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APRIL 2021

SOLUTIONS 13 | Anatomy of an effective preconstruction strategy Subcontractor prequalification one important parameter

13 15

COVER: Manufacturers are moving their most important business and technology applications to cloud environments. Courtesy: Global Shop Solutions

15 | What you need to know about cloud computing The why and how of a move lots are making

EDITOR’S INSIGHT 5 | The instrument technician’s evolving role

INSIGHTS

18 | Integrated automation suites solve 24/7 connectivity problems Edge solutions deliver data insights that increase uptime

7 | Let IIoT do the dirty work Sewage treatment case study tracks early success, including accuracy and reliability

9 | Chemical manufacturers, oil & gas face growing technical obsolescence Companies seek support in knowing what they have and what they need

18 21 | Robotic vacuum impregnation reduces scrap due to porosity Small footprint of work station integrates into existing workflow

PLANT ENGINEERING (ISSN 0032-082X, Vol. 75, No. 3, GST #123397457) is published 9x per year, monthly except in January, July and November, by CFE Media, LLC, 3010 Highland Parkway, Suite #325, Downers Grove, IL 60515. Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. PLANT ENGINEERING copyright 2019 by CFE Media, LLC. All rights reserved. PLANT ENGINEERING is a registered trademark of CFE Media, LLC used under license. Periodicals postage paid at Downers Grove, IL 60515 and additional mailing offices. Circulation records are maintained at CFE Media, LLC, 3010 Highland Parkway, Suite #325, Downers Grove, IL 60515. E-mail: pe@omeda.com. Postmaster: send address changes to PLANT ENGINEERING, PO Box 348, Lincolnshire, IL 60069. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: PO Box PO Box 348, Lincolnshire, IL 60069. Email: pe@omeda.com. Rates for non-qualified subscriptions, including all issues: USA, $165/yr; Canada/Mexico, $200/yr (includes 7% GST, GST#123397457); International air delivery $350/yr. Except for special issues where price changes are indicated, single copies are available for $30 US, $35 foreign. Please address all subscription mail to PLANT ENGINEERING, PO Box 348, Lincolnshire, IL 60069. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, and regardless of whether such errors result from negligence, accident or any other cause whatsoever. Technology TM

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PLANT ENGINEERING

April 2021

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SOLUTIONS 34 | Tools troubleshoot industrial Ethernet problems APRIL 2021

SOLUTIONS 24 | Seven shortcomings of commodity casters

Technology ranges from the simple to the sophisticated

37 | Tackle obsolescence with additive manufacturing 3D printed spare parts are a revolutionary force

The right application-specific casters and wheels can help optimize workflow

27 | Fire safety best practices for manufacturing facilities Are the lights, alarms, extinguishers and sprinklers inspected every year?

37 40 | More answers on what you need to know about cybersecurity Below are more answers resulting from a cybersecurity webcast on cybersecurity architectures, training, best practices, risk assessment and trends based on research.

INSIDE: APPLIED AUTOMATION 29 | Install medium voltage cables in petrochemical plants How to ensure code requirements are satisfied

UPCOMING WEBCASTS APRIL 13, 2021: Understand and control compressed air system costs APRIL 15, 2021: How to Tune Servo Systems: Force Control (Part 4) APRIL 20, 2021: Solving Oilfield Chemical Management’s Four Biggest Challenges To view all upcoming webcasts for Plant Engineering visit WWW.PLANTENGINEERING.COM/WEBCASTS

• April 2021

PLANT ENGINEERING

A5 | How to achieve remote automation success In a remote, yet connected world, this is how to keep pace with the changing face of automation in manufacturing

A8 | How to accelerate data visualization As the volume of industrial data grows exponentially, human-machine interfaces (HMIs) are providing improved data visualization and storytelling tools to support intelligent automation and strategic decision making www.plantengineering.com

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EDITORIAL ADVISORY BOARD H. LANDIS “LANNY” FLOYD, IEEE Life Fellow H.Landis.Floyd@gmail.com JOHN GLENSKI, President, Automation Plus jglenski@processplus.com SHON ISENHOUR, Partner, Eruditio LLC sisenhour@EruditioLLC.com DR. SHI-WAN LIN, CEO and co-founder, Thingswise, LLC Industrial Internet Consortium (IIC) board member shiwanlin@thingswise.com JOHN MALINOWSKI, Senior manager of industry affairs (retired), Baldor Electric Company DAVID SKELTON, Vice president and general manager Phoenix Contact Development and Manufacturing dskelton@phoenixcontact.com BILLY RAY TAYLOR, Director of commercial and off-highway manufacturing The Goodyear Tire & Rubber Billytaylor@goodyear.com LARRY TURNER, President and CEO, Hannover Fairs USA lturner@hfusa.com MARK WATSON, Senior director, manufacturing technology, IHS Markit Mark.watson@ihsmarkit.com

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Content For Engineers. That’s what CFE Media stands for, and what CFE Media is all about—engineers sharing with their peers. We welcome content submissions for all interested parties in engineering. We will use those materials online, on our Website, in print and in newsletters to keep engineers informed about the products, solutions, and industry trends. * www.plantengineering.com/contribute explains how to submit press releases, products, images and graphics, bylined feature articles, case studies, white papers, and other media. * Content should focus on helping engineers solve problems. Articles that are commercial in nature or that are critical of other products or organizations will be rejected. (Technology discussions and comparative tables may be accepted if non-promotional and if contributor corroborates information with sources cited.) * If the content meets criteria noted in guidelines, expect to see it first on our websites. Content for our enewsletters comes from content already available on our Websites. All content for print also will be online. All content that appears in our print magazines will appear as space permits, and we will indicate in print if more content from that article is available online. * Deadlines for feature articles intended for the print magazines are at least two months in advance of the publication date. Again, it is best to discuss all feature articles with the content manager prior to submission.

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and

Technology

INSIGHTS

By Kevin Parker, Editor

The instrument technician’s evolving role Until recently it might have been possible to say that plant-floor technicians were confined to relatively siloed roles. But given shortages of skilled labor in the industry, and an emphasis on lean, many of those technicians are being asked to do more, says Ryan Williams, product manager for solutions & services, Endress+Hauser USA, Greenwood, IN. In addition, today’s plant floors are populated by a widening variety of electro-mechanical, process measurement, automation control, IIoT-enabled and other field device types. Thus, today’s technicians need a toolset enhanced to meet the increased needs of the day. Using digital interfaces, instruments now transmit status, diagnostics and other information. Endress+Hauser estimates that of the 40 million of its process instruments installed worldwide, 90% are digital, smart devices. These smart instruments deliver data from the edge that is of benefit beyond the control realm, to maintenance management, asset management, inventory control and other enterprise and business applications. But Endress+Hauser further estimates that 97% of the data generated isn’t being used.

Smart talk

If a single smart instrument, such as a Coriolis meter can provide a few dozen items of status and diagnostic information and a plant has several thousand similar instruments, the host systems have to deal with huge amounts of data arriving in near real time. Instrument makers have software that uses that data from the edge to diagnose problems and schedule maintenance. Endress+Hauser’s solution for the IIoT ecosystem is called Netilion. While smart instruments provide diagnostics to indicate problems with electronics www.plantengineering.com

or subcomponents, this is often done by way of the traditional automation system. “This type of solution presents challenges. Networks can be unduly burdened with data transmissions, historians can become bloated, and there can be time lags between data collection and recognition by the IIoT software,” said Williams. An alternative solution, Williams suggests, is to deliver all of the edge data to IIoT software via the cloud, thus bypassing the automation system completely. By connecting the instruments to an Ethernet-based network, the data can be captured by an edge device to transmit it to IIoT software in the cloud.

Sources and servers

Software and hardware are needed to extract data from the plant’s Ethernet network or devices and transmit it to that cloud-based software. Netilion Connect includes the edge devices, cloud platform and application programmable interfaces (API) to do that. The API provides simplicity in achieving connectivity. Of special interest to field technicians is E+H’s Field Xpert, which includes device configuration software that directly links to the Netilion platform. Selecting the right devices and instrumentation can’t be decided on a one-sizefits-all basis. At sites including hundreds of instruments, high-speed data acquisition is used to push the measurements to the cloud. Where instruments-based edge devices run at basic speed, information can be transmitted in small amounts. “The Netilion ecosystem is based on an open-source technology platform that includes analytics software, process health diagnostics and the means to access appropriate documentation,” said Williams, thus providing technicians with what they’ll have need for in future. PE PLANT ENGINEERING

April 2021

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INSIGHTS

THE INDUSTRIAL INTERNET OF THINGS

By Caitlyn Cagglia

Let IIoT do the dirty work Sewage treatment case study tracks early success, including accuracy and reliability

s global urban population continues to grow, water pollution and water scarcity are increasingly important problems for communities, businesses, and governments. Sewage management is key to both keeping water sources clean and maximizing efficiency in reclaimed water processing. Sewage system monitoring impacts nearly every aspect of treatment plants. For many plants, monitoring is performed locally using a host computer and programmable logic controllers (PLCs). In such setups, monitoring is only accessible on-site, so traditional systems are restricted by labor cost and data availability. Isolated, in-house data monitoring not only requires expensive hardware, but also loses many advantages of big data processing, like shared history from other plants. Future monitoring systems that are enabled by the Industrial Internet of Things (IIoT) have already demonstrated advantages in performance, reliability, and affordability.

Raising the bar

PLCs have a continuing role to play as part of sewage treatment systems.

Most current sewage systems manage complex, nonlinear processes. With over a thousand different devices that require monitoring, additional complication stems from converting between analog and digital signals. Further, as cost, volume, and safety requirements become increasingly demanding, remote monitoring has become a near-term requirement for sewage treatment plants. An optimal system must efficiently process and store large volumes of real-time data, manage both digital and analog signals, and support network connectivity.

Advantages of introducing

Immense investment in IIoT devices has delivered products that are competitive in price and level of service to the installed base. Cloud processing is typically cheaper and experiences less downtime than on-site servers. Commercial cloud systems are highly tuned for big data processing, and are able to share data, such as logs, between systems or plants. IoT sensors are relatively low-cost, which allows for additional readings from new system components or multiple measurements of one component. Redundant values from several sensors on the same component can be compared to increase the accuracy of system readings, improving safety and reliability. Support of remote automatic, remote manual, or onpremise control access provides operators with flexibility to respond to alarms faster. When there is a crisis, teams already have all the critical system information in a centralized cloud database that’s easily shareable.

Benefits of PLCs w/ IIoT

There are many ways to bring automation and IIoT to sewage treatment facilities. Even in a world of IIoT, use of PLCs deliver some unique benefits. • Stable, reliable control with simple programming. While some current systems rely on a single host computer, using IIoT-enabled control improves reliability and performance by eliminating a single point of failure. • Energy efficiency, bringing cost and power savings across the plant. Energy use can be further reduced through IIoT control and system-wide optimization. • Low-profile, compact size for minimal interference with existing infrastructure. For plants that already utilize PLCs to some degree, conversion to an IIoTenabled monitoring system is further simplified.

Performance in China

Researchers have already started fielding and testing IIoT technology in sewage treatment plants in China. One particular case study replaced a traditional monitoring system that used PLCs and www.plantengineering.com

PLANT ENGINEERING

April 2021

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INSIGHTS

THE INDUSTRIAL INTERNET OF THINGS a host computer with low-cost STM32 processors and IoT connectivity via a WeChat Applet. The plant in this study sought to significantly increase daily treatment capacity from 20,000 tons to 50,000 tons. To establish reliability, the researchers outfitted each sensor with a standalone backup power supply and a redundant Wi-Fi network to avoid service outages. Specific components were also outfitted with multiple sensors for redundancy. Each user had unique on-site and remote access permissions to maintain security. Comprehensive system logs were recorded through various fault tests of the system to vet automatic responses to changing conditions. Questions remain on the scalability of their cloud service provider; however, in this simple proof-of-concept, the researchers modernized processors costing thousands of dollars to microcomputers under $100, enabled remote monitoring and control of a sewage treatment system, and utilized cloud computing to meet new capacity demands.

