A&D Feb Mar 2014 by print design

Automation & Drives

AUTOMATION & DRIVES

www.AandD24.in

Automation & Drives

A U T O M AT I O N & D R I V E S

Remote collaboration, optimisation & operations

Cross-industry perspectives Efficient Manufacturing

FEB-MAR 2014 I VOLUME 05

Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong

FOCUS Power & Energy

P. 34, 40, 46

ROUND-TABLE Building future factories

A&D - Interview

P. 28

Rob Gremley WWW.AandD24.IN

Executive Vice President PTC

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Efficient Manufacturing

VOL 06 | FEB-MAR 2014 | ` 100

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Inductive

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EGP – Small Parts Gripper better gripping force-mass ratio

Your modular assembly automation. It’s time to make use of your machine’s full potential. www.in.schunk.com/machine-potential Jens Lehmann, Brand Ambassador of SCHUNK, the family-owned company

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Responding to challenges Continuously rising costs, fierce competition, fluctuating markets, the remote location of many plants and a global scarcity of qualified and experienced operating and maintenance personnel have fundamentally changed the way in which manufacturing plants operate. Moreover, factors like costs and competition have stimulated global consolidation and an ongoing search for increased efficiency and reduced operational costs. The industry is responding to the challenges by building flexible capacities, increasing productivity, enhancing reliability and utilisation, with the ultimate aim of lowering operational costs. The basic technology of any manufacturing process has changed very little over the past twenty years. However, the most significant developments have occurred in the control and modernisation of the plants. Over the past decade, the internet has played a major role in supporting innovative solutions for the manufacturing industry. With this, information can be made available anywhere and at any time, thereby leveraging scarce expertise and helping to optimise manufacturing processes. Not enough, though, new collaborative schemes are being developed that offer innovative and appropriate solutions to many of the challenges described above. More recently, remote collaboration environments, combining local and remote resources and automation systems, are being considered for operating in dissimilar industries adopting similar solutions to meet common imperatives. Check out this issue to know more on such topics. I am sure you will enjoy reading the articles in this edition!

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editorial advisory board

Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net

Vijay Srinivasan Partner, Effectus Consulting LLP Anup Wadhwa Director – AIA (Automation Industry Association) P V Sivaram MD – B&R Automation Member – AIA Anant Maheshwari Managing Director Honeywell Automation India

 Repeatibility <1µm  Diameter, gap, width and position measurement

Ganapathiraman G Vice President & GM (South and South-East Asia) ARC Advisory Group Ravi Agarwal Director, Pepperl+Fuchs (Factory Automation) Raj Singh Rathee Managing Director Kuka Robotics India

Dr KLS Sharma Advisor Automation Education & Training Mandar Phadke CEO, Abhisam Software Former Head – Process Control Lanxess India Pvt Ltd Arcot Rajabahadur Automation Consultant

Jasbir Singh Vice President – Electrical & Instrument Essar Project Management Consultants

Thampy Mathew Chairman, Fieldbus Foundation India Regional Sales Director, Pepperl+Fuchs (Process Automation)

Overseas Partner: China, Taiwan, Hong Kong & South-East Asia

A&D India | Feb-Mar 2013

www.micro-epsilon.in MICRO-EPSILON | 94496 Ortenburg / Germany Phone +49 85 42/168-0 | info@micro-epsilon.com Representative for India: IPS Integrated Process Systems | 600 004 Chennai 3 Phone +91 44 24981786 | www.ipsindia.in

CONTENTS

Market

Management

10 NEWS

26 India presents a better opportunity to have a best-partner eco-system

14 “A conscious action to implement safety”

Interview with Sagar Bhosale, Managing Director, Schmersal India 16 “Increasing reliability of drive trains”

Interview with Wolfgang Weissler, Vice President, Drive Technologies, Siemens

Interview with Rob Gremley, Executive Vice President, PTC 28 ROUND-TABLE

Building future factories

Industry experts in discussion on technology and demand drivers for the Factory of the Future

Focus

Power & Energy 34 Centralised operation of T&D assets

An article on the implementation of emerging automation and IT in Tata Power to achieve operational excellence 40 Fieldbus for power plant automation

A read into the various advantages of Fieldbus technology in power plants 46 Energy fingerprint for power plants

70 Vision for a better economy

A post event report on F&S’ annual forum on “Enhancing manufacturing competitiveness: New age solutions driving change” 72 Optimising production processes

A pre-event report on Hannover Messe, Germany

This article proposes an automated energy assessment tool for power plants

CONTENTS

Advt

Technology

Cover Story 18 Cross-industry perspectives

NETWORK & CONNECTIVITY

Internet of Things

The article focuses on remote collaboration solutions across multiple industries

A read on industrial IP that can help industrial production by consolidating automation, control and facility management within a single infrastructure

50 DRIVES & COMPONENTS

Providing maximum versatility A feature on Nord Drivesystemsâ&#x20AC;&#x2122; solutions used in the development of the largest discontinuous toothpaste production system in the world by Ekato

A technology trend story on Machine to Machine communication which has a real-time delivery of reliable data 64

Evolving the connected factory

The article highlights the advantages of the Connected Factory

52 SOFTWARE & ENGINEERING

Enhancing profit by sustainable solutions

The article showcases unique software developed to address challenges in manufacturing world with a logical approach

M2M opportunities

67 CONTROL & REGULATION

Keep cool and stay hot

The article discusses the need for climate control in electrical and automation cabinets

56 MANUFACTURING IT

A step-by-step approach

A read into the best practices in product lifecycle management

TECH TALK

Designing a safe sustainable machine

An insight into five best-practice design principles for machine builders 75

Innovative cabling solutions

The column discusses cabling solutions for automated nuclear buildings and research laboratories

Cover image courtesy: SHUTTERSTOCK

New Products Test terminal blocks; Metal flow control valve; Multi-touch functionality panel; Pick & place units 77 CAN repeaters; AC variable frequency drive; Safety brake control; PGV positioning system 78 Safety relay; Non-contactless inductive universal encoder; Distributed networking motion controller; Preplanning & detail engineering platform 76

Columns 05 Editorial 08 Contents 80 Highlights - Next issue 80 Company index

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market | news

HARTING & SAP demonstrate sensor-controlled processes

Siemens PLM Software awarded the Company of the Year

HARTING Technology Group and SAP are set to collaborate even closer at this year‘s Hannover Messe (April 7-11, 2014) show. Visitors to the two companies‘ trade fair stands will be shown the identical exhibit in the field of SMART SERVICES. Both exhibits will be connected to each other via sensors and the Cloud. A pump will be exhibited to illustrate “the tangible Cloud”. This concrete practical example will illustrate extensive vertical integration within the enterprise – meaning all the way from a machine‘s measurement data to back-end systems and onwards to the management of business processes. What Sensor readings are is new here is that specific maintenance transmitted to the Cloud, from processes can be initiated directly from where concrete business data monitoring. Sensor readings are processes are then performed transmitted to the Cloud, from where concrete business processes are then performed. The M2M platform relays the system‘s sensor data into the SAP HANA database.

Frost & Sullivan has awarded Siemens PLM Software as “Company of the Year for PLM in India, 2013”. The award was announced at their 2013 Industrial Technologies Awards function in Mumbai, India. Frost & Sullivan recognises outstanding industry achievements by awarding top companies in regional and global markets in various categories. “Siemens PLM Software has a well chalked out strategy to penetrate the Indian market with its range of solutions and customer centric delivery model. The enhanced value addition delivered by Siemens PLM Software to its customers has enabled it to maintain its market leadership in India,” said Niju V, Director, Automation & Electronics Practice, Frost & Sullivan. “We are honoured to receive this recognition once again. This award is a testament to our unwavering commitment to the manufacturing industry in the country. As manufacturers in India we strive to achieve competitiveness within an increasingly complex global business environment,” said Suman Bose, VP & MD, Siemens PLM Software, India.

> MORE@CLICK ADI03387 | www.AandD24.in

> MORE@CLICK ADI03388 | www.AandD24.in

Engineers optimise test strategy National Instruments has released its Automated Test Outlook 2014, highlighting the company’s research into the latest test and measurement technologies and methodologies. Engineers and managers can use the report, which examines trends affecting a wide range of industries, to take advantage of the latest strategies and best practices for optimising any test organisation. The talent pool for test engineers is shrinking and test managers must improve organisational proficiency Engineers and managers can use through smarter hiring, better on boarding the report, which examines trends and greater investment in training to ensure a affecting a wide range of industries, properly skilled and staffed test organisation. to take advantage of the latest New technologies deliver greater feature sets strategies and best practices for on test equipment, helping test managers optimising any test organisation monitor the health of their test systems, lowering test costs and maximising uptime. Traditional test frameworks limit profitability by not providing the ideal balance of performance and cost or the ability to scale based on actual product demand. Similar to the IT industry, cloud computing applied to automated test can alleviate these growing test concerns. > MORE@CLICK ADI03389 | www.AandD24.in

Ultra solar power project An Ultra Mega Solar Power Project (UMSPP) with a cumulative capacity of 4,000 MW will be set up in Rajasthan. Significantly, with the commissioning of this plant and commercial utilisation of the harvested energy therein, this would become the largest single location solar electricity generation project in the world. A joint venture company will develop The solar plant will be set up in the solar power project with equity two phases over a period of seven participation from Bharat Heavy years with phase-I comprising 1,000 Electricals Limited (26%), Solar MW and the balance 3,000 MW in Energy Corporation of India (23%), subsequent phases Hindustan Salts Limited (16%), Powergrid (16%), Satluj Jal Vidyut Nigam Limited (16%) and Rajasthan Electronics & Instruments Limited (3%). The project set up on land provided by SSL will have equipment supplied by BHEL, power evacuation by POWERGRID, sale of electricity by SECI, O&M by REIL and project management by SJVNL. The plant will be set up in two phases over a period of seven years with phase-I comprising 1,000 MW and the balance 3,000 MW in subsequent phases. > MORE@CLICK ADI03390 | www.AandD24.in

A&D India | Feb-Mar 2014

news | market

More manufacturers with 350,000 component data The EPLAN Data Portal provides over 350,000 component data from 56 manufacturers. The latest additions include General Electric (GE) in the field of high-voltage current switchgear, Numatics with fluid power components, Murrelektronik, for example with field distributors, Omron, and cable manufacturers Schweiger, Sigmatec, Stego & TKD Kabel. Efficient design starts with the smallest unit – with a standardised component that is added to the respective Numerous companies e.g. design project via EPLAN Data Portal. GE, Murrelektronik, Sigmatek Manufacturers that are already represented in and Omron have made the portal such as Phoenix Contact have component data available in extended their product portfolio. Over 20,000 the EPLAN Data Portal. In total, new and revised data are currently available 56 manufacturers are now – around 12,400 of them macros, 600 of which represented in the portal are in 3D. Companies such as ABB, B&R, Weidmüller and Sick have included additional parts and Festo has also increased its range in the EPLAN Data Portal. With currently 34,000 records of which about 20,000 are functional macros and almost 9,000 are 2D graphic macros the company from Esslingen covers a wide spectrum of fluid power and electrical engineering parts. > MORE@CLICK ADI03391 | www.AandD24.in

Sandhar Technology join hands with Korean firm

Transformational change by creating social and financial inclusion CII organised an interactive session with Anand Sharma, Union Minister of Commerce and Industry at Sophia College in Mumbai. Faculty members and students from the college had participated in the session. Sharma said that the creation of democratic freedom is one of the most powerful events that happened post-independence because of the initiatives of great leaders. The minister stated that India has the highest voter turnout and year-after-year its citizens have done a good job of electing the right representatives. According Anand Sharma, Union to him, liberalisation and the spread of Minister of Commerce information technology and communication stated that India has the helped emerging countries to come up in the highest voter turnout backdrop of a unipolar global economy. and year-after-year its Speaking about India’s demographic advantage citizens have done a good he said that median age of the population is job of electing the right 23-24 years and about 68% fall below the age representatives of 35, which implies that the country will be one of the largest suppliers of manpower to the ageing developed economies. > MORE@CLICK ADI03392 | www.AandD24.in

Setting course for the production of tomorrow

Sandhar Technology has invested $5 million (` 31.3 crore) in an equal joint Siemens presentation at the Hannover Messe 2014 will be focused on venture (JV) with Korean setting the right technological course for the production of the future. company Hang Sung. Han Sung “Advancing digitisation and networking has specialisation in high and the convergence taking place precision press parts, insert between the virtual and real worlds moulded components, terminals, are decisive drivers for manufacturing parts for relay switches, industry. Companies are increasingly switches etc. Looking at the turning to innovative and integrated increasing consumption of technologies in a bid to strengthen electronics in the automobile, their competitive position”, said The plant will be set up in Gurgaon (NCR) Sandhar has been increasing its Siemens presentation at the Hannover Anton S Huber, CEO, Siemens Industry with an investment of ` 31 crore presence in this segment of Messe 2014 will be focused on setting Automation Division, at the Press the right technological course for the business. This new venture will Conference ahead of this year’s production of the future enable Sandhar Technology manufacture high precision parts and also Hannover Messe. “With its Digital have backward integration of electronic relays which the company is Enterprise Platform, the company is manufacturing under a new technical alliance with Korea’s relay technology working on an overarching approach linking PLM software with engineering leader Jinyoung Electro-Mechanics Company Ltd (JEM). Sandhar is applications and integrated automation. This is the approach which will country’s one of biggest manufacturer for automotive locks mirrors and create the foundation for Industrie 4.0”. Alongside new products for its spools for seat belts. The company headed by Jayant K Davar looks at Integrated Drive Systems (IDS) and the Totally Integrated Automation (TIA) achieving a top line turnover The plant will be set up in Gurgaon (NCR) with portfolio, the company will also be presenting its new “Data-Driven Services” an investment of ` 31 crore of $1 billion in the next three years. based on the acquisition, analysis and evaluation of production data. > MORE@CLICK ADI03393 | www.AandD24.in

A&D India | Feb-Mar 2014

> MORE@CLICK ADI03394 | www.AandD24.in

market | news

Approval for semiconductor wafer fabrication manufacturing facilities The Cabinet has approved setting up of two semiconductor wafer fabrication on the development of electronics system design and manufacturing eco(FAB) manufacturing facilities in India. These FAB units are to be set up by system across the country. It will help to set up a critical pillar required to two business consortia, and broad project parameters that includes promote electronics system design and manufacturing in India. The Jaiprakash Associates Limited (with IBM, USA and Tower Semiconductor semiconductor wafer fabrication units, will stimulate the flow of capital and Limited, Israel as partners). In this, the total technology, create employment opportunities, estimated project cost is ` 34,399 crore; help higher value addition in the electronic technology: 90/65/45/28 nm with a capacity products manufactured in India, reduce of 40,000 WSPM at Yamuna Expressway, Uttar dependence on imports, and lead to innovation. Pradesh. The second business consortia The incentives extended will comprise 25% include HSMC Technologies India (with ST subsidy on capital expenditure and tax Microelectronics and Silterra Malaysia Sdn. reimbursement as admissible under Modified Bhd. as partners) wherein the estimated Special Incentive Package Scheme (M-SIPS) project cost is ` 29,013 crore; technology Policy; Exemption of basic customs duty (BCD) 90/65/45/28/22 nm with a capacity of 40,000 for non-covered capital items and 200% WSPM at Prantij, Gujarat. The final agreements deduction on expenditure on R&D as are expected to be signed by August 2014. These FABs will have a big impact on the development of admissible under Section 35(2AB) of the The Empowered Committee has been electronics system design and manufacturing eco-system Income Tax (IT) Act. Investment linked across the country deductions under Section 35AD of the IT Act authorised to take all decisions to implement the FAB projects in furtherance of the decision. and interest free loan of approx. ` 5124 crore The proposed FABs will create direct employment of about 22,000 and each will be the added incentives. > MORE@CLICK ADI03395 | www.AandD24.in indirect employment of about one lakh. These FABs will have a big impact

Eplan in for Rockwell Automation Encompass program

ANSYS wins DesignCon vision award

Eplan, a Global Encompass partner, has added the Eplan Fluid and Eplan Harness proD products to the Rockwell automation Encompass Program. With the Eplan suite of products, users can bidirectionally compare their engineering data with the control systems from Rockwell Automation.These products join All products of the Eplan Platform have Eplan’s other approved systems now been approved for inclusion in the such as Eplan Electric P8, Eplan Encompass Product Reference program Pro Panel and Eplan PPE. This of Rockwell Automation means that all the systems of the Eplan Platform are now listed. Eplan has been a Global Encompass Partner of Rockwell Automation since 2008. Eplan Fluid is an engineering tool for design and automatic documentation of circuits for fluid power systems in hydraulics, pneumatics, cooling and lubrication. It connects the fluid-specific engineering with all other engineering disciplines, so that various engineering tasks can be executed in parallel. This accelerates the whole engineering process – even when combined with other disciplines, such as electrical engineering.

ANSYS has recently won the DesignCon 2014 DesignVision Award for the Integrated Circuit (IC) Design Tools category for PathFinder-D technology. A comprehensive layout-based on electro-static discharge (ESD) integrity solution, PathFinder is critical to custom IC designers because it helps identify weak areas of the design in layout or circuit that could potentially cause ESD failures.“It is with great pride that ANSYS accepts recognition from DesignCon for the third consecutive year,” said Norman Chang, VP & Senior Product Strategist, ANSYS subsidiary Apache. “As electronics products become smaller and smarter, ensuring design reliability has become increasingly challenging. This DesignVision award further underscores our commitment to provide best-in-class technology to our customers and the electronics industry.” DesignVision award winners were selected based on three criteria: how well the product met the market’s vision and offered unique insight into customer needs; the originality of the solution and the quality of the implementation and how well it meets the market requirements.

