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VIEWPOINT
INSIGHTS
12 | How to leverage workforce dynamics when adopting technologies
How to keep the workforce engaged and developing as we continue to implement industry 4.0 17 | How TSN helps manufacturers enable edge computing capabilities
Edge computing is becoming increasingly more crucial to optimizing data-driven activities
20 | Mitigate arc flash hazards in medium-voltage electrical systems
Mitigating arc flash hazards in medium-voltage systems could be performed in synergy to achieve optimal system reliability and safety
What to consider when sizing your compressed air system
There are many factors to consider when sizing compressed air systems
SOLUTIONS
In many cases, digital twins can be implemented to help improve asset performance 34 | The benefits of adopting an all-inone automation engineering platform
To unlock engineering efficiency, combining platforms streamlines and adds consistency 38 | Key benefits and strategies to implementing plant automation
To transform operations in the production and delivery of 5G equipment, a Lighthouse approach was achieved 42 | When does preventive maintenance really begin?
Preventive maintenance should begin before a critical asset is installed
Characteristics and test properties of rotating electrical machine bearing lubricants
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Having people work in teams will always be relevant; everyone has the opportunity to teach and learn.
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EDITORIAL ADVISORY BOARD
H. LANDIS “LANNY” FLOYD, IEEE Life Fellow
JOHN GLENSKI, President, Automation Plus
MATTHEW GOSS, PE, PMP, CEM, CEA, CDSM, LEED AP, Senior Vice President, CDM Smith
CONTRIBUTORS WANTED
Are you a subject matter expert in one of these topics? Would you like to author an article on one of the topics below? If so, please submit an idea to: https://tinyurl.com/PlantEngineeringSubmissions
• Expert Q&A: Maintenance
• Expert Q&A: Power and electrical systems
• Lubrication
• Plant automation
• Plant hardware and software
• Pipes, fittings and valves
• Power systems
CFE Media Contributor Guidelines Overview
Content For Engineers. That’s what CFE Media stands for, and what CFE Media is all about — engineers sharing with their peers. We welcome content submissions for all interested parties in engineering. We will use those materials online, on our Website, in print and in newsletters to keep engineers informed about the products, solutions and industry trends.
* https://tinyurl.com/PlantEngineeringSubmissions gives an overview of how to submit press releases, products, images and graphics, bylined feature articles, case studies, white papers and other media.
* Content should focus on helping engineers solve problems. Articles that are commercial in nature or that are critical of other products or organizations will be rejected. (Technology discussions and comparative tables may be accepted if nonpromotional and if contributor corroborates information with sources cited.)
* If the content meets criteria noted in guidelines, expect to see it first on the website. Content for enewsletters comes from content already available on the website. All content for print also will be online. All content that appears in the print magazine will appear as space permits, and we will indicate in print if more content from that article is available online.
* Deadlines for feature articles vary based on where it appears. Print-related content is due at least three months in advance of the publication date. Again, it is best to discuss all feature articles with the content manager prior to submission.
LEARN MORE AT: https://tinyurl.com/PlantEngineeringSubmissions
TM Technology and
INSIGHTS
Are you at the forefront of the renewable energy revolution?
Is it still a revolution? Probably not; sustainability should be embraced
As the economy continues to benefit from a renewable energy revolution, industrial leaders must seize the opportunity to create more sustainability options. The increased use of renewable energy, driven by global concerns about climate change, demands a proactive response from the manufacturing sector.
Respondents to a recent Plant Engineering research study agree. When asked about current challenges in the global engineering market, 41% indicated “addressing climate change and sustainability goals” was a key challenge and opportunity.
implement circular economy principles, ensuring the production process minimizes waste and maximizes resource efficiency. This not only aligns with environmental goals, but also enhances the reputation of companies as socially responsible entities.
Think of environmental, social and governance (ESG) guidelines being written for many companies and the impact they can have.
Editor-in-Chief
One of the key areas where industrial leaders can make a significant impact is in integrating renewable energy sources into their operations. The cost of renewable energy generation, particularly solar and wind power, has witnessed a remarkable decline thanks to technology advances.
Moreover, the surge in electric vehicles (EVs) presents an exciting option for industrial professionals. The need for robust battery manufacturing infrastructure is evident, and energy storage companies must produce even more advanced batteries to support the EV market.
As the demand for clean energy rises, so does the importance of responsible resource management. Industrial leaders should prioritize sustainable sourcing of materials and
However, embracing renewable energy goes beyond the factory floor. It requires a holistic approach that encompasses supply chain management. Industrial professionals should work collaboratively with suppliers to ensure sustainability is ingrained throughout the entire production chain.
The shift toward renewable energy is an inevitable and positive trajectory for the industrial sector. Plant engineers and industrial experts must view this transition as an opportunity rather than a challenge. By incorporating renewable energy sources, supporting the growth of EVs and adopting sustainable practices, industrial leaders can not only meet the demands of the present, but also pave the way for a more sustainable future.
The time to act is now, and the responsibility lies on the shoulders of those who shape the industrial landscape.
This content was enhanced with ChatGPT. Due to the limitations of AI tools, all content was edited and reviewed by our content team. PE
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ENGINEERING SOLUTIONS
What are the key benefits and strategies to implementing plant automation?
Plant automation offers many potential benefits, but it requires precise strategies that consider the entire facility to achieve the best possible result.
QUESTION: What are the key advantages of implementing automation in a manufacturing plant?
Joe Wagner: Remote system monitoring, easy data access, and powerful data visualization options are just a few key advantages of implementing automation in a manufacturing plant. Automated systems often make it possible to remotely access and interact with the system from anywhere in the world in a secure way, which also enables quick and easy access to data generated by the automated system.
This data is very useful, as it can be analyzed for process improvements or factored into real-time calculations while also being visualized on a touchscreen interface for easy monitoring and interaction. Overall, automation enables an enhanced level of access and control that can lead to increased uptime, efficiency gains, and quality improvements.
Q: What are the emerging trends and technologies in plant automation that are shaping the future of manufacturing?
Mithun Nagabhairava: Artificial intelligence (AI) is playing a pivotal role
in advancing automation to autonomy for industrial manufacturers, akin to the transformative impact autonomous vehicles have changed the automotive realm. Cutting-edge AI and machine learning (ML) technologies, robust computing resources, and cost-effective large-scale data collection are enabling to revolutionize the way factories operate, unlocking unprecedented levels of efficiency, productivity, and quality.
To address the fast-changing customer preferences, workforce challenges, and increased competitive landscape, manufacturers are accelerating digital transformation efforts and prioritizing the application of AI and ML to solve their complex production challenges. Enabled by the advancements in AI/ML, leading industrial manufacturers have already expanded the role of AI to enable autonomous decision-making, as well as augment the remaining human decision processes with context and decision support mechanisms.
Joe Wagner: One emerging technology in plant automation that is shaping the future of manufacturing is the message queuing telemetry transport (MQTT) protocol. MQTT was originally designed for connections with devices in remote locations with resource constraints or
Respondents
limited bandwidth, making it very lightweight and efficient at moving data to and from a data broker (either locally or in the cloud). More specifically, MQTT is capable of “report by exception” which means that data is only transmitted when it has changed. MQTT is not necessarily “new” but is still relatively new to the world of manufacturing with many companies just starting to adopt this powerful technology.
Q: How can plant managers ensure automated systems are adaptable and flexible to changing production demands?
Mithun Nagabhairava, Senior manager, data science and AI, Kalypso, Austin, Tex
Daniel Pender, Global manager, markets and strategy, Rockwell Automation, Milwaukee
Joe Wagner, MS, Field application engineer, Red Lion, Sacramento
ENGINEERING SOLUTIONS
Daniel Pender: Plant managers should ensure their team selects automation systems that are scalable, expandable, cyber aware, and designed to be supported and maintained in flexible ways. To futureproof automation and control systems, operational budgets must allocate appropriate annual funding to support operations and maintenance activities. Operator and maintenance training, continuing information technology/operational technology (IT/OT) interactions, cyber and network upgrades all help to support production needs outside of the physical systems and technologies.
Plant managers that leverage their annual capital budgets to support expansions or migrations and acknowledge their environmental, social and governance goals will have the best chance of adapting towards the future.
Joe Wagner: One way to describe this ability to be adaptable and flexible to changing production demands
is “future-proofing.” When it comes to ensuring that automated systems are as future-proof as possible, there are several factors to consider such as: compatibility with multiple communication protocols and devices, ability to quickly expand the communications capabilities of the system, and the ability to easily expand the input/output (I/O) capabilities of the system. By choosing the right hardware with this level of flexibility, users can ensure that their system will be adaptable and ready for many years of changing production demands.
Q: What are the most critical considerations when selecting automation technologies for a specific manufacturing process? Describe the challenge and solution.
Daniel Pender: Critical considerations when selecting technologies include abilities to scale and change function. It is impossible to anticipate all future needs
today. Even if the process is unchanged, the platform should provide a foundation for data, analytics, and information, because today’s manufacturing demands will certainly change or grow in the future. In any industry, companies need to consider process and discrete controls. For example, in the power space, highspeed tripping and closing of breakers can require millisecond response time for load shedding, whereas in a chemical plant, process variables might require 250-ms updates to support control schemes. In some industries, like paper mills, companies might need to consider controls enabling both slow- and high-speed cycle times.
Joe Wagner: When selecting automation technologies for a specific manufacturing process there are several critical considerations to keep in mind, some of which will depend on the process itself. Some of the more general considerations include ensuring compatibility with existing devices/processes, being flexible
FIGURE 1: Advances in artificial intelligence and machine learning technology are helping manufacturers solve their complex production challenges throughout the enterprise. Courtesy: Kalypso
2: Autonomy and closed loop optimization can be achieved at various levels through vertical integration. Courtesy: Kalypso
FIGURE 3: Increase the probability of success and access time-to-value of new-phase tactical projects. Courtesy: Kalypso
FIGURE
ENGINEERING SOLUTIONS
and ready for future changes or additions to the process, and selecting robust hardware that is easy to configure. When considering the challenge of being flexible and ready for future changes, one solution is modular hardware that allows users to easily expand the communications capabilities or input/output (I/O) capabilities of a device in the field with minimal disruption to production.
Q: What are the main challenges faced when integrating automation into an existing manufacturing process?
Joe Wagner: When integrating automation into an existing manufacturing process, users should expect at least a few challenges along the way. For example, it is very common for manufacturing plants to have several pieces of legacy hardware which may not be able to communicate
directly with newer automation hardware using modern protocols. In cases like this, users can implement an appropriate protocol converter to overcome communication barriers and achieve a high level of connectivity. Another challenge worth considering is operator training. Any time changes are introduced in a manufacturing environment, users should expect at least some operational learning curve and be ready to address any unexpected issues that may pop up.
Q: How can knowledge transfer and training programs be effectively implemented to upskill the workforce for a more automated environment?
Mithun Nagabhairava: Many industrial organizations are undergoing a significant time of transition. As a generation of highly skilled employees are reach-
ing retirement age and leaving the workforce, they are taking with them decades of hard-won experience and tribal knowledge that the next generation will not have. In addition, the new workforce is more inclined to leverage digital technologies and embrace AI-driven solutions for optimizing processes and fostering innovation.
This shift necessitates a strategic approach to knowledge transfer, training, and upskilling. Leading manufacturing organizations are adopting AI-enabled autonomous capabilities to be central for enterprises to preserve the wisdom of the past and harness the potential of emerging technologies to shape the next-generation workforce.
By harnessing autonomous control strategies, organizations can develop robust models that integrate operator insights with knowledge gleaned from
FIGURE 4: A continuous reinforcement loop of control adjustments aimed to reduce variability and optimize target process variables enabled by a robust digital twin of a physical system. Courtesy: Kalypso
historical data to determine the necessary system adjustments for optimal results. With these advanced capabilities, AI is elevating the role of an operator from making repetitive manipulations to managing the performance of the machines.
Q: What key factors influence the return on investment (ROI) for plant automation projects?
Mithun Nagabhairava: As organizations are advancing their automation and digital capabilities, it is important to start with assessing the current level of performance across the manufacturing process. This would help to determine which areas are the most challenging and would provide the best opportunities to improve asset availability, optimize process consistency, enhance quality control, and reduce energy usage.
Leading organizations prioritize high-value use cases, demonstrating
their worth through limited deployments and devising strategic plans for scalable implementation.
Q: How can automation improve product quality and consistency in a manufacturing plant?
Daniel Pender: Critical considerations when selecting technologies include abilities to scale and change function. It is difficult to anticipate all future needs today. Even if the process is unchanged, the platform should provide a foundation for data, analytics and information because manufacturing demands will change or grow in the future. In any industry, companies need to consider both process and discrete controls. For example, in the power space, high-speed tripping and closing of breakers can require millisecond response time for load shedding, whereas in a chemical plant, process vari-
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Typical Full Flow filtration using existing pump.
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ables might require 250 ms updates to support control schemes. In some industries, like paper mills, companies might need to consider controls enabling slowand high-speed cycle times.
Joe Wagner: There are a number of ways automation can improve product quality and consistency in a manufacturing plant, but one word that can describe it very well is “data.” Automated systems are capable of tracking relevant data points over time and displaying that data in clear ways while keeping a historic record of measurements for analysis. For higher-urgency situations, automated systems are capable of alerting users via text and/or e-mail when certain alarms are active, allowing for a quick response and correction. Finally, automated systems may be capable of making automatic realtime adjustments to processes to account for any deviations, ensuring a high level of quality and consistency. PE
Typical Side Stream filtration of basin using a recirculating pump.
Typical Side Stream filtration using existing pump.
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ENGINEERING SOLUTIONS
NETWORKING SYSTEMS AND EDGE COMPUTING
John Kan and Chase Wentzky, Motion Automation Intelligence, Birmingham, Alabama
When and how to leverage workforce dynamics when adopting technologies
How to keep the workforce engaged and developing as we continue to implement industry 4.0
The introduction of modern technologies into manufacturing is an ongoing and continuous process. However, the rate at which innovative technologies are being adopted and how quickly things are changing is unparalleled. We have all learned, especially during the “pandemic years,” that working groups are more dynamic yet chaotic because of the balance of employees working on-site versus remotely.
