Control, Instrumentation and Automation in the Process and Manufacturing Industries September 2020
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Empower innovative business models
Mobilising real-time remote operations Securing the IoT by design
Why bother with functional safety management?
The rise of the PAC
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CONTENTS Staying one step ahead of the hackers
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
In the modern world there is a need for us all to be more aware of our own cyber security, as hackers continue to find new and inventive ways to access our personal data for financial gain. The theme is pretty much the same across industry too, as many features in this issue point out, cyber security can never be a fit-and-forget fix, instead it needs to be considered as a continuous and ongoing battle to stay one step ahead of the hackers. Luckily there are guidelines, standards and tools available to help ensure the hackers do not win! Also in this issue of Control Engineering Europe we take a look at the importance of functional safety systems management (pg 22) and find out more about the differences and similarities of PLCs and PACs, with a view to helping you choose the right solution for your application (pg 18). Suzanne Gill Editor – Control Engineering Europe suzanne.gill@imlgroup.co.uk
INDUSTRY REPORT
WIRELESS TECHNOLOGY
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24 Is 5G ready for deployment in the real world?
Equipment-as-a-service models are gaining in popularity
28 Connecting industrial applications to a private 5G network
EDITOR’S CHOICE 6
Reducing cabling effort with an integrated motor controller; Adaptable pressure transmitters
FINAL WORD 30 While ladder logic is challenging for industrial programming, it is a valuable skill for engineers looking to enhance their skill set according to David Breen
CYBERSECURITY 10 Guidelines for securing industrial networks 12 Securing the IoT by design 14 Looking at simple strategies to achieve the most value from cyber risk assessments 16 Good reasons for system integrators to comply with IEC 62443
CONTROLLERS 18 What’s the difference between a PLC and PAC and which one should you choose for your application? 20 Leveraging the most suitable machine control solution for a factory automation project
FUNCTIONAL SAFETY 22 Why bother with functional safety management?
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
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September 2020
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INDUSTRY REPORTS
Equipment-as-a-service business models are gaining popularity A new report from Relayr highlights the current mood of the US and German manufacturing industries, setting out to look at the attitudes toward current developments in the industry and any short or long term impact that the current pandemic will have on operations. Over 200 leaders in the US and German manufacturing industries were involved. Topics ranged from how the crisis affects operations and how they are dealing with challenges presented by the pandemic to their assessment of future economic development. Most respondents said that Covid-19 has affected existing customer groups and regions, and many manufacturers are looking for ways to adapt. Almost all respondents say technological advantages, such as industrial IoT (IIoT), big data, and artificial intelligence, support their ability to cope with uncertainty. US companies have been hit hard by the crisis: Most respondents (67%) say that the crisis has had a somewhat negative or very negative impact on their businesses. Their biggest challenges are a decline in new orders (58%), their employees’ concerns about a possible Covid-19 infection (56%), and a decrease in sales (54%). However, only 11% of US companies are seriously concerned about remaining in business. Half of the US companies surveyed expect their investment behaviours to be lower than 2019, while 14% are unsure. In contrast, just over one-third (36%) plan to make investments at the same level or higher than last year. What measures have the surveyed companies taken to meet the challenges of the crisis? ‘Increased flexibility’ was at the top of the list for US manufacturers (59%). Other top measures include improving customer service and relying on technical innovations to counteract the crisis’s effects. Equipment-as-a-Service business models are becoming increasingly popular: A complete business model overhaul was an option for only a few of the surveyed companies and 16% of US companies are planning to transform at the moment. However, a majority of those surveyed recognise that new business models, such as pay-per-use models (equipment-as-
a-service), represent an advantage for both the supply and demand sides in the current crisis. In the US, 34% said pay-per-use models represent a big or a very big advantage, while 29% consider it a slight advantage. Almost half of the companies surveyed also stated that they use a pay-per-use model themselves (18%), offer it (15%), or do both (9%). Predictive analytics is on the rise: The respondents are adopting various technologies to gain a competitive advantage. In the US, 38% of businesses are implementing predictive analytics, followed by big data (33%) and IIoT (32%). Of note, more German companies (47%) use IIoT and AI to gain a competitive advantage, while US manufacturers have higher usage rates of predictive analytics. These innovative technologies not only represent a fundamental advantage for the respective businesses but are especially beneficial in the current situation. Among the companies that use one or more of the listed technologies, 99% of the US respondents believe technology will help their company in the crisis. Easing of lockdown measures shows positive effects: The first loosening of lockdown measures is already leading to positive effects. Since restrictions have lifted, 14% of US companies have felt a significant increase in demand for their products, and 45% have had a slight increase compared to the weeks before the easing. Commenting on the report findings, Josef Brunner, CEO at Relayr, said: “These unprecedented times and developments cannot be compared to anything in the recent past. Therefore, it is encouraging that the manufacturing industry is fairly optimistic about the future. It clearly shows modern technology, flexibility, and customer focus are extremely critical factors for economic success in general and for building resilience as a business. Thus, even in these unusual times, companies can build the most solid basis for shaping and securing their future and the future of the industry.” relayr.io/forsa
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Endress+Hauser expands logistics capacity Endress+Hauser is strengthening its logistics capabilities in Europe with the news that Hellmann Worldwide Logistics is to operate a modern, highperformance logistics center on behalf of the Group near Frankfurt Airport in Germany. The hub is scheduled to be completed and in operation by mid2021 and this will replace the current logistics center in Nieder-Olm, Germany.
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“In order to reliably supply customers around the world with measurement and automation technology despite the pandemic, our logistics hub in Nieder-Olm served as a solid foundation,” explained Oliver Blum, corporate director of supply chain. “Although 100% availability was crucial, having the flexibility to ensure
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that thousands of measurement instruments were delivered to customers that were in lockdown was particularly important.” There are also plans to put a larger logistics center into operation only a few kilometers from the current location, which will be able to handle eight times the volume of the old facility. Control Engineering Europe
INDUSTRY REPORTS
Robot sensor market looks like it has a healthy future According to a recent study, from market research firm Global Market Insights, robotics and automation have emerged over the past few years to become an indispensable part of modernday manufacturing. The majority of manufacturers are integrating robotic systems into their production facilities to enhance production capacity, boost profit margins, and cut operational costs. These trends have created a substantial demand for robotic components, including robot sensors like 3D vision, forcetorque, and tactile sensors. It is estimated that the global robot sensor market will be worth more than US$4 billion by 2026. The integration of AI and IoT is expected to expand the application scope of these sensors. In terms of product, the Robot Sensor Market is divided into force/ torque, tactile, ultrasonic, laser range, vision and proximity sensors. The research estimates that the ultrasonic segment may grow at 11% CAGR during the forecast timeframe give to these sensor’s economical cost
compared to laser range sensors and its capability to integrate into smart factory robots for sensing and pre-sensing purposes. Developments in ultrasonic technology has also enabled several companies to launch new sensors. In 2019, Toposens introduced the 3D ultrasonic sensor, which is applicable in indoor robotic practices such as collision avoidance and object detection. Considering the regional outlook, Europe robot sensor market share is poised to witness a CAGR of over 8% through 2026. The regional growth can be largely attributed to growing digitalisation in Germany.
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EDITOR’S CHOICE
Reducing cabling effort with an integrated motor controller The EP7402 EtherCAT Box from Beckhoff aims to help the control architecture and cabling of roller conveyor systems become more efficient. With an IP67 protection rating, the compact motor controller for brushless DC (BLDC) electric motors is said to be suited to conveyor applications in intralogistics and assembly technology as well as in the packaging, food and beverage industries. The EP7402 EtherCAT Box offers two outputs with integrated motion controller for the direct connection of 24 V DC conveyor roller motors or other BLDC motors (up to 3.5 A). Eight additional digital inputs/outputs enable connection of photoelectric switches and
communication between the different box modules in operation without a PLC. The controller takes complete control of a roller motor independently of the conveyor or motor manufacturer without the need for sensors. Maximum rated current, acceleration or deceleration ramps and various other parameters can be configured, allowing optimal adaptation to different applications. In conveyor operation the EP7402 can also be operated without a PLC and provides functions such as Zero Pressure Accumulation
(ZPA) single or block discharge. Further EtherCAT devices, such as digital and analogue IOs, barcode readers or safety devices, can be connected to the additional EtherCAT junction.
Condition-monitoring function pack simplifies machine learning solutions STMicroelectronics has released a free STM32 software function pack that enables users to quickly build, train, and deploy intelligent edge devices for industrial condition monitoring using a microcontroller Discovery kit. Developed in conjunction with machine-learning expert, Cartesiam, the FP-AI-NANOEDG1 software pack contains all the necessary drivers, middleware, documentation, and sample code to capture sensor data, integrate, and run Cartesiam’s NanoEdge libraries. Users without specialist AI skills should be able to quickly create and
export custom machine-learning libraries for their applications using Cartesiam’s NanoEdge AI Studio tool running on a Windows10 or Ubuntu PC. The function pack simplifies complete prototyping and validation free of charge on STM32 development boards, before deploying on customer hardware where standard Cartesiam fees apply. The straightforward methodology established with Cartesiam uses industrial-grade sensors on-board a Discovery kit to capture vibration data from the monitored equipment both in normal operating modes and under induced abnormal conditions.
NanoEdge AI Studio analyses the benchmark data and selects precompiled algorithms from over 500 million possible combinations to create optimised libraries for training and inference. The function-pack software provides stubs for the libraries that can be easily replaced for simple embedding in the application. Once deployed, the device can learn the normal pattern of the operating mode locally during the initial installation phase as well as during the lifetime of the equipment, as the function pack permits switching between learning and monitoring modes.