> MORE@CLICK ADI03396 | www.AandD24.in

> MORE@CLICK ADI03397 | www.AandD24.in

A&D India | Feb-Mar 2014

market | interview

‘A conscious action to implement safety’ Suggesting that various industries are now developing their requirements for safety related technologies, Sagar Bhosale, Managing Director, Schmersal India, in this interview with Sumedha Mahorey, affirms that the industry is moving from traditional technologies to newer technologies in the safety domain. Which are the demand trends shaping up in your business? One of the most important demands is the desire to have correct knowledge about safety. Another demand is on how to use the safety standards for various applications. Like in other sectors, there is movement of demand toward higher technologies. What kind of technology trends are you witnessing in the industrial safety domain? In our market, there are some areas where implementation of safety is minimal. When we talk to these customers, they show interest to adopt safety, but they cannot scale from 0 to 100 at one go. These customers move step-by-step. First, they move to contact technology; next, to non-contact technology; third, moving ahead of non-contact technology, people are shifting toward RFID technology which is gaining strongly in safety sensors. Traditionally, all safety devices are wired to safety relays. Now, these relays are replaced by safety controllers and safety PLCs. Other safety technology developments are more customised to specific industries. For example, in the food industry, end-users want safety sensors which are more hygienically safe. Typically, they require a particular class of stainless steel enclosures, higher degree of ingress protections, etc. O&G or chemical industry demands sensors which are explosion proof versions. We are seeing maximum demand from food & beverages, followed by the textile sector.

equipment safety. Indian companies will thus catch up with global standards soon. How do you plan to increase your company’s contribution to Schmersal’s global market share amid the current market scenario? We place special emphasis on training our customers in-house. We also hold safety seminars in industrial pockets like Chennai, Baddi, etc. With these seminars, the customers feel much more confident that they have a competent partner in implementing safety. We are also developing our people expertise in every sector we cater to, for example, food & beverage. With sector specific resources, we are able to give suggestions to the customers who have specific requirements for their machine processes and at the same time, pass on the feedback to our engineering team. Thus, we are able to develop the products for the future, taking into consideration what the market needs. What benefits has the Ranjangaon plant brought to your India operations? Schmersal follows its customers globally. We started with the subsidiary in 2007 which was purely a sales subsidiary. In 2-3 years, we realised that customers needed faster deliveries. With the Ranjangaon plant, we can deliver, in days rather than weeks and are closer to the market. Also, now we can provide switches which are prewired or assembled as per customer specific requirement, helping the customer to make his assembly faster. Our customers can also have all the possible trials on the new technologies they intend to use in the Application Centre of our factory. We also conduct regular safety basics and product trainings at the plant.

How is the progress in Indian machine safety technologies as compared to its competitors in the global market? In India, companies are becoming more and more aware about safety. There is a conscious action to implement safety. There are many companies in India which have collaborated, or are the subsidiaries of European or the US companies. What are your expectations from 2014-2015? These companies follow same safety standards all over the The economic situation has a very small impact on our business world. Also, Indian manufacturers handling global players are as demand for safety is more related to the awareness for it. We offering latest technologies at their plants. We have seen that have very high expectations for next year with the increase in Indian manufacturers go step-by-step but there is apparently awareness. ☐ > MORE@CLICK ADI03398 | www.AandD24.in a trend among Indian customers to place special emphasis on

A&D India | Feb-Mar 2014

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market | interview

‘Increasing reliability of drive trains’ Wolfgang Weissler, Vice President, Drive Technologies, Siemens, briefs on the two-pronged approach of the company to address not only manufacturing & process sectors, but also the SMEs which forms the backbone of Indian industry, during a conversation with Sumedha Mahorey How are the current demand trends emerging in drive trains? Companies operating in the process and manufacturing industries need to meet the combined challenges of everincreasing production complexity, growing cost pressures resulting from rise in the price of raw materials and energy, and the continuing trend towards product individualisation. Furthermore, the market is demanding ever shorter product development cycles. The need to find effective answers to these challenges has given rise to significant technological changes in recent years. This technological change was driven primarily by the many advances made in the fields of information and communication technology and in automation & drive systems. And this trend is set to continue. Any technology innovations coming up in the near future? We have launched Integrated Drive System (IDS) initiative in India. It is the world’s first true one-stop solution for entire drive trains. The core element of IDS is the three-way integration of the drive train – horizontally from coupling and gearbox to the motor and converter along the flow of energy as an intelligent mechatronic unit; vertically within the automation pyramid into the control architecture of industrial manufacturing process, based on the proven concept of ‘Totally Integrated Automation’ (TIA); and its third dimension within the product lifecycle for all industries with the end-to-end integration. We expect significant demand from sectors where power ratings are high. Some of these sectors could be material handling or cement. However, we also see demand coming from OEMs who see the benefits in engineering time when shifting to Siemens IDS. Can you suggest measures to increase the reliability in industrial drives? As we look at the complete drive train, one can achieve increased reliability of the drive train with the benefits achieved out of the perfect integration of the components which are perfectly interacting. Take, for instance, sophisticated drive train of vertical mill in the cement industry where it is very

important to co-ordinate gearing, coupling, motor & converter to achieve optimum working point without overloading the mechanical system of the machine. With IDS, the entire drive train consisting of motor, converter, gearbox & coupling can be simulated in advance under real load conditions and the vibrations of the system analysed. The optimised design of the entire drive train can be determined from the results of this process. This boosts output by up to 15%, reduces energy consumption by up to 5%, shortens the restart time, and increases the availability and reliability of the entire machine. What are your company’s plans for the Indian market? As far as Indian market is concerned, we have two-pronged approach wherein we will address not only the manufacturing & process sectors like cement & mining, cranes, etc, but also the SMEs which forms the backbone of Indian industry. With our unique IDS portfolio, we want to work with the customer to help increase productivity, efficiency and reliability of their plant or equipment. Please detail us on your global market expectations in 2014-15. The Euro crisis seems to be of the past and US economy has recovered. With the new Chinese government settled, the global economy should see some increase over the next 12 to 18 months. In India, we might still have to wait a little longer for economy to pick up as the pre-election phase will slow down government investments and also the private sector will wait for the outcome of the elections before launching new projects. There is certainly significant money waiting to be invested into India. However, we will see the results not before the last quarter of 2014. When it comes to IDS, we certainly see a growth beyond the general GDP growth as productivity improvement will be one of the key drivers. The positive feedback we have received from the global market since the IDS launch during the Hannover Fair last year proves us right. Hence, we can expect IDS to have the same positive impact in India. ☐ > MORE@CLICK ADI03399 | www.AandD24.in

A&D India | Feb-Mar 2014

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c o v e r s to r y | t e c h n o l o g y

Remote collaboration, optimisation & operations

Cross-industry perspectives

Image Courtesy: Shutterstock

Christophe Romatier Strategy Leader Lifecycle Services & Solutions Business Honeywell Process Solutions

Drawing from experience across multiple industries, from mining and minerals to commercial business management, this article showcases remote collaboration solutions and highlights best practices with an emphasis on how remote collaboration can be tailored to the oil & gas industry to achieve transformative results.

A & D I n d i a | F e b - M a r 2 0 1 34

t e c h n o l o g y | c o v e r s to r y

Be it local, regional, national, international or global, oilfield, and what will be called “remote collaboration” as its businesses today confront multiple, complex and often extension in other industries: The ability to manage operational interrelated challenges to growth, sustainability and activities in real-time, independent of their location. profitability. In fact, the broader an enterprise’s scope of business and the wider its geographic reach, the greater the Remote collaboration, optimisation & operations potential impact of a growing list of global business and For illustrative purposes, examples from some programs competitive trends and factors. During the last century and a half, oil & gas business has that Honeywell has been involved in have been used. produced over one trillion barrels of oil. It is estimated today that slightly more than one trillion barrels could still be 1. Improved work process consistency Consistency in work processes is a necessary step within a extracted from known fields, and some estimate that another three trillion barrels could be produced with the use of digital oilfield implementation, although experience proves production techniques, future discoveries and so-called that this is very hard to achieve. When one thinks about unconventional oil. However, the era of ‘easy oil’ is behind us. performing work remotely, one must first comprehensively Current production rates satisfy existing demand, but with understand how people interact with the object of their work. demand growing by an average of 1 to 1.5% per year, producing To do that, one must document all interactions between the oil in environments that would have been almost unthinkable operator and the process, and then create the tools necessary to decouple the operator from the process. Once one does this, a few years ago must now be considered. it makes sense that to achieve scale one first needs to achieve standardisation through consistency of interactions across Value drivers for a new operating paradigm assets. This in turn allows us to achieve interoperability, i.e. This poses new challenges to the industry that are any operator can seamlessly operate processes of a certain type compounded by an increasing difficulty to attract & retain the across all assets. The path to scalability sounds deceptively necessary talent to operate its assets. Operations in these new simple, but O&G has long been operationally insular. environments drive companies to seek improvements in Historically, assets have been run independently of one another several key areas which include safety, reliability, productivity, to a large extent as a result of being widely dispersed both production, staffing and expertise. physically and organisationally. And although interoperability Over the past decade, operating companies in O&G have is now technologically possible, long-entrenched practices sought to use next-generation technology to help overcome make it difficult to achieve. Examples from what others do in challenges, and much of this work has been done under the other industries can provide additional insights into achieving banner of “digital oilfield”. process consistency. Despite some very important advances & achievements, The aircraft industry: The first example comes from the the industry, for a variety of reasons, has not widely adopted Honeywell Aerospace Division. There, the division’s Zing new technology. However, some of the barriers to adoption are Services has used extremely well-documented processes as the being conquered. For instance, it was common practice in the basis for an innovative and transformative solution for aircraft early days of digital oilfield to adopt a ‘build it and they will maintenance. Zing Services monitor, diagnose, trend and come’ approach to the technology. Given the profound impact analyse equipment to optimise maintenance, ensure safety and on the way work is done, companies are now internalising the improve dispatch availability. The full solution embeds a multi-faceted approach necessary to ensure a successful dedicated unit on-board certain types of aircraft for ongoing outcome to such programs. They are integrating the technology real-time monitoring of critical parameters associated with into processes and workflows, enabling staff to interact with it. engine health. Data is wirelessly uploaded to Zing Services This article has adopted the following definition for digital servers, where advanced analytics enable condition-based

A&D India | Feb-Mar 2014

c o v e r s to r y | t e c h n o l o g y

In many instances, dissimilar industries are adopting similar solutions to meet common imperatives such as the need to simplify work processes, improve knowledge management and find new ways to adapt and thrive in accelerating business environments. One such solution is remote collaboration

equipment maintenance rather than interval-based or run-tofailure maintenance. The Zing Services system monitors critical components and then notifies operators of relevant maintenance procedures and recommendations. By proactively monitoring engine health, spare parts can be taken to the aircraft on the first trip. This is the key to avoid unplanned maintenance or repair at remote locations. The key value comes from the on-going automated background monitoring of the equipment, paired with the automated, “learning” data analysis and condition-based monitoring step, and lastly the automatic tying-to-action items such as ordering equipment. A supplier to the industry such as Honeywell does not have the operating knowledge & experience alone that would enable it to develop maintenance procedures to deliver such outcomes. This requires deep knowledge and understanding of aircraft operations and equipment failure modes, and associated root causes as well as their normal modes of operations. In many cases, required knowledge can be gained by working with operators individually. However, this is a costly exercise that results in customised applications for each operating company. Fortunately, one key difference that enabled the creation of a standard system deployable industrywide is the high level of oversight that exists for aircraft operations. In this case, Honeywell was able to leverage extensively documented and mandatory maintenance procedures and embed them within the Zing Services system to consistently flag issues. Although today a similar body of knowledge does not exist in O&G, the regulatory landscape is evolving & could provide a basis for clearly documented consistent operations. Beyond the burden that this may place on operating companies, the silver lining could be a newfound ease in the implementation of digital oilfield programs. Alumina refining: A program developed for a major international producer of primary & fabricated aluminium

demonstrates the value of remote collaboration, optimisation and operations when it is extended across an entire global production system. In alumina refining, the business case for optimal production control is its potential for increasing production rates and improving process efficiencies by reducing variability and operating closer to practical limits. For the refiner in question, reducing variability alone meant potential savings of US $40 million per year, with process control as a key enabler. There was also a sense of the opportunity for intangible savings associated with making real-time process information available for process improvement and business decisions throughout the network. Although this is difficult to qualify and quantify, it is in many cases the largest benefit that can be derived from such an initiative. Prior to the program, developed through Honeywell collaboration with the customer, the refiner’s ability to improve process control had been constrained by a lack of skilled resources and availability of funds required to implement a common infrastructure and a common application portfolio. Process control use across the refining system was variable — a mixture of control, automation and process information systems. The same application was implemented in different ways or degrees at different sites. Common system architecture was developed in 1997, but progress on implementing a set of standard applications had been limited. Cost & availability of resources was a barrier, and the benefits of process control were not universally agreed upon, so only limited resources were devoted to improvement. The solution was a program that standardised process control infrastructure & extended control solutions across multiple refineries in six countries. The program generated key benefits – each refinery operates with process controls for each unit operation; variability is minimised; operation is close to practical limit, with minimum operator intervention or nuisance alarms; production control

A&D India | Feb-Mar 2014

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The increased geographic spread and complexity of operations has made it ever more important to incorporate and share best practices and lessons learned across assets as rapidly as possible

applications are developed once, and implemented at many sites, and the customer has gained competitive advantage by capturing critical real-time business data to optimise unit operations and enterprise resources. While the scope of collaboration is limited to production control & optimisation infrastructure, the program is fully global in nature. The operator has accrued more than $100 million in benefits through the institution & enforcement of global standards. Power distribution: Standardised work processes that deliver consistency across assets can also enable different operating models. In the US, gas distribution operations are fairly simple when compared with operating an offshore oil platform. But what one large gas distribution company achieved may provide a fresh look at opportunities for O&G. The companyâ&#x20AC;&#x2122;s initiative minimised the operating expense of staffing full shifts at each facility. Once procedures & processes were fully understood, standardised and shared across assets, the company was able to delegate instead of centralise operations. Facilities became able to assume management of one another on an on-going basis, with data flowing seamlessly between all facilities. This enables some facilities to have entire shifts completely assumed by other facilities, flexibly mitigating staffing needs based on resource availability. This program underlines the opportunities that may lie in evaluating the benefits of remote collaboration programs not only in the traditional hub-and-spoke model, but also in a point-to-point model. Once the prerequisite of establishing connectivity between assets and the arduous task of fully internalising work processes are achieved, there are many opportunities to achieve new operating paradigms. 2. Supplier integration models Because remote collaboration programs are still fairly new, they therefore incorporate an element of risk in their

implementation. Such programs are still highly customised to the particular needs of an operating company, and a welldefined, shared representation of the outcome is usually absent until fairly late in the program. Therefore, a large part of the supplier selection process relies on trust and proven (and implicitly duplicable) experience. Once the relationship is established, traditional supplier/operator interaction models may lead to obvious pitfalls, despite both partiesâ&#x20AC;&#x2122; best efforts. Issues with contractual engagements predicated on deliverables have obvious issues because in many cases, the digital oilfield is a journey of discovery, and the end goal is elusive until attained. The degree to which deliverables can be specified at any stage lacks the nuance that would ensure the upfront confidence in the benefits of the program outcome. This may lead to the undesirable outcome in which, under pressure, a supplier may decide to interpret the covenants of the contract in the manner most advantageous to it, thereby supplying only to the most restrictive interpretation, and not to the benefit of the initiative and its overall outcome. One way to mitigate this is to stage deliverables and progressively increase their precision, but this can lead to a great deal of contractual overhead while only somewhat mitigating the issue. Conversely, contractual engagements that are structured around the actual cost of labour and materials may on the surface hold the promise of a committed supplier working to deliver the best possible outcome. But such engagements also may lead to over-engineered, bloated solutions that risk significant cost overruns. This stark depiction of contractual risk must obviously be taken with some perspective, since there are motivations for shared positive outcomes. These motivations can be further enhanced. Letâ&#x20AC;&#x2122;s consider examples of how this has been done. Commercial building management: Honeywell put together an offering in which it manages energy consumption

A&D India | Feb-Mar 2014

c o v e r s to r y | t e c h n o l o g y

Digital oilfield/remote collaboration programs provide a framework with tremendous promise for far-reaching solutions

at customer facilities. It uses advanced technology such as scheduling and occupancy detection; on-going revision of energy management strategies; daylight harvesting; demand ventilation; load shedding; and monitoring of real-time prices of electricity in the electric grid, and adjusting each of the above to take advantage price variability. To mitigate upfront risks associated with the purchase of costly equipment, and staffing to execute a non-core task, HBS deploys this technology through a management contract structure. The system is sold as a service, with a pay-forperformance contract. To achieve this arrangement, there is an upfront benchmarking phase in which the supplier evaluates the opportunity based on their experience, and then proposes a scheme in which any benefits from a mutually agreed upon baseline are shared between the operator & the supplier. Remote collaboration in mining: Mining and metals processing has seen explosive growth in remote collaboration over the past few years. One of the largest copper producers in the world was facing a challenge because of its aging infrastructure in sites spread over several thousands of miles throughout Chile. Some of these sites are at altitudes of over 12,000 feet, and staffing these sites with experts to support their operation as well as any new infrastructure was also a challenge. In this particular case, in order to create a step change in their operations, the company decided to upgrade the infrastructure at their different sites, then implement connectivity to Chile’s capital, Santiago. This would allow them to create a collaboration centre there and staff it with experts that could be leveraged across their multiple sites. They quickly realised that they lacked a core competency regarding many of the activities surrounding the management and support of infrastructure and the use of advanced tools to provide on-going optimisation of their operations. To alleviate the burden on their organisation while still ensuring optimal

results, the company entered into a joint venture with Honeywell, creating an entity that would take ownership of the optimal operation of the infrastructure. This bold step created the right incentives for both supplier & operator to act in both companies’ best interests, ensuring optimal operations and effective collaboration throughout the lifecycle of the operation. The critical benefit of this interdependency is to better ensure the sustainability of still-exploratory programs such as remote collaboration. With some thought and planning, good incentive mechanisms can be put together to foster the right behaviour to maximise continued success for these ventures.