Efficiency in India

The World Economic Forum identified that improving wastewater treatment procedures and manage-

ment in India was a critical target to reduce pollution and supplement agricultural water demand. This has inspired further research to automate and optimize wastewater treatment, as demonstrated in another recent case study. In this case, PLCs were applied to control each treatment step: preliminary treatment, primary clarifying, aeration, secondary clarifying, and tertiary treatment. These processes remove physical impurities, like oil and grease, as well as biological impurity. IIoT-enabled sensors tracked various status indicators, including sludge volume, chlorine levels, and pH levels, to regulate and optimize the end-to-end wastewater process to maximize the amount of reusable water. With the communication between sensors, PLCs, and operators via IIoT, this system enabled successful automation of a practical process. Researchers in this study successfully reclaimed more than 98% of wastewater as safe for agricultural use. PE Caitlyn Caggia is an experienced systems integrator and solutions architect focused on analytics and artificial intelligence initiatives. Caitlyn holds her MS in Electrical and Computer Engineering from Georgia Tech.

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INSIGHTS

SURVEY ON PROCESS CONTROL & INSTRUMENTATION

By Kevin Parker

Chemical manufacturers, oil & gas face growing technological obsolescence Companies seek support in knowing what they have and what they need

esults of a recent CFE Media survey, sponsored by engineering corporation M S Benbow & Assoc., Metairie, LA, illustrate the changing landscape for instrumentation and control systems in industrial environments. Survey respondents questioned the long-term viability of the installed base of process control and automation systems in chemical manufacturing, oil & gas and other industries. In fact, nearly 60% of respondents from the chemical manufacturing industries expressed concerns about the growing technical obsolescence of these systems. Nearly 50% of respondents from the downstream oil & gas industry expressed similar concerns (See Figure 1). At the same time, companies use planned shutdowns to equip their plants for greater access to the data needed to manage their processes.

Figure 1: Nearly 60% of respondents from the chemical manufacturing industry expressed concerns about the growing technical obsolescence of their 4 systems. Courtesy: CFE Media

Figure 1: What are you top 2 concerns related to your current instrumentation and controls system configuration? Upstream

Midstream

Downstream

Chemical Manufacturing

59% 50%

47%

42%

45% 41%

37% 32%

30%

28%

www.plantengineering.com

Technical obsolescense

Challenges faced

More than 70% of survey respondents from chemical manufacturing industries expressed concerns about control software no longer being supported and 47% expressed similar concerns about PLCs, SCADA and HMIs. Nearly 40% of respondents in the upstream oil & gas sector expressed similar concerns (See Figure 2). “That software continues to be an increasing concern is acknowledgement that automation is migrating away from purpose-built devices to the use of software to deliver more process flexibility,” said Ledet. In addition, the survey found: • Nearly 40% of respondents in all industries surveyed cited concerns about the lack of an accurate blueprint of current systems and software used. • About 40% of respondents expressed concerns that their systems were obsolete given today’s IT-driven advanced control systems.

21%

Lack of skilled resources

“What we see are companies performing upgrades as a means to avoid technology obsolescence and to standardize on technologies. All of today’s replacement systems are equipped with network connectivity from the start, allowing more real-time data gathering and analytics use. But the core concerns of operators remain the same,” said Ronnie Ledet, program manager, instrumentation and controls, M S Benbow. M S Benbow supports clients from project conception to completion across a wide range of engineered systems, including process measurement and control, distributed control systems, SCADA and PLCs, analytical measurements and critical safety instrumented systems. Other topics addressed in the survey included current control system challenges as well as concerns for the future. While optimization and reliability were the respondent’s primary goals, increased networking of machines and equipment, increasingly softwarebased systems and supply chain reconfigurations are clearly part of their future.

No clear upgrade plans

• More than 40% said they saw challenges in their installed base due to lack of standardization in respect to PLCs, control software and HMIs. PLANT ENGINEERING

April 2021

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tion

INSIGHTS

SURVEY ON PROCESS CONTROL & INSTRUMENTATION Figure 2: More than 70% of survey respondents from chemical manufacturing industries expressed concerns about control systems no longer being supported. Courtesy: CFE Media

Figure 2: Which of the following is a challenge to your control engineers and technicians? Upstream

Midstream

Downstream

Chemical Manufacturing

tion (29%) or during a scheduled outage or turnaround (32%). While more than 40% of respondents say they have the in-house resources to plan and execute a migration, nearly the same number will turn to outside support for the following (see Figure 3): • To determine capabilities and technologies needed to reach operating goals (38%).

71%

53% 42%

38%

41%

42% 42% 41%

39%

37%

35%

30%

• Develop total cost estimate with feasibility analysis and cost justification (37%). Lack an accurate blueprint of current systems and software used

Parts or software no longer supported by OEM supplier

• Facility control system audits to assess current assets (29%).

Systems are obsolete given today’s IT-driven advanced control systems

The road ahead

As wou l d b e assu me d, su r ve y re sp ond e nt s expected any control system replacements to be accomplished by means of a phased migraFigure 3: More than 40% of respondents say they have the in-house resources to plan and execute a migration. Courtesy: CFE Media

"Keeping up with the latest technology and how to apply it requires a full-time effort. Knowing how to use the hardware, along with the software development tools available, is key,” said Ledet. Respondents perceive the primary goal of their facility’s efforts as being evergreen: • To increase productivity or optimize production processes (43%). • To increase equipment reliability or product quality (26%).

Figure 3: To achieve a smooth migration, what help do you need in doing the front-end engineering? Upstream

Midstream

Downstream

Chemical Manufacturing 58%

53%

50% 44%

46%

44%

42% 35%

40% 39%

37% 33%

29%

31%

24%

Develop total installed cost estimate with feasibility analysis and cost justification

•

April 2021

Facility control systems audit to asses current assets: Hardware, software and networking

PLANT ENGINEERING

Determine capabilities/technologies to march operating goals

We have the resources in-house to plan and execute

“The change that’s happened,” said Ledet, “is that facilities are getting their equipment on the network and doing that is part of today’s upgrades. Clients recognize the need to address cybersecurity risks. And they’re interested in new ways of achieving mobility and remote operations. Whether that’s labelled as the industrial internet of things (IIoT) or simply greater involvement of the information technology function in operations management is really beside the point.” While not strictly a technology issue, respondents across the industry sectors surveyed said one of their biggest concerns is a lack of skilled human resources, with nearly 45% owning up to the challenge. PE www.plantengineering.com

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SOLUTIONS PLANTS & FACILITIES By Aman Singh

Anatomy of an effective preconstruction strategy Subcontractor prequalification one important parameter

For complex capital projects, a subcontractor’s fluency with project management software — including their willingness and ability to train all team members on the software — can be a differentiator. Courtesy: Graycor Southern

or capital projects, having a preconstruction phase is known to control costs. Many contractors, practiced in their planning role, are able to accurately estimate conceptual designs, align costs with scope and schedule during the design phase. Modeling and forecasting receive a lot of attention in discussions of preconstruction best practices, but subcontractor prequalification is equally important. Along with establishing financial protections against subcontractor defaults and monitoring subcontractors during a job, prequalification is a key strategy for mitigating risk. That said, the most effective prequalification procedures go beyond a narrow focus where risk is measured only by a subcontractor’s financial status — specifically, its ability to borrow money and avoid default. At its best, prequalification is an early opportunity for a general contractor to find partners with complementary business values, streamlining the path to project success.

Prequalification part of preconstruction

Research performed by Hamzah Alshanbari, a graduate student at the University of Florida, found a correlation between project cost performance and the associated preconstruction investment. Many general contractors report success associated with preconstruction planning consistent with Alshanbari’s findings. These

general contractors find that investment in a focused preconstruction phase not only allows project teams to develop a well-structured plan but provides significantly better transparency for clients. The result is on-time, onbudget project completion and greater client confidence. Many project delivery methods emphasize the importance of preconstruction — particularly the benefit of early input from contractors, which brings an experienced viewpoint on a project’s constructability. Contractor input typically improves estimating and procurement, scope and scheduling, value engineering, waste elimination and risk identification. Maximum value can be derived by using the early contractor involvement (ECI) project delivery method, which brings contractors to the table at the earliest stage of a project, typically during the conceptual design or schematic phase.

Key qualifiers

During a recent preconstruction conference, more than 80% of respondents identified as working on construction projects with 30% or greater subcontractor participation, with several being over 50%. This substantiates the need for identifying the right subcontract partners for active management of project risks. Experienced engineer/procure/construct (EPC) contractors will assess subcontractors according to a checklist of critical considerations. Among these are: • Safety (largely based on past performance records) • Financial stability • Bonding capacity • Relevant experience • Current capacity / backlog • Reputation and references. As the construction industry moves increasingly toward the adoption of new technologies, a subcontractor’s technical sophistication may also be a consideration. For complex capital projects, a subcontractor’s fluency with project management software — including their willingness and ability to train all team members on the software — can be a differentiator. While ideally every subcontractor achieving “prequalified” status would be completely free of any trouble spots on its application, this is not always

www.plantengineering.com

PLANT ENGINEERING

April 2021

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SOLUTIONS PLANTS & FACILITIES

realistic. Fortunately, many issues can be addressed by the general contractor in a risk mitigation plan. For example, if a subcontractor is a good fit in terms of expertise or company culture, but has safety incidents on their record, the general contractor may elect to put extra stipulations in the contract that ensure adequate safety measures are taken. A general contractor should have a clear review process in place for considering and approving exceptions to their prequalification standards. It may also be necessary for the general contractor to devote additional manpower to managing known risks associated with a given subcontractor. Even when a subcontractor appears low risk, it is a good idea for general contractors to have risk mitigation plans in place. This is particularly true for trades that are generally considered high-risk and for trades in new geographic regions or markets. General contractors who “check all the boxes” as part of their prequalification routine are in the best position to improve project outcomes — a win not only for the construction company itself, but for the entire team, including the project owner.

Cultural Alignment

It goes without saying that a general contractor’s leadership must exemplify the company’s core values, such as integrity, safety, diversity and taking a long-term perspective. But these values should also be manifested at every level of the organization and on the jobsite, including by subcontractor representatives. Therefore, subcontractor prequalification is not just about data gathering, nor it is about finding the company with the lowest-priced proposal. Going beyond the numbers is the only way to ensure that a subcontractor aligns with the general contractor’s values and is truly a good fit. General contractors should seek to establish that a subcontractor has similar views on risk, including risk tolerance and commitment to risk mitigation. Going beyond the numbers is again useful when examining a subcontractor’s safety statistics. Some incidents will have greater relevance and significance than others, so when evaluating a subcontractor’s safety record, the general contractor should examine the specific case surrounding any incidents and should consider them in the context of trade-wide trends. An important point is that the prequalification phase offers an opportunity for subcontractors and general contractors to begin to build a positive relationship. To accomplish this, the general contractor should be careful to conduct information-gathering in a way that is respectful and supportive. For example, the general contractor can offer in-person meetings, create (and maintain) a feedback loop for subcontractors who are working through the prequalification process, and explicitly express appreciation for the subcontractor’s participation.