Due to societal and workplace changes, an employee working their entire career for one company is now a rarity. It is generally accepted that someone will have several different jobs during a career.
Objectives Learningu
• Build a training culture that is flexible, economically sustainable and attracts and nurtures top talent.
• Understand the interplay of three key groups and their roles in technology adoption and training.
• Review suggested industry 4.0 technical skills to cover in on-boarding training.
This premise readily establishes the importance of teamwork and the working dynamic between management and the unique experience groups. Figure 1 portrays the interplay between three key groups: current manufacturing executives and other decision-makers, the existing workforce of manufacturing professionals and the incoming workforce comprising millennials (born between 1981 and 1996) and Generation Z (born between 1997 and 2012).
The first group encompasses decision-makers or executives — individuals with managerial roles in the manufacturing sector. These stakeholders typically exercise final authority over manufacturing technology adoption, given their responsibility for financial metrics such as profit and loss. Furthermore, they steer the direction of the firm’s projects, deciding which areas merit exploration. This group
also significantly influences retention and hiring strategies for their facilities, determining employees’ scope of assignments, their objectives and the workforce composition and size.
The second group, the existing workforce, consists of manufacturing professionals with several decades of experience within their environment. They typically have a comprehensive understanding of manufacturing processes and a unique conception of their firm’s standards. Statistically, they likely spent most of their careers with the same firm, which engenders substantial “tribal knowledge” about inputs leading to desirable outcomes regarding products, equipment and overall operational efficiency. While this group might not be as acquainted with the latest manufacturing technology, especially concerning machine learning and artificial intelligence (AI), they are well equipped to identify where connectivity and remote monitoring solutions will deliver the most value.
The third and final group of interest, the incoming workforce, comprises younger manufacturing professionals who often have limited or no experience in their specific fields. While less familiar with the specific operations and equipment that contribute to their firm’s success, they are more exposed to the state-of-the-art technology available to manufacturing firms. Their education makes them more likely to have encountered collaborative robotics, machine learning algorithms and AI tools. This group plays a pivotal role as the inheritors of current manufacturing processes, which are typically well integrated into a firm’s value stream.
Interaction for success
For managers of any level, it is critical to be stewards of an organizational structure that provides a consistent — but flexible when needed
— process for individuals to interact. They must possess the following attributes:
• Being able to work within a team.
• Listening to other viewpoints and disciplines when solving problems.
• Identifying process bottlenecks with both machinery and human workflow. Much of this entails pinpointing areas where individuals can be cross-trained.
• Ensuring information is accessible and upto-date. If a new team member is introduced, they can quickly learn the basics of a team’s function.
All this work takes time and there is always the danger of “paralysis by analysis.” But using standardized procedures and checklists can often lay the foundation for a sustainable work culture.
This leads to the importance of the interaction between the second and third groups of interest: the existing workforce and the incoming workforce. Having people work in teams is always going to be relevant. The incoming workforce has more expo-
FIGURE 1: Teamwork and the unique knowledge of what each group brings to the table are critical to technology adoption success. Courtesy: Motion Automation Intelligence
‘ Due to societal and workplace changes, an employee working their entire career for one company is now a rarity. ’
sure to machine learning and AI tools but lacks the wealth of experience of their veteran counterparts. It’s crucial for the existing workforce to share their understanding of current manufacturing processes with these newcomers. Everyone in this situation can teach and learn.
Manufacturing executives, interacting with both groups, guide the firm’s technology adoption and often have the final say on investments in industry 4.0 technologies. They need to acknowledge the importance of retaining long-term talent and ensuring sufficient knowledge transfer between the existing and incoming workforces.
Workforce training
The Motion Automation Intelligence team has been to manufacturing plants and heard managers say, “We used to have much more training, but our turnover is so high, we just do the minimum!” This approach is a self-fulfilling prophecy, invariably leading to a poor long-term outcome.
Insightsu
Workforce development insights uWhen considering your plant’s workforce, look at the work experience, skill level and ability to adopt new technology.
uEach generation in the workforce approaches digital transformation, artificial intelligence and automation differently.
ENGINEERING SOLUTIONS
FIGURE 2: As firms increasingly adopt collaborative robotic technologies and other related robotic guidance systems, understanding current manufacturing processes is crucial for their integration. Courtesy: Universal Robots
Many organizations actively produce training material in smaller blocks and online, video and inperson sessions. They focus on providing that work to a dedicated project team. Interaction skills are more crucial here than ever.
The Motion Automation Intelligence team does a great deal of onboarding training on technical skills that we consider fundamental to customer interaction. The group often calls this “knowledge at the point of sale.” The following skills pertain specifically to an automation solutions provider:
• A clear grasp of how machine control is accomplished. Understanding how electrical panels with relays were the basics. Understanding why programmable logic controllers (PLCs) are so widespread now and how recent technologies and platforms can coexist with older equipment.
• Industrial connectivity and visualization: tying machines, different lines and infrastructure together.
• Understanding communications at the serial level (RS-232, RS-485), the intermediate bus technologies (e.g., Profibus, DeviceNet, Interbus-S, CCLink, Data Highway Plus) and industrial Ethernet, which is only growing.
• Understanding how PLCs, human-machine interface (HMI), supervisory control and data acquisition (SCADA) and input/output (I/O) are often tied together via Ethernet, as the information technology and operational technology worlds converge. This means knowing the important differences between unmanaged and managed switches, copper versus fiber, etc.
• Newer control technologies such as CODESYS are especially important for the experienced groups not to dismiss.
Combining unique workforce skills
Separate groups must come together and define how to assemble the different puzzle pieces of automation for a project. For example:
• What is at the actuating or “work” end? Knowing when to employ hydraulics, pneumatics, electric actuators, mechanical devices such as ball screws and servo motors has always been a basic need.
• Where robotics work with these existing technologies. Understanding the differences between robot types continues to evolve.
• Sensors and remote types of I/O — always a factor.
• Safety, a critical consideration as humans interact closely with robots and machines.
• Network security and devices to create “defense in-depth,” crucial for all the Ethernet connectivity and the omnipresent danger of hackers and saboteurs.
• Edge computing, taking over some of the functions previously done with a PLC, traditional HMI or SCADA.
• Cloud technologies, which have changed the landscape and provide new opportunities and challenges for envisioning architectures and security. These include remote-access virtual private networks, always-on data collection and virtual dashboards.
A single person is rarely an expert in all these technologies, so teamwork is more important than ever. As the three groups interact, certain interaction points should be emphasized as companies adopt emerging industry 4.0 technologies. Machine learning and AI tools’ effectiveness hinges on the quality of input data used to generate actionable outputs.
Besides automating data collection and analysis, similar challenges arise with physical types of auto-
mation that have recently emerged in the manufacturing technology scene. As firms increasingly adopt collaborative robotic technologies and other related robotic guidance systems, understanding current manufacturing processes is crucial for their integration. If these existing manufacturing processes’ nuances are overlooked, the implementation of emerging robotic technologies can easily derail. Similarly, just as machine learning and AI tools struggle without quality input data, robotic implementations can fail with insufficient data on highvalue projects suited to these technologies.
In summary, these are unique times regarding technological advancement. Although people will change jobs more than previous generations, it is proven that good, relevant training is still a priority. Commonly, someone will start at a company in an entry-level position, leave for other jobs to gain experience and different perspectives and then return to offer even more to their original employer. It is for the good of society if everyone “raises their game” because we are all interconnected.
A clearly defined company culture will always be paramount. It means valuing all employees and providing an environment to succeed while encouraging teamwork. How we treat our most important resources — our employees — will be a guiding principle regardless of technological advances. PE
John Kan is Connectivity Products Manager with Motion Automation Intelligence.
Chase Wentzky is a Robotics Specialist with Motion Automation Intelligence.
FIGURE 3: Having people work in teams will always be relevant; everyone has the opportunity to teach and learn. Courtesy: Universal Robots
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Thomas Burke, CC-Link Partners Association (CLPA) Americas, Vernon Hills, Ill.
How TSN helps manufacturers enable edge computing capabilities
Edge computing is becoming increasingly more crucial to optimizing data-driven activities, supporting the implementation of innovative digital technologies and ultimately the creation of the smart factories of the future.
High volumes of data are being generated by smart applications and technologies, providing the foundation to create an in-depth understating of equipment status, processes and activities. This can be translated into unique actionable insights to improve productivity, performance and efficiency.
Large datasets are another raw material required by competitive enterprises. But having a solid, reliable infrastructure to share process data, information and knowledge is equally important to succeed. Edge computing also is instrumental to creating frameworks capable of quickly and securely evaluating data.
This technology conducts analytics for real-time decision-making at the periphery of the network, close to where data is being created, while also supporting knowledge generation by filtering what should be sent to the Cloud or other higher-level systems. As a result, the edge can reduce latency and network costs as well as optimize bandwidth usage, increase speed, security and scalability. The edge also can achieve enhanced transparency, flexibility and availability.
At the cutting edge of industrial networks
In order to take advantage of all the opportunities offered by edge computing, setting up a suitable network that can support key aspects of this technology is critical.
An ideal industrial communications system should support a converged architecture that allows real time process traffic and asynchronous process data to share the same network without compromising the overall function of the system. This is achieved with a foundation of determinism, ensuring all data types flow across the network in a predictable manner to deliver the required performance.
Time-sensitive networking (TSN) can help deliver a converged and deterministic architecture. It allows the critical data running the process to coexist with the critical, but perhaps less time-sensitive, data about the process. It is this latter data type that is the lifeblood of the edge server. Using TSN lets these different, but equally vital, streams of traffic use a single network architecture. This helps reduce costs, simplifies maintenance and reduces project time.
Companies should look for an open solution that can provide maximum connectivity. This means supporting communications with different devices, whether on the shop floor or higher up in the automation hierarchy. Openness, interoperability, and an integrated solution for automation on different levels are therefore essential.
The CLPA can help enable network technologies for edge applications. This began with open gigabit industrial Ethernet. By leveraging a token-passing method and 1 Gbit/s bandwidth. The different versions of these Ethernet networks,
Insightsu
Edge computing insights
uSmart applications generate unprecedented data volumes, enabling deep insights into equipment status and processes, leading to enhanced productivity and efficiency improvements.
u A robust infrastructure and edge computing are crucial for processing and evaluating real-time data, reducing latency, costs, and optimizing network resources for industrial networks.
ENGINEERING SOLUTIONS
‘Time-sensitive networking (TSN) can help deliver a converged and deterministic architecture.
’
Objectives Learningu
• Understand network considerations with edge computing.
• Learn how time-sensitive networking (TSN) enables faster reaction time in manufacturing.
• Learn how real-time decision making can be enabled with TSN.
FIGURE 1: The CC-Link network with TSN enables operational technology as well as IT and other communication networks to exist on a single Ethernet cable, which supports more reliable communication. Courtesy: CC Link Partner Association
which supplement each other and cover different aspects of industrial communications, could connect the various parts of an enterprise needed to create connected industries.
There are even further advancements in the ability to support edge computing, enhancing and expanding the capabilities of this solution.
TSN-compatible components, businesses can gain a unique, competitive edge in the marketplace. PE
Thomas J. Burke is global strategic advisor for the CC-Link Partner Association (CLPA) Americas, a CFE Media and Technology content partner.
ENGINEERING SOLUTIONS NGINEERING
Bibek Karki, PE, National Field Services, An IPS Company, McKinney, Texas
How to mitigate arc flash hazards in medium-voltage electrical systems
Mitigating arc flash hazards in medium-voltage systems could be performed in synergy to achieve optimal system reliability and safety
Protective relays are the brain and intelligence behind a medium-voltage protective device. They are critical infrastructure for proper medium-voltage system operation and protection and increase system reliability.
With electromechanical and solid-state protective relays being obsolete and nearing their end of life, upgrading them with their microprocessor counterparts is paramount for reliability of power systems. Microprocessor relays provide advanced communication, monitoring and automation capabilities along with all basic protection and control platforms.
It is critical to upgrade them to the current technology and standards. Many electromechanical and solid-state relays are becoming obsolete, which means upgrading them is inevitable — either through unplanned failures or during planned outages. As older protective relays near their end life, they cannot be relied on for the equipment protection they provide. Instead of providing system protection and reliability, these relays now become a safety hazard and liability.
Objectives
The advancement in technology in the power industry, coupled with increase in awareness about arc flash hazards, has brought a wave of arc flash hazard mitigation processes and procedures. If the protective relay upgrade project is planned, the arc flash hazard mitigation could become an amazing complementary result along with the relay upgrade. The key to this process is: adequate planning and selecting appropriate relays to achieve both goals.
• Understand how a typical protective relay upgrade process aligns with arc flash hazard mitigation.
• Learn how hierarchy of risk control from NFPA 70E could be incorporated in mitigating arc flash hazards.
• Follow the various steps in upgrading relay process and review engineering software simulation and case studies.
Introduction
Protective relays are an integral part of the medium-voltage power system because they ensure protection for equipment during fault and abnormal operating conditions. If these protective devices are installed, engineered, programmed and maintained properly, they keep the power system safe and reliable.
One of the critical factors affecting arc flash hazard is the protective device fault clearing time. The faster the fault is cleared, the lesser the incident energy resulting in lower arc flash hazards. One of the best methods of mitigating arc flash hazard is reducing the fault clearing time and this is where the advanced microprocessor relays come into the picture.
Most advanced relays have capabilities of detecting the fault faster and interrupting them a lot quicker than their electromechanical counterparts. Another feature that microprocessor relays provide is their advanced communication and automation abilities. This means the overcurrent device could be operated from a safe distance, which increases the working distance and reduces the arc flash hazard.
A well-planned relay upgrade project could easily be complemented with the arc flash hazard mitigation one. Upgrading protective relays and mitigating arc flash hazard have a common goal of maintaining power system reliability and promoting worker and equipment safety. With meticu-
‘ One of the best methods of mitigating arc flash hazard is reducing the fault clearing time and this is where the advanced microprocessor relays come into the picture. ’
lous planning, well-thought equipment (protective relay) selection along with smart engineering practices can help achieve both processes and their common goal (see Figure 1).