Poised to deliver transformational results Everywhere in the world, globalisation is presenting industries and businesses of every kind with myriad challenges to growth, sustainability and profitability. Oil and gas, no less than any other industry, is confronted daily with a need to improve reliability, productivity, production, yield and safety — while competing in an increasingly rigorous environment marked by intensifying regulation, declining supplies and recovery and an aging workforce, among other issues. Digital oilfield/remote collaboration programs provide a framework with tremendous promise for far-reaching solutions. However, as the different experiences outlined in this article demonstrate, there is high potential for tremendous value & return for those operators willing to push the digital envelope. The growing, increasingly sophisticated and powerful capability to monitor and manage operational activities in real time, regardless of location, offers O&G operators the opportunity to create multiple value streams to their organisations while achieving transformational results. ☐ > MORE@CLICK ADI03400 | www.AandD24.in

A&D India | Feb-Mar 2014

management | interview

“India presents a better opportunity to have a bestpartner eco-system” Rob Gremley, Executive Vice President, PTC, shares his insights on the strategies for the current year, initiatives to educate the industry, while elaborating on the PLM space in the global market, during a candid conversation with Srimoyee Lahiri. How do you look at the PLM space in the global market? Please detail us about PTC’s initiatives to educate the PLM space is growing. More and more companies are realising industry. that they need a system of technology and processes that the For a semi-complicated business like ours, one way of education technology can support. We are focused on PLM. If we go back happens face-to-face. Some years back, we created a PTC to the idea of digitisation, it was one of the first stages where Value Road Map to educate the industry about our processes manufacturers digitised all their product information. But & technologies. This road map discussed business initiatives we don’t term it as digitisation, rather it is the digital product that have been sponsored by our customers and the current information that they take and combine. If companies possess technologies in PTC’s portfolio of PLM and CAD. the powerful combination of digital product information, it can be issued anywhere in the world, essentially for free. Thus, Do you think the Indian mindset is open to experimenting this phenomenon of first digitising the information and then with the latest hi-tech automation related to technologies globalising it was not a new concept, and the technology is with better and more functionality? becoming much more approachable. Even smaller mid-sized Since many years, we have been in discussion with our customers manufacturers are realising the need of PLM to compete as a around the world – the US, India, Germany, Japan, China, etc. global company. There are two ways of looking at each of these markets. One,

A&D India | Feb-Mar 2014

interveiw | management

“Even smaller mid-sized manufacturers are realising the need of PLM to compete as a global company.” Rob Gremley

the manufacturers are mobile in India, and other is that they are more than likely to be presented with the same channel opportunities like in the US or China. These manufacturers are wrestling with globalisation and regulations. The questions that are being faced include how they are going to meet the increasing government and non-government regulations? How can they provide better software intensive features? How can they do better servicing so that technician cost can be brought down? Answering this, we provide single software and make it productive & valuable. Each market is different and they address different issues. How is PTC pursuing its service strategies in India? We have a major service strategy. Like in the US or China, we have direct services in India as well. We also want to take advantage of the larger ecosystem. Every year, we have increasingly started to grow in the particular ecosystem that we want to grow our partners and services in. Here in India, there are many partners that we work with. India presents a better opportunity to have a best-partner ecosystem. What are your strategic plans for 2014-2015? It is a good time to answer this question. We are witnessing major growth overall. We have been helping companies with CAD and PLM solutions. Our focus has been on helping companies create their products. For instance, companies like Caterpillar sell their equipment build with the help of our solution and they service it for 30-40 years. Thus, the experience that our customers have with us creates the revenue opportunity for them. Companies like these are trending their sites with abbreviations of their service business. How do we design service procedures? How do we direct our service personnel there? How do we equip the service technician with the right materials and the right parts they need in order to

A&D India | Feb-Mar 2014

service the equipment in the first visit? These companies need a technology enabler, a guide, a company like us which can optimise the process in the servicing business just like how we helped them in the creation or designing stage. So PTC holds a mega advantage in realising this as we come from product life cycle management sector. We have good product knowledge and bring that to our business of SLM (Service Lifecycle Management). This notion is enabling manufacturers to focus more on the SLM space. It is called “servitisation” and it is happening among all manufacturers as they have to drive more productivity and more efficiency and it leads to profitability of their business. The second interesting thing is Internet of Things (IoT). The IoT in the manufacturing sector is doing well. In a recent study by McKinsey, it has been stated that among the top 10 sectors that are going to use IoT extensively, first is healthcare and the second is manufacturing sector. According to McKinsey, the IoT is about 6 trillion dollars’ worth of economic value per year by 2020. It means that it will generate extra revenue. For manufacturing sector, it will generate between $1.8 – 2.3 trillion of economic value by 2020 by taking an advantage of IoT. This is a massive opportunity for manufacturers. Also, we have recently acquired ThingWorx, the leading company that helps to create software-based platform designed to build and run the applications of the connected world. The equipment has sensors and they transmit the functional data to the cloud and Caterpillar monitors it. Caterpillar has a massive IoT initiative and has an IoT Council that has been formed to study the opportunity to create connected products. With this combination of SLM with “servitisation” together with the economic opportunities of the IoT and PTC’s acquisition of ThingWorx has created a very broad PTC portfolio. SLM and IoT are the big initiatives of PTC in the coming days. ☐ > MORE@CLICK ADI03401 | www.AandD24.in

m a n a g e m e n t | r o u n d - ta b l e

Building future factories This feature discusses the various facets of the Factory of the Future – distributed, automated, ever-improving, reliant & responsive – and analyses industry’s views on the present demand and technology drivers that will make this evolving concept a well- and widely-accepted reality. With manufacturing technologies reaching higher and higher levels of maturity, industry giants are getting equipped to adapt their operations to fit consumer needs and market changes in real time. They are aligning their manufacturing structures to get better every day. Gaining an edge over the closest competitor and staying ahead of the curve in a marketdriven environment has created the need to become more agile, self-sustaining, flexible and yet be cost-efficient. With this in the background, many global manufacturers are setting up formal processes to look at how factories and plants will be organised in the near future to suffice market demands in an ever changing business environment. Analysing views by industry giants such as Sunil Khanna, President and Managing Director, Emerson Network Power India; Vipul Gautam, Business Head – Plant Solutions (India Region), Tata Consultancy Services; Ganapathiraman G, Country Manager, ARC Advisory Group, India; Dr Michael Haag, Executive Vice President, R&D, KUKA Roboter GmbH; Kishore Karandikar, Automotive Electronics Expert and Sameer Prakash, General Manager & Head, Automation

Sumedha Mahorey Deputy Editor sumedha.mahorey@publish-industry.net

Business, Siemens Ltd, this feature highlights how manufacturers are planning to align their Factory of the Future with major focus on current technology & demand drivers. A Factory of the Future (FoF) is an amalgamation of highperformance software with state-of-the-art hardware and digitisation of product development and production. As a result, all process steps merge to form a whole. This results in higher efficiency, shorter time-to-market and greater adaptability, thus allowing manufacturers to produce efficiently and flexibly while gaining global competitiveness.

Demand drivers for FoF In a technology driven world, where “integration and collaboration” is the mantra, the manufacturing sector will drive the demand dynamics for FoF. Ganapathiraman elaborates, “Manufacturing is critical to both – emerging and mature economies. In emerging economies, it leads to rising incomes and living standards. In mature economies, it is a hotbed of innovation and competitiveness, making

A&D India | Feb-Mar 2013

r o u n d - ta b l e | m a n a g e m e n t

“Factory of Future is combining the virtual and real world to get a holistic view of the complete value chain”

Sameer Prakash, General Manager & Head, Automation Business, Siemens Ltd

contributions to R&D, trade, and enhancing productivity. But the manufacturing sector is dynamic and has witnessed many changes. Bringing both opportunities and challenges, and to compete & survive in the new global manufacturing environment, it is imperative to follow the concepts of FoF.” Adding to his thoughts, Gautam says, “The sectors that keenly lead in adopting technology are O&G, automotive, aerospace, consumer packaged goods (CPG) & pharma industry.” As per Khanna, the growth in final domestic demand due to increased global consumption and the thrust on more productivity can be the key drivers for demand dynamics for FoF. He avers, “Volatility of supply, constraints of resources, raw materials and new environmental regulations will change the factories in 2050.” Other sectors that may act as the demand drivers include food and food processing, infrastructure development – like road, telecommunication, electricity generation, etc. Prakash notes, “From discrete industry, we foresee the automotive sector to drive the demand for FoF. Reason being, an automotive manufacturer has to mass produce different varieties with shorter lifecycle time (mass customisation).”

Features of future manufacturing facilities

“Change management will play a key role in the evolving smart factory” Vipul Gautam, Business Head – Plant Solutions (India), Tata Consultancy Services

bringing new goods to market and this trend will be more pronounced. Advanced robotics makes automation cheaper and more flexible. New materials, such as nano particles will give new properties to products. Trends such as 3D printing are already used for converting design to finished goods.” As per Karandikar, the features will include smart manufacturing facilities for quick supply and varied customer needs. These factories will have high and efficient ERP system modules and good market research with the capability for quick set-up changes and efficient supply chain modules.

Key change constants: technology drivers

Understanding the technology drivers that will transform With the demand drivers in place, what will be the distinct the manufacturing future is the key to remain globally features of the future manufacturing facility? Answering this, competitive and stay ahead on manufacturing effectiveness. Ganapathiraman points out, “The distinct features will be end- Ganapathiraman suggests, “The key change constants will to-end data and information connectivity across the plant continue to be the need to be innovative; cost reduction to floor; interconnected with supply chain, distribution and remain competitive; adherence to market regulations; and business systems. The future belongs to the Internet of Things continuous improvement initiatives.” Adding to his thoughts, which facilitates technology fusion – comprising of the gamut Gautam notes, “The ability to handle big data, at the machine, from mobility, energy efficiency, RFID, Big Data, analytics, line, plant, multi-plant across geographies and at the enterprise cloud computing and ensures connectivity at all times.” level; over and above to be able to handle the real-time data As per Gautam, the distinct features of smart manufacturing and provide “relevant” analytics on the go to all personnel and will be information, integration and intelligence – information managers for better manufacturing will be the drivers. Relevant about equipment reliability, improving overall equipment is the key in the big data world. Big Data, role-based predictive efficiency, targeting key productivity issues with mobility. He analytics, cloud computing, mobility have started making their says, “Integration for agile manufacturing to respond to in-roads into the factory and will play a decisive role in the customer needs and signals, supply chain visibility for higher future.” Also, wireless will play a big part, providing scope for and relevant production, integrating work processes for R&D, better operation and maintenance. According to Prakash, the engineering & production and intelligence to enable smarter technology drivers will be industry software, resource decisions for operation and maintenance, analytics for smarter efficiency and industrial integration. He avers, “Industry decisions and predictive insights. All this will lead to a better software is a key element of modern manufacturing and return on assets, higher operating margins, and lower TCO.” automation processes. Comprehensive data storage enables On the challenges front, Khanna elaborates, “Computer-aided companies to link product development and production design and simulation has already reduced the time & cost of processes together and thus, maintain control over constantly

A&D India | Feb-Mar 2013

m a n a g e m e n t | r o u n d - ta b l e

“Understanding how an adaptable, highly flexible, partly self-organising production system could be implemented, with the capability of responding swiftly to changing market requirements is the key” Dr Michael Haag, Executive Vice President, R&D, KUKA Roboter GmbH

increasing levels of complexity.” One of the major initiatives that have been taken towards adopting future manufacturing technologies is Industry 4.0. Dr Haag avers, “Understanding how an adaptable, highly flexible, partly self-organising production system could be implemented, with the capability of responding swiftly to changing market requirements is the key. This will enable production that is flexible in terms of batch size and variants. But which technologies are required to turn this scenario into reality? As far as IT is concerned, many technologies are already available, such as service-oriented architectures with encapsulated software services that can communicate with one another via a network and organise themselves during the runtime rather than beforehand. The individual software services can thus, perform joint tasks that the programmer had not even thought about when creating them.

chains rooted in China. Automated manufacturing may cause some jobs to be replaced by machines, but long-term benefits will far outweigh the losses as humans will then be upgraded to technicians than just being an assembly line worker.”

Influencing factors while conceptualising FoF

Designing future production plants

Flexible manufacturing will be the key influencing factor along with intelligence, integration and interoperability. Gautam elaborates, “Within manufacturing, systems that help in better asset utilisation and higher inventory turnaround, higher energy efficiency and better waste management, better return on asset, overall higher margins across disciplines. Integrating various disciplines from a supply chain perspective, be it R&D, engineering and design into production providing higher and better supply chain flexibility and efficiency. Over and above, how good manufacturing practices can be replicated to bring in lower cost of ownerships while keeping localised customisation to the minimum and wherever required.” Commenting on the needs that will act as the influencers, Ganapathiraman says, “The major influencing factors will be the pressing requirement to streamline processes, mitigate risk, and reduce costs to remain afloat in a competitive marketplace. And this will be possible only by deploying state-of-the-art technology to enable seamless and integrated connectivity, traceability and virtual plants.” On the global front, Khanna avers, “Today Asian countries, especially China, have emerged as the hub of global manufacturing. However, developments in robotics in the United States can change this trend and ‘reshore’ these hubs back to the home countries in future. It is known though that shifting manufacturing away from Asia won’t be easy, especially for technology companies that rely on tightly integrated supply

With the influencers, technology as well as demand drivers in place, which requirements need to be considered while designing future production plants? Ganapathiraman explains, “In terms of automation and modernisation, determining if updated automation technologies will make a significant difference in ROI and defining viable & profitable modernisation options is the key. For this, a four-step approach is essential – conceive ideas, prepare an implementation plan, estimate potential benefits, identify improvement opportunities and evaluate current systems.” Also, identifying one’s position in the marketplace would help. Gautam elaborates, “There are various factors that can be considered for design. These needs to be driven primarily by the road map of an organisation and where they stand in the maturity curve for technology adoption. Sometimes, adopting many technologies together may not yield expected. Having said that, mature factories need to consider technology fusion as they embark on this journey. Keeping minimum level of various technologies will be simple, though this could be easier said than done. Organisations need to consider horizontal and vertical integration through value networking. Alongside, change management will play a key role in this evolving smart factory. Human capital and their adoption of this information across disciplines will be the binding force for success.” Elaborating on the environment front, Khanna suggests, companies cannot afford to dump waste and throw things

“Automated manufacturing may cause some jobs to be replaced by machines, but long-term benefits will far outweigh the losses as humans will then be upgraded to technicians than just being an assembly line worker”

Sunil Khanna, President and Managing Director, Emerson Network Power India

A&D India | Feb-Mar 2013

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“Considering that energy cost will be continuously increasing, manufacturing set-ups will have to heavily depend on smart automation.” Kishore Karandikar, Automotive Electronics Expert

without concern for the environment. For instance, a sugar plant will have a bio-ethanol facility to produce ethanol from leftovers and a mechanism to capture the heat from waste to be harnessed for other productive purposes and emissions captured to be put to good use or recycled and not let out into a smoke chimney with no concern for the environment.” According to Prakash, the first and the foremost requirement is digitisation of the entire plant. However, to achieve this, factors like a framework for dynamic network of local controls; enhanced real-time communication for machine-to-machine interface; digital models of the overall process and participants; process optimisation in dynamic networks; rules and mechanisms for secure data transfer; and skilled workforce that would define rules and frameworks for decision making, need to be in place. On the other hand, Karandikar suggests that technology may not be the only criteria while designing a FoF. He avers, “It is the availability of continuous support, which is very important. With the challenges thrown by the customer, design may have to be improved/changed dynamically, without stoppages of production. Hence, change in requirements will demand suitable changes in plants.

Strategy changes in operations management To implement the FoF concept, companies will have to reformulate their manufacturing operations. Detailing on this, Ganapathiraman avers, “The strategy changes in the future factory that will be evident in terms of manufacturing operations across the globe will be technologies that are more flexible, interdisciplinary, intelligent, integrated and information driven. At a global level, the FoF should be efficiently networked, consolidating resources and processes. The ability to supervise and coordinate activities across all levels for real-time visibility will need to be fine-tuned. Another strategy that must be adopted is to set up centres of excellence. Additionally, all these strategies must ensure compliance to global standards and regulations.” As per Karandikar, as market needs change, these will have to be captured by business and factory R&D will have to access the implementation. He says, “Strategy will always be to keep business profitable (ethically) and to do this, the factory management will need all the tools to carry out the changes successfully. It is hence essential that future factory is equipped with trained manpower or is ensuring that regular training

“In terms of automation & modernisation, determining if updated automation technologies will make a significant difference in ROI and defining viable & profitable modernisation options is the key” Ganapathiraman G, Country Manager, ARC Advisory Group, India

programs are implemented. Commenting on the current changes that the industry is witnessing, Gautam avers, “Organisations have already starting adopting a unified culture across various disciplines of production, operations and maintenance for better manufacturing. They are building efficiency not only in their core production but also in energy and waste management for lean operations. Also, from an enterprise level, the CIO and CFO are now becoming key stakeholders in manufacturing operations. The adoption of technology within manufacturing is largely influenced by the enterprise and its technology road-map, which was not there earlier. Internet of Things (IOT) is being looked at very carefully and seriously on the factory shop floor and how it can benefit the shop-floor and the enterprise. The biggest change that I see is that manufacturing operations is being viewed as an enterprise within an enterprise with all of its functions. Commenting on the revenue side, Khanna observes, “Manufacturing has been traditionally considered to be a process that turns raw materials into physical products. The scenario has changed and today; the physical part of production is at the centre of a much wider value chain. Manufacturers are increasingly generating revenue from other activities, many of which are categorised as services. This trend will gain more traction in the future.”

The takeaway The manufacturing sector is entering a dynamic new phase and adopting changes is on everyone’s to-do list. As technology advances and the FoF becomes a reality, more global companies are entering this space to become more productive, efficient and competitive. The benefits that will be accrued by these companies in the long-term are far more exciting. ☐ > MORE@CLICK ADI03402 | www.AandD24.in

A&D India | Feb-Mar 2013

power & energy | Focus

Agile communication network with decentralised substation automation and centralised control centre architecture ensures that Tata Power keeps up its commitment of reliable and stable power to the consumers. Technology infusion with a philosophy of unified operations has reshaped the automation scheme and brought in excellence outnumbering the earlier performance of the companyâ&#x20AC;&#x2122;s transmission & distribution wires. Tata Power formulated vital inclusions in automating its substation with centralised control centre. This information intelligence blended power system operations has paved the way for new inception of technologies to meet the growing consumers, regulatory needs and grid disciplines.