Adaptable pressure transmitters A new range of pressure transmitters, designed to meet key requirements in most manufacturing and production industries, has been launched by ABB. The rugged PxS100 range is suited to use in the water, wastewater, metals, mining, pulp and paper, cement, and power ancillary sectors, fulfilling all routine requirements for pressure measurement. Interesting features include QR codes for easy access to online operational instructions and advice; abrasive resistant technology to protect the metallic diaphragm and extend working
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life; and ABB’s H-shield to protect against monatomic hydrogen and ensure measurement accuracy. The PxS100 series can be rapidly configured to accommodate hundreds of mountings, spans, and certification-equivalent options. A simple HMI rotates for visibility from any angle, features ‘through the glass’ configuration capabilities and can be ordered with easily accessible backlight for low light environments. In alignment with specifications requested by its reference market, the PxS100 provides base accuracy
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of 0.25% of span, with the option of improvement to 0.1%. It is available in both Gauge and Absolute sensor variants and offers five different measurement ranges, covering applications from 40 mbar up to 100 bar. Control Engineering Europe
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COVER STORY
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FDT: EMPOWERING BUSINESS MODELS WITH A STANDARDISED IIOT ECOSYSTEM Glenn Schulz, managing director at FDT Group, explains how and why the FDT standard is helping to support the digital transformation for manufacturers.
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or the global industrial community, implementation of FDT Group’s standard is a forwardlooking strategy for the new era of automation. FDT® technology supports digital transformation for manufacturers with an open, enterprisewide IIoT integration platform empowered with new, built-in features mobilizing real-time remote operations for the current COVID pandemic environment. The goal is to expand secure access to critical device data in order to increase productivity and create a safer workplace.
Enabling digital transformation FDT has evolved from a single-user, desktop environment to a distributed, multi-user client/server approach for enterprise-wide integration and asset management. The recently released FDT 3.0 standard builds on this solid foundation and delivers a new, featurerich FDT IIoT Ecosystem, including the FDT Server natively integrated with OPC UA and Web Servers, as well as new FDT Device Type Managers™ (FDT/DTMs™) empowering the industrial workforce with a webUI to mobilize remote operations. The standard also provides device developers with an industryexclusive feature – automatic platform independence. The FDT transformational solution unlocks universal device integration and a data-centric platform with modern and diverse deployment options, including cloud, enterprise, edge, on premise, and single-user desktop environments. Key to this development was creation of remote access and mobility features utilising standard web browsers. The move from a physical device to a remote, virtualised device improves asset management practices, allowing end-users to configure, diagnose and
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maintain devices remotely. The modernised DTM environment inherent in FDT 3.0 also transforms the device developer world. Indeed, the new standard makes it easier to create compliant FDT/DTMs than ever before. Thanks to the DTM Common Components, DTMs are automatically compatible with OPC Unified Architecture (UA) – no additional coding required – and compliant with the NAMUR NE 107 status recommendations for predictive maintenance. FDT 3.0 DTMs automatically make device data available via the OPC UA server embedded on the FDT Server. This enables innovative capabilities such as a data-driven approach to maintenance and integration of live plant data with MES and ERP systems and asset management as service.
Advancing business innovation According to FDT Group member companies, ‘the sky is the limit’ with the FDT 3.0 standard and new modernised development environment. Today, automation suppliers can easily jump start development to enhance their product offerings with essential, standards-based, platform-independent, information-driven business models. FDT 3.0 enables open, secure and scalable skid-to-cloud architectures and sensor-tocloud integration. It also includes robust, inherent security features that eliminate the need for vendors to develop their own detailed security models. Release of the FDT 3.0 standard has key implications for both the supplier and end-user communities: • Suppliers no longer have to install a driver on the customer’s PC to demonstrate their product. Rather,
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they can show the features of a device utilising a server on the cloud. • With the new FDThub™, all DTMs are immediately available from an online repository. Customers no longer have to search for the right DTMs for their project. • End-users can install a single instance of an FDT Server and make it accessible across their facility for deployment. They do not need to install multiple FDT applications. • All real-time data from the installed devices is automatically available through OPC UA to any enterprise level application such as MRP, ERP, dash boards and CMMS applications.
Conclusion FDT Group’s updated standard simplifies the move to IIoT and Industrie 4.0 for both Greenfield and Brownfield applications for all process, hybrid and discrete applications. It is the only device configuration standard providing builtin mobility, native OPC UA integration, robust security, and platform independence. These and other features of the technology will transform the outlook for automation stakeholders around the world. ! To explore innovative business models empowered by FDT, download our white paper www.fdtgroup.org/innovation. Control Engineering Europe
CYBERSECURITY
GUIDELINES FOR SECURING INDUSTRIAL NETWORKS
Because component suppliers are playing an increasingly important role in Industrial Internet of Things (IIoT) networks, it is useful to understand the security requirements they must meet when designing devices for deployment on them. Susan Lan reports.
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n 2002, the International Society for Automation (ISA) produced the ISA-99 document to advise businesses operating in automation industries how to protect against cybersecurity threats. Since publication, the ISA documents have been aligned with those more frequently used by the International Electrotechnical Commission (IEC). Currently, the IEC 62443 standard constitutes a series of standards, reports, and other relevant documentation that define procedures for implementing electronically secure Industrial Automation and Control Systems (IACS). Following these guidelines can significantly reduce the chance of a successful cyber attack. IEC 62443 guidelines define four security threat levels. The security standard level 2 is the baseline requirement of the automation industry. It relates to cyber threats posed by hackers, which is the most common attack experienced by system integrators who secure industrial networks. Level 1 is to protect against accidental
unauthenticated access and Levels 3 and 4 are against intentional access by hackers who utilise specific skills and tools. Within the standard are several subsections that relate to different parties. The component requirements are derived from foundational requirements, including identification and authentication control, use control, data integrity and confidentiality, as well as backup for resource availability. Infrastructure: If a network component allows users to access devices or applications, the network component must be able to uniquely identify and authenticate all users, including humans, processes, and devices. This allows separation of duties and the principle of least privilege that ensures every user only has access to information and devices that are essential for them to be able to perform their role within the network. It is essential to avoid the unnecessary security risk of granting users greater access to the network than is necessary. Following this guideline
Because collaborative robots cannot be caged by a physical guarding mechanism it is vital to ensure that ESPE is not neglected.
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will help secure the infrastructure of a network and provide a solid foundation to develop networks. Account management: The ability to support the management of accounts – including establishing, activating, modifying, disabling, and removing accounts – must be supported across the network. This ensures that no accounts are created, modified, or deleted unless permission has been granted, and forbids embedded devices from making any unauthenticated connections. The management of accounts feature has several possible scenarios, which if not implemented, could cause problems for asset owners. For example, a person who works on the network gets promoted, so they now require more access to devices and applications, and their privilege level must be adjusted accordingly. Another frequently encountered example is when an employee leaves an organisation. As soon as they cease being an employee they must have their network privileges revoked. Identifier management: Any component of the network with a direct user interface must directly integrate into a system that identifies individuals by user, group, role, and/ or system interface. This stops users from being able to access devices connected to the network that they have not been granted access to. As those with different roles on a network have different privileges, a network administrator’s account can often manage device configurations on a network, but someone who has guest level access can only view devices, but not alter configurations. In addition, there should be security procedures in place if an account has not been Control Engineering Europe
CYBERSECURITY accessed for a certain period of time that allows the account to be deactivated. The identifier management feature controls each user’s account on the network and ensures that users are confined to just the roles assigned to them by network administrators. Authenticator management: All devices on a network must be able to confirm the validity of any requests for system/firmware upgrades, and verify that the source is not trying to upload any viruses or malware. This is achieved by requiring the use of tokens, keys, certificates, or passwords. If no authenticator management system is in place, anyone wishing to attack the network could very easily upload malware, allowing them to change settings or take over control of the network. Password-based authentication: For network components that utilise password-based authentication, the network component must integrate a password policy that enforces the following: • The password composition must state what type of characters are allowed, as well as the number of characters required before a password will be accepted as valid. • The frequency that the password must be changed. A password is a simple way for network administrators to protect their network without requiring any additional work from a system engineer. Utilising an effective password policy will keep out the majority of hackers who gain access to networks by using brute force to break weak passwords. Public key authentication: Public key authentication should be used to build a secure connection between servers and devices, or device-to-device connections. To enable this function, each network component must be able to validate certificates by checking the authentication of the signature, as well as the revocation status of a certificate. In addition, it should construct a certification path to an accepted Control Engineering Europe
certification authority, or in the case of self-signed certificates deploy certificates to all hosts that communicate with the subject to which the certificate is issued. Public key authentication is important because it stops information from being sent to the wrong place, and also stops confidential information that should remain within the network from being transferred to unverifiable sources outside. Use control: All the devices that appear on a network must support login authentication. To restrict unwanted users from gaining access to a device or the network, it is necessary to limit the number of times a user can enter the password incorrectly before being locked out. As the majority of attacks on industrial networks are performed by hackers using brute force attacks, login authentication is an effective method of stopping hackers from gaining access to a network. In addition, the system or device must also be able to inform users whether their login attempt was successful or not. Informing users that they are logged into the network allows them to confirm their current status and proceed knowing that changes or alterations they make to network settings or devices have been authenticated. Data integrity: Data integrity plays a vital role across all IIoT networks. It ensures that data is accurate and that it can be processed and retrieved reliably. There are several security measures that can be utilised to protect the data, including SSL, which enables encryption between a web browser and a server. As data is constantly moving around a network, operators need to be sure that the data is moving in a safe, reliable, and efficient manner. If the data is sent
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to unintended recipients the network operators will not only lose control of their data, but also leave their networks vulnerable to hackers. Backup for resource availability: All of the applications or devices that are found on a network must be able to back up data without interfering with network operations. The main advantage of performing regular backups is to ensure that no data is lost and that if the network experiences some problems the network can utilise the data that has been backed up to return the network to normal. In addition, the backup process must ensure that any private information that is on the network is stored in accordance with data protection policies and is not accessible by anyone who should not have access to that information. In some cases this means that data can’t be stored outside the network. Any data breach containing users’ personal information is extremely damaging to network operators as well as to those whose data has been accessed by those it shouldn’t be accessed by.