Typical protective relay upgrade process aligning with arc flash hazard mitigation
Project planning and raising user awareness: The initial and the most important step in upgrading relays has been planning the entire project with keeping arc flash mitigation as one of the goals or end result. This includes understanding customer’s expectations and goals and providing consultation and coaching. Many customers are not aware that upgrading relays could aid them in mitigating arc flash hazards and in some cases may not be aware of the arc flash hazards at all. It is vital to educate the user about potential arc flash hazards and how upgrading the relays could help mitigating them.
Gathering data and procuring protective relays: The next step in this process is collecting accurate data such as existing device settings, drawings, short circuit, coordination and arc flash studies, operating sequence and other original equipment manufacturer documents. Having well-established and updated documentation helps in maintaining existing equipment operation procedure and provides room to improve functionality on existing system.
Procuring relays follows the data gathering process. The key here is being judicial while selecting the proposed relay. For instance, selecting an overcurrent relay with capabilities of having arc flash sensor would be an excellent choice for both upgrading the relay and mitigating the arc flash hazard. This selection of relay aligns with the common goal of this paper and could be a cost-effective
solution for arc flash hazard mitigation. Procuring relays as soon as project scope has been outlined helps in reducing the original equipment manufacturer lead times as well.
Performing engineering studies, creating relay setting and updating existing drawings: Performing accurate and up-to-date engineering studies consisting of at least short circuit, coordination and arc flash analysis, with minimal assumptions, is another critical step of the relay upgrade process. It is not recommended to convert the existing settings into the upgraded relays. Electromechanical and solid-state relays have very limited functionality and capabilities, whereas microprocessor relays have elaborate functions.
For instance, an overcurrent (ANSI device 50/51) electromechanical relay only has time overcurrent and instantaneous overcurrent settings, whereas a feeder protection microprocessor relay has both of these functions with multiple group settings, directional element, reverse power and so on.
FIGURE 1: This image includes the medium-voltage circuit breaker with a protective relay. Courtesy: National Field Services
ENGINEERING SOLUTIONS NGINEERING
FIGURE 2: These images are the before (left) and after pictures of the medium-voltage switchgear after relay upgrade work has been performed.
Courtesy: National Field Services
Insights
csemag.com
Medium-voltage electrical system insights
u Differentiate between these concurrent topics in current power industry and how the communication and automation capabilities of microprocessor relays could be leveraged in arc flash hazard mitigation.
u Review the various methods and procedures for arc flash mitigation such as maintenance mode settings, programming a breaker open/close delay, remote opening and closing the device and installing virtual main.
u Arc flash hazard mitigation goals can be achieved, without compromising power system reliability, by harnessing the advancement in protective relaying technology.
Updating existing drawings to replace existing equipment is good and highly recommended practice while upgrading relays. This process helps in the field wiring of new relays and provides customers with updated protection schemes and documents that could be used for troubleshooting in future. Updating existing drawings also provides design engineers with an opportunity of incorporating remote operation of overcurrent devices. Remote close and trip of circuit breakers could easily be incorporated in the upgraded system. This is one of the vital components of engineering controls for arc flash hazard mitigation.
Off-site wiring, uploading settings and testing relays: It is recommended wiring relays and their associated test switches to the relay doors or insert panels off-site. Another good practice is to upload relay settings, test relay elements and logic off-site. This reduces the outage duration in the field and helps accomplish milestones in the upgrade process.
Reducing outages is one of the important factors in the relay upgrade process. Not being able to schedule an outage is one of the hindering factors on relay upgrade projects. Relays are a huge part of the power system automation and protection. Thus, any facility can only afford to have minimal downtime involving them.
Medium-voltage systems will be without any protection and automation features if relays are safely taken out of the service. This could compromise the reliability and safety of the power system. Many relay upgrade projects are postponed or suspended because of the lack of switchgear shutdown or inability of any facility to schedule the outage.
On-site demo, install, test and commission: The final and most important step in relay upgrade project is bringing everything together in the form of a field installation. It is always recommended documenting all existing wires and maintaining integrity and aesthetic property of wires in compartment while wiring.
Another important final step is commissioning the entire system. This includes at minimum verifying polarities, current transformer (CT) ratios, phase rotation and direct current trip checks to list a few. The goal is to improve the system reliability and safety without any nuisance power interruptions. Those calculations should be redone and documented at this time. It is imperative to have detailed plans and procedures for existing system uninstallation, new relay installation, testing and commissioning, contingency plans for unexpected surprises during this entire upgrade process (see Figure 2).
ARC flash hazard mitigation methods
Arc flash hazards can be calculated by calculating the incident energy. This can be accomplished by using any commercial software. The main components of incident energy calculations are the amount of available fault current, the overcurrent protective device fault clearing time and working distance. This article dives into the second two components: fault clearing time and working distance. The methods and goals of relay upgrade aligns with NFPA 70E: Standard for Electrical Safety in the Workplace hierarchy of controls for hazard mitigation. Some of the arc flash mitigation engineering methods are listed below:
Eliminating the hazard is at the top of the hierarchy. This is the most effective method of arc flash hazard mitigation because this method eliminates the hazard. The following engineering methods are useful in eliminating the arc flash hazard from the medium-voltage systems. These methods are based on reducing the fault clearing time.
METHOD
1: Using reduced instantaneous setting with aalternate ggroup/mmaintenance mode ssetting
This is one of the simplest and most effective methods of reducing incident energy and arc flash hazards. Most microprocessor relays have provision for multiple group settings. The groups could be transferred over automatically using relay programming logic or manually using the selector switches that could be mounted anywhere in the switchgear.
For instance, Group 1 would have the normal system protection settings. Short circuit, coordination and arc flash study needs to be performed to design the reduced instantaneous settings. This reduced instantaneous value would then be programmed into Group 2 settings.
The reason for creating separate groups is to maintain the system reliability and functionality. The user would have to switch settings into Group 2 before performing any switching or interacting with the medium-voltage equipment. Once this electrical work has been performed, it is imperative to return the maintenance switch back to its original position or change the relay logic back to enabling Group 1 protective device settings.
Figure 3 shows the time current curve (TCC) created using SKM Systems Analysis Inc. along
with the calculated fault current on how this reduced instantaneous setting could be calculated. If this reduced instantaneous setting values is set below the fault current line (dotted line), the reduced instantaneous setting could be calculated.
METHOD 2: Using concept virtual main
This method involves installing additional hardware and relays in the existing system. However, this is an effective method in reducing arc flash hazards in existing systems. Most power systems in the past were designed without a physical main overcurrent protective device such as a circuit breaker or fused disconnect. Thus, whenever there is a medium-voltage switchgear powering up a medium- to low-voltage transformer, the incident energy is high on the secondary side of the transformers. Without an actual main interrupting device, there are not a lot of options of reducing the incident energy.
This concept of virtual main fills the void on the switchgear that is not designed to have an actu-
FIGURE 3: SKM Systems Analysis Inc. software time current curve displaying the reduced instantaneous settings (blue curve) versus normal instantaneous settings (red curve). Courtesy: National Field Services
ENGINEERING SOLUTIONS NGINEERING
al main circuit breaker. In this method, CTs are installed on the secondary side of the transformers and/or the switchgear. Two sets are typically included in this scheme. Then, instantaneous overcurrent devices located upstream of this transformer are designed to operate if there were any fault current events on this downstream switchgear.
Substitution in medium-voltage systems
Ideally, eliminating the hazard is the best way to reduce arc flash hazards. However, this might not be feasible in all practical applications. If the hazard could not be eliminated, then the next method on hierarchy of risk control is substitution. This method involves designing engineering processes to substitute the hazard.
The following two methods are innovative on substituting arc flash hazards in the medium-voltage system. These methods are based on increasing the working distance.
METHOD 1: Designing relay logic for remote switchgear operations
CASE STUDY: Reducing incident energy
SOFTWARE HELPED analyze arc flash reduction
SKM Systems Analysis Inc. software was used to prepare and analyze this typical engineering project that incorporates several methods of reducing arc flash hazards. The protective relay was programmed with the reduced instantaneous settings, which reduced the incident energy on medium-voltage switchgear bus from 22.8 cal/cm2 to 1.14 cal/cm2 This protective relay pushbuttons were programmed with the delay of 20 seconds for additional arc flash hazard mitigation.
The concept of virtual main was implemented in order to reduce the incident energy on low-voltage switchgear bus. Current transformers (CTs) were installed on the secondary of the 2,000 kilovolt amperes (kVA) transformer. These CTs were connected to the existing protective relay. Short circuit, coordination and arc flash engineering study was performed on this new system. Instantaneous settings were designed for this virtual main and programmed into the protective relay.
The incident energy on the low-voltage switchgear bus was reduced to 6.85 cal/cm2 from 137 cal/cm2. This is a significant decrease in incident energy.
This method is simple to implement and effective in most power systems equipped with automation. Most modern medium-voltage systems are equipped with remote operation. The design engineer could simply incorporate remote bits in their circuit breaker operation logic to achieve this. Because the protective relays would open or close the circuit breaker, the operator does not have to be present physically in front of the switchgear during the switching process.
This method increases the working distance from a few inches to several feet, thus aids in keeping system operators out of the harm’s way. The only caveat for this method is that the switchgear must have automated switching capabilities, which could be an issue for older switchgear.
METHOD 2: Engineering controls
This method is simple and effective in both older and newer switchgear systems. The switchgear does not have to be automated, unlike the previous substitution method. This method could be attained by programming logic in the relay for
FIGURE 5: Single line diagram modeled in SKM Systems Analysis Inc. engineering software. Courtesy: National Field Services
circuit breaker open and close operation and performing minimal changes in wiring during the upgrade process.
Typically, the microprocessor relays have push-button in their front panel. Incorporating a small delay of 10 or 20 seconds provides ample time for an operator to push a button and safely move out of the switchgear room. For the relays that do not have the push buttons, the control switch that operates the circuit breaker could be programmed in similar fashion. This process is cost effective and could be achieved with simple engineering design modifications.
Medium-voltage electrical system safety
Protective relays are the backbone of the protection, automation and control for medium-voltage systems. They are critical to power system perfor-
FIGURE 4: Microprocessor relay with pushbuttons. Courtesy: National Field Services
mance and reliability; thus, utmost importance should be given to the maintenance and upgrade of these relays.
Arc flash hazard mitigation is a critical part of electrical safety. This helps to protect lives and maintain the efficiency and reliability of the power system. All the arc flash reduction methods in this paper could be carried out with the relay upgrade process as a comprehensive project. Using engineering brainpower and harnessing the advancement in technology, we can keep our electrical system safe and reliable. cse
Bibek Karki, PE, is Engineering Manager at National Field Services, An IPS Company.
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ENGINEERING SOLUTIONS
COMPRESSED AIR
Brian Mann, Hitachi Global Air Power, Louisville
What to consider when sizing your compressed air system
There are many factors to consider when sizing compressed air systems such as capacity and pressure, but also its role in the company short- and long-term.
Selecting an air compressor for a facility presents many questions. The wrong size compressor can operate at an inefficient part-load condition or lack capacity to meet the peak demand in the plant, costing plenty in energy costs and down time.
When it comes sizing air compressors, there are often two parameters that come to mind: capacity and pressure. To be certain, those must be properly specified for the application to be a successful one.
Another consideration is the role of the compressor in the system. Will it be a base-loaded com-
pressor that always runs at full capacity, or is it intended to be a trim compressor, which will run at varying loads?
Selecting the trim compressor entails a host of decisions, not only determining the appropriate full load capacity but also its turn down capacity (how far below full load it can operate) and how the turn down capacity compares to the capacity(ies) of the existing base load air compressor(s). When weighing these considerations, it is not just the turn down capacity, but also the efficiency of the machine at the part load(s) at which it will operate.
The compressor selection comes down to a simple question; what is the best business decision for the organization? In most cases, the best business decision comes down to the lowest cost of ownership with the highest degree of reliability. For industrial air compressors, the primary component of the total cost of ownership (TCO) is often the cost of electrical power.
Energy, efficiency and capacity standards
The U.S. Department of Energy Compressed Air Challenge estimates up to 80% of the ten-year total cost of ownership of an industrial air compressor is electrical power. Hence, the efficiency of the compressor, not only at full load, but at the partial load at which it may operate, become important points of comparison not only between competing manufacturers, but between competing capacity control technologies.
As it turns out, there is a lot more to sizing a compressor than actual cubic feet per minute (acfm) capacity and psig operating pressure. The good news is that there is a dependable and accessed source of information to help guide the decision-making process.
Manufacturers participating in the Compressed Air and Gas Institute (CAGI) performance validation program publish data sheets that provide
FIGURE 1: Histogram of demand. Courtesy: Hitachi Global Air Power
FIGURE 2: This combination of compressors meets the identified criteria; the total capacity matches the required system capacity (when adjusted for summer operating conditions), and the turn down capacity of the variable speed compressor exceeds the capacity of the fixed speed compressor, so that the potential for control gap is mitigated. Courtesy: Hitachi Global Air Power
information including package power (kW), capacity (acfm), specific power (kW/100 cfm) and isentropic efficiency at full load. For variable displacement and variable speed-controlled compressors, the package power, capacity and specific power information is published for part-load conditions.
The data sheets are available on most manufacturer’s websites or can be accessed through links found on the CAGI website. Users can navigate to the CAGI Air Compressor Performance Verification and Testing Results page and access the participant directory.
Consider the application illustrated in Figure 1. The peak demand for the facility is between 2,000 and 2,100 standard cubic feet per minute (scfm) and occurs 6.34% of the time. The compressed air system must be capable of meeting this demand. If this were an intermittent demand, the application of controlled storage would be appropriate. In this case, the demand is sustained, and the system must be capable of regularly generating the stated capacity.