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PLANT ENGINEERING

Good partnerships, good projects

All steps involved in subcontractor prequalification must be performed in an efficient manner to optimize the cost/benefit of the preconstruction phase and to avoid deterring trades from bidding. Prequalification is a multi-step process, so ample time should be allowed for its completion. Collecting and reviewing information early — not immediately before accepting bids — can improve subcontractor responsiveness, translating to better project outcomes. This is especially true when subcontractors are not experienced with prequalification procedures; when this is the case, the general contractor may need to devote time to educating potential applicants. The first step for subcontractors to take when seeking prequalification is to fill out a questionnaire or form that has been created by the general contractor. While these forms frequently need to be customized to the general contractor’s specific needs, common elements include: • Past sales and current backlog information • Financial standing information such as statements, history and a surety letter • Past project references with relevance to project size/market/complexity • Safety information such as EMR/TRIR/LTIR/violation statistics, safety affiliations and programmatic information • Quality/project controls programmatic information • Trade affiliations and geographic preferences. General contractors can improve response rates by ensuring that their questionnaires and other forms are simple, streamlined and easy to access. The forms should avoid unnecessary questions or repetitiveness and they should be easily accessible online. Using a software-based system with automatic reminders can help subcontractors stay on track during the process, as well. Again, in order to build the best relationship with their future subcontractors, general contractors should not stop at putting out a questionnaire but should follow-up with applicants answering any questions they may have and helping them work through trouble spots. When seeking subcontractors in new markets or regions, Inperson interactions can be beneficial. Like other preconstruction procedures, subcontractor prequalification can result in a solid return-oninvestment. Not only are risks assessed and proactively addressed before they become issues on the jobsite, but prequalification offers the best opportunity for a general contractor to find like-minded partners. Prequalification lays the groundwork for better working relationships and, ultimately, better project outcomes. PE Aman Singh is manager of preconstruction services, Graycor Southern. www.plantengineering.com

SOLUTIONS CLOUD COMPUTING By George Thuo

What you need to know about Cloud ERP The why and how of a move lots are making

Manufacturers are moving their most important business and technology applications to cloud environments. Courtesy: Global Shop Solutions

migration is taking place in the manufacturing industry, one that’s changing the way growing numbers of manufacturers manage the most important tool in their business — their enterprise resources planning (ERP) system. The migration involves a shift from managing ERP onsite to the cloud. Cloud ERP involves accessing data management and other computing services over the internet rather than using onsite servers and other hardware. These services can include data storage, databases, networking, software, analytics, business intelligence, security and more. Cloud ERP allows management to stabilize and lower operating costs, run their infrastructure more efficiently and scale the business as customer or industry needs change.

Why manufacturers are moving

The reasons for moving to the cloud vary depending on the size of the business and the markets served. Smaller manufacturers often don’t have the budget or resources to manage the information technology

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(IT) function in-house. Cloud ERP avoids the expense of buying and maintaining hardware and software and the costs of IT staff or outsourced IT consultants. It also eliminates the need to update the hardware as technology advances, or to install new versions of the software because the cloud service provider handles those and other system maintenance tasks. Cloud ERP provides a high degree of flexibility — a real advantage in today’s rapidly evolving manufacturing industry. When the COVID-19 pandemic caused employees to work remotely, businesses scrambled to adjust their computing infrastructures so people could do their jobs at home. Cloud ERP provides access to the company’s data anywhere internet access is available. It also keeps the data safe and secure because it resides in the cloud, rather than on employee computers. Manufacturers in the defense, aerospace, and other industries involved in government contracting are often required to maintain their ERP systems via the cloud. In many cases, they must comply with government requirements and funding programs such as the Federal Risk and Authorization Management Program (FedRAMP) and the International Traffic in Arms Regulations (ITAR). Some manufacturers migrate to the cloud because they don’t want the hassle of managing their ERP. Running ERP on premise requires having a high level of IT expertise on staff or hiring consultants to source the hardware, maintain the network, install upgrades, integrate with third-party software applications, and more. A cloud-based system hosts all the ERP data on the provider's servers, including data backups, and works with the ERP vendor when installing version upgrades, new features and functionalities and other changes to the software. Outsourcing these and other ERP management functions gives manufacturers more time to address key strategic issues involving products, customers, and growth of the business. PLANT ENGINEERING

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SOLUTIONS CLOUD COMPUTING

attacks. Data is stored and accessed using the highest encryption standards in the industry. • High availability. Cloud service providers store client data in multiple geographically distanced locations, and use redundant data backup to ensure data doesn’t get lost. Combined with highly efficient incident management and reporting mechanisms, Cloud ERP has a 99.9998% up-time rate. By outsourcing ERP as a service, manufacturers enjoy less complexity and minuscule risk of losing their data through hardware failure, natural disaster, failure to back up their data or getting it hacked by cybercriminals.

Transitioning to the Cloud

A cloudbased ERP system hosts all data on the provider's servers, including data backups, and works with the supplier vendor when installing version upgrades, new features and functionality. Courtesy: Global Shop Solutions

Advantages of Cloud ERP

Cloud ERP offers multiple benefits for today’s timepressed manufacturers. Users pay only for the cloud services they use, which helps lower operating costs, run the company’s infrastructure more efficiently, and scale as business needs change. Other benefits include: • Predictable costs. Cloud computing does away with common ERP management issues, such as hardware recycles and system downtime, that add cost and reduce efficiency on the shop floor. Knowing what you will pay each month for the service makes it easier to budget. • Faster system performance. Cloud services run on very fast fiber-optic technology that delivers faster data and transaction processing for ERP users. Global Shop Solutions customers report performance increases ranging from 40 to 200% depending on the type of hardware and infrastructure they used before migrating to the cloud. • Scalability. When adding a new facility, Cloud ERP doesn’t require network upgrades, hardware profiling and installation, and other costly IT activities needed to get the plant up and running. Upsizing or downsizing the business is quick and easy. • Security. Cloud ERP creates a worry-free system by mitigating the risk of data loss, downtime from hardware failure and malware

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PLANT ENGINEERING

The amount of time required to migrate ERP management to the cloud depends on a number of factors, starting with the type of ERP system you employ and the amount of data that needs to be transferred. Some smaller ERP packages only manage a few key production activities, such as scheduling, labor time collection, costing and inventory. Comprehensive ERP systems offer a complete package that handles everything from shop floor management to inventory, purchasing, accounting, customer relationship management, quality control and much more. The time it takes to test the ERP system, which involves running the on-premise and cloud systems concurrently to ensure a successful migration, can also vary. Larger, more complex systems typically have more data that requires more time to upload and test. Using a lot of third-party software interfaces, such as CAD/CAM, EDI or Nesting, with your ERP system will also extend the time required for comprehensive testing. It also takes time to research and create the cloud budget. Cloud ERP requires highly reliable internet access. Having redundant internet services, such as satellite, is recommended. Cloud experts also recommend having a firewall for your local network that supports IPSEC and AES encryption. Depending on the size of the budget, you may need to reallocate funds or renegotiate contracts with external IT firms. On average, it takes about four to six weeks to transition to the cloud. Companies with fewer modules and integrations can go live in as little as two weeks. Companies with more data and full ERP use can take up to three months. Migrating ERP to the cloud doesn’t require much of a learning curve because the system looks and www.plantengineering.com

works just as it does onsite. The screens look the same. Commands are the same. Menu options remain the same. For many manufacturers, the only training they need involves how to link or upload files to the cloud.

Cloud service must-haves

Cloud service providers come in many different shapes and sizes, with some offering a lot more features and functionalities than others. Before choosing a provider, make sure they offer the following capabilities: • Integration capabilities. The ability to integrate with any local data storage you maintain, as well as work collaboration tools such as SharePoint, tooling machines, and e-commerce, is essential for an efficient cloud experience. • Automated performance monitoring and logging. This enables you to monitor your applications, respond to system-wide performance changes, optimize resource utilization and get a big-picture view of operational health. Programs such as Amazon’s CloudWatch identify anomalous behaviors in your system and troubleshoot issues to keep your applications operating smoothly. • Secure access to important business management data. One of the real strengths of ERP software is the customizable dashboards that provide high-level summaries of executive, management, WIP, shipping and other data categories for quick analysis. Access to these dashboards should be readily available and secure via your cloud connection. • High-level security technology and practices from the cloud provider. These should include multi-factor authentication, regular traffic inspections, and ongoing scans for attempted malware attacks. Your cloud service vendor should provide tools to help you inspect your deployment into the cloud and flag any incorrect deployments. Your ERP system should also be able to assist with security. For example, Global Shop Solutions ERP software can limit access to the cloud data only through your company’s facility. If the business has employees working at home, our system can shut down the firewall on each employee’s computer and only allow the program to run from the company’s IP.

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Who should consider moving

Cloud ERP is a no-brainer for international companies with facilities around the world that struggle to manage a central system due to different time zones. With all the data in one central location via the cloud, time zones no longer matter. The cloud also provides an effective option for companies that are expanding quickly through acquisition or building new facilities. New locations can ramp up quickly because the cloud eliminates the need to source and set up new hardware infrastructure. It also provides a cost-effective option for small manufactures who can’t afford in-house IT expertise, and for those with a quality ERP system that runs slow all the time. Any manufacturer that needs the ultimate in data security and/or has compliance requirements can benefit from Cloud ERP. End-to-end encrypted data, multiple redundant backups, and disaster recovery all become simpler and less costly with a cloud solution. Hosting your ERP on premise can be a deal-breaker when bidding for government contracts for lack of compliance. And when it comes to reducing ERP management time and costs, cloud computing gets the job done. The rapidly-growing Internet of Things (IoT) is changing manufacturing in ways we couldn’t imagine 10 or 15 years ago. As machines get better at talking to each other and the technology becomes more complex, the need for services like Cloud ERP to facilitate and manage machine-to-machine relationships will dramatically increase. For many, the decision ultimately comes down to the total cost of ownership. When evaluating Cloud ERP services, don’t just compare your current IT expenditures to the costs of the service. Instead, look at your IT budget over the next 10 years. Take into account the cost of frequent hardware and software recycles, downtime from hardware failure, ongoing changes in security technologies, data loss and other factors that can occur when managing your ERP onsite. Cloud ERP can reduce costs, improve ERP performance, make remote work easier and safer, provide better data security and more. It also offers a benefit that’s hard to put a price on — peace of mind. PE George Thuo is director of cloud & technology, Global Shop Solutions. He has extensive experience in Cloud ERP implementations, software updates and technical support for manufacturers. As director of cloud & technology for Global Shop Solutions, he led the process of building the hardware and software infrastructure required for the company’s ERP software to integrate with the Cloud. PLANT ENGINEERING

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SOLUTIONS PROCESS CONTROL & AUTOMATION By John DeTellem and Ramey Miller

Integrated automation suites solve 24/7 connectivity problems Edge solutions deliver data insights that increase uptime

Figure 1: Integrated tool sets can generate consistent system diagnostic schemes across multiple machines for facilitating quick recovery when issues arise. Courtesy: Siemens

dvances in digitalization are providing manufacturers with data insights and stable remote connectivity. While digitalization and connectivity used to be competitive advantages for manufacturers, they are now essential for achieving profitability and longevity, along with responsiveness to rapidly evolving market trends. Fortunately for machine builders, connected components are in abundance, and it is easier than ever to equip machines with smart sensors, analyzers, variable frequency drives and other intelligent devices. However, there are many challenges to maintaining stable remote 24/7 connectivity. With a substantial focus on data and connectivity, it is easy to overlook the basics, like system and process diagnostics. But these elementary building blocks provide the foundation for entire automation solutions. With careful planning from conception of an automation system to implementation, the right hardware and software tools are keeping manufacturers connected to their data with confidence, providing consistent uptime.

System reliability, connectivity

To provide continuous and reliable access to plant data, manufacturers must first ensure a stable automation system base, and with many connected machines and devices, integration is often not performed in a consistent fashion. When this is the case, it can create misunderstanding, operational delays and unplanned downtime.

This lack of uniformity is often a result of deficiencies in engineering and automation standards. While one machine may use a particular scheme of interlock checks and means of flagging basic faults, another may be designed entirely differently. Through careful planning and programming, it is possible to consistently implement alerting across multiple machines, although this can be challenging to maintain, especially when introducing changes and reprogramming machines later in their lifecycles. Once a reliable automation system is carefully architected, the next challenge is defining the channels by which to access plant data, both real time and historical. While developments in the industrial internet of things (IIoT) are making it possible to connect remotely to numerous intelligent devices, direct connection from device to cloud is not the best practice in most manufacturing environments. In a plant setting with potentially hundreds of intelligent devices, direct connection brings about bandwidth constraints and security concerns. Additionally, many machine components still require an intermediary device for pre-processing raw device data and converting it to cloud-friendly packets, and communication must be encrypted to ensure safe operation and protect sensitive information. For these reasons, most modern plants maintain PCbased solutions to collect, store and interpret historical performance data for optimizing production. These solutions, however, can be difficult to configure and clunky to support, and managing data across multiple facilities in a nationwide or global enterprise requires still another layer of software oversight.