Conclusion As more devices are added to networks, the security of these devices is of paramount concern to asset owners. It is acknowledged throughout the industry that adopting the best practice approach to security gives asset owners the best chance of protecting their network from those with malicious intent. The complete system-level security must be built upon the foundations that consist of each individual component’s security functions. ! Susan Lan is a product manager at Moxa. September 2020
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CYBERSECURITY
SECURING THE IOT BY DESIGN Joe Lomako offers advice on the preventative measures that can be taken to secure processes against cyber attacks.
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s devices, systems and processes become increasingly digitised and interconnected, the Internet of Things (IoT) offers opportunities for industry. However, the same technologies which enable value creation, also provide new attack surfaces for cyber criminals. In the IoT age, every wireless-enabled product represents a potential threat to data security and privacy, but proactive, robust security planning enables a manufacturer to manage cybersecurity risk to mitigate attacks. Preventative security measures should begin at the design phase, or even the concept phase, employing the principle of ‘Secure by Design’. Although, as the name suggests, this is aimed at the design stage, it is important to understand that security is a continuous process. So, the Secure by Design principal is sensible. However, that in itself has to be defined. This process should therefore begin with an assessment of the business
impact and probability of risks. Without clearly understanding and prioritising risks, it is not possible to determine the appropriate security requirements for that product and indeed of the IoT system as a whole.
Evaluation After risks are understood, the next step is to evaluate the hardware and software – the ‘attack surface’. Testing of the individual components against requirements determined by the risk assessment is the foundation of a secure product. Security is very difficult to install as a software add-on after product development. Every aspect must therefore be assessed for vulnerabilities, including device hardware (chipsets, sensors and actuators), wireless communication modules and protocols, device firmware (OS and embedded applications), cloud platforms and applications. Following component testing, an endto-end assessment should be performed to determine the attack resilience of the individual components and support services. It is important that this process is continuous. The questions, ‘have we found every vulnerability?’ or ‘have we introduced new vulnerabilities?’ are always in the air. Thus, implementing a
process of security validation for updates during the product lifecycle is also important. There is often a perception that because a system is complex that it is automatically secure. Unfortunately this is not always the case. The introduction of the NIS Directive (security of network & information systems) in Europe is intended to improve this situation, but uptake is slow, as is the introduction of the standards required to assist in improving cyber security. However, standards do exist, or are being developed by international organisations, aimed at providing baseline protection which would help to deliver basic security provisions for a first line in cyber defence. The two main standards for IoT devices are NIST 8259 (US) and Draft EN 303 645 (EU). The scope of the NIST has been written with the intent to address a wide range of IoT type products, which have at least one transducer. So, it follows that it can apply to Industry 4.0 products. More importantly this standard has been mandated in California under State Bill No. 327, and it will likely pervade across the US. However, the scope of the Draft EN 303 645 standard is aimed only at consumer IoT devices, so is not applicable for industrial products, although the general principles therein can certainly be applied generically to afford some modicum of protection.
Taking control
Every wireless device represents a potential threat to data security.
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There is some debate that the present cyber security standards are lacking detail and do not adequately cover the scope of typical industrial applications. So, manufacturers should consider their own programmes and a starting point would be: • Think ‘Secure by design’ and take a proactive approach to cybersecurity recognising that attacks are ‘when not if’. Control Engineering Europe
CYBERSECURITY • Ensure up to date compliance with all standards. • Constantly review ‘cyber resistance’ status. Ongoing investment in cyber security is crucial to keep up with both technological developments for competitive advantage, alongside effective measures to combat new forms of hacker attacks into critical IT infrastructure. For example, companies often neglect IT-security training of their staff, even though social engineering has long been a standard weapon in every cybercriminal’s arsenal. Following new IT investment or company acquisitions, businesses also often forget to disconnect obsolete or unused equipment. These may be
running unsupported operating systems and are missing updated security patches and this opens gaps for hacker attacks. Traditionally ‘pattern matching’ has been used to identify security risks in the IT infrastructure, but this is no longer enough as cyberattacks are increasingly implemented with the use of machine learning and artificial intelligence. So companies should focus on identification of anomalies by deploying AI in their cyber security efforts. Cyber security is becoming a focal topic not only for IT managers, but increasingly also for C-level management. However, executives and IT experts often do not communicate effectively and adopt different perspectives on many issues. In this case, it is helpful to adopt a level of
communication that is appropriate for the respective target group. Otherwise, communication problems may delay necessary IT security investment. While having some level of internal security knowledge, many manufacturers will benefit from working with external specialists who have wider exposure to assessing various types of product or infrastructure and be better equipped to help manage new and evolving cyber threats. Tackling the problems of cyber security risks can only be realised by comprehensive planning, periodic evaluation, updates and monitoring – from design through to obsolescence. ! Joe Lomako is business development manager (IoT) at TÜV SÜD.
Industrial cybersecurity is a game without end! The constant cyber threat is now a fact of life and everyone needs to have an understanding of data protection, argues Rainer Brehm, CEO of Factory Automation at Siemens Digital Industries. With the rapid growth of the Internet of Things (IoT) and the convergence of OT and IT, there are many more potential targets. Taking into consideration the costs of disruption to production operations, and the threat to human safety when physical systems are compromised, cyber-criminal activities are becoming more lucrative for attackers and cyber security has become a never-ending process that is constantly evolving as the methods and capabilities of attackers become more sophisticated. A favoured method of attack is to identify and exploit vulnerabilities in industrial control systems. For manufacturers of automation systems, such as Siemens, it is imperative to develop products securely, but also to provide comprehensive information and solutions – such as a security patch Control Engineering Europe
– as quickly as possible when new vulnerabilities are discovered. Cyber mature manufacturers collaborate with security researchers who identify and report vulnerabilities in products before malicious attackers have the chance to exploit them. One such company is a Siemens partner, Claroty, which performs security research on Siemens products and solutions. Put simply, the researchers do their best to hack those products – thereby revealing potential vulnerabilities. Just as future technologies are incorporated step-by-step in the Siemens Totally Integrated Automation (TIA) portfolio, a similar principle applies to security features: constantly adapting to the everchanging threat landscape to ensure that solutions remain secure. Experiences with security research can also offer insights into how to approach security. In the last decade we have seen certain types of cyber-attacks occur (and frequently succeed) again and again. This tells us that perimeter-based defences alone cannot effectively keep attackers out indefinitely. It
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is smarter to assume that attacks will penetrate defences and to be prepared for that with, for example, multiple layers that provide ‘defence in depth’ and segmentation that restricts movement to other parts of the network. Integrity (to protect data from unauthorised modification or deletion) and confidentiality (to prevent unauthorised access to data) are key security goals for a holistic security concept. Security features such as strong machine-to-machine and user-to-machine authentication based on custom digital certificates; and fine-grained access control will become mandatory in the future. Given the growth in potential vulnerabilities and the improvement capabilities of the attackers, a holistic cyber security concept for the whole value chain – one that adheres to leading international standards, such as IEC 62443 – is required to ensure clarity and structure. Risk assessment becomes more effective, so decision makers can clearly see where the priorities lie and what the implications for business operations are. September 2020
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LOOKING TO THE FUTURE Alexandre Peixoto and Rick Gorskie discuss some simple strategies to achieve the most value from cyber risk assessments.
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ost process plant automation systems are engineered over decades to ensure operations are repeatable, reliable, available and safe. More recently greater connectivity to business systems has increased exposure of control systems to the internet so organisations need to consider the implications of cybersecurity so that industrial automation and control systems remain secure and stable. A good starting point is a risk assessment to evaluate gaps in currently implemented strategies and technologies, and to provide a roadmap for identifying, prioritising, and eliminating vulnerabilities. Over many years of performing assessments, Emerson has identified three common missteps that operational technology (OT) teams should be aware of when performing or requesting assessments: assuming their own team already knows and understands all the risks, pursuing ‘magic pill’ solutions, and not acting due to the considerable number of issues, along with a lack of prioritisation and limited funding. Organisations actively arming themselves against these roadblocks to success can more easily reap the benefits of a risk assessment, driving more cybersecure operations and providing the business justification most securityoriented projects lack.
identify, document, prioritise, and build a roadmap around the highest threat vulnerabilities. This roadmap provides a guide for creating solutions to provide sufficient security. Once the assessment is complete, resources created and shared by partners can expand knowledge of cybersecurity tactics and techniques directly related to the leading vulnerabilities. Automation providers – and other technology providers – will offer a variety of security manuals, secure architecture guidelines, cybersecurity webinars, and continuing education to help OT teams learn, develop, and improve the strategies used to secure critical systems. In addition, teams must not assume their operators know all there is to know about cybersecurity. Policies and procedures should be documented, shared, and regularly updated (Fig 1). Personnel must be trained to operate under new guidelines established after an assessment. New policies will often upset tried-and-true methods to which operators have become accustomed. Instead of relying on users’ inherent cybersecurity knowledge, the cybersecurity team should teach them
how to perform actions under the new guidelines. Once new guidelines have been put in place, the cybersecurity team should regularly evaluate their implementation. The best way to create secure systems and procedures is to periodically review implementation to ensure proper and appropriate practices are in place. Even the best all-in-one solution is not a substitute for a cyber assessment. Regardless of the assessment’s results, a holistic approach, supported by a roadmap, will always be the best path forward. Technology solutions alone will never remove the need for understanding what is important to each organisation, along with a flexible strategy reflecting operational and business needs. Though a hot new solution may provide a quick fix to an existing or emergent vulnerability, if it interrupts one of the control system core functions, it is unlikely to deliver value over the lifecycle of the automation system, and the organisation may face more serious difficulties. Automation vendors can provide selected cybersecurity solutions certified
Risks and solutions Cybersecurity is an evolving arms-race that may seem overwhelming to an OT team, or even some cyber-experienced information technology (IT) teams. Learning that anti-virus software and a firewall is no longer sufficient protection can be intimidating. A cyber risk assessment removes the need for an OT team to determine every potential cyber vulnerability in the plant. The assessment can help
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Fig 1: Cybersecurity is an ongoing process, with constant updates required based on new solutions and improvements.