The application engineer must also consider the other ranges of demand because the plant operates at other demand levels for much of the time. Specifically, the range of 1,400 to 1,500 scfm must be given priority as the plant operates in that range of demand about one-third of the time, or 56 hours per week.
In this example, oil flooded rotary screw air compressors will be considered, but the philosophy would be applicable to oil free rotary screw compressors as well. The common approach to sizing compressors of providing a baseload, trim-load and back-up compressor will be used. This arrange-
ment can be desirable as it represents N+1 redundancy to minimize the risk of unplanned downtime, while providing the lowest cost of acquisition among alternatives.
Mind the control gap
A commonly overlooked aspect of sizing a combination of air compressors is control gap. Control gap occurs when the demand for compressed air falls into a range where neither the variable speed drive (VSD) nor the fixed speed compressor or compressors can effectively meet the demand. The result is often unstable plant pressure as the on-line compressor(s) seek to meet the demand which falls outside of the turn down range for the trim compressor.
Courtesy: Hitachi Global Air Power
In a two-compressor system, control gap can often be avoided by selecting compressors where
Table 1: Tabulated demand data
ENGINEERING SOLUTIONS
IMAGE 1: Defining the control gap when synching VSD and full load compressors is an important consideration when right sizing a compressed air system.
Courtesy: Hitachi Global Air Power
Objectives Learningu
• A review of overlooked factors when sizing a compressed air system including dryer purge rate, compressor control gap and more
• Types of compressors - fixed and/or variable speed drive compressor – and their impact on efficiency in a compressed air system
• Utilizing efficiency data sheets and other tools and formulas in right-sizing a compressed air system
the turn down range of the trim compressor is greater than the capacity of the fixed speed (baseload) compressor. The control gap is often associated with VSD controlled compressors but can be present with any capacity control technology.
For this application, a VSD trim compressor and a fixed speed base compressor will be selected to meet the demand profile. A back-up compressor will be selected to provide N+1 reliability.
The demand data provided in this example is shown in scfm, while the compressor capacity data is shown in acfm. The demand and capacity information must be expressed in consistent terms so the compressors can be properly sized. For this example, the demand data will be converted to acfm.
In many applications, the end user will stipulate the compressed air system must always provide a defined capacity at the specified pressure and air purity. Often, the capacity is expressed as scfm, and the design conditions (extreme summer and winter) are provided.
In the case of a rotary screw air compressor, the combined effects of altitude, temperature and humidity present in summer conditions result in the de-rating of the compressor capacity when the capacity is expressed as scfm instead of acfm. The relationship between acfm and scfm is provided below.
Where:
ps = standard pressure (14.5 psia for CAGI standard conditions)
pa = actual atmospheric pressure at location (corrected for altitude)
ppwv = partial pressure of water vapor at saturated condition, actual temperature
rh = relative humidity at site conditions
Ta = actual or design temperature
Ts = standard temperature
For this application, the specified site summer conditions are as follows:
1250 ft above sea level (14.1 psia atmospheric pressure)
90 °F (0.698 psia, not corrected for altitude)
60% relative humidity
Substituting values into the equation:
The CAGI data sheet shown in Figure 2 illustrates the full-load capacity of the compressor as 1,660 acfm @ 125 psig. Also note its turndown range is 1,225 acfm (1,660 acfm at full load – 435 acfm at minimum flow). A base load compressor complementing the trim compressor that provides a minimum capacity of 669 acfm is needed so the compressor meets the total demand required by the plant.
VSD and fixed speed
Another point of interest is the efficiency of the VSD controlled compressor (CAGI data sheet on
‘ An industrial air compressor, if properly maintained, should last ten years or more. ’
the left). At the 1,500 to 1,600 scfm demand level (corrected to 1663 acfm for summer conditions) the VSD compressor is very near full load, representing an efficient operating point. Below this point, the VSD compressor will be on its control curve, where the specific power begins to increase (less efficient). However, the increase in package specific power is reasonable, such that at minimum flow, the specific power is 21.9 kW/100 cfm. What happens when the demand exceeds the capacity of the VSD controlled compressor? The fixed speed compressor comes on-line, and operates at full load, contributing its capacity to the plant demand. The VSD compressor output falls to 958 acfm, as it is reduced by an amount equal to the capacity of the fixed speed compressor (702 acfm). The reduced output of the VSD air compressor falls at a location on the control curve slightly more efficient than the full load specific power for the compressor.
In this scenario, the capacity of the back-up air compressor would need to be equivalent to the VSD controlled compressor, as it is the largest in the system.
With the technology available today in many of the on-board microprocessor controls, two VSD controlled compressors of equal capacity could be selected and operated in a load-sharing arrangement, where they modulate together to meet the varying demand. Fewer, smaller compressors often represent larger initial and maintenance costs, however.
Don’t forget the purge
It would appear the specifier has completed the analysis and is ready to place the purchase order for the compressors. Perhaps he or she is, or perhaps he or she has overlooked an important consideration: dryer purge loss.
If the plant is using regenerative compressed air dryers, the purge rate contributes to the total
demand. It is also important to remember that most manufacturers state the average purge rate on their equipment specifications. The instantaneous purge rate can be higher. It is important to have a clear understanding of the dryer operation and its National Electrical Manufacturers Association (NEMA) purge cycle to accurately determine the demand associated with the dryers.
Maintenance matters
One last thought about sizing a compressor, or more appropriately, about selecting a compressor. An industrial air compressor, if properly maintained, should last ten years or more. Often, the compressor distributor will provide maintenance and service for the life of the compressor (and the associated equipment).
Considering the capabilities of the service provider is an important part of the selection process. It is so important the Compressed Air Challenge Best Practices for Compressed Air Systems includes an entire chapter on the topic, “Guidelines for Selecting a Compressed Air System Service Provider.” A trusted service team can ensure the perfectly sized compressed air system performs optimally.
In the end, many factors should be considered when sizing a compressed air system, not just capacity and pressure. Properly analyzing all variables – VSD, base load, control gap, dryer purge, and maintenance — will result in the most efficient and reliable system for an operation. PE
Brian Mann ME, PE, is the product manager — service plan and warranty products for Hitachi Global Air Power.
IMAGE 2: Maintenance is critical to keeping your rightsized compressed air system running optimally. Courtesy: Hitachi
u
Insights
Compressed air insights
uSelecting the right air compressor is critical for efficiency and cost-effectiveness. The primary cost of ownership is often electrical power, accounting for up to 80% over ten years.
uControl gap, often overlooked, occurs when demand falls outside the capacity of compressors. Careful consideration of compressor types and capacities is necessary for stable plant pressure.
Global Air Power
ENGINEERING SOLUTIONS
DIGITAL TRANSFORMATION
Judith Ponniah and Geeta Pherwani, AspenTech, Bedford, Massachusetts
Understanding life cycle digital twin technology for sustainability
In many cases, digital twins can be implemented to help improve asset performance with advanced visualization in a manufacturing setting
Most companies fall short of their capital project expectations. The industry is faced with unpredictable market requirements and stakeholders are finding their projects chronically behind schedule or over budget; therefore, seeing missed market opportunities and decreased asset profitability.
Asset-intensive industries are investing in digital technology solutions to create contingency plans, manage execution, optimize construction sequences and prevent budget and material overruns. In addition, they are reviewing assets from a sustainability outlook, garnering support from the public and financial institutes as they promote sustainability in the design and work process to increase energy efficiency while reducing waste and emissions.
nance, spare part inventory, advanced process control and supply chain optimization.
Digital twins provide a solution from a bird’s eye view that’s necessary for different applications and use cases, whether greenfield or brownfield. No matter where in the digital transformation journey a company is, digital twins can easily be implemented to help improve asset performance with advanced visualization. An offline digital twin during the early project phases allows engineers to design the most optimized, lowest capital expenditure process. An online digital twin delivers previously unattainable critical insights to idealize operations while dealing with ever changing environmental regulations.
As the industry pivots to meet their ambitious net-zero targets, the energy transition projects are bringing in new opportunities for technology licensors and EPC firms.
Licensor and EPC firms can help owners secure the benefits from a holistic digital twin model by transferring this digital twin from the feasibility stage to final investment decisions to operations and maintenance.
• Learn how digital transformation can update the process within assetintensive industries.
• Understand how a digital twin can improve a plant’s sustainability.
• Review how digital twin models can enhance carbon capture.
To achieve a more effortless execution, the solution method must be simple and frictionless. The common issue facing engineering, procurement and construction (EPC) companies and process industry owners is that the current digital solutions do not focus on the overall project life cycle aspects, necessitating the need for multiple digital technology solutions to achieve sustainability and profitability goals during an asset’s life cycle.
Digital twin technology
The manufacturing industry needs a holistic solution that starts in design and is used throughout start up, commissioning and operations. It can become the cornerstone for the implementation of more digital solutions to support predictive mainte-
Life cycle digital twin for carbon capture process
Carbon capture is one of several imminent technologies helping organizations meet their sustainability goals faster as we transition to a decarbonized economy. Leading companies are looking for solutions that can help support tactical, strategic and business decisions through key phases of design and operations.
Organizations supporting greener and newer technologies such as carbon capture, utilization and storage (CCUS) can alleviate growth pains through implementation of a life cycle digital twin. This holistic approach helps with increasing project feasibility and risk mitigation.
A life cycle digital twin can support organizations by providing insights into new technologies and making informed decisions for each phase of the asset life.
Investment decisions: Technology evaluation takes place during the initial conceptual design of a project to assess potential technologies available for adoption. Based on future energy and renewables prices and emissions targets, an appreciable number of capture technologies are available in the market. Low-carbon hydrogen production is also accelerating momentum toward carbon capture projects. With a diversified mix of available technologies, investors are challenged with evaluating trade-offs between the return on investment and total carbon dioxide (CO2) captured.
Digital solutions help investors look at different system configurations to identify the conditions where risk across the entire CCUS system is minimized including the efficiency gained through scale and integration of system components. In the case of carbon capture employed to achieve low-carbon hydrogen, there are more energy and process efficiencies to be gained.
Risk and planning: Models can provide insights to compare available technology options quickly for technical and economic feasibility, reducing and quantifying the risk associated with capital expenditure investment. In addition, better insights enhance collaboration between investors and other key stakeholders, aiding with informed selection of the best technology to support organizations with their long-term profit and sustainability goals. For
FIGURE 1: The phases of a life cycle digital twin can help asset-intensive organizations leverage technology advancements to accelerate sustainability initiatives. Courtesy: AspenTech
‘ No matter where in the digital transformation journey a company is, digital twins can easily be implemented to help improve asset performance with advanced visualization. ’
example, amine-based absorption for carbon capture is a mature technology, but it is energy intensive, hence necessitating new solvents innovation to find the balance between energy and capital expenditure investments.
Scenario analysis for conceptual design: Scenario analysis is crucial for exploring possible financial outcomes based on different factors. With the business environment being ever-changing and filled with uncertainty, conducting regular what-if scenario analysis will allow organizations to see how different internal and external inputs might cause business key performance indicators to change. This can help organizations make proactive planning decisions that account for a range of possibilities in design, both positive and negative.
Most projects involve engineers using multiple files to represent various scenarios with topological differences, which requires them to manually change inputs in a series to better understand the system. All these steps are time consuming and error prone.
Process simulator models integrated with economics can help to perform techno-economic evaluation through rigorous modeling of the carbon
Insightsu
Digital twin insights uManufacturing facilities that employ a digital twin may achieve more sustainable outcomes. uCarbon capture, use and storage is a process that captures carbon dioxide emissions from sources like coal-fired power plants and either reuses or stores it so it will not enter the atmosphere.
ENGINEERING SOLUTIONS
capture process. Robust process simulators (and associated integrated workflows incorporating safety and layout) help innovate and drive down capital expenditure by up to 20% and operating expenditures by 15%-30%.
In addition, offline digital twin models offer agile workflow to quickly run thousands of scenarios in parallel while leveraging high performance computing or better, cloud-based parallel computing, artificial intelligence and visualization tools for data analysis. Scenario analysis can provide early visibility into how design decisions may constrain feedstock selection, environment and climate impact, equipment availability, reliability and maintenance strategies. These early insights into identification of process operation strategies enable stakeholders to make better decisions for profitable and sustainable operations.
‘ In addition to helping companies close the talent gap, advanced technology and digital twins allow for a seamless approach to reducing training costs and mitigating operator-driven risks. ’
Moving digital twins to 5D
Front-end and detailed design: Once the technology has been selected and finalized, a robust design becomes essential for seamless startup and operations.
As process decisions made early on lock in capital costs, a collaborative front-end tool that digitalizes front-end engineering deliverables lowers the risks of late design changes through transparency across disciplines, ensuring communication of each change made.
Front-end digital twins let organizations visualize five dimensions (5D) of the project early in the design phases. Early visibility into 3D layout plus cost and schedule at design stages allows organizations to make informed decisions to improve sustainable outcomes, avoid project risks and estimate the impact of proposed changes in the design. This visibility can be obtained through conceptual layout, conceptual cost and schedule modeling. These early insights prevent and miti-
gate change orders and project overruns, hence eliminating financial risk associated with upcoming high value sustainability projects.
Eliminating the delays early in the design have helped companies accelerate the project duration by nearly 20%. In addition, 5D visibility with front-end digital twins have helped organizations select the design concepts 87% faster.
Startup and commissioning: During start up and commissioning, already prepared robust digital twin models validate the process control system and the operating guidelines, enabling faster operator training. Running a digital replica in parallel with the actual plant operation creates a valuable means of training operators and technicians to familiarize them with the control schemes and processes in an offline and risk-free environment before startup. Hence, the operations team is better equipped to successfully control any process upsets or abnormal operational situations by rehearsing such events. For newer, complex processes such as both point source and direct air capture technologies for carbon capture, which have fewer than 30 operating facilities, proficient training and expertise is crucial in creating a riskfree environment.
Operator training system: With the industry struggling to attract talent and much of the experienced workforce heading to retirement, ensuring operators can practice in the safety of an office environment or remotely if they choose, is essential to reducing risk, enhancing production and attracting a new generation of skilled workers. Furthermore, adding technologies such as carbon capture require experienced operators to revise and update their training.
