and respond to. For this reason the need to modernise how these threats are addressed should be a top priority. Adopting a risk-based approach to cybersecurity can help identify potential vulnerabilities and make strategic decisions based on the likelihood and impact of each vulnerability. There are some important questions that need to be asked when addressing the risks and trying to stay ahead of emerging threats. The easier it is to monitor network activity, the faster a facility can respond once an attack is detected, which will ultimately reduce the impact of an attack. Therefore, one of the most important steps in protecting your programmable logic controllers (PLC) and programmable automation controllers (PAC) control systems from security threats should begin even before an attack is detected. Using network communication port monitoring will make checking for unexpected network protocols, connections, or communications types easier. While unexpected activity on a network may not end up being a threat, it should raise a red flag, and is always worth investigating. Most enterprises are aware that they should implement anti-malware software on HMI and SCADA servers, but it is just as critical to set up antimalware software on every device that will connect to these control systems – including laptops, tablets, smartphones, or any other device that might share a network with the control system because a compromised ancillary device may provide a hacker the perfect gateway to a system’s data.

May 2020

When implemented across an entire facility, centralised anti-malware software can prevent, detect, and remove malicious software, making the monitoring process more effective and efficient.

Limiting damage No matter how prepared you are, security attacks and breaches can still happen. Therefore, it is important to not just try to prevent them from occurring, but also to ensure that if they do occur, the damage is as minimal as possible. One way to limit network damage is to have more than a single security control; implement a robust, tiered approach with security controls at many independent levels that an attacker must breach in order to truly compromise the entire system. Having the right cybersecurity defence indepth strategy helps avoid safety issues and plant shutdowns. Segmenting networks into logical zones helps to thwart internal threats, which, while less common, can often result in the most damage. Having separate zones – often described as enhanced network segmentation – is more challenging to implement and maintain compared to traditional network segmentation; however, it is considered one of the best ways to protect control assets. At a minimum, facilities should ensure secure deployment with firewalls and segmentation to block unsolicited incoming traffic, as well as isolate networks to restrict data transfer to its intended locations. Use of advanced or application layer firewalls is a good approach to increase this capability.

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Another way to limit the effects of a breach is by utilising redundancy or including backup components in a system, so that it can continue to function in case of a component failure or security breach. Finally, one of the most important ways to limit the impact of a security breach is establishing effective and sound business continuity or recovery processes and policy that are practiced, so that a breach can be dealt with before its impact has the chance to spread, and mitigated from future threats. Locking down all unused communication ports and turning off all unused services are other simple steps that should be taken to reduce the surface area that can be attacked. Facilities should work with vendors who have proven certifications – such as Achilles – for PLCs and PAC systems that span the design and engineering technical security requirements for a control system. Certifications enable control system vendors to formally illustrate compliance of their control system produced with cybersecurity requirements. Monitoring machine-to-machine communication within a facility is another critical step when striving to ensure an attack is not occurring. All communications should be done securely through protocols for industrial automation such as OPC UA, which offers robust security that consists of authentication and authorisation, and encryption and data integrity. By monitoring the network communications, newly opened ports or protocols being used alert you a potential threat. Control Engineering Europe

MACHINE CONTROL

Managing PLC user authentication Unintentional behaviours can be one of the most critical threats to an organisation. To lead change it is important to adopt best in class behaviours and help educate the workforce on steps to mitigate risk. For example, one of the biggest threats to security is password selection. In a world where some of the most common passwords are ‘password’ or ‘123456’, it cannot be stressed enough how important it is to instruct users to select strong passwords and to offer guidelines about how to do so. Require user authentication between a client application(s) and a server to ensure that only authorised users are accessing the server. Multi-factor authentication and role-based access control are the best options if a system can support this level of security.

Isolating the PLC network The biggest risk posed by remote network access is that it makes it possible for a hacker to gain deeper access to an organisation from outside of it, and once they do, it becomes very challenging to prevent unplanned

shutdowns, loss of control, data loss, etc. Businesses should also audit their PLC network to locate any obscure access vectors a hacker might use, and regularly monitor the access points. A company can implement multi-factor authentication, which requires a user to successfully present two or more pieces of evidence – or factors – to an authentication mechanism in order to be granted access to a device, application or information. Two-factor authentication is a

commonly used subset of multi-factor authentication. This method confirms a user’s claimed identity by using a combination of two of the following different factors: something they know, like a password; something they have, like a keycard or software token; or something they are, like presenting fingerprint or facial identification. ! Steve Ward is director of application engineering EMEA at Emerson Automation Solutions.

IPC provides compact, fanless control at the edge The new C7015 ultra-compact Industrial PC (IPC) from Beckhoff has been designed with IP 65/67 protection to allow for direct installation onto machines or other equipment. The edge device is suited to decentralised installation, providing powerful multi-core computing performance. When used as a control computer, the device also offers control cabinet space savings. The space-saving, fanless device is said to be suited to high-performance automation, visualisation and communication uses in applications ranging from classic machine control to decentralised edge computing. The C7015 is equipped with an Intel Atom multi-core CPU with up to four processor cores. Compared to Control Engineering Europe

conventional ARM-based edge devices, it is able to support more demanding applications as well as decentralised data pre-processing and the acquisition of large data volumes. The IP 65/67 IPC also serves as a machine controller. Installing it directly in the field can save valuable electrical cabinet space. This reduces machine footprints significantly, especially when combined with other Beckhoff components with a high protection rating, such as the AMP8000 distributed servo drive system and the EPP series EtherCAT P I/O modules. These solutions can simplify machine design while also minimising the effort of subsequent system expansions, such as the addition of an energy data acquisition system.