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CYBERSECURITY to work with their systems, and these are the solutions most suited for safely eliminating vulnerabilities discovered in a cyber risk assessment. Automation vendors develop and rigorously test layered cybersecurity solutions using third-party security technologies and accompanying architectures to ascertain which work best with their products. In addition, these solutions are constantly retested and reevaluated so that the security posture is reassessed, automation vendor suppliers are also realigning their products to meet new needs. Some third-party solutions are inherently integrated into industrial control systems so that they become part of the automation solution, allowing automation vendors to provide full support in an OT-centric context. In some cases, the third-party provider becomes a strategic partner for the control system supplier so that the updated reference architecture does not impact the core values of the automation system (Fig 2). Automation system support teams are already well versed in the security technologies surrounding the control system. This means that OT teams can rely on the automation vendor’s single support network – one that typically offers 24x7 support to keep any downtime to a minimum. The simplest example of inaction is a small department handling both information technology (IT) and OT with a limited budget. It is easy for such a team to become overwhelmed because there are so many vulnerabilities to be addressed – and never enough time, resources, or overall funding.
Prioritising Even large, well-funded organisations need to start with individual solutions and build toward a comprehensive defense-in-depth strategy. A good cybersecurity risk assessment will create a prioritised roadmap to build the defense layers that will close gaps over time and at a reasonable cost. Another important strategy is reliance on a trusted partner to perform or help with assessments. Partner organisations Control Engineering Europe
Fig 2: A comprehensive risk assessment will provide a roadmap for continual assessment and improvement.
have strategies and tools to help make the case for cybersecurity enhancements to management, justifying the investment by examining information regarding the cost of cybersecurity breaches. Taking concrete steps in response to a cyber risk assessment is not as daunting as it may seem. While it is true that new cybersecurity risks may appear in the future, these risks are not nearly as well known or as likely to be exploited as old risks that are covered by security patches, hotfixes, and upgrades. An organisation is far more likely to be targeted using an old exploit that they never patched than by a new, freshly discovered vulnerability. These are the vulnerabilities most likely to be discovered with an assessment and deterred by basic defense layers. A defense-in-depth strategy starts with a good context definition so that each protection layer can be properly designed and then prioritised against available resources. A cyber risk assessment helps build a good context definition appropriate for the organisation’s needs. Being proactive with a cyber risk assessment can also help OT ensure any security measures do not impact operations. If OT waits too long to identify and pursue solutions
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suited to operations, IT may step in and provide its own solutions without fully understanding the unique needs of operations. When risks are assessed and solutions are deployed appropriately, cybersecurity becomes a bridge between IT and OT that mutually benefits both groups. This is particularly valuable at a time when organisations are forced to operate leaner and remotely to ensure operations and business continuity. Increased connectivity to business systems has raised cybersecurity protection needs for control systems. Starting with a cybersecurity assessment to identify where the organisation is in its journey prepares the team to write policies and procedures to better secure automation systems. The time invested in defining specific context will help establish defense layers to meet needs. A comprehensive cyber risk assessment will also help build the roadmap that is essential to preparing for the unexpected needs of the future, whether that is more remote operations, shared data for analytics, or the move toward a digitallytransformed organisation. ! Alexandre Peixoto is DeltaV product marketing manager, at Emerson. Rick Gorskie is the global sales manager for cybersecurity at Emerson. September 2020
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MACHINE SAFETY
REASONS FOR SYSTEM INTEGRATORS TO COMPLY WITH IEC 62443 Massimiliano Latini explains why system integrators need to ensure that their automation systems are IEC 62443-compliant to adhere to international cybersecurity requirements.
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he evolution of automation and industrial control systems, in terms of digital connectivity, including the use of cloud systems, industrial cyber security has become crucial. While digital connectivity allows for the implementation of increasingly cutting-edge systems, as well as the implementation of more advanced services, it also opens the door to operational technology (OT) cyberattacks. In terms of liability for system integrator, their customers – end-users who succumb to a cyber-attack on a system with no minimum security capabilities, or on a system not implementing protection measures expected by the state-of-the-art – could claim damages. This is especially true in the event of a lack of security implementation, incorrect configuration or inadequate documentation while equipping the plant with prevention measures. The IEC 62443 standard represents the state-of-art in terms of industrial cyber security. It provides a guideline for the protection of industrial control systems, following the life cycle presented by the standard. The system integrator must also comply with IEC 62443 requirements to release an adequately secured automation system to the end user, who will then manage the system according to specific security rules. So, the IEC 62443 relies on the work jointly carried out by the three actors – manufacturer, system integrator andend user. There are several valid reasons why a manufacturer should comply with IEC 62443: • To integrate in an offer, clear performances in terms of cyber security, where security represents a priority. • To expand the whole offer, compared to competitors.
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• Cyber security can also be seen as an opportunity, as end users may need to adapt their old systems to the new standards; so, effective solutions can be proposed to better upgrade existing systems. • Lastly, to meet halfway insurance companies to contain the expected malus. The implementation of a cyber security program in compliance with the IEC 62443 requirements for manufacturers must cover both the organisational assets related to cyber security and business processes; this shall consider any technical aspects related to the automation systems, according to the IEC guideline. Because a cyber security implementation usually takes longer to develop than the final market is able to wait to implement effective cyber security solutions, it is recommended to work in stages. The selection of the system integrator is therefore crucial because: • System integrators allow greater flexibility and less rigid processes, since they are assigned to specific projects and contracts. • The system integrator, as the last actor across the supply chain, would be the first to be called into question, while
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integrating systems and components which are already in compliance with the IEC standard. It is recommended that a first basic security goal is established without necessarily applying all of the requirements and solutions required by the standard, but by selecting only those minimum requirements applicable to security requests with medium complexity. Then it is possible to use minimal solutions that comply with basic technical standards, to protect the system integrator, while delivering a robust and well-configured solution for the end user, accompanied by the necessary technical documentation that demonstrates compliance with IEC 62443. Subsequently, it will be possible to integrate the requirements and business processes aimed at increasing the security level and offering IEC 62433 compliant solutions. At this stage, solutions will be more complete and will include the basic automation support systems, which, in turn, allow for better and safer integration with the customer’s OT and security systems. ! Massimiliano Latini is ICS Cyber Security & Special Projects Director at H-ON Consulting. Control Engineering Europe
UK INDUSTRY REPORT
NEW ADVANCED TECHNOLOGY CENTRE FOR LOTUS SERVICE CENTRE FOR Lotus is to create a dedicated and specialist advanced technology centre, which will also be home to a new headquarters for the company’s engineering consultancy, on the University of Warwick’s Wellesbourne Campus. The new facility is being established in partnership with WMG at the University of Warwick. WMG provides collaboration between academic research, teaching, training, and industry. Initially, 130 engineers will move into the facility, complementing the 500-strong engineering team at the home of Lotus Cars in Hethel, Norfolk. Commenting on the announcement, Matt Windle, executive director, engineering, at Lotus Cars, said: “This is a big step forward for Lotus and our engineering consultancy. Our team and specialist skills have grown significantly in the last two years as renewed impetus has been put in to the business with new shareholders and management. The
INDUSTRIAL GEAR UNITS
all-electric Evija hypercar is the first new Lotus Cars product for us to deliver, with significant focus on this at Wellesbourne as we complete the project and continue to advance its technologies for our future programmes.” Phil Popham, CEO, Lotus Cars, added: “Our engineering and R&D strategy around advanced propulsion systems is lock-in-step with the Government’s vision and broader global ambitions for a low-carbon automotive future. We look forward to working in collaboration with Government and with our new campus neighbours on this future.”
SEW Eurodrive has opened a new sales and service centre in Cumbernauld, to meet demand for its wide range of maintenance and service options, as well as new industrial gear units in Scotland. The new service centre has the capability to service and repair any industrial gear unit regardless of its age or the original manufacturer. It features a fully equipped workshop with all the latest tooling for assembly and testing and has a large stock of genuine spare parts. The new facility, staffed by SEW Eurodrive’s trained engineers, is able to provide a fast response. Its Complete Drive Management (CDM) service is also available from the new site, as is its Premium Protection Package which provides an additional 12 months warranty in addition to the two years already provided on new products.
Expand the possibilities for autonomous material transport New HD-1500 Mobile Robot from OMRON with 1500kg Payload Capacity The 1500kg payload capacity of the HD-1500 from OMRON enables transportation of large automotive components such as car chassis and voluminous pallet size payloads - items that would have traditionally been moved using forklifts.
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Control up to 100 mobile robots with different sizes, configurations and payload capacities under one system to automate complex material transport and logistics applications with OMRON’s industryfirst Fleet Manager. Contact us for proof-of-concept testing!
PROCESS VALVES
FIVE TIPS FOR SELECTING THE CORRECT PROCESS VALVE Choosing an industrial valve for process applications depends on a variety of parameters. Matthew Glicksman offers five tips to help with process valve selection.