Companies are also looking for dynamic ways to train their employees quickly and efficiently. Software simulator based digital twins have been expanded into using augmented and virtual reality to speed up learning through an immersive and scenario-based virtual environment. Operators can perform multiple scenarios in a simulation environment, which mimics high-stress conditions and allows for object recognition. In addition to helping companies close the talent gap, advanced technology and digital twins allow for a seamless approach to reducing training costs and mitigating operator-driven risks.
Ongoing plant operations and maintenance
Operations and maintenance: Once the plant is operational, the accuracy of the digital twin can be continuously enhanced with plant data taken directly from the process as it becomes available. This real-time online digital twin model provides critical insights into operations for continuous monitoring of equipment and increased plant performance. Greater insights into equipment health supports operations to avoid risks associated with unscheduled downtime.
In addition, online digital twin models can be used to optimize process control targets to maximize captured CO2 while minimizing energy consumption to reduce total capture costs based on the current process inputs.
Capital project success is critical to keeping companies competitive and profitable, especially during trends of market instability or volatility. Digitalization is the key to meeting these business goals, making new and sustainable technologies easily accessible and cost friendly. Using digi-
‘ Greater insights into equipment health supports operations to avoid risks associated with unscheduled downtime. ’
tal twins from feasibility to operations organizations can align quickly on goals of sustainability and operational excellence while reducing risks to production.
Digital twin is more than just a visual, virtual representation of process, operation or system. It is an approach that aligns with the industry need to enable collaboration, transparency and improvements across an asset’s life cycle.
A life cycle digital twin then becomes a holistic solution for new and sustainable technologies, including but not limited to carbon capture, hydrogen, biofuels, bio-feedstocks and process improvements associated with circular economy. PE
Judith Ponniah is Industry Marketing Director at AspenTech. Geeta Pherwani is Senior Product Marketing Manager at AspenTech.
The Bridging the Gap Podcast discusses major industry topics and features experts covering everything from Arti cial Intelligence to technology integration.
OCTOBER 24, 2023
EPISODE 1: Challenges of AI Integration with Jeff Winter
NOVEMBER 7, 2023
EPISODE 2: AI Implementation with Jeff Winter
ENGINEERING SOLUTIONS
SYSTEM INTEGRATION
John DeTellem, Siemens Industry, Atlanta
The benefits of adopting an all-in-one automation engineering platform
To unlock engineering efficiency, combining platforms streamlines and adds consistency
Agile data analysis and simulation for the design and operation of new lines is a requirement for manufacturers to stay competitive. Advantages can be found in implementing one common engineering platform for all life cycle phases of adding new lines or expanding existing ones: machine design, planning, engineering, commissioning and service.
A common engineering platform offers uniform usability, data consistency and transparency within all disciplines. This combination requires the integration of databases and systems that have traditionally been isolated.
How does unifying engineering platforms increase engineering efficiency?
Objectives Learningu
• Learn how integrating engineering systems for collaboration increases efficiency and competitiveness.
• Understand how vast amounts of data create a challenge in integrating systems and doing decision-making analysis.
• Gain insights on why IT/ OT integration is important for security as well as collaboration and data analysis.
A common engineering platform conveys significant competitive advantages for operations and maintenance as well as the implementation of new machines. One platform for all engineering tasks intrinsically links programmable logic controllers (PLCs), networks, input/output devices, human machine interfaces (HMIs), drives, safety, communication and peripheral devices, and provides one consistent data platform with open interfaces to collaboration platforms.
This allows the parallelization of engineering processes, including standardized exchange formats and a common database, minimizing the need for the extraneous coordination efforts found with multiple platforms. A unified platform should be designed for fully automated workflows, including automated
PLC code generation and automated HMI visualization generation, and allow automation of the repetitive tasks in an engineering workflow.
A shared platform for all stages of the machine life cycle facilitates the creation of a standardized library of reusable software components that ensure software quality, promote efficient design and support modular, flexible machines. New features can be added as modules without risk to existing functionality. Open interfaces for data import and export ensure visibility into all levels of operation and the use of edge data analytics on the plant floor for agile decision-making.
Standards-compliant programming (e.g., PLCopen, International Electrotechnical Commission) and automation markup language allow the reuse of configuration data across tools during the planning process across engineering departments. User management and the library and versioning mechanisms support clear code structuring and accountability, while namespaces avoid troubles with projectwide duplicated naming.
Support for fail-safe programming ensures that proven, tested safety code can be applied seamlessly to new machines. Integrated testing and simulation within a scalable environment provide integrated logic testing and automated testing via continuous integration approaches, delivering consistent, reliable diagnostics with automatically generated system diagnostics.
Integrating massive volumes of siloed data
Modern equipment generates immense amounts of real-time data: operations parameters, machine logs, sensor data, output efficiency data, energy consumption data, user access information
and more. Often these different critical databases are siloed, making holistic analysis difficult. Effective analysis and decision-making require vertical data integration, contextualization and data model synchronization. Implementing systems that reach across business and production and through all life cycles of adding or expanding new lines is critical to staying competitive but can be complex.
This complexity can be approached more readily by edge devices at the machine level. Machine-level analytics, data “tagging,” and live exporting of data to unified cloud reporting systems can all be automated through edge devices. By leveraging real-time insights delivered by robust operational technology (OT) edge computing solutions, manufacturers have access to the analytics to streamline supply chain operations, implement proactive maintenance strategies, enhance quality control, optimize energy consumption and enable agile decision-making. By doing some data processing at the machine level, both analysis and better integration with information technology (IT) systems can be achieved, as well as directly feeding plant- and companywide reporting.
OT data delivers invaluable insights, making agile decision-making, process optimization and predictive maintenance possible. Edge computing enables direct analysis and visualization of operational data on the plant floor, ensuring that operators and plant managers can make the critical decisions needed to meet production needs. By harnessing the power of real-time analytics, manufacturers can reduce costs and enhance their competitive advantage through improved decision-making.
To do this, they need robust edge computing solutions on the plant floor that can analyze data in real time on the plant floor and then properly tag and categorize it before storing it in the cloud for high-level reporting. According to Dresner Advisory Services, 89% of manufacturers with analytics and business intelligence initiatives consider them successful, outpacing their peers in comparable industries.
IT/OT integration and multiuser engineering
Poor connectivity between IT and OT systems makes data visibility and decision-making difficult. Lack of adequate data-sharing between IT and OT
can lead to duplication, inconsistencies or potential data loss, harming decision-making.
IT/OT integration and securing data are critical aspects of the modern industrial workplace. When implementing a unified platform to increase efficiency, it must be designed to support multiuser engineering, enabling simple collaboration and tracking on the project server and facilitating mul-
‘
Open interfaces for data import and export ensure visibility into all levels of operation and the use of edge data analytics on the plant floor for agile decision-making. ’
tiuser commissioning. Asynchronous commissioning supports the download of PLCs, including safety applications and access protection. This shortens time-to-market by allowing cooperation on a multiuser project during the engineering and commissioning phases. Parallel working on the project server is empowered by simple code merging, which automates marking modified objects and update notifications. Tracking of changes and the possibility of rolling back are critical features for efficient collaboration.
With a project server in a central data center with worldwide access, IT can link to the company's existing user administration (e.g., Windows
Insightsu
Integration insights u By linking platforms, manufacturing and industrial plants can use one consistent data platform.
uIntegration of data from different systems allows for easier and more efficient use.
FIGURE 1: One common engineering platform from human machine interface design to programmable logic controller coding to network commissioning and drive optimization. Offering uniform usability, data consistency and transparency within all disciplines. Courtesy: Siemens Industry
ENGINEERING SOLUTIONS
Active Directory). In this way, projects, libraries and groups can be assigned to individual users or groups for access protection. IT/OT integration is the basis for the efficient administration of personalized security in the system, allowing open communication standards (e.g., OPC unified architecture) protected by state-of-the-art security (transport layer security) and central user management (universal message authentication code, user master catalog).
IT can define project users and roles and assign them, permitting project-independent setups and enabling maintenance of users only once for the system, ending the reproduction of work across projects and ensuring secure processing of automation data.
Efficiency and collaboration are necessities in today’s business environment. An all-in-one engineering platform enables efficient collaboration, shortens time to market and reduces the need to
‘ Understanding the key features of a unified platform is important so that increased efficiency and data visibility do not come at the cost of security.’
duplicate tasks and processes that increase costs. Understanding the key features of a unified platform is important so that increased efficiency and data visibility do not come at the cost of security. As plants adapt to shifting demands and unexpected supply chain challenges, agility and efficiency go hand in hand. To effectively meet the challenges seen by manufacturers, decision-makers need to ensure that their teams can work together seamlessly to deliver the best results. PE
John DeTellem is the Totally Integrated Automation Portal product manager for Siemens Industry in the United States.
FIGURE 2: Standardized platforms allow engineering, collaboration and simulation while seamlessly integrating with both information technology and operational technology hardware. Courtesy: Siemens Industry
The Energy Advantage is Yours
Flowserve’s Energy Advantage program is a holistic flow control approach aimed at helping operators reach their sustainability objectives of carbon reduction and lowering total cost of ownership. The program provides you with Flowserve engineering expertise, a systematic data-driven evaluation process, and a complete offering of products and services to help you:
• Reduce carbon emissions.
• Increase energy efficiency through optimization of pump and valve power consumption.
• Improve plant productivity and reliability.
• Achieve operational savings. Contact us today to see how the Energy Advantage program can accelerate your energy transition plans to achieve net-zero. EnergyAdvantage@Flowserve.com Flowserve.com/EnergyAdvantage
ENGINEERING SOLUTIONS
DIGITAL TRANSFORMATION
David Hart, Manufacturing Ericsson North America, Lewisville, Texas
Accelerating Industry 4.0 realization: How to create a 5G Lighthouse smart factory
To transform operations in the production and delivery of 5G equipment, a Lighthouse approach was achieved
In 2019, as carriers were beginning to roll out 5G technology, Stockholm-based Ericsson set its sights on becoming a powerhouse in the production and delivery of 5G equipment. Unfortunately, in the late 2010s, industry circumstances were threatening its very ability to produce quality 5G products.
During the previous two years, many companies in the 5G equipment space faced component shortages, making 5G radio production very difficult. Long lead times and overseas shipping translated into higher risks for producing faulty products. Simultaneously, Ericsson planned to produce a new
series of 5G radios. The team realized that bringing production closer to their customers in the U.S. would shorten lead time from order to production, reducing the risk of surplus inventory due to changing customer demand.
As the team at Ericsson looked at how they would face the current industry shifts, they were left with one conclusion — they must become part of the Global Lighthouse Network. In other words, it needed to build an industry-leading equipment production factory, meeting the World Economic Forum (WEF) standards and applying Fourth Industrial Revolution (4IR or Industry 4.0) standards to embrace vision, innovation and responsibility across production networks to unlock value and prioritize environmental sustainability.
The yearlong process — spanning 2019 to 2020 — to create a Lighthouse-worthy smart factory had its share of hurdles, but ultimately, the team at Ericsson completed a 5G smart factory in Lewisville, Texas, that was worthy of Lighthouse status and an example to equipment manufacturers across the globe.
Achieving 4IR Lighthouse status for a 5G smart factory
The WEF’s Lighthouse status is only provided to a select few companies around the world. Companies looking to nominate a facility for this status must follow very specific steps to become a Lighthouse. Among the requirements are to show impactful change in operational models, deploy integrated technology use cases at scale, and enable more efficient processes with industrial internet of things (IIoT) and increased workforce engagement.
Courtesy: Ericsson
Meeting the Lighthouse requirements for the 5G smart factory was a unique situation because the team was dealing with a greenfield factory. This meant the team was working on 4IR status at the same time as the factory construction, equip-
FIGURE 1: At the Lewisville, Texas, facility, technicians have the capability to use Microsoft Hololens glasses equipped with cameras that transmit their perspective to remote engineers. These engineers can then overlay arrows or provide work instructions directly onto the technician's visual field.
ment installation and startup. Also, they had to train a team that had very little factory experience and they had to implement brand-new technology throughout the factory.
However, to begin the 4IR processes, they first had to identify use cases in their current production processes that would best benefit from 4IR practices. So, in mid-2019, the Lewisville team implemented several strategic steps to identify those use cases.
Identifying use cases
The first step was to develop a performance monitor with daily and weekly reports. The team had to know what went awry at other facilities to make sure those mistakes didn’t occur at the Lewisville location. Ericsson’s team visited existing “brownfield” sites and interviewed the engineering teams to identify where current issues existed. The discovery process included speaking to operators on the factory floor, including process engineers and quality engineers, and then working to identify major causes of downtime and delay in the production process.
The Ericsson team also visited other factories to test which pieces of equipment worked well and which did not. If issues existed, the team sought to highlight those problems and ensure they were visible in real time — even before the weekly “morning reports” came out. The visibility helped the team identify defect rates and other equipment performance metrics. Any area demonstrating a higher-than-expected defect rate warranted further investigation, often presenting specific use cases where 5G technology could help.
Finally, the team examined areas within the workforce where employees were engaged in repetitive tasks, offering the potential for automation. For instance, if an individual’s position primarily involved being stationed at a particular spot on the production line and repetitively pushing buttons to allow product access, an excellent opportunity existed for process automation and potentially, using technologies such as vision systems to replace the role.
Ericsson could then transition the worker into a higher-value position with the objective of enhancing the product’s value proposition while simultaneously reducing the labor force required for production. This strategic realignment allows reassignment of its existing personnel into perfor-
mance-enhancing roles, thereby optimizing the overall process while providing opportunities to upskill the current workforce.
Improving operational efficiency
One of the major issues the team uncovered was in their ability to collect actionable data on factory processes. At other factories, teams and equipment were often siloed, which prevented teams from enacting holistic solutions to factory problems. Efficient data collection is one of the best practices noted in Industry 4.0, enabling organizations to act on real-time insights and establish historical patterns. Ericsson’s USA 5G smart factory's success hinged on integrating data from those isolated islands of equipment while consolidating data sources for visibility. Robust data governance ensured standardized data labeling, aligned timestamps and consistent data definitions, allowing for the fostering of a reliable and comprehensive dataset.