Diagnostic solutions

To maintain uniformity across machines reliably, integrated automation suites automatically generate system diagnostic and alerting schemes based on hardware configuration, reducing error-prone custom system diagnostic declarations. This provides consistent alerting and readout of alarms among programmable logic controllers (PLCs), human-machine interfaces

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PLANT ENGINEERING

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(HMIs), edge devices, plant workstations, webservers and remote sessions through the cloud (Figure 1). Because these diagnostics are automatically generated rather than manually programmed, changes to the hardware configuration automatically update system diagnostic infrastructure across a connected enterprise, increasing manufacturer confidence when managing systems remotely. Integrated automation suites also simplify alarm management by leveraging a methodology whereby alarm text definitions are defined with process data values. This keeps alarm message readouts consistent across panel HMIs and other connected visualization devices such as laptops, smartphones and tablets. These features apply to all local and remote real-time plant visualization solutions. Even with robust condition monitoring programs, occasional downtime is inevitable for plants, but reliable and easily understood system and process diagnostic information results in quicker recovery. Diagnostics provided by integrated automation suites translate system faults to intuitive error messages in the runtime environment, quickly directing operations and maintenance staff to root causes.

Insight at the Edge

Building on a stable automation system are edge devices installed on the plant floor to make efficient use of bandwidth for secure communications outside the plant, along with reliable remote connectivity. Engineering, operations and maintenance staff alike must be able to visualize, analyze and interact with machines to keep a plant running in an efficient manner, and unified HMIs at a network’s edge facilitate these functions. Unified HMIs provide different capabilities than standard edge controllers, with built-in apps for managing edge devices and data, and they bring advanced information technology (IT) capabilities to the machine level in a cost-effective manner. When implemented, they serve as a central repository for data across a plant floor, enabling direct visualization and analysis of machine health and performance through a single interface (Figure 2). In addition to running built-in and scalable edge apps, manufacturers can develop their own apps using the unified HMI’s docker engine. This docker and container infrastructure incorporates security intrinsically, enabling developers to focus on app logic and functionality, instead of spending time building and maintaining app infrastructure. As a result, unified HMI apps are highly configurable, as opposed to programmable, because the underlying infrastructure is already vetted. For machine builders short on time, there is likely already “an app for that.” Native and third-party apps are available for purchase to run on unified HMIs, accomplishing tasks such as: • Performing advanced production algorithms and calculations www.plantengineering.com

• Connecting to data from multiple sources over multiple protocols • Visualizing data • Automating workflows • Managing inventory • Simulating production with a digital twin • Analyzing machine and drive health and calling out predictive maintenance • Analyzing performance and creating insights • Creating notification pipelines and sending alerts. Furthermore, unified HMIs are repositories for data collection, analysis, storage and forwarding. With the right apps, users can connect to automation controllers, drives, OPC UA-enabled devices and other edge devices (Figure 3). Using the MQTT protocol, these devices can efficiently publish data to the cloud while consuming minimal network resources, for efficient remote access and analysis. Due to their multilingual properties, unified HMIs perform well as interfaces for establishing key performance indicators and measuring actual production output from multiple machines. Unified HMIs also eliminate the need for PCs in many applications because they can execute many of the IT functions performed by PCs within their industrially hardened HMI housing, and at lower cost and in smaller footprint. Adding another IT characteristic, unified HMIs include enterprise management. Machine builders and manufacturers can centrally manage devices and apps

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Figure 2: A human-machine interface (HMI) can act as a server for remote connectivity, configurable with a wide variety of apps and dashboards for machine visualization and analysis. Courtesy: Siemens

Figure 3: The right industrial apps ease connectivity between the cloud and plant-floor devices. Courtesy: Siemens

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Using unified HMIs’ remote management capabilities, the machine builder is able to remotely push updates to machines around the world whenever they release a new revision, comparable to app updates on a smartphone or patches on a PC. Unified HMIs’ native support for the MQTT protocol makes cloud connectivity possible, while OPC UA protocol support enables users to connect their new machine with other machines in their facilities, and with intelligent devices.

Focus on optimization

Figure 4: A machine builder can remotely push updates to machines around the world whenever they release a new revision. Courtesy: Siemens

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from on- or off-premise through a web-based interface independent of the HMI automation project file. This can be done from any device capable of hosting a web browser, such as a laptop, smartphone or tablet.

Results

A leading original equipment manufacturer (OEM) of crosscut saws significantly improved its production automation system and enhanced its global customer service by standardizing on the Siemens TIA Portal integrated automation suite. By using the TIA Portal’s automatic system diagnostic and alarm generation, residing within the hardware configuration tool, the OEM was able to reduce its programming time by 30%. The saw manufacturer now provides its end user customers with in-depth troubleshooting, accessible from the HMI. Using the integrated system diagnostic view, the OEM’s customers are able to self-service many issues, and when problems are escalated to the OEM, the HMI’s clear display of system alarm conditions makes resolution of issues much quicker. The result is less downtime for end users, and fewer support calls to the OEM. For an industrial heater manufacturer, struggling to keep up with growing demands from its stakeholders, implementing Siemens WinCC Unified HMI software and panels enabled it to deliver greater functionality and performance to its users. This platform also empowered the manufacturer to develop its own apps for machine and performance analysis, and for maintenance support. The HMI’s docker ensured app security, and it saved development time because the pre-built container infrastructure allowed effort to be placed on app functionality. PLANT ENGINEERING

As industry grows more agile and geographically dispersed, machine builders need always-on access to data. At the same time, customer and corporate expectations are becoming more demanding, requiring manufacturers to maintain consistent uptime by implementing solutions for remote connectivity. Modern integrated automation suites ease the burden of managing diagnostics and alarms for manufacturers, freeing them up to focus on plant and data connectivity solutions. Paired with a capable edgebased software and hardware system, manufacturers can place more focus on refining machine functionality through data insights, with less concern about machine downtime and lost production. Unified HMIs installed at the automation edge effectively connect users to their data, while bridging OT plant data with workflows and IT tools, phasing out the need for plant floor PCs in most applications. These Unified HMIs are empowering machine builders to: • Connect with their data from anywhere • Integrate machine performance data directly with business process workflows • Deploy out-of-the-box or customized apps for interaction with their data. As 24/7 connectivity matures, manufacturers are relying on edge devices to branch out further, supporting an increased breadth of cloud and factory floor communication protocols. These advances will improve machine performance, reduce downtime, enable greater profitability for machine builders and fuel connected enterprises through the IIoT. PE John DeTellem is the TIA Portal product marketing manager for Siemens Industry in the United States. John has been with Siemens 14 years. He holds a BSEE from the University of Iowa. Ramey Miller is the HMI/Edge product marketing manager for Siemens Industry in the United States. Ramey has more than 15 years of industrial automation experience and has been with Siemens for four years. www.plantengineering.com

SOLUTIONS MANUFACTURING SYSTEMS By Bob Remler

Robotic vacuum impregnation reduces scrappage due to porosity Small footprint of workstation integrates into existing workflow

t is no surprise to learn that the automotive industry in the United States is the single largest user of metal die casting. In today’s vehicles, a high proportion of components — including cylinder heads, engine blocks, transmission cases, e-motor housings and structural parts — are produced using high-pressure die-casting processes. The automotive industry wants to reduce environmental emissions, increase fuel economy and deliver better performance. Automotive suppliers constantly seek ways to reduce vehicle weight or accomplish other efficiencies. Ways can include combining thinner walled castings with lighter-weight metals such as aluminium and magnesium. Hand in hand with continuing research and new casting processes and techniques, is growing process automation. Industry 4.0 points the way toward smarter factories that include — over and above automation of repetitive processes — incorporation of cobotics (involving collaboration between a person and a robot), digital supply networks and artificial intelligence.

Figure 1: Lighter and thinner castings means porosity sealing technology will become an increasingly vital step in manufacturing. Courtesy: Ultraseal International www.plantengineering.com

While some industry pain points may disappear as manufacturing technology and processes evolve, one legacy challenge remains — that of porosity. Porosity is one of the defects most frequently encountered in aluminium die casting. These microscopic voids reduce component density, leading to leaks. For parts that go into applications that need to be air- or fluidtight, such as fuel or cooling systems, this can be a critical issue. Untreated, casting porosity formation wastes materials, energy and production time and results in costly scrappage.

Challenges faced

A leading U.S.-based maker of engines, off-road vehicles and motorbikes found its production of die cast engine components was plagued by high scrappage rates due to porosity and leaks. With supply chains under increasing pressure, treating porosity has become an important part of the manufacturing process. Previously, the company addressed the issue by shipping parts to another state for vacuum impregnation processing. That process used a specially formulated resin to fill porosity in automotive castings. However, this arrangement was far from ideal. Besides shipping costs, the process was time consuming, often adding a week to production times. To overcome lags in production, the company resorted to keeping a week’s worth of inventory on site, taking up valuable production space and increasing working capital needs. Yet, despite the time and effort, the scrap rate was still around 11%.

Automated, on site solution

To mitigate the issues and find a more efficient and cost-effective solution, the company turned to Ultraseal International. A PLANT ENGINEERING

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SOLUTIONS MANUFACTURING SYSTEMS

Figure 2: The Ultraseal Sealant Recycling System allows the sealant washed off the parts to be reclaimed from the cold wash solution, allowing both the sealant and the cold wash solution to be reused. Courtesy: Ultraseal International

leader in sealing porosity and leak paths in die cast, sintered and electrical components, Ultraseal proposed an automated process using robotic component handling that offered improved productivity, greater cost-effectiveness, more reliable sealing rates and improved environmental performance. Ultraseal engineers worked with the company to design and install a fully automated, robotic vacuum impregnation system. The bespoke solution offers fast cycle times combined with best-in-class performance, reducing the 11% scrappage to nil during the initial trial, and the one-week turnaround to a speedy 12 minutes.

The small footprint of the workstation enables it to be integrated into the existing manufacturing line without compromising on workflow or floor space. The system is designed to process parts from two different production lines. It can be pre-programmed to treat components from either line, or alternate between both, offering complete flexibility. Automation use results in improved output quality. Besides offering 100% sealing effectiveness, the solution also addresses issues with component damage resulting from handling and processing, by using a consistent gloss black finish. It eliminates corrosion issues by employing a multifunctional corrosion inhibitor. The Ultraseal system is integrated with software that offers process control visibility and data logging. Besides ensuring batch traceability and process control, the system can be used for remote diagnostics, optimized system performance and minimized unplanned downtime.

Reducing costs with robotics

While Industry 4.0 adoption is still an evolutionary process, elements of the smart factory are increasingly used in production lines, as smart technology and internet of things (IoT) connected devices replace or improve traditional manufacturing processes. Once only achievable for larger enterprises with large budgets, robotic automation is now more affordable and available to organizations of every size. It reduces floor space and allows production processes to run for longer periods. Automated systems offer increased repeatability. In the case of Ultraseal’s robotic vacuum impregnation system, equipment, chemicals and processes are more economical and environmentally sustainable than the traditional alternatives. Figure 3: Bespoke automated robotic solution offers fast cycle times improved output quality. Courtesy: Ultraseal International

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PLANT ENGINEERING

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Typically, casting impregnation is carried out in three stages: first, parts are placed in an autoclave and a vacuum applied to draw air out of any voids before a liquid sealant is introduced. Second, parts are washed in a cold wash cycle to remove excess sealant from component surfaces and critical areas such as threaded holes. Finally, parts undergo a hot cure cycle where heat polymerizes the sealant within the porosity, turning it from a liquid state into a solid polymer. Like other manufacturing processes, vacuum impregnation produces waste. In a standard impregnation process, around 95% of the sealant is washed off the components during the cold wash cycle. These chemicals are not recoverable. They must be handled as effluent that needs to be treated or trucked away for disposal off site, adding replacement chemical costs to the process and considerable environmental management processes for the user. The Ultraseal Sealant Recycling System allows the sealant washed off the parts to be reclaimed from the cold wash solution, allowing both the sealant and the cold wash solution to be reused. This makes the cold wash cycle operate Bills, envelopes... Simple and on in a closed loop, negating the need toLetterhead, continually top up white background - darker blue with PMS 877 for contrast white volume with copious volumes of fresh water with theonsame going to drain. This automated process offers best-in-class sustainability, lowering sealant consumption, reducing water consumption, and minimizing effluent discharge. Taking the system in BLUE = C90.M50.Y5.K40 house further lowers the manufacturer's carbon footprintPMS by7462 SILVER = PMS877 or C47.M38.Y38.K2 eliminating the need to ship components to distant suppliers.