Centralised operation Evolution of open standards and protocol has flipped the monarchy of proprietary links. Open platform of OS and userfriendly SCADA system architecture has seamlessly integrated Tata Powerâ&#x20AC;&#x2122;s transmission & distribution assets for centralised control & monitoring. This Power System Control Centre (PSCC) is designed in a redundant fashion with Main Control Centre (MCC) and Backup Control Centre (BCC) in geographically different locations to address disaster. The IP based IEC104 open protocol is implemented in the control centre level and the sharing of network data with state LDC is on Inter Control Centre Protocol (ICCP). Advanced

A&D India | Feb-Mar 2014

Focus | power & energy

Emerging automation and information technologies have helped renovate the structure of operation & maintenance at Tata Power. This article provides details on the implementation of these technologies at various levels by the utility to achieve operational excellence. Jacob Joseph HoD – Automation Project Engineering The Tata Power Co Ltd Amok Agarwala Group Head – Automation Project Engineering The Tata Power Co Ltd

Mohammad Ghouse Mohideen Lead Engineer The Tata Power Co Ltd

Ashwin Iyer Lead Engineer – Automation Project Engineering The Tata Power Co Ltd

energy management, load optimisation and SCADA applications help the company’s operation engineers to tactically manage the grid’s rythm for a zero unscheduled outage motto. PSCC operations are enhanced by the integration of switchyard CCTVs of each station. Separate channel of FO cable has been dedicated to route the video traffic and provide real-time visual monitoring of the operations. Remote relay parameterisation and retrieval of disturbance records for functional analysis from a common location has made life simpler for our protection analytic experts. This central bench ensures structured maintenance of configurations and settings for relays of different make and type. The other addendum to the control centre is the security

A&D India | Feb-Mar 2014

and surveillance system to support the operations. Safety of the assets & vigilance of our unmanned sub-stations are micromonitored using this integrated security and surveillance system. Another saliency of the centralised SCADA is the common quality assurance and testing server for new station inclusion or modifications. An operator training simulator is also part of this centralisation which is used to groom new & young operation engineers on SCADA. Thus, PSCC has become the nerve centre of Tata Power and is directing the Network Mobile Maintenance Crew (NMMC) apart from its basic functioning of load forecasting, energy management and scheduling of power.

Image courtesy: Tata Power

Centralised operation of T&D assets

power & energy | Focus

The 18 RSS were segregated & operated from the zone-wise six SCADA systems

Few highlights in the process include distribution management system with integrated Outage Management System (OMS) and Workforce Management System (WFM) and GIS for T&D network planning, SCADA integration and asset management. By automation, the goal is to create benchmarking performance parameters of CAIDI, SAIFI & SAIDI in the distribution business.

their sources/field equipments for a better response. The IEC 61850 protocol has been used more than a protocol and has become unprecedented success in this power utility. Dedicated GPS master clocks are installed in each station to prevent nuisance or mal-operation of the switchgears due to the time drifted, buffered or delayed signals. All the IEDs are time synchronised using SNTP protocol through the redundant gateways. Power Quality Meter (PQM) has been installed as a pilot to evaluate, improve and provide a more stable power our Substation automation consumers. These PQMs of fixed type and portable type are All receiving stations of transmission, distribution sub- installed for transmission and distribution stations respectively. stations and few key consumer substations are automated in PQMs would form the prequel for the Wide Area Monitoring the distributed fashion to break the single point failure of System (WAMS). automation equipments. Migration to decentralised station The automation systems of stations are clustered into nodal level automation has multiplied the reliability and the system for integration to the Power System Control Centre. availability of the SCADA system. The stations are modernised Mini RTU technology is another advent used for consumer for versatility with Bay Control and Protection Units (BCPU). substations and package substations to optimise space and This includes integration of legacy relays on IEC 103 protocol cost. Other explorations and implementations in this SAS with the Gateway. The minimum requirement is established domain are digital substation enabled by full-fledged process for the SCADA system which is atleast monitoring of the bus using merging units, optical CTs & PTs and WAMS for power system from PSCC during failure. To achieve it, each interconnection nodes of the Tata Power transmission network. bays are equipped with multi-function meters and are The challenge would be utilisation and maintenance of the integrated with their respective voltage level wise redundant volume of data from WAMS. Gateway on MODBUS TCP/IP or serial protocol. All the green field substations are diagnosed with condition monitoring Communication backbone equipments for breakers and transformer. Dedicated automation WAN is created for protection from Load flow study of the station is supported by the data from weather monitoring devices. The IEDs of these stations cyber attacks. This WAN spreads connectivity between all the are integrated on IEC 61850 protocol in the station bus level substations, PSCC and Plant Information System. The for a future ready automation and greater electrical protection communication backbone uses Fibre Optic (FO) technology function coordination. All the IEDs are almost located near to strengthened by about 1000 Circuit Kilometre of Optical

A&D India | Feb-Mar 2014

power & energy | Focus

Truly integrated centralised operations provide seamless and incredible monitoring & control

Power Guard Wire (OPGW) based FO cable and substantial underground FO cable. The network is made comprehensive and highest available by the Synchronous Digital Hierarchy (SDH) technology which provides redundant layer and multiple ring option for an alternate communication path. The FO channels are widely utilised to transport data signals of substation automation, tele-protection signals and CCTV signals for video surveillance. The challenging distribution automation devices are communicated using CDMA mobile technology for ease of access. Today, the availability of the automation network is 100% ensuring a complete reliable operation of our power system.

not only rewritten the operations of Tata Power but has renovated the structure of the operation & maintenance (O&M) of the utility. The company has understood the behaviour of the expanding MegaWatt-to-GigaWatt market. Thus, they have carefully designed the substation automation and power system control network. Risk of nascent technology and practices have been avoided carefully to prevent cyber security concerns. When, centralised systems and open standards/protocols reduce the dependency on the OEMs; expertise availability and skills development within the utility is a boon. IEC 61850 has almost become the blood group of sub-station automation and SCADA system of Tata Power.

Benefits accrued

Conclusion

The best automation practices of Tata Power have fructified and yielded benefits such as centralised operations enabled better handling of the power system during critical grid conditions; effective occurrence analysis and quick restoration of power supply; same look and feel of the network; unmanned sub-stations; optimised O&M resources; better planning and adherence to maintenance schedule; improved security and safety by built-in security features such as interlocks, safety tagging; and operator training simulator for enhancing operatorsâ&#x20AC;&#x2122; efficiency. Motivated by these merits, Tata Power has a strong plan to seamlessly integrate the multiple systems viz transmission SCADA, DMS, GIS, security and surveillance system through a common application for a truly integrated and a homogenous view for all the operations from a single integrated display. The emerging automation and information technology has

The company is in the continuous process of capturing technology to propel its vision and mission. The utility is also in the process of evaluating and implementation of Common Information Model (CIM) which would frame the network semantics and database modelling wide the automation system, thus, layering the automation system uniformly for future plug-in integration. Implementation of new automation technology for power utilities is always a challenge because of the regulated business nature. But the capital expenditure pays off the returns in a long term. Improvised automation techniques will yield optimisation to any utility in terms of time, money, space and manpower. This is why Tata Power is the most preferred quality electricity service provider by the consumers. â&#x2DC;?

Courtesy: PAC-2013 - ISA CPRI seminar > MORE@CLICK ADI03403 | www.AandD24.in

A&D India | Feb-Mar 2014

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POWer & Energy | Focus

Fieldbus for power plant automation Out of the many digital technologies available in the market, Fieldbus is widely accepted and used in power plant automation because of its efficiency, reduced cost and proactive maintenance feature which helps reduce the plant down time. This article discusses the various advantages of Fieldbus in power plants. 40

UnniKrishnan R Manager â&#x20AC;&#x201C; Technical Support Pepperl + Fuchs uravindranath@in.peppperl-fuchs.com

A&D India | Feb-Mar 2014

Image courtesy: P+F

Focus | POWer & Energy

In a power plant, we require the right information at the right time and at the right place with minimum investment and maintenance costs. Traditional power plant control systems focus on controlling the process operation of the power plant. The power plant control system controls the different processes to achieve maximum power output at lowest operational cost. Todayâ&#x20AC;&#x2122;s state-of-art control systems are highly automated, and in many installations, allow one operator in a central control room to manage the entire production. With the introduction of latest technologies in power industry, the initial investment and operational costs can be brought down. Digital technology is increasingly driving

A&D India | Feb-Mar 2014

changes in the power industry. Its application is evident in all sectors of the power industry, including instrumentation. The introduction of fieldbus technology for instrumentation is closing the digital data communication gap between automation systems and field devices. The result is more accurate values and transmission of values, bidirectional communication, and flexible structures with fewer components. The conventional technology has reached a saturation level and the limitation in having more diagnostic features resulted in lesser demands. By contrast, the digital signal transmission offers broader bandwidth for plausibility checks and status signals. The digitisation of process signals and the associated decentralisation

POWer & Energy | Focus

Fieldbus technology implementation allows a single cable to connect a number of digital devices in comparison to the dedicated wiring from each field device to the DCS I/O

represents the most important development that paves the way for the application of a fieldbus system. The subsequent introduction of the fieldbus in power plants has changed the structure of control systems. Fieldbus technology allows shifting central functions into field devices and leads to decentralised structures in the automation systems. These decentralised structures reduce the costs for wiring and assembly and increase the plant availability. Plants down time/ unplanned shutdowns are decreased by improved maintenance and diagnosis through smart instrumentation. Additional cost improvements can be achieved for installation, commissioning, operation, and also space requirements. The introduction of fieldbus technology for instrumentation is closing the gap of digital data communication between automation systems and field devices. The technology implementation allows a single cable to connect a number of digital devices in comparison to the dedicated wiring from each field device to the DCS I/O. This helps in significant reduction of the number of wiring and cable tray counts including reduction in I/O models count in control room resulting in decrease in space requirement.

which is 5 times more costly than predictive maintenance and 60% of preventative maintenance is unnecessary because of lack of proactive maintenance strategy. All these points resulted in Foundation Fieldbus which is a standardised, open, digital, two way, multi-drop communication system for the various applications in power plant automation. In Foundation Fieldbus, the protocol is based on the international standard IEC 61158. The technology is suitable for replacement of discrete and analog signals.

Advantages of Fieldbus in power plants

The introduction of Foundation Fieldbus or Profibus technology has closed the gap of digital data communication between automation control systems and field devices. The improved functionality of these Fieldbus technologies offers advantages throughout all stages of a project. In the installation phase, it provides reduced wiring, material saving for cabling, reduced hardware such as I/O cards and cabinets and therefore, it saves engineering and installation time; faster assembly and reduced errors. Instruments can be installed in locations close to the process for direct measurement; right design concepts such as fully Predictive maintenance in power plants redundant High Power Trunk (HPT) is available that extends Predictive maintenance allows the operator to learn when the digital communication to maximum field devices with the device is about to fail henceforth allowing to diagnose the longest cable distance possible to reach every process location problems in advance avoiding unplanned shutdown. Field and multivariable fieldbus devices, e.g. single fieldbus devices instruments maintenance cost reduction drives power plant could handle eight temperature inputs or discrete inputs. users. In power plants, 40% of manufacturing cost is for In the commissioning phase, with onboard integrated maintenance; 50% of maintenance time is for corrective action Advanced Diagnostics Device (ADM) on the Fieldbus power which is 10 times more expensive than preventative supply, to supervise the physical layer, the commissioning time maintenance. Preventative maintenance utilises 25% of time, is reduced to > 50%; a single technician can handle the

A&D India | Feb-Mar 2014

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POWer & Energy | Focus

Advantage of using Fieldbus technology is that each device requires about half the energy of its conventional analogue counterpart, while providing far more information

commissioning procedure from the control room and there is no need to have large resources; communication faults can be located from the control room and unlike 4-20 mA devices, calibration is not required since the digital device measures the full range of process values. In the operation phase with the Fieldbus technology, high resolution of the measured value can be attained; the original signal is not altered by analog/digital conversion; higher transmission reliability is a given; digital communication is not subject to noise or other environmental disturbances; multipleinformation from the field device is made available to improve availability. ADM continuously monitors the Fieldbus network and report to DCS system to increase the operational reliability. Physical layer health and the device diagnostic information are continuously available at DCS for predictive maintenance in the maintenance phase. In this phase, maintenance is performed only when scheduled or required; easy and fast troubleshooting from the control room with expert system advice provided by physical layer Advanced Diagnostics device is available. It also helps in achieving fewer trips to the field; no periodic calibration is required and plug & play by downloading replaced instrument settings to the new instrument can be done. The Pietrafitta Nuova Power Plant & La Casella Power Plant owned by ENEL Production located in Umbria, Italy is one of the first power plants to adopt the Fieldbus technology. The first feedback from this realization is that the Fieldbus technology has allowed a significant reduction of cabling, marshaling cabinets and I/O cards. The equipment rooms were consistently reduced. Moreover, it has allowed new and more efficient

commissioning procedures halving commissioning time. The capability to remotely configure, calibrate and analyse the diagnostics problems of any instrument from the control room allowed timely intervention. Due to the unique benefits of Fieldbus technology, ENEL Production chose to apply this technology to all of its new combined cycle plants and included the adoption of Fieldbus as binding requirement in its technical specifications for all the new power plants. With the demonstrated advantages at every stages of the power plant process, Foundation Fieldbus technologies offer faster time to commission the plant and increase the availability of the plant to its highest level.

Conclusion Fieldbus provides seamless data communication between the plant and control system while supplying power to all field devices. Fieldbus topologies fit the demands of power plant industries with its proven technological and economic advantages. Recent interface components are optimised with higher power delivering capability to the field, thus achieving economical fieldbus design. The decentralised architecture and the diagnostic information especially are increasing availability of plants. Additional availability can be achieved by choosing the right design concepts in Foundation Fieldbus or Profibus technology and extending the digital communication to maximum field devices. The risks are limited because of proven identical communication protocol with advanced diagnostics capability at the physical layer and at the device level. â&#x2DC;? Courtesy: PAC-2013 - ISA CPRI seminar > MORE@CLICK ADI03404 | www.AandD24.in

A&D India | Feb-Mar 2014

P OWER o w e r & ENERGY energy | Focus

Energy fingerprint for power plants This article proposes an automated energy assessment tool for power plants which is user-friendly, involves comprehensive energy analysis through qualitative and quantitative assessment and can be used by less experienced domain experts.

Dr Naveen Bhutani Scientist ABB Corporate Research

Image courtesy: ABB

Jinendra K Gugaliya Scientist ABB Corporate Research

A&D India | Feb-Mar 2014

Focus | Power & energy

Automation has a crucial role to play in improving the power plants productivity, energy efficiency and safety. A variety of advanced solutions/products are available in market to improve the base level performance of power plants. The level of automation can be different from plant to plant. Therefore, to establish the need for automation and application of advanced solutions, it is best to first establish the base level performance of plant and subsequently estimate benefit potential from such applications. In this work, an advanced tool for energy assessment, benchmarking, opportunity identification and optimisation in utility and captive power plants is developed. The tool facilitates systematic and quick opportunity identification for energy efficiency/productivity improvements along with cost-benefit estimates in a typical power plant. The tool calculates various key performance indices, recommends measures/proposals to improve efficiency and performs cost-benefit analysis to prioritise the proposals. The scope of this tool is not limited to performance assessment but also mapping the identified opportunities with advanced tools/solutions/products for improved operation, automation and control.

correlation/KPI-based quantitative assessment. The quantitative assessment is performed considering the standards applicable for power plant audits. During assessment, the areas of improvements are identified and a list of proposals is prepared and prioritised based on project payback time. Further, it is possible to perform techno-economic feasibility studies of various proposals (including automation) and prepare a well-defined energy efficiency improvement plan, with timelines for implementation for the power plant.

Energy assessment & benchmarking: Methodology

Conventionally, the energy assessment for industrial processes is performed by domain experts/engineers, based on their experience, by performing steps like recording, analysis, comparing/benchmarking, targeting, and finally reporting and control. This onsite energy assessment exercise is tedious, costly, and prone to human errors and often lacks thorough analysis. Thus, an automated energy assessment tool for power plants which is user-friendly, involves comprehensive energy analysis through qualitative and quantitative assessment and can be used by less experienced domain experts is being proposed. Background The qualitative assessment is done through easy-to-answer Almost 50% of total electrical power generation capacity is questionnaires which are prepared with due consideration of distributed between fossil fired power plants (FFPP) and power plant domain knowledge. In the qualitative assessment, combined cycle power plants (CCPP) globally. The fleet of an interview is set up with power plant management, engineers, FFPPs constitutes mix of 20-40 year old power plants which and operators and answers are obtained. Based on these are running at very low efficiencies due to outdated answers, the tool automatically identifies the improvement technologies, degraded equipment and limited automation. areas in the plant and possible solutions needed to improve the The CCPP are relatively more efficient due to modern plant performance. technology. However, significant opportunities exist for Qualitative assessment: In the qualitative assessment, the energy efficiency improvement in both FFPPs and CCPPs. overall plant is sub-divided into subsystems: boiler island, The energy efficiency of power plants can be improved in steam turbine and condenser system, compressed air system, multiple ways by application of advanced process automation pumps and fan systems. The assessment is executed in three and control, replacement of less efficient equipment with aspects of these sub-systems â&#x20AC;&#x201C; monitoring and benchmarking more efficient equipment, waste heat recovery, effective practices; maintenance and operation practices, and control & operation and maintenance practices, efficient loading of optimisation practices. The tool prompts questions related to various equipment and plant wide optimisation. each of these subsystems and then based on the answers There is an apparent need to perform detailed studies to automatically profiles the plant practices against the best in assess the energy efficiencies and Key Performance Indicators class. (KPIs) of various equipment of a power plant, to identify areas Quantitative assessment: The details of various steps involved of improvement. The tool supports both a questionnaire- in quantitative analysis include: 1. Data preparation and data preprocessing: This step based qualitative assessment, and a simplified model/

A&D India | Feb-Mar 2014

Power & energy | Focus

The quantitative energy assessment is simplified to the key steps mentioned here, which are also the functions of the energy assessment tool

involves identifying the right tags, collection and storing historical data from plant historian. Typically, the historical data is noisy, abundant with missing data and outliers. So, the purpose of data preprocessing function is to filter out noisy and missing data; performs outlier-detection and replacement. 2. Energy assessment and KPI analysis: A power plant would typically have boilers, air pre-heaters, coal grinding mills, fans, pumps and heat exchangers associated with the ‘Boiler Island’, and steam turbines, gas turbines, heat recovery steam generators (HRSG), condensers, water heaters, pumps etc in ‘Turbine Island’ and power transformers, generators in the ‘Power Island’. The tool allows configuration and calculation of energy losses and various KPIs such as plant hourly profit, heat rate, efficiency of equipment, and boiler blow down rates, etc. The outputs are displayed by means of trends plots, charts, histograms, pie charts, etc for ease of analysis. The tool also reports the mean and standard deviation of all the KPIs and inputs. 3. Benchmarking and gap analysis: The current operating performance of the power plant is compared against a benchmark established based on historical/design data and/ or standards. Various proposals, such as steam blow down heat recovery, flue gas heat recovery, reduction in variation of key variables such as excess oxygen in flue gas, superheated steam temperatures, increase in inlet temperature of the steam turbine, augmenting pumps and fans with variable frequency drives (VFDs), etc, are then evaluated from cost benefit viewpoints.