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any times, the choice of valve type – ball, butterfly, gate, angle seat, or solenoid – rests on installed base or tradition. For example, a water treatment facility tends to use butterfly and gate valves for cost effective throughput. Some applications fall into a grey area where multiple valve types could fulfill requirements. In these cases, there is not always a right answer or a clear preference for industrial process valve selection. Below are five tips and tricks to help determine which process valve is most suitable based on a variety of parameters. The comparison between valve types is intended to be a guideline for most general-purpose applications and may not apply to more unique or extreme conditions.
and polytetrafluoroethylene (PTFE) seats. PTFE is a plastic said to have a low coefficient of friction and good insulating properties. However, the larger an angle seat valve becomes, the lower its pressure rating, losing some of its advantage in this category. TIP 3: Angle seat and solenoid valves are tops in terms of number of cycles: For high-cycle-rate applications, like filling machines, start by exploring angle seat valves for pneumatic automation and solenoid valves for electric automation. These have the highest lifecycle ratings, while ball and butterfly valves have the lowest. In applications where the valve may only open a few times per day, the number of life cycles are less of priority, and ball and butterfly valves can be still a good choice.
TIP 4: For small footprint, look at angle seat and solenoid valves: When size or weight is an issue – skid applications, for example – angle seat and solenoid valves offer an advantage for automated solutions due to their compact nature with integrated actuating mechanisms. TIP 5: The fastest valve on the block is the angle seat: The design and internal actuation make the angle seat the best selection for fast open and close rates. These valves often are found in highspeed filling applications to provide precise and accurate volumes. ! Matthew Glicksman is product manager – process automation at Festo. The article originally appeared on www.controleng.com.
TIP 1: Butterfly and gate valves are typically the best fit for lines of greater than 2in: The principal reason to consider butterfly and gate valves for pipes 2in and larger is because these valves scale up to larger sizes more cost effective than ball, angle seat, and solenoid valves. Butterfly valves have the best price of the two, and they are the easiest and most cost-effective to automate. Gate valves, on the other hand, are best for slurry, sludge, high particulate media and proportional control valve applications. TIP 2: For high pressure and high temperature, ball and angle seat valves have a clear advantage: As pressure and/or temperature increases, ball and angle seat valves provide an overall advantage due to the standardisation on highly-resilient materials like stainless steel housings
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Figure 1 shows how the two standard industrial valves compare in relative terms to important considerations for automated applications. A one-star rating has the lowest relative value in the category while a three-star rating offers the highest. Courtesy: Festo
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| PI11-01E |
Automation and process technology in a single system: with PC-based Control
www.beckhoff.co.uk/process With a comprehensive range of components for explosion protection and the common interfaces in TwinCAT, Beckhoff offers the possibility to integrate automation and process technology in a system without barriers into Zone 0/20. The range extends from the narrow, intrinsically safe EtherCAT Terminals from the ELX series and the high-grade Control Panels and Panel PCs from the CPX series through to EtherCAT, the fast process technology fieldbus, and the TwinCAT control software with specific process technology interfaces. This allows users to directly connect intrinsically safe field devices and to realise integrated control architectures with barrier-free process technology.
TwinCAT 3: with process technology interfaces
Complete EX range: from Panels and Panel PCs to the I/Os
NEW PRODUCTS
Machine guarding interlock range gets smarter Euchner has added new Modular and Classic variants to its Multifunctional Gate Box (MGB) range, which was created to provide a totally integrated lock and handle solution. The MGB2 Modular and MGB2 Classic offer more variations, additional functions, different networking options and intelligent communication features, including diagnostic data, to help reduce equipment downtime and increase productivity. The MGB2 offers a combination of a safety switch, bolt, escape release and door locking mechanism rolled into one. Some production processes need an integrated emergency stop to safely stop the processes, while others need additional request and acknowledgement buttons fitted directly onto the safety
door. The MGB2 Modular and Classic solutions can be adapted to meet individual requirements for integrated operator controls and indication. MGB2 Modular uses PROFINET PROFIsafe to communicate all the safety, non-safety and diagnostic signals to the main controller. It also includes a built-in web-server to allow straightforward interrogation of the unit without the need for specialist software
or programming knowledge. The locking modules can be equipped with controls such as pushbuttons, selector switches, key-operated rotary switches or emergency stop buttons as needed. Submodules allow up to six different control elements in the locking module, which can be replaced with the minimum of disruption due to their hot-pluggable features. Only one fieldbus module is required for up to six locking modules. Besides fewer devices, the user also requires less on-machine cabling and PLC I/Os. If space is limited, the bus node can be installed remotely in another suitable location. The MGB2 Classic is hard-wired directly to the relevant control system – making it a good solution for non-networked installations.
Multifunctional pressure sensing solution SICK has upgraded its pressure sensor offering with the multifunctional PBS Plus, combining electronic pressure control, measurement and real-time monitoring in one IO-Link enabled device. The sensor is said to combine application versatility and highmachine availability with an improved measurement capability between 0.4 and 1000 bar (gauge pressure).
Its 0.5% accuracy, and a scalable analogue output with 5:1 turn-down ratio, supports the ability to set even small measurement ranges to suit the application. The corrosion-resistant stainlesssteel membrane and IP67 heavy-duty plastic housing make the sensor a good solution for many common process applications, such as measuring system pressure, hydrostatic level measurement
or monitoring cylinder pressure in hydraulic presses. The SICK PBS Plus pressure sensor sends process data via IO-Link to the control as measured values in bar, as well as displaying and transmitting process temperature readings in °C. It records and counts over-pressure events, as well as logging operating hours together with high and low pressures and temperatures.
Ethernet connector offers fast and secure data transmission HARTING is now offering expedient interfaces, in the form of its Han 1A series of miniaturised industrial connectors for Ethernet networks which need to connect sensors, machinery, control systems, computers and data centres. The series features two new inserts to facilitate fast and secure data transmission. A D-coded version
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can provide end devices with up to 100 Mbit/ sec Cat 5 Fast Ethernet, facilitating Profinet-based communication. The second, X-coded version can provide end devices with up to 10 Gbit/sec, Cat 6A connections - HighSpeed Ethernet. This performance is required, for example, by applications involving live camera
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systems. Both data versions feature complete shielding and are fitted with crimp contacts. The Han 1A series offers compact, lightweight and versatile connectors in a rectangular plastic housing. They are said to be particularly well suited to connecting decentralised devices, promoting modular system design and supporting miniaturisation in machine building automation. They require up to 30% less space by comparison with the next-smallest rectangular connectors in the current HARTING portfolio. Control Engineering UK
ENERGY EFFICIENCY
GETTING A GRIP
With energy consumption being one the biggest costs to industry, Mike Loughran discusses some approaches that can help reduce these costs.
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ore energy efficient equipment is a great starting point for reducing energy costs! For example, a fixedspeed motor on a fan will be designed for the maximum demand of the system regardless of the airflow needed. So, even having the fan at 50% output, a fixed-speed motor will still use energy as if it were at 100%. Replacing that drive with a variable speed drive allows users to throttle back both the fan and the energy usage and make instant savings. To be truly energy efficient, it is important to understand energy usage data with much more context. Achieving the required level of contextualised data requires a fully connected enterprise with data enabled technologies throughout. The latest plant hardware is built with data in mind and can be connected to the Enterprise Resource Planning (ERP), Historian and control and monitoring software or SCADA systems. Such a system enables: • Real-time information display about assets’ energy usage to mitigate peak loads. • Defined energy costs per product. • The capability to automate legal requirements regarding documentation of energy usage. Being armed with actionable intelligence gleaned from enterprise data offers ways to optimise energy usage. There are other benefits, as equipment that runs less efficiently often requires greater attention.
Legacy equipment Installing new hardware is not always an option. Legacy equipment, designed to operate for many years, was often installed before the data capability of the Industrial Internet of Things era, Control Engineering Europe
so many process businesses are unable to retrieve accurate energy usage data and, in some instances, the only way to know how much energy equipment is using is to manually read a meter, record the output and then log it into another system. Achieving real-time energy usage control requires a network of hardware and software in constant communication. From sensors on equipment through to energy management software dashboards that allow for real-time visualisation control; information must flow freely throughout the plant. Operating legacy equipment does not preclude engineers from receiving these benefits. However, the correct software combination to unlock these capabilities must be deployed. With a robust system in place, it is possible to meet the requirements for reporting and define the assets that use the most energy. A recent example of the benefits of such a system involved a metal forge keen to reduce its energy consumption. The assets in the plant that used the most energy were the three furnaces. By allowing communication between the furnaces, it was possible to reduce energy consumption without affecting output by never operating more than two at full output at any time. In this particular example, the company saw energy savings from the reduced energy
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load being pulled down from the grid and was even able to negotiate existing contracts with energy suppliers based on actual usage data, further reducing energy costs.
Conclusion There is no one size fits all approach to reducing energy use. Whether a plant is running legacy hardware or a brand-new manufacturing facility with the highest level of real-time analytics, results will vary from plant to plant. And how facility owners approach energy management will also vary as processes differ. The ubiquitous and unvarying benefit of energy use management is seen on the bottomline. No matter what is manufactured, or the process being undertaken, getting a grip on energy use will hit the constant objective facility owners have for saving on fixed costs. Environmental impact is something manufacturers must take as a personal responsibility, even the slightest changes within facilities reduce the emissions from power plants. Reducing the by-products that come with energy production creates a cleaner and safer environment for all future generations to come and only by taking care of the environment can we continue to expand human possibility. !. Mike Loughran is CTO at Rockwell Automation. September 2020
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CONTROLLERS
THE RISE OF THE PAC
David Humphrey explains the difference today between a PLC and PAC and offers advice on which would best suit different applications within the manufacturing environment.