Things of the past

BLACK ONLY LOGO - FAX, ETC.

As automotive manufacturers turn to lighter and thinner castings, porosity sealing technology will become an increasingly vital step in manufacturing. Incorporating vacuum impregnation into production lines can help the automotive industry reduce scrap andGRAYSCALE material LOGO wastage, increase component life cycles and improve environmental performance. Ultraseal provides a range of best-in-class equipment and sealant solutions, including recycling and automated systems that can deliver efficiency and boost environmental credentials. Customers can opt to work with Ultraseal in whichever way best suits their operational requirements, using on site managed services, external service centres or TECHNICAL SERVICES GRAY completely automated owned installations. C78.M64.Y50.K39 By owning the vacuum impregnation process, manufacturers have peace of mind that they have given their best in terms of quality, sustainability and environmental responPACKING AND PACKRYT BLUE sibility — at a fraction of the prohibitive costs involved in C90.M50.Y5.K40 scrapping components. For more about Ultraseal International’s complete range of vacuum impregnation products and services,FUTURE please BLUE visit C91.M53.Y0.K0 www.ultraseal-impregnation.com/us/ PE Bob Remler is technical sales manager, North America, Ultraseal International. FUTURE GRAY C60.M46.Y41.K10

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FRUSTRATED WITH MECHANICAL SEALS? We understand. We know your pumps are workhorses, not pretty ponies. Plant conditions seldom match the engineering laboratory. Installing mechanical seals on degraded equipment or on applications where the flush is insufficient or intermittent leads to premature failure and costly downtime.

MECHANICAL SEALS ARE OVER-PRESCRIBED. Engineering, reliability, and maintenance departments have long considered SILVER = C0.M0.Y0.K30 minimizing seals' use for these reasons. DARK BLUE = C90.M50.Y5.K40 LIGHT BLUE = PMS285 or C91.M53.Y0.K0 Orange = C0.M56.Y92.K0

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SOLUTIONS MATERIAL HANDLING By Eric Hassen

Seven shortcomings of commodity casters The right application-specific casters and wheels can help optimize workflow

“I

f it ain’t broke, don’t fix it.” But if it is broke, don’t keep replacing it with the same inferior part. That logic applies to “commodity casters,” the wheel systems on the undersides of the material handling carts and platform trucks plant floor associates use every day. Original equipment manufacturer (OEM) cart manufacturers often specify inferior-quality casters and wheels that aren’t built to last so they can keep purchasing costs down for end users. Too often these commodity casters quickly show signs of wear, if not completely fall into disrepair, within six to 12 months of service. This, in turn, can result in issues like unplanned downtime, excessive noise and even workplace injuries (see Figure 1). In manufacturing and distribution center environments, more forethought is warranted about the wheels and casters on carts. To specify the right casters, it’s prudent to consider factors like load requirements: how far, at what speed and for how long the cart will be moved; flooring surfaces; and

more. There are many things to consider rather than just making a go at it with the default caster and wheel that comes with the cart. Commodity casters aren’t designed to address specific applications, whereas advances in application-specific casters and wheels can provide custom solutions to match precisely how they’ll be used on the floor. There are several inherent shortcomings in OEM casters that can lead to tangible, measurable issues in a plant’s operations. The following is a breakdown of the top seven:

1. Reliability

Many OEM carts have poor quality casters that fail prematurely. Most commodity casters use a standard kingpin design, the most common point of failure in a caster. The kingpin will likely stretch out over time, causing the housing to come loose, bearings to fall out and push-pull actions to require more effort. Failed casters directly result in lost productivity when carts and trucks are taken out of commission.

2. Ergonomics Figure 1: Typical cost of unplanned downtime. Courtesy: Caster Connection

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Casters with a high rolling resistance cause physical overexertion by associates, the primary cause of workplace injuries. If it takes more effort to push or pull, it increases the chance for injury. The U.S. National Safety Council pins the average insurance claim per workplace incident at $60,000 to $80,000. Lower back strain caused from pushing and pulling carts is a leading workers’ compensation claim in the United States. It happens regularly due to repetitive motion and overexertion from associates. These behaviors account for nearly 20% of injuries and illnesses in the workplace. Only the common cold accounts for more lost days at work. Commodity casters typically have standard swivel leads, which are harder to push, pull and maneuver. A standard swivel lead has a short distance roughly straight up and down from the center point of the kingpin to the center point of the www.plantengineering.com

Figure 2: Application-specific casters can come with an extended swivel lead. Courtesy: Caster Connection

axle. Application-specific casters can come with an extended swivel lead (see Figure 2). This added distance enables reduced push-pull forces, improved maneuverability and decreased noise and chatter.

3. Safety

The wrong wheel built for the wrong operation can cause a failure that compromises the load being carried and, in turn, the operator pushing or pulling it. Figure 3 shows what happens when the wrong wheel was used in a tugging operation. This is a polyurethane on aluminum wheel that has de-bonded. That means it was spinning too fast and created heat from the bearing that worked its way up to the core. It got so hot the glue that holds the polyurethane onto the core melted and caused the tread to fall off. If a cart is taking a 90-degree turn with a full load and the caster fails, it’s likely to cause a severe injury to the operator and any associates standing nearby.

4. Versatility

Commodity casters are inherently not versatile. By design, they’re one size fits none. There’s no factoring in of any operation-specific dynamics that

Ford Motors case study Ford Motor Company’s issues with casters centered on durability, or lack thereof. The parts on its casters were failing at a high rate, around the six-month period. This is fast for a caster. Second, the plant was experiencing a high volume of push-pull issues with its carts. Associates were having a hard time and incurred an injury. Ford wanted to make sure any caster solution would lower the push-pull force on a fully loaded cart and help prevent injury. Third, caster-related noise in the facility was an issue. Ford uses power tuggers that pull three or four carts in a row, and those tuggers were making a lot of noise due to chatter and flutter associated with the casters. Caster Connection sent an individual onsite to assess the applications being run at the plant, the carts being used and the casters. The recommended solution resolved all three issues. First, a proper swivel caster with the proper raceway was specified to eliminate the durability issue. Next, proper wheels and bearings were used to help reduce push-pull forces by 35%, and without having to change Ford’s internal processes. Finally, for the noise issue, proper wheel tread was specified to essentially add a built-in shock absorber to reduce the noise by roughly 16%. Using the proper caster for specific applications can have a dramatic effect. Noise, push-pull and bottom-line return on investment (ROI) were improved in this instance, and a commodity caster that used to last six months was replaced by one that was now lasting more than three years. www.plantengineering.com

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SOLUTIONS MATERIAL HANDLING

Figure 3: The photo shows what happens when the wrong wheel is used in a tugging operation. This is a polyurethane-on-aluminum wheel that has de-bonded. Courtesy: Caster Connection

would improve productivity or durability of the part. The correct casters for the application, on the other hand, can solve more than one problem for an operation. And properly specified, they can be versatile enough to improve operations at multiple facilities and on multiple types of carts and trucks, keeping part number ordering and inventory at a minimum. The right caster can be standardized across an entire corporate network.

5. Maintenance

Plant and distribution center maintenance teams likely are kept busy doing many higher priority tasks than changing, greasing and running maintenance on casters. Commodity casters typically have open raceways with constant need for greasing, which takes valuable time. The right application-specific caster can minimize a plant’s maintenance, repair and overhaul (MRO) expense. Purchasing teams often reorder the same part because that’s what is known and familiar. The more they’re aware of other options and how they can impact operational safety, productivity and the bottom line, those options become more likely to be chosen in the future. When casters break, and they commonly do, they need to be replaced with the correct caster for a plant’s specific operation.

6. Floors

Caster wheels made from phenolic and other inappropriately hard materials collect debris that imbed into the wheel’s tread. Debris retention can damage floors. Further, the wrong caster tread for the application can wear a groove in the floor, causing an automated guided vehicle (AGV), if used, to go offline and interrupt production. OEM casters typically use inexpensive tread materials, and often they’re rather hard. Phenolic,

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glass-filled nylon and polyolefin are common examples. When there are multiple carts with hard treads on their wheels that consistently traverse over debris and in the same pattern, they’ll wear grooves into the floor. They’ll also travel over thresholds, elevators, dock plates and even extension cords. Hard casters often don’t do very well when they encounter gaps or bumps. The smaller the wheel, the more difficult it can be. They’ll get stuck and cause operators to overexert themselves to move the cart. Properly specified casters and wheels, conversely, can be softer, larger and more forgiving on gaps or raises in the floor.

7. Noise

The wrong wheel and caster combination can cause an aggravating amount of noise. Consider having a tugging application that uses a standard lead swivel caster. That’s a short distance between the center point of the kingpin and center point of the axle, and when the caster gets moving as fast as 5 mph, it can start chattering and fluttering back and forth because it doesn’t have any room to trail. This can cause a tremendous amount of noise, particularly when carts are unloaded and there is nothing to keep those casters on the ground. A loose raceway can cause loud noise as well. The wrong material can create excessive noise because there’s no resiliency to the tread. Considering multiple variables, a caster made with specific polyurethane or rubber wheels can be softer and significantly reduce the amount of noise.

Final thoughts

Manufacturers and distribution centers don’t have to live with commodity casters. Awareness of the specific shortcomings inherent in commodity casters and knowledge about what application-specific alternatives are available and how they can improve operations are key to making the best purchasing decisions. PE Eric Hassen is director of business development for Caster Connection, a manufacturer and distributor of high-performance casters, wheels and other material handling products based in Columbus, Ohio. www.plantengineering.com

SOLUTIONS FIRE SAFETY By Chad Connor

Fire safety best practices for manufacturing facilities Are lights, alarms, extinguishers and sprinklers inspected every year?

n estimated 37,000 fires occur at industrial and manufacturing properties every year resulting in $1 billion in property damage, 279 injuries and 18 deaths, according to Occupational Health and Safety Administration. As a professional fire safety inspector, the author has inspected hundreds of manufacturing properties. During inspections, there are overlooked areas when it comes to fire safety that need immediate attention. Identifying and correcting these issues will help ensure the safety of your tenants and property during a fire emergency.

Conducting regular inspections

A manufacturing facility should have its lights, alarms, extinguishers and sprinklers inspected every year (see Figures 1-3). Many companies neglect their annual services. Neglecting the fire safety system can cause the equipment to erode over time resulting in faulty equipment. After a professional inspection, a facility will receive a report from the inspection company. The report will include the date of the inspection, name and address of the property, type of occupancy, any issues to address, contact details of the building owner and those interviewed during the inspection. Facilities are required to keep this on file for at least one year, but five years are recommended. Beyond the fire code standard of keeping records for one year, many insurance companies require longer timeframes for record keeping. Contact the insurance company to be aware of its requirements.

Placing signage

Maintain the exit lights in manufacturing facilities. During a fire, conditions can be chaotic and confusing. Smoke can obscure vision and make it difficult to navigate the facility. Illuminated exit signs make it easier for people to see where to go and how to get out of the building. Exit signs are designed to switch to emergency power when they no longer receive electricity. These lighted signs need regular testing by the facility safety teams to ensure proper operation. Often, this involves pressing www.plantengineering.com

the test button on the side of the sign to ensure they correctly switch to the standby power source. If the signs do not switch to the standby power source, they must be replaced. If the facility uses chemicals, the supervisors must make sure the outside of the building has the hazard communication sign indicating firefighters of what hazards may be inside. The hazard communication sign incorporates the NFPA 704-2022: Standard System for the Identification of the Hazards of Materials for Emergency Response fire diamond to communicate the hazard of short-term, acute exposures to chemicals that could occur as a result of a fire, spill or similar emergency. The fire diamond is color coded representing different risk levels: blue for health, red for fire and yellow for reactivity and instability. These hazards are ranked on a scale of 0 to 4 for severity of danger allowing fire firefighters to better understand the situation if they are called to fight a fire.