Because the company’s operational model relied on cross-functional teams organized around IoT development, use case development and information technology (IT) platform management, they used agile methodologies and daily stand-up meetings to promote efficient cross-team communication, swift issue resolution and iterative development. Furthermore, the teams strictly followed a minimal viable product (MVP) approach, testing and refining use cases to drive rapid progress.
Additionally, cross-functional expertise played a pivotal role in accelerating delivery and ensuring the success of Industry 4.0 initiatives. Front-line operators' insights were incorporated to integrate the voice of the customer, while stakehold-
Objectives Learningu
• Learn about the evaluation methods and processes Ericsson used to identify its initial list of smart manufacturing use cases.
• Understand how Ericsson refined its initial use case list — focusing on the cases that would deliver the largest impact with the simplest implementation.
• Review the approach the company used to successfully implement its factory use cases.
FIGURE 2: The first 5G radio device rolled off the lines in March 2020. Courtesy: Ericsson
ENGINEERING SOLUTIONS
er engagement with IT, procurement, IT security, operations management and finance fostered trustbased partnerships.
‘
Private 5G networks enable the integration of additional sensors, such as vibration and heat sensors, onto existing hardwired machinery.
’
Foundational training also played a critical role in the project's success, ensuring the project team was well-versed in both manufacturing and Industry 4.0 concepts. Before the start of the 4IR transformation, much of the team was relatively new to the intricacies of factory operations. Teaching professionals new skills can be difficult, but the new team was eager to learn the skills necessary for the smart factory to run smoothly. First, each team member had to familiarize themselves with the existing factory processes to gain insights into potential areas of improvement.
Furthermore, the team underwent comprehensive training on the fundamental concepts of the 4IR and how they could contribute to enhancing factory operations. These trainings paved the way for continuous learning and capability building, allowing team members to contribute effectively to the project's roadmap. This training also played a crucial role in upskilling and reskilling the current staff, a key component of Industry 4.0. Today, factory personnel collaboratively manage the smart factory’s roadmap with input from all employees.
Throughout the transition to a 5G smart factory, the team discovered the importance of effective communication. The team held multiple standup meetings throughout the day to streamline
Table 1: Transforming operations
• Identified 80+ digital use cases to transform end to end operations
• Prepared a roadmap detailing 25 use cases to develop in the first 12 months
• Built the strategy to either develop or procure all use cases
• Defined the data needs and features for each use case
• Conducted an Azure design workshop in Redmond, Washington, with Microsoft engineers
• Detailed all the data flows between Azure and the factory
and expedite the resolution to specific challenges. This allowed for a seamless flow of information throughout the supply chain while also facilitating swift problem-solving.
Leveraging 5G technology to build 5G equipment
Upon identifying use cases, Ericsson assessed the potential of 5G technology to enhance these use case scenarios. This would help Ericsson enable the latest in IIoT technology and deploy multiple 4IR use cases at scale — each a requirement to achieve Lighthouse status. The combination of 5G's low latency and high data speeds enable real-time decision-making and action, the use of millimeter wave networks allows increased low latency, resulting in very high round-trip data speeds.
Private networks, in contrast to Wi-Fi networks, ensure stable and reliable connectivity, minimizing the risk of data interference and loss. The team understood that the choice of connectivity influences the breadth and accuracy of data collection, thereby directly impacting the efficacy of these use cases.
Private 5G networks enable the integration of additional sensors, such as vibration and heat sensors, onto existing hardwired machinery. This integration enhanced data collection and enabled the extraction of valuable insights to optimize performance, without completely overhauling the existing infrastructure.
• Conducted a weeklong release planning exercise with the development teams to define requirements and estimate effort
• Divided work into six sprints based on dependencies and interim deliverables
• Organized daily cascading stand-ups between the architecture and development teams to rapidly iterate between design and implementation
• Held regular technical problem-solving sessions and lunch and learns with Microsoft engineers to upskill the development teams and refine designs
• Implemented three MVP use cases and the industrial internet of things platform on the factory floor
• Enhanced the architecture to support new waves of use cases
• Continually deployed use cases with a smaller pool of team members — 25 use cases deployed within 12 months
TABLE 1: A four-step approach was followed to design the factory use cases and stand up a modern industrial internet of things stack. Courtesy: Ericsson
Thanks to 5G-enabled low latency and fast round-trip data speeds, Ericsson’s production team could more effectively use information to make decisions and act to improve production or to remove problems. For example, the Lewisville team was able to leverage augmented reality to repair equipment with the help of equipment experts. The team was able to share video, audio, and annotations with minimal lag so they could address equipment malfunctions as soon as possible.
How to power better outcomes
The factory’s shift to smart manufacturing has yielded substantial enhancements in operational efficiency. In one notable example, the factory used digital twins to improve and optimize the smart manufacturing accelerator line. Through the implementation of this digital twin, the line saw a 25% improvement in throughput, a 30% improvement in waste and error and a 50% decrease in unplanned downtime.
Smart factory improvements also afforded the factory team with a holistic view of production processes. For the first time, Ericsson gained the ability to comprehensively monitor the entire radio product process from a data-driven perspective. Furthermore, the cost-effective storage and streamlined retrieval of data allows for enhanced research efficiency for process engineers.
Ericsson's achievements with its 5G smart factory have solidified its standing in the industry, especially in the United States, positioning the company as a pioneer in manufacturing innovation. The project's success played an instrumental role in establishing a dedicated Industry 4.0 team within Ericsson, with plans to integrate Industry 4.0 principles across its global facilities.
After starting construction in 2019, Ericsson applied for Lighthouse status in 2020 and the Lewisville factory achieved Lighthouse status in 2021. PE
David Hart is Director Business Development at Manufacturing Ericsson North America.
Insightsu
5G insights
uWhile working to deliver 5G equipment, one manufacturer applied Fourth Industrial Revolution (Industry 4.0) standards to achieve a streamlined manufacturing facility. u To achieve Industry 4.0 initiatives, Lighthouse status was obtained.
GEARS AND BEARINGS
Wyatt Phillips, Motion, Prince George, British Columbia
When does preventive maintenance really begin?
Preventive maintenance should begin before a critical asset is installed — with the proper storage of the asset
It is about 2:30 a.m. when you are startled awake by a phone call. Your night-shift team at the plant is calling to let you know that one of your critical assets has just failed. After the initial anxiety, you are relieved as you remember that you purchased a complete spare just a few years ago. After directing your team to install the spare, you relax again, smiling as you remember how you persuaded management to add that costly spare to the budget. However, a couple of hours later, the anxiety returns with a second phone call.
The crew reports that the new spare installed on that critical asset is making noise and running hotter than it should. Now, with the spare facing imminent failure, you are faced with production losses and an uncomfortable report on why that spare is not providing the insurance against downtime you promised. What went wrong? To answer that, I will relate an experience I had in the field as a technical representative.
FIGURE 1: Damage from water etching is a common cause of premature bearing failure. This etching typically results from condensate accumulation in the bearing due to temperature fluctuations and poor storage conditions. Courtesy: Motion
I received a call from a customer at a remote location requesting me to help them identify a spare conveyor pulley assembly they had on-site. After arrival, I met with a warehouse supervisor who directed me to where the item should be. I searched for 20 minutes but could not find the pulley. I returned to the warehouse supervisor and apologetically asked for more precise directions. He told me I was looking in the wrong place, saying, “The location for that item is over there,” as he pointed out the door to an empty snow-covered lot across from the warehouse.
The critical spare was outside where it had been for two years and under 4 feet of snow. I found the pulley and forwarded the specifications requested to the warehouse along with a report on its condition. Several months later that spare was needed for a conveyor repair. But before installation, they discovered that water contaminated the bearing housings and rendered the spare unusable without significant repairs.
That may seem like an extreme example of poor critical-item storage. However, inadequate storage is more common than we may realize. An improperly stored asset can be compromised with damaged bearings, corroded gearing, leaking seals and contamination from environmental exposure, making that critical asset an enormous liability.
Preventive maintenance is a regular focus of most plants. Sometimes overlooked, however, is that preventive maintenance begins before a critical asset is installed with the proper storage of the asset. What is proper storage? Ask any classic car enthusiast or collector, and he or she will tell you how storage is directly related to maintaining environmental conditions such as temperature, humidity and cleanliness. Proper storage is about keeping those conditions within acceptable limits.
The biggest factor in maintaining condition is proper location. Poor storage is not always caused by negligence or a lack of knowledge; instead, it is often due to working with unfavorable circumstances.
For example, many plants are designed and built with proper spare storage as an afterthought. Even in some new plants, the space allotted for warehouse needs is insufficient. This forces warehouse personnel to improvise and sometimes store spares in undesirable locations exposed to extreme temperature changes, weather, equipment vibrations or contaminants.
What can be changed?
How to properly store assets
Every piece of critical equipment that rotates or is susceptible to corrosion is at risk. Here are storage guidelines for three main asset types that almost all industrial plants have.
Bearings: From the start, proper storage is critical. Bearings should always be stored in a clean, temperature-controlled, low-humidity environment free of dust, shocks and vibrations. Many top bearing manufacturers coat them with a preservative oil film to protect against corrosion. Long-term storage times can be achieved by storing bearings in their original, unopened factory packaging.
To maximize the bearing’s operating life, use the “first in, first out” inventory policy. If a bearing is open (unsealed and not lubricated), bearings can be stored for up to 10 years without compromising service life (see Table 1).
For capped bearings (bearings with seals or shields), the storage time is limited by the lubricants and should be stored for a maximum of three years to avoid degradation of the grease fill.
To prevent deterioration of stored bearings, consider these basic storage factors:
Table 1: Storage time for unsealed bearings without lubrication
TABLE 1: Watch for different factors when storing unsealed bearings.
Courtesy: Motion
• Store bearings indoors in a condensation-free area, maintaining the environment’s ambient temperature, ensuring a maximum of 105°F (see Figure 1).
• Store in vibration-free conditions. Vibration can damage raceways, so storing bearings directly on a floor should be avoided.
• Store bearings horizontally (flat), if possible, to avoid damage caused by the bearing falling on its side from the upright position.
• Do not open or damage the original packaging. If your maintenance personnel open a bearing package to identify it, they need more training.
Gear reducers: Storage location is also the primary consideration for a gearbox. As directed for bearings in general, store the gearbox in a place free of ground vibration from sources like heavy equipment (e.g., vehicles, large forklifts, cranes) or railway activity. While stationary, rotating elements do not have a sufficient film layer between the metallic surfaces, vibrations can cause false brinelling from rollers oscillating against the raceways. False brinelling is a recipe for failure. To further deter bearing damage, the shafts of gear reducers should be rotated a couple of full rotations every two months to distribute the lubrication film and prevent false brinelling and fretting corrosion. Tag the reducers, noting the storage date of the scheduled rotations, then ensure someone is responsible for keeping them on schedule.
Temperature is a condition that must be controlled for proper gearbox storage. Depending on the season and the location of your plant, temperature variations can be severe. The goal with tem-
‘ The biggest factor in maintaining condition is proper location. ’
• Understand why storage matters for critical assets.
• Learn which storage conditions are required to preserve bearings, gearboxes and conveyor pulley assemblies for the long term.
• Know the practical steps to improve critical asset storage.
ENGINEERING SOLUTIONS
perature is consistency; although 70-80°F is optimal, 65-100°F is acceptable. Keeping the gearbox sheltered and protected from weather conditions is also essential, as condensed moisture can accumulate within the reducer housing, causing rust and corrosion of gears and bearings (see Figure 2).
Gearmotors consisting of a gear reducer and motor combination may require special consideration for storage life if the motors use greasefilled sealed bearings. As noted above, grease has a storage limit, so know the grease-lubricated equipment’s shelf-life limitations and establish a regreasing schedule if needed.
For internal conservation, manufacturers recommend using vapor corrosion inhibitors (VCIs), which are applied inside the free space of the gear unit. Except for some food-grade lubricants, many VCI brands are specially designed for use with lubricating oils so that any existing oil may remain in the gearbox.
Storage insights
uConsider three main asset types and the best storage practices of each to preserve their service potential.
uPreventive maintenance is a regular focus of most plants.
If an air vent is installed, replace it and close the air vent hole with a sealing plug. Before putting the gearbox into service, a drain and flush with the recommended lubricant is always a good practice. To prevent rust damage to the external machined surfaces such as shafts, flanges and threaded attachment points, apply a manufacturer-recommended corrosion preventive.
Seals can be coated with bearing grease to protect them from ultraviolet (UV) damage and contaminants. A high-strength polyethylene resin with UV stabilizers should then be sealed around the exterior housing to protect the ferrous metal of the gearbox from corrosion. Desiccant should be stored under the cover with the gearbox and replaced periodically.
Often, spare gearboxes will not be put into service for 5-10 years, so it is highly recommended to order a gearbox from the distributor/factory with longterm storage preparations included. Long-term storage packages consist of all the foregoing preparations. A properly treated gearbox — with a suitable location and periodic shaft rotations — should be in like-new condition and ready for service when needed.
However, you should always check the gearbox condition before installation. A good practice is using a noninvasive borescope to inspect the gearbox internally and ensure its functionality.
Conveyor pulleys: A conveyor pulley with worn lagging, contaminated or damaged bearing assemblies, or corroded shafts can make a simple changeout a material handling nightmare. Here are recommendations for storing conveyor pulleys longer than three months.
Pulley assemblies should be stored indoors at a consistent temperature and the atmospheric humidity of the storage environment should be no greater than 40% relative humidity. High-humidity areas may require additional measures like dehumidifiers to maintain the atmosphere. If a pulley assembly must be kept for any length of time outdoors, it should be covered with a water-repellent tarp. It is best to avoid using poly sheeting or other nonbreathing tarp materials because water vapor can be trapped, causing condensation and rust. Using such nonbreathable materials may require adding desiccant bags under the covering to absorb the collecting moisture (see Figure 3).