4. Reporting: In this step, all the energy efficiency proposals can be prioritised and consolidated with their return on investment (ROI) calculations and captured in an energy assessment report.

Results and discussion The tool for power plant energy assessment is a standalone executable which can operate on any Windows-based system. The front end user interface of the tool is shown in the above figure. The tool has menus for creation of new projects, configuration of equipment, and energy calculations and report generation. The proposed tool has been applied on representative FFPP power plants. A historical data period of six months was used with a sampling period of 1 hour. The tool then allows for automatic filtering of data and outlier removal and also manual deletion of some data based on high and low limit range. The plot option also allows the user to compare the cleaned data with the raw data. The selected clean data is then utilised for equipment configuration and KPI calculations. The next step involves configuration of various equipment items in a modular fashion. The equipment configuration window displays the list of inputs which can be mapped with the tag from Tag ID list. Once the inputs are assigned with relevant tags, the tool automatically updates the KPI status in the KPI table. The KPI which is configured turns active. After configuration, the next step is KPIs calculations.

A&D India | Feb-Mar 2014

Focus | Power & energy

Energy assessment tool for power plants

The KPI calculation and analysis window allows performance analysis by means of trend analysis, histogram analysis of inputs and KPIs. The tool provides extensive plot options: As an example case, the trend plot for boiler efficiency calculated by the indirect method (KPI). The curve fit and TABLE 1: opportunities identified using energy assessment tool Opportunity

Description

Controls (APC, automatic control)

APC to minimise variations in main steam temperature, O2 % in flue gas. Loop tuning (auto/manual) Control logics

Heat recovery

Blowdown heat recovery Improved flue gas heat recovery

Maintenance (Air leakage)

Excess power consumption in boiler ID fans due to air leakage Heat loss due to air preheater leakage Predictive maintenance Vibration issues

Sensors and measurements

CO, O2 measurements, faulty sensors power consumption at sub-system level Water metering Compressed Air

VFDs

Application of VFD for boiler feed water pumps Application of VFD for ID fans, FD fans, cooling tower fans

Design change

Minimise throttling of steam, let down of compressed air Replacement of motors/fans size

Peformance monitoring and assessment

Real time performance monitoring and trending for operations Efficiency/KPIs (all major equipment) Losses (carbon in ash, partial conversion) Losses (Throttling of steam, compressed air, etc) Energy Map

A&D India | Feb-Mar 2014

segregation of KPIs and inputs based on weather conditions and time of the day is also possible in the tool. Lastly, the tool has a powerful feature to run multiple “what if ” case scenarios and estimate savings, from application of a blow down heat recovery system, advanced process control for tighter oxygen and temperature control, flue gas heat recovery etc. The tool can also be used to plot and analyse the parasitic load distribution and efficiency of key equipment for selected duration of plant historical operation. A list of opportunities that can identified using the tool are listed in Table 1.

Conclusion The energy assessment method is automated to assist the energy auditor to assess the performance of the power plant and identify the key opportunities for plant performance improvement. The tool has variety of features for effective analysis of KPIs and to identify the key gaps in the plant performance. The various built-in what-if scenarios provide a framework for calculating the dollar potential and payback period of the important improvement opportunities. The tool with its powerful features helps in reducing the time for conducting a power plant energy audit, and also reduces the dependency on high skilled domain experts for performing a thorough efficiency analysis. ☐ Courtesy: PAC-2013 - ISA CPRI seminar > MORE@CLICK ADI03405 | www.AandD24.in

d r i v e s & c o m p o n e n t s | a p p l i c at i o n

Providing maximum versatility The article deals with Nord Drivesystemsâ&#x20AC;&#x2122; solutions used in the development of the largest discontinuous toothpaste production system in the world by Ekato, a manufacturer of customised industrial agitator Many manufacturers with a global reach are interested in concentrating production capacities in a few places. The hygiene and personal care industries certainly follow this trend. Accordingly, there is a demand for ever larger batch sizes for products such as toothpaste. Furthermore, a larger range of variants is produced at each site. Therefore, modern plants must be capable of producing large volumes while at the same time providing maximum versatility. With this

Alexander Lukas Head of Research & Development Ekato Systems

Peter Dittmers Managing Director Germany Nord Drivesystems

complex task in its sights, Ekato Systems from Schopfheim at the southern Black Forest has constructed a new plant for the discontinuous production of toothpaste.

The need The maximum capacity of toothpaste production plants used to lie between 4,000 and 5,000 litres, with outputs of

A&D India | Feb-Mar 2014

a p p l i c at i o n | d r i v e s & c o m p o n e n t s

The geared motors from Nord Drivesystems meet the standard set by the record-sized plant

approximately 2,000 to 3,000 litres hourly. Continuous or homogeniser were configured according to the mixing batch production is possible. Continuous systems enable high performance equation for mixing technology. Based on its throughput but are not very versatile with regard to product extensive experience, Ekato determined the power coefficient changes; since different ingredients sometimes require their “Ne” (or Newton number) for each respective impeller and the own dispensing and blending technology; recipe changes product’s specific viscosity curve. In addition to the product often bring about conversions and readjustments. It also concentration, the equation furthermore contains the speed comes into play that toothpaste cannot easily be reworked and the diameter – with the exponents 2, 3, or even 5, these when it is not sufficiently homogeneous. The biggest challenge values are especially important. That is why the correct with continuous plants is ensuring the uniform dispersion of configuration of the agitator and homogeniser drives is crucial. active ingredients such as sodium fluoride, even after changes The drive supplier Nord was required to configure motors and to the dispensing systems. On the other hand, the production gear units with the performance according to Ekato’s rate of existing discontinuous plants cannot be significantly calculations, and to make them as efficient and durable as increased without major modifications in plant equipment. In possible. Since the agitator drive is installed on top of the order to meet the demands of a toothpaste manufacturer, production mixer, it should be as compact as possible despite Ekato, therefore, had to construct larger plants. the high performance required.

Production mixer design

Agitator drives as large as a city car

Toothpaste production systems basically consist of an evacuable vessel with an agitator, a homogeniser, and various dispensing systems for the introduction of ingredients into the process. Liquid ingredients are either measured and then vacuum-inserted into the vessel or dispensed by gravimetric methods. Powders and thickeners to increase viscosity can be added via the integrated homogeniser or drawn into the vessel through a valve at its base.

This application, which depends on homogeneous product quality, calls for speed and continuity. The radial and axial loads on the agitator shaft, which are very high due to the high product viscosity, must be taken into account for the drive configuration. Nord Drivesystems configured and supplied two 250 kW motors with industrial gear units which provide nominal output torques of 242,000 Nm. Nord is the only manufacturer worldwide to produce such extremely large industrial gear units in this power range in the proven onepiece UNICASE housing. Hence, the type SK 15407 3-stage helical bevel gear units, though of an impressive size, are still relatively compact as the UNICASE design allows for larger rolling bearings which can accommodate higher forces. ☐

Complex calculations for the scale-up For larger mixer dimensions, Ekato had to determine the components’ dosage and dispersion times, blend and homogenisation times, vacuum values, and the necessary agitator and homogeniser performances. The agitator and

A&D India | Feb-Mar 2014

> MORE@CLICK ADI03406 | www.AandD24.in

s o f t wa r e & e n g g TOO L S | T E C H N O L O G Y

Enhancing profit by sustainable solutions The article showcases a unique software developed to address the challenges in a manufacturing world with a logical approach Sustainability has been the latest buzz word amongst the corporates. Out of the three spheres viz. environment, social & profitability, the first two have been more in the limelight and the third one has been the underlying imperative which the corporates are investing to find a sustainable answer. With the recent economic scenario, whether it is the exchange rate syndrome or be it the liquidity control measures by the RBI, the profitability of corporates have really been a challenge. The recent announcement by the Finance Ministry on a 2% mandatory spending on CSR further puts pressure on the third sphere of profitability. The operations for any organisation are now under immense focus from a cost standpoint. The endeavour of all the corporates has been to reduce waste & drive operational excellence.

Sayantan Roy Director â&#x20AC;&#x201C; Software Sales GE Intelligent Platforms sayantan.ray@ge.com

Operational challenges & cost pressures The first and foremost challenge for any operations is how to integrate the silos. From an automation standpoint, no plant can have the similar set of systems from the same vendor even if one chooses to have one. One cannot avoid the choice of the OEMs. The disparate automation systems generate a lot of data which needs to be captured and interpreted in the right context to understand the challenge in the equipment performance. This gives rise to the next challenge which is poor access to historical data. Historical data is the key to understand any challenge and arrive at a resolution. Process variations & emissions are the next level of challenges in operations which causes a lot of waste and loss in

A&D India | Feb-Mar 2014

T E C H N O L O G Y | s o f t wa r e & e n g g TOO L S

Compare variants between batches to find optimal settings

throughput. Quality rejects or waste is like cash personified and can be one of the biggest causes for margin depletion if not arrested. Most of the software systems focus more on the quality assurance aspect which is definitely important from the standpoint of customer satisfaction. But how does the organisation ensure service to oneself ? Of course, by not letting any waste occur. To understand the root cause of the waste one needs to understand the reasons for a good batch. Only then can one be able to compare the same with a bad batch and find the answer for the gap. The next level of challenge is to avoid equipment failures. Equipment failures have a direct impact both on the variable cost and fixed cost. The challenge is to predict failures and avoid downtime.

Countering the challenges with Proficy Proficy is an unique software platform from GE which provides an apt solution for all the above challenges with a three prong logical approach. It includes integrated visibility; advance analytics & predictive diagnostics and value chain integration. The Proficy platform provides a modular, scalable and integrated approach for all the three steps. Modularity helps the customer to plan their investment as well ensures smooth change management. Integration & scalability are important to grow along with the business needs without creating further silos.

Performance monitoring Proficy solution for integrated visibility monitors KPIs and

A&D India | Feb-Mar 2014

provides accessibility of dashboards and plant information from anywhere. Thanks to the Proficy mobility solution which provides access on any standard tablet or smart phone. The robust Proficy historian ensures the availability of past data on the figure tips. The key technology here is the fast retrieval of the complex process data which is very difficult to retrieve in a RDBMS platform. The availability of past data enables the user to do the benchmarking and identify the gaps. From a financial standpoint the solution creates visibility of the variable cost as well as identifies the optimum cost of goods sold (COGS).

Enhancing the performance Once the data and the visibility are available, the next logical step is to identify the root causes of the gaps. There are gaps which can be identified based on the deviation from the design parameters for any equipment or process. But the major challenge is to understand the root cause of the gaps and detecting the potential failure early enough. These causes are difficult to be defined by a 1st principle modeling or any logical equation. It is here one needs to take help of data science. Proficy Advance Analytics provides a perfect blend of foresight and insight. With Proficy troubleshooter one can identify the cause of the variance. Thanks to the advanced algorithms like PCA & Neural network working in the background. From a quality standpoint this adds a lot of value. The user can not only identify the signature of a golden batch but also the process parameters responsible for the batch to be a golden one. This greatly helps in analysing the cause of the bad batches by comparing them with the golden batch. This enables

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Golden batch score plot comparison with complete batch data set

proactive quality management and ensures repeatability of good batches in future. The proficy platform provides a wizard driven platform, thereby protecting the genesis of a process expert by not turning him into a statistician. Proficy Smartsignal (SS) provides a state-of-the-art foresight with its advance predictive diagnostics. It not only provides the predictive alerts but also the fault that can occur and the apparent cause. From a financial standpoint identifying unclear root causes as well predictive failures greatly reduces both the variable cost and the fixed cost, thereby maximising the margins. Proficy Advance Analytics thus creates a benchmark of proactive insight & maintenance which is a combination of predictive, corrective and preventive maintenance.

Value chain integration The major challenge in a business process or operation is to enable end-to-end visibility and thereby drive accountability. The common challenge for any business process to succeed is to bring together the different entities. With the advent of ERP this challenge could greatly be reduced in the business process and this established the subject of business process management (BPM). But in operations especially in manufacturing industries a similar digitisation is required which in turn arises the need for work process management (WPM). Aging workforce is a growing challenge especially in India where the operations are more labour centric. To counter this, one needs to enable a role centric operation and eliminate the commonly practiced person centric operation. The starting point for such

an activity is to follow the SOPs (Standard Operating Procedures). But ensuring adherence of SOPs on real time basis has been the major challenge. The Proficy platform resolves this pain area by digitising the SOPs on real time basis. Thanks to its workflow. This enables value stream mapping which is the starting point for defining an optimum process. It also provides visibility, tracking, tracing, genealogy and scheduling for a manufacturing process. This complimented with Proficy Analytics drives the desired operational excellence which is the need of the hour. The buck finally stops with the integration of the business systems to real time operations. From a financial standpoint reducing the Takt time improves the inventory turns enabling sales. Throughput improvement reduces cost and increase margins.

Proficy enabling the path to the ROI Each of the logic step as evident from the above enables a business benefit which defines the path to the ROI. Integrated visibility identifies optimum performance. Advance analytics and decision support ensures optimum performance thereby increasing the throughput and reducing cost of failures. Value chain integration enables system efficiency. The final outcome of all these steps is high margins and return on investment. The journey has already started in India with various majors in power, metals & manufacturing standardising on Proficy. â&#x2DC;? > MORE@CLICK ADI03407 | www.AandD24.in

A&D India | Feb-Mar 2014

m a n u fa c t u r i n g IT | t e c h n o l o g y

A step-by-step approach

A read into the best practices in Product Lifecycle Management

(PLM) that has become one of the most sought-after processes for improving enterprise wide collaboration, time-to-market, reducing costs, and increasing the bottom line amongst the major manufacturing industries. Rakesh Pandey Global Business Unit Head Manufacturing Vertical Xchanging

According to a research report by Frost and Sullivan titled â&#x20AC;&#x153;Analysis of the Indian Product Lifecycle Management (PLM) Marketâ&#x20AC;?, the PLM market in India is projected to increase from $130 million in 2010 to more than $400 million by 2017. At the same time, the compound annual growth rate (CAGR) between 2010 and 2017 is estimated to be more than 15%. Businesses are also adopting PLM in non-engineering departments such as marketing and finance to allow the product development process in becoming more cost-efficient.

Timely upgrades â&#x20AC;&#x201D; key to an effective PLM system Often, buyers neglect in aligning the PLM systems with the latest system patches, software updates and business process improvements, which help in resolving issues (in terms of performance, sustainability, maintainability and stability) in the existing PLM deployment; addressing platform incompatibilities owing to the evolution of the underlying software and hardware platforms and leveraging additional capabilities of the next generation platforms.

Where are the road blocks? As PLM vendors introduce next-generation platforms to address the dynamic business requirements of product strategy formulation and implementation, the chief information officers (CIOs) often find it challenging to optimise their existing PLM investments, in addition to managing the risks on their IT investments and data assets. The CIOs are also challenged with issues such as evolving business processes or systems; ensuring operational continuity; non-scalable PLM deployment; rolling out upgrades in heterogeneous enterprise systems; non-traceable configuration management and addressing the integration complexities. Other significant challenges on the user front include restraining change and insufficient training.

Achieving PLM upgrade seamlessly The good news is that enterprises can minimise the risk involved in the upgrade and generate maximum return on

A&D India | Feb-Mar 2013

t e c h n o l o g y | m a n u fa c t u r i n g IT

A six step approach for upgrading PLM environment

their investment, by introducing the following step-by-step six best practices: Qualification: Before initiating a PLM product upgrade, static and dynamic platform baseline information is established. This information is gathered in the following essential formats that includes customer survey and infrastructure analysis; database and application export customer source environment setup; target V6 OOTB environment setup and performance benchmark baseline. Pre-upgrade exhaustive technical fit analysis: At the outset, it is pertinent to evaluate the impact of the PLM upgrade implementation on the overall system architecture and fitment of the new functionalities, infrastructure components and changes in user experience. The technical fit analysis process is critical in determining the overall success of the upgrade. It helps users in identifying common document model and data migration issues, creating upgrade plan and estimates validating quality assurance test plans. Upgrade assessment and proposal: Leading up to the implementation process, it is imperative to decide the upgrade strategy, which requires a detailed assessment of existing PLM system from a technical and functional standpoint. The upgrade strategies include — comprehensive upgrade that addresses issues in the existing system, thus making it more robust and Hybrid approach which is followed for specific PLM applications (done under comprehensive upgrade) and for the remaining, a plain upgrade is done. After determining which approach to go for, selection of the right upgrade implementation partner is needed. The one with a strong cross-functional experience in supporting the transition to be seamless and hassle-free is best suited to take up the implementation. Upgrade implementation and validation: This phase often presents a number of challenges in the areas of

A&D India | Feb-Mar 2013

implementing within the scheduled timelines. It is also critical to ensure minimum disruption to the users and establish contingency to handle unforeseen issues. In an upgrade project, users need to ensure code merging so that none of the current functionalities from the existing system or from the new release get inadvertently overridden. PLM implementation typically includes the following code elements—custom source code, out-of-the-box (OOTB) source code, custom configurations, and OOTB configurations. The way in which the data is handled is another key factor to consider in PLM upgrade implementation. Packaged delivery: PLM upgrade may or may not have a significant impact on the user experience, but keeping customers informed is a good practice for achieving smooth transition. This can be done by preparing the training material highlighting ‘what’s new’ in terms of user experience between the two versions; updating the current user guides and related content; giving a demonstration of the upgraded platform; prior to release, prepare a list of common issues to help address queries on new platform and organising a help desk team at multiple locations to handle user requests. Post-deployment support: This is an on-going process, and a very critical one. Post-deployment support includes steps like customer acceptance test; production go-live and post-production support.