Communicating your emergency action plan

Manufacturing facility supervisors should provide written emergency action plans for employees to ensure everyone knows the exit routes and what fire emergency procedures are in place. Emergency action plans should cover designated actions employers and employees need to take to ensure their safety during fire emergencies, according to OSHA. These actions include which equipment needs shutdown and when fire suppression efforts should take place. The supervisors need to ensure all employees understand fire suppression procedures and escape routes to be followed by each location in the facility. Supervisors are required to review the emergency action plan with each employee at certain times including when the plan is developed, when an employee’s responsibilities change and when the plan changes.

Proper racking system placement

Manufacturing plant supervisors need to alert employees of any debris or racking systems blocking doorways PLANT ENGINEERING

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SOLUTIONS FIRE SAFETY

Another challenge is emergency exits blocked by debris. It is recommended that employees regularly inspect doorways for clear egress. Move any boxes, equipment or trash from doorways that can slow down the process of getting to safety quickly.

Figures 1-3: A manufacturing facility should have its lights, alarms, extinguishers and sprinklers inspected every year. Courtesy: Affordable Fire & Safety

Placing fire extinguishers

and fire notification devices. Keep the notification devices areas clear. Consider a printing facility with many boxes of paper placed in the racking systems on pallets. If the racking systems are placed directly against the wall, the notification devices, such as strobe lights, can’t do their job in alerting people of a fire. Also, most of the manufacturing facility buildings were built as a shell to install manufacturing equipment. Having racking systems improperly placed against walls can prevent the water sprayed from sprinkler systems to reach the necessary places in case of a fire. Keep racking systems away from the walls and when adding racking systems, facilities will also need to install additional sprinkler systems so the water can reach all of the areas surrounding them.

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Multipurpose extinguishers rated class A, B and C, capable of putting out small fires involving wood, paper, oils and gases are required in manufacturing buildings. Extinguishers need to be placed 75 feet apart throughout the building according to OSHA guidelines. More specific classes of fire extinguishers are also needed in manufacturing facilities. Locations that contain Class B flammables such as workshops, garages and warehouses require that all employees have access to a Class B extinguisher. These extinguishers are capable of putting out fires involving flammable liquids such as glues, paints and other woodworking finishing chemicals. Class B extinguishers need to be within 50-feet of the working area according to OSHA guidelines. Class C extinguishers are required when electrical equipment is being used. Unlike liquid based extinguishers, Class C extinguishers use a smothering agent allowing the fire to be put out without damaging any electrical equipment like computers and servers. Class C extinguishers need to be spaced out based on the size of the room. If the facility has a server room that is 20 feet long by 20 feet wide, it requires one Class C extinguisher placed by the door. In larger rooms, it is recommended these extinguishers are placed every 50 feet. Class D extinguishers need to be present in areas where there are combustible metal, shavings or similarly sized materials are generated. Class D extinguishers especially need to be in areas where employees are working with titanium, magnesium or any other metal ending in –“ium.” These metals are highly flammable. Class D extinguishers need to be placed no more than 75 feet from the potential hazard. Make sure fire extinguishers are at the proper weight or gauge limit. This information can be found on the label located on the side of the extinguisher. Replace or recharge extinguishers if they are not at the required levels and after every use. Following these fire safety reminders will ensure the manufacturing facility will be safer in case of a fire emergency. If there are questions about fire safety systems and plan, contact the local fire marshal. PE Chad Connor is the president of Affordable Fire & Safety located in Gilbert, Ariz. Affordable Fire & Safety conducts thousands of fire inspections each year. www.plantengineering.com

SOLUTIONS ELECTRICAL DISTRIBUTION By Garrett Nariman, PE

Install medium-voltage cables in petrochemical plants How to ensure code requirements for hazardous environments are satisfied

M Figure 1: When it comes to operating mediumvoltage equipment, petrochemical facilities come with many unique challenges. Courtesy: Samuel Engineering

edium voltage (MV) equipment is commonly encountered in today’s petrochemical facilities. Electric motors operating at 2.3 kV to 15 kV are often deployed for larger horsepower equipment such as compressors and pumps. Petrochemical facilities come with many unique challenges (see Figure 1). Principal among these is the presence, or possible presence, of flammable concentrations of gas in the atmosphere, or release of flammable liquids due to equipment failure. Electrical systems installed in these demanding and hazardous environments must satisfy the requirements of NFPA 70-2020: National Electrical Code (NEC). Specific requirements for MV wiring methods are often grouped at the end of relevant NEC articles. These MV requirements can either amend, or completely supersede the low voltage requirements. The design process can often require one to completely understand both the low voltage and the MV sections. Add the requirements for classified areas into this mix, and it is easy to see where confusion may set in. This article explains some of the more common aspects of MV cable installations in hazardous environments and how to ensure code requirements will be satisfied.

Conductor sizing

A typical MV motor feeder circuit often originates at a motor control center starter cubicle or a switchgear circuit breaker compartment. These are typically located in a non-hazardous location remote from the motor. From the source, one or possibly more MV cables are usually routed in cable tray to the load (see Figure 2). Because of the thickness of MV cable insulation and required bending radius due to the metallic tape shield, cable tray is most often preferred over conduit for MV applications (see Figure 3). The conductors must be sized in compliance with NEC Articles 430 and 311 with necessary adjustments for cable tray fill and spacing per Article 392. Note that according to Article 430, MV motor conductors are not sized based on motor full load amps (FLA) as is done for low voltage motors, but instead selected based on the motor overload protection setting. Additionally, the grounding requirements for MV circuits are grouped at the end of Article 250. These requirements supplement and modify the previous sections of this long article. Note that cable selection based on ampacity requirements must be done according to the requirements of Article 311 factoring in derating for ambient temperature and mutual heating effects encountered in grouped underground installations rather than relying solely on manufacturers data sheet values.

Classified area considerations

Once the cables and cable tray are properly sized for the load served, requirements for the portion of the circuit that lies within the classified area must be considered. For this discussion, assume this scenario consists of the cable and tray going out to the load and the cable terminations at the load. The discussion s focused ion Class 1 Division 2 (C1D2) Group D environments, which are www.plantengineering.com

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SOLUTIONS ELECTRICAL DISTRIBUTION

Figure 2: Medium and low voltage cable trays leaving an electrical substation routed on pipe supports to individual loads. Courtesy: Samuel Engineering

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common in petrochemical facilities. It will also touch on the differences between Division 2 and Division 1 installations. The requirements for electrical installations in hazardous areas are specified in NEC Articles 500 and 501 for North America, or alternately Article 505. Before the circuit design is approached, the classification, division, group and extents of the hazardous area must be evaluated. As required by NEC Article 500.4, this information is documented on area classification plans, details and often elevation drawings. The authority having jurisdiction (AHJ) will need this information to verify the adequacy of the electrical design. With this background information in hand, the MV circuit design and material specifications can proceed. One question that is commonly asked at this point is “do I need a special MV cable type for classified areas?” This is one of those areas where confusion often arises. In MV applications, “Type MV” cable is normally selected. The use, installation and construction of Type MV cable is detailed in NEC Article 311. However, if one looks in section 311.32, “Uses Permitted,” no mention of classified areas is found. However, below this list is an informational note stating the “Uses Permitted” is not an all-inclusive list. One should search through Article 501 and read section 501.10 “Wiring Methods” to see that Type MV cable installed in cable tray with approved termination fittings is approved for C1-D2 locations. PLANT ENGINEERING

If your installation is in a Division 1 location, you may likely specify Type MC-HL cable. Furthermore, this cable is allowed only for industrial facilities with limited access and full-time qualified maintenance onsite. The “HL” stands for hazardous location. The “MC” stands for metal clad, so you will need to specify the correct fittings to properly terminate the cable armor. This is typically a cable gland. Your C1-D2 cable specification should specifically state “Type MV” and include language requiring that the cable be approved for cable tray use and is sunlight resistant. Although these are fairly standard among manufacturers, having this stated up-front protects the end user from costly rework. Also the cable temperature rating should be specified. Usually this is either the 90 C rated MV-90, or the 105 C rated MV-105 type. The 105 C rating is usually selected to allow for better short-term overload performance and ability to withstand downstream short circuits in feeder applications. Unlike single conductor cables, 3 conductor type MV cables are usually also approved for direct burial.

Cable terminations and sealing

Once a cable is selected and sized, consider cable terminations at the load end. Assume this is designated as a C1-D2 location. Cable termination selection is a complex subject. The termination will be selected according to cable and conductor type, voltage level, indoor versus outdoor, load terminals, among other things. The size of the enclosure at the motor and whether current transformers (CTs) are required should be determined. Smaller motors often have terminal boxes that are quite confined. Another issue to be considered is most motor terminal boxes are set up for bottom cable entry and often cannot be rotated as with low-voltage motors. Be mindful of cable bend radius requirements found in NEC Article 300.34 (see Figure 4). Applying the cable, conduit and boundary sealing requirements of NEC Article 501.15 in hazardous areas for MV equipment often causes confusion as well. The text of the NEC does not make this task easier. NEC Article 501.15 is overdue for a rewrite and better explanatory notes. However, it is important to know that the sealing requirements www.plantengineering.com

are the same for MV cables and the more commonly applied low-voltage cables in petrochemical plants. In fact, the requirements of NEC Articles 500 and 501 apply equally to both medium- and low-voltage wiring methods. Unlike other articles in the NEC, there is not a separate section created for MV levels to amend low-voltage requirements. How compliance with NEC Article 501.15 is achieved depends on several variables. Again, for this discussion, assume C1-D2 areas commonly encountered in petrochemical plants. In the case of a typical 3-conductor plus ground Type MV or MC-HL cable with polyvinyl chloride (PVC) jacket, consider first the NEC requirement for boundary seals at the transition from the non-classified to the classified area. Typically, in petrochemical plants the MV or MC-HL cable will be run in a ladder type cable tray, so the requirements for conduit seals at the boundary do not apply as one would expect. However, be aware that the cable itself may transmit gas across the boundary. That consideration is addressed by NEC Article 501.15 (E)(4), which requires a seal at the boundary for “Cables Without a Gas/Vaportight Sheath.” This wording is one of the areas that causes much confusion. Some questions may arise here such as: “How do I know if my cable has this?” and, “The manufacturer’s data sheet for my cable only refers to a “jacket,” is this the same as the sheath mentioned in this section?” Unfortunately, the various entities — Underwriters Laboratory (UL), National Electrical Manufacturers Association (NEMA) and the NEC often do not use the same terminology, making things even more confusing. In NEMA/UL terminology, if you have an un-armored Type MV cable, the “jacket” is the outer covering of PVC or similar material that holds the conductors together and provides protection for the contained MV insulated conductors. It can be considered the same as the “sheath” referred to in NEC terminology. On the other hand, manufacturer’s data sheets for an MC-HL three conductor cable will commonly refer to a continuously welded corrugated aluminum armor as the sheath, while the thin PVC covering over the armor is the jacket. This type of cable can additionally be used in a Class 1 Division 1 location. Be aware that you can also get interlocked armor type MC cables that are not rated for Division 1 environments. Returning to the original question on boundary seals for multiconductor cables per NEC Article 501.15(E)(4), in the case of non-armored Type MV cables, UL does not require testing to assure the jacket is truly gas/vapor tight. And for the most part, www.plantengineering.com

cable manufacturers will not state that the jacket performs as such. However, most MV cable manufacturers point out that the chances of holes forming all the way through the jacket due to manufacturing irregularities are very small. Most manufacturers test the jacket to comply with UL thickness requirements and for defects during manufacturing, but this will generally not detect small pinholes that could allow gas to enter. This possibility should rarely be a concern as it would take holes in the jacket inside the classified area that allow gas to enter in flammable concentrations, and enough pressure differential through the cable core to drive the gas to the termination in the nonhazardous area, such as a switchgear lineup. Figure 3: Medium-voltage cables pulled to pump motors via cable tray. Cable trays generally facilitate the larger MV cable bending requirements, save labor and facilitate future expansion. Courtesy: Samuel Engineering