Protecting pulley surfaces from damage is a good investment. All pulleys with urethane, rubber or ceramic lagging should have all circumferential surfaces wrapped with a steel sheet securely banded around them. The purpose of this sheet is to protect these surfaces from mechanical and environmental damage — such as UV rays — during transport, storage and initial installation. All exposed and unpainted surfaces, such as the shafts and hubs, should be covered with an approved rust inhibitor.
FIGURE 2: This gear from a gearbox shows the results of storage without corrosion inhibitors and warehouse temperature and humidity controls. Courtesy: Motion
Pulleys can be very heavy and that mass must be distributed to avoid damage to the lagging surface. All lagged pulley assemblies weighing more than 10,000 pounds should be supported in wooden cradles designed to distribute the pulley assembly weight over an area and eliminate pressure on the lagging surface.
If the pulley must be stored with bearings preinstalled, all bearing housings should be filled to the maximum with grease to minimize any air pockets where condensation could occur. Pulleys with bearings should be inspected and rotated regularly every 90 days to prevent sagging, puddle corrosion or other issues. This rotation schedule will maintain proper lube film between rollers and bearings.
Support for long-term storage solutions
Preventive maintenance begins when spare equipment arrives or even before that if you order the spare already prepared for long-term storage. Each plant’s storage circumstances are different and even if there is not ideal storage for
GET ON THE BEAT
each asset, start with the most critical items and go from there.
Distributors and manufacturers want you to get the whole, reliable service life out of your required spare components, so contact them for advice and specific guidelines to create your storage plan. A local industrial solutions provider may even provide services to inspect stored assets and assist with scheduled storage checks and maintenance. With a little advanced preparation, you can rest peacefully — even after a breakdown — knowing that spares are ready for service. PE
Wyatt Phillips is Motion’s Prince George, B.C., Branch Manager.
treated with rust preventive and accompanied by desiccant bags under the protective wrap. It is ready for long-term storage and scheduled bearing rotations.
Courtesy: Motion
Factory Direct
Your order ships in 5 days or less. Quantity Discounts Available
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FIGURE 3: This drive pulley assembly is cradled, its shafts
ENGINEERING SOLUTIONS
LUBRICATION
Thomas H. Bishop, PE, EASA Inc.
Characteristics and test properties of rotating electrical machine bearing lubricants
Key considerations with greases and oils include their suitability for an application. Knowledge of lubricant characteristics and test properties helps ensure the correct selection for rotating electrical machine bearings
Lubrication is needed to reduce friction between the rolling elements and stationary parts of bearings in rotating electrical machines. By reducing bearing friction, lubricants also help prevent undue temperature rise and dissipate some of the heat that is generated. But some rotating electrical machine applications require different lubricants than others. With that in mind, here’s an overview of some key characteristics and test properties of greases and oils.
Characteristics of greases
Grease technology continues to be a complex topic as new formulations emerge to help solve practical problems. Such solutions typically involve varying the type, hardness and percentages of thickeners/soaps; changing the oil types, viscosity and percentage; and modifying other additives. From a chemical perspective, greases are mixtures consisting of:
• Approximately 75% lubricating oil
• Approximately 15% thickener/soap
• Up to 10% additives
Base oils: The properties of a grease depend primarily on the type of base oil used, as well as on the thickening agent and other additives. Base oils consist of mineral oil or synthetics such as ester oil, synthetic hydrocarbon oil or ether oil. Generally, greases with low-viscosity base oils are best suited for low temperatures and high speeds. Those with high-viscosity base oils are superior at high temperatures and high loads.
FIGURE 1: Example of an application with a grease-lubricated ball bearing motor driving a blower. Courtesy: EASA
Thickening agents are compounded with base oils to keep grease in a semi-solid state. These include metallic soaps (lithium, sodium, calcium and aluminum) and two types of nonsoap thickeners: inorganic (silica gel, bentonite) and organic (polyurea, fluorocarbon). Note that polyurea is a synthetic organic thickener that is widely used for electric motor bearing lubricants because it can withstand temperatures exceeding 250°F (120°C).
Various special characteristics of grease — such as temperature range limits, mechanical stability and water resistance — mostly depend on the type of thickening agent used. For example, sodium-based greases generally provide poor water resistance, while greases with polyurea and other nonmetallic soap thickening agents usually have superior high temperature properties.
Additives: Depending on the purpose, various additives may be used to modify grease properties. These typically include anti-corrosives, rust preventives, fillers, wetting agents, extreme pressure (EP) additives and antioxidants. Antioxidants are used to delay deterioration of greases in most types of rolling bearings. EP additives are best for bearings subject to thrust and/or shock loads but otherwise are not advised because they can shorten grease life.
Grease consistency: Consistency indicates the hardness and fluidity of grease based on penetration units and NLGI (National Lubricating Grease Institute) consistency numbers. As Table 1 shows, each NGLI number covers a range of penetration values.
Table 1: NLGI consistency
‘ Grease technology continues to be a complex topic as new formulations emerge to help solve practical problems. ’
• Understand the consistency of grease.
• Understand the meaning of an NLGI number.
• Recognize important characteristics and test properties of greases and oils.
FIGURE 2: The low viscosity of this lubricant was caused by mixing incompatible greases. Courtesy: EASA
TABLE 1: NLGI consistency and comparison numbers. Courtesy: EASA
ENGINEERING SOLUTIONS
Courtesy: EASA
Table 1: NLGI consistency
The higher the number, the harder (firmer) the grease and the better it stays in place, which is useful where leakage is a concern. A lower NLGI number indicates a softer grease that flows better. Rolling element bearings use NLGI 1, 2 and 3 greases.
Grease penetration values depend mostly on the base oil viscosity and the percentage of base oil in the lubricant. Penetration is the depth, in tenths of millimeters that a standard weighted cone sinks into grease under prescribed conditions. High-viscosity oils tend to stiffen greases and decrease penetration values, so they work well for heavier loads. They also make greases less susceptible to atomization and thinning at higher temperatures. Low-viscosity oils increase grease penetration values for use with lighter loads and lower temperature applications.
Special-purpose greases are available for lowand high-temperature applications, including synthetic greases for both low and very high temperatures. These special synthetic greases usually
FIGURE 3: Although the oil may be correct, an oil leak can cause a bearing failure due to insufficient lubricant.
TABLE 2: Table 2: Typical characteristic properties of a turbine oil. Courtesy: EASA
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are designed to meet specific application issues–primarily very high temperatures. Of these, perhaps the most common are silicone greases, which use silicone oils in place of mineral oils. There are also synthetic greases with low-noise characteristics. Note that while special greases are often well suited for specific applications, they usually are less than optimal in average temperature ranges and applications.
‘ Lubricant manufacturers or blenders typically use qualification testing to ensure that lubricant blends meet the stated minimum criteria. ’
Testing properties of grease
Of the many standardized tests of grease properties, here are a few of the most important ones: Penetration and worked penetration tests: These tests measure the stiffness or movability of grease as well as its channeling or self-leveling properties.
Accelerated tests: These tests check the oxidation rate or aging properties of grease. Oxidized greases are poor lubricants and tend to accelerate corrosion.
Bleeding rate test: This test determines how quickly the oil in grease tends to separate from the thickener/soap. Judiciously choosing a grease with the appropriate bleeding rate can compensate for the severity of the application.
Emulsification tests: These tests are especially important for applications in humid conditions. A grease that emulsifies easily would normally be flushed out of a bearing very easily in wet applications. At the same time, this type of grease would best dissipate small quantities of moisture.
Characteristics and testing properties of oils
Note: Rotating electric machine bearings use turbine oil. Automotive oils contain detergent additives and should not be used in these applications.
Lubricating oils have simpler compositions than greases, so this discussion covers both the characteristics and test properties of these lubricants.
Lubricant manufacturers or blenders typically use qualification testing to ensure that lubricant blends meet the stated minimum criteria. Table 2 lists some of the more important and useful characteristic properties of turbine oil, including:
Viscosity: Considered the most important property of a lubricant, viscosity provides a lubricating film, cools machine components and seals and controls oil consumption. Liquids that resist flow or flow slowly, such as honey or dish soap, have high viscosity. Liquids that flow easily or quickly, such as water or vegetable oil, have low viscosity. The viscosity index (VI) is the rate at which the viscosity of an oil changes with temperature. The higher the VI, the less the viscosity of an oil changes with temperature.
Oxidation stability: Oxidation stability is the ability of a lubricant to resist chemical combination with oxygen. If that occurs, it can create sludge deposits and increase the viscosity of the oil. Heat, light, metal catalysts, acids formed by water contamination and other contaminants can accelerate the oxidation rate.
Pour point: This is the lowest temperature at which an oil will flow under prescribed test conditions. The number of wax particles that remain after crude oil processing determines the pour point. The more particles there are, the higher the pour point. The fewer there are, the lower the pour point.
Rust resistance test: The rust resistance properties test measures the ability of industrial oils to prevent rust in water contamination situations.
Foaming characteristics test: The foaming characteristics test empirically rates the foaming tendency of lubricating oils and the stability of the foam.
Since some rotating electrical machine bearing applications require different lubricants than others, it helps to understand key characteristics and test properties of greases and oils when making those selections. PE
Thomas H. Bishop, PE, is a senior technical support specialist at EASA Inc.
Innovations
Power supply to achieve SIL 3 rating
The new QUINT 10+ power supply is designed to help users achieve SIL 3 rating without external redundancy. The device has an integrated decoupling MOSFET and a redundant overvoltage protection (OVP) circuit, which eliminate the need for external components. The QUINT 10+ power supply has a conformal coating and ATEX, IEC 61508, IEC 61511, and Class I, Division 2 approvals, so it can be mounted within potentially explosive areas (Zone 2). If the voltage rises above 30 Vdc, the device will switch off within 20 milliseconds, creating a safe state with no output voltage. The power supply connected in parallel ensures reliable power. The power supply has a 10 A nominal output current and an operating range of -40 to 75 oC.
Phoenix Contact, www.phoenixcontact.com/us
Air extend and spring retract gage head sensors
NewTek GAR Series Spring-loaded Gage Heads are used in automated dimensional gaging applications as part of inline inspection processes when it is ideal for the sensor probe to move out of the way between readings. The probes of these LVDTs extends when taking dimensional measurements, then retract to their original position to avoid damage to the sensor or next conveyed product. In manufacturing conveyor lines, these Air Extend/Spring Retract Gage Heads conduct tolerance checks as part of quality assurance measures. The LVDTs provide dimensional feedback to verify if parts have any variance in size and other physical properties. The GAR Series Gage Head Sensors check dimensions when their probes contact the measured object. In operation, low-pressure air (10 to 40 psi) extends the sensor shaft.
NewTek Sensor Solutions, www.newteksensors.com
Belt aging stand
An accelerated belt aging stand for use in belt noise testing is designed to subject belts to dynamic loads, temperatures, and stresses that will give them the physical characteristics of aging belts. Artificially accelerating the aging process introduces the noise characteristics that can then be properly tested to ensure they meet SAE J2432-2012 standard, Performance Testing of PK Section V-Ribbed Belts in actual conditions. This new standard covers accessory drive belt testing methods and includes test configurations, pulley diameters, power loads, and guidance for interpreting test data. The belt stand can age up to 3 belts at a time, reducing the time necessary to test a given belt design. Sakor Technologies, www.sakor.com
VOC gas detectors
The VOC Gas Detectors provide a range of fixed sensors and portable gas monitors for the detection of volatile organic compounds. It is important for many industries to have accurate and fast detection of harmful VOC gases to avoid the gas reaching dangerous toxic levels. Discover our range of VOC gas detectors and associated instruments. Designed specifically for the detection of a wide range of volatile organic compounds. The detectors can help with risk assessments for specific applications and the design of effective gas detectors and detection systems. GasDoc, www.gasdoc.com
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Multiloop and multifunctional safety logic solver, alarm
The IEC 61508 certified SLA multiloop logic solver with built-in voting and enhanced math capability provides safety practitioners a cost-effective, powerful, yet easy-toemploy logic solver that fills the large functionality gap between high-end safety PLCs and the limited capabilities of single-loop logic solvers within safety instrumented systems (SIS). The SLA also can handle everything from simple alarming to more complex schemes that include 1oo2, 2oo3 or even 5oo8 voting architectures, enabling it to act on potentially hazardous process conditions; warn of unwanted process conditions; provide emergency shutdown; or provide on/off control in SIS and traditional alarm trip applications. Moore Industries-International, Inc., www.miinet.com
Inrush current limiter
The ESB001 inrush-current limiter series requires just 17.5mm space on the top-hat rail, which commonly is only the dimension of a single-phase circuit breaker. The ESB001 is suitable for protecting contact fires on load relays or protecting multiplexed MUX channels from damaging inrush currents. Due to the low heat production of only 1.1 W @230Vac at 99.97% efficiency, the ESB001 can be mounted wall-to-wall with neighboring devices in the control cabinet. Therefore, the ESB001 units show their strength wherever space in the control cabinet is very tight. Camtec Power Supplies GmbH, www.camtec-powersupplies.com
Case studies provide valuable discovery of challenge situations, recommended solutions, and implementation actions to solve specific real-life issues.
Plant Engineering magazine invites you to explore the pages to follow while you learn and benefit from the case study success stories and project details shared by the companies listed at right:
Global pharmaceutical packaging company achieves green building initiative with ultra premium efficient motors
challenge: A leading multi-national pharmaceutical packaging corporation sought to implement more environmentally sustainable processes and technologies in its manufacturing facilities, in part by upgrading to more efficient motors.
solution: The company purchased one highly efficient Baldor-Reliance ® EC Titanium™ motor to test against the motors currently running in its plants. The test demonstrated a significant reduction in energy consumption while lowering operating costs, potentially providing a full return on investment in less than two years.