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he term PAC is often used as a synonym for a programmable logic controller (PLC), but there are some important differences. A programmable automation controller (PAC) is an open control platform that supports and integrates multiple automation disciplines – typically logic and motion control – but also other functions. A common tag database to which all devices have access ties the platform together. Developed in the 1960s as a replacement for hard-wired relay systems, the PLC quickly became the machine control workhorse in factories around the world. Designed initially to solve bit-logic, PLC capabilities grew rapidly over the decades – Integer and floating-point variables were added together with high-level mathematical operations, and a slew of hardware modules were introduced to address specific manufacturing tasks, from weigh-scales through to machine vision. Five PLC programming languages were standardised under IEC 61131-3, and industrial networks started the trend to connected machines. Plant-floor software typically runs on industrial PCs (IPCs), ruggedised versions of their office brethren that can be installed on the plant-floor close to the process. As more data are collected, stored and processed locally, PLCs and IPCs are now often integrated into the same chassis. Alongside this journey, other devices for machine control – such as motion controllers – quickly evolved and needed to be integrated with PLCs, so a marriage of the two became inevitable. With the launch in the late 1990s of new PLC platforms such as ControlLogix and SIMATIC S7, the term PAC was coined by Craig Resnik, an ARC analyst, to define
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this new concept. These platforms are ‘open’ in that other devices and systems can communicate with them via industrial networks with ‘open’ protocols such as Profinet and EtherNet/IP. In the 1990s we also saw the dawn of industrial software, which has been transforming automation solutions ever since. Windows-based visualisation software was added to PLC solutions and CRT terminals were replaced by LCD operator panels with touchscreens. Manufacturing execution systems (MES) software also emerged as a layer between the PLC and enterprise software.
A software explosion The past two decades have witnessed an explosion in the market for industry software. Product lifecycle management (PLM) software brings together the worlds of product and process design and simulation, helping to shorten timeto-market with the introduction of the digital twin, a software rendition of a product or production equipment that accompanies the ‘real thing’ from design through operation. Today, the PLC is well integrated in the design process and PLM software can generate PLC code automatically. According to ARC market research, PACs now make up nearly two-thirds of the $12 billion PLC market,
and this segment is growing faster than traditional PLCs. So, why did the PAC become so popular? One reason is that when a vendor launches a new product today, it is much more likely to be a PAC than a traditional PLC. Machine builders and end users no longer want to spend time making dissimilar systems, instead preferring to buy integrated solutions. Today, most large and many small controllers qualify as PACs. Only lowcost micro and nano controllers are still considered to be PLCs. Another reason for the migration from PLC to PAC is the challenge from software-based and virtualised controllers. A software-based controller is often a good choice in applications that gather, store and process a lot of production data during manufacturing, because these data can be shared easily with other software running in the same environment. While PLC functionality has come a long way, data processing and storage are not among the PLC’s strengths. On the other hand, traditional PLCs are still the preferred solution for applications that require speed and repeatability, quick and simple deployment, and above all – low cost. ! David Humphrey is research director, Europe at ARC Advisory Group.
The market for PLC and PLC-based PAC (Millions of US Dollars) Source: ARC Advisory Group.
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MACHINE CONTROLLERS
Sponsored article
LOGO! SIEMENS SMALLEST CONTROLLER GOES CLOUD!
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hy is cloud connectivity such a big deal? If you need more transparency in your application, want to analyse machines or distributed systems a cloud connection is the right choice. All controllers from Siemens offer a cloud interface to connect to the IoT in the future – from small to large, from simple to complex. SIMATIC controllers offer an open interface via MQTT protocol to connect to Amazon Web Services (AWS). LOGO! will offer a preconfigured interface to AWS, allowing new business models and functions to be implemented. From data analysis and push messaging, to secure remote access for visualisation and control, the new AWS cloud connectivity that will soon be available as part of the LOGO! v8.3, opens up possibilities for new applications as well as providing a cost effective method of connecting existing machinery to the AWS cloud environment. By connecting remote assets to a central system, users can monitor service life to plan maintenance across a globally installed machine product, or record performance data to implement process improvements and improve product quality with the benefit of remote alarming, data logging, or indeed any other feature contained within their AWS cloud environment. Alternatively, cloud connectivity can simply provide an easy and secure route to access the LOGO! web pages remotely.
A good choice for cloud connectivity? LOGO! controller has become the first choice for those wishing to control a simple machine or process. Its flexible and modular concept allows users to connect to a range of digital and analogue standard signal types, as Control Engineering Europe
well as the capability to communicate with the SIMATIC controller range, and even third-party systems via its Modbus TCP communication protocol. Because LOGO! includes, as standard, a built-in web server for building/hosting web page designs, as well as being able to communicate through SMS and email messaging using the CMR2020 module, there is plenty of power embedded within the LOGO! controller portfolio. The simplicity of LOGO! has always been key to its success. Writing logic programs is easy with the drag and drop LOGO! Soft Comfort programming software environment. This functionality is even utilised when configuring communications between LOGO! Controllers – yes they can even be networked together to distribute control over an Ethernet network! If you would like to try this for yourself, you can download a demo copy of the software from this link - https:// sie.ag/3atf0Af To make the new cloud connectivity as simple as possible, existing software tools are used so that no new learning is required. The setup of the cloud connection is performed via the existing Properties menu where extra tabs of configuration will allow users to securely login to their AWS cloud account and allocate the addresses from the LOGO!
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program that will be made available to the cloud. For building visualisation, there will be a new version of the LOGO! Web Editor software. Existing web pages can be included in a cloud environment via a simple tag setting change, or new pages can be created specifically for cloud hosting, making use of a new selection of display and control elements in the new software version. Using these existing tools and skills, users will be able to pick up the LOGO! v8.3 devices and connect to the cloud with no more effort than would normally be used to setup a program and web pages. !. For more information go to: https://sie.ag/3atfczt. September 2020
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CONTROLLERS
ADDING MACHINE CONTROLLERS TO THE FACTORY FLOOR Martin Gadsby explains how factory automation projects can leverage the most suitable machine control solutions.
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achine controllers are at the heart of Industry 4.0 applications. They allow factories to run automated processes while ensuring product quality, consistency, efficiency and high throughput. This is why choosing the right solution and implementing it correctly can make a significant difference to the success of an industrial automation project. Having a clear overview of the intended automated application and what it needs to achieve are the first aspects to consider when selecting a machine controller. This helps determine the equipment’s operational needs and the desired results expected from its control system. Based on this knowledge, businesses can identify controllers that meet these requirements and functions.
The right capabilities Traditionally choosing a controller would come down to whether programmable logic controllers (PLCs), programmable
automation controllers (PACs) or industrial PCs (IPCs) were most suited for a given application. However, the boundaries between PLCs, PACs and IPCs have now blurred, as their functionalities are often overlapping. So now it is important not to focus on identifying a type of controller, but rather choose a product with the capabilities to address the application’s known key requirements. Also look for solutions that have the ability to grow in the future to address the need for change. For example, when the position or velocity of machines needs to be operated with high accuracy and precision, it is necessary to implement high-performance, high-speed motion control solutions. Therefore, the controller should offer appropriate response times and dynamic tracking, independently of whether it is a PLC, PAC, IPC or dedicated controller. Similarly, if an application requires the use of Proportional Integral Derivative (PID) algorithms to regulate a machine or process, such as temperature control,
choosing a solution with built-in PID functions can be helpful, making it possible to reduce the time, cost and resource utilisation associated with programming these functions. Systems integrators should be able to help navigate the variety of solutions available and can help to determine the best controller for a particular application. Consulting an expert from the very beginning of a factory automation project – from the very start of the process design before control platform vendor discussions start – will help lead to the specification of the correct control platform and also to the optimisation of factors such as product and production quality, efficiency and ease of use, all of which can have a direct effect on return on investment (ROI). It is important that the initial process design is completely agnostic in relation to control system vendor. However, it is critical that an automation expert is involved, to point out at an early stage a function or feature that may have a
Skilled automation specialists and system integrators can help deliver machine control solutions that address the particlar needs of an application.
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CONTROLLERS significant financial impact and help direct the design into a highly effective solution. By working with skilled specialists, companies can ensure they are opting for a compatible and costeffective solution.
The right controller Even after the optimum machine controller has been selected, correct programming will also play a central role in ensuring the best performance in operation. In effect, machine or process availability is optimised through good coding. The right code can provide a solid backbone to make automated solutions scalable and flexible. It is important to program controllers in a way that is straightforward, that minimises complexity and is easily maintainable. In addition, documentation should be created and associated with the code. This helps to make a programme easier to understand and modify. As a result,
engineers looking to modify functions or upgrade the system can do so in a short space of time. Depending on the process, compliance with standards such as International Society of Automation’s guidelines ISA88 for batch process control and ISA95 on automated interfaces between enterprise and control systems should be considered. In addition, the code should be modular, well structured, well annotated, robust and easy to analyse to allow engineers and operators to quickly troubleshoot it. Well documented stress testing, such as factory acceptance testing, is strongly recommended in order to achieve a seamless site installation. To benefit from reliable, accessible and highly effective controller codes, businesses should rely on a specialist with experience in programming the selected control system. A system integrator should also be able to provide key insight into the
MASS FLOW CONTROLLERS for Air and Specialty Gases
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requirements to connect machines and controllers with other components or facilities. As Industrial IIoT-driven applications become increasingly popular, it is important to make sure that the installed controllers are not simply self-contained islands of automation. They should be integrated in order to share data with different machines, units or enterprise systems. Control engineering plays a crucial role in the development of industrial automation solutions. Involving a system integrator from the earliest stages, when specifying the automation strategy, gives the best chance of creating an efficient and effective solution. In addition, businesses can leverage flexible and scalable control set-ups as well as wellorchestrated and seamlessly integrated solutions, to reap the full benefits of Industry 4.0 applications. ! Martin Gadsby is director at Optimal Industrial Automation.