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Figure 4: Terminations installed on a medium-voltage cable inside a motor terminal box. MV motor terminal boxes need extra space to properly terminate and land the conductors. Courtesy: Samuel Engineering

The AHJ will need to be on board with this reasoning. If there is any concern for an application, an MC-HL cable may be a better choice for compliance with this requirement. The continuously corrugated sheath is typically pressure tested by manufacturers and allows them to state that the cable is impervious to gas/vapor entry. However, the manufacturer’s data sheets for the cable should be reviewed to confirm this level of performance. Within the confines of the hazardous area, one needs to be mindful of the NEC cable sealing requirements at the terminations. As with requirements for cable boundary seals, the language of the code can be confusing here as well. Consider

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a typical scenario of a 3-conductor plus ground Type MV cable run in a tray system terminating at a motor in a C1-D2 area. The cable sealing requirements are spelled out in NEC Article 501.14(E)(1) through 501.14(E)(4). As stated previously, even though the NEC refers to “cables that do not transmit gasses or vapors through the core,” it also notes that the interstices of conductor strands are not considered part of the cable core and may transmit gas. Compact stranding may minimize this but the potential to transmit gas through the strands in sufficient quantity to create an explosion hazard may exist. At this point, applying cable seals to minimize passage of gas through the cable core aside from the strand interstices should be discussed. Again, there is a disconnect between typical manufacturers’ data sheets and NEC language. This section of the code is not easy to follow and is often not addressed clearly in manufacturers’ data sheets, so compliance may hinge on interpretation by the AHJ. Much this will amount to whether the AHJ considers the cable sheath as gas/vapor tight, and the cable core as capable or not of transmitting gas. Typical MV cable data sheets will not state performance of cables with respect to these two modes of potential gas transmission. In a practical sense, this prevents NEC Article 501.14(E)(2) and 501.14(E) (3) from being applicable to Type MV cable design in C1-D2 areas unless mandated by the AHJ. Now consider NEC Article 501.14(E)(1), which requires a sealing fitting to be installed at conduit/ cable entries when the termination takes place inside of an enclosure required to be explosion proof. Most motor terminal boxes for C1-D2 rated motors are not explosion proof. The last part of this section also creates some confusion. It can be interpreted to require cable seals for essentially all multiconductor Type MV cables regardless of the enclosure rating. Again, if possible, it is advisable to have a conversation with your AHJ to get an interpretation of this requirement as the writing of the Code leads to various opinions on this subject. This may even include no cable seal for cables longer than several hundred feet. Due to the cable run length and fillers in the cable core, some AHJs consider the cable to inherently minimize the passage of gas back to the non-classified area. If it is deemed by the AHJ that passage of gas through the cable from the C1-D2 area must be addressed, the options available depend on what type of cable is being used. The objective is to minimize the passage of gas through the cable core. www.plantengineering.com

Hot or cold shrink termination kits on the individual phase conductors are installed to evenly distribute electrical stress and protect the exposed conductor insulation. These often can be ordered with a “breakout boot” to seal the cable assembly. While in practice, these may restrict the passage of gas through conductor core and interstices to some degree, manufacturers generally do not test or label their performance in hazardous area applications. If there is any concern about passage through strand interstices, it is advisable to specify compact stranding on the MV cables. To minimize passage of gas through the cable core if you are using an MC-HL cable, it is probably easiest to select a cable gland fitting listed for MC-HL cable that is sold with a compound applied inside the gland (see Figure 5). The purpose of the compound is to provide an explosion-proof seal similar to the commonly used conduit seals. But whether your terminal enclosure is explosion proof or not, the gland also serves to minimize the passage of gas through the cable core. If you are using a type MV cable, it gets a little more complicated. If you want to use a cable gland with an MV type cable, you will need to verify the gland is approved for this type of cable. Many are not. The other option is an explosion-proof conduit seal placed at the cable breakout. However, this approach is often challenging as well. Installation of a conduit sealing fitting on larger size conduits is often difficult, particularly in the congested area around the motor terminal box. Removing the cable jacket and fillers at the seal fitting exposes the shields and insulation to possible damage. More so than low voltage tray cable, even minor damage to MV cable construction can lead to premature failure. It is probably best to have a discussion with the AHJ before this route is taken so that an acceptable strategy to minimize the potential for gas transmission can be established.

Acceptance testing

This leads to the final topic to be discussed: acceptance testing after installation. Most petrochemical plants typically require acceptance testing of MV cables before energization. Some also call for periodic maintenance testing. Usually, this is by means of high potential dc testing, or dc Hi-Pot. This topic is one with a wide variety of opinions and recommendations associated with it and the reader is encouraged to research the wealth of technical www.plantengineering.com

Figure 5: MC-HL cable with gland installed at a medium-voltage motor terminal box. Courtesy: Samuel Engineering

papers available and recommendations of cable manufacturers. Generally, acceptance tests should be conducted in accordance with IEEE 576: IEEE Recommended Practice for Installation, Termination and Testing of Insulated Power Cable as Used in Industrial and Commercial Applications using the recommended voltage level for the cable insulation rating. This is typically considered a “go, no-go” test in that the actual test current leakage values are of less importance than the plotted curve shape with respect to the test time. The leakage values during the test should initially start out relatively high and fall to a stable value for the remainder of the test period, typically 15 minutes. Note that this type of testing is influenced by humidity, moisture in raceways and temperature. These conditions are difficult to control, and the test results should be reviewed by a person with experience in interpreting the results.

Final thoughts

Designing and installing MV cables in petrochemical facilities presents a number of challenges and requires a holistic approach to the entire installation. Specifically, a comprehensive design approach is warranted that includes an understanding of the MV cable construction, an understanding of the terminations, physical limitations of the load equipment and involvement of the AHJ to sort through the relevant NEC requirements. PE Garrett Nariman, PE is a senior electrical engineer at Samuel Engineering. PLANT ENGINEERING

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SOLUTIONS IT AND OT INFORMATION NETWORKS By Mark Mullins

Tools troubleshoot industrial Ethernet problems Technology ranges from the simple to the sophisticated

ue to its inherent reliability, performance and interoperability, Ethernet has rapidly become the communication protocol of choice for automation and control systems in the industrial environment. In fact, recent surveys found that 70% of all newly installed factory automation nodes employ Industrial Ethernet. This includes Industrial Ethernet applications like Modbus TCP/IP, EtherCat, EtherNet/ IP and Profinet encapsulated with Ethernet frames to send and receive supervisory and control information between industrial devices and systems. All of these applications are designed to work over Ethernet-based twisted-pair copper or fiber cables and connectors that have been hardened to stand up to factors such as vibration, dust and liquid ingress, chemicals and electromagnetic interference found in the industrial environment. The ability to maintain operations and productivity via Industrial Ethernet is only as good as this underlying cabling infrastructure, but even after that infrastructure has been installed, tested and apparently doing its job, problems can arise that bring industrial operations to a screeching halt. Whether caused by accidental damage and contaminants to cables and connectors in the harsh industrial environment, interference from new machinery, or changes to infrastruc-

ture that went awry due to the wrong components or improper installation, plant managers and operations technology (OT) staff need to act fast to locate and fix the problem to keep machines in production. With more than half of Industrial Ethernet problems traced to the cabling infrastructure, knowing the most effective way to troubleshoot can mean the difference between an hour of unplanned downtime versus days that could wreak havoc on production standards and translate into millions of dollars of lost revenue. The good news is that there are plenty of simple, inexpensive troubleshooting tools available that can help you quickly identify and locate copper and fiber cabling problems to expedite repair and reduce costly unplanned downtime.

Simple tools, simple problems

When machinery shuts down because it isn’t receiving Industrial Ethernet control signals over the cabling, the problem could be something as simple as a lack of continuity caused by a cut or break in the cable or a bad termination at the connecting interface. Checking for continuity is easily accomplished with wiremap testing that looks for potential problems like opens caused by broken conductors, shorts from improperly terminated or damaged connectors, or miswirings that result in reversed pairs, cross pairs or split pairs, where conductors within the cabling have been terminated to the wrong pin position at a connector interface. Rather than bringing in outside help with expensive testing equipment, you can use a simple, low-cost wiremap tool to quickly identify the problem. A good wiremapper will also indicate which pair is causing the problem, as well as verify the integrity of the shield on the cable — which is ideal for industrial environments where shielded twisted-pair cabling is the norm.

Figure 1: The ability to maintain operations via Industrial Ethernet is only as good as this underlying cabling infrastructure, but even after being installed, tested and apparently doing its job, problems can arise. Courtesy Fluke

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www.plantengineering.com

If the termination at the connector interface isn’t the problem and the fault exists somewhere along the length of the cable, downtime can be reduced by identifying the location with a tone and probe. Some wiremappers may even have tone generation built-in so all that’s needed is a low-cost probe. A tone and probe works by injecting a high harmonic signal onto a conductor that generates an audible noise at the fault location. However, in some industrial environments, it can be difficult to access the entire length of the cable — especially if it is installed in protective conduit, located up near the ceiling, or traverses through other areas of the plant floor where production is still running. In this scenario, a somewhat more sophisticated Time Domain Reflectometer (TDR) can be used to indicate the exact distance to a cabling fault. TDRs are available that can locate faults on any copper cabling and include an integrated toner to narrow in on the actual problem conductor pair within the cable. When choosing one of these simple troubleshooting tools, it’s important to ensure that it supports the type of cabling and the distances of the cabling runs. To ease the process, consider a tool with a user-friendly graphical interface that simply and clearly identifies the problem. You may also want to look for a tool with ample battery life and rugged construction to stand up to the harsher industrial environment. When using a tone and probe, another consideration is the ability of the probe to filter out interference from common 50 or 60 Hz noise from nearby industrial machinery.

When the cabling is fiber

While fiber cabling is not as common on the factory floor, where lengths tend to be shorter and transmission speeds are typically less than 1000 Mb/s, some areas having longer links, higher working temperatures and immunity from electromagnet interference call for fiber optic cables. While fiber installation and initial testing requires more expertise and specialized tools, there are some inexpensive options available that you can use to troubleshoot. There is a chance that the problem with fiber cabling is caused by a bend or break somewhere along the link. When fiber is bent beyond its recommended bend radius, which is typically 20 times the diameter of the cable, it can cause light signals to leak out of the fiber and prevent proper data transmission. These bends can happen during or after installation; small microbends that may have gone unnoticed during installation can cause the fiber glass to crack over time. Other poor installation practices like exceeding tensile load on the cable can also eventually lead to breaks. One low-cost, simple troubleshooting tool for determining continuity in a fiber and finding a bend or break is a visual fault locator (VFL) that illuminates a www.plantengineering.com

Figure 2: Use a power quality analyzer to characterize electrical system dynamics in generator startups, UPS switching and other tasks. Courtesy: Fluke

fiber with a visible laser that will “leak” out where the fiber is broken or bent. However, a VFL only works well if you can visually inspect the entire fiber run. If the fiber is difficult to access or runs through conduit, you might need to invest in an optical fault finder. These more advanced tools send out a light pulse through the fiber and measures the power and the timing of the light reflected back from breaks, bends, and connections along the length of the cabling run. They are also ideal for locating the end of a fiber. By measuring the timing of the light reflected back, an optical fault finder can quickly indicate the distance to a problem. In addition to a ruggedized design and use-friendly graphical interface, when choosing an optical fault finder, you want to make to use one that can detect live optical signals on the line before troubleshooting, as light from a fiber transceiver can be harmful to the human eye. You will also need it to work with your infrastructure’s type of fiber cabling and connectors. If you have multiple types of fiber connectors installed in your factory to accommodate various I/O interfaces, ideally you want an optical fault finder with interchangeable adapters. PLANT ENGINEERING

April 2021

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SOLUTIONS IT AND OT INFORMATION NETWORKS

Figure 3: Use a power logger to gain fast insight into overall electrical system health. Courtesy: Fluke

Another notable feature of an optical fault finder is its ability to identify contaminated connectors. Dust or dirt on the endface of a fiber connector is the most common cause of fiber optic failures. Light transmission needs a clear path along the link, and even a single speck of dust can cause reflections and degrade a signal. Industrial environments are inherently dusty so it’s no surprise that a dirty fiber endface could be the problem. If an optical fault finder identifies that the problem lies at a connector, another tool to have on hand is a fiber inspection camera or microscope. While using a microscope to look at a fiber connector endface can require the expertise to know what you’re looking at, there are fiber inspection tools available that have built-in intelligence to analyze the fiber endface for you. They do this by analyzing the number and size of defects and scratches on the endface and comparing it to industry standards like IEC 61300-3-35 that specify criteria for endface cleanliness. Of course, if you do discover a dirty fiber endface, you want to ensure that you have the onsite skillset and consumables required to clean the endface. If not, you may need to reach back out to the contractor that originally installed the fiber infrastructure in the first place.