Key takeaways A well-defined set of processes lead to a seamless upgrade process. By following a multi-step approach, as encapsulated above, users can minimise the risks and difficulties involved in upgrading solutions and provide a sense of consistency to the process and support. ☐ > MORE@CLICK ADI03408 | www.AandD24.in

N e t w o r k & C o nn e c t i v i t y | t e c h n o l o g y

Internet of Things

An article on industrial IP that can help industrial production by consolidating automation, control and facility management within a single infrastructure to boost efficiency. Prepare your plant for the “Internet of Things” — the proliferation of digital devices that promises to revolutionise industrial production through the ubiquitous interconnectivity of the Internet Protocol (IP). Many of these “things” already are operating on the plant floor. Today, IP-enabled microprocessors — the brains inside digital devices — seamlessly connect conventional automation equipment such as I/O modules and variable-frequency drives. But the true catalyst behind the transformation of the industrial landscape is the explosive growth of digital devices adopted from other disciplines. Video cameras, RFID readers, digital tablets, security swipe cards are examples of open-standard, IP-enabled devices that are helping manufacturing and process operations reach new heights of production quality, efficiency, security and safety. Even more powerful technological trends will drive the expansion of Internet of Things deeper into the industrial fabric. Those factors include the unprecedented ability to combine hardware and software over industrial ethernet for ever-greater levels of performance and connectivity. Add to that the exponential increase in processing power, storage and

bandwidth available at lower costs. Then there is the emergence of mobile and cloud computing, along with the ability to analyse big data and turn it into actionable information. To get full benefit of this intelligence, all devices within a plant need to talk with one another, as well as those at the enterprise level, using a unified networking infrastructure that is IP-centric. That’s because only Internet Protocol suite — the world’s defining network technology — can ensure the scalability and harmonious coexistence of the Internet of Things, and support their innovative services. Today and in the future, all industrial networking infrastructures must harness the end-to-end connectivity of the IP software suite for every application.

Barriers to industrial IP Despite all the business advantages of industrial network convergence, a proportion of the automation world still deploys individual networks for individual applications. However, there’s a high cost to running multiple networks and attaching the hardware required to connect them to the rest of the IP-

A&D India | Feb-Mar 2014

t e c h n o l o g y | N e t w o r k & C o nn e c t i v i t y

connected operation. Also, the price and complexity of network infrastructures will rise as IP-connected devices continue to multiply within plants, requiring a profusion of additional gadgetry to connect them. The consequences of separate networks go beyond unnecessary cost and complexity. Two or three networks consume more physical space than just one, and managing and maintaining multiple networks requires more people and training. Most importantly, such a complex network infrastructure lacks the scalability and flexibility that will be necessary to meet the digital demands of the future — and take full advantage of the opportunities. For example, what if one could access “prognostics” along with diagnostics, so he would not only know what’s happening in your plant, but also what problems are likely to arise. Off-

site experts could reduce the impact of an aging workforce by analysing a multimedia data stream, including instant messaging, with an option of voice or video. Every handheld digital device in the plant could report the status of every fixed device, giving personnel mobile access to real-rime, actionable information. Wearable sensors could help track the location of each employee in the factory, so one could ensure safety in case of a fire emergency. These capabilities and more will become possible because of the many intelligent devices that is expected to become part of the Internet of Things over the next 10 to 15 years. The overwhelming majority of these digital things will naturally depend on IP because of its overarching interoperability. However, the greatest value of Industrial IP is its ability to increase the amount of information and the level of

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Your requirement is our drive HANNING pumps, motors and drives perfectly meet the growing demand within India for customer-specific designs, software or interfaces. Our drive systems are specially developed for winding applications, textile or plastic industry as well as for elevator applications. Regardless of the nature of your requirement, our components increase your machine performance and decrease the energy consumption of your entire system. HANNING MOTORS INDIA Pvt. Ltd. · E-115/A GIDC Manjusar Savli · Vadodara 391 775 · Gujarat · India · Tel +91 2667 264820 Fax +91 2667 264819 · info@hanning-hmi.com · www.hanning-hmi.com A&D India | Feb-Mar 2014

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The greatest value of industrial IP is its ability to increase the amount of information and the level of communications associated with production processes, creating more room for agility and innovation

communications associated with production creating more room for agility and innovation.

processes,

Advances in IP technology Automation providers who’ve stayed with nonstandard, multiple networks have convinced their customers that separate networks lead to high-performance production. That myth has been busted by the widespread adoption and use of EtherNet/IP™. Instead of overriding the power of IP, Ethernet/IP puts the software protocol to work, allowing New Industrial IP Community Supports Deployment To reap the full benefits of the digital revolution, industrial operations need a holistic communications “fabric” that harnesses the end-to-end connectivity of the Internet Protocol (IP). Cisco, Panduit and Rockwell Automation have created an online community — www.industrial-IP.org — where IT, engineering, maintenance and operations professionals can exchange information and strategies to help deploy IP across their operations. Today, many manufacturers use multiple networks and disparate devices, and not all are IP-compatible. Cisco, Panduit and Rockwell Automation are united in helping companies see the benefits of deploying an IP-based infrastructure to support all communications and applications within plant operations. Those benefits include the improved productivity and operational efficiency that’s possible with seamless communication between digital devices such as video cameras, RFID readers and digital tablets, processes, systems and people — from the plant floor to the corner office. IP enables these innovative services to be applied on plant floors in a manner that delivers optimum levels of security, performance and ease of integration. Industrial IP Online Community www.industrial-IP.org

industrial producers to easily take advantage of higher-level protocols that IP supports. Among these are functions the rest of the computing world. For example, FTP to send files, SMTP to send an email, HTTP for web browsing and more recent and powerful digital communication technologies such as VoIP (Voice over Internet Protocol). Other protocols have been developed specifically for industrial applications, such as the Common Industrial Protocol (CIPTM). CIP encompasses a comprehensive suite of messages and services for manufacturing automation applications control, safety, synchronisation, motion, configuration and information — and is designed to integrate these manufacturing applications with enterprise and Internet applications. To take full business advantage of this communications revolution, the whole of industrial automation must move to a holistic digital communications fabric that supports all subsystems present within industrial applications. These subsystems will become services to operational management, with IP ensuring coexistence and enabling shared services in a consistent way. Industrial IP can bring together automation, surveillance, facility management and access-control subsystems within a single infrastructure to reduce deployment and operational costs. It will ensure consistency of security policy, practice and procedure. These are all done by eliminating duplicated networks, freeing both human and financial resources to focus on improving production and increasing innovation. ☐ Courtesy: Rockwell Automation > MORE@CLICK ADI03409 | www.AandD24.in

A&D India | Feb-Mar 2014

ICP_210X273.pdf

20/02/2014

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I m age c ourT es y: Hannover Messe

N e t w o r k & C o nn e c t i v i t y | t e c h n o l o g y

M2M Opportunities A technology trend story on Machine-to-Machine communication which has a real-time delivery of reliable data and easy access to a device or machine across the world Machine-to-Machine (M2M) is a technology that allows two or more intelligent machines to communicate with each other without human intervention, via a communication network. Once the data is transmitted over the network, it is collected for analysis, and assessed properly to extract essential information. M2M technology has been predominantly used in telematics applications. Of late, it has become important in applications such as smart grids, industrial automation, retail, healthcare, and consumer electronics. An end-to-end M2M solution consists of a combination of sensors, wireless sensors, general packet radio service (GPRS) modems and routers, mobile communication networks, and relevant software.

M2M adding value to manufacturing industry Remote monitoring and controlling have been basic needs

in several industrial applications. M2M enables such industrial processes to be more efficient and simplified, empowered by real-time data transmission and faster reaction times. M2M facilitates early detection of system failure, remote diagnostics, increased operational efficiency and reduced downtime. M2M communication is being used to remotely monitor machines and installations by using cellular networks and the Internet. In manufacturing it allows for information exchange between machines and devices with the help of sensors and controllers, during collaborative machining processes and motion control. In a manufacturing environment, industrial M2M serves as an integral component of a complex manufacturing infrastructure, where it can mean intelligent bidirectional plant floor communications to PLCs (Programmable Logic Controllers), SCADA (Supervisory Control and Data Acquisition) systems to MRP (Manufacturing Resource

A&D India | Feb-Mar 2014

t e c h n o l o g y | N e t w o r k & C o nn e c t i v i t y

Planning) systems or often ERP (Enterprise Resource Planning) systems. The technology has also been used to emulate common industrial protocols such as Modbus and Profibus over wireless communication. Prior to M2M in manufacturing, industrial automation used direct wire connections between the sensors, actuators and controlling PCs. However, it is sometimes difficult to implement cabled communication in industrial automation either due to the complex nature of the environment or because of the high cabling system cost. M2M offers a much easier solution with the help of RFID tags, sensors, and wireless communication.

Key spheres in the manufacturing eco-system Downtime Reduction: A M2M solution enables remote, real-time, continuous information collection about machine and processes and thus helps to develop a predictive model, which can be applied to discover possible faults. Remote monitoring of equipment allows manufacturing plant supervisors to provide timely service and repairs to avoid major breakdowns. After-sales service: For new revenue streams and to strengthen their market position, manufacturing companies are adopting smart after sales service solutions, enabled by M2M technology. The companies can now track their products and provide immediate after sales services as and when required. Supply Chain Management: M2M can be easily configured for remote inventory management as it can automatically collect all the product delivery information along with suppliers and contractors details, and feed them directly to the ERP system. M2M simplifies the whole supply chain management procedure. Device-level Safety: As M2M facilitates communication between controllers and intelligent machines, which have inbuilt device level logic; it can ensure higher safety of the devices/ machines. The central controller can exchange command signals and status of machines to improve operating efficiency and in case of anticipated failures, intelligent decisions can be made by the devices, which mitigates larger risk or machine failure.

Challenges Key critical issues in implementing M2M solutions are lack of standards and security concerns. While many standards, such

A&D India | Feb-Mar 2014

as EDGE, 3GPP, and LTE are being established at the communication layer of an M2M solution, very few standardization activities are found to improve the interoperability between devices that are meant to communicate with each other using cellular networks. M2M system gathering information about machines and production facilities and the central controller providing command signals to the machines are exposed to the communication service provider. The communication service provider is a third party vendor and it should be ensured by them that the manufacturing companyâ&#x20AC;&#x2122;s data is protected to the extent necessary to protect integrity and confidentiality. To ensure this, a significant investment on network infrastructure is necessary.

Outlook In India, the number of connected devices is continuously increasing, with revenue reaching INR 67.5 crore in 2012 and expected to reach INR 178.3 crore by 2016. The market of M2M modules in India picked up momentum recently due to the increasing demand for remote monitoring and control across different industrial applications such as automotive, transport and logistics, utilities, and others. Organisations are looking to M2M solutions to increase efficiency and reduce the cost of the process. M2M communication technology adoption in the manufacturing sector is opening up new possibilities for RFID technology. Cheap and advanced RFID systems can be used to make business processes more efficient and to increase productivity. Inventory management in manufacturing plants and tracking assets to collect detailed product information are the key opportunities for RFID and M2M vendors. RFID tag price should come down to enhance adoption of M2M in the manufacturing sector. The widespread adoption and proliferation of affordable wireless communication will also contribute to the greater demand for M2M solutions. In another 3-5 years, the manufacturing sector will emerge as one of the top motivators for M2M adoption. Industrial manufacturing has been using M2M concepts and technologies for quite some time, but the changing business scenario will accelerate the adoption of M2M in this sector. â&#x2DC;? Courtesy: Frost & Sullivan > MORE@CLICK ADI03410 | www.AandD24.in

N e t w o r k & C o nn e c t i v i t y | t e c h n o l o g y

Evolving the connected factory The article highlights the advantages of the Connected Factory — reduced operational costs, better visibility and control of assets. It demands a new approach to the concept of factory automation. With the thoughtful integration of supporting components that are designed specifically for this goal, the ability to connect, monitor and control will drive productivity into the future.

Mike Granby President Red Lion Controls

Right now, someone half a world away from a manufacturing 2014, four of the top five emerging trends for the coming year plant is monitoring and controlling its devices, rather than directly impact the ongoing development and adoption rate of standing a few feet away from them. That person may be sitting Connected Factory principles: mobile device diversity and at a desk watching over a global network of facilities, or management, mobile apps for business, the Internet of checking the latest production statistics from a smartphone. Everything and the widespread adoption of smart machines. Automated factory networks are becoming more intelligent, What used to be a science-fiction “what-if ” is materialising in self-configuring, self-regulating and even able to collect data real applications and use cases: humans and devices are now to suggest efficiency improvements. This concept is known as working side-by-side on factory floors, with their productivity the “Connected Factory” – and it is evolving from concept to tracked on visual displays and sent to remote locations for reality at an unprecedented speed. analysis. There are more than 10 billion networked devices currently While many global manufacturers are eager to realise the communicating over the Internet; and the number is expected benefits of the Connected Factory, such as reduced operational to increase to about 50 billion connected devices by 2050, costs and better visibility and control of assets, it is unrealistic according to the European Commission’s recent Big Data and cost-prohibitive for them to construct green-field facilities report. In Gartner’s recently issued top ten predictions for or orchestrate a “rip-and-replace” of all legacy equipment.

A&D India | Feb-Mar 2014

t e c h n o l o g y | N e t w o r k & C o nn e c t i v i t y

Instead, plant managers are better off leveraging industrially fluent communications devices and adapting the legacy sensors, RTUs and communications protocols that have served them well for years in order to create modern, real-time reporting and control systems. But bringing the factory into the 21st century involves more than just connecting IP-enabled devices to existing Ethernet and wireless networks. The fundamentals of a successful Connected Factory must be prepared to ensure that facilities produce information that can be accessed, monitored and controlled from anywhere. To begin this process, manufacturers should enable devices to speak the same language; rethink operational efficiencies so more devices to talk to each other and provide a secure, seamless platform in which these devices can communicate.

Breaking the language barrier The challenge with retrofitting legacy equipment into the

A&D India | Feb-Mar 2014

Connected Factory is that it often uses older protocols or even serial links that donâ&#x20AC;&#x2122;t easily fit into the TCP/IP world. Engineers of an organisation must first ensure that the devices can speak the same language. Plant engineers often source network switches used to build industrial networks from the IT world, a decision that may make sense for higher-level infrastructure, but one that essentially introduces technology that is not purpose-built for machine-level control systems. For example, a modern machine may have every component networked and may allow every conceivable piece of status information to be displayed on its HMIs, but the network switch itself â&#x20AC;&#x201C; the failure of which could take down the entire machine â&#x20AC;&#x201C; sits alone or is loosely integrated via expensive and seemingly incomprehensible SMNP drivers. To avoid this scenario, manufacturers must use a complex combination of drivers to provide protocol compatibility, replace existing hardware with more complex devices or choose advanced HMIs, protocol converters and industrial-

N e t w o r k & C o nn e c t i v i t y | t e c h n o l o g y

Connecting equipment that can’t easily be reached in remote or geographically rugged locations enables real-time information access and greatly enhances remote troubleshooting capabilities

grade switches that offer industrial fluency and multi-protocol hierarchical nature of the industrial world–with PLCs and support. HMIs grouped into machines, and these machines grouped The first two options add complexity and development into cells and cells grouped into factories–it may seem that costs to the system. The third – deploying equipment with assigning an IP address to every PLC and sensor is a native support for all required standards and protocols – management nightmare. provides a simpler solution. However, there are new approaches to network design and configuration that take full advantage of the available connectivity and control. Instead of assigning individual IP Get more devices talking addresses, for example, engineers can solve the problem by Connecting equipment that can’t easily be reached in using a rugged appliance that manages communications with remote or geographically rugged locations enables real-time dozens of disparate devices (including sensors, PLCs and information access and greatly enhances remote troubleshooting HMIs) while serving as a single point of contact for the capabilities. It can also result in safer working conditions for network. the humans who must monitor, regulate and troubleshoot this equipment. Think about the value of automated devices in an Looking ahead oil and gas facility, for example. This clear value proposition The true value of the Connected Factory of the future isn’t for remote connectivity is driving the current boom in cellular M2M connection. Consider Metcalfe’s law as it applies to the derived from the sheer volume of connections; it comes from Connected Factory: the value of the network increases creating more meaningful connections, and the competitive edge gained by the harmonious dialogue between devices and exponentially with the number of connected assets. With this in mind, manufacturers must invest in issuing all the humans managing them. The ability to seamlessly remote assets a cellular connection. Cellular routers and communicate with operators, control systems and software modems now provide native support for industrial automation applications, combined with practical networking options and equipment and protocols, including models that support 4G support for native features and protocols, delivers exponential network connectivity. These products enable two-way meaning to data extracted from industrial devices. These communications from facility to facility, and enable information capabilities create the context to take automation and remote exchange with remote assets, such as offshore platforms or management to new levels, thereby making the connected factory a reality. unattended substations or pipelines. The Connected Factory demands a new approach to the concept of factory automation. With the thoughtful integration A better place to talk of supporting components that are designed specifically for Another challenge facing manufacturers as they seek to this goal, the ability to connect, monitor and control will drive assign an IP address to networked assets is the available productivity well into the future. ☐ bandwidth remains static in spite of the ever-increasing volume > MORE@CLICK ADI03411 | www.AandD24.in of networkable devices and data points. When factoring in the

A&D India | Feb-Mar 2014

t e c h n o l o g y | C o n t r o l & R e g u l at i o n

Keep cool and stay hot The article discusses the need for climate control in electrical and automation cabinets to reduce downtime & bring in operational efficiencies

Most engineers intuitively know itâ&#x20AC;&#x2122;s a good idea that electronic/electrical panels are designed so that its internal environment can be monitored and controlled. They understand that there are limits operating temperatures for the components inside a panel and that the overall reliability of the equipment shall conform to such application and operating condition. It is clear that in many industries and applications, particularly those that are critical, it is almost certain that the project has been tested according to the calculations of risk analysis MTBF (Mean Time Between Failures) of the final equipment, where aspects of macroclimate are carefully considered.