Result: The company purchased additional EC Titanium motors for immediate installation on its high-priority production lines and is in discussions to upgrade all lower-efficiency motors in its main manufacturing facility.
summaRy: This company, with more than 4,500 employees in 140 locations worldwide, has taken a leadership approach to the development of cleaner processes and technologies, including construction of what will be the world’s greenest-ever pharmaceutical plant. Company leadership understands that a large portion of the world’s electricity is used to power electric motors, and upgrading to high-efficiency motors will help reduce energy consumption and environmental impact while lowering costs.
By incorporating new technologies, ABB’s motor system achieves a high level of energy efficiency while using sustainable materials. The packaging company purchased one EC Titanium motor to test against current lowerefficiency motors, and the benefits were instantly recognizable. EC Titanium achieved an energy reduction of 12.59 kWh per day, translating to a cost savings of $520 per year, per motor. This cost savings would realize a complete return on investment in less than two years, while greatly reducing energy usage and environmental impact.
It has been estimated that replacing 80 percent of motors currently in operation around the world with newer technologies that achieve higher efficiency levels could save more than 160 terawatt-hours of electricity each year and cut total global electricity consumption by as much as 10 percent.
479.646.4711
baldor.abb.com
SCAn To lEARn moRE
e S tudy
DigiKey Delivers Automation Efficiency in New Product Distribution Center Expansion
Challenge: After years of record growth, DigiKey needed to expand its product distribution center in Thief River Falls, Minn., while also reducing the delivery cycle time.
Solution: The largest component of the newly automated system is the KNAPP Order Storage and Retrieval (OSR).
ReSult: Last year, after five years of building and planning, DigiKey opened its state-of the-art warehouse expansion. The automation systems in the new facility allow the company to pick, pack and ship nearly three times the previous daily average of 27,000 orders to customers in more than 180 countries around the world.
SummaRy: The new Product Distribution Center expansion, or PDCe, is nearly fully automated; DigiKey has developed many proprietary systems to aid in ensuring customers get the right part in the right quantity every time. The implementation of a KNAPP OSR system provides the right parts to the picker, eliminating walk time and providing an ergonomically appropriate environment for the picker.
This high level of automation improves efficiency by up to 35% for picking and improves packaging quality and efficiency.
The PDCe features two primary sorting systems to provide redundancy in the case of a breakdown and to enable future growth. Creating a team-friendly work environment while also planning for scalability and growth were top of mind in the plans and design of the building. There are over 27 miles of automated conveyor belt in the facility, and an average order will travel more than 3,200 feet inside the building.
Sustainability was also an integral part of the planning and construction of the facility. DigiKey specially designed a conveying system that maximizes energy usage and efficiency.
DigiKey has released a video series called “Revolutionizing Automation,” which takes you behind the scenes of the PDCe. Visit digikey.com/revolutionizing-automation to learn more about the future of automation at DigiKey.
sales@digikey.com 1-800-344-4539 www.digikey.com
C a S e S tudy
Refinery Gains New Funding and Finds an Operating Edge with the Energy Advantage Program (EAP)
Challenge: A German refinery wanted to leverage government funding for energy efficiency improvements of pumping systems.
Solution: The Flowserve Energy Advantage Program (EAP) targeted an initial set of eleven pumping systems, nine of which were found to have substantial energy efficiency opportunities and defined solutions to match process pressure and flow-rate requirements. Modifications ranged from simple impeller trims to low-flow hydraulics, drop-in pumps, non-metallic wear rings and new control valves.
ReSult: They expect to qualify for government funding plus the following annual improvements: Power consumption reduction: 2229 MWh; Carbon footprint reduction: 1338 MT; Financial benefit € 334k, and Process control to be improved by upgrading from hand- to automated-control valves.
SummaRy: The German government began to offer new funding to plant operators for energy efficiency project implementation. A refinery was already looking for ways to help drive the energy transformation happening in Germany.
They contacted Flowserve to achieve greater energy efficiency within the plant’s flow loops — flow control and process equipment, piping, instrumentation, and control elements that move liquids and allow refining processes to operate. Eleven flow loops were identified and analyzed for optimization via Flowserve’s Energy Advantage Program (EAP). The EAP flow loop optimization process analyzes representative operating data to establish actual process requirements in terms of pressures and flow rates. It then defines flow control solutions to match those process requirements with improved energy efficiency. EAP specialists found nine of the eleven loops had substantial opportunities for measurable improvement.
The equipment modifications required to capitalize on these opportunities ranged from simple impeller trims to low-flow hydraulics, drop-in pumps, non-metallic wear rings and new control valves. The EAP helped the refinery get on track to qualify for government funding. Additionally, the program has helped identify ways to significantly reduce power consumption, carbon footprint, and find measurable process control improvements and financial gains.
Cli C k or Scan QR to learn more about the EAP
CaS e S tudy
General Dynamics’ Critical Communications for Space Programs Gets Boost from iBase-t’s Solumina Manufacturing Operations Platform
Challenge: Quick, top-down visibility into quality and other issues affecting equipment which cost tens of millions of dollars per unit. Avoiding costly teardowns and launch delays.
Solution: Implement a completely paperless shop floor to achieve major productivity improvements.
ReSult: General Dynamics realized a 90% reduction in shop floor paperwork. Cost reductions specifically centered around the new system-enabled process improvements from iBase-t’s Solumina Manufacturing Operations Platform.
SummaRy: General Dynamics AIS Integrated Space Systems, located in Scottsdale, Arizona, has been delivering critical communications products to space programs for over 40 years including Explorer, Voyager, Space Station, Orion, NATO Satellites, Mars Pathfinder, and Mars Rover.
With the help of the experts at iBase-t, the General Dynamics production facility went from a highly paper-based and manually controlled process to one where the manufacturing and quality management system, Solumina, is the focal point for building hardware. Given the complexity and criticality of the work, a comprehensive system was needed to help control workflow and to provide the checkpoints, to prevent unauthorized work and an integrated system that would house this detailed data and provide its history upon demand.
The facility also leveraged Solumina to support continuous improvement efforts. Defect and production data are monitored to look for trends and set improvement goals. Customers are seeing the direct benefit. Automated quality metrics have eliminated the need to have a dedicated person on each project focused on generating weekly/monthly reports.
Training of users on the Solumina Manufacturing Execution and Quality system happens once, and as users go from project to project, the system is the same. It takes 4-8 hours to train shop floor personnel and 32-40 hours to train the process planners. The learning curve for new personnel has been greatly reduced.
Customers including Boeing, Lockheed Martin and NASA have audited the company’s procedures and the systems and processes have been noted as best-in-class amongst hi-reliability space manufacturers.
+ 1 949.598.5200 www.ibaset.com
ClIC k or scan QR to request a demo
CaS e S tudy
Computerized Maintenance Management System Organizes Inventory for Ethanol Producer
Challenge: Heron Lake BioEnergy had a CMMS but wasn’t utilizing all of its features to its full potential.
Solution: Hired a system administrator who inputted inventory information into MAPCON CMMS.
ReSult: Having organized information at one’s fingertips greatly improved their efficiency and productivity.
SummaRy: Heron Lake BioEnergy produces 67.5 million gallons of ethanol annually, which is sold to petroleum marketers in Minnesota and across the nation as a clean-burning, highoctane fuel additive. It uses 22,000,000 bushels of corn annually. As a co-product of ethanol production, the plant annually creates 164,000 tons of distillers dried grains (DDGS). This is sold to livestock producers as a high-value nutritional supplement.
The plant was using MAPCON for preventive maintenance and work orders but not inventory. A system administrator was hired, who then entered all inventory into the MAPCON and organized existing items and stock locations. Then she assigned inventory to the equipment, input vendor information, and attached quotes, instructions, and other files to the inventory or equipment. This provided co-workers with the information they needed to maximize their productivity.
The system accommodates company growth, allowing the administrator to add information as needed. MAPCON also provides the benefit of generating specific reports for management and for reordering stock. Changing the stockroom layout in the system is easy, should the company ever add or rearrange their stockrooms. MAPCON’s coordination and organization of inventory, assets, and purchasing make employee’s day-to-day activities far more productive and hassle-free.
CLiC k or scan QR to learn more
sales@mapcon.com 515-331-3358
www.mapcon.com
Deep learning and machine vision solve complex advanced inspection for foil seal, tamper-evident packaging
challenge: The FDA, following a malicious product contamination incident in the 1980s, mandated tamperevident packaging for all pharmaceutical OTC products. Capping processes impact the formation of a complete and robust seal resulting in damaged/under formed seals which are hidden under a plastic cap.
solution: The seal is induction heated, making it adhere to the bottle rim. A thermal camera acquires an image of the foil thermal signature through the plastic cap in the post induction heating process. Some defects are clearly defined in the thermal images, while others are more difficult to quantify. The successful inspection solution is accomplished by combining analytical vision tools with deep learning in a “hybrid” imaging analysis.
Result: The system accurately captured important seal defects while maintaining a minimal false failure rate. Based on saved defect seal data, key areas of improvement identified resulting in improved cap torquing. This resulted in improved seal integrity and lower reject rates.
summaRy: This application shows how a hybrid inspection system may be developed and deployed successfully in the field utilizing analytical machine vision and deep learning technologies. To achieve high detection accuracy for both the clearly defined defect features and the poorly defined defect features, the system’s strengths are effectively combined. One such system for diverse products was effective in deploying it to numerous places. The technology maintained a low false failure rate while accurately detecting significant seal flaws. Finding variations in cap torque based on seal integrity and completeness was a crucial area for process optimization. The cap torque was changed to achieve tighter seals and decrease product rejects using the continuing process data.
Liquid on the cap and bottle, which could cause issues with later operations like labeling, was also discovered using thermal imaging. As a result, the overall quality was raised. Additionally, even uncommon flaws like fractured caps that would have gone unnoticed were effectively recognized by the system.
This program skillfully integrates cutting-edge imaging methods and analytical tools to significantly improve a crucial industrial process. The use of tried-and-true industrial thermal imaging techniques and an original combination of deep learning and discrete vision tools are essential to the solution. The outcome is a comprehensive solution with broad application in industry.
info@ai.motion.com • 800-AUTOMATE • ai.motion.com
L-R: 2D thermal images of a good seal, a bad seal containing an underheated section (magenta), and a bad overheated seal.
Airport Prevents Safety Incidents and Downtime with Smart Pump Monitoring
Challenge: An airport’s jet fuel transfer operation team faced safety risks, related to disintegrating pump coupling shims during intermittent operation; this was complicating maintenance coordination and stressing the coupling with multiple start/stop cycles.
Solution: RedRaven’s permanent monitoring system enabled continuous expert monitoring. A sudden vibration increase prompted immediate action, preventing a potential safety incident.
ReSult: Timely alerts helped the operator avert a catastrophe, increasing plant safety and eliminating costly, unplanned downtime.
SummaRy: An airport’s jet fuel transfer operation team faced safety risks, relating to disintegrating pump coupling shims during intermittent operation. This was complicating maintenance coordination and stressing the coupling with multiple start/stop cycles. They decided to deploy RedRaven, Flowserve’s predictive maintenance service. Soon after deployment, RedRaven and Flowserve’s monitoring specialists detected a sudden pump vibration spike and alerted the operator of potential danger. They were immediately able to plan and proactively address the potential coupling failure and prevented what could have been a catastrophic safety incident in the jet fuel transfer area.
The timely intervention not only safeguarded the plant and its personnel but also averted substantial financial losses by eliminating unplanned downtime. The implementation of RedRaven’s monitoring system proved its value by providing real-time insights, enabling proactive responses, and ensuring seamless operations; this underscores the critical importance of advanced monitoring technology in industrial settings, where a single moment of oversight can lead to dire consequences. Constant monitoring by systems and personnel continues to enable the operator to mitigate risks and optimize operational efficiency — reinforcing the value of investing in cutting-edge solutions for industrial safety and productivity.
case study
Mineral Powder Handling Solution
Helps Oil Industry Giant Increase Productivity
challenge: Spiroflow Systems was recently working with a large oil industry customer who needed to upgrade its equipment at one of their existing facilities. They needed a bulk bag unloading and feeding solution that ensured dust from the mineral powders being processed were adequately controlled and contained - all while working around the technical challenges presented by confined space in the facility.
solution: Spiroflow put together a mineral powder discharging, handling and feeding solution that included three Spiroflow Bulk Bag Dischargers, six Spiroflow Aero Mechanical Conveyors, and one Spiroflow Flexible Screw Conveyor — all seamlessly integrating with the customer’s existing controls system.
Result: With Spiroflow’s application expertise and industry-leading dry bulk material handling equipment, they engineered the perfect solution for this oil industry giant. Today, the company safely and efficiently unloads and processes nearly 100 mineral powder recipes with 20 different base products at the facility.
summaRy: Testing was a vital part of the solution that Spiroflow provided to this oil industry customer. Spiroflow took the time to understand the current situation before creating an engineered solution to meet the requirements by participating in a week-long field study to monitor the operations and identify points for process optimization. This field data and due diligence was invaluable in putting together the comprehensive solution to meet the client’s needs.
The comprehensive solution enabled our client to discharge 2000lb (907.2 kg) bulk bags, or smaller 50lb (22.6 kg) bags, in a custom combination discharger and efficiently feed the wide range of powders into mixers. The system also included low headroom hoists to help overcome the technical challenges of fitting the equipment into the space available. Spiroflow also customized the equipment with integral dust collectors to ensure dust containment at in-feed points. Additionally, the fact that Spiroflow’s custom dischargers were able to be paired with the most appropriate conveyor from their wide range of offerings allowed an optimal solution to be provided.
In addition to the range of equipment provided, Spiroflow was able to provide complete Automation and Controls Solutions for this project. Spiroflow Automation Solutions provides control systems solutions to fit any engineering projects across a wide range of industries and processes.
To see more about our bulk bag discharging solutions CLICK here or scan the Qr code at left.
Spiroflow Aero Mechanical Conveyor
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TM Technology and
experts in bulk solids handling get stuck sometimes.
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The ultimate in power density just got better. When space is at a premium, the Baldor-Reliance RPM AC motor is the answer. RPM AC features a power-dense laminated steel frame with custom power and speed ratings to match demanding variable speed application requirements.