FUNCTIONAL SAFETY
WHY SHOULD YOU BOTHER WITH FUNCTIONAL SAFETY MANAGEMENT? David Green explains why functional safety management guidance is important.
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or over 60 years the provision of safety protection within hazardous industries across Europe has relied on instrumentation systems and the utilisation of hardware only components – such as electromechanical relays, pressure switches etc – was commonplace. The term utilised for such systems is Functional Safety (FS) and the management of these systems is as important to the effective operation as the technical implementation of the solution.
Legislation The European Union SEVESO III directive (2012/18/EU) is the framework which provides guidance for member states to follow with regards to the prevention of major accidents involving dangerous substances. The member states are then obliged to implement this in their local laws. The first edition of the directive was produced in 1982, this was revised
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in 1999 with the SEVESO II directive. The main change between the first two revisions was the inclusion of the requirement to have a safety management system for the establishment. This revision for some member states resulted in little change to the legislation, as their systems already included this requirement for establishment operators. However, in other member states this was a new requirement that needed to be incorporated.
Requirements The safety management system should cover all aspects of safety which contributes to the safe operation of the facility. This includes a full process safety management scope, including (not exhaustive) relief streams, hazardous area / ATEX, Functional Safety systems. The progression of technology in the 1980’s led to the development of International standards for the specification / requirements for FS
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systems. The issuing of IEC 61508 (Functional safety of electrical / electronic/programmable / electronic safety-related systems) was the first standard that provided common guidance across the globe. This covers safety-related systems within electrical, electronic and programmable electronic systems. The standard has been used to develop other sector specific standards (such as IEC 61511 for the process sector). The IEC 61508 series of standards each include requirements based on management, competence, auditing, and technical requirements. There is a misconception that the standards and controls of instrumented systems are purely related to technical requirements and achieving a Safety Integrity Level (SIL). The omission of the correct management system will lead to potential issues resulting in the inadequate definition, design, maintenance, and modification to the systems resulting in unacceptable risk levels to the operation of the facility. The FS management system (FSMS) should define the procedures, techniques and controls required for the full safety lifecycle, from design concept to decommissioning. This should be included within the company quality management system to ensure that the system is maintained with regards to the quality governance / auditing programs of the organisation. An FSMS should include the following key components: Functional safety governance: • Roles and responsibilities • Competence and training requirements for all personnel involved with safety-related systems. • Supplier management. Safety lifecycle documentation: Control Engineering Europe
Control Engineering Europe
Conclusion The correct implementation of an FSMS will ensure that the company meets the standard requirements for the SEVESO III directive for the Instrumented protection systems. The better definition within the system will assist the staff within an organisation to implement, maintain and manage the systems more efficiently. There is no off-the-shelf system that suits every organisation – it needs to be appropriate for the organisation and the equipment that is being protected against. The most important aspect is that there is a robust system in place. !
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The inadequate definition of an FSMS will lead to issues of business continuity. Key personnel leaving the organisation will lead to the organisation being exposed to implementing inadequate systems. The ultimate consequence would be an incident and there have been many globally due to failed safety-related systems, including Buncefield in the UK with non-operation of the high high trip (human error/equipment failure), Capeco in Peurta Rico when level systems failed and there was no high tgh trip (design error), and Deep Water Horizon in the Gulf of Mexico which was as a result of blow out preventer failure (equipment failure).
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But, why bother with an FSMS? The answer to this question is that implementation of an FSMS does not only satisfy the regulatory requirements under the relevant legislation for the implementation of the SEVESO III directive, it also provides benefits to the organisation. These include: • The definition of the rules within the organisation ensure consistency between different plants / units / machines irrespective of the personnel involved or the project implementing the functionality. • It ensures the adequate implementation, operation and
maintenance of the safety-related functions. This will mean that the system will operate as expected when called upon and provide the required protection to prevent the hazardous event from occurring and the harm to people, the environment or the asset. • It provides definitive guidance to those managing the competence of personnel and sub-contract organisations to allow better training and procurement processes.
from
• Definition of the documents to be produced during the lifecycle of the safety-related system. For example, during all phases including design, operation, maintenance, and modification. Procedures: • Definition of the company rules to be used in the safety management of the safety-related systems. • Definition of the techniques to be used within the company (including definition of the acceptable risk targets, methodologies for SIL determination, definition of preferred data sources, modification etc). Assurance measures: • Definition of the auditing requirements (during each safety lifecycle phase). • Definition of the independence requirements of those being requested to audit the activity. • Validation and assessment requirements in advance of the introduction of the hazards to the facility. Monitoring and investigation: • Ensuring robust recording and reviewing of observed deficiencies within the safety-related systems (e.g. failures and demands). • Processes are defined for the prevention of the repeats of issues with the specific location or similar equipment within the facility.
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FUNCTIONAL SAFETY
David Green is associate director at Engineering Safety Consultants. He can be contacted for support in reviewing FSMS at d.green@esc.uk.net. September 2020
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WIRELESS TECHNOLOGY
IS 5G READY FOR DEPLOYMENT IN THE REAL WORLD? Brendan O’Dowd comments on the rise of 5G mobile technology, as the industry gets set to test its ‘six 9s’ capability.
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ntil the launch of 5G, every previous generation of mobile phone technology was primarily intended to improve the operation of the handset. It was not until 4G technology was adopted in 2008 that real smartphone capability was enabled and 4G mobile broadband led to the development of smartphone apps, a proliferation of multimedia and streaming services, and high-speed internet access on-the-go. The installation today of 5G networks marks the first time that a new generation of mobile technology has been built around the needs of machines and systems rather than of handset users. The telecoms industry’s plan for 5G envisaged technical breakthroughs in three main parameters – latency, reliability and determinism; the density of connections; bandwidth, and speed of data transfer. The reason for enhancing performance in these parameters was to enable real-time monitoring and control of dense concentrations of devices communicating concurrently. The requirement for latency, density and bandwidth is met by three technology enhancements embodied in the 5G standard specifications. These are: • Ultra-Reliable Low Latency Communication (URLLC) for real time control systems. • Enhanced Mobile Broadband (eMBB) to support new bandwidthdependent use cases including augmented and virtual reality. • Enhanced/massive Machine Type Communications (eMTC) for low-power, wide-area wireless networking.
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These features make 5G technology capable of supporting the requirements of factory control systems for real-time determinism and ‘six 9s’ (99.9999%) availability. Yet the real-world experience of most mobile handset users accessing 2G, 3G or 4G networks is still, to this day, of black spots where coverage is weak or non-existent, and of occasional and unpredictable dropped connections. So, is there a realistic prospect that mobile phone technology will be used to connect mission-critical, time-sensitive industrial machines?
Longevity of 4-20mA For all the hype around state-of-the-art 5G technology, the reality is that most new process equipment installations today include provision for control via wired 4-20mA links – a proven,
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dependable technology. This speaks to industry’s need for certainty and the avoidance of risk when implementing mission- or safety-critical control systems. But the tides of change cannot be beaten back for ever, and innovations in the way factories operate give control system designers good reason to evaluate 4-20mA alternatives. As Industry 4.0 accelerates the pace at which factory operations evolve, two trends are driving the introduction of new networking technologies: the introduction of autonomous mobile machinery, and the development of more flexible manufacturing facilities to meet growing consumer demand for personalised or configured products. In factory and warehouse settings, the use of autonomous guided vehicles (AGVs), cobots and other autonomous Control Engineering Europe
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WIRELESS TECHNOLOGY
mobile devices offer an effective way to increase efficiency and productivity. The new generation of autonomous mobile devices such as AGVs requires a wireless communications connection which offers low latency for real-time control, high bandwidth to carry the signals from multiple sensors such as LiDAR scanners and video cameras, and high immunity to interference – the hallmarks of 5G mobile networks. When a factory operator replaces wired with wireless connections, they also gain the flexibility to reconfigure factory equipment quickly to meet new or varied demands from consumers. The rise of e-commerce has driven rising expectations from consumers for nearinstant delivery of ordered products, and for the ability to choose from a wider range of product options than ever before. The ability to move production or process equipment more quickly and easily is growing in value. A fixed, wired communications infrastructure is less flexible than a wireless network to which equipment can connect from any location. Wireless networks also reduce the cost, inconvenience and technical difficulty involved in installing communications cabling. Over the long term, then, factory operators are open to the benefits of wireless control capability alongside established wired communications technologies. In the immediate future, however, industry has to make a priority of its most important requirements, for high reliability and availability; security; robustness to cope with challenging industrial operating conditions; and ultra-low latency. These factors underlie the longevity of the 4-20mA standard for factory communications. And, while factory operators are looking to replace 4-20mA technology, their focus today is on the implementation of the Time-Sensitive Networking (TSN) standard for wired industrial Ethernet communications, rather than for anything wireless. TSN has emerged as the preferred standard for high-bandwidth, wired data communications in the factory,
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since it offers the ideal combination of reliability, robustness, a high datatransfer rate, low latency measured in microseconds, and easy integration with enterprise IT network systems. Because the TSN specification is a standard benefiting from cross-industry support, it is rapidly developing a rich ecosystem of suppliers of TSN components and systems, which includes Analog Devices.