A&D India | Feb-Mar 2013

Harshit Bhardwaj Manager - Sales & Marketing Finder India Pvt Ltd h.bhardwaj@findernet.com

However, for most apparently less arduous applications, temperature control is not addressed particularly accurately, although there is a trend towards miniaturisation of components and enclosures, along with higher density packaging - all this requires all the more attention on climate control inside.

Quantifying the need If there is any need to justify the modest cost and effort incurred in adding the temperature control of a panel, respected references that are worth being taken into consideration are the rule of 10Â°. This rule says that for every increase of 10Â° K temperature, the average reliability is reduced by 50%. If we

C o n t r o l & R e g u l at i o n | t e c h n o l o g y

Typical mounting arrangement of fans and exhaust filters

can lower the temperature of 10° K, we can expect reliability to be multi-folded. Basically this is a rule associated with electronics as well as other components where there is the possibility of failure due to electro-chemical action. A good example is electromechanical components such as relays, switches, and contactors - switching loads of low value or low levels of voltage and current. These can be particularly affected by corrosion, electrolytic action and the formation of oxides and sulphides. Another useful source of information is the operating reliability Handbook “HDBK - 217D”. One can find mathematical expressions to calculate the probability of failure of numerous electrical and electronic components and equipment according to various application scenarios and environments. The difference here is that the failure modes described in the manual are derived from practical tests, rather than in a theoretical basis. As an example, the failure mode (part λT) relays to show the service with a reduction of 10° K with life at room temperature reduction is 1.6. Also, for example, a specific rate of failure when it comes to moisture there is, this is part of the fault (πE) environment, and the values for the distinction between a climate controlled and an uncontrolled environment is based on a factor 2.3. Therefore, the importance of humidity on the reliability is evident. It is important to be aware that high temperature is not necessarily the only question when it comes to long term failures in equipment. Exceeding the maximum operating temperature can make the components inside the cabinet stop

working almost immediately and often surprises the designers.

Practical application It should now be apparent that some form of climate control within a panel or enclosure is probably desirable, and quite possibly essential. Thus, following three approaches that should be observed include putting a thermostat cooling (or air) temperature that monitors in conjunction with a chassis fan to ensure the operation of equipment and/or to ensure that the maximum operating temperature characteristics of the components are not met. The other approach is placing a heating thermostat that monitors temperature in conjunction with a heater, particularly to ensure that the internal temperature does not drop below the dew point. Although high levels of relative humidity, especially in conjunction with higher temperatures to 65° C are not desirable, it is particularly important that the level of water vapour is maintained in suspension in the air, or is not permitted to the same condense on the equipment for obvious reasons - the effects in the medium and long term will directly affect the insulation and safety equipment. Put both thermostats for ventilation and for the heating separately wherever necessary.

Selecting the proper thermostat Choose a thermostat with a specific field of monitoring to be used and mounted in an enclosure. It should be simple and compact and fit directly into a 35 mm rail. What has a bimetallic

A&D India | Feb-Mar 2013

t e c h n o l o g y | C o n t r o l & R e g u l at i o n

Typical IP 55 Pressure Compensating Devices are usually mounted on the upper side of the cabinet

contact sensor element that should provide an accurate switching, completely free of any electronic circuit, fully adapted to their function and application, being able to provide a long electrical life? The adjustment range of 0° C to 60° C, generally meets the majority of application. If RH (relative humidity) is high, the thermostat will have a higher heat setting with respect to ventilation by minimising the temperature difference and therefore the risk of condensation. If the probability of a high relative humidity is small, it can be used to extend the range of the two temperatures, which, although still within the specification of the components will allow greater fluctuation in temperature at a lower rate switching and higher electrical life for the thermostats.

Heaters and fans The amount of detail behind the design of the heater or a fan is beyond the space available for this article, but there are a number of factors that need to be considered and characteristics that need to be known. Briefly, the data required are estimating the RH and lifting the maximum difference of internal temperature allowed; cabinet dimensions; position of the component relative to other components of the adjacent cabinet; coefficient of heat transfer cabinet (depending on material); the difference in temperature desired (interior and exterior in relation to the case) and self -assessment of internal power dissipated by the components.

A&D India | Feb-Mar 2013

Appropriate use of accessories There are typical accessories that may be considered for optimum climate control. These include pressure compensating devices. In sealed cabinets and enclosures, the internal pressure can vary due to changes in temperature. The internal vs external pressure differential needs to be relieved while maintaining a high level of protection thus, preventing the ingress of dust and moisture into the cabinet. Pressure compensating devices used are in accordance with DIN EN 62208 standards. Other accessories include filters. Nine classes of filters have been specified within DIN 24185. These are categorised into 4 course dust filers and 5 fine dust filters. The coarse dust filters (EU1-EU4) are able to filter particles >10 µm. The fine dust filters are able to filter particles(1...10) µm.

Conclusion Overall, controling the climate inside an electrical panel need not be expensive, if the design is considered during the initial stages of the project. Furthermore, considering the benefits in terms of improved reliability, reduction or elimination of downtime on the cost of rewiring the equipment, and other expenses incurred, this monitoring could become almost mandatory. ☐ > MORE@CLICK ADI03412 | www.AandD24.in

EVENT | report

Vision for a better economy The industrial automation and process control practice of Frost & Sullivan recently concluded its annual forum “Enhancing manufacturing competitiveness: New age solutions driving change” on discrete automation and process automation in Mumbai. A report... Developing solutions ‘for India in India’ is as much the need of the hour as is keeping pace with the rapid advancements in global manufacturing techniques. Manufacturing renaissance is an important aspect that can potentially contribute to the increase in contribution of manufacturing sectors toward India’s gross domestic product (GDP) growth. Addressing these challenges in the manufacturing sector, the industrial automation and process control practice of Frost &

Sullivan had recently conducted its annual forum “Enhancing manufacturing competitiveness: New age solutions driving change” on discrete automation and process automation in Mumbai. The two-day event focused on sharing best practices and ideas on how to leverage innovative technologies and bestin-class solutions as a resource to address evolving challenges and equip the manufacturing sector for the future. The discrete automation event was followed by an awards

A&D India | Feb-Mar 2014

report | EVENT

A panel discussion on emerging technologies and investment scenarion in the automation sector was held during the summit

banquet that witnessed industry’s best-in-class companies being recognised with Frost & Sullivan’s Excellence in Industrial Technologies Awards, India.

Trends in manufacturing sector

Africa that may ultimately share similar requirements”, said Niju V, Director, Automation & Electronics Practice, Frost & Sullivan. “The two-day deliberations and discussions have clearly demonstrated the readiness of Indian industrial customers toward adopting best-in-class solutions that could drive change,” added Niju V. He also said that in order to capitalise on these opportunities, the suppliers should work toward winning end-user confidence on their ability to address their unique needs.

The manufacturing sector is likely to witness a healthy growth over the next two to three years, which is in contrast to the current scenario of declining manufacturing share in total GDP. According to Frost & Sullivan’s analysis, the recent dip (2012-13) can be considered as a temporary phenomenon because the fundamentals defining Indian manufacturing Addressing solutions growth story are quite strong. The National Manufacturing “Solution to India’s forex problems is not in running after Policy (NMP) is likely to be one of the key drivers. While there is a concern on investment slowdown, Frost & Sullivan’s more US dollars but by excelling Indian manufacturing analysis indicates that Indian manufacturers are focused on through continuous innovation”, said K Nandakumar, President, operational excellence improvements, which are a key to Automation Industry Association (AIA). He added that in order to convert the customers’ craze for imported products to manufacturing renaissance. The push toward making the industrial corridors a reality, domestic solutions, ensuring impeccable quality is a must. increasing urbanisation, rise in working age population, and Commenting on the key requirements for enhancing India’s focus on smart factory are some of the mega trends that could manufacturing competitiveness, S Sriram, General Manager, potentially drive manufacturing renaissance. The increasing Marketing, Mitsubishi Electric India said, “The Indian per capita expenditure and penetration of assets spanning manufacturing sector is facing unprecedented challenges urban and rural household demonstrate the strong owing to domestic and global environment. Driving toward fundamentals that support India’s manufacturing story. “The enhanced quality and productivity is an inevitable need, which key requirement is the need to shift from ‘value for money’ to the Indian manufacturing sector needs to achieve to leap into ‘value for many’ business models. Indian end users demand the top league in the shortest possible time. Manufacturing quality and relevant features customised to their needs and not sector will best be served by adopting the presently available a product with stripped down features at low cost. Several highly effective solutions, which can enable best practices and solution providers have recognised this requirement and are have clear return on investment metrics.” ☐ already focused on developing products for India in India. An Courtesy:- Frost & Sullivan > MORE@CLICK ADI03413 | www.AandD24.in added benefit is the market beyond India in countries as far as

A&D India | Feb-Mar 2014

EVENT | preview

Optimising production processes The world’s leading trade fair for industrial technology - Hannover Messe will run from April 7 to 11, 2014, at Hannover, Germany. This year’s edition will have a strong emphasis on industrial automation and IT, energy and environmental technologies, industrial subcontracting, production engineering & services, and research & development. The ripples of change are spreading far and wide as the pace of innovation and development in the industrial sector moves into overdrive. “The year 2014 will see a great shift towards automation in industrial manufacturing and the ongoing transformation of the world’s energy systems,” says Dr Jochen Köckler, member of the Managing Board, Deutsche Messe. “To remain competitive, companies need to make their manufacturing processes more efficient, and that means greater investment in state-of-the-art automation technology. Their competitiveness also hinges on access to a reliable, sustainable energy supply. The world’s leading providers of automation solutions and energy technology will be showcasing solutions to these challenges at Hannover Messe 2014.”

With industrial automation & IT, energy & environmental technology, industrial supply and R&D among its keynote themes, “Integrated Industry – NEXT STEPS” as its overarching motto, this year’s Hannover Messe will be the world’s leading trade fair for industrial technology and the go-to event for international decision makers from the manufacturing and energy industries. “Hannover Messe’s leading position is reflected in the high number of exhibitor registrations confirmed to date. At this stage it seems that we will top the outstanding result achieved in 2012, which, with its even-year exhibition lineup, is the most recent directly comparable Hannover Messe year,” added Dr Köckler.

A&D India | Feb-Mar 2014

preview | EVENT

The upcoming fair looks at the steps which industry needs to take in order to get from its smart-factory vision to a real-life, integrated Industry 4.0 factory

Step-by-step to the integrated, Industry 4.0 factory With “Integrated Industry – NEXT STEPS” as its lead theme, Hannover Messe will maintain its focus on integration as a challenge of pivotal importance for the future of industry and will map out the next steps along the road to tomorrow’s intelligent, self-organising factories. To stay competitive, manufacturers need to make their factories as efficient as possible. They need to be able to respond swiftly to changes in the market, while at the same time satisfying the growing demand for product individualisation and customisation. In short: they need flexible, intelligent factories – factories of the future, in which machines, plant and products can talk to each other. This interaction relieves the skilled workers in physical labour and puts them in a position to focus on controlling and optimising the production process. Many technologies for achieving this have been developed over recent years. The next steps are about integrating these technologies into industrial production in such a way that they form a harmonised and fully networked whole. Precisely this is the focus of Hannover Messe 2014. The upcoming fair looks at the steps which industry needs to take in order to get from its smart-factory vision to a real-life, integrated Industry 4.0 factory.

and making sense of these massive data flows. If networking and integration extend beyond the factory, for instance, by encompassing subcontractors and suppliers, then what about data security? Another big challenges is standardisation — ensuring software compatibility across all the components, machines and factories that are to be networked with each other. All of these challenges will be addressed at Hannover Messe 2014.

From inflexible energy monolith to nimble, intelligent energy network

The event also signals the way forward in the ongoing transformation of the world’s energy systems. In this process, the important steps are to upgrade and expand energy transmission and data networks and to find viable ways of replacing the current energy system, which is based on mere dozens of central power stations, with a decentralised system comprising hundreds of thousands of small natural-gas, solar, wind and biomass-powered generation units. “In the future, the smart grids that carry energy and the end devices that consume it, will communicate with each other, unlocking enormous potential for energy savings. Making this vision a reality requires collaboration and coordination across an incredibly diverse range of industries. For all companies and organisations with a stake in this process, Hannover Messe is the perfect technological and political platform for marshaling Addressing the challenges future-defining technologies and concrete solutions in the There are a number of challenges along the road to achieve interests of facilitating the transformation from an outmoded, this reality that necessitate intensive information sharing, inflexible energy monolith to a nimble, intelligent energy investments and coordination. For example, if all robots, work- network,” concludes Dr Köckler. ☐ pieces and machines in the production process end up being Courtesy: Hannover Messe able to share information with each other, then, somehow, > MORE@CLICK ADI03414 | www.AandD24.in there will be a need for IT systems that are capable of analysing

A&D India | Feb-Mar 2014

T E C H N O L O G Y | TA L K

Designing a safe sustainable machine The column this time features the five best-practice design principles for machine builders to deliver safer, more cost-effective and sustainable machines. Manufacturers across many industries are placing increased emphasis on machine designs that support safety & sustainability initiatives, and drive economic prosperity. Machines that improve safety, minimise waste, consume less energy and deliver maximum return on investment are critical to the success of any sustainable production program. Building such a machine requires a holistic approach to analyse operational efficiency, safety, functionality, productivity, ease of operation and maintenance. The five best-practice design principles for a safer, more cost-effective and sustainable machines include: Perform a safety audit after mechanical design, but before control system design: This helps engineers chart the course for an effective safety solution, and evaluate & investigate risks early in the development process. This saves critical time and helps machine builders get their equipment to market faster. In addition, the machine’s end users gain optimised production, thanks to an automation system that helps operate machinery and processes in the most efficient way. Guard or control access to moving parts: Where hazards cannot be removed through design, machine builders typically will install a fixed physical barrier that protects users from the hazard. When frequent access to the hazardous area is required, non-fixed guards are used, such as removable, swinging or sliding doors. In areas where non-fixed guards are impractical, guarding solutions that monitor the presence of the operator rather than the status of the gate can be used. Use integrated safety systems to reduce

control system complexity: The more designers integrate the standard and safety control functions of a system, the better the opportunity is to reduce equipment redundancies and improve productivity and economic factors. This integrated control functionality reduces the number of unique components in use on the factory floor, which in turn reduces crib inventory costs, as well as maintenance team training requirements. End users also benefit from less waste with fewer parts to maintain and replace throughout the machine life cycle. In addition, integrated control systems have broader intelligence regarding machine operation and status, and reduce nuisance shutdowns and prolonged restarts, further improving machine efficiency and productivity. Make better use of diagnostics: With the ability to embed intelligence-gathering devices into machines without redesign or retooling, machine builders provide customers with self-diagnostic equipment capable of predicting and preventing failures, thereby boosting productivity and reducing repair costs. Moreover, this technology relays the machine condition information back to the machine builder for value-added monitoring and analysis services without compromising existing resources or hindering profitability. From the end user’s perspective, turning the maintenance function over to the machine builder makes good business sense. It improves machine performance, maximises capital investments and allows for more cost-efficient use of internal resources. Design IT connectivity into the machine: Building information-enabled machines capable of connecting into an end user’s IT infrastructure, provides them with

The more designers integrate the standard and safety control functions of a system, the better the opportunity is to reduce equipment redundancies and improve productivity and economic factors

critical operational insight, including energy efficiency and overall equipment effectiveness (OEE) calculations. This insight, in turn, helps plant managers reduce waste and optimise productivity.

Conclusion Thanks to advancements in technology and best practices, machine builders can play an important role in helping companies implement safer machine designs that support sustainable production practices. By following the above core design principles and leveraging the best of today’s advanced technologies, machine builders can create safer, more cost-effective and reliable equipment. ☐ Courtesy: Rockwell Automation For more details, visit: http://discover.rockwellautomation.com/_Safety_ Solutions_Full.aspx > MORE@CLICK ADI03415 | www.AandD24.in

A&D India | Feb-Mar 2014

TA L K | T E C H N O L O G Y

INNOVATIVE Cabling solutions According to World Nuclear Association, India’s primary energy consumption has doubled nearly by 25,000 PJ from 1990 to 2011. The article discusses cabling solutions provided to one of the largest establishment of Department of Atomic Energy for their requirement of high performance, reliable cables for the construction of their automated nuclear buildings & research laboratories Electricity demand is increasing rapidly in India. With huge transmission losses – 222 TWh in 2011, this has resulted in 774 billion kWh consumption. Gross generation comprised 836 TWh from fossil fuels, 33 TWh from nuclear, 131 TWh from hydro and 53 TWh from other renewables. Coal provides 68% of the electricity at present, but reserves are limited. The per capita electricity consumption figure is expected to double by 2020, with 6.3% annual growth and reach 5000-6000 kWh by 2050, requiring about 8000 TWh/yr. There is an acute demand for more and more reliable power supplies. One-third of the population is not connected to any grid. India has a flourishing and largely indigenous nuclear power program and expects to have 14,600 MWe nuclear capacity on line by 2020. It aims to supply 25% of electricity from nuclear power by 2050. Lapp supplied high quality innovative cabling solutions to the one of the largest establishment of Department of Atomic Energy which was set up with the main objective of conducting broad based multidisciplinary programme of scientific research and advanced engineering, directed towards the development of sodium cooled fast breeder reactor technology in India. Over the years, the centre has established comprehensive R&D facilities covering the entire spectrum of FBR technology related to sodium technology, reactor engineering etc and has developed a strong base in a variety of disciplines related to this advanced technology.

A&D India | Feb-Mar 2014

Solution requirements The requirement is for high performance, reliable cables for the construction of their automated nuclear buildings and research laboratories. The required specific cabling solutions are: • Power cables to supply power to all the rsearch equipments and the various control panels in the labs. • High-speed data communication cables to transmit signals from the control panels to automate the building. • Highly flexible and long lasting instrumentation cables for monitoring, metering and various parameters in the laboratory. • Reliable cable glands and connectors to ensure secure connections and to reduce chance of loose or broken connections due to vibrations and other high stress factors.