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The integrated EtherCAT P connection creates a range of new options for efficient sensor/actuator connection via the IP 67-protected EPP modules. This enables even complex diagnostic or condition monitoring tasks to be decentralised and supported with minimal installation effort.

May 2020

FINAL WORD

Will Coronavirus force manufacturers to enhance automation and digitalisation? Jan Zhang reports that COVID-19 is forcing manufacturers to rely more on automation and digitalisation for long-term operations to reduce the financial impact from epidemics and other potential economic challenges.

he COVID-19 outbreak is becoming a global stress test. As the outbreak subsides in China, there are some major short- and long-term effects the Chinese manufacturing industry is feeling, which will carry over to other countries. For many of the infected regions, the economy will fall sharply in the short term, and then rebound after the epidemic is over, but COVID-19 is unlikely to have a huge long-term impact. Epidemic prevention and control measures from local governments will be a key factor. In February 2020, China’s manufacturing purchasing manager index (PMI) was 35.7%, down 14.3 percentage points from the previous month. Meanwhile, the Production Index was 27.8%, down by 23.5 percentage points from the previous month, indicating that manufacturing production activity had slowed down radically. As outbreaks continue to unfold around the world, external demand will falter, further hampering recovery. According to analysis of data segments such as power generation, population migration, and transportation; the work resumption rate in China is about 65% (except for students). Although the overall recovery of enterprises is better, it is more difficult for small and medium-sized enterprises and lifestyleservice industries to return to work. It is expected that production and operation will get back to normal completely by May. COVID-19 may have a far-reaching impact on the capacity layout and supply chain network of many enterprises. Multinational enterprises in particular will further improve their disaster

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emergency mechanisms and supply chain management. Many enterprises will now be thinking about relocating manufacturing. During the 2011 earthquake in Japan, even companies who were hardly hit by supply chain issues decided to relocate. However, cross-border relocation of production capacity is not an easy decision to make, and many factors need to be taken into account, such as local market capacity, time and investment required, local government policies, infrastructure and logistics, labour costs, and skill levels.

Exposing problems For manufacturing enterprises, the epidemic has exposed problems and risks that already existed. As such, it might force industry to undertake much needed reforms to automation, digitalisation and logistics processes and systems. For manufacturing enterprises, the short-term impact of the epidemic is a decline in revenue and profits. For example, under China’s stringent prevention and control measures, a large number of manufacturing enterprises were completely suspended,

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and the loss of production capacity is expected to be 1 to 3 months in total. Production recovery cannot be achieved overnight, and the resumption of work may also face difficulties in the form of recruitment problems, an insufficient supply of raw materials, and other issues such as logistics and cash flow. Operating costs will also clearly remain high during this period, further eroding profit. Small and medium-sized enterprises, and those with insufficient cash flow, will feel the pressure most. For enterprises with good operation and high capacity utilisation, the focus must be to restore production as soon as possible. The COVID-19 epidemic has brought unexpected difficulties and challenges to governments, industries and enterprises around the world. But it is a shortterm effect and it will eventually pass. In the long run, COVID-19 is a chance for industries to make much-needed operational improvements. ! Jan Zhang is a research director at market analyst firm Interact Analysis. This article originally appeared on www.controleng.com Control Engineering Europe

PRODUCT FORUM •

www.controlengeurope.com to read the full story

Alarm systems management

Complex industrial systems require complex control systems – but carefully thought out alarms systems EEMUA is the acknowledged leader in the field, with EEMUA 191, ‘Alarm systems - a guide to design, management and procurement’, being regarded as the benchmark in alarm systems management. The EEMUA Alarm Systems e-learning module provides an introduction to EEMUA 191 and is positioned at the awareness level. It offers simple and practical guidance to managers, designers, supervisors and operators on how to recognise and deal with typical human-factor problems involving alarm systems. Its scope covers many sectors, including the energy, process and

utilities industries. The e-learning is recommended for both discipline and project-focused engineers from a variety of backgrounds who want to gain an introduction to the fundamental principles for design, management and procurement of alarm systems. The course is also relevant to engineers and managers from operating companies as well as specialist contractors and equipment suppliers. Visit the EEMUA website for further details. www.eemua.org

Creating a successful control environment Know what you want, plan what you’ll get, check that you’ve got it! The EEMUA Control Rooms e-learning module provides guidance to engineers and the wider teams involved in the design of control rooms, control desks and consoles. It will help during newbuild and modification projects, as well as evaluating existing set ups where people operate industrial processes and activities on facilities such as chemical plants, power stations and oil refineries. The e-learning will benefit anyone with an interest in process plant control rooms and control desks using Human Machine Interfaces. It is especially relevant to control engineers, control room console (and HMI) designers and vendors, control room

operators, engineering consultants, engineering contractors, engineering managers, facilities managers, graduate engineers, plant operations managers, process safety managers, SCADA engineers and systems support managers. The e-learning is positioned at the awareness/introductory level and is an optional precursor to working through EEMUA 201, ‘Control rooms: A guide to their specification, design, commissioning and operation’. Visit the EEMUA website for further details. www.eemua.org

TO BE FEATURED IN THE CEE PRODUCT FORUM Contact Adam Yates on +44 (0)7900 936909 or email Adam.Yates@imlgroup.co.uk Control Engineering Europe

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May 2020

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Articles inside

Jan Zhang reports that COVID-19 is forcing manufacturers to rely more on automation and digitalisation for long-term operations to reduce the financial impact

Polarisation helps to reveal often hidden details; Ethernet communication for Ex areas

A cost-effective solution to prevent tank overfill

Smart factory investment is at a critical stage

Cybersecurity should be your indispensable digital transformation co-pilot

Taking critical plant floor data to higher levels

Staying in the loop