Sometimes experts needed

When all else fails and the use of simple troubleshooting tools by your internal teams still doesn’t identify the problem with the network, it may be time to call in the experts with more sophisticated testing and troubleshooting equipment. They were likely the ones that

• April 2021

PLANT ENGINEERING

installed and tested the infrastructure in the first place, so they should be well-equipped to find and fix the problem. But by all means, if you have the expertise on staff, use it and invest in more advanced tools that prevent you from having to wait and pay for outside help to get up and running. For troubleshooting copper beyond what you can accomplish with a simple wiremap tool, tone and probe, and TDR, a good qualification tester will do the trick. Not only can a qualification tester do everything that a wiremap tool and TDR can do, it can also measure network speeds and identify less-obvious performance problems like crosstalk. Ultimately, a qualification tester may help you identify that the cabling infrastructure itself isn’t the problem. When it comes to more advanced fiber troubleshooting, the next step up from an optical fault finder is an expensive optical time domain reflectometer (OTDR). While this more complex troubleshooting tool requires skill to operate, it has the capability to identify and locate events along the fiber that are causing reflections and measure their impact on the overall loss of signal, which may be what is causing the malfunction. While calling in the experts may ultimately be inevitable, the important thing to remember is that there are simple, easy-to-use tools that you can use as your first line of defense to get your production back up and running sooner and cost you less in the long run. PE Mark Mullins is a product manager with Fluke Networks. www.plantengineering.com

SOLUTIONS MANUFACTURING By Claudia Jarret

Tackle obsolescence with additive manufacturing 3D printed spare parts are a revolutionary force

bsolescence is an unavoidable part of any manufacturing environment. However, it’s concerning that so many companies admit they do not know when vital equipment requires replacing, or when they do, they scramble to find replacements. The latest developments in additive manufacturing could provide an answer to the obsolescence problems. Additive manufacturing is a transformative approach to industrial production that enables the creation of components using a variety of 3D printing techniques. Before delving into issues surrounding obsolescence, let’s first define what we mean by 3D printing. The process starts with a component material, initially in the form of powder, which is melted with a laser layer-upon-layer to obtain the desired shape. Fundamentally, it’s about adding material

instead of removing, as in traditional subtractive manufacturing. The range of materials that can be used is almost endless — from innovative plastics and metal alloys, to concrete, wax, resins and even human tissue. One of the newest advances in additive manufacturing is the possibility, recently explored by Sandvik Coromant, to print with diamond powder, shaping the hardest material on Earth into any desired geometry. Because, with additive manufacturing, it is possible to print intricate and hollow shapes with no scrap, only the necessary amount of material is added to the process. This has made it a popular technique in fields that require the production of highly specialist components in a small production run, such as aerospace or the biomedical sector, and has led to exploring how additive manufacturing could

Figure 1: A new generation of 3D printing machines will provide an alternative means for securing difficult to procure replacement parts. Courtesy: EU Automation www.plantengineering.com

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April 2021

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SOLUTIONS MANUFACTURING

Figure 2: Prototypes manufactured using 3D printing. Courtesy: EU Automation

help manage the obsolescence of manufacturing components.

Obsolescence problems

Our society is characterized by rapid technological developments in the use of big data, automation and computing. These technologies have had

a positive impact on manufacturing, allowing plant managers to maximize productivity, reduce waste and create a safer working environment for their employees. On the other hand, technolog y comp onents, both hardware and software, tend to have a short lifespan. As newer versions of the same components are marketed, the original equipment manufacturer (OEM) may stop producing the version purchased by the manufacturer, making it obsolete. When obsolete components break, it can be hard to find like-for-like replacements. Managing obsolescence is therefore critical since the breakage or malfunction of obsolete components exposes the

Figure 3: Detail of a 3D printing operation. Courtesy EU Automation

• April 2021

PLANT ENGINEERING

www.plantengineering.com

business to risk of costly downtime, or even to the possibility of having to upgrade an entire system. Material engineers are currently researching the potential of additive manufacturing to manage some aspects of obsolescence. The core idea is that if a component is no longer available from the OEM, it could be simply 3D-printed. For example, the US Airforce has launched research into 3D printing replacement parts for old planes using the Figure 4 3D Printing Platform designed by 3D Systems. The US Airforce will examine how Figure 4 3D Printing Platform can reproduce components for aircrafts that are no longer in production. The US Airforce often requires out-of-production parts due to manufacturing obsolescence, poor documentation and costs-to-create. And, as replacement parts can be built much faster and in smaller batches through additive manufacturing, no minimum order quantity is required. This can reduce the time of aircraft spend on the ground, and the need for warehousing space.

The question of electronics

As promising as this sounds for the aerospace industry, there are still questions that need to be answered before additive manufacturing can become a standard way of coping with component obsolescence in other industries. First of all, it is unclear to what extent additive manufacturing could help manage the obsolescence of electronic components. This sector is one of those that most suffers the consequences of the increasingly short lifespan of components, due to the speed at which new products and solutions are launched on the market. While almost any mechanical component could be fabricated using 3D printers, it’s much harder, though theoretically not impossible, to 3D print something like a circuit board or cables and wires. Even when possible, manufacturers should consider the cost and complexity of 3D printing spare components. Having onsite additive manufacturing capability may require an initial investment and a dedicated design engineering team. While these investments can make sense in an R&D environment, they might be counterproductive to produce spare parts that are only occasionally needed. In cases like this, it is much faster and cheaper to rely on an automation parts supplier that specializes in obsolete components. Although obsolescence is an unavoidable part of any manufacturing environment, manufacturers do not need to scramble to find replacements. 3D printed spare parts could be an answer to replacing obsolete parts, but won’t completely replace the need for a strong parts supply network across the United States. PE

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Claudia Jarrett is a country manager for EU Automation. PLANT ENGINEERING

April 2021

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SOLUTIONS WEBCAST ON CYBERSECURITY By Mark T. Hoske

More answers on what you need to know about cybersecurity Below are more answers resulting from a cybersecurity webcast on cybersecurity architectures, training, best practices, risk assessment and trends based on research

cybersecurity webcast Dec. 3, 2020, raised more questions than two expert responders had time for at the end, and their answers to those additional questions on industrial control system cybersecurity are available below. The webcast, with one PDH available, is archived for one year. Register for the webcast with the following link: “Cybersecurity: What you need to know.” Two presenters answered the additional questions below. • Brad Bonnette, technical director, Wood Automation and Control, Wood • Anil Gosine, global projects, MG Strategy+

More ICS cybersecurity answers QUESTION: What are often overlooked cybersecurity best practices that represent weak links? Do they differ widely by organization and industry or are there commonalities for all? Bonnette: Seemingly simple things like, turning off or actively managing USB, Bluetooth and removable/portable media connections. Lack of management of unused accounts, personnel departures, (temporary) personnel, contractor or vendor access credentials. Not monitoring firewall or security monitoring software reports or alerts. Gosine: Proper configuration of the systems procured and under estimating the time/effort needed to continuously maintain and address issues. You want to avoid similar situations like operators ignoring alarms and then requiring another effort for alarm management years after initial ICS deployment. An article published in Control Engineering, “Key security components and strategies for ICS,” is a good reference. Q: Are there special cybersecurity recommendations for supervisory control and data acquisi-

• April 2021

PLANT ENGINEERING

tion (SCADA) and programmable logic controller (PLC)-based systems? Bonnette: Edge protection and defense-indepth are still principal base models. However, if the context of SCADA includes utilization of cloud or wide-area network (WAN) that is not exclusively controlled by the owner/operator, additional measures must be considered to authenticate traffic, endpoint devices, users and protect (encrypt) data being carried over cloud or contracted carrier networks. The external network should be treated as an untrusted edge. However, just because your company owns a specific LAN or WAN does not mean it may not need to be considered untrusted just as well, depending on technical and physical access control to the networks. External networks should always be considered untrusted and considered a potential threat vector. Reference: ISATR100.15.01-2012 Technical Report “Backhaul Architecture Model.” Q: Is there a need for firewalls on Apple products? Bonnette: Yes, both to protect the device, but primarily to protect the rest of the system from the device. Apple OS are just as exploitable as Microsoft Windows (Linux as well). At a minimum, any type of networked device may be used for distributed denial of service attacks (DDoS) and robot data storm attacks, or as a pivot point to an operating technology (OT) system or network. Mobile phone malware has caused OT incidents, transmitting malware to the OT system by plugging in a mobile phone (smart phone) to a USB to charge it on an OT workstation, resulting in crypto locking or virus infection of facility control systems. Gosine: Apple Wireless Direct Link protocol to create mesh networks can be exploited as noted in recent security notifications. www.plantengineering.com

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Q: Are there particular advantages to hard wiring? Or to keeping all data in house?

available corporate news feeds/webcast updates also may be beneficial.

Bonnette: “Hard-wiring” may be easier to protect physically with barriers and physical access controls. However, as soon as the network leaves a physically controlled boundary, any points of connection or distribution are accessible, but typically not as accessible as wireless systems. There is a lot of debate on keeping data “in-house.” If you are overwhelmed with maintaining the security and integrity of your data systems and data, outsourcing may actually be a means of improving the security or integrity of the system, but risks in the supply chain (the service supplier’s) integrity, security practices and capability need to be assessed as if it were your own estate. Gosine: You need to weigh the risks/benefits of losing the cloud-based data analytics capabilities that increase productivity, efficiency and increase margins when keeping data internal.

Q: What determines how often a cybersecurity risk assessment should be done? Should miniassessments be completed in certain areas more frequently than all of operations, all of the enterprise, or all of the connected supply chain?

Q: We’re trying to determine what cybersecurity staff training should include for whom and when?

An architecture document that defines the cybersecurity architecture and risks helps in justifying what needs to be done and why, according to the Control Engineering webcast, “Cybersecurity: What you need to know.” See www.controleng. com/webcasts/ past. Courtesy: MG Strategy+, Wood Automation and Control and Control Engineering

• April 2021

Gosine: Know where your organization’s understanding is through a baseline Q&A that follows the NIST Framework Categories. There will be a need for distinct training course materials for operators, security administrators and general users. Annual workshops for operation and security administrators. Operators — training on detecting anomalies; Administrators — tools, management techniques and prioritization in risk assessment; General users — social engineering and situational awareness. Incorporating relatable security information into

PLANT ENGINEERING

Bonnette: The frequency of risk assessments should be commensurate with the previously assessed risk. Systems or zones with higher potential consequence of compromise should be assessed more frequently than lower potential consequence areas. Interim risk assessments for a single zone or subset should consider conduit connections to other zones. Gosine: Critical operational processes are getting done more frequently to show risk avoidance/mitigation to C-level (potentially every 18 months). This will be based on how fast remediation efforts are getting completed. Regulatory requirements where applicable will include minimum frequency requirements that are required. Q: With software updates, vulnerabilities may be exposed. Is there a repository where control system software security status is available? Gosine: Yes, see https://us-cert.cisa.gov/ics and https://www.strategicefficiency.org (membership required). PE Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.

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Articles inside

Tools troubleshoot industrial Ethernet problems

Fire safety best practices for manufacturing facilities

Install medium voltage cables in petrochemical plants

Tackle obsolescence with additive manufacturing

Seven shortcomings of commodity casters