Validating the claims Alongside the implementation of TSN networks, however, the scope for enhancing factory operations, through the implementation of wireless networking, is also coming under active evaluation. Some early adopters in the industrial community have already begun the work of testing, validating and evaluating the operation of 5G networking systems inside the factory, while concurrently replacing legacy 4-20mA systems with new TSN Ethernet networks. This validation process will find the most suitable applications for 5G technology. So, factory operators are now starting to test innovative features of the 5G specification, such as ‘massive MIMO’ capability – the use of arrays of antennas to provide multiple physical transmission paths between transmitter and receiver. An array may be configured to form multi-antenna beams transmitting to multiple receivers. This allows the implementation of techniques such as channel hardening, beamforming, rapid channel estimation, and antenna (spatial) diversity, the effects of which are to dramatically improve reliability and reduce latency compared to 4G mobile networking. Indeed, one of the aims of the developers of the 5G standard was to enable wireless networks to achieve six 9s reliability for packet delivery, comparable to that of a wired Ethernet network, and equivalent to a packet error ratio of 1:1,000,000. Latency of just 1ms is also possible, which is well within the limit imposed by many industrial
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control applications. The question is, can this performance be achieved in the real-world conditions experienced inside a factory, where communications equipment might be subject to multiple sources of highamplitude radio-frequency interference, transient voltage events, high temperatures and other disturbances? In validating the real-world performance of a 5G installation, factory system designers have a choice: they can take advantage of 5G coverage provided by mobile network service providers. But the 5G standard also makes provision for the implementation of private systems, or so called Non-Public Networks (NPNs) covering, for example, an industrial campus or a large factory complex. Different industrial users and use cases will favour a different choice of public or private network. The implementation of 5G networking in the factory is also facilitated by the development by mobile network operators of the OpenRAN (Open Radio Access Network) specification. This has opened up the market for 5G radio and core equipment to a broader range of suppliers in addition to those which have traditionally served the telecoms equipment market. This has the potential to broaden the choice of equipment available to meet the needs of use cases different from those of the mass-market public network operators, and to encourage the development of 5G products by suppliers which are focussed on the industrial market. While the immediate future clearly belongs to wired industrial Ethernet technology, it is easy to imagine a future in which AGVs and robots inside the factory transmit and receive time- and mission-critical data payloads via a 5G network – and the availability of 5G network coverage means that this is an actual rather than a theoretical possibility today. ! Brendan O’Dowd is general manager (Industrial Automation) at Analog Devices. Control Engineering Europe
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WIRELESS TECHNOLOGY
CONNECTING INDUSTRIAL APPLICATIONS TO A PRIVATE 5G NETWORK Control Engineering Europe finds out more about an industrial 5G router for private networks, by speaking to Frank Hakemeyer, director of communication interfaces at Phoenix Contact Electronics.
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hoenix Contact, Quectel and Ericsson have been collaborating to jointly develop and deploy the first industrial 5G router for local industrial applications in a private 5G network, to allow industrial applications such as machines, controls and other equipment to be connected to a private 5G network, and thus be orchestrated in their resource usage, priority and behavior. This offers an advantage over previous mobile radio solutions, which can only use all – mostly license-free – radio bands with a best effort principle and which have to accept performance losses in equal measure when the radio spectrum is heavily occupied. Q: What benefits might this system offer for end-users in industrial applications, when compared to other mobile radio systems using mostly license-free radio bands? Phoenix Contact has a long term experience in license free wireless solutions based, for example, on Bluetooth, Wifi, or Trusted Wireless and on licensed wireless solutions based on cellular technology such as 2G, 3G, or 4G. We have offered wireless products and solutions for nearly 20 years so can create the right technical solution for a particular application. From experience, license free wireless solutions mainly suffer from three main challenges: • No guaranteed quality of service – due to the nature of using a license free frequency band you can never manage and guarantee the communication. It is always a ‘best effort’ approach. Medium Access Mechanisms like ‘listen before talk’ gives all users of the license free
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band an equal access and an equal degradation of service in case of congestion of the band. In cellular networks the frequency bands are licensed to operators, or in private networks to plant or factory owners. • In license free wireless solutions there is no single technology that works for all use cases. You need to select the technology according to the requirements of the use case. In the end you have a heterogenous world of technologies and products which are difficult to combine and challenging to manage at a single location. In a 5G network the management of resources, the orchestration of all applications and the prioritisation of use cases is a characteristic of the architecture of the cellular technology. • There have been activities to develop industry-specific, license free wireless solutions – WirelessHart, or some proprietary technologies such as Trusted Wireless from Phoenix Contact. These can offer a good solution but they will never become a mainstream technology such as cellular based communication. The amount of engineering effort, optimisation and cost reduction is not comparable to a mainstream technology. So, the 5G approach – especially with new enhancements (private 5G networks, network slicing, ultra-reliable low latency communication, etc.) can overcome challenges from the license free world. Q: Could you suggest some typical industrial applications that would benefit from this solution?
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Clearly any mobile application could benefit. Some applications, like AGVs (automated guided vehicles), electric monorail conveyors, mobile tools, or machine parts that can be part of different production lines, can be difficult to realise without wireless communication. But I do not think there is a single killer application for an industrial (private) 5G network. I believe the biggest potential of a private 5G network is to become a new communication backbone in industrial automation. If the factory or plant owner can run a variety of applications through the same 5G network infrastructure, if they can manage and prioritise applications within a single communication network, this is the strongest reason to make use of 5G. Q: Could you go into more detail about the ‘industrial-grade performance’ of the solution? The first industrial 5G Router from Phoenix Contact focusses on stand-alone (SA) networks. This is the description for a 100% 5G based infrastructure. The opposite is nonstand-alone (NS), which means you need a 4G and a 5G network to operate your devices. If you run a 5G SA network in a private mode (also called campus network) then you can connect your industrial applications such as AGVs, robots, sensor concentrators etc. via the 5G Router to your network. Of course, the 5G Router is designed for industrial use, meaning the circuits are designed for industrial environments and the interfaces and the feature set are specified for the industrial automation world. Control Engineering Europe
WIRELESS TECHNOLOGY
5G SA private networks and most users want to make use of it to realise their first 5G installations.
Q: Could you explain how the solution could be integrated into an existing plant set up? The 5G private network can become a wireless communication backbone for many different use cases in the plant or factory. To set-up a private network a plant or factory owner must decide whether to operate and manage this network on their own, or whether they want to have a service provider doing so. It is important to think about this decision and especially how the data
comes ‘out of the 5G network’ and how it is re-inserted into the automation network (network and control level), or the ERP level. Of course, this is very much related to the different use cases running through the 5G network. The new TC 5G PRIVNET ROUTER enables users to connect different use cases by Ethernet to the 5G private network. It supports the release 15 specification of 3GPP and it can be used in SA and NSA networks. The main focus with this device is on
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Q: Should end-users take any security precautions to protect their networks and data when employing this solution? The TC 5G PRIVNET ROUTER offers many security features such as VPN connections based on IP Sec or OpenVPN, as well as a firewall. These are well known features that are used if data somehow runs through the public networks (cellular or wired) – which means in the end: the Internet. So, in those cases where the application is connected to a public cellular network from any carrier, it is always recommended to use these mentioned security mechanisms. If it is a private 5G network, then those mechanisms are not needed and the wireless communication between a base station and the devices will already be secured by 3GPP mechanisms. !
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FINAL WORD
LOOKING AT THE BENEFITS OF LEARNING LADDER LOGIC FOR INDUSTRIAL PROGRAMMING While ladder logic is challenging for industrial programming, it is a valuable skill for engineers looking to enhance their skill set, says David Breen.
I
started programming as a teenager, received a bachelor’s degree in computer science and have worked as a software and web developer for over a decade. I was a programmer before attaining the degree: teaching myself, learning new languages and trying new things. Transitioning to industrial programming was the biggest changeup in my history, but also a valuable one.
Adding ladder logic The first thing you notice when adding ladder logic to industrial programming is that it looks like a bad visual integrated development environment (IDE). Like somebody tried to give you a flowchart you could drag and drop onto. Considering it is mostly a mix of logical gates, it really does behave like that. Once you start to tinker and get your head around it, however, it is usable. Yes, basic structures like loops are a mess and the variable structure is ugly. The whole program is stuck in an infinite loop. The thing that’s going to slow you down the most is how much you need a mouse. With object-oriented language (OOL) such as Java, Visual Basic (VB), or any common scripting language, navigation requires very infrequent mouse usage. Get to the place you want to edit and start typing. There’s a double-click here and there, but it’s mostly typing because it is all characters and symbols. To speed things up, many industrial design engineers will have an autocompletion function built-in.
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Learning ladder logic can be challenging, but it is a valuable skill for those working in industrial programming. Image courtesy Breen Machine Automation Services.
Navigation
Looking forward
In ladder logic, keyboard shortcuts can keep things moving, but navigating between rungs with only the arrow keys can be tedious, slowing down the execution, and derailing your train of thought. Ever walk into a room and forget why you went in there? Imagine that happening every 10 seconds. OOL and a modern IDE provide autocompletion of variables and method names, easy navigating, better code organisation and structure and more effective use of screen real estate. Instead of a bunch of boxes and arrows to space things out, all that appears are letters and numbers. The user can see much more information without having to scroll around. The biggest hurdle when switching to industrial programming is how slow it is. It is a beast of its own in a variety of ways, and there is only so much that can improve speed. Things are going to take longer to write in ladder. It’s a given.
As for the other issues, they are remnants of the early days of an industry that has been slow to adapt. That is exactly why I think the industry needs more PC programmers. The manufacturing industry hasn’t seen significant changes to its programming methodologies in decades despite immense improvements in other fields. It needs fresh ideas and modern concepts. PLC programming is not fun, not efficient and not easy to maintain. And yet, it remains a very worthwhile skill. Frankly, the more PC people who learn it, the faster we can help the industry evolve its methods to more accessible and maintainable solutions. !
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David Breen is lead programmer at Breen Machine Automation Services. 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 projectfocused 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
TO BE FEATURED IN THE CEE PRODUCT FORUM Contact Adam Yates on +44 (0)7900 936909 or email Adam.Yates@imlgroup.co.uk 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
Control Engineering Europe
engineers, control room console (and HMI) designers and vendors, control room operators, engineering consultants, engineering contractors,
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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
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