Cabling solutions For power & control applications, the company supplied cables designed with a tough outer sheath and consists of doubly insulated PVC single conductor. The cables are also cost effective making these ideal for fixed installation both indoors and outdoors. For instrumentation applications, the company has provided aluminium taped cables with the outer sheath halogen free and flame retardant. These are used for transmitting analog signals from measuring instruments. The cables’ sturdy decontaminated

The range of cables provided are specifically made for applications related to automation, panel indication, motor and AC control

sheath removed the needs of additional conduits. All cables are radiation, flame retardant and HFFR compliant. An important quality that these cables should behold is low smoke and low toxicity through halogen-free materials. Lapp supplied appropriate data transmission cables based on customised data transmission needs. The range of cables provided are specifically made for applications related to automation, panel indication, motor and AC control. These cables also consists of copper braided screening which contributed to the reduction of electromagnetic interference.☐ Courtesy: Lapp India > MORE@CLICK ADI03416 | www.AandD24.in

technology | news

Test terminal blocks

Metal flow control valve

Connectwell’s CDS6U & CDS6UTS disconnect & test terminal blocks are used for measuring, control and regulatory circuits. These provide a clear functional advantage for the devices having the utility instruments and associated transformers. Separate testing points facilitate insertion of test probes. Disconnection is achieved by means of a slide link operated with a screw driver. In CDS6U/TS, the insulated test point screw system is integrated. Its specifications The terminal blocks are include terminal pitch of 8 mm preferred for the connections connection possibility of 1.5 – 6 sq.mm, that involve safety requirements rated voltage of 800 V and rated current ESI Standards, British of 41 A. These terminal blocks are CEGB regulations and NTPC preferred for the connections that involve applications safety requirements of the Electrical Supply Industry (ESI) Standards, British CEGB regulations and NTPC applications.

Janatics has offered metal flow control valve in various sizes - M5, 1/8”, 1/4”, 3/8”, 1/2”, & 3/4” with elegant design and finish. One of the main features of the product is fine regulation of air flow housing made of aluminium casting easily mountable on the cylinders valves. Adjustment of the air flow can be done by rotating the slotted head type needle, which can be adjusted from top side. This also ensures that the set air flow is protected from manual The metal flow control valve is designed mishandling. It is designed with male thread (G) on one end and with male thread (G) on one female thread on the other end end and female thread on the other end. One touch fittings with the desired tubing can be assembled in the female end. Metal flow control valve is available in two types including exhaust control and supply control.

> MORE@CLICK ADI03417 | www.AandD24.in

> MORE@CLICK ADI03418 | www.AandD24.in

Multi-touch functionality panel

Pick & place units

B&R’s Panel PC 900 with multi-touch functionality offers the absolute highest level of total computing power. Combining new display sizes with multi-touch operation, the new flagship system is more versatile than ever. The Panel PC 900 takes full advantage of the state-of-the-art projected capacitive touch screen also used in the automation panel widescreen display series. These multi-touch displays allow new and With an edge-to-edge, innovative user interactions, such as zooming anti-glare glass surface with two fingers or quickly paging forward and high-resolution with swipe gestures monitors, maximum functionality and an advanced design have been integrated into a single operator panel. Displays ranging from 15.6” to 24” with Full HD resolution ensure that every possible requirement is covered. These multi-touch displays allow new and innovative user interactions, such as zooming with two fingers or quickly paging forward with swipe gestures.

The linear directly driven pick & place units of the PPU-E series from SCHUNK are the fastest pick & place units on the market. The largest size PPU-E 50, is an expert for dynamic handling of medium-weight masses up to 5 kg. For a complete cycle with a 280 mm horizontal and 150 mm vertical stroke the unit has a cycle time of 0.98 seconds with a tooling mass of 1.5 kg and 2 x 60 ms (for gripper). As the two smaller sizes The largest size PPU-E 50, is an expert PPU-E 15 and PPU-E 30, the for dynamic handling of medium-weight PPU-E 50 is also moved via masses up to 5 kg a wear-free direct drive, and not by a guidance transmission. This minimises the maintenance effort, increases the continuous repeat accuracy, and simplifies programming.The narrow housing and the media supply via the back panel allows a compact, maintenance and assembly friendly sandwich construction of several units next to each other.

> MORE@CLICK ADI03419 | www.AandD24.in

> MORE@CLICK ADI03420 | www.AandD24.in

A&D India | Feb-Mar 2014

news | technology

CAN repeaters

AC variable frequency drive

HMS Industrial Networks has launched a range of CAN repeaters under the IXXAT brand. These products enable coupling of two or more CAN network segments, provide them with galvanic isolation, and eliminate the effects of EMI (Electromagnetic Interference). The CAN repeaters are offered under HMS’s recently acquired IXXAT brand and enable machine builders and system integrators to use The integrated galvanic extended CAN topologies including tree or star isolation provides a built-in topologies. Furthermore, the integrated protection against over galvanic isolation provides a built-in protection voltage and the anti-noise against over voltage and the anti-noise circuit circuit of the units eliminates of the units eliminates the effects of EMI. These the effects of EMI repeaters are especially designed for use in industrial environments, meeting high demands for robustness, temperature ranges and safety. With the use of a repeater, it is possible to build independent electric segments that can be optimally terminated in terms of signals. The repeater substantially increases system reliability, partly because it increases the signal quality, and partly because it makes it possible to isolate malfunctions – keeping the remaining CAN-system fully operational.

Parker Hannifin has recently launched their new series of AC variable frequency drive, the AC30V. The drive has been designed to provide users with exceptional levels of control, from simple open-loop pumps and fans through to closed-loop process line applications. Its flexible and highly modular construction enables a wide range of communications and I/O modules to be easily added as required. The AC30 has been designed with simplicity in mind, but this doesn’t compromise its functionality. Integrated macros for a range of applications and PLC functionality enable more capable users to create sophisticated control that would previously have required a separate PLC. Designed for operation in environment class 3C3 and 3C4 for The AC30 has been designed with Hydrogen Sulphide (H2S) as standard simplicity in mind, but this doesn’t (tested at 25 ppm for 1200 hours), compromise its functionality temperatures up to 50 °C with optional integrated EMC filter to C2 1st environment and DC link choke to reduce line harmonics. AC30V also complies with RoHS substance restrictions in accordance with EC Directive 2011/65/EU.

> MORE@CLICK ADI03421 | www.AandD24.in

> MORE@CLICK ADI03422 | www.AandD24.in

Safety brake control

PGV positioning system

Mayr power transmission presents a new, reliable brake control for their proven ROBA-stop safety brake construction series. The ROBA-SBCplus brake control, developed together with the safety experts Pilz, is technically superior in terms of safety contactor circuits. The prototype module inspected by the TÜV (Technical Inspectorate) can be deployed up to the highest Performance Level PLe and SIL 3. In order to enable safety brakes to contribute towards risk reduction in machines and systems, they require a reliable control. Vertical axes, for example, rank among the particularly hazardous machine parts through which people The ROBA-SBCplus brake can be severely injured. A similar hazard control prototype can be potential arises from stage equipment, if deployed up to Performance actors are performing beneath suspended Level PLe and Safety Integrity loads. In order to protect people from all Level (SIL) 3 hazards in such situations, the remaining functional risks in accordance with safety standard DIN EN ISO 13849-1 should be assessed, and subsequently suitable measures for the reduction of risks must be taken. As a mechanical component, the brake falls under the category of functional safety in accordance with this standard.

Pepperl+Fuchs’s PGV positioning system is the only product that offers a combination of optical colour band tracking for driving; data matrix codes for positioning and control codes for navigation, making it the optimal solution for controlling automated guided vehicles. Thanks to the camera system’s powerful, integrated signal processing facility, the X and Y position, the speed, the angle, and the operating status are accurately detected at all times and are continuously reported. The wide reading window can The unique combination of colour cope with any branches, crossovers, band tracking and code reading and even tight curves with precise makes the PGV an ideal solution position feedback at all times. The for automated guided vehicles PGV’s revolutionary camera technology makes it completely insensitive to ambient light. Even dirt on or damage to the colour band or codes do not trouble the PGV. Shiny floors, changing ambient light, and strong light reflections interfere with conventional optical positioning systems, since they do not have a balanced selection of aperture, lens, and shutter speed. On the new PGV positioning system, the optical components are purely focused on the “region of interest”.

> MORE@CLICK ADI03423 | www.AandD24.in

A&D India | Feb-Mar 2014

> MORE@CLICK ADI03424 | www.AandD24.in

technology | news

Safety relay

Non-contactless inductive universal encoder

The new Allen-Bradley Guardmaster 440C-CR30 from Rockwell Automation is a flexible, cost-effective and easy-to-use configurable safety relay ideal for applications requiring 4 to 10 safety circuits and control of up to 5 zones. The Guardmaster 440C-CR30 is configured through Connected Components Workbench (CCW) software – the same programming environment used by the Micro 800 family of controllers, PanelView component HMIs The new Allen-Bradley and PowerFlex drives – for simple and Guardmaster 440C-CR30 is for seamless programming of standard and applications requiring 4 to 10 safety logic in separate devices. The safety circuits and control of up distinct graphical user interface and to 5 zones drag-and-drop capabilities of CCW help guide users through a simple process of selecting certified safety function blocks for the 440C-CR30. This means users can create, control and monitor a safety system in the same software environment as their standard control, resulting in increased productivity and reduced programming time.

Turck’s new non-contact encoder in IP69K eliminates the need for compromise. It is the first manufacturer to offer a non-contactless inductive universal encoder, this means that the user no longer has to make a compromise between resolution and rugged design. All the measures required to protect encoders from mechanical stress using springs or double bearings are no longer necessary. Apart from the interference immunity and wear-free design of the This single model can replace system, the user also benefits several 100 different encoder types from the parameterisation and mounting concept that allows a single encoder model to be used as a universal encoder for a countless number of applications. This single model can replace several 100 different encoder types. The mounting concept also keeps this universal approach. Adapter rings make it possible for the user to fit the positioning element. The user has to keep a single encoder in stock which he can use for all applications on shafts up to 20 mm in diameter.

> MORE@CLICK ADI03425 | www.AandD24.in

> MORE@CLICK ADI03426 | www.AandD24.in

Distributed networking motion controller

Preplanning and detail engg platform

Elmo Motion Control has recently released Gold Maestro Motion Controller Version 1.1.2.0, including a range of powerful new features that make complex motion tasks easier to program and faster to implement. Elmo’s Gold Maestro (G-MAS) is an advanced, fast, precise, user-friendly and cost-effective distributed networking motion controller that leads the market. The Gold Maestro offers full Delta Robot Support, including linear, circle, polynomial, table spline and table PVT. Simply define the delta robot part lengths, and the machine is ready to run. Enhanced error correction support is another new feature of the updated Gold Maestro Motion Full Delta Robot support, Controller, enabling position correction of enhanced error correction both single and multi-axis positions in support and superimposed real time, based on correction data. motion are now an Superimposed management of error integrated part of the Gold correction is fully supported. The Gold Maestro Version 1.1.2.0 Maestro enables Flying VisionTM with Superimposed Motions (that is, adding another profiler on top of an ongoing motion in real time), significantly improving machine throughput.

Eplan has integrated the preplanning and detail engineering with the new Eplan Platform 2.3. These innovative functions have increased project quality and data consistency, and at the same time, reduced configuration costs. Whether it is graphical overviews, placeholders for functions, initial project data for drives, sensors and PLC inputs/outputs, or parts lists for calculations comprehensive preplanning tasks can be processed directly Integrated engineering from preplanning in the Eplan Platform. The to basic engineering from systems subsequent enclosure production overview down to electric schematic and detailed design of the can be done in the new platform system is based on comprehensive data without new data entry or transfer from other systems. Users can benefit from very easy entry into this new planning method based on the Eplan Platform. This additional integration allows the user to increase data consistency and project quality. The central dialogue in the Eplan Platform is the new preplanning navigator. In this dialogue, the defined segments for preplanning are displayed and administered within the project.

> MORE@CLICK ADI03427 | www.AandD24.in

> MORE@CLICK ADI03428 | www.AandD24.in

A&D India | Feb-Mar 2014

h i g h l i g h t s | c o m pa n y i n d e x | I m p r i n t

Highlights - Apr/May 2014 (6th Anniversary) impRINT

Automation & Drives

Publisher / Chief Editor  ShekharManufacturing Jitkar Efficient shekhar.jitkar@publish-industry.net Deputy Editor Sumedha Mahorey sumedha.mahorey@publish-industry.net Sub-editor & Correspondent Srimoyee Lahiri srimoyee.lahiri@publish-industry.net

»»Chemical & Process Change is dramatic in the chemical & process engineering industry. A major factor is the globalisation of industry. The old competitive advantage of inventing and keeping technologies in-house and then using them around the world has become an outdated model. The next issue takes a look at how chemical and process engineering developments have transformed in the present manufacturing landscape and analyses the various innovations and technology developments on-site.

»» Gears & Motors As per recent reports, the global industrial gear motors and drives market is set to grow at a CAGR of 4.98% over the period 2012-2016. One of the key factors contributing to this market growth is the growth in the emerging markets. The market has also been witnessing the increased demand for precision geared products. The next edition will thus delve into latest technology developments in industrial motor and its application benefits and the gears section will highlight trends in the application of new age gears manufacturing.

»»Safety & Integration Industrial machinery risk analysis and risk reduction techniques can create a very complex matrix of solutions. Industrial safety integration can help one to make informed decisions that will help keep employees safe. In order to meet the ever-increasing requirement to assess industrial safety, the coming issue details on the various safety & integration technologies & its applications for the manufacturing sector.

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company Index Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page ARC Advisory Group . . . . . . . . . . . . . . . . . . 28 ABB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Ansys . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 B&R Industrial Automation . . . . . Cover, 8,9, 78 Bharat Bijlee . . . . . . . . . . . . . . . . . . . . . . . 23 BHEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 CII . . . . . . . . . . . . . . . . . . . . . . . . . . . 79, 10 Connectwell Industries . . . . . . . . . . . . . . 13, 76 Contrinex Automation . . . . . . . . . . . . . . . . . 31 Deutsche Messe . . . . . . . . . . . . . . . . . . . . . 72 EPLAN . . . . . . . . . . . . . . . . . . . . . . . . . 11, 76 Emerson Network Power India . . . . . . . . . . . . 28 Elmo Motion Control . . . . . . . . . . . . . . . . . . 76 Festo Controls . . . . . . . . . . . . . . . . . . . . . . . 2 Finder India . . . . . . . . . . . . . . . . . . . . . 43, 68 Frost & Sullivan . . . . . . . . . . . . . . . . 10, 62, 70 Faro Business Technologies . . . . . . . . . . . . . 37 GE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Galil Motion Control . . . . . . . . Back Inside Cover

Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page

Honeywell . . . . . . . . . . . . . . . . . . . . . . . . . 20 Harting Technology Group . . . . . . . . . . . . . . 11 HMS Industrial Networks . . . . . . . . . . . . 33, 77 Hummel Connector Systems . . . . . . Back Cover Hanning Motors . . . . . . . . . . . . . . . . . . . . . . 59 Hilscher India . . . . . . . . . . . . . . . . . . . . . . . 17 ICP Das . . . . . . . . . . . . . . . . . . . . . . . . . . 61 ifm electronic India . . . . . . . . . . . . . . . . . . . . 55 igus India Pvt Ltd . . . . . . . . . . . . . . . . . . . . . . 4 Janatics . . . . . . . . . . . . . . . . . . . . . . . 25, 76 Lapp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Kuka Roboter GmbH . . . . . . . . . . . . . . . . . . 28 Kubler Automation . . . . . . . . . . . . . . . . . . . . 15 Mayr Power Transmission . . . . . . . . . . . . . . . 77 Micro-Epsilon . . . . . . . . . . . . . . . . . . . . . . . . 7 Mifa Systems . . . . . . . . . . . . . . . . . . . . . . . 65 Mitsubishi Electric . . . . . . . . . . . . . . . . . . . . . 3 Messe Frankfurt . . . . . . . . . . . . . . . . . . . . . 21 Nord Drivesystems . . . . . . . . . . . . . . . . . . . 50

National Instruments . . . . . . . . . . . . . . . . . . . 11 Omron Automation . . . . . . . . . . . . . . . . . . . . . 5 Pepperl + Fuchs . . . . . . . . . . . . . . . . . . 40, 77 PTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Parker Hannifin . . . . . . . . . . . . . . . . . . . . 1, 76 Pilz India Pvt Ltd . . . . . . . . . . . . . . . . . . . . . 45 Red Lion . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Rockwell Automation . . . . . . . . . . 6, 12, 58, 74 Renu Electronics . . . . . . . . . . . . . . . . . . . . . 39 Schmersal . . . . . . . . . . . . . . . . . . . . . . . . . 14 Sandhar Technology . . . . . . . . . . . . . . . . . . . 11 Schunk Intec India . . . . . Front Inside Cover, 78 Siemens . . . . . . . . . . . . . . . . . . . . . . . . 16, 28 Siemens PLM Software . . . . . . . . . . . . . . . . 10 Tata Consultancy Services . . . . . . . . . . . . . . 28 Tata Power . . . . . . . . . . . . . . . . . . . . . . . . . 34 Turck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Xchanging . . . . . . . . . . . . . . . . . . . . . . . . . 56

Board of Directors  Kilian Müller (CEO - Worldwide) Hanno Hardt (Head - Marketing & Business Development) Frank Wiegand (COO - Worldwide) Shekhar Jitkar (Publisher / Chief Editor)  Subscription  Annual Subscription Price: Rs 600 includes shipping and VAT. em.india@publish-industry.net Ph: +91-20-6451 5754 Printing  Kala Jyothi Process Pvt Ltd, S.No: 185, Kondapur, R R District, AP 500 133, INDIA Copyright/Reprinting  The publishing company holds all publishing and usage rights. The reprinting, duplication and online publication of editorial contributions is only allowed with express written permission from the publishing company. The publishing company and editorial staff are not liable for any unsolicited manuscripts, photos and illustrations which have been submitted. Internet http://www.aandd24.in

A&D India | Feb-Mar 2